NOV-DEC 2025
Coreweld 46 LS: the low-silicon, high-deposition, low-heat-input consumable
ESAB / esab.com
salesjhb@esabsa.co.za www.esabsa.co.za
Contents
Nov-Dec 2025 FEATURES 6 The SAIW 2.0 Transformation Project
SAIW Training and Technical Manager, Confidence Lekoane, highlights the progress being made towards the full
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implementation of the SAIW 2.0 Renewal Project. 8 Shaping the future of welding excellence
Our SAIW Member Profile for this issue comes from Aurex Constructors, which has maintained ISO 3834-2 since 2012, ensuring consistent welding quality and traceability. 10 Coreweld 46 LS: for faster, cleaner and more efficient welding A component fabricator supplying a mobile equipment OEM increased productivity by 17% by switching from a conventional metal-cored welding consumable to ESAB’s Coreweld 46 LS. AF talks to ESAB product manager, Kevin Xaba. 12 Fronius Fortis: flexible, networked and powerful MIG/MAG Fronius has launched its next-generation Fortis series MIG/MAG and multiprocess system, a versatile range of solutions for high- quality manual MIG/MAG, TIG and MMA welding. 15 Two decades of growing agri equipment success A collaboration between Bolt and Engineering Distributors (B.E.D.) Klerksdorp and BPI Manufacturing continues to drive agricultural equipment reliability. 16 Steinmüller Africa: South Africa’s strategic welding innovator Steinmüller Africa is leading an 18-month boiler construction project, Vuselela, that showcases a powerful blend of engineering excellence and cutting-edge technologies. 19 Air Products’ 17025 laboratory accreditation Air Products has obtained ISO/IEC 17025:2017 accreditation for the two central and three satellite laboratories, ensuring that Air Products’ gases meet purity requirements and contamination limit specifications. 20 A refocused Abicor Binzel SA adopts a direct distribu- tion model African Fusion meets Abicor Binzel South Africa’s MD and specialists to discuss the integration of the THERMACUT® product line and DEKRA Industrial South Africa has strengthened its position as a leader in hydrogen-induced cracking inspections through a strategic combination of advanced NDT techniques and investment. 24 Afrox Hardgoods, ready to support you all the way Afrox’s Dewald Bodenstein and Johann Pieterse discuss Afrox’s hard goods product offering and the comprehensive welding solutions Afrox can provide. 26 Unique Welding’s expanding footprint Unique Welding has emerged as one of South Africa’s most influential players, due to bold thinking, technical mastery and a deeply held belief in the power of partnerships. 28 Cosmo delivers fibre laser cutting solution African Fusion talks to Petrus Pretorius of the Cosmo Group and Johan Griesel of Jubilee Suppliers, about the state-of-the-art 6.0 kW Jinan Acme/Max Photonics fibre-laser cutting system. 30 GSI celebrates 40 years First Cut’s training subsidiary, Gas Safety International (GSI), is proud to celebrate 40 years of pioneering work in compressed gas safety, training and equipment supply. REGULARS 3 Message from the President 4 Front cover story: CORE MMA expands Böhler’s ex- tensive equipment portfolio 31 Welding and cutting 32 Today’s technology: YASKAWA SA and IMS-SA launch Megmeet laser welding cell Abicor Binzel’s EWR2 gas management products. 23 DEKRA enhances HIC inspection offering
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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
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Voestalpine Böhler Welding has launched the CORE MMA range of modern single-phase MMA and lift- TIG welding power sources, built for the most demanding onsite and workshop environments.
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www.africanfusionmagazine.co.za
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The SAIW has shaped technical excellence for over 77 years. Today, we’re forging a new chapter - anchored in credibility, driven by innovation, and focused on leading Africa’s welding and inspection future. From AI-powered training to global certifications, we’re not just rebuilding. We’re redefining. From legacy to leadership - this is the SAIW way forward. 77 YEARS STRONG. Just Getting Started.
