1. MAINTAINING THROUGH INNOVATION
COMPANY PRESENTATION
“Maintaining through Innovation is both an ethos that we instil in the work we deliver, as well as
a promise to our clients regarding their experience of our service.”
As a market leader we pride ourselves on exceptional service delivery.
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2. Background
R & D Contracting was established in 2006, with the vision of servicing the industrial and commercial
sectors of the market by adding a level of service innovation not yet experienced in the South African
market.
Our streamlined operation is very well equipped to manage any maintenance challenge necessary. It’s our
guiding principles surrounding health and safety, quality controls and the high-level supervision through
the entire process of the job that ensures our offering is innovative in every sense. With our management
team boasting over 45 years of experience in the field, we understand what it takes to meet the high
expectations of service delivery in the market.
Management Structure
To streamline an organisation effectively means not only ensuring you’re big enough for the task, yet small
enough to work swiftly through the delivery, more importantly to maintain control in the right areas all the
time through a hands-on approach without losing sight of the job.
At R & D Contracting, we subscribe to a ‘tripod management style’ in all our operations whereby our clients
are able to deal directly with the three company managers – the General Manager, Production Manager
and Sales Manager when required.
The hands-on work ethic and down-to-earth attributes of our Managers themselves is a clear advantage in
instilling the quality control from the top of the company down to all staff involved on-site.
Why R&D?
• We pride ourselves on an innovative style of service delivery, adding a fresh approach to the industrial
and commercial maintenance industry.
• Our hands-on management style, core specialisations and guiding principles ensure the highest
standards in quality, reliability and service.
• Our transparent BEE status is a clear sign of our commitment to both the macro transformation
compliance and on a micro level, our synergy and shared objectives within the management team.
• Our management team boasts a combined 45 years of experience in various specialised fields within
general maintenance contracting.
• We adhere to and apply the most stringent health and safety procedures to ensure the safest possible
working conditions.
• The streamlined and dynamic operation enables a fast turnaround on all aspects of service delivery.
• We only use the highest quality netting systems for easy access to the work face for multiple
technicians.
ABOUT US
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Maintaining through innovation is both an ethos that we install in the work we deliver, as well as a
promise to our clients regarding their experience of our service.
Our mission
As a market leader we pride ourselves on exceptional service offering. We are a dynamic,
streamlined and highly specialised industrial and commercial maintenance company.
Our VALUES
We offer an array of solution driven services based on accurate site analysis, selective product
specification and project oriented methodology ranging from core drilling and mast refurbishment
to specialised access and large-scale industrial rebranding.
Our SOLUTION
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MAINTAINING THROUGH INNOVATION
3. FULL-SERVICE industrial
Maintenance company
SPECIALISED ACCESS AND
NETTING SYSTEMS
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MAINTAINING THROUGH INNOVATION
ROOF REFURBISHMENT AND
SHEETING INSTALLATIONS
INDUSTRIAL COATINGS
ASBESTOS REMOVAL AND
ENCAPSULATION
TURNKEY SPECIALIST
SIGNAGE APPLICATION
CORE DRILLING
CONCRETE AND
SPALLING REPAIR
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4. 0861 072 6333, Remo Torrente 083 255 3415 or David Williams 083 235 9006
Roof Refurbishment and Sheeting Installations
• We excel in providing roof refurbishments, removal and installation of new sheeting, incorporating
new purlins, skylight vents, gutters, down-pipes, handrails and the installation of maintenance
coating.
• Our attention to detail and superior quality of workmanship is a direct result of our teams having had
the very best training.
• Our maintenance procedures comply with the most stringent of quality standards and always adhere
to the strictest safety regulations.
Industrial Coatings
The most important part of any project is surface preparation
• Painting as a rule is perceived as a fairly simple task, but by far the most important part of any project
is surface preparation.
• Preparation techniques are as important as the specification of coating products suited to prevailing
environmental conditions and the creation of a clean abraded surface significantly increases the life
expectancy of the coating system.
• All coatings are applied by our experienced brush hands, full time on-site Supervisors monitor quality
including Health and Safety with regular management site visits ensuring compliance.
• Specifications are graded on a site specific basis taking into consideration the site location,
environmental and exposure conditions.
• Strict adherence to supplier application directives is enforced which allows for long term results and
superior quality.
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Specialised Access and Netting Systems
• We have several highly trained and experienced teams to utilise and safely manage the most
sophisticated and contemporary access systems and equipment.
• Safety remains our primary concern and area of expertise. We only use qualified teams with the most
modern and up to date equipment and therefore always provide you with the appropriate solution
that does not compromise on safety.
• If you are looking for mobile access system, scaffolding, and rope access or netting systems, we have
the expertise and infrastructure to deliver it to you efficiently and effectively.
Concrete Spalling and Repair
• Successful concrete repair is very complicated. Incorrectly treated concrete repairs will rapidly reoccur
and may lead to further problems.
• The quality and longevity of our finished product directly correlates with our initial assessment, where
the appropriate specifications and method statement is applied to the site specific requirements.
