Project Background
New Age Engineering Solutions (NAES) was awarded the contract to fabricate and construct a 5,000-ton Ammonium Nitrate storage tank at the Omnia Fertiliser Plant in Sasolburg.
Ammonium nitrate is used to make both fertilisers for farming and explosives for mining. These two industries are essential in South Africa, creating jobs and helping the country grow. By adding more storage, the plant can now better meet the needs of farmers and mining companies.
The project required complex structural work, adaptive engineering, and close collaboration between stakeholders to deliver safely and on schedule.
Tank Dimensions
- Diameter: 19 metres
- Height: 14.6 metres
This large-scale tank was fabricated in phases, using plates of varying thickness to ensure structural integrity and alignment with safety and operational requirements.
Roof Fabrication & Installation
One of the most significant engineering challenges was a complete redesign of the originally approved roof. This required a full revision of materials and fabrication methods:
- Material: 8mm stainless steel plate
- Fabrication Time: 6 weeks
- Installation: Lifted into place using a 400-ton crane
- Post-lift Work: Roof attachments installed after final welding
This redesign demonstrated NAES’s flexibility and ability to adapt to changing specifications mid-project without delaying the schedule.
Scope of Work Highlights
Tank Fabrication – By Phase:
- Phase 1: 3 metres using a 16mm plate
- Phase 2: 3 metres using a 12mm plate
- Phase 3: 1.5 metres using a 10mm plate
- Phase 4: 1.5 metres using an 8mm plate
- Final Phase: 3 metres using a 6mm plate
Staircase Installation:
A custom staircase was added mid-project through a joint effort between NAES and Omnia. This was not part of the original scope and required agile integration.
Quality Control & Surface Treatment:
All welds were inspected and approved by the Quality Control team and the Approved Inspection Authority (AIA). The tank was then pickled and passivated, ensuring the stainless steel was free from contaminants and corrosion-ready.
Adaptability in Action
As the project evolved, NAES worked closely with the client to adjust the scope and update technical drawings in real time, demonstrating our team’s responsiveness and solution-oriented mindset.
Challenges and Solutions
- Design Revisions: Responded swiftly to continuous drawing updates
- Weather Delays: Adopted night shifts and built temporary welding shelters to maintain progress
- Scope Creep: Strategically managed resources and schedules to accommodate expanding project requirements
- Multi-Stakeholder Coordination: Maintained close collaboration with the client, Megchem, and other contractors through regular site walks, planning sessions and open communication channels.
- Tight Deadlines: Delivered the project within a tight timeframe using schedule-driven execution methods
Conclusion
The project was completed on time, with all additional work incorporated seamlessly. The success was made possible through the collaborative effort between NAES, Megchem, Omnia, and other service providers.
