MARCH-APRIL 2026 FUSION Journal of the Southern African Institute of Welding
POWERING what’s possible
Contents
March-April 2026 FEATURES 6 SAIW reintroduced Level 3 NDT courses to its offering The SAIW’s Lemogang Maclean explains why the SAIW has reintroduced Level 3 NDT courses in Visual, Liquid Penetrant, Magnetic Particle and Ultrasonic Testing for 2026. 9 SAIW Lab ISO 17025 renewal reaffirms testing excellence The SAIW Materials Testing Laboratory is renewing its ISO/IEC 17025 accreditation, reinforcing the facility’s role in supporting quality assurance, safety and technical compliance. 10 Customised, specialised, high-quality manufacturing from GENMAC African Fusion speaks with Keegan Govender of GENMAC (Pty) Ltd about the niche, customised manufacturing and construction solutions offered by this ISO 3834-2-certified company. 12 Transforming production: from manual to automated welding voestalpine Böhler Welding highlights, through case studies, the advantages of moving away from manual welding by adopting more automated solutions. 14 Fronius’ new Artis and Ignis options With the launch of the Artis 300 and Ignis 250 welding power sources, Fronius extends the power and capabilities of the Artis TIG series and Ignis MMA series. 16 The Magmix 3 Compact from Air Products Air Products South Africa has launched a unique customer-owned 20 ℓ welding gas cylinder, the Magmix 3 Compact. 17 B.E.D. appointed as Harris Products distributor The Harris Products Group has appointed Bolt and Engineering Distributors Group (B.E.D.) to represent its full portfolio of metalworking equipment and consumables in South Africa. 18 Steinmüller Kendal Team recognised for Transformative Community Investment Steinmüller Africa’s Kendal Power Station team has been recognised at the Eskom Managers Awards 2025 as a key player in Corporate Social Investment (CSI). 20 From manual to smart welding automation Andrew Crackett of Yaskawa Southern Africa highlights a quiet shift in fabrication that is lowering the barrier to entry for SMEs and manufacturers who previously felt robotics was out of reach. 23 iBOTone and iROB: automation with creative freedom ABICOR BINZEL believes that modern automation, using robots or cobots, can help alleviate the growing skills shortages facing fabrication companies. 25 Transformative 2025 for Aurex Constructors Leading industrial construction, turnaround and maintenance company Aurex Constructors closed out 2025 delivering record progress and expanding its geographic reach. 26 Laser Welding: Precision, Power, and the Thermamax Pro Unique Welding has launched the Thermamax Pro Laser Welding range to meet the growing demand for more accessible hand-held laser welding technology. 28 Hardox® HiAce: where abrasion, corrosion and heat meet Swedish-based special steel maker, SSAB, has introduced Hardox® HiAce, an innovative wear-resistant material engineered to outperform conventional abrasion-resistant (AR) steels. 29 OmniScan™ X4 PAUT and ToFD Flaw Detector The OmniScan™ X4, available in South Africa through Techtra Engineering Consultants, is a comprehensive multi-technology inspection toolbox. REGULARS 3 Message from the president 4 Front cover story: ESAB advances welding automation range 30 Welding and cutting forum 32 Today’s technology: Fronius Velocity Assistant MIG/ MAG welding
Published three times a year, in March-April, July-Aug and November- December, circulated via email and posted online. Crown Publications (Pty) Ltd Crown House Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140
10
Bedfordview 2008 Tel: (011) 622 4770 Fax: (011) 615 6108
Editor: Peter Middleton E-mail: peterm@crown.co.za Advertising: Peter Middleton E-mail: peterm@crown.co.za Managing Director : Karen Grant Publisher: Wilhelm du Plessis Production & layout: Darryl James Circulation: Brenda Grossmann Printed by: Tandym Print, Cape
14
20
ESAB South Africa is launching a new and comprehensive automa- tion range into South Africa this year, starting with the company’s new COBOT solution, while also including dedicated solutions for bore clad- ding with a continuously rotating torch (CRT), a tank welder for jack- up tank construction, and several welding tractors for butt, fillet, rail and double-sided stiffener welding.
23
29
www.africanfusionmagazine.co.za
1
March-April 2026
AFRICAN FUSION
78 Years Strong. Just Getting Started.
Your reputation depends on qualified professionals. Ours is built on producing them. With internationally recognised auditors, digital platforms, and new strategic alliances, the SAIW is the partner you can trust again and again.
Welding’s gold standard is back. Work with the best.
