Planning for Eskom’s second new coal-fired power station, Kusile, started in 2007 and construction work began on the 5 200-hectare site, 40km outside Witbank in Mpumalanga, in 2008. While the primary contract is for the boilers and turbines, the main civil engineering contract was awarded to Stefanutti Stocks, Group 5, Basil Read and WBHO Construction who joined forces to form Kusile Civil Works Joint Venture.
The JV specified a wide range of Sika’s versatile products in Phase 1 of the project which involved construction of the power station buildings, administration buildings, a high voltage yard and roads.
Seven Sika products have been used for waterproofing various structures, including: SikaTop Seal-107 ZA, a polymer-modified cementitious waterproofing slurry; Sikalastic-150, a fibre-reinforced, cement-based coating, and various products in the Sikalastic-600 series with their proven moisture-triggered chemistry (MTC) technology and a performance track record of over twenty years. Designed for roofing, they are all cold-applied, seamless, highly elastic, polyurethane base coats or top coats.
Sikagard-720 EpoCem, an epoxy-modified, cementitious, thixotropic micro mortar, has been used on vertical and horizontal concrete surfaces of the structures for levelling and surface sealing.
Sikagard-63 N, a solvent-free epoxy resin coating providing excellent chemical and mechanical resistance, has been used as an anti-corrosion application and products in the Sikalastic-800 series have also been used as anti-corrosion coatings.
Sika’s MonoTop series of polymer-modified mortar products is being used for concrete repairs on the project. Sika MonoTop-610, a bonding and anti-corrosion reinforcement primer, Sika MonoTop-632, a self-levelling repair mortar, and Sika MonoTop-612, Sika MonoTop-615 HB, and Sika MonoTop-620 are all being used for specific applications.
Other concrete repair products in use include Sika Rep and Sika Rep LW as well as SikaTop Armatec 110 EpoCem which is a cement-based epoxy-modified, anti-corrosion agent providing excellent adhesion and a high degree of mechanical strength.
Specialised grouting products from Sika are also being used and the Sika Anchorfix range of products is being used for structural repairs. Sika’s internationally renowned CarboDur Plate, pultruded carbon fibre-reinforced polymer (CFRP) laminates designed for strengthening concrete and masonry structures, are playing a key role in securing the structure.
In addition, a number of Sika’s internationally approved flooring products have been supplied to ensure the power station’s horizontal surfaces meet stringent specifications. These products include Sikafloor-261 ZA (SS2) and Sikafloor-20N and -21N PurCem screeding products.
After Medupi Power Station in Limpopo, Kusile will be Eskom’s second most advanced coal-fired power plant. Consisting of six units, each with a nominal installed capacity of 800MW, Kusile will generate a total of 4 800MW. The first unit is due to come into operation in 2014 and the further units will be commissioned over eight-month intervals, with the last unit due to be operational by 2018.