First Africa Guide (2025)

10/07/2025

Bolt security for the railways sector

Bolt security is essential for optimum safety in all industries, particularly in the railway sector, where demands on rail lines and train components are under increasing pressure, as trains and railway networks become more sophisticated.

“Bolt loosening anywhere on railway infrastructure and rolling stock can be costly and even fatal if a train is in motion. It is critical to ensure that the selected bolt securing product holds firmly, despite a train’s high-speed travel when carriages are under constant vibration and strain,” says Maryna Werner, BMG’s Fasteners Sales Manager. “Included in BMG’s solutions for the railways industry is the Nord-Lock bolt securing system, which is based on advanced wedge-locking technology designed to safely secure bolted joints that are exposed to severe vibration and dynamic loads in extreme conditions.

“The Nord-Lock X series ensures there is no bolt loosening in safety-critical areas of railway bogies, coupling devices, brake systems, rail dampers and housings. These robust washers provide maximum security for critical bolted joints that are exposed to bolt loosening and slacking – ensuring they remain secure, no matter how fast the train is travelling. The Nord-Lock bolt securing system improves personal safety, reduces the risk of lost production or material damage due to bolt failure and also lowers maintenance requirements.

“We recommend the use of NLX10, NL10ss and NL12ss on various components, including signal bonds, contact splices and rail and mast bonds. The use of Nord-Lock washers on the contact splices means there is no need to re-tighten components at a later stage, which means fewer hook-up incidents, reduced maintenance requirements and minimal downtime.”

Extensive testing indicates that X-series washers have performed to required specifications in arduous conditions, with no slip occurring. To date, no incidents have been reported regarding hook-ups caused by contact splices that are fitted with Nord-Lock washers.

The multi-functional design of the Nord-Lock X-series offers the highest security against spontaneous bolt loosening and slackening – even at the highest levels of vibration caused by rail traffic, which normally put bolted joints at risk. This wedge-locking construction prevents spontaneous bolt loosening and is enhanced by an integrated spring-effect that compensates for the loss of preload due to slackening.

The Nord-Lock X-series, which is quick and easy to install and remove with standard tools, has been certified for quality and safety by TŰV, a leading international institute in quality and safety certification.

Each washer pair has cams on one side and radial teeth on the opposite side to secure the bolted joint with tension, rather than friction. The conical shape of these washers creates an elastic reserve in the bolted joint to compensate for the loss of preload and prevents slackening.

On tightening the fastener, the washers flatten and the serrations engage the contact surfaces. Since the cam angle ‘α’ is greater than the thread pitch ‘β’, the wedge-locking effect will prevent any rotation of the fastener. Directly after tightening, the joint settles and the fastener sinks into the surface material. The washers immediately deflect and the spring-effect counteracts the slackening movement of the bolt, thereby preventing loss of preload of the joint.

These multiple functions continuously act on the bolted joint to maintain preload and prevent spontaneous bolt loosening, providing an effective solution for vibration, dynamic loads, settlement and relaxation.

The Nord-Lock range of securing washers, distributed and supported by BMG, is the only brand on the market that currently displays the CE quality mark of approval from leading global authorities. The prestigious CE marking is certification that these wedge-locking washers adhere to stringent safety and quality regulations required in many industries.

BMG offers a technical advisory service to determine the dimensions and load conditions of existing or required bolted joints. Current tightening methods are evaluated and bolt preloads, for absolute reliability and durability, are calculated by the highly skilled team.

BMG

10/07/2025

Galvanized rebar reinforces the future of infrastructure

The International Zinc Association (IZA) Africa is urging infrastructure developers and consulting engineers to prioritise durability and sustainability by adopting hot dip galvanized reinforcing steel (rebar) in concrete used in civil engineering and construction. With the South African economy demanding cost effective and resilient infrastructure, galvanized rebar presents a proven, cost-effective solution for extending the lifespan of vital structures while reducing maintenance costs.
Concrete is one of the most widely used construction materials globally, yet its strength and longevity are frequently compromised by the corrosion of embedded steel rebar. With South Africa’s long coastline and six large coastal cities and ports and billions of rands infrastructure, the case for galvanizing concrete rebar becomes ever more urgent.

