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At Genrec, we know that a company’s products
are a reflection of the team that creates them.
Our people are the underlying force driving the
delivery of your vision with embedded values to
deliver beyond our customers’ expectations.
Working with honesty, accountability and care, our
collective team is committed to fabricating innovative
steel solutions to meet your specific needs. Genrec’s
capabilities extend from Total Project Management;
Design and Detailing; Planning and Programming;
Light, Medium and Heavy Structural Fabrication to Site
Logistics and Erection.
The company also retains the in-house capacity and
competency to conduct precision Heavy Machining. At
Genrec, our team is happy to discuss the value we can
add to your projects with our resources, be that a single
capability or the entire project offering.
Mission, Vision and ValuesMISSION
Empowering, motivating and leading our people to
supply steel solutions and fabricate quality steel work
at the lowest cost while adhering to safety standards
and exceeding stakeholders expectations.
VISION
To be the preferred supplier of world class fabricated
steel solutions.
VALUES
• Care
• Honesty / Integrity
• Respect
• Accountability
• Commitment
• Ubuntu (Humanity to others)
ABOUT THE COMPANY
Genrec, a BEE level 2 Company, as a division of leading
engineering and contracts group Murray & Roberts,
offers a unique combination of engineering disciplines
in its field of operation. A comprehensive range of
services is provided from structural steel fabrication
and erection, to heavy fabrication and machining.
Genrec covers the full spectrum of engineering,
structural detailing, procurement, fabrication and
construction.
As a member of the Murray & Roberts Group of
companies, Genrec can offer complete turnkey
solutions.
Genrec’s combination of manufacturing, construction
and site management services, provide clients with a
one-stop service.
Situated in Wadeville, just outside of Johannesburg,
South Africa, Genrec’s facility extends over a site area
of 12,6ha, with 55,000m2 undercover workshops and
19,500m2 of open areas under crane. Genrec has the
latest systems, CNC equipment, welding processes as
well as high volume blasting and painting resources.
HISTORY
From humble beginnings in 1953 in a small office, in the
heart of the Free State gold fields of South Africa,
Genrec has grown into one of the largest engineering
companies in Africa.
From being a one-man business, with its base in
Wadeville providing breakdown and repair services to
gold mines, the business rapidly grew into a vibrant
family business throughout the fifties and sixties.
Genrec started trading as General Erection, and by
1974 with a good track record, Genrec had grown large
enough to list on the Johannesburg Stock Exchange,
under the name of Genrec.
In the same year, Murray & Roberts, a large
engineering and construction Group, decided to
diversify its operations, and acquired 30% of Genrec
shares. In 1988, Murray & Roberts acquired the
controlling share holding and in 1992, Murray &
Roberts acquired 100% equity and delisted the
company.
Genrec has since continued to grow and has specialised
in major projects locally and abroad and continues to be
a major player in the African market.
History
Genrec’s Vision for Health, Safety and the Environmentis “Together to Zero Harm”, in line with Murray &Roberts’s Vision. Genrec’s employees and ManagementTeam are committed to honouring the company’svalues of Honesty, Integrity, Accountability, Care,Respect, Commitment and Ubuntu (Humanity toothers).
We aspire for zero harm in the interest of Health, Safetyand the Environment to our employees, our company,its shareholders, clients and business partners, thenatural and built environment impacted by ouroperations and society at large and Zero Harm to ourEnvironment.
“Together to Zero Harm” is an aspiration that drives ourstrategy for, and response to, the health, safety andenvironment (HSE) challenges faced by GenrecEngineering. Continuous motivation and education ofour employees to take responsibility for themselves,their colleagues and the environment is a key driver forGenrec Engineering and through this we strive toembed HSE values and a safety culture built on theprinciple of Stop. Think. Act.24/7. The social, economicand health dynamics in our South African environmenthave a profound impact on our employees and isreflected in our safety performance.
SHEQ
2008 2009 2010 2011 2012 2013Years
LTIFR last 6 Years
0
1
2
3
4
5
6
7
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Frequency
7,55
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1,690,66 0,39
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YOU! HELP!ARE YOU
SAFE!
