- The South African Wind Energy Association (SAWEA) reports that the casting of the 1,425 keystones required for the construction of a wind farm cluster near the Impofu Dam in the Eastern Cape has successfully commenced at a custom-built concrete tower manufacturing facility.
- Production is expected to ramp up significantly in the coming months to meet the demands of this large-scale renewable energy initiative, with additional keystones scheduled for delivery to the site next month.
“This custom-built factory, located 52 kilometres from the wind farm site, is a key investment in the region’s renewable energy infrastructure and we are pleased to be able to announce that the facility is ready to ramp up in line with the construction milestones,” explained David Moncasi Hortet, Head of Sales for Africa at Nordex Energy South Africa.
Each of the wind turbine concrete towers comprise 25 individual keystones, with the heaviest keystone cast to date weighing over 57 tonnes, measuring 20 metres in length and over 5 metres in width. In addition to concrete, rebar is a crucial structural component, ensuring the strength of the keystones by absorbing tensile forces that concrete cannot withstand on its own. Rebar installation is completed in one day, followed by a 4-5 hour casting process, and the keystones are cured for 7-10 days to achieve the necessary strength for transport.
“Considering the local content contribution, including steel rebar, concrete, and aggregate—each sourced locally—the production of the towers not only supports job creation but also provides an additional boost to the South African economy,” added David Moncasi Hortet.
Image credit: SAWEA
Given the size and weight of the keystones, 13 of the 25 required for each turbine tower will need police escorts for transportation. With the factory’s proximity to the wind farm site, the logistical process is streamlined, ensuring smooth delivery of these essential components.
Developed as part of a broader strategy to stimulate the local economy, the facility is creating approximately 350 ongoing jobs and spans nearly 10 hectares. Its strategic location near the Port of Ngqura supports efficient logistics for both the manufacturing and transport of the keystones, further cementing the Eastern Cape as a renewable energy hub.
This cluster of wind farms is a significant milestone in South Africa’s renewable energy efforts, with the casting of the first keystone marking a crucial step in the project’s construction progress. As manufacturing accelerates, the project will continue to contribute to the country’s clean energy goals and bolster the local economy.
Author: Bryan Groenendaal