Hot dip galvanized rebar involves coating steel with a protective layer of zinc, offering both barrier and sacrificial protection against corrosion. The alkalinity of concrete prevents the zinc coated rebar from corroding and the galvanized coating is an excellent barrier. This dual mechanism not only prevents rust from forming but also prolongs the structural integrity of concrete in aggressive environments such as coastal zones, marine facilities, bridges, and seaside infrastructure.

The benefits of using galvanized rebar in concrete are multifaceted. Firstly, its exceptional corrosion resistance extends the service life of concrete structures, reducing the need for costly maintenance and repairs. Secondly, galvanized rebar can enhance the bond strength between the rebar and concrete, leading to improved structural performance. In addition, galvanized rebar can contribute to sustainable construction practices by reducing the environmental impact associated with premature failure and replacement of concrete structures.

“South Africa and the wider African continent stand at a crossroads where long-term investment in sound infrastructure must meet the realities of atmospheric and environmental resilience,” says Simon Norton, Director of IZA Africa. “Galvanized rebar is not just a technical upgrade; it is an economic and environmental imperative. The City of Cape Town now mandates its use in all new bridge constructions and repairs, a policy that other municipalities and countries should consider adopting.”

Galvanized rebar significantly reduces the risk of structural cracking, spalling, and corrosion-induced failure. Its compatibility with concrete chemistry, even in the face of carbonation and chloride ingress, makes it ideal for modern, sustainable construction practices. Case studies, include marine-facing retaining walls at Clovelly, Cape Town, the N1 road bridge walls near Woodstock and the sea retaining wall at Green Point consistently show its superior performance compared to traditional uncoated rebar steel.
There are 24 hot dip galvanizing plants in South Africa, including excellent plants in Cape Town, Johannesburg, Port Elizabeth, Durban and Richards Bay, that can galvanize reinforcing steel for concrete. “Consulting engineers and civil engineers should be specifying and requiring galvanized rebar in their projects,” says Norton.

“As Africa builds the long-lasting infrastructure of the future, from smart cities to resilient coastal defences, hot dip galvanized rebar offers an unmatched opportunity to reinforce both physical structures and long-term development goals,” concludes Norton.

08/07/2025

Linear motion systems boost railway maintenance safety and efficiency

BMG has expanded its portfolio of motion control technologies with the introduction of Rollon linear guidance systems, designed for high efficiency in many industries, including the rail sector in Southern Africa.

These advanced systems – developed by Rollon, a member of The Timken Company – are specifically engineered to deliver high-performance motion solutions in demanding environments, including railway infrastructure and maintenance applications.

The Rollon Compact Rail system, which has shown success in European maintenance locomotives, offers a robust solution that enhances both safety and functionality. By facilitating smooth manual adjustment of onboard equipment, like seating mechanisms, this system enables technical teams to improve lateral visibility and react more effectively to track-side conditions during maintenance operations. The system also allows operators to slide across to observe both sides of the locomotive, without relying on powered components, which reduces failure risks and improves operator performance.

Leon Koekemoer, BMG’s Linearway and Ball Screw Product Specialist, states, “Rollon’s linear motion guidance solutions are built to accommodate misalignment and can be mounted on standard fabricated steel, without the need for precision machining. This makes them ideal for heavy-duty and mobile environments, as seen in the railways sector. In addition, the telescopic rails within the range offer market-leading load capacities, ensuring long-term reliability.

“Rollon’s approach is based on delivering modular and configurable motion systems that integrate easily into various industrial structures. For railway operators, this translates into reduced fabrication costs and greater flexibility in vehicle interior layouts. Beyond seating, the same principles are being applied to tool storage, inspection bays and other areas, where adaptable linear movement can contribute to better ergonomics and workflow.”