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SERVICES
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Asbestos Removal
• Asbestos removal is a hazardous operation and as a result all contractors need to be certified
according to legislation. The contractor’s certification is renewed on an annual basis.
• The act stipulates that all processes are to be monitored and recorded in agreement with its disposal
and handling procedures.
• We make certain that our staff members are medically monitored to ensure that they have not been
exposed to any harmful material. This includes exit medicals on completion of the scope of work.
• After we have successfully completed cleaning operations, depending on conditions, we seal the
asbestos in with a sealer coat to prevent future exposure or we dispose of the asbestos.
• We make it our responsibility to guarantee that a registered disposal company disposes of all
materials collected from operations.
Core Drilling
• Our core drilling division is very versatile and we are able to drill from ground level right up to, and
including, very high applications.
• Our core sampling division is geared to drill a 25mm to 400mm diameter hole down to a depth of
900mm which could be sent for analysis.
• We use only top quality drilling equipment and tools to ensure accuracy and efficiency that delivers the
best service to meet your expectations.
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Turnkey Specialist Signage Application
• This is our area of expertise whether you require re-branding or the removal of existing branding.
• Our innovative approach allows us to turn your signage into a focal point rather than an afterthought.
SERVICES
6. MARKETS
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Mining
R & D provides a wide range of services to the mining industry which includes asbestos removal, sheeting
and cladding scopes as well as other related services such a corrosion protection and the like. These
services are offered using a wide range of techniques which include rope access, netting, scaffolding and
all other conventional access methods.
Petrochemicals
We offer the same services as normal to this industry but are
focused on maintenance scopes through the refinery from
storage vessels through to communications facilities such as
towers. We can offer high specification coating systems
for internal and external linings.
Bridge and Highway
Our main are of focus within this environment
is concrete spalling and corrosion protection
of structures.
Telecommunication
Markets
Pulp and Paper
Our capabilities include corrosion
protection, concrete placement, steel
erection, equipment installation, pipe
fabrication, pipe installation, boiler
installation, and sheeting.
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Commercial
We supply advanced waterproofing systems within this area as well as building maintenance using rope
access which offers a remarkably cheaper alternative when applying coating to elevated structures
Food
We offer hygiene coatings within this industry which have proven anti-
bacterial and anti-microbial properties to ensure the environment within
the food production area is sterile and easily cleaned. We also of
course offer our entire ambit of services within the industry as
well.
Water and Wastewater
Power
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7. CASE STUDIES
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AfriSam
Infrastructure refurbishment project tackles corrosion issues.
The Afrisam ReadyMix plant in Coemore, KwaZulu-Natal, is one of the leading suppliers of superior quality
construction materials and technical solutions. Afrisam, founded as far back as 1934, has established
itself as an organisation committed to delivering value to its customers and seeking to deliver superior
performance on all frontiers.
ABI Devland
New roofing system will vastly improve in-plant lighting and ergonomics.
When the time came for Amalgamated Beverage Industries (ABI) to refurbish the roof of its bottling plant
in Devland, it looked for a business that has earned a reputation in the industry for its expertise in dealing
with unusual roof designs.
Coca-Cola Canners
R&D’s Coca Cola success worth shouting from the roof tops.
The Coca-Cola Canners of SA plant in Wadeville is one of the largest beverage manufacturing plants in
Africa. When R&D Contracting were asked to provide a solution for the maintenance and repair of the
roofing at the plant, it involved challenges on a number of levels. Not only did the company need to take
into consideration both functionality and aesthetics, but furthermore, the project needed to be completed
without impacting the plant’s busy production schedule.
Nissan South Africa
Implementing new, 54 000m² roof requires a pioneering approach.
Nissan South Africa’s assembly plant in Rosslyn, Pretoria, produced over 50 000 vehicles during 2014.
This massive plant, which assembles the NP200 half ton bakkie and NP300 Hardbody one-ton pick-up,
along with various other model Ds and derivatives, plays a key role in the company’s strategy to secure a
significant share of the new vehicle market in Africa and South Africa.
Nissan South Africa
Implementing new, 54 000m² roof requires a pioneering approach.
Nissan South Africa’s assembly plant in Rosslyn, Pretoria, produced over 50 000 vehicles during 2014.
This massive plant, which assembles the NP200 half ton bakkie and NP300 Hardbody one-ton pick-up,
along with various other model Ds and derivatives, plays a key role in the company’s strategy to secure a
significant share of the new vehicle market in Africa and South Africa.
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MAINTAINING THROUGH INNOVATION
Infrastructurerefurbishmentprojecttacklescorrosion
issues.
TheAfrisamReadyMixplantinCoemore,KwaZulu-
Natal,isoneoftheleadingsuppliersofsuperiorquality
constructionmaterialsandtechnicalsolutions.Afrisam,
foundedasfarbackas1934,hasestablisheditselfas
anorganisationcommittedtodeliveringvaluetoits
customersandseekingtodeliversuperiorperformance
onallfrontiers.