Tel: 011 298 2100 • Email: training@saiw.co.za • www.saiw.co.za
Message from the president
L ast month, we lost an extraordinary character, an exceptional teacher, a champion in the Inspection and NDT fields, and, to many of his students, an excel- lent mentor. On behalf of the SAIW, I would like to convey our sorrow and heartfelt con- dolences to Mark Digby’s family and all his friends and colleagues. He will be missed, and at SAIW, we will strive to keep his legacy alive. After stabilisation of the SAIW in 2025, we look forward to completing the third and final stage of our transformation process in 2026. Unfortunately, we have to revisit the executive director’s position. Still, Confidence Lekoane has again stepped up as Acting Executive Director, with the support of the chairman and the board, and we have every confidence in her abilities. We are also operating without a Certifica- tions Manager to handle SAIW personnel cer- tification and company certification schemes. Our General Manager, Shelton Zichawo, is suc- cessfully handling the ISO 3834 Certification workload, but we would like to give him more time to dedicate to general management. We have added to our NDT offering for 2026 with several new Level 3 courses. Follow- ing the tragic loss of Mark Digby, therefore, we now also need to strengthen the NDT depart- ment, particularly at the higher levels. We would welcome applications or suggestions of suitable people to take on this role. The key roles at the Institute have now been filled or are being covered by contrac- tors, so there are no longer any risks to the delivery of SAIW training services, support for the welding community or to the Institute’s sustainability. The welding, NDT, inspection, and Certifi- cation services SAIW offers will be particularly important for meeting South Africa’s imme- diate preparation and future needs in its
infrastructure redevelopment programmes, most notably the IRP 2025 plans for our en- ergy transition. IRP 2025 favours renewables, gas, and nuclear energy to achieve our net-zero tar- gets. On the nuclear side, 5 200 MW of new nuclear capacity is a central pillar of the new strategy to replace coal and provide reliable baseload power. As our population grows, we will require more infrastructure and energy, in particular. So the Government has made the right decision to expand energy capacity using clean nuclear power at this stage. At SAIW, we have been discussing future training needs in the nuclear field for some time, and with our transformation near com- plete, these plans are beginning to take shape. We intend to convene a stakeholders’ meeting early in the year to develop a set of training modules that align with nuclear standards. We hope to attract young profession- als and recently qualified students from our universities and the SAIW. South Africa needs to upskill a new generation of profes- sionals in preparation for the nuclear new build: nuclear engineers, welding engineers, welding inspectors, NDT professionals and safety personnel. These programmes will be impossible to achieve without considering the core execution teams, such as welders, who are critical for joining the materials. SAIW will look to coordinate and form ATBs across the country to deliver training for welders, boilermakers, and pipe fitters. In the nuclear industry, professionals need to be equipped with a niche set of high-level skills, along with a specific ethical culture regarding risk and safety. Nuclear energy technology has proved exceptionally reliable and safe when all internationally required safeguards are implemented. The International Atomic En-
ergy Agency (IAEA) oversees these safeguards and ver- ifies whether due diligence is being
applied. This includes stipulating the regula- tions to be applied and the qualifications and competencies required of nuclear personnel. SAIW has been an IAEA Regional Desig- nated Centre (RDC) for many years, providing Non-Destructive Testing (NDT) training and certification. This has led to our collaboration to establish a Nuclear School of Excellence for NDT in South Africa, which is progress- ing well. We are therefore ideally placed to take our collaboration further, helping the broader industry in training a new generation of nuclear professionals. We need to do it very soon, though. The first 1 200 MW unit is expected to be delivered by 2036, with a phased rollout of subsequent units planned for 2037, 2038 and 2039. This is an enormous task, but an exciting oppor- tunity for the SAIW. In addition, in the recent State of the Nation address, our President, Cyril Rama- phosa, announced a committee to review the delivery of new water infrastructure. This will require mechanical, welding and inspection skills. In addition to metallic welding, there is increasing use of high-density polyethene (HDPE) for water pipelines. As part of SAIW’s strategic approach to developing skills in materials suitable for specific environments, we have begun exploring plastic welding as a potential new offering. I am pleased with the progress we have made and are continuing to make in prepar- ing the SAIW for our future. And this future is looking like it will need the SAIW’s services more and more. Joseph Zinyana
SAIW Board and Management Team Governing Board President: Joseph Zinyana – New Age Engineering Solutions Johan Kruger – Sasol
Nthabiseng Maledi – Wits Morris Maroga – Eskom Dawie Olivier – OSG
Tony Paterson – Retired Johann Pieterse – AFROX Carel van Aswegen – Steinmüller Kevin Xaba – ESAB General Manager Shelton Zichawo Tel: (011) 298 2102 shelton.zichawo@saiw.co.za
Executive secretary Dimitra Kreouzi Tel: (011) 298 2102 dimitra.kreouzi@saiw.co.za
Executive Director (acting) Confidence Lekoane Tel: (011) 298 2101 confidence.lekoane@saiw.co.za
3
March-April 2026
AFRICAN FUSION
Cover story: ESAB
ESAB advances welding automation range ESAB South Africa is launching a new and comprehensive automation range into South Africa this year, starting with the company’s new COBOT solution, while also including dedicated solutions for bore cladding with a continuously rotating torch (CRT), a tank welder for jack-up tank construc- tion, and several welding tractors for butt, fillet, rail and double-sided stiffener welding. “These COBOTs are made for welders, not programmers,” Bronkhorst assures.
ESAB UR10e COBOT is a fully self-contained, small-footprint and mobile robotic MIG/MAG welding system.
W elding automation, according to Jannie Bronkhorst, Technical Director for ESAB SA, enables fabricators to bridge the skills gap, increase productivity, and deliver consistent, high- quality welds. “We offer a diverse portfolio ranging from easy-to-program collab- orative robots (cobots) for high-mix, low- volume work, to heavy-duty automated solutions, including submerged arc welding (SAW) tractors and custom-built column and boom systems,” he tells African Fusion . He says the cost of adopting automation solutions has been falling for several years, driven by developments such as collabora- tive robots (cobots) and by enterprises of all sizes seeking to stay competitive in an increasingly demanding market. ESAB’s new UR10e COBOT ESAB UR10e COBOT is a fully self-contained, small-footprint and mobile robotic MIG/ MAG welding system designed to help fabricators increase production volumes and quality without additional people.