A notable feature of the Compact Rail TLC43 and ULC43 models is their ability to perform under harsh operating conditions, including vibration, dust and shock.

These rails use rollers rather than balls, providing smoother and quieter motion, while withstanding accelerations of up to 3G’s and functional loads of 150 kg. This solution is suitable for both new installations and retrofitting in mobile maintenance units, where ease of integration and minimal electronic control requirements are advantageous.

In addition to maintenance in the railways sector, Rollon Compact Rail – with its self-aligning and compact design – is used in diverse industries, including industrial machines, material handling, packaging, aerospace, electronics, food and beverage, machine tools, building and furniture, special vehicles, robotics and automation and healthcare.

As part of the extensive Timken portfolio, Rollon products benefit from global standards in quality assurance and supply chain integration. BMG’s appointment as the authorised distributor in Africa ensures that the local market has access to both the product range and the necessary local support, including technical selection, condition monitoring and retrofit consultation.

BMG supports industry with motion control solutions that combine performance, durability and ease of use. The Rollon system enhances this offering, particularly for rail customers seeking dependable and efficient components for fleet upgrades and new builds.

BMG

08/07/2025

Quick and easy residue removal

BMG’s Liqui Moly range of oils, additives and care products includes a highly efficient sealant remover that not only ensures thorough cleaning of mechanical components, but also reduces maintenance time.

“Liqui Moly sealant remover – designed for use in many industries, including automotive applications - is a combination of solvents, selected for their excellent cleaning properties,” explains Carlo Beukes, Business Development Manager, Agricultural, Automotive and Lubrication divisions, BMG. “This fast-acting sealant remover is suitable for use on components manufactured from steel, iron and non-ferrous metals, as well as ceramics, wood and glass. This liquid product is conveniently packaged in aerosol form for easy application on valve covers, cylinder heads, water pumps, oil sumps, fl**ge seals and vehicle, engine, exhaust and mechanical parts.

“Baked-on and hardened sealing compounds, adhesives and residues are quickly dissolved and removed and a notable feature is this sealant remover also adheres to vertical surfaces.

“We have received positive feedback from customers who claim this product offers substantial savings in time and effort, making a cleaning task that was previously laborious and costly, totally painless.”

Apart from use in the automotive sector, this sealant remover is also suitable for industrial, construction and agricultural applications.

Liqui Moly chemicals, which have been developed in Germany to the highest quality standards, reduce operational and maintenance costs and also enhance environmental protection.

Other Liqui Moly products available from BMG include a highly efficient silicone gasket sealant, engine oil additives, transmission fluids and care products.

For more information, click on the youtube link https://www.youtube.com/watch?v=LgwM-5LUOqY

BBMG

04/07/2025

Integrated Air Solutions empower customers with reliable, flexible and cost-effective rental compressed air with zero CapEx

Countless industrial plants rely on compressed air to power operations. Flexibility, reliability, efficiency and cost control are fundamental to long-term sustainability. Rental solutions deliver exactly that. Subsequently more businesses are turning to Integrated Air Solutions for rented on-demand compressed air, without the burden of capital expenditure.

“The argument for renting compressed air is a strong one, built on a foundation of benefits that enhance and streamline every link in a customer’s value chain,” says Rudi Denton, Rental Sales Manager who heads up Integrated Air Solutions’ rental division. Starting with the machines themselves, Denton affirms that Integrated Air Solutions’ extensive and versatile rental portfolio which includes rugged, high-performance industrial screw diesel and electric models, deliver flexible compressed air tailored to meet virtually every operational need.

“Our diesel screw compressors cover an impressive range from 185 cfm at 8 bar all the way up to the powerful 1500 cfm, 24 bar machine which is further complemented by our diesel oil-free compressors that provide clean air at 1500 cfm and 10 bar.” For customers seeking electric options, Integrated Air Solutions offers compact 15kW units at 6 bar up to the more heavy-duty 250kW compressors at 10 bar. The extensive rental fleet enables the air solutions specialist to cater to project-specific needs with the flexibility to upscale or downscale equipment as required. This allows Integrated Air Solutions to serve virtually every market segment - from construction, civils and infrastructure, and general industry to borehole drilling, oil & gas, logistics, and even the residential sector.