from legacy to leadership SAIW2.0
Tel: 011 298 2100 • Email: training@saiw.co.za • www.saiw.co.za
Message from the president
T his year has been a year of transforma- tion for the SAIW. We ended last year in disarray, needing to make some urgent interventions to secure the sustainability and credibility of the Institute. I am pleased to say that this process has been largely successful. First and foremost, we needed to drasti- cally improve our interaction with students in terms of turnaround times between examina- tions, results being made available and certifi- cates being issued. This turnaround has been most successful. We have appointed several new lecturers, who are enthusiastic and do- ing well. And until all positions are filled, we have secured the services of contractors to help deliver the services and turnaround performance our students deserve. We are also carefully monitoring complaints, which enables us to act quickly on the issues stu- dents are experiencing. Since July, student numbers on all our courses have been healthy, and complaints have decreased significantly. We are going further, though, to improve every aspect of the student experience. At the starting point of this process is the new SAIW website. We have incorporated an easy-access portal into the website, enabling potential students to browse our courses with immediate access to register and pay for a course. We have de- veloped a new Student Management System that integrates with this portal, which will soon provide students with quick access to their exam results. Additionally, their end- of-course certificates will be made available digitally as soon as all course requirements have been met. Work is also underway auto- mate the setting of examinations and mark-
ing, which will remove some of the workload from lecturers and allow all students to receive same-day results for each examina- tion they take. We are striving to modernise our welding courses. As well as having introduced virtual welding units into our courses to help weld- ers adapt more quickly to real-world welding, we are also introducing laser welding to our offering. We hope this process will extend the SAIW’s reach into the automotive manufac- turing industry and its many Tier 1 and Tier 2 suppliers. Beyond that, it’s a way of mak- ing welding more exciting for the upcoming digital-age generation. With Necsa, the SAIW has also initiated upskilling our NDT training team in prepara- tion for the full launch of the Necsa Centre of Excellence for NDT. This is in preparation for the nuclear new-build programme out- lined in the 2025 Draft of ESKOM’s Integrated Resource Plan (IRP), which now has Govern- ment approval. The initial training course in the advanced NDT Techniques has now been completed, and our SAIW specialist NDT Team is primed to take this programme forward in the new year. Our surveys suggest that this modern ap- proach is what students want, and that our initiatives are bearing fruit. Also very pleasing is the successful trans- formation of our Certification services. For Company Certification, for example, we are now using a digital platform to capture and store the necessary documentation to certify a company according to the SAIW ISO 3834 Company Certification Scheme. This makes the management of compliance according
to the scheme far more efficient, for both SAIW auditors and the company seeking cer- tifications. The digital database of certified companies can be easily kept up to date. Once the development is completed, companies and their clients will be able to access this database via the SAIW Website. Also being digitised in the near future are our Personnel Certification databases, includ- ing the Competent Person’s (CP), Inspectors or Pressurised Equipment (IPE), NDT and IIW databases of registered professionals. I thank the welding community for their commitment and support for the SAIW throughout this process: for continuing to believe that we are on the right path and that the SAIW is the best organisation to deliver to their expectations. And thank you to all the staff, both those who are new and those who have persevered with us. You are making a positive impact, and it is being noticed. I wish you all a peaceful, restful and happy end-of-year break, and I look forward to con- tinuing this journey with you in the new year. 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
General Manager Shelton Zichawo Tel: (011) 298 2102 shelton.zichawo@saiw.co.za Tony Paterson – Retired Johann Pieterse – AFROX Confidence Lekoane - SAIW Carel van Aswegen – Steinmüller Kevin Xaba – ESAB
Executive secretary Dimitra Kreouzi Tel: (011) 298 2102 dimitra.kreouzi@saiw.co.za
Executive Director Vicus Burger Tel: (011) 298 2101 vicus.burger@saiw.co.za
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Cover story: Böhler Welding
CORE MMA expands Böhler’s extensive equipment portfolio AF talks to Keith Saunders, Equipment Business Development Manager for the MEA region of voestalpine Böhler Welding, about the company’s expanded welding equipment range which, as well as the premium Uranos and heavy-duty Terra ranges, now includes the CORE MMA range of modern single-phase MMA and lift-TIG welding power sources, built for the most demanding environments. ing the company’s extensive portfolio of premium welding consumables.
T o appreciate the strong foundation of voestalpine Bohler Welding’s current range of state-of-the-art in- verter-based welding equipment, we must go back to 1979 – the year Selco, a proud family-owned manufacturer of arc welding equipment for 40 years, was established. With a passion and focus on innovative solutions, the company was among the pioneers of portable inverter-based tech- nology in the design and manufacture of welding power sources, which is now the industry standard. In June 2019, Voestalpine acquired Selco and shortly thereafter introduced the Terra and Uranos ranges of high-end welding equipment to the market, complement-
RapiDeep, PulsDrive, and QuickPulse for PULSE MIG/MAG machines; and DcDrive, DcPulse, FastPulse and EasyArc for the TIG DC HF units. “The TERRA NX is our industrial work- horse: a robust, reliable and economical machine for heavy industry, making it our fastest mover and ideal for the demanding South African work environment,” he adds. “Within voestalpine Böhler, we talk about a Böhler arc and a Universal arc. Our Böhler arc programmes have been meticulously developed to suit specific Böhler Welding consumables, delivering optimum ma- chine and wire performance,” continues Saunders. URANOS NX welding systems are devel- oped with this whole solution philosophy in mind. They offer all the features of the TERRA platform, but with increased memory, faster communication capacity and enhanced integration between weld- ing consumables and machine parameters. This focus on specific welding requirements makes it the ideal solution for welding jobs involving complex alloys and the highest levels of weld quality. URANOS NX for optimised performance URANOS NX welding systems use a high- speed CANBUS internal communication system, which is totally immune to elec- tromagnetic noise, minimising deviation at the arc and enabling the system to respond much more quickly. They are delivered with customer- specific job applications in mind, featuring more than 600 welding programs tailored for various applications and industry The CORE 210 MMA features Advanced Pulsed MMA for better out-of-position, thin plate and pipe welding applications; TIG LIFT and TIG LIFT Spot Welding, a cost-effective solution where space is limited and frequency-sensitive devices are present; and Welding Parameter Storage.