Intuitive app-based software enables the welder to choose the weld type in the app on a phone or tablet before moving the cobot arm to key start and end points around the weld. Then, welding can start. “Rather than replacing them, this cobot empowers skilled welders to take advan- tage of the automatic manipulation a robot can deliver,” he adds. There is no need to swap skilled weld- ers for skilled programmers. Powered by the Beacon app from Hirebotics, the ESAB COBOT uses familiar technology and termi- nology, enabling welding experts to quickly and productively deploy automation to achieve high-quality results. The fully integrated multifunctional welding system includes a UR10e robot arm, a microcontroller cabinet, a colour teach pendant, an ESAB Aristo 500iX power source with the Aristo RoboFeed3804W wire feeder, and a TBI RM 82W-22° water-cooled welding torch. A worktable surface with workpiece fixing brackets is also included. “Cobot automation systems
On the fixed automation side, ESAB SA is introducing a hot-wire TIG-based column and boom cladding systems for high-integrity small-bore cladding of internal pipe surfaces. key feature of this system is a continuous- rotating torch (CRT), which eliminates the need for a workpiece rotator. Simple and complex internal bore shapes can be clad, with an arc voltage control (AVC) slide accurately maintaining the distance between the tungsten torch and the workpiece, regardless of the sur- face profile. The system comes complete and ready to weld, with the column and boom mount- ed on a base plate, the CRT Head with a internal wire feeder, a 600 mm long torch lance suitable for access into internal bores above 50 mm (2-inches), the HMI interface for programming and process control, an ESAB Aristo 5000 iw welding system for powering the TIG arc, and an additional ESAB Rogue ES 200i for the delivery of hot wire into the TIG arc. From a process control perspective, an in-built data logging system collects data from the system and transmits it to a wire- less HMI/controller with a 10-inch multi- touch screen. Multi-page data displays and alarms can be accessed. In addition to the current, voltage and wire feed rates for each job, welding parameters such as weld depo- sition rate (kg/hr), layer thicknesses (mm), wire consumed (kg), and gas consumption
are designed to be allocated and used by a shop floor welder in the same way as a manual welding machine would be. But instead of weld speed and quality depending on the con- sistency of the welder’s arm, they become dependent solely on the welder’s teaching experi- ence,” suggests Bronkhorst. Bore cladding and CRT On the fixed automation side, ESAB SA is introducing a hot- wire TIG-based column and boom cladding systems for high-integrity small-bore clad- ding of internal pipe surfaces. A
Collaborative robots (cobots) are easy to program and ideal for high-mix, low-volume work in small- to medium-sized fabrication shops.
4
March-April 2026
AFRICAN FUSION
quality; smooth wire feeding from a 4-roll drive mechanism; and a very wide range of ESAB welding con- sumables is available for any specific weld- ing application. “Fuel tank con- struction is acceler- ating in South Africa due to our increased dependence on im- ported fuels, a wors- ening shortage of fuel
The ESAB automatic Rail Welder, RW1, is a multi-function
ESAB AGW1 series of tank welders is the best yet for 2G welding construction in jack-up fuel tank construction.
storage capacity, ageing infrastructure and rising energy demand. Well-designed welding solutions such as the ESAB AGW1 tank welder can make the construction of these storage facilities far more cost, time and resource efficient,” Bronkhorst notes.
rail welding system for flat and vertical welding of flat, horizontal, vertical and overhead butt joints. ESAB’s new HCD-500B Stiffener Welder, a double-sided fillet-welding tractor, is the third new mechanised solution being intro- duced by ESAB South Africa this year. Also rail-free, wireless, and battery-powered, this tractor can hold two welding torches to simultaneously place fillet welds on both sides of a stiffener strip. Configured to weld ribs up to 390 mm high, this system is ideal for manufacturing I-beams, T-beams, and reinforced ribs. Underpinning all of the new mechanised solutions is ESAB’s Rustler EM 350C Pro Syn Pulse welding power source, a premium, full-featured modern welding machine. Equipped with the latest inverter technol- ogy, the Rustler MIG PRO combines low en- ergy consumption with optimised welding performance in MMA and MIG/MAG/FCAW for all common base materials. The machine includes welding programs for carbon steel, stainless steel, aluminium, brazing, and flux-cored wires, with the add- ed benefit of synergic control, which saves setup time, promotes consistency, and helps less experienced welders produce optimal welds. “These new Rustlers have simple, intuitive controls and are ideal for small fabricators and welding fleets. This also makes them particularly well-suited for use with our extended mechanised tractor range. Rustler inverters are robust, reliable and energy-efficient, making them ideal for small fabricators and welding fleets, particularly those migrating towards automated or mechanised welding solu- tions,” says Jannie Bronkhorst. “When it comes to welding automation, we at ESAB South Africa can offer best-fit solutions to meet almost any welding need, along with the support to ensure that our customers see the cost and quality ben- efits,” he concludes. http://esabsa.co.za
