At Genrec, we know that a company’s products

are a reflection of the team that creates them.

Our people are the underlying force driving the

delivery of your vision with embedded values to

deliver beyond our customers’ expectations.

Working with honesty, accountability and care, our

collective team is committed to fabricating innovative

steel solutions to meet your specific needs. Genrec’s

capabilities extend from Total Project Management;

Design and Detailing; Planning and Programming;

Light, Medium and Heavy Structural Fabrication to Site

Logistics and Erection.

The company also retains the in-house capacity and

competency to conduct precision Heavy Machining. At

Genrec, our team is happy to discuss the value we can

add to your projects with our resources, be that a single

capability or the entire project offering.

Mission, Vision and ValuesMISSION

Empowering, motivating and leading our people to

supply steel solutions and fabricate quality steel work

at the lowest cost while adhering to safety standards

and exceeding stakeholders expectations.

VISION

To be the preferred supplier of world class fabricated

steel solutions.

VALUES

• Care

• Honesty / Integrity

• Respect

• Accountability

• Commitment

• Ubuntu (Humanity to others)

ABOUT THE COMPANY

Genrec, a BEE level 2 Company, as a division of leading

engineering and contracts group Murray & Roberts,

offers a unique combination of engineering disciplines

in its field of operation. A comprehensive range of

services is provided from structural steel fabrication

and erection, to heavy fabrication and machining.

Genrec covers the full spectrum of engineering,

structural detailing, procurement, fabrication and

construction.

As a member of the Murray & Roberts Group of

companies, Genrec can offer complete turnkey

solutions.

Genrec’s combination of manufacturing, construction

and site management services, provide clients with a

one-stop service.

Situated in Wadeville, just outside of Johannesburg,

South Africa, Genrec’s facility extends over a site area

of 12,6ha, with 55,000m2 undercover workshops and

19,500m2 of open areas under crane. Genrec has the

latest systems, CNC equipment, welding processes as

well as high volume blasting and painting resources.

HISTORY

From humble beginnings in 1953 in a small office, in the

heart of the Free State gold fields of South Africa,

Genrec has grown into one of the largest engineering

companies in Africa.

From being a one-man business, with its base in

Wadeville providing breakdown and repair services to

gold mines, the business rapidly grew into a vibrant

family business throughout the fifties and sixties.

Genrec started trading as General Erection, and by

1974 with a good track record, Genrec had grown large

enough to list on the Johannesburg Stock Exchange,

under the name of Genrec.

In the same year, Murray & Roberts, a large

engineering and construction Group, decided to

diversify its operations, and acquired 30% of Genrec

shares. In 1988, Murray & Roberts acquired the

controlling share holding and in 1992, Murray &

Roberts acquired 100% equity and delisted the

company.

Genrec has since continued to grow and has specialised

in major projects locally and abroad and continues to be

a major player in the African market.

History

Genrec’s Vision for Health, Safety and the Environmentis “Together to Zero Harm”, in line with Murray &Roberts’s Vision. Genrec’s employees and ManagementTeam are committed to honouring the company’svalues of Honesty, Integrity, Accountability, Care,Respect, Commitment and Ubuntu (Humanity toothers).

We aspire for zero harm in the interest of Health, Safetyand the Environment to our employees, our company,its shareholders, clients and business partners, thenatural and built environment impacted by ouroperations and society at large and Zero Harm to ourEnvironment.

“Together to Zero Harm” is an aspiration that drives ourstrategy for, and response to, the health, safety andenvironment (HSE) challenges faced by GenrecEngineering. Continuous motivation and education ofour employees to take responsibility for themselves,their colleagues and the environment is a key driver forGenrec Engineering and through this we strive toembed HSE values and a safety culture built on theprinciple of Stop. Think. Act.24/7. The social, economicand health dynamics in our South African environmenthave a profound impact on our employees and isreflected in our safety performance.

SHEQ

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WEAROUR PPE

Quality CertificationQuality is an approach to understanding precisely what customers need and to consistently deliver accurate solutions

within budget. Quality will ensure the effective design of processes that verify customer needs, product life cycle and

the design, production and delivery of the product.

This incorporates measuring all process elements, the analysis of performance and the continual improvement of the

products, services and processes that deliver them to the customer. Genrec’s Quality Certifications, include:

• ISO 9001:2008

• ISO 14001:2004 +Cor1 : 2009

• BS OHSAS 18001:2007

• SANS ISO 3834 Part 3

• API ISP/TS 29001

• BEE, Level 2 Contributor

3D VIEW OF TRESTLE

GENREC DRAWING OFFICE

Genrec Engineering is in a key position, where Genrec

can respond to any structural project requirements

with a dedicated, permanent team of Professionals.

These Engineers and Detailers can achieve maximum

benefit for the client by supplying innovative steel

solutions, cost effectively designed and detailed by

applying the principles of value engineering.

From the commencement of a project, our skills,

people and systems are set up to utilise Genrec’s

performance capabilities to produce optimal solutions.

Genrec Engineering offers a full design and shop

detailing service, utilising state of the art software such

as Tekla, Xsteel, Autocad, Strucad and Strumis, under

our Engineering Team.

SERVICES PROVIDED

Our Engineering Services comprise of:

• Preliminary, Basic Design & Analysis

• Professional Engineer Certification

• Steel Structure Cost Estimates

• Alternative cost saving design concepts

• Construction and Erection Studies

• Cost saving input into client requirements

• Connection Designs to suit fabrication & erection

• Fabrication Drawings

• Site support and management

• Project Management

CapabilitiesEXPENDITURE PROGRAMME

Genrec completed an optimising expansion drive in2010 to increase all aspects at its current facilities inWadeville. This was done to support the building of theMedupi and Kusile Power Stations. The fabrication andworkshop facilities now extend to 74,500m2 undercrane area equipped with the latest systems, CNCequipment, welding processes as well as high volumeblasting and painting equipment. Resources,equipment, training and logistics increase capacity wellabove 2,500 - 4,000 tons per month. All ranges of steelcomplexity can be fabricated within the facility.

One of the key factors of expansion drive has been skillsdevelopment. The training facility providesdevelopment and training of boiler-makers, detailers,computer numerically controlled operators, riggersand inspection personnel. Genrec has trained over 197artisans over the past 3 years. With a drive as extensiveas this, Genrec is