The introduction of the next-generation product, URANOS NX, was launched in Oc- tober 2021 as a premium welding machine, built to optimise welding performance for the full range of materials and con- sumables, with synergistic programmes customised for welding applications using Böhler consumables. The TERRA NX followed in 2023, a ro- bust, reliable, productive and easy-to-use welding machine for heavy-duty applica- tions in the metal fabrication and mechani- cal industries. Built to ‘Get the job done’, the TERRA NX is optimised for steel welding to make ‘perfect weld seams’ easy to achieve. TERRA NX: ensures productivity while maintaining quality The TERRA NX range is designed for in- dustrial applications, with reliability and productivity in mind. “The focus has been to make the machines easier for a welder to use, to help them achieve the quality needed for every job. The machines have a full colour display, with an interface that is intuitive and easy for a welder to use,” says Keith Saunders. TERRA machines produce a reactive and dynamic arc that is optimised for heavy- duty steel welding. The units are reliable and robust, and the welding programs are all upgradable, which means that each machine can be customised to an indi- vidual welder’s needs and preferences, he continues. There are 13 different TERRA options in the range: five standard MIG/MAG options and five PULSE MIG/MAG options with out- put capacity ranging from 320 A to 500 A and three TIG DC HF machines ranging from 270 A to 400 A. From a welding characteris- tic perspective, each machine offers various options designed to optimise welding char- acteristics and performance: ArcDrive and RapiDeep for MIG/MAG machines; ArcDrive,
Voestalpine Böhler Welding has launched the CORE MMA range of modern single-phase MMA and lift-TIG welding power sources, built for the most demanding onsite and workshop environments.
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The TERRA NX is an industrial workhorse: a robust, reliable and economical machine for heavy industry.
Combined, these features make CORE MMA power sources reliable, durable, and resilient. The largest version, the CORE 210, weighs in at just 9.5 kg. They are built to last, and a five-year warranty on all models backs this up. “The range offers premium perfor- mance with a stable and smooth arc across all electrode types. Synergic func- tions offer quicker set-up times and tran- sitions between different welding tasks, while the expansive high-contrast display ensures readability, indoors and outdoors,” says Saunders. Advanced, customisable, easy-to-read controls make setting parameters intuitive, and smart monitoring features keep weld- ers informed. CORE’s ergonomic design is free from sharp edges, and the handle and shoulder strap make these machines easy to carry to where the welding is needed. The CORE 165, CORE 185 and CORE 210 all include Adjustable Hot Start and Arc Force functions to ensure smooth arc starts and to prevent electrode sticking. Additional features in the CORE 185 and CORE 210 include: • Advanced Pulsed MMA, which offers welders better out-of-position and thin plate capabilities with a more stable and manageable arc, reduced spatter, less post-weld cleaning and faster travel speed. This feature is ideal for welding thin-gauge materials, out-of-position welding, or pipe welding applications. • TIG LIFT and TIG LIFT Spot Welding, in which arc initiation is controlled so the tungsten electrode can touch the workpiece without contamination or sticking. TIG Lift is a cost-effective so- lution, suitable for use where space is limited and frequency-sensitive devices are present. • Welding Parameter Storage, which en- ables specific parameters for welding procedures to be saved so consistent and repeatable results can be achieved for future work. “Power, portability, easy set-up and smart features, combined with up-to-date weld- ing technology, enable our CORE MMA welding equipment to deliver consistency and performance in the toughest condi- tions,” says Saunders. “We are a leader in the welding industry with extensive consumable and equipment product portfolios and welding expertise. We understand complex welding applica- tions and can offer comprehensive and unique solutions to deliver the perfect weld seam,” concludes Keith Saunders. www.voestalpine.com/welding
The URANOS NX features a high-speed CANBUS communication
system, which is immune to electromagnetic noise, and enables the system to respond much more quickly.
date. This automated system ensures that all members of the welding team have the latest data, increasing transparency and reducing reliance on manual records. For enhanced security, Process Manager runs exclusively on proprietary on-premis- es hardware, with all information securely stored locally within the company’s net- work. This ensures complete control over data and eliminates any reliance on cloud- based solutions, Saunders notes. And while all machines are delivered with a standard set of welding programs and software, should a customer need a welding line for a new application or ma- terial, even on a one-off basis, this can be downloaded via weldNet and added to the machine, he adds. CORE MMA: built to last! In September 2025, the company launched its latest addition to the equipment range. With a completely new look, this single- phase range of portable welding power sources, CORE MMA, is designed to suit on-site work on the most challenging sites. The CORE series for MMA welding is a new generation of single-phase, portable welding machines engineered for perfor- mance and designed to meet the demands of professionals in light fabrication, light construction and the repair sector. “Our CORE welding equipment is designed to de- liver unmatched reliability, on shop floors, on-site or in extreme outdoor conditions. The design reflects decades of welding expertise combined in each unit,” notes Keith Saunders. The range includes three models: the CORE 165, the CORE 185 and the CORE 210, all of which feature a high-grade, hybrid- composite and galvanised steel construc- tion. They have ‘wind tunnel’ cooling management, which keeps the electronics dust-free while delivering adequate cool- ing. They also feature automatic input volt- age sensing and switching for either 115 V or 240 V single-phase, with an allowable input voltage fluctuation of ±15 %.
segments, includ- ing carbon steel, stainless steel, nickel alloys, clad-
ding, hard-facing, and dedicated crane and lifting packages. These programs are developed to ensure a perfect fit between the welding task and the consumables. The URANOS NX has the capacity to hold a further 240 customer programs based on their field experience. Additionally, URANOS NX inverters are designed to include patented greenWave® technology, which enables significantly better energy efficiency through optimised power consumption. Conforming to the strictest EN61000 standards, greenWave delivers a reduction in reactive energy consumption of between 70 and 100%, and over 50% reductions in joule-effect losses, both of which help to reduce power con- sumption and associated CO 2 emissions. Packed with Böhler’s full suite of weld- ing arc control features, URANOS offers a state-of-the-art solution for any combina- tion of filler material, welding process and application. For both TERRA NX and URANOS NX machines, it’s all about communication. voestalpine Böhler Welding has developed a software platform, weldNet, that enables standard synergic welding lines to be up- loaded to the Terra NX range of machines as well as customised synergic lines for the Uranos range of machines. Within weldNet, Process Manager provides a digital monitoring solution that optimises welding activities. With weldNet® Process Manager, all weld details are recorded in a central, secure database that is easily accessible and always up to
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SAIW News: SAIW 2.0 Transformation
The SAIW 2.0 Transformation Project
SAIW Training and Technical Manager, Confidence Lekoane, highlights the progress being made towards the full imple- mentation of the SAIW 2.0 Renewal Project.