(ℓ/m) are recorded and displayed. “This new high-precision system is ideal for bore cladding in the exotic mate- rials needed for chemical, oil and gas, and nuclear applications, where uncompro- mising precision and very high-quality are required,” says Jannie Bronkhorst. Jack-up tank construction system “Our new ESAB AGW1 series of tank weld- ers is the best yet 2G welding construction system for jack-up fuel tank construction,” continues Bronkhorst. This construction method is a well- established top-down erection method for large storage tanks, where the roof and top shell are assembled first at ground level. Hydraulic jacks then lift completed sec- tions, allowing each consecutive section of the shell to be welded underneath. The method eliminates the need for cranes and welding at height, increasing safety, speed and efficiency. The ESAB Tank welder is a lightweight, tractor-based SAW welding system de- signed specifically for circumferential welds on storage tanks under construction. The new system uses a flexible aluminium rail attached to the shell using magnets. For welding, ESAB LAF1001 or LAF631 power sources can be used with the ESAB PEK Process Controller. A flux belt is used to hold the SAW weld- ing flux, as in other girth welding processes. This can carry a 20 or 30 kg flux hopper, and a built-in flux recovery system is included. For optimal wire feeding in the 2G position, 1.6 or 2.0 mm wire is recommended. Interconnection cables of up to 50 m are available, depending on customer requirements. Key advantages include easy assembly and preparation for welding, with no need for any welded brackets for mounting the track; digital process control and monitor- ing from the PEK Digital Process Controller for enhancing welding performance and
Application-specific tractor solutions
In addition, three other new tractor solu- tions are being introduced into the South African market to help fabricators meet their quality and productivity needs. Each of these is purpose-designed to meet com- mon mechanisation needs on shop floors. The first is ESAB’s new Fillet Welder, a small, lightweight tractor designed for vertical, horizontal, and overhead butt and fillet weld seams, which delivers precise control of travel speed, weaving speed, weaving angle, and dwell times. This versatile autonomous welding trac- tor is designed for rail-free operation across flat, vertical and overhead positions. With a dual-motorised 4-wheel drive, it offers precise steering and optimal traction, even on curved or uneven surfaces. The system is powered by a lithium battery pack that can supply 10 hours of continuous operation, so no external power supply is required. Easy to operate, the tractor/carriage is driven by a guide wheel and attached to the work surface via magnetic adsorption. The second new tractor, the ESAB auto- matic Rail Welder, RW1, is a multi-function rail welding system for flat and vertical welding of flat, horizontal, vertical and overhead butt joints, using MIG/MAG or FCAW processes. Also wireless and pow- ered by lithium-ion batteries, the system is designed to be operated by a welder, offering adjustment of the travel angle and weld torch position during welding. Tracked using a magnetic guide wheel and an adsorption clutch handle, the ESAB RW1 system can be used on both flat and curved surfaces.
5
March-April 2026
AFRICAN FUSION
SAIW News: SAIW Level 3 NDT courses
SAIW reintroduced Level 3 NDT courses to its offering
• The Visual Testing (VT) Level 3 course covers the principles, techniques, and equipment used in visual inspection to detect surface defects. The course includes inspection procedures, evalu- ation and reporting, quality require- ments, and developments in visual testing. • The Penetrant Testing (PT) course pro- vides advanced knowledge of liquid penetrant testing for detecting surface- breaking defects. Topics include test- ing principles, equipment, inspection procedures, results evaluation, quality control, and safety considerations. • Magnetic Particle Testing (MT) Level 3 focuses on magnetic particle inspection for identifying surface and near-surface defects in ferromagnetic materials. The course covers testing principles, equipment, inspection procedures, evaluation, quality aspects, and safety considerations. • Ultrasonic Testing (UT) Level 3 develops expertise in ultrasonic inspection for de- tecting internal material defects. Train- ing covers the principles of ultrasonic testing, equipment operation, inspec- tion techniques, result interpretation and quality assurance. • Radiographic Testing (RT) provides advanced knowledge of radiographic testing for identifying internal defects in materials and welds. The course includes radiographic principles, equip- ment, inspection procedures, result interpretation, and quality aspects. At Level 3, technicians progress from per- forming inspections to designing inspec- tion plans, selecting and approving tech- niques, interpreting codes and standards, validating results, and taking responsibility for inspection outcomes.
Lemogang Maclean, SAIW’s Acting Training and Technical Manager, explains why the SAIW has reintroduced Level 3 NDT courses in Visual, Liquid Penetrant, Magnetic Particle, Ulrasonic and Radiographic Testing for 2026, motivated by the increasing need to secure the safety and integrity of new and in-service structures and industrial plants.
S outh Africa has an increasing num- ber of high-risk industrial sectors where structural integrity is es- sential. We therefore need NDT inspectors with the knowledge and skills to validate the integrity of the welded connections in these structures, to minimise the risk of expensive failure and, more importantly, the potential for loss of life. Safety is the key motivation for NDT. From a localisation perspective, offering Level 3 NDT training here at the SAIW also helps develop high-level technical exper- tise within the country, reducing reliance on external specialists and strengthening our national inspection capability. This is particularly relevant to key in- dustries the SAIW serves, including power
generation, oil and gas, petrochemical pro- cessing, mining, rail, pressure equipment and fabrication, where inspection reliability directly impacts safety, regulatory compli- ance and asset life. The new Level 3 courses on offer This year, we have introduced Level 3 courses in the common NDT Techniques: Penetrant Testing (PT), Magnetic Particle Testing (MT), Ultrasonic Testing (UT), Radio- graphic Testing (RT) and Visual Testing (VT). While these courses are not new, they have not been available locally over the past 4-5 years, so their reintroduction provides an important opportunity for professionals to upgrade their skills and progress into senior inspection roles.