Asabusinessrenownedforitstechnicalexpertiseand
abilitytoprovidehighqualityconstructionmaterialsand
excellentservice,itisnosurprisethatwhenthetime
cameforthecompanytorefurbishitsCoemoreplant,it
turnedtoanorganisationequallyrenownedforitsskills
andcustomerservice.
R&DContractingwasbroughtonboardtoassistinthe
refurbishmentofmuchoftheplant’ssteelinfrastructure.
Thisincludedprovidingcorrosionprotectioninthe
relativelyharshcoastalenvironment,wherehumidity,
saltandrustcombinetocreatemajorchallengesfor
businesses.
Theprojectrequiredtherepaintingoftheplant’s
siloes,aswellasitshoppersandconveyers.Inaddition,
structuralsteel,includingwalkwaysandstanchions,
requiredcorrosionprotection.
Project planning
AccordingtoSibusisoDludlu,R&D’sSiteSupervisor,The
projectinitiallydemandedthataqualitycontrolplanbe
developed,followingasiteinspection.Inaddition,he
adds,regularandongoingsiteinspectionsareconducted
notonlybyR&Dandtheclient,butalsobyanaccredited
thirdpartyinspector.
Dludlu,whobeganhiscareerasacasuallabourerwith
thecompany,someeightyearsago,isashiningexample
ofR&DContracting’sfocusonupliftment.
Hesuggeststhathavingworkedhiswayuptheladder
totheseniorrolehenowfulfils,hehasgainedthekind
ofhands-onexperiencethathasenabledhimtosharply
focusonbringinghisskillstobearonthisproject.
“ItisclearthattherefurbishmentoftheCoemoreplant
isnecessarytomaintainitslongevity,whileatthesame
timeboostingAfrisam’scorporateimage.Onceonsite,I
immediatelytooknoteoftheseriouscorrosionissues–
whichhadthepotentialtocreatesafetychallengesifleft
untreated,byimpactingontheinfrastructure’sstructural
integrity–andbeganplanningexactlywhatwouldbe
requiredtosolvetheseproblems.”
“Ourworkatthisplant,whichbeganinDecember2014
andwillconcludeshortly,hasencompassedthreeofthe
ReadyMixsilos,aswellasthescaleplatformandloading
bay.Inaddition,wehavedealtwiththehoppersandfour
conveyers,aswellasstairwells,stanchionsandrelated
infrastructure.”
Obviously,hesays,sincethisprojectinvolvespainting
corrosionresistantcoatingsontothesteel,theonemajor
challengehisteamfacedwasthatoftheweather,soit
wasinevitablethatsomedelayswerecausedbyrain.
Harsh environment
AccordingtoDavidWilliams,ManagingMember
andTechnicalSalesDirectoratR&DContracting,the
environmentinwhichtheplantexistsisanaggressive
one.Notonlyaretherethetypicalchallengescoastal
buildingshavetodealwith,includingsaltcorrosionand
humidity,butthereisalsothegenerallytoughnatureofa
manufacturingenvironment.Inaddition,beingacement
plant,thereisalsoaninordinateamountofdustthathas
tobecontendedwith.
“Obviously,thesaltisoneofthekeyreasonsforthe
corrosioninthefirstplace,butissueslikedustandin
particular,humidity,playabigroleinhowandwhenwe
areabletoactuallypaintthesurfaces,andthusalsoin
thechoiceofcoatingused,”hesays.
Forthisreason,heexplains,itwasnecessarytoutilisea
three-coatindustrialcoatingsystem,asopposedtothe
usualtwo-coatsystem.
“Generally,weliketoutiliseanepoxypolyurethane
coatingsystem,asepoxyprimersneedtobecorrosion
inhibiting.Inthisinstance,wemadeuseofSigmacover
630,atwocomponent,surface-tolerant,highbuild
polyaminecuredepoxyprimercoating,whichisasurface
tolerantepoxy.
“Thethree-coatsystemisspecifiedforcoastal
environmentsandinvolvesutilisingtwocoatswhich
ofthechosenfinish,whichareappliedincontrasting
colours.So,forexample,theintermediatecoatmaybe
red,whilethetopcoatispaintedingrey–thismakesit
easytoseewhetheranyareashavebeenmissedonce
thetopcoathasbeenapplied.
WilliamssaysthatfortheAfrisamproject,R&D
ContractingmadeuseofSigmadur550,atwo
component,aliphaticacrylicpolyurethanefinish,which
offersexcellentresistancetoatmosphericexposure
conditionsandisalsoresistanttosplashesfrommineral
andvegetableoils,paraffinandpetroleumproductsand
evenmildchemicals.
“Inadditiontothis,wealsoappliedwhatisreferredtoas
astripecoat,whichineffectisanadditionallayerpainted
overbolts,edges,joinsandhard-to-reachplaces.These
aretheareasthataremostpronetocorrosion,sothis
stripecoatsimplyprovidesanaddedlayerofprotection.”
AfriSam
CASE STUDIES: AfriSam
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9. R&D Contracting installs state-
of-the-art roof for ABI Devland
New roofing system will vastly improve in-plant
lighting and ergonomics.