T hroughout this year, the SAIW has focused on stabilising day-to-day operations, strengthening the Insti- tute’s certification infrastructure, advanc- ing its digitisation strategy, modernising its training and certification offerings, and securing the long-term sustainability of the organisation. “We have now completed a massive business restructuring process, which has made a significant impact on stabilisa- tion across the organisation. We are not entirely where we want to be yet, but the overwhelming backlog and daily opera- tional pressure have eased considerably,” says Lekoane. She adds that significant progress has been achieved in both company and personnel certification, as well as in the digitisation of several key systems critical to the SAIW’s future. “We have now completed a massive business restructuring process, which has made a significant impact on sta- bilisation across the organisation. We are not entirely where we want to be yet, but the overwhelming backlog and daily operational pressure have eased considerably,” says Lekoane. Digital transformation The newly launched SAIW Website high- lights the comprehensive nature of the SAIW’s digital transformation. “We have made excellent progress on the website, which has received very positive feedback,” she says.
The completely redesigned website is more than just a repository for information and news; it has been designed as a portal for all current and future SAIW members, students and clients to access exactly what they need from their own phones, tablets or computers. Embedded in the new site is direct ac- cess from anywhere to the newly developed cloud-based student management system, along with the online Course Prospectus, which provides searchable information about SAIW course offerings and the de- livery calendar for each course. A student wishing to take a course can register with SAIW through a process as simple as reg- istering for any online shopping platform. Once registered, a course can be booked, and students will instantly receive a system-generated quotation. Work is still being done on resits of examinations, transition exams, and recertification, which we hope will be bookable via this system in the near future to improve customer service and turnaround time. To enhance training quality and consis- tency, SAIW has implemented a Learning Management System (LMS) to manage and deliver training. This is a digital platform where students can access learning materi- als online, while lecturers can upload notes, videos and assignments. Assessments and quizzes can be done on the platform in preparation for examinations. The platform also serves as a centralised communication and announcements platform between lecturers and students. “We are exploring the possibility of marking exam papers automatically, which
SAIW’s Technical and Training manager, Confidence Lekoane. is not only faster – potentially within min- utes of having completed an exam – but it can also improve marking consistency and reduce bias,” she explains. Most importantly, SAIW is committed to ensuring dramatic improvement in the time between exam completion and the release of results, one of the Institute’s big- gest customer-service priorities,” Lekoane assures African Fusion . Also in the development pipeline is a system to compile examination questions for all the courses offered. In this regard, Artificial Intelligence (AI) can help to ensure consistent examination standards year to year and optimise language use to better suit the broad range of students who do not speak English as their first language. This innovation positions SAIW at the forefront of modern assessment best prac- tice and aligns with international expecta- tions for training and certification bodies. The development of Personnel and Com- pany Certifications is underway. The Cer- tification infrastructure has been updated, and a new filing infrastructure has been installed. For ISO 3834 Company Certification, SAIW has introduced the digital auditing System, Weldex, which can manage all aspects of ISO 3834, from welder qualifica- tions to quality management, eliminating paperwork and offering certified compa- nies real-time insights into their opera- tions. Integrating this purpose-developed and proven system into the ISO 3834 Cer- tification offering meets a core aim of de- livering affordable operational excellence to the South African fabrication industry, while fulfilling the SAIW’s core mandate of Personnel and Company Certification
The completely redesigned SAIW 2.0 website has been designed as a portal for all current and future SAIW members, students and clients to access exactly what they need.
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SAIW News: SAIW 2.0 Transformation
driving up quality standards. The Weldex system provides a compre- hensive digital solution, from preparation before an audit to a paperless auditing process that can be conducted via a tablet or laptop. “This reduces complexity, im- proves the company experience and makes ISO 3834 certification more affordable and accessible,” she assures. The National Personnel Certification databases of accredited persons, which the SAIW manages on behalf of the SAQCC for Competent persons (CP), Inspectors of Pressurised Equipment (IPE), NDT person- nel and IIW-accredited welding technolo- gists and welding engineers, are also being digitised and modernised to make them easy to access and automatically updated. Training and Technical success. Since July, Lekoane reports, the number of students enrolled in SAIW Welding Co- ordination, Welding Inspection, Practical Welding, NDT, Competent Persons, and all of ASME, AWS, and other training courses has increased again. “We have recently developed an Intro- duction to Laser Welding training course, which focuses on the fundamentals of laser technology, laser safety, suitable applica- tions, and hands-on practical laser welding. Laser welding is particularly well-suited to thin-sheet welding, making it ideal for those entering or already involved in the automotive industry. The course has now been added to the prospectus and is avail- able from 2026. On the technical side, she says the SAIW Materials Testing Laboratory is ready and available to assist clients and suppliers with approvals, welding procedures and any other testing work. “In addition, consul- tants are on hand to add value to projects and businesses through productivity and quality improvement, problem solving, de- velopment work and investigation services. Build national capacity in advanced NDT methods. Non-destructive testing (NDT) is crucial for ensuring the safety of critical components and systems in nuclear facilities, as well as for enhancing the quality of industrial products and ensuring the safe operation of equipment and plants, including metallic and concrete structures and constructions. South Africa is embarking on expanding its nuclear programme, which will see the construction of a multipurpose research reactor and 2 500 MW of nuclear generation capacity, which will require critical skills development, such as advanced NDT
Ray Turner, a global specialist in the ToFD NDT method, presents an ‘expert’ training course to the SAIW team of specialists: Front from left: Lesego Mocumi, Ray Turner, Mark Digby. Back row: Mark du Plessis and Jan Cowan.
