Engineering Capabilities

Driving Plant Performance

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At Steinmüller Africa, engineering is not just a service, it’s the foundation of our legacy.

Our highly skilled and experienced engineering teams are dedicated to solving the most complex challenges in power generation and process industry, whether it’s brownfield expansions or greenfield development.

We leverage deep domain knowledge, cutting-edge technology, and a commitment to innovation. This enables us to provide comprehensive, life-cycle solutions that ensure efficiency, reliability, and sustainability for our clients.

From prefeasibility studies to detailed plant inspections (including advanced drone inspection techniques), we cover every stage.

Our experts are available to discuss your needs. Call +27 11 806 3000 or fill out the form today.

Interested in our engineering capabilities?

Turnkey solutions for complex challenges

Process Engineering

Our Process Engineering team focuses on optimising the performance of your plant from concept through to operation. We specialise in:

Boiler and Heat Exchanger Process Design: Expert design for coal, oil, and gas-fired boilers, pulverised fuel burners, and various heat exchangers, including industrial shell and tube heat exchangers for the power generation and oil & gas industries.
Plant Optimisation: Comprehensive reviews and investigations of steam generating and reticulating plants to identify areas for improved efficiency, performance, and reduced environmental impact.
Numerical Analysis and Simulations: Utilisation of advanced tools for thermal system analysis, computational fluid dynamics (CFD), and combustion modelling.
Fuel Analysis: Expertise in analysing fuel characteristics to ensure optimal combustion processes.
Power Cycle Analysis: Detailed analysis of various power cycles and optimisation of the boiler island for maximum output.
Prefeasibility Studies: Conducting initial assessments to determine the viability of expansions/modifications to existing plants (brownfield) and new projects (greenfield).

Mechanical Engineering

Our Mechanical Engineering department provides robust design and life extension solutions for critical assets. Our services include:

Specialised Design of Pressure Parts: Precision design of both fired and unfired pressure parts, encompassing boiler pressure parts, pressure vessels, and headers.
Plant Audits and Life Extension Studies: Audits conducted to assess plant performance, pinpoint necessary modifications, and devise strategies for extending asset operational life.
Maintenance Engineering System Implementation: Designing and implementing robust maintenance engineering systems to guarantee increased uptime and long-term reliability.
Fitness for Service (FFS) Assessments: Evaluating the mechanical integrity of components to determine the suitability for continued safe operation.
Plant Inspection: Thorough on-site inspections using a range of methods to assess the condition and performance of plant equipment.

Piping Engineering

Our Piping Engineering team delivers expert design and lifecycle optimisation for high-pressure piping systems, ensuring safe, efficient, and compliant operation in demanding industrial environments. Our capabilities include:

Design of High-Pressure Piping Systems: Specialised design for both new and existing thermal power stations and other industrial applications.
Stress Analysis and Flexibility Studies: Ensuring the structural integrity and safe operation of complex piping networks.
Lifecycle Optimisation Solutions: Providing solutions aimed at maximising the lifespan and operational efficiency of piping systems.

Drawing Office and Digital Engineering

We translate intricate designs into precise, executable plans leveraging modern digital engineering tools and methodologies:

Cutting-Edge Technologies: Our drawing office utilises advanced software such as AutoDesk Product Design Suite, including AutoCad, Plant 3D, and Inventor (for parametric design).
3D Laser Scanning: As-built 3D modelling of existing plant and equipment, utilising point cloud registration.
3D Parametric Modelling: Employed to streamline design processes for product lines, optimise manufacturing sequences and proactively highlighting areas of concern during fabrication.
Drone Inspection: Utilising Utilising advanced drone technology for visual and laser scanning inspections of physically inaccessible areas. Our drone technology reduces inspection time and improves safety by eliminating the need for human entry into hazardous areas like boilers and confined spaces.

Manufacturing and Fabrication

Our large-scale, state-of-the-art fabrication facilities in Pretoria are truly unique on the African continent, enabling us to control quality and delivery:

High-Pressure Component Manufacturing: Production of boiler pressure parts, pressure vessels, large and small-bore piping, HP heaters, headers, and pipe supports.
Advanced Welding: Expertise across various welding processes, including automated welding, Regulated Metal Deposition (RMD) and unique explosive welding for tube to-tube sheet joints in heat exchangers.
Specialised Bending: We possess the only Cojafex PB 850 EHR induction bending machine in Africa, allowing us to produce complex, large-radius, and multiple bends without the need for additional welds on large bore thick wall piping.
Heat Treatment: In-house furnace capabilities for precise post-bend heat treatment to normalise and temper material.
PED Certified: We are a Pressure Equipment Directive (PED) certified manufacturer of heavy, large, and high-pressure equipment in South Africa, facilitating exports to the EU.