When the time came for Amalgamated Beverage
Industries (ABI) to refurbish the roof of its bottling
plant in Devland, it looked for a business that has
earned a reputation in the industry for its expertise
in dealing with unusual roof designs. Since the ABI
plant had been built using a very specific ‘origami
style’ roof, a contractor with both this specific
proficiency and an extensive track record in the
commercial and industrial maintenance sector was
required. Based on previous experiences with the
organisation, ABI turned to R&D Contracting to solve
its roofing challenges.
The ABI bottling plant in Devland is a world-class
manufacturing site, which has been producing cool
drinks for the South African market for decades.
However, as with any older facility, the plant’s roof
was reaching the end of its natural lifespan, having
become victim to corrosion, caused by the harsh
vagaries of South African weather. The engineers
who originally built it adopted an ‘origami style’ for
the roof, which utilises very specifically folded steel
that is designed to be self-supporting.
When it came time to replace the roof, says David
Williams, Managing Member and Technical Sales
Director at R&D Contracting, retaining the origami
style was not cost-effective, as although it is
self-supporting, it utilises large volumes of steel.
“Instead, we decided to base the design of the new
roof on a previous project we had completed for ABI
at its Wadeville Coca Cola canning plant,” he says.
Williams explains that the project currently sees
R&D removing around six tons of steel from the roof
every week. This is being replaced by a far lighter
zinc aluminium composite – known as zinc alum –
that is just 0.55mm thick. He states that on average,
the company is installing between 12 and 18 metres
of the new roofing per day.
The galvanised support beams are specially designed
for the project, and are certified by engineers, prior
to implementation, he adds. Williams also points
out that R&D is using sisalation underneath the zinc
alum roofing for the purposes of insulation. This is
also far thinner than the previous insulation used,
but thanks to a reflective coating on the outside, is
just as effective at keeping the factory cool.
“The sisalation is a key innovation here, as it
improves vastly on the old roof, which utilised
sponge, fitted between double steel, for insulation
purposes. Sponge works fine in a new roof, but as
the roof ages, it becomes easier for this sponge to
get wet. I can tell you that vast tracts of wet sponge
add an enormous additional weight load onto the
roof. Fortunately, this is all negated now by the far
lighter zinc alum roofing and the sisaltion we are
using instead.”
Intense preparation
Williams explains that the project is expected to
take approximately 10 months from site set-up
to conclusion. This, he adds, does not include
the additional time required for preparation and
fabrication prior to starting.
The preparation included ensuring that the zinc
alum roof sheets were rolled to the correct size, that
the supporting beams were properly prepared and
certified, and that everything was delivered to the
site on schedule.
“In addition, there were aspects like health checks
and safety lectures for the workers, ensuring that all
the necessary tools are available on site and making
sure that the site manager has access to an office
with Internet connectivity, so he can stay in touch
with the head office, so any potential challenges can
quickly be dealt with.”
“Another feature of this project is that R&D is
focused on improving skills. This means that we
will bring in three or four new employees to gain
experience here, over the course of the entire
project. By allowing them to learn on the job, they
are able to gain valuable experience that will stand
them in good stead as they continue their career,”
says Williams.
This high level of preparation is vital, continues
Williams, because ABI needed the plant to remain
fully functional during the re-roofing project.
The nature of the plant is such that it would not
be cost effective to ABI to shut it down for any
extended period, which is yet another reason why
the company turned to R&D in the first place –
the company has a reputation for being able to
undertake projects like this without impacting on the
work done within the facility.
He points out that the intense preparation
beforehand has so far meant that the project
has remained on track and, when the new roof
is fully installed, it will be both safer and more
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CASE STUDIES: ABI Devland
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MAINTAINING THROUGH INNOVATION
ergonomically friendly than the one it has replaced,
meaning it should provide effective protection from
the elements for several decades at least.
Better light, more ergonomically
sound
Johny Kruger, Site Manager at ABI Devland, points
out that the ergonomics of the new roof can be
found in how effectively it improves the natural light
coming into the plant.
“The old roof had been designed with raised
segments, which in turn had glass fibre sheeting on
the sides. This was supposed to allow light in, but it
is very old technology and was probably not really
ideal even when it was implemented – let alone
when one considers how little light was coming in
after decades of weathering,” he says.
Kruger indicates that in order to increase the natural
light coming in, R&D utilised polycarbonate sheeting
to allow sunlight into the building. He says that
one in every five roofing sheets was made of this
polycarbonate material, which diffuses the light and
ensures that there are no bright pinpoints of light
at certain times of the day. These, after all, can be
blinding and thus create a safety hazard.
“We are utilising a colour known as Opal White,
which offered the best diffusion of light when we
tested different colour sheets. Even though only 20%
of the roof is composed of these sheets, we expect it
to increase the amount of available light entering the
building from under 400 lux to upwards of 1300 lux.”