The SAIW Materials Testing Laboratory Team – comprising Kegomoditswe Dire, Metallurgical Technician; Rumani Mawela, Metallurgical Laboratory Assistant; and Walter Mahlangu, Laboratory Assistant – is ready and available to assist clients and suppliers with approvals, welding procedures, and any other testing work.
examination team: Mark Digby, Jan Cowan, Clayton Calvert, and experienced NDT technicians Mark du Plessis and Lesego Mocumi. The PAUT training is scheduled for early next year,” she adds. With this growing capability, the SAIW intends to offer these advanced NDT courses independently in the near future,” she tells African Fusion . “We continue to strive to help the weld- ing, fabrication and engineering industries better meet the challenges they currently face, and we are now receiving a great deal of positive feedback from our students and the public regarding the excellent progress we are making. We are inviting anyone wishing to make suggestions or comments to go to our new website, where we now have a communication channel for input on any aspect of the SAIW’s service delivery or developmental progress,” Confidence Lekoane concludes. https://www.saiw.co.za
techniques, to ensure the programme can be safely and successfully implemented. “In view of South Africa’s relatively limited NDT capabilities, advanced NDT methods, including Phased Array Ultra- sonic Testing (PAUT) and Time of Flight Dif- fraction (ToFD), are becoming increasingly important in industry as they improve the probability of flaw detection and dramati- cally increase the reliability of inspection results. To address this national skills gap, the International Atomic Energy Agency (IAEA) is providing support to build the capacity required for these advanced meth- ods,” explains SAIW Technical and Training Manager, Confidence Lekoane. “ As part of this support, the SAIW, through its cooperation with NECSA and the IAEA, is receiving specialised train-the-trainer pro- grammes to enhance internal capability. The overseas expert for ToFD, Ray Turner, has already completed the first phase of training with the SAIW NDT training and
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SAIW Member profile: Aurex Constructors
Aurex Constructors: for uncompromised excellence
Aurex Constructors is a proudly South African construction, maintenance and turnaround service provider for the oil, gas, chemicals and mining sectors, as well as the thermal and renewable power sectors. African Fusion meets with Sector Director Clive Garner and Quality Manager Wentzel Houston.
A urex Constructors, which traces its roots back to the 1980s as Kentz Engineers and Constructors, was initially focused on electrical and instru- mentation (E&I) work, particularly on maintenance and shutdown projects. The company built a strong presence in the petrochemical and oil and gas sectors of Southern Africa. “Over the years, we’ve established our- selves as a leading provider in the energy industry, delivering construction, turn- arounds and maintenance solutions,” says Clive Garner, Sector Director for Oil, Gas, Chemicals and Mining at Aurex Construc- tors. In 2014, Kentz was acquired by SNC- Lavalin and continued to serve as a leading contractor in the energy space. Then in 2020, following a management buyout led by current CEO, Stuart Kent, the business re-emerged as Aurex Constructors. Following the buyout, Aurex retained its core team and operational focus in South Africa, preserving its reputation and cli- ent relationships. The company has since expanded its footprint across sub-Saharan Africa, delivering comprehensive SMEIPP services – structural, mechanical, electrical,
instrumentation, piping and platework – across tankage and terminal infrastructure, mineral processing facilities and energy plants spanning petrochemical, renewable, and thermal technologies,” Garner tells AF . Fabrication facilities and capacities Aurex’s fabrication facility in Chamdor, Krugersdorp, west of Johannesburg, is a strategic enabler of the company’s op- erations. Originally established to support field execution, it now plays a pivotal role in delivering high-quality, preassembled components that drive efficiency, safety and performance across the company’s business lines. “We have nearly 24 000 m 2 of space at this facility, with 7 000 m 2 of under-roof manufacturing workshops,” says Garner. According to the company’s Quality Manager, Wentzel Houston, the Chamdor facility has maintained ISO 3834-2 since 2012, ensuring consistent welding qual- ity and traceability. “Our fabrication work adheres to global standards including ASME B31.1, B31.3 and VIII Div 1 Appen- dix 10,” he explains. “We specialise in high-pressure piping systems, small to
Aurex Constructors’ operations director Clive Garner, along with quality manager Wentzel Houston. medium-sized pressure vessels, and heat exchangers of up to 6.0 metres in diameter.” The facility also supports the fabrication of tank components for on-site assembly and the fabrication of structural steel sup- port systems. It is critical to our tankage and terminals division and is widely used across mining, petrochemical, and renew- able energy sectors. “We complete 60-70% of the welding under controlled conditions in the Chamdor workshop, while preparing the remaining joints for efficient on-site assembly,” Houston adds. Additional facilities extend Aurex’s operational reach. “Our Head Office in Mid- rand, Gauteng, houses management and functional support teams, along with engi- neering services for the renewable energy sector and detailing services for tankage and terminal projects,” says Garner. “In Secunda, we’ve optimised the layout of our facility to deliver real value to clients and projects,” he continues. “Dedicated zones for training, assessments and cod- ing of welders and project staff ensure that every team member deployed meets our exacting standards. This translates directly into safer, faster and more reliable execution in the field, especially on high- specification projects where quality and compliance are non-negotiable.” The Secunda site also includes a central- ised warehouse for assets and equipment. “It serves as a logistics hub for managing, servicing and maintaining our fleet of vehicles, cranes, welding machines and other critical tools. Keeping our assets in peak condition ensures uninterrupted project delivery and rapid mobilisation,” Garner tells AF . In Namibia, Aurex Constructors operates from an office in Walvis Bay, where work- shop facilities support the company’s first tank contract in Lüderitz for the local ter- minal sector. “We’ve also introduced site- specific training and assessment protocols to ensure our teams are equipped to meet
Aurex Constructors’ Chamdor facility has maintained ISO 3834-2 since 2012, ensuring consistent welding quality and traceability.