“This brings me to CapEx,” continues Denton. “Renting an air compressor eliminates the need for significant upfront capital investment, making it an ideal solution, even more so when budgets are tight. Moreover, instead of tying up resources in equipment ownership, businesses can allocate funds elsewhere.”

Further elaborating on the added flexibility of rental solutions, Denton explains that the customer can rent a compressor to meet the air demands of a specific project, and once the contract ends, the unit is simply returned, eliminating the cost of equipment lying idle after project completion.

With one of the youngest equipment fleets in Southern Africa, Integrated Air Solutions is committed to supplying premium quality, efficient machines equipped with state-of-the-art features and cutting-edge technologies. Customers gain access to the latest, most advanced compressed air equipment and technology without the hassle of updating inventory or worrying about depreciation and instead, can capitalise on the significant advantages this brings. Additionally, customers pay solely for what they use, effectively reducing waste and avoiding unnecessary expenditure.
Following the launch of their rental offering three years ago, Integrated Air Solutions has seen a rapid expansion of their customer base. “Staying true to our core mandate, we remain committed to delivering high-quality service to all our customers, whether they rent or purchase compressed air equipment," asserts Integrated Air Solutions Managing Director, Grant Robinson. “In order to sustainably meet our customers’ unique and evolving compressed air requirements, we are focused on continuously expanding our rental fleet with carefully selected compressors."

With fleet strength, quality and range forming the backbone of Integrated Air Solutions’ rental business, a dedicated team stands firmly behind every piece of equipment, delivering exceptional service and comprehensive after-market support. “Customers can say goodbye to their maintenance headaches as our rental solutions include full support to keep their equipment in peak condition and ready for deployment,” asserts Denton. “With our fast service delivery, machines are up and running in no time, minimising operational downtime and optimising production efficiency for customers.”

“Our tailored solutions and total flexibility ensure that irrespective of whether customers have a short-term requirement or a complex, multi-site, long-term project, we craft bespoke compressed air systems precisely engineered and perfectly aligned to each customer’s unique requirements.”

Denton adds that they go beyond rentals. “As an integrated service provider, we manage both our core products as well as customers’ externally sourced equipment. Moreover, we support Integrated Air Solution’s sales operations by providing customers with reliable temporary compressed air solutions, ensuring continuous production while their existing compressors are being repaired or replaced."

“Our integrated rental air solutions deliver unmatched flexibility, significant cost savings and operational efficiency at every stage, empowering customers to focus on what they do best, while we power their compressed air needs seamlessly and reliably,” concludes Denton.

Established by Johannesburg based GiGi Investments in 2017, Integrated Air Solutions supplies innovative, technologically advanced premium-brand industrial electric and diesel-driven compressors to Southern African industry. The B-BBEE level 4 organisation is the exclusive regional sales and service partner in South Africa for ELGi Equipment, FS Elliott, Aircom and the local service partner for ABC

04/07/2025

Machinery maintenance and the hidden cost of fuel adulteration

Fuel adulteration remains one of the most insidious threats to industrial machinery, safety, and environmental compliance across multiple sectors. Craig FitzGerald, Chief Executive Officer of ISO-Reliability Partners, discusses how this widespread issue undermines not only mechanical performance and operational safety but also poses significant legal and financial risks.
“Adulterated fuel is not just a matter of poor performance; it is a direct threat to equipment integrity, worker safety, and environmental sustainability,” says FitzGerald. “The problem is far more prevalent than many realise, and the consequences are escalating.”

Quality Concerns

At the heart of the issue is the adulteration of diesel with substances such as illuminating paraffin (IP), used transformer oil, and gear oils. These agents significantly degrade fuel quality. “IP, for instance, drastically reduces diesel’s lubricity, which is essential for the protection of high-pressure fuel injection systems. Without proper lubrication, you are essentially guaranteeing elevated costs, premature wear and mechanical failure,” explains FitzGerald.
In addition, adulteration alters the fuel’s viscosity and density, directly affecting combustion efficiency and engine output.