YOU’RESAFE!
HOOKUP
DANGER! WELLDONE!
TOGETHERTO ZERO HARM
STOP.THINK. ACT. 24/7
WEAROUR PPE
Quality CertificationQuality is an approach to understanding precisely what customers need and to consistently deliver accurate solutions
within budget. Quality will ensure the effective design of processes that verify customer needs, product life cycle and
the design, production and delivery of the product.
This incorporates measuring all process elements, the analysis of performance and the continual improvement of the
products, services and processes that deliver them to the customer. Genrec’s Quality Certifications, include:
• ISO 9001:2008
• ISO 14001:2004 +Cor1 : 2009
• BS OHSAS 18001:2007
• SANS ISO 3834 Part 3
• API ISP/TS 29001
• BEE, Level 2 Contributor
3D VIEW OF TRESTLE
GENREC DRAWING OFFICE
Genrec Engineering is in a key position, where Genrec
can respond to any structural project requirements
with a dedicated, permanent team of Professionals.
These Engineers and Detailers can achieve maximum
benefit for the client by supplying innovative steel
solutions, cost effectively designed and detailed by
applying the principles of value engineering.
From the commencement of a project, our skills,
people and systems are set up to utilise Genrec’s
performance capabilities to produce optimal solutions.
Genrec Engineering offers a full design and shop
detailing service, utilising state of the art software such
as Tekla, Xsteel, Autocad, Strucad and Strumis, under
our Engineering Team.
SERVICES PROVIDED
Our Engineering Services comprise of:
• Preliminary, Basic Design & Analysis
• Professional Engineer Certification
• Steel Structure Cost Estimates
• Alternative cost saving design concepts
• Construction and Erection Studies
• Cost saving input into client requirements
• Connection Designs to suit fabrication & erection
• Fabrication Drawings
• Site support and management
• Project Management
CapabilitiesEXPENDITURE PROGRAMME
Genrec completed an optimising expansion drive in2010 to increase all aspects at its current facilities inWadeville. This was done to support the building of theMedupi and Kusile Power Stations. The fabrication andworkshop facilities now extend to 74,500m2 undercrane area equipped with the latest systems, CNCequipment, welding processes as well as high volumeblasting and painting equipment. Resources,equipment, training and logistics increase capacity wellabove 2,500 - 4,000 tons per month. All ranges of steelcomplexity can be fabricated within the facility.
One of the key factors of expansion drive has been skillsdevelopment. The training facility providesdevelopment and training of boiler-makers, detailers,computer numerically controlled operators, riggersand inspection personnel. Genrec has trained over 197artisans over the past 3 years. With a drive as extensiveas this, Genrec is well equipped to meet your futureneeds.
CAPABILITIES
Genrec capabilities include but are not limited to:
• Total Project Management• Design, Detailing & Shop Drawings• Planning & Programming• Light, Medium & Heavy Structural Fabrication• Heavy Machining• Blasting, Painting• Trial & Pre-Assembly• Logistics & Transport• Site Services (Workshop / Modifications / Engineering
/ Site Logisitics)• Erection• Steel Track & Trace • QC Control, Inspection Services
Total Project ManagementCAPITAL EXPENDITURE PROGRAMME
Genrec Engineering has empowered and developed its
employees, contributing to the improvement and
upliftment of the Structural Steel Industry, through In-
House Training and Formal School for Draughting,
giving employees both technical education and
practical experience.
Genrec’s core values are to work with Care, Honesty
and Integrity, Respect, Accountability and Commitment
and Ubuntu and is committed to the delivering of quality
products on time, to standard and within budget.
The Genrec Engineering team comprises of the
following disciplines and resource levels:
Engineering Team
Chief EngineerProfessional EngineersTechnical SpecialistsEngineersGraduate Engineers
Detailing Team
Drawing Office ManagerSection LeadersLead Detailers (15 years experience)Senior Detailers (10 years experience)Detailers (5 years experience)Junior DetailersTrainee DetailersTechnical Support Clerks
Technical Registry Team
Consisting of Senior Document Controllers andDocument Controllers
SHOP DETAILING DELIVERABLES
The drawing content and presentation is standardised,
using good quality industry norm practices, which will
be agreed with the client prior to commencement of the
project, creating the opportunity to both share our
capabilities and understand your requirements.