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SAIW Member profile: Aurex Constructors
acceptance rate last year. That’s because we can detect and correct variations in real time before they cause downstream issues,” he explains. Aurex also differentiates its quality metrics by application to drive continuous improvement. “On tanks and linear welds, we’re achieving a zero-defect rate, and on the thicker bore piping, of over 10 mm wall thickness, we’re consistently below 2.5%,” he notes. “Our current overall average rate is down to 1.9%, which reflects the strength of our systems, our people, and our com- mitment to quality.” Aurex is expanding its footprint across Southern Africa to meet growing demand for energy infrastructure, fuel distribution and sustainable power solutions. With South Africa’s refining capacity declining, Garner is seeing increased investment in infrastruc- ture to support the import and distribution of fuel. “This includes tank farms and fuel distribution hubs that support offloading and redistribution across the region.” In Namibia, Aurex is constructing on-site fuel tank infrastructure to support terminal operations, which is expected to unlock fur- ther opportunities in the local mining sec- tor. In Mozambique, the company is execut- ing tank refurbishment and construction projects in Matola and Beira, strengthening the country’s fuel storage and distribution capacity while supporting key clients in the energy and petrochemical space. New markets: Expanding with purpose In addition, Aurex has been delivering utility-scale solar photovoltaic (PV) projects for over 12 years, establishing itself as a trusted partner in South Africa’s renew- able energy landscape. With over 1.3 GW of installed solar PV capacity across 16 solar plants, the company offers flexible support across the full EPC scope, including trench- ing, cabling, mechanical, electrical and instrumentation services. Recent highlights include solar projects ranging from 10 MW to 140 MW, as well as the flagship 540 MW solar park with battery storage in Kenhardt, Northern Cape – one of the largest hybrid solar and storage projects in the world. “Our diversified portfolio, welding expertise and proven quality standards enable us to deliver tailored solutions for tankage, terminals, petrochemical fa- cilities, mining operations and renewable energy projects across Southern Africa,” Garner concludes. “We’re not just respond- ing to market shifts, we’re helping shape the region’s energy future.” www.aurex.com
Above: For piping with wall thicknesses up to 6.0 mm, Aurex typically use GTAW, which allows for precise control and high-quality welds with minimal rework. Right: On thicker-bore piping with wall thicknesses exceeding 10 mm, Aurex consistently achieves rejection rates below 2.5%.
able where precision and repeatability are critical, particularly in high-spec piping systems. “Ultimately, the choice of process depends on the technical requirements and client preference,” Houston says. “Some end users restrict certain methods, so we always engage early to determine the best-fit approach before finalising weld- ing procedure specifications (WPSs) and conducting quality acceptance testing,” he assures. On the consumable side, Aurex relies on trusted consumable brands, such as Böhler Welding and ESAB, for critical applications, with Afrox providing accessible day-to-day supplies. “We select welding equipment based on project requirements rather than brand preference, and we’re actively evalu- ating advanced technologies, including pulse welding modes, to enhance our pro- ductivity and precision further,” he adds. ISO 3834 accreditation The Chamdor workshop was the first facil- ity to be ISO 3834 certified in 2012,” says Houston. At the time, the primary driver was the need to fabricate pressure vessels and components that met the evolving standards of the energy and petrochemi- cal sectors. As client expectations evolved, so did Aurex’s quality framework. “More and more clients began specifying ISO-3834 compli- ance, so we extended our certification across all our facilities, including Secunda and Namibia, and to all of our onsite weld- ing activities,” he tells AF . Houston continues: “Once embedded, the culture of ISO 3834 had a measurable impact. Over the past five years, we have consistently met our reject rate target of under 4%, and for the past two years, we’ve brought that down to below 2.5%,” he tells AF . These figures reflect performance across all certified sites, including field- based work. “In our controlled workshop, the results are even stronger,” he adds. “At Chamdor, for example, we achieved a 100% weld
project demands and client expectations from day one,” he explains. “This approach reinforces our commitment to safe, high- quality delivery in new markets.” In Mozambique, Aurex Constructors Lim- itada operates from Maputo, supporting the country’s growing energy sector. The team has delivered and is actively execut- ing tank construction projects in Beira and Matola, contributing to the development of terminal infrastructure and fuel storage capacity. These projects involve SMEIPP scope and are closely coordinated with the fab- rication hub in South Africa. The Mozam- bique operation also provides detailing, site support and project integration ser- vices, ensuring seamless execution aligned with client expectations. “As part of Aurex’s Southern Africa footprint, Mozambique strengthens our ability to mobilise skilled