Maintenance and Lifetime Extension

We provide a full spectrum of maintenance operations, both planned and unplanned, aimed at maximising asset availability and extending operational life:

Field Service & Local Workshops: We offer prompt on-site support and dedicated local workshop facilities.
Boiler Island Maintenance: Includes thorough inspections (utilising NDT methods such as metallurgical replicas, UT, MPI, PT, XRF), boiler tube failure repairs, refurbishment, and component replacements.
HP Piping Maintenance: Comprehensive services covering lifecycle assessments, engineering method statements for repairs and component replacements (bends, spools), and elevation surveys.
Mills and Coal/Ash Handling Equipment: Include inspections, grinding element replacement and refurbishment, pulverised fuel (PF) piping repair, and installation. Our specialised team delivers expert girth gear installation and complete mill drive train alignment
Innovative Lifetime Extension Solutions: We have developed and qualified non-standard explosive tube plugging processes for HP heaters, a unique offering in Africa.

Construction and Erection

Our expert teams manage and execute large-scale industrial construction and erection projects:

Site Establishment and Management: Comprehensive planning and execution of project sites.
Mechanical Installation Services: Including the installation of steel structures, pressure parts, fans, flue gas ducts, tanks, and other critical systems.
Greenfield Projects: Providing full engineering, procurement, and construction (EPC) services for entirely new industrial facilities.
Brownfield Projects: Specialising in the modification, expansion, or upgrade of existing industrial plants, minimising disruption and optimising integration.

Benefits

The key advantages of partnering with Steinmüller Africa are:

Full Lifecycle Support: We provide an end-to-end service, from initial engineering design and manufacturing through to construction, installation, commissioning, and ongoing maintenance and lifetime extension.

Reduced Complexity and Risk: By having a single, highly capable partner for multiple phases of a project, clients reduce the complexities of managing multiple vendors, leading to fewer interfaces, better coordination, and significantly lower project risks.

Decades of Legacy: With over 60 years of operation in South Africa, Steinmüller Africa boasts a profound understanding of the unique challenges and requirements of the African industrial landscape.

Specialised Knowledge: Our teams comprise highly skilled engineers and technicians with in-depth knowledge in niche areas like high-pressure steam generation, boiler technology, and advanced welding.

Proven Track Record: We have a long history of successful projects with major clients like Eskom and Sasol, including the construction of new power stations (e.g. from Hendrina to Majuba), de-mothballing older stations (e.g. Camden, Grootvlei, Komati), and securing long-term maintenance contracts.

Cutting-Edge Manufacturing: Our Pretoria facility is equipped with unique, world-class machinery, such as the Cojafex PB 850 EHR induction bending machine and advanced submerged arc welding (SAW) equipment (including the only Oerlikon SAW stub welding machine in South Africa). This allows for superior quality, faster fabrication, and cost-effectiveness.

Innovative Welding Solutions: We offer specialised welding techniques like explosive welding which provides highly durable, time-saving, and cost-efficient solutions for high-pressure parts and repairs.

Enhanced Efficiency: Through expert process design, plant data collection, and continuous optimisation studies, we help clients improve the efficiency of steam generation and reticulation plants.

Extended Asset Life: Our focus on maintenance engineering systems, life assessment studies, and innovative repair methods significantly extends the operational lifespan of critical assets.

Reduced Downtime: By providing fast, high-quality fabrication and repair solutions (e.g. faster welding methods, explosive plugging for HP Heaters), Steinmüller Africa helps minimise plant downtime and maximise availability.

Rigorous Standards: Steinmüller Africa adheres to stringent international quality and safety standards.

Commitment to Safety: Our focus on rigorous standards, careful planning, and skilled personnel (including in-house training for welders) ensures high quality and safety throughout operations.

African Focus: With deep roots and a strong presence across Southern Africa, we understand the local context, regulatory environment, and logistical challenges.

Bilfinger Group Strength: Being part of the global Bilfinger Group provides us with access to international best practices, advanced technologies, and a vast network of expertise.

While initial costs for specialised services might be competitive, the long-term benefits of reduced maintenance, extended plant life, improved efficiency, and minimised downtime contribute to a lower total cost of ownership for our clients.

Industries

Industries that benefit most from Steinmüller Africa’s services include:

Power Generation

Coal-fired power stations and other energy-producing facilities benefit from maintenance, repair, and efficiency solutions.

Pulp and Paper

Engineering, fabrication and maintenance services support the construction and maintenance of pulp and paper infrastructure.

Sugar Milling & Refining

Our optimised approach to total cost of ownership is particularly important in price-sensitive sectors such as the local sugar industry.

Industrial Manufacturing

Services like custom fabrication and component manufacturing aid various industrial manufacturing sectors.

Petrochemical

Specialised boiler/heat exchanger design, welding and piping solutions support the maintenance and operation of petrochemical plants.

Fertiliser and Explosives

Our innovative boiler designs assist our clients to remain internationally competitive.

Mining

Engineering solutions and equipment maintenance support the mining industry’s operational needs.

Metallurgical

In a highly competitive industry, our boiler, piping and valve expertise improves reliability and reduces maintenance costs.