A large infrastructure investment at the Weir Alrode manufacturing facility in Gauteng has positioned the site as a global centre for the production of the company’s ENDURON Elite banana screens, making it the first in the world dedicated solely to manufacturing the range.

The expansion adds a further 1 600 m² of dedicated production space under roof, equipped with two 63 t gantry cranes operating at a clearance height of 18.5 m, according to Weir integrated supply chain director Alandré van Vuuren. The upgrade was driven by a £53-million contract awarded to Weir by Barrick’s Reko Diq copper/gold project in Pakistan, which includes the supply of fine grinding, separation, and tailings solutions.

The facility boasts two dedicated assembly stations for the high capacity double deck screens – each weighing nearly 50 t, with deck dimensions of up to 4.3 m wide by 8.5 m long.

“This expansion marks a significant boost to South Africa’s manufacturing capacity,” says Van Vuuren. “Facilities with heavy engineering capability and crane clearance at these heights are rare in the country, yet they are essential to support the ambitious manufacturing plans we are rolling out at Alrode.”

The upgraded facility enables the assembly of large screen components such as the subframe, screen body, screen deck and exciters, with completed units reaching heights of over 15 m, Van Vuuren notes.

The new production bays will have capacity to manufacture at least two ENDURON Elite screens a month, while continuing the output of small, medium and large screens across the broader range.

In addition, Weir notes that its expanded facility serves as one of the company’s pilot sites for water-based paint application, with the goal of lowering carbon emissions across both the production process and supply chain.

“The facility is running entirely on renewable energy from a solar power generation system - with the only exception being the variable speed drive used to start up the screens,” says Van Vuuren. He emphasises the broader economic benefits of the expansion, from boosting local procurement and export earnings to creating jobs and developing skills. While most of the ENDURON Elite screens produced at Alrode will be destined for export, nearly all components and materials are sourced locally.

“The expansion opened up around 40 new technical positions at Alrode, including roles in screen assembly, hand-lining and painting,” Van Vuuren explains. “We upskilled some of our current employees as assemblers and fitters - giving them a path into formal trades and supporting career growth from within. At the same time, we are creating opportunities for new entrants in lower-skilled roles, with a focus on developing their potential over time.”