teams and deliver compliant, high-quality tankage solutions across borders,” he adds. Welding choices Aurex employs a range of welding processes tailored to project specifications and cli- ent requirements. Houston explains that GTAW/TIG, SMAW/stick, GMAW/MIG/MAG, and FCAW are all routinely used across the company’s fabrication and field operations. “For piping with wall thicknesses up to 6.0 mm, we typically use GTAW, which allows for precise control and high-quality welds with minimal rework,” says Houston. “We’ve built a strong team of highly skilled welders who consistently meet the quality standards required for these applications,” he adds. For thicker sections and structural steel, Houston notes that GMAW with solid wires is preferred due to its speed and cost-effec- tiveness, while flux-cored wires are used where enhanced mechanical properties are required. “GMAW is generally our go-to for productivity, but flux-cored options can offer better performance depending on the material and design,” he adds. Orbital welding capabilities are avail-
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Coreweld 46 LS from ESAB
Coreweld 46 LS: for faster, cleaner and more efficient welding African Fusion talks to ESAB South Africa’s product manager for filler metals, Kevin Xaba, about the premium gas- shielded, low-silica metal-cored wire, Coreweld 46 LS, a high- deposition, low-heat-input welding consumable designed to deposit exceptionally low amounts of silica on the weld surface.
E SAB Coreweld metal-cored wires have been developed to meet the needs of demanding welding ap- plications for structural steel, heavy equip- ment, pressure vessels, petrochemical plants, offshore rigs, railway vehicles, ships and general fabrication. “ESAB pioneered the development of gas-shielded flux-cored welding (FCAW) nearly 60 years ago, so we can now offer the broadest variety of carefully crafted mild steel and low alloy flux- and metal-cored wires,” says Kevin Xaba, ESAB South Africa’s product manager for filler materials.
“Fabricators have a wide range of weld- ing processes and consumables to choose from, each with their own advantages and disadvantages. Within this mix, metal- cored wires are becoming increasingly popular because they offer higher deposi- tion rates and faster travel speeds, and improved cost-effectiveness,” he continues. Metal-cored welding wire comprises tubular wire filled with metal powders, alloying elements and arc stabilisers. “Our Coreweld metal-cored wires combine high deposition rates and efficiencies, high travel speeds, excellent penetration and ease of use. They also provide excellent arc stability and outstanding penetration and wetting, with superior root and sidewall fusion,” Xaba notes. ESAB Coreweld 46 LS Coreweld 46 LS is a high productivity wire capable of welding at high deposition rates with relatively low heat input compared to solid wires. This is due to a higher cur- rent density. “Coreweld 46 LS is a fantastic metal-cored wire for fabricating and/or repairing yellow-metal equipment such as the dump truck and excavator buckets used in South Africa’s mining and construction sectors,” notes Xaba. Most notably, he says the Coreweld 46 LS is formulated to remove silica deposits from the weld metal, producing an excep- tionally clean weld surface free of silicon islands. Designed for welding both thin and thick steel plates with Ar+CO 2 shielding gas mixtures, Coreweld 46 LS produces a wider
arc than conventional solid wires, allowing larger gaps to be accommodated. The wire classification is SFA/AWS A5.18: E70C‑6M H4; EN ISO 17632-A: T 46 4 M M20 2 H5 and has approvals from all the following: BV: 4Y40 H5 (M20 and M21); DB: 42.039.38; VdTÜV: 12152; ABS: 4Y400M H5; BV: 4Y40 H5; CE: EN 13479; DNV: IV Y40MS(H5) (M20 & M21); and UKCA: EN 13479. Delivering yield strength of 485 MPa, tensile strength of 545 MPa, 29% elonga- tion, Charpy impact values of 72 J at -40 °C, and diffusible hydrogen levels of less than 4.0 ml/100 g, this wire is ideal for welding C-Mn steels, including those susceptible to hydrogen-induced cracking. “Deposition rates are a particular advantage, with the 1.2 mm wire diameter offering 1.3-8.0 kg/h, depending on amperage and voltage set- tings,” Xaba adds. A yellow-metal success story In a case study for a component fabrica- tor supplying a mobile equipment OEM, the fabricator increased productivity by 17% by switching from a conventional metal-cored welding consumable to ESAB’s Coreweld 46 LS. “The fabricator was producing hydraulic links for mobile vehicles using two robot- based welding systems and a competitor’s metal-cored wire. Production capacity was limited by the accumulation of sili- con islands during multi-pass welds. This forced the operator to stop each robot for five minutes to remove the silicon islands from the welds of every component before restarting the welding cycle. “The switch to using a 1.2 mm Coreweld 46 LS eliminated the need for inter-pass grinding, enabling the robots to complete each component without interrupting the cycle. In addition, the welding capacity at both welding stations increased by 17%. Combined, the switch resulted in total production cost savings of 13% and an an- nual cost savings of €60 000,” Xaba explains. “While very low levels of silica on the weld surface were key to this success,
ESAB offers complete fabrication solutions, along with the support needed to ensure that products such as Coreweld deliver the results fabricators need.