The result is increased maintenance frequency, unexpected breakdowns, and ultimately, far higher operational costs.
“We are seeing cases where seemingly minor dilution leads to major engine damage, simply because the physical and chemical properties of the fuel are no longer within operational parameters,” adds FitzGerald.

Safety Risks and Invisible Hazards

The safety implications extend well beyond engine wear. Used transformer oil, a common adulterant, often contains polychlorinated biphenyls (PCBs), a class of highly toxic chemicals strictly regulated under the Basel Convention.
“The combustion of PCBs in engines produces extremely harmful by-products, including hydrogen chloride and dioxins, many of which are carcinogenic and mutagenic,” notes FitzGerald. “When you are running adulterated fuel, you are creating chemical hazards that affect both operators and the broader environment.”
Mechanical reliability is also compromised. Poor fuel quality can cause diesel engines to fail under load, potentially creating hazardous conditions, particularly in heavy industrial or transport environments.

Environmental and Economic Fallout

Fuel adulteration does not just harm equipment and people, it undermines environmental protections and public finances. “This practice allows for the illegal disposal of hazardous industrial oils, leading to long-term soil, air, and groundwater contamination,” says FitzGerald. “It is a form of environmental abuse hiding in plain sight.”

Moreover, the economic consequences are staggering. FitzGerald highlights that losses to the South African fiscus from fuel adulteration and associated tax evasion are estimated to exceed R3.6 billion annually. “These are funds that could otherwise support environmental enforcement, infrastructure, and community development,” he says.

Proactive Industrial Measures

FitzGerald advocates for a combination of advanced technology and sound procurement practices to combat adulteration. Real-time sensor technology like the Yateks® Africa FuelTrust system allows for real-time on-site detection of critical fuel parameters, including density, viscosity, dielectric constant, which flags contaminants such as paraffin and PCBs, as well as moisture content and temperature. These sensors are particularly suited for continuous monitoring in high-volume operations.
In addition to technological solutions, regular fuel sampling, laboratory testing, and comparative analysis against EN590 standards remain essential. “Even when using unbranded or ‘white site’ fuel suppliers, it is critical to analyse lubricity and chemical composition to avoid surprises,” highlights FitzGerald.

Accountability from Suppliers

ISO-Reliability Partners advises industries to tighten their fuel procurement standards. FitzGerald recommends demanding written certification of compliance with EN590 or similar recognised standards, batch test results for viscosity, density and sulphur, and contractual audit rights. “Fuel suppliers must be held accountable. Choose branded suppliers with traceability and reputation to lose as these are statistically far less likely to be involved in adulteration.”

He also emphasises the value of contractual protections: “Include clauses that enforce penalties for non-compliance, allow immediate termination if adulteration is detected, and mandate traceable sourcing. This creates both a legal and ethical deterrent,” urges FitzGerald.

Pursuing Accountability

When adulterated fuel causes equipment failure, industries have strong legal recourse, provided evidence supports the claim. “If damage can be forensically linked to contaminated fuel, and a supplier is found to have breached contract or acted negligently, litigation is absolutely viable,” asserts FitzGerald.

The legal framework is robust. South Africa’s National Environmental Management Act regulates substances like PCBs, while the Consumer Protection Act supports claims of defective or misrepresented fuel. “Service-level agreements are key here,” says FitzGerald. “They provide the foundation for enforcing quality expectations and pursuing legal remedy.”
He also notes that government oversight is catching up. The Department of Mineral Resources and Energy has confirmed over 70 failed fuel samples in a recent inspection, which bolsters industry claims and highlights the regulatory awareness of the issue.

A Call to Industry

As South Africa’s industrial sector grapples with economic pressures and environmental challenges, ensuring fuel integrity has become non-negotiable. “The time for passive reliance on fuel suppliers is over. With the right tools, contracts, and vigilance, industries can protect their machinery, personnel, and the environment,” says FitzGerald.