This, continues Kruger, not only improves working
conditions within the plant, but also reduces ABI’s
electricity costs. In fact, he says, R&D estimates
that within a decade years, the electricity savings
alone will enable ABI to recoup the cost of the entire
roofing project.
“Safety laws around lighting inside a plant of this
nature are quite strict and as I understand it, the
minimum lux that is acceptable is around 500 lux.
With the new roof, the plant achieves over 1 000
lux, even on cloudy days – and this is from natural
light alone, it doesn’t take into account the electrical
lighting that is also present.”
The other important benefit of this sheeting is that
it improves the ergonomics within the plant as well.
For example, says Kruger, better lighting helps to
keep employees more awake and thus less likely to
make errors; it reduces eye strain; and it generally
improves the working conditions for employees.
This has additional tangible benefits, since happier
employees are more productive employees.
“In addition, we will also be installing extractor fans
in the roof, which will help to remove fumes from
the from the exhausts of the ever-present forklifts.
This will also help to improve the general wellbeing
of employees in the plant and the overall working
environment,” states Kruger.
Safety is critical
According to Williams, the company has
approximately 15 staff on site at any given time,
which makes the issue of safety, health and
environment (SHE) a critical one.“SHE is very
important to R&D and ABI, and is a vital component
of a project of this nature. Quite aside from the
obviously crucial safety measures taken while
working on the roof itself, we also take the health
and welfare of employees a step further. There are
regular medical check-ups scheduled for all our
employees. These focus specifically on hearing-,
eyesight- and respiratory-related matters,
He adds that after each employee has undergone
their first medical check-up, this is used as a baseline
against which all subsequent tests can be measured
and compared, in order to check for deviations from
the norm.
“As for our employees on site at ABI, the company
also takes it upon itself to conduct regular ‘toolbox
talks’ with employees. These meetings revolve
around site-specific SHE issues and involve basic
explanations of what to do and what not to do,” says
Williams.
Furthermore, he indicates that R&D also conducts
a site-specific risk assessment every week at the
facility. Workers operating on the roof are also fitted
with redundant safety lines – in fact everything
up there is double secured – to ensure that risk
is minimised, both for R&D’s workers and the ABI
employees inside the plant.
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CASE STUDIES: ABI Devland
10. “It is particularly important from an ABI perspective to know that its plant can continue functioning normally
and ensure that the integrity of its bottling lines is not compromised, even as R&D goes about replacing
the roofing. To this end, safety nets that can hold up to 400kg per square metre are placed underneath the
working environment. These provide additional protection for our staff – should they accidentally slip and
fall – and also added protection for employees in the factory from any accidents occurring that involve large
items of equipment. This net is an additional safety measure, above and beyond the double-securing that is
undertaken on all our equipment.”
“It is always satisfying to be involved in a project of this nature. Not only are we able to radically improve
ergonomic conditions within the plant, we are able to bring our technical skills and expertise to bear in a way
that will provide ABI with a new roof that will withstand the elements for decades to come. Furthermore,
a project like this enables R&D to further hone both its skills set and its development of better roofing
techniques. At the end of the day, R&D Contracting is a solutions-oriented company and we are always eager
to find new and better ways to do things,” concludes Williams.
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CASE STUDIES: ABI Devland
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CASE STUDIES: Coca-cola canners
R&D’s Coca Cola success worth shouting from the roof tops
The Coca-Cola Canners of SA plant in Wadeville is one of the largest beverage manufacturing plants in
Africa. When R&D Contracting were asked to provide a solution for the maintenance and repair of the
roofing at the plant, it involved challenges on a number of levels. Not only did the company need to take
into consideration both functionality and aesthetics, but furthermore, the project needed to be completed
without impacting the plant’s busy production schedule.
To this end, R&D Contracting stuck to its guiding principles surrounding health and safety, quality control
and the high-level supervision through the entire process of the job. The company implemented a safety
netting and mesh system; designed to protect workers and machinery from falling debris, while installing
M16 Chemical anchors which was doubled up for reduncency and load tested before installing the safety
net cables. R&D’s innovative thinking, experience and attention to detail thus ensured the project was
completed with minimal impact to the plant.
A key consideration for the venture was that it required the redesigning of the old roof system. This
needed to be done in such a way as to ensure that the technology being implemented could match the
existing construction, without compromising structural or functional integrity. Additionally, the new design
was expected to improve internal ambience, lighting and worker comfort, while also being a suitable
design to fit with the client’s high public profile.
R&D adopted a sectional approach to the project, installing the safety netting and mesh over one section
of the plant at a time, while replacing that particular segment of the roof. The company even went as far as
to custom design and build a hoist unit to transport new and salvaged material from height. Over the past
12 months, R&D has also installed steel works, PVC wire, Alububble and sheeting, while spacers have been
fitted to raise the rafters to accommodate existing steelworks.
There is little doubt of the project’s success, with internal Lumen readings having improved by 500%.
Moreover, the new roof has created a sleeker and more modern appearance to the structure, without
removal or damage to any supporting members or change in the water flow pattern. R&D’s use of
modern materials has also resulted in an almost 25% reduction in weight of the roofing system. Crucially,
throughout the project, factory production remained unaffected by any execution of the scope of works.