DELIVERABLES INCLUDE:
• Assembly drawings
• 2D single component drawings
• Erection general arrangement drawings with piece
marks and section sizes
• Floor covering General Arrangements
• NC files Cam – for nesting plates and cutting
sections
• Dstv – for nesting plates and cutting sections
• Full-size plate DXF’s (templates) – for manual
cutting of plates
• Struwalker – for location of item in the 3D model
• Fabtrol documentation
• Engineer approved drawings
• Full Size Originals
REPORTS - FABRICATOR & ERECTOR:
• Full 3D modelling progress tracking system
• Assembly lists
• Parts lists
• Material Lists
• Drawing Registers
• Integrated revision control
• Bolts lists
• Procurement lists
• BIM Information
Site ServicesGenrec has experienced site teams capable of carrying
out the following types of site activities:
• Erection of Steel Structures both Heavy and Normal
Structural Steel
• Modifications to Erected steel on site
• Logistics Support and Management in the form of
Electronic Track & Trace, receipt and issue of steel
components and all necessary BIM reporting.
• Site Quality Services including:
- inspection of existing structures
- structural integrity inspection and reporting, and
- connection certification
• Plant and Shutdown Maintenance for Industrial
Plant, Power Station, Mining Structures, etc.,
specialising in compressed program shutdowns
involving steel component replacement,
strengthening and repair. Professional Engineering
inspection of structures as required by the
Occupational Health & Safety Act, 1993 (Act No. 85 of
1993), Construction Regulations Clause 9(4) Annual
structure inspection.
• End of Life Refurbishment of Industrial Steel Plant
and Structures, including corroded and damaged
steel replacement and repair.
• Hire of high capacity craneage to selected
construction sites.
Structural Steel ManufactureGenrec was awarded Overall Winner at the SAISC SteelAwards in 2013 for excellence in the use of structuralsteel in the Main Frame and Boiler Grid Support at theMedupi Power Station. Details of the Structural SteelManufacturing facility are as follows:
FACILITY
Structural Bays:5 x 175m long, 19m wide (9m under crane hook)
Preparation Bays:5 x 125m long, 19m wide (9m under crane hook)
Paint Bays:5 x 72m long, 19m wide (7m under crane hook)
CRANEAGE
Structural Bays / Preparation Bays / Paint Bays:• 5 x 20 ton overhead gantry cranes• 17 x 10 ton overhead gantry cranes• 2 x 10 ton semi portal cranes • 17 x 5 ton overhead gantry cranes• 6 x 5 ton semi portal cranes• 12 x 2 ton semi portal cranes
EQUIPMENT
Plate processing:• 3 x Plate stripping machines (Oxy fuel)• 2 x Plate profile CNC machines (Oxy fuel and Plasma)• 2 x Plate profile drill and punch CNC machines (Oxy
fuel and Plasma)
Angle and flat section processing:• 2 x Angle and flat section profile CNC lines
I beam/section processing lines:• 2 x Beam drill lines (CNC)• 4 x Band saws, miter and straight (CNC)• 1 x Beam lay out marking machine (CNC)
Surface preparation/Blasting:• 3 x Pre blasting machines (Wheelabrators)
WELDING EQUIPMENT:
• 2 x 12 ton beam rotators• 2 x 15 ton beam rotators• Boom welder (2 heads, 1000A per head)• Gantry welder (2 heads, 1000A per head)• 8 x submerged arc tractors• 2 x squirt welders• Numerous MIG, ARC, TIG welding machines• Manipulators and rotators
Heavy Steel ManufactureEQUIPMENT
Plate Rolls:• 1 x 150mm thick x 3m wide
• 1 x 40mm thick x 3m wide
Plate processing:• 3 x Plate stripping machines (Oxy fuel)
• 2 x Plate profile CNC machine (Oxy fuel and Plasma)
• 2 x Plate profile drill and punch CNC machine (Oxy