This year, SAIW has introduced Level 3 courses in Penetrant Testing (PT), Magnetic Particle Testing (MT), Visual Testing (VT), Radiographic Testing (RT) and Ultrasonic Testing (UT).
6
March-April 2026
AFRICAN FUSION
SAIW News: SAIW Level 3 NDT courses
Candidates who may benefit These courses offer a career pathway for both private candidates and company- sponsored personnel seeking to upgrade their NDT skills and assume greater respon- sibility, as qualified Level 3 NDT personnel are highly valued by industry, authorised inspection service providers, inspection authorities, and professional bodies. This course is ideal for NDT Level 2 per- sonnel who want to advance their careers. Level 3 training elevates their expertise from mainly executing inspections to higher-level responsibilities, including interpreting stan- dards, developing procedures, and making technical decisions. It prepares them to progress into senior roles such as NDT Level 3 specialists, and Responsible Persons, or Quality Managers within inspection and integrity management systems. In addition, for engineers and manag- ers, this training will provide a clear un- derstanding of what NDT can and cannot do, as well as how inspections are used to manage risk. This will help them make bet- ter, well-informed technical and business decisions that affect safety, quality, and asset performance. Advanced PAUT and ToFD course While we are not yet ready to offer ad- vanced Phased-Array Ultrasonic Testing (PAUT) or Time of Flight Diffraction (ToFD) this year, we are in the process of building our capacity to offer them in the near fu-
lower-level inspectors to maintain safety and asset integrity. Without highly skilled NDT personnel, the risk of undetected defects, equipment failure, or non-compliance with regulatory requirements increases, potentially com- promising safety, causing costly delays, or leading to serious accidents. The SAIW’s reputation as a centre of excellence with decades of experience in technical training, assessment, and indus- try support makes it a training provider of choice for NDT, Inspection and Welding courses. We have passionate, highly quali- fied, and experienced instructors, which makes all the difference in delivering practi- cal, hands-on learning. We have also digitised our classrooms to make training more appealing, engag- ing and accessible, and to progress our standards to those typically used in the modern world. SAIW training continues to open op- portunities for career advancement, professional recognition, and increased employability. An empowered employee with the right skills and knowledge is a real asset to any company. So, for companies, SAIW training assures quality and compliance, as our courses align with national and in- ternational standards, helping staff achieve the competence needed to deliver safe, efficient, and reliable results. https://www.saiw.co.za
ture. Possibly, start with ToFD in 2027, once we have reestablished core Level 3 NDT training programmes that ensure that the curriculum, resources, and quality systems are well aligned with industry standards. We are also planning to include the advanced Phased-Array ultrasonic tech- nique in the near future. This need is closely aligned with South Africa’s future energy infrastructure needs, particularly in light of IRP 2025, which includes plans for nuclear capacity alongside renewable and gas projects. These developments will require the construction and maintenance of high-integrity systems such as pressure vessels, piping, and structural components, all of which demand strict quality assur- ance, inspection, and safety compliance. From an NDT perspective, these projects will increase the demand for highly skilled Level 3 personnel in all techniques, who can develop inspection procedures, interpret codes, and ensure reliability. So expanding advanced NDT training locally will be essen- tial to support the country’s infrastructure goals, enhance safety, strengthen regula- tory compliance, and reduce reliance on international expertise. Large-scale projects, such as nuclear power plants, pressure systems, pipelines, and heavy fabrication, require accurate and reliable detection of defects, which depends on expert interpretation of results, development of the most appropriate inspection procedures, and supervision of
Mark Digby: his legacy lives on M ark Digby was born on 29 April 1961 in England and im- migrated to South Africa in 1969. He matriculated in 1979 from Sunward Park High School. He married Helen in 1983, and together they had four children and four grandchildren, whom he loved dearly. Mark loved sport. Whatever sport he pursued, he embraced with near-obsessive dedication. He was passionate about cycling and triathlon, and in later years, running and walking. He could join in any sport, anywhere, at any time, and was a talented and enthusiastic all-rounder. He began his career in Non-Destructive Testing (NDT) at Hall Longmore, where he also completed his Electrical Trade qualifi- cation. He worked in the NDT field at CIS, HOWDEN, ESKOM, and the SAIW (on two separate occasions), and was self-employed for a period. He firmly believed that, as a trainer, it was essential to remain active in the field to continually update and strengthen one’s practical knowledge. Mark was a dedicated lecturer at the Southern African Institute of Welding (SAIW), a true master of NDT, a mentor, and a friend. He was more than an educator – he was a custodian of knowledge. His passion for NDT was evident in every lecture he delivered, every workshop he facilitated, and every student he guided. He possessed a rare depth of technical understanding, com- bined with the practical insight that only years of industry experi-
ence can bring. As a lecturer, he had the remarkable ability to simplify complex principles – whether explaining ultrasonic wave behaviour, radiographic interpretation, or the finer details of penetrant and magnetic parti- cle testing. His classroom was not merely a place of instruction but a space of inspiration, discipline and professional growth. Mark’s contribution to the NDT community extended far beyond course material. He shaped ca- reers, strengthened industry
standards, and instilled in his students the importance of integrity, precision and ethical responsibility. To many, he was a mentor. To others, a colleague. To all who knew him, he was a man of character, humility, and unwavering commitment to excellence. Though he is no longer with us, his legacy lives on in every tech- nician he trained, every inspector he certified, and every profes- sional who carries forward the knowledge he so generously shared. On behalf of colleagues, students, and the broader NDT fraterni- ty, we extend our deepest condolences to his family and loved ones. Rest in peace, Mark. Your contribution to the world of NDT will never be forgotten. He will be deeply loved and profoundly missed by his family.