From start to finish, R&D delivered the highest levels in quality, reliability and service, thereby ensuring
project effectiveness and complete client peace of mind.
coca-cola canners
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CASE STUDIES: Nissan South Africa
Implementing new, 54 000m² roof
requires a pioneering approach.
Nissan South Africa’s assembly plant in Rosslyn,
Pretoria, produced over 50 000 vehicles during
2014. This massive plant, which assembles the
NP200 half ton bakkie and NP300 Hardbody one-
ton pick-up, along with various other model Ds
and derivatives, plays a key role in the company’s
strategy to secure a significant share of the new
vehicle market in Africa and South Africa.
The plant itself has been in operation since the
1960s, meaning that certain parts of the facilities
were reaching their end-of-life, notably the plant’s
roof. In particular, water leaks were becoming more
and more apparent, due to wear and tear, and it
was decided that the time had come to replace the
structure.
Nissan SA decided that a contractor with a robust
reputation in the industry, strong proficiencies
in the field of roofing work and an extensive
track record in the commercial and industrial
maintenance sector was required. It was thus
no surprise that the organisation turned to R&D
Contracting to solve its roofing challenges.
Massive project
According to R&D Contracting’s Site Manager,
Nikki van den Berg, the initial planning stage of
the project was begun in October 2014. This, he
explains, encompassed order planning, tender
documents, equipment orders and initial site
planning. This was followed by site establishment,
moving all the necessary equipment on site and
ensuring that all employees involved in the project
were trained to requirements.
“Only once all this was done could the actual site
preparation begin. This involved the cleaning of
gutters and surfaces, prior to beginning the actual
installation. In projects of this size, is inevitable that
there is a long preamble before the actual work
gets underway. After all, being prepared is critical
to a project’s success,” he says.
Van den Berg adds that the total scope of the
project is huge, with the roof area covering some
54 000m². The company has already completed
some 19 000m² of the roofing, and according
to the current schedule, the project should be
completed in September 2015. Once completed,
he says, the installed roof will come with a 25-year
life expectancy, which was something specifically
requested by the client.
“In addition, R&D is also contracted to install the
downpipes and launders that will transport water
from the roof gutters away from the building.”
“These downpipes and launders have created the
one real challenge we have faced on this project –
namely, the need to install these on weekends only.
As we are working inside the assembly plant with
these downpipes, we are only allowed to operate
during periods when the plant is shut down. This is
purely for safety reasons,” he says.
Specialist roofing system
Van den Berg states that R&D was informed that
the original roof had been installed as far back as
1967, making it very old and clearly in desperate
need of refurbishment. With millions of rands
worth of specialised equipment within the plant,
water leaking through the roof and its potential to
cause damage had become a huge challenge.
“In order to overcome this challenge, we chose to
implement a specialised system that is designed to
negate the possibility of water leakage, particularly
around the screws which are used to hold the roof
in place.”
“By fitting a new roof using the AshGrid spacer
system from Ash and Lacy, we were able to avoid
such challenges, as this system utilises a clip-lock
operation that allows the roof sheets to simply be
clipped into the spacers already placed on top of
the original roof,” he states.
Furthermore, he explains, since the spacer brackets
are fitted to the original roof with 25mm tech
screws through the existing roof purlins, and the
new roof sheeting is simply clipped onto these
brackets, the existing roof is completely concealed
and there is no danger of any leakage through the
holes made for the tack screws.
“The roofing consisted of Pro Lok 700 roof sheets,
made of 0.8mm Chromadek in Dove Grey colour,
something that was specified by the client. Not only
does this system prevent leaks, it is also designed
to withstand winds of up to 280 km/h. This is more
than 100 km/h faster than most other roof sheeting
systems.”
According to van den Berg, the roof at Nissan SA’s
vehicle assembly plant is huge, spanning some
300m by 150m, creating a massive area of work.
To put it into perspective, he says, the company
anticipates utilising some 30 000 AshGrid spacer
bars to complete the project.
Unique innovations
To transport the heavy roof sheets and spacer
system to the roof, adds van den Berg, R&D became
one of the first organisations in the country to make
use of a lifting system imported from Germany.
This is, in effect, an industrial-type lift mechanism
that can carry up to 250kg, and lifts the heavy roof
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sheets up the side of the building and on to the
roof.
“This was far from the only innovation we brought
in at this project. In truth, we really lived up to our
company motto, which is: ‘maintaining through
innovation’, as on this project, we had to be
particularly innovative, if we were to complete it on
schedule.”
“Firstly, the sheer size of the roof meant that
moving the heavy roof sheets from one end of the
roof to the other – a distance of 300m – would be
extremely time consuming and labour intensive.
Therefore, we invented a solution that would solve
this challenge, in the form of a trolley system that
we installed temporarily across the existing roof.”