fuel and Plasma)
PLATE GIRDER ASSEMBLY LINES:
• 4 x manual plate girder assembly lines
• 1 x automated plate girder assembly line (4 x 1000A
submerged arc, tandem welding process)
Genrec’s Heavy Steel Manufacture Facility typicallymanufactures products such as Stacker Reclaimers andDraglines. This facility comprises:
FACILITY
Heavy Bay:305m long, 31m wide (21m under crane hook)
CRANEAGE
Heavy Bay:• 2 x 100 ton overhead gantry cranes
• 1 x 35 ton overhead gantry crane
• 3 x 20 ton overhead gantry cranes
• 4 x 10 ton semi portal cranes
Plate Yards:• 2 x 20 ton overhead gantry cranes
• 2 x 10 ton overhead gantry cranes
Machining
Typical Projects Completed:Crusher – Machining of bores and facesGirth Gears – Machining of faces, outer diameter and inside diameterRiding Rings – Machining of outer diameter, inside diameter and facesCrusher – Machining of bores and facesImpeller – Machining of centre bore, recesses and facesWinder Brake Disc – Machining of brake disc internal diameter andfacesWinder Drum Assembly – Machining of winder drum and discassembliesTrunnions – Machining of faces
Typical Projects Completed:
Impeller – Machining of centre bore, recesses and facesWinder Brake Disc – Machining of brake disc internal diameter andfacesWinder Drum Assembly – Machining of winder drum and discassembliesCast Iron Ladle – Machining of facesTippler End Rings – Machining of rings and railsGirth Gears – Machining of faces, outer diameter and inside diameterRiding Rings – Machining of outer diameter, inside diameter and facesTrunnions – Machining of facesHP & LP Valves – Machining of bores and faces
CRAVEN VERTICAL BORING MILL:Specifications:Table Load 40 TonTable Diameter (mm) 5 500Max. Swing Diameter (mm) 5 300Max. Height Under Cross Slide (mm) 2 600Distance Between Columns (mm) 6 400Vertical Travel of Cross Slides (mm) 2 750Horizontal Travel of Cross Rails (mm) 2 200 x 2Taper Of Main Ram 30ºTable Speed (RPM) 0.45 - 18Min. Bore Diameter (mm) 300Max. Chucking Diameter (mm) 5 500Side Box Details 2m up/downSide Box Taper 60º inclusiveAchievable Tolerance (mm) 0.05
SCHIESS DEFRIES – VERTICAL BORING MILL:Specifications:Table Load 65 TonTable Diameter (mm) 8 000Max. Swing Diameter (mm) 8 200Max. Turning Height below Tool (mm) 3 700Distance Between Columns (mm) 8 200Vertical Travel of Cross Rails (mm) 4 200Horizontal Travel of Cross Rails (mm) 4 500 x 2Taper Of Main Ram 30ºTable Speed (RPM) 0 - 7Drive Power 127Kw
AC MotorMin. Bore Diameter (mm) 450Max. Chucking Diameter (mm) 8 000Main Ram Details 1,8m up & down travelAchievable Tolerance (mm) 0.05
Genrec is well known for its heavy machining capabilities and has successfully machined products such as WinderDrums and Brakes over the past 60 years. Some of the workshop equipment and equipment capabilities are listed below:
BORING MILLS:
Vertical • Schiess: Chuck Dia: 7,860mm, Swing Dia: 8,300mm, Height: 4,600mm
Horizontal • Schiess: Long Travel: 9,300mm, Height: 4,300mm, Spindle Travel: 2,200mm• Union: Long Travel: 8,300mm, Height: 2,800mm, Spindle Travel: 900mm• Crovel: Long Travel: 5,000mm, Height: 5 ,500mm, Spindle Travel: 2,700mm• Ki Heuls: Long Travel: 10,000mm, Height: 3,800mm, Spindle Travel: 600mm
MachiningTypical Projects Completed:
Medupi & Kusile & Structural Steel Columns –Machining and drillingof facesWinder Brake Disc Segments – Machining of faces and key slotsContainer Cranes - Machining of bores, faces and bogeysGirth Gear Half Sections - Butt facing and joint holes
Typical Projects Completed:
Medupi & Kusile & Structural Steel Columns - Machining and drilling