7
March-April 2026
AFRICAN FUSION
EXPERIENCE THE PERFECT WELD SEAM WITH BÖHLER WELDING
Böhler Welding creates Lasting Connections by aligning cutting-edge welding machines, consumables, and technologies to meet the changing needs of customers worldwide. Our commitment is clear: Delivering the Perfect Weld Seam. Count on Böhler Welding for unrivaled quality, productivity, and precision in every solution we offer.
Scan for more information
voestalpine Böhler Welding www.voestalpine.com/welding
SAIW reaffirms testing excellence
SAIW Lab ISO 17025 renewal reaffirms testing excellence The SAIW Materials Testing Laboratory is renewing its ISO/ IEC 17025 accreditation through the South African National Accreditation System (SANAS), reinforcing the facility’s role in supporting quality assurance, safety and technical compli- ance across South Africa’s welding and fabrication industries.
I SO/IEC 17025 SANAS accreditation applies to SAIW’s materials testing laboratory, which performs mechani- cal testing, provides welding qualification support, and conducts failure investiga- tions for industry. In sectors such as min- ing, infrastructure development, pressure equipment manufacturing and structural fabrication, reliable laboratory testing is essential to ensure that welded structures and components meet required engineer- ing standards. ISO 17025 is the internationally recog- nised benchmark for testing and calibra- tion laboratories. Accreditation confirms that a laboratory has the technical com- petence, equipment, procedures and qual- ity systems required to produce valid and traceable results. In South Africa, SANAS independently audits laboratories to verify compliance with these strict requirements. For the welding and fabrication sector, accredited testing provides independent verification that materials, welding proce- dures and finished components meet both national and international standards. This is particularly important for projects involv- ing critical infrastructure, where structural reliability and safety are paramount. Simulating real industrial conditions SAIW Senior Lab Technician Kegomoditswe Dire explains that the laboratory plays an important role in validating welding pro- cedures and material performance before fabrication work takes place in the field. “Our laboratory essentially replicates welding and material conditions encoun- tered in industry. Before critical compo- nents are deployed in applications such as bridges or heavy structural systems, we conduct controlled welding and me- chanical testing to verify properties such as tensile strength and material toughness. This assures that both the materials and welding procedures will perform reliably under service conditions,” she explains. Mechanical testing of welded materials forms a critical part of engineering design and certification. Tests such as tensile
SAIW Senior Lab Technician Kegomoditswe Dire.
Walter Mahlangu sets up SAIW’s high-definition digital microscope and measurement system to analyse weld test samples. strength, impact toughness and bend testing help determine whether welded joints can withstand the stresses and envi- ronmental conditions they will encounter during operation. The SAIW laboratory offers a range of services that support welding procedure qualification and technical investigations. These include destructive mechanical testing, metallurgical analysis and detailed examination of welded components. The facility also works closely with other technical departments within the institute, including welding specialists and training instructors, who may assist with technical investigations or provide specialist insight during complex analyses. Non-destructive testing (NDT) tech- niques used by the institute include radio- graphic testing, magnetic particle testing, penetrant testing and ultrasonic testing. These methods allow technicians to detect internal or surface defects in welded joints without damaging the component being inspected. By combining welding services, NDT and mechanical testing capabilities within a single facility, SAIW can support companies through multiple stages of welding qualifi- cation and technical evaluation. This inte- grated approach helps reduce turnaround times while maintaining consistent testing standards.
Hardness testers in the SAIW Materials Testing Laboratory.
Failure analysis and industry support
In addition to qualification testing, the laboratory plays a key role in investigat- ing failures when welded components or structures fail in service. When a failure occurs, companies often require indepen- dent analysis to determine whether the root cause lies in the base material, the welding procedure, fabrication practices or operational conditions. Dire says the laboratory combines multiple testing techniques to provide a comprehensive assessment. “In addition to qualification testing, the laboratory con- ducts detailed investigations when welded components fail in service. By combining mechanical testing, metallurgical examina- tion and non-destructive inspection, we can determine the root cause of a failure and provide recommendations that help prevent similar incidents in future.” Looking ahead, as South Africa continues to invest in infrastructure development, mining operations and industrial expansion, the availability of credible testing and certifi- cation facilities remains essential. By renew- ing ISO 17025 accreditation through SANAS, the SAIW aims to reaffirm the reliability of its laboratory services while strengthening the technical foundation of the country’s welding and fabrication sector. www.saiw.co.za
9
March-April 2026
AFRICAN FUSION
SAIW Member profile: GENMAC
Customised, specialised, high-quality manufacturing from GENMAC
African Fusion speaks with Keegan Govender, QA Manager at GENMAC (Pty) Ltd, about the niche, customised manufacturing and con- struction solutions offered by the company’s ISO 3834-2 certified facilities in Richards Bay, KwaZulu-Natal.