“ISO-Reliability Partners is committed to helping clients implement these safeguards effectively. In an industry where fuel adulteration continues to threaten operational stability, the message is clear: awareness, action, and accountability must go hand in hand,” he concludes.

04/07/2025

Bühler celebrates INWED 2025 theme of

International Women in Engineering Day (INWED), celebrated on 23 June, is a global campaign to honour the achievements of women engineers and inspire the next generation. This year’s theme, , highlights the power of collaboration and inclusion in building the future of engineering. Bühler Johannesburg proudly spotlights three remarkable women whose journeys embody resilience, excellence, and the spirit of unity.

Khaya Mxenge, Project Automation Engineer
Khaya’s journey at Bühler began as an intern in the Automation team. Now a Project Automation Engineer, she plays a pivotal role in designing and developing control systems for new plants and retrofit projects. She also provides ongoing automation support for existing sites.

A key highlight of her career was leading her first solo project, the Thuso Mills Mercury retrofit, from concept to commissioning. Another proud moment was graduating with a B.Sc. Eng in Mechatronics from the University of Cape Town, supported by a Bühler bursary.

Reflecting on gender representation, Khaya notes, “When I joined, I was the only woman in the automation team and still am. But Bühler has taken steps to support Black women in engineering through its bursary programme, which is helping to break down barriers to entry.”

For Khaya, is about uniting people from diverse backgrounds to solve problems for the greater good. “Diversity brings fresh ideas. Our solutions should reflect the people they serve,” she explains.

Her advice to young women entering male-dominated fields? “Be true to yourself. Speak up for yourself and others. And remember, you belong in the room.”

Samantha Fourie, Junior Process Engineer
As a Junior Process Engineer in Bühler’s Technology Department, Samantha is responsible for creating process flow diagrams that form the backbone of technical design. Securing a permanent role at Bühler has been a major personal milestone for Samantha, especially as a single mother of two. “It’s propelled me forward and shown my children what’s possible,” she says.

Samantha sees Bühler as a company that celebrates growth and individuality: “It is an empowering place that encourages further education and embracing your achievements.” To her, means collective strength: “When women uplift each other, we can create a better future.”

She acknowledges positive shifts in the field but highlights the continued need for equal pay and recognition. “Women bring strong organisational skills and a nurturing lens to engineering, traits that are vital in high-performance environments,” she says.

Looking ahead, Samantha aspires to become a Lead Process Engineer, sharing her expertise and becoming a trusted resource in milling technology. Her advice to other women is simple yet powerful: “Own your identity and intellect. Be unapologetically yourself.”

Savanna Rouessart, Quotation Engineer
In her role as Quotation Engineer, Savanna works at the intersection of technical precision and strategic thinking. She prepares detailed proposals in collaboration with sales, engineering, and procurement teams to ensure client-aligned solutions.

Completing her N6 in Civil Engineering marked the beginning of her journey. “Joining Bühler has opened doors to professional and personal growth,” she shares. “It has helped me build resilience, balance, and a commitment to lifelong learning.”

Savanna has seen Bühler’s strides toward gender equality and empowerment, with mentorship, training, and inclusive leadership shaping her career path. , to her, reflects the importance of diverse, collaborative teams in driving innovation and inclusivity.

She hopes to step into project management in the next five years and is committed to inspiring young women to pursue engineering if it aligns with their passion. “Diverse teams deliver better outcomes,” she says. “When women thrive, the entire industry benefits.” Her message to young women is clear: “Believe in yourself. Your perspective matters. Build your network, find mentors, and keep pushing forward.”

Bühler recognises that engineering is not just about machines, it is about people, progress, and purpose. The stories of Khaya, Samantha, and Savanna are a powerful reminder that when we work together, support one another, and champion diversity, we engineer a stronger, more inclusive future. This International Women in Engineering Day, Bühler reaffirms its commitment to building an environment where all voices are heard and where every engineer, regardless of gender, can thrive.

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