of facesContainer Cranes - Machining of bores, faces and bogeysGirth Gear Half Sections - Butt facing and joint holesTransnet Bogies - Machining of faces, spigots and bores
Typical Projects Completed:
Cast Iron Ladle - Machining of facesCutter Booms - Machining of bores, faces and recessesCrusher - Machining of bores and facesTippler Rings - Machining of pads and butt facing of rail segmentsWinder Brake Disc - Machining of disc segment faces and key slotsDrag & Hoist Gearbox Base - Machining of bores and facesTrunnions - Machining of facesHP & LP Valves - Machining of bores and facesRotor Cores - Machining of facesMedupi & Kusile Structural Steel Columns - Machining & drilling offacesContainer Cranes - Machining of bores, faces and bogeysGirth Gear Half Sections – Butt facing and joint holes
UNION HORIZONTAL BORING MILL:Specifications:Max. Vertical Travel of Headstock (mm) 2 700Max. Traverse of Column (mm) 8 500Max. Boring Depth (mm) 1 300Spindle Diameter (mm) 150Distance from Table - Top Spindle min: 675Centre (mm) max: 2 700Bed Size Length (mm) 10 500Bed Size Width (mm) 4 000Spindle Speeds (RPM) belt: 2.8 - 560
gears: 2.8 -112Feed Range (mm/min) boring: 0.05 - 48
KI HEUNG CNC HORIZONTAL BORING MILL:Specifications:Long Travel (mm) 11 000Column Height (mm) 3 200Spindle Length (mm) 1 500Table Length (mm) 9 000Table Width (mm) 2 000Table Depth (mm) 400Motor Power (Kw) 28/38Speed Variation 0 - 1 000
1 000 - 4 000Fast Feed x 15m/min;
y,z 10m/minRapid Feed Rate x 10m/min;
y,z 5m/minAngle Head rotation 360°Achievable Tolerance (mm) 0.02
SCHIESS - HORIZONTAL BORING MILL:Specifications:Max. Vertical Travel of Headstock (mm) 4 500Max. Traverse of Column (mm) 9 300Max. Boring Depth (mm) 1 500Spindle Diameter (mm) 190Quill Diameter (mm) 800Distance from Table - Top Spindle min 1 100Centre (mm) max: 4 500Bed Size Length (mm) 11 800Bed Size Width (mm) 500Spindle Speeds (RPM) belt 200 - 380
gears 1.7 - 266Feed Range (mm/min) low 0 - 35
high 0 - 1 000Achievable Tolerance (mm) 0.02
MOBILE DRILLING MACHINE:Specifications:Direction X, Y, ZMax. Drill Diameter (mm) 5
Markets and Clients
GRDMinprocC O N C O RLimited
MARKETS
Genrec specialises in the manufacture of
structures and equipment in diversified
markets such as:
• Power Generation
• Mining
• Petrochemical
• Mineral Beneficiation
• Infrastructure, Oil and Gas, and Industrial
CLIENTS
Our clients include highly respected companies such as:
• January 2012 – SABS Certification of Recognition20 Years of Loyalty, Commitment & Compliance toSABS Quality Management System CertificationScheme
• June 2013 - Sasol HSE Work Team of the MonthHSE, Work Team of the Month, WRG Secunda
• SAISC Steel Awards 2013 – Overall Winnerfor excellence in the use of structural steel - MedupiPower Station
• Contractor of the Quarter at the Water RecoveryGrowth Project, Sasol Secunda
AWARDS RECEIVED
• 2002 / 2003 – 2nd Place International Project (Strucad Award) for Abu Dhabi Zayed Cricket Stadium
• 2004 / 2005 – 1st Place International Project (Strucad Award) for Khalifa Sports Hall
• September 2006 – SAISC Steel Awards - OverallWinner for excellence in the use of structural steel -Khalifa Indoor Sports Hall
• 2010 / 2011 – 1st Place International Project (Strucad Award) for Medupi Power Station
Successfully Completed Projectsand AwardsProject Name: El Abra Copper MineLocation: ChileClient: BechtelMass: 3 300tDuration: 12 Months
Project Name: Burj Al Arab HotelLocation: Dubai - UAEClient: M&R and Fletcher JVMass: 11 000tDuration: 24 Months