K eegan Govender, the Quality Assur- ance Manager of GENMAC (Pty) Ltd, studied Mechanical Engineering, specialising in structural design. “Before I joined GENMAC, I was at a local Titanium Dioxide plant, also as a quality manager, but with additional responsibilities on the ecology side,” he tells AF. He also holds an Outcomes-Based Assessment qualifica- tion from the Assessment College of South Africa, Welding Inspection Diplomas from SAIW in SANS 347 & PER Regulations, and for the Overview of ISO/SANS 3834 Part 2 course. In 2002, GENMAC opened its Fabrica- tion Workshop facilities in Richards Bay. Together with Directors Govy Govender, Keelan Govender and the rest of the Team, the company strives to maintain its mis- sion statement: ‘To uphold and maintain a leading reputation by providing a quality service with the highest levels of profession- alism, integrity, honesty & fairness to all stakeholders’. A niche customised offering “The good thing about our business is that it is so specialised. We perform Fabrica- tion work on large structures, such as fur- naces, pontoons, barges, pressure vessels,
cranes, and convey- ors, to meet the needs of minerals-handling and mining supply companies, including the Richards Bay Coal Terminal (RBCT), Rio Tinto, Sandvik, Met- so, Tronox and many
A dredger manufactured and supplied for suctioning material from rivers or sea beds and sending heavy mineral concentrate directly to processing or separating plants.
that pressurised vessels are used to trans- port the titanium-rich, heavy material to shore. “There are two ways to transport mined material to shore: using a conveyor system or by loading the material into a pressurised vessel and then transferring it to shore via a pipeline,” he says. “The barges we manufacture are fully equipped. The small one for Madagascar is 8 meters long and 4 meters wide. It has a full set of on-board hydraulics, a small crane, a skipper’s chair, propulsion systems, con- trols and a rudderless Z-drive propeller for manoeuvrability. It’s a purpose-built vessel for servicing floating mining plants,” he points out. An interesting larger version was also manufactured for Senegal and delivered towards the middle of 2025. The 15×8 m barge had to be delivered from the Rich- ards Bay facility to the Port of Senegal and then 21 km overland to the mine, passing through a residential area with an access limit of 6 m. So we had to manufacture the barge in two sections for transportation, then send a crew up there to weld the sec- tions together, pressure-test it and float it to the mine’s pond. “That barge is also equipped with two back actors, which are used to hold the barge to the shore during loading or un- loading, and an on-board crane for loading and offloading pumps and anything else required for the plant,” says Govender, adding that “every application is different, so all of our work is uniquely customised to best suit the designs and needs of the plant and the customers’ requirements.” “GENMAC has been specialising in barge
more, including cross-border companies. Increasingly, though, a lot of the work passing through GENMAC’s Richards Bay workshops is for local and cross-border clients. He cites a recent success story for maintenance barges for a mineral sands operation in Senegal and Madagascar: “These are used to service the mines’ float- ing plants, which are pumping mineral-rich sands such as Ilmenite (FeTiO 3 ) from the ground. “We build the floating mainte- nance barges for moving equipment from the shore to the floating plant and back to shore,” Govender says. This work involves significant structural fabrication, including plate work for the wa- tertight hulls. “We also make conveyor sys- tems, piping, safety walkways and stacking solutions for floating plants, pontoons and the barges that service them,“ he adds. On the pressure-vessel side, he says
A GENMAC-manufactured and supplied barge equipped with two back actors, a crane for loading and offloading plant equipment, a full hydraulic system and a Z-Drive for propulsion.
10
March-April 2026
AFRICAN FUSION
SAIW Member profile: GENMAC
Above: A 42 m boom manufactured and supplied for use on a ship-loader. Right: A complex valve manifold system for a furnace that was manufactured, assembled and pressure-tested in GENMAC’s Richards Bay facility to the client’s specifications.
“It also helps the welders to understand the whole welding process. I can tell the welder what needs to be done, and during the process, we put monitoring systems in place to ensure every aspect of a welding task is carried out thoroughly. At the end of the process, NDT and further quality checks kick in before we send anything to the machine shop or painting plant,” he notes. “ISO 3834 ensures that welding is done as a more in-depth, holistic process, which ensures much better results. On the qual- ity side, problems can be detected much earlier, preventing costly rework. And regarding customers, we can call them in to witness each quality hold point, to demonstrate what we have done, prove we are on track, and provide an opportunity to take part in negotiations on how to take a project forward,” Keegan Govender tells African Fusion. Regarding SAIW’s role in auditing and managing GENMAC’s ISO 3834 accredita- tion, he is very satisfied. “From their side, the SAIW has been excellent, and we don’t have any issues. Shelton and his team are a phone call away. But if they are unavail- able, they always call back and are always helpful. Welding choices and training Since no two welding projects are ever the same, GENMAC prefers manual weld- ing using the semi-automatic GMAW and flux-cored processes. “Manual processes are easier and quicker to implement and control, because robots and mechanised systems all need to be programmed, which takes longer for the type of work we do. We are shifting more and more towards using flux-cored welding wires, though, which, compared to solid wire GMAW, now accounts for 50% of our consumable use,” he adds.