A component fabricator supplying a mobile equipment OEM increased productivity by 17% by switching from a conventional metal-cored welding consumable to ESAB’s Coreweld 46 LS.
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delivering savings on downtime per cycle for each robot station, Coreweld 46 LS also offers other production advantages: a high deposition rate with relatively low heat input compared to solid wires, for example, and if used manually, these wires are easier to use than solid wires and offer far better productivity for those still using stick electrodes,” he adds. Remanufacturing mine drill bits Citing a second Coreweld 46 LS success story, Kevin Xaba says the wire is also ideal for weld repair and build-up applications. In a welding remanufacturing depart- ment, two welding robots were being used with solid wire to build up the profiles of worn drill bits before hard-facing. Several problems were encountered: the 1.2 mm solid wire required a relatively low deposi- tion rate to minimise heat input; excessive spatter caused downtime for cleaning the welding torches; and costly grinding opera- tions were necessary to remove spatter from each component. This was causing capacity shortages and production bottlenecks. Test welding was performed using the ESAB 1.4 mm Coreweld 46 LS wire, yielding very good results: essentially no spatter
ESAB Coreweld metal-cored wires offer faster, cleaner and more effective welding, while meeting the needs of demanding welding applications for structural steel, heavy equipment, pressure vessels, petrochemical plants, offshore rigs, railway vehicles, ships and general fabrication. higher current density associated with metal-cored wires, the heat input could be kept low at the higher deposition,” Xaba explains, adding that lower silicon levels compared to using solid GMAW wires are also an advantage in this type of applica- tion. “As a world leader in Welding, cutting equipment and consumables, we at ESAB can offer complete fabrication solutions for virtually every application, along with the support needed to ensure that products such as our Coreweld 46 LS deliver the re- sults that South African fabricators need,” concludes Kevin Xaba. www.esabsa.co.za
“Coreweld 46 LS is a fantastic metal-cored wire for fabricating and/or repairing yellow- metal equipment such as the dump truck and excavator buckets used in South Africa’s mining and construction sectors,” notes Xaba. and a significantly higher deposition rate. The company therefore decided to switch from the previously used 1.2 mm solid wire to a 1.4 mm Coreweld 46 LS wire. This increased production capacity by 42% at the two robot stations. It also resulted in less downtime due to lower torch-cleaning requirements and less time spent cleaning spatter from drill bits after welding. The total production cost for this part of the remanufacturing operations was reduced by 17%, resulting in annual cost savings of €100 000 from these two robot stations. “In this case study, the higher deposi- tion rate associated with Coreweld 46 LS was the critical factor, and because of the
SUPPLYING INDUSTRIAL AND SPECIALTY GAS PRODUCTS TO THE SOUTHERN AFRICAN REGION
www.airproducts.co.za
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November-December 2025
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Fronius’ next-generation Fortis
Fronius has launched its next-generation Fortis series MIG/ MAG and Multiprocess system, a versatile range of solutions for high-quality manual MIG/MAG, TIG and MMA welding with an all-new modern design that meets the diverse require- ments of small and medium-sized businesses. Fronius Fortis: flexible, networked and powerful MIG/MAG
T he new generation Fronius Fortis range was launched at FABTECH in Chicago (USA) and SCHWEISSEN & SCHNEIDEN in Essen (Germany) in Sep- tember this year. “Fortis combines robust technology and intuitive operation with maximum connectivity to set new stan- dards in the metalworking industry,” said Peter Fronius, Head of System Solutions at Fronius International. The Fortis product range comprises several powerful devices operating in the 270-500 A welding current range. They are available as either compact all-in-one systems or as split versions with external wire feeders, which provide a significantly extended operating range. All models can be equipped with proven Fronius functions, including pulse welding, SynchroPulse, stitch welding, TAC tacking, HotStart and anti-stick. The Fortis XT complements the portfolio as a highly energy-efficient all-rounder for
three-phase mains voltages ranging from 200 to 600 V and single-phase operation at up to 320 A, featuring an advanced cel- lular electrode (CEL) welding mode. As a result, these machines are ideally suited for worldwide use, saving energy thanks to their higher power factor and offering a higher output characteristic curve for even greater welding performance. Rounding off the range is the Fortis Duo, which combines a compact Fortis MIG/MAG machine with an additional, external wire feeder, enabling the use of two wire spools and two welding torches from a single power source. “This enables the welder to easily switch between different materials or wire diameters at the touch of a but- ton, all without any retooling,” explained Michael Eisterhuber, Product Line Manager at Fronius International. “Users save an
enormous amount of time through this feature, which is ideal for frequently
The Fortis product family covers the 270-500 A range. Compact all-in- one systems that can include integrated
water cooling, or split versions with external wire feeders for a significantly
extended operating range, are available.
Rounding off the range is the Fortis Duo, which combines a compact Fortis MMA machine with an
additional, external wire feeder, enabling the use of two wire spools and two welding torches from a single power source. changing tasks in contract manufacturing, steel construction or welded assembly.” Developed for flexible working In many companies, welding tasks change daily, with new materials and different seam shapes on various components. The Fronius Fortis was developed as a solu- tion to aid in this dynamic. With up to 240
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