Project Name: Emirates TowersLocation: Dubai - UAEClient: Besix & MultiplexMass: 800tDuration: 24 Months
Project Name: CMT Spinning MillLocation: MauritiusClient: Construction Management
& Allied ServicesMass: 1730tDuration: 14 Months
Project Name: Khalifa Sports ComplexLocation: Qatar - UAEClient: SNC LavalinMass: 2 795tDuration: 14 Months
Project Name: Sheik Zayed Cricket Stadium
Location: Dubai - UAEClient: Abu Dhabi Cricket AuthorityMass: 800tDuration: 12 Months
Project Name: Muskeg River Oil SandsProject
Location: CanadaClient: Shell, Chevron, Marathon OilMass: 800tDuration: 18 Months
Project Name: Carnival CityLocation: RSA (JHB East)Client: WBHOMass: 700tDuration: 14 Months
Project Name: Jacket - MossgasLocation: RSAClient: Camfil - FarMass: 2 551tDuration: 14 Months
Project Name: Mopani Winder HouseLocation: Kitwe, ZambiaClient: Mopani Copper Mines PLCMass: 220tScope: Detailing, Fabrication,
Delivery to site & Erection (Concor)
• Ekurhuleni: Hand-in hand with Ekurhuleni’s job
creation initiative, Genrec has engaged the services
of 15 students on a learner program for a one year
period. These students are gaining experience in the
fields of Safety, HR, Quality Control, Production
Planning and other disciplines. The experience
gained will ensure high probability for future
employment and make them valuable employees to
any employer. Genrec is proud to be in a position to
assist the Ekurhuleni Council in this initiative.
Training and development is a crucial part of any
business and not only does it benefit your employees,
but it also benefits the overall motivation, efficiency,
capacity and innovation of our company.
The importance of training can thus never be
overemphasised, especially when considering the
dynamic nature of the business world and changing
technologies. By creating a culture of “training and
development” at Genrec, we will stay competitive in the
global market by ensuring that our people are abreast
of changes in the industry, especially in terms of new
technology, work practices and competitive strategies
therefore ensuring the satisfaction of our clients and
fulfilling their expectations.
Training and Skills DevelopmentTHE IMPORTANCE OF ONGOING TRAINING
Genrec believes in the importance of ongoing training,
ensuring that our people have the ability to achieve
their full potential, delivering our future and ensuring
the fulfillment of our client’s needs.
While it is well recognised that South Africa struggles
to meet the demand of skills required in the
Engineering Sector, Genrec has risen to this challenge
at a number of levels:
• Apprentices - Genrec’s Apprentice Artisans form
part of the Manufacturing Production Teams and
apply their learning in the day-to-day fabrication
work they produce. Over the past 4 years, Genrec
has trained and qualified 11 apprentices.
• In-House Artisan Training – the AATP undergo an
18 month intensive on-the-job and institutionalised
training in respective Trades. 187 people have
successfully completed this programme since 2009.
• Supervisors are selected from the existing
workforce on appropriate role fit, through a rigid
assessment and training process.
• Graduates form part of the Murray & Roberts
graduate program, while under the mentorship of
in-house professionals.
• Specific training is given to Specialists once they
have shown commitment to the business.
Cnr Dekema & Niemann Roads, Wadeville, 1428, Johannesburg, South AfricaTel: +27 11 876 2300 I Fax: +27 11 827 1733 | Email: [email protected] www.genreceng.co.za
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