Regarding brands, he says that while premium welding brands such as ESAB are preferred, some clients have their own brand preferences, which GENMAC is happy to accommodate. To retain and develop welding and boiler-making skills, GENMAC runs an ap- prenticeship training programme, using its own skilled welders to upskill and mentor young talent. “As well as being employees, we train our people here, and when they are ready, we send them for their welding or boilermaker trade tests. “It takes about 2 years to train a learner, and they must first complete various theory modules. Once they get shop floor sign-off for their practical abilities, then we can start the process of getting them qualified as Red Seal artisans,” he explains, adding that being a qualified assessor helps him to negotiate the paperwork required by ap- prentices to satisfy trade test requirements. The future outlook There are several titanium companies in the Richards Bay Area that all have expan- sion and local beneficiation plans in place. “Operations are also expanding, so we are very optimistic about future work. “We are a quality-driven company, and we are fully committed to Richards Bay and its youth development. One of our subsid- iaries invites youngsters from our local rural areas to training programs in swimming and sailing, ranging from small boats to large mono- and multihull sailing boats. “At GENMAC, we make the structures of- ten featured on the DStv show presented by The Engineer, and we make these products with commitment to safety, quality, the environment, customer satisfaction, em- ployers and the Richards Bay community,” concludes Keegan Govender. https://www.genmac.co.za/
manufacturing for several years, and as a result, we have now made it easier for our customers. Customers can now order our small, medium, or large barges, and we will then spec them to meet their specific requirements,” he tells AF. GENMAC’s Richards Bay facilities From its Richards Bay facilities, GENMAC has the manufacturing capacity to pro- cess 200-250 t of steelwork per month. “Our facilities sit on 5,000 m 2 of land, with 2x1,000 m 2 under-roof workshops. For heavy fabrication, our first workshop is served by two 10-ton cranes and a 5-ton crane, where our welders and boilermak- ers manufacture and assemble various structures and components. “Our second workshop, with one 5-ton and a 2-ton crane, is a fully fledged machine shop, where we machine various types of components”, he says. Since February 2025, GENMAC has been an ISO 3834-2-certified company under SAIW’s Welding Manufacturer Certification Scheme. “We have also held ISO 9001 and ISO 45001 accreditation for many years before that,” he says. “We like ISO 3834 because it is welding- related. The step-by-step processes you need to follow to ensure weld quality are made clear from the beginning. For much of our business, this certification is not nec- essary, but our clients are now interested in it. We showcase its value to them, with respect to better confidence in the quality produced and better traceability of the processes, procedures and materials used. It helps clients to understand welding as a complex process that has to be tackled in the right way from start to finish,” he says. The value of ISO 3834-2 accreditation
11
March-April 2026
AFRICAN FUSION
Böhler Welding: Transforming production
Transforming production: from manual to automated welding
In this white paper, voestalpine Böhler Welding highlights, through case studies, the advantages of moving away from manual welding by adopting more automated solutions, using solutions such as the company’s CO-BRO® FLEX collaborative robot, or mechanised solutions, such as railRunner.
R aising productivity at high-com- plexity levels, while meeting high- quality, flexible production and tight scheduling requirements are universal modern-day challenges for the welding industry. Additionally, tough competition, along with growing skill and competence short- ages, is driving a shift towards automation in this industrial sector. It should also be noted that optimum productivity does not only require the highest possible welding speed, but also fast setup, low downtime and high reliability. As a trusted partner for automated welding solutions, voestalpine Böhler Welding supports fabricators worldwide in mastering their transition to automation with confidence and technical excellence. With smart integration options, user- friendly interfaces, data-driven quality management, and global technical sup- port, productivity gains can be achieved effectively. Whether starting with light au- tomation, exploring collaborative robotics,
or scaling to high-performance industrial robotic welding, voestalpine Böhler Welding can deliver the tools and knowledge to transform production from manual to automated welding.
CO-BRO® FLEX from voestalpine Böhler Welding is a high-tech workstation for robotic collaborative MIG-MAG welding.
Collaborative robotics For fabricating components in small batch- es in facilities where flexible production is the norm, industrial robotic solutions are seen as unattractive to welding shops because they are not versatile enough. Run- ning a robotic welding cell requires signifi- cant setup time and program fine-tuning, which is only feasible for high-volume production cycles. There is an alternative, however, the collaborative robot. The main difference between industrial robots and collaborative robots lies in how they interact with operators in the work area. Due to the lighter weight and slower arm movement of a collaborative robot, the operator can access the working area during operations, directly move the arm to
create a welding program, establish weld- path points, and make position adjust- ments. Consequently, collaborative robot solutions are ‘plug and play’. They are easy to move around the workshop to meet the needs of different welding tasks. A CO-BRO® FLEX success As an example of a typical and successful collaborative robot user, one of voestalpine Böhler Welding’s customers provides turn- key manufacturing solutions for more than 100 different types of small- and medium- sized steel components. The company implemented Böhler Welding’s CO-BRO® collaborative robotic solution using the Uranos NX 3200 GSM welding power source in its manufacturing facility. After a few hours of programming, using the Böhler Welding PulseDrive pulsed arc welding process, it was possible to increase bracket productivity from 250 to 400 pieces/ day while maintaining high quality and reliability. Light automation for longitudinal seams Böhler Welding also offers wheeled- and track-based carriages for longitudinal seams, ideal for large tanks, beams, frames and shipyard applications. Typically, these solutions can reduce welding time by up to 90% compared to manual welding, par- ticularly when using Bohler Welding’s fully mechanised railRunners combined with flux-cored wires in the vertical-up position. This level of productivity is also achievable for longitudinal weld seams on larger tanks. In a welding study involving a 9% Ni consumables for use on LNG storage tanks,
Böhler Welding’s CO-BRO® collaborative robotic solution, using the Uranos NX 3200 GSM welding power source, is in use, welding 250 to 400 brackets per day.
12
March-April 2026
AFRICAN FUSION
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36www.africanfusionmagazine.co.za
Made with FlippingBook flipbook maker