Having undertaken various infrastructure and process upgrades to increase production capacity, engineering company Weir is on track to reach 1 000 t/y of casting capacity at its Heavy Bay Foundry (HBF), in Gqeberha, this year.

Weir is positioning the HBF operations as a key global manufacturing hub within the group’s supply network, producing high-performance cast components for Weir’s pumps, screens and crushers.

The latest additions to the plant include casting pit extensions, melt shop upgrades and the integration of an advanced pattern development system.

With the new pattern development system, Weir can serve a wider range of global markets, including in the Middle East and Central Asia, where the company is seeing rising demand from the mining sector.

The company installed new 4-t and 6-t induction furnaces at the plant, which were commissioned in early 2026. Additionally, the furnaces are complemented by new heat-treatment furnaces, fettling booths, automated grinders and paint booths.

“Each of these targeted initiatives is aimed at removing bottlenecks and enabling higher production throughput,” says Weir HBF plant operations manager Coenie de Jager.

The foundry’s installed capacity for heavy castings – exceeding 500 kg – has risen to 600 t/y, with Weir targeting 1 000 t/y, following additional process optimisation efforts.

Weir HBF is among the few foundries in South Africa capable of producing large castings of up to 4 m × 4 m.

Another milestone in HBF’s growth journey has been the acquisition of Xmeco Heavy Engineering, which is a fully equipped machining facility that adds to Weir’s capabilities to deliver a comprehensive end-to-end manufacturing solution.

For example, following the acquisition for Xmeco, HBF can now machine components weighing up to 13 t, with hardness levels of between 650 Brinell and 750 Brinell – a capacity matched by very few facilities worldwide.

“By consolidating our operations into a vertically integrated manufacturing facility, we have gained full visibility and control over every stage of production. This allows us to strengthen delivery reliability and minimise dependence on external suppliers,” Weir integrated supply chain director Alandré van Vuuren states.

He adds that, with HBF now having in-house capabilities, spanning design, research and development, foundry and machining, the company is driving higher levels of precision, product quality and efficiency.

Moreover, with the melt shop offering more efficient melting cycles following the upgrades, Weir has managed to lower the HBF operation’s electricity requirements per ton.

“As we expand our capacity, we are also improving our environmental performance. We are sourcing renewable energy from regional solar and wind farms, which is wheeled through the national grid and the Nelson Mandela Bay network,” De Jager explains.

Weir aims to procure one-third of HBF’s total yearly electricity consumption from renewable-energy sources by mid-2026 and is targeting 80% within the next five years.

Sustainability and circular economy remain key focus elements for Weir, with the company also reclaiming and re-melting worn components from customers.

On the socioeconomic front, the HBF’s production capacity upgrades have created new local employment, skills development and small business supplier opportunities.

De Jager says HBF collaborates with the Nelson Mandela Bay Business Chamber to identify candidates for training and development programmes that uplift the local workforce. Van Vuuren adds that the global Weir Group has a strong talent development and succession focus, which includes regular opportunities for employees to learn from other Weir sites.

“This initiative benefits local employees by providing opportunities to learn best practices from a global network of factories,” Van Vuuren says.

Additionally, Weir often identifies local businesses and develops them as vendors of specialised services for HBF, which enhances the regional manufacturing ecosystem.

De Jager concludes that HBF is, ultimately, helping to sharpen Weir’s competitive edge by allowing for faster turnaround times, “exceptional and consistent quality”, as well as a dependable supply chain, which aligns with Weir’s broader global strategy to ensure on-time delivery performance and superior customer service.