He points out that the system required just a simple
track laid across the roof from one end to the other,
upon which a dolly could be moved. This dolly
allows workers to lay up to 10 sheets on it at a time,
horizontally, which can then be moved across the
roof by just a couple of workers.
“This is indicative of our innovative spirit at R&D –
this simple system allows us to do in a single day
what would otherwise have taken us a week of
intense effort. It is just the latest example of our
ongoing dedication to innovation.”
Of course, adds van den Berg, this was not the
only example of innovative thinking the company
applied at the Nissan plant. He explains that
another challenge was discovered during the
installation of the roofing sheets – the existing air
vents on the roof had a tendency to act as water
traps during a downpour, creating pools of water
that had the potential to create additional leakage
problems.
“To overcome this, we designed what we call
‘backflashing’, which was created on the fly from
offcuts of roof sheeting. By placing it at a 90 degree
angle to the rest of the roof, we were able to create
conduits that channel the water flowing down
behind the vents off to the sides, where it can easily
run off into the existing gutters,” he states.
Safety and social issues
“With 30 employees on site, safety is obviously
a core concern for R&D. Our employees at the
assembly plant are divided into teams: an AshGrid
team, a sheeting team and an additional team of
five that are the ‘ground’ team. This group does
the other jobs – such as cleaning and equipment
maintenance – required to keep the project running
smoothly.”
Naturally, he says, all employees on site are trained
to use their harnesses properly. This is vitally
important, as when people are working at heights,
harness safety is critical. In addition, continues van
den Berg, R&D has a qualified Roper Level One who
checks that the workers’ harnesses are attached
properly.
“Additionally, there are special harnesses used by
employees that have to work on or near the edges
of the roof, notably when working on the side
cladding.”
The single biggest safety concern on a project of
this nature, suggests van den Berg, is also the one
over which the company has no control, namely
rain. He points out that when the roof is wet, it
becomes dangerous and creates a situation where
it is easy to slip and fall.
“Therefore, the only solution is to suspend work
completely while it is raining, which can cause
delays to a project. Fortunately, we haven’t lost
more than a handful of days so far to the weather,”
he adds.
Asked about the crew working on the project, he
explains that the team were hired according to
R&D’s standing policy of uplifting people in the area
in which the project takes place. In this instance,
most of the employees were sourced locally, from
the nearby townships of Soshanguve and Ga-
Rankuwa.
Van den Berg describes how R&D brought these
workers in, trained them up and ensured that they
were certified to do the job required, by providing
the skills training necessary to implement the
project, prior to launch.
“All of our employees are now certified. This means
that even once the project is complete, they are left
with a sustainable skill that can help them obtain
work in future. In fact, as we do projects all over
the country, we also point out to them that if they
are willing to relocate, we can retain them for other
projects too. For example, we had one person who
began with us four years ago as a casual labourer
and is now one of our site managers, an indication
of the long-term opportunities we also create for
employees.”
“Ultimately, a project of this nature is vast and
intensive, and requires plenty of innovation.
In other words, it is an ideal project for R&D
Contracting, as it enables us to bring our technical
skills and expertise to bear in a way that will
provide Nissan SA with a new roof that will
withstand the elements for decades to come.
Perhaps the most enjoyable aspect of this particular
project is the manner in which it has driven us
to find new ways of operating and allowed us to
demonstrate our ability to be truly innovative,”
concludes van den Berg.
MAINTAINING THROUGH INNOVATION
12. Effective service delivery in this industry could not be achieved if
the prescribed and stringent health and safety regulations are not
adhered to.
We at R & D Contracting make it our business to ensure that safety is at the core of our service delivery.
The continuous training that our staff go through, relating to health and safety has a tremendous positive
effect on the levels of service delivery achieved. Our various specialised applications demand from all staff
and management a cellular comprehension of safety and effective implementation of safe practices at all
times. To this end, we are proud to say that we conform to the Occupational Health and Safety Act (Act 85
of 1993).
• A very comprehensive site safety plan is drawn up at the beginning of every job undertaken.
• A detailed copy of this plan may be perused at your request.
• Continuous improvement in health and safety
• Risk reduction and monitoring
• Establish safety committees
• The company will ensure employees are provided with such information, instruction, training and
supervision as is necessary to secure the health and safety at work of all employees.
HEALTH & SAFETY
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CERTIFICATION
In an industry that demands stringent compliancy across all
aspects of service delivery, it is imperative to adhere to all the
necessary certifications.
• Ashgrid Approved Installer Certificate
• Workers Compensation Certificate
• Standard Terms and Conditions of Sale
• BEE Certificate
• Asbestos Registration Certificate
• Tax Clearance Certificate
• Sasol Safety Compliance Certificate
2014006506
CALL CENTER NO: 0860 105 350
REG NO
: 990000351751
FAX NO
: 0123456789
ISSUE DATE
: 2015-04-24
CERTIFICATE NO : 2014006506
R & D CONTRACTING & CONSULTING
PO BOX 237
BUCCLEUCH
LETTER OF GOOD STANDING
COMPENSATION FOR OCCUPATIONAL INJURIES AND DISEASES ACT 130 of 1993 (AS
AMENDED).
With reference to sections 80, 82, 86 and 89 of Compensation for Occupational Injuries and Diseases Act
130 of 1993 (As amended), I hereby certify that:
R & D CONTRACTING & CONSULTING
has complied with the requirement of the above Act and is at present in good standing with the
Compensation Fund.
Nature of business :GENERAL CONSTRUCTION
Expiry date :2016-04-30
IMPORTANT NOTICE:
Any fraudulently obtained Letter of Good Standing shall constitute a criminal offence.
The Compensation Commissioner shall institute criminal proceedings against any perpetrators who
unlawfully alter or deface this letter with intend to defraud or misrepresent facts contained therein.
PLEASE, use the Below link (Website Address) to check if the Letter of Good Standing is valid:
https://cfonline.labour.gov.za/VerifyLOGS
Yours faithfully
CO
MPENSATION CO
MMISSION
ER
W.As. 48
Compensation
House, Cnr Hamilton and Soutpansberg Road, PO
Box 955, Pretoria, 0001 Fax:(012)357-1817 Website:http://www.labour.gov.za
13. R&D Cuts to the core
December, 2014
Core drilling is highly specialized and is used when a job calls for the drilling of circular holes in reinforced
concrete, precast concrete, asphalt, brick, and other structural materials.
Our highly trained technicians can drill through almost any high density material under many different
conditions and our unique access systems allow us to core drill where most other contractors cannot.
Our core drilling equipment caters for;
• Holes from 25mm to 400mm in width and 1200mm deep
• Drilling up to a 45 degree angle
• Compression testing of cores can be facilitated through the Concrete Institute of South Africa
R & D Contracting is one of South Africa’s leading core drilling specialists providing an expert service to the
construction industry. David Williams, Managing Member boasts “We have successfully completed projects
in mining and construction, to food preparation and medical facilities”. Williams went onto say, “Other
industries serviced include electrical, plumbing, heating, demolition, construction and many more”.
R&D = Multiple Skills X Multiple Projects
September, 2014
We often highlight a specific project based on the particular skill set in an isolated field of the industrial
maintenance sector. However, our recent projects each delivered such successful results and highlighted
a key aspect of R&D’s service, namely, our multi-skilled operational expertise that it made it impossible to
only pick one signed-off project.
In the past month we successfully signed-off on the painting of an operational cement plant, asbestos
sheeting removal at a school, a factory roof sheeting replacement project and the removal of asbestos
pipes at a water treatment facility. In addition we also launched Phase 2 of the roof design and
replacement for Coca Cola Canners and the replacement of a 54 000m² over-roofing project at Nissan
Rosslyn.
This list of projects is impressive enough when spaced over a year’s operations let alone a month. It
requires meticulous planning, accommodation of clients’ requirements and internal policies as well as the
identification and management of a variety of risks and challenges. Any compromise in the co-ordination,
planning, materials acquisition or staff complement on any of these projects would have resulted in serious
consequences for all parties concerned.
NEWS
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MAINTAINING THROUGH INNOVATION
Thanks to the excellent management skills, training and flexible command structure inherent in R&D
Contracting we managed to provide our clients with top level service. On each of these projects we
exceeded the client’s expectations by meeting commencement schedules, submitting compliant safety
files, delivering on time and in budget and achieving 100% safety records.
The scheduled completion of these multiple projects, spanning an extensive range of disciplines again
highlights the dynamic operational expertise you can expect from R&D Contracting. Did we mention that
these massive projects were undertaken simultaneously – all in one month?
R&D Cuts to the core
December, 2014
Core drilling is highly specialized and is used when a job calls for the drilling of circular holes in reinforced
concrete, precast concrete, asphalt, brick, and other structural materials.
Our highly trained technicians can drill through almost any high density material under many different
conditions and our unique access systems allow us to core drill where most other contractors cannot.
Our core drilling equipment caters for;
• Holes from 25mm to 400mm in width and 1200mm deep
• Drilling up to a 45 degree angle
• Compression testing of cores can be facilitated through the Concrete Institute of South Africa
R & D Contracting is one of South Africa’s leading core drilling specialists providing an expert service to the
construction industry. David Williams, Managing Member boasts “We have successfully completed projects
in mining and construction, to food preparation and medical facilities”. Williams went onto say, “Other
industries serviced include electrical, plumbing, heating, demolition, construction and many more”.
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14. PRODUCTION:
Email: remo@r-d.co.za
Cell: 083 255 3415
Tel: 0861 072 633
Fax: 086 694 4369
P.O.Box 237
Buccleuch
2066
23 Margaret Avenue
Buccleuch, Johannesburg
8 Minorca Avenue
Pinetown, Durban
GPS co-ordinates:
S 26°03’11.2”, E 28°06’30.7”
Sales:
Email: david@r-d.co.za
Cell: 083 235 9006
Tel: 0861 072 633
Fax: 086 694 4369
CONTACT US
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MAINTAINING THROUGH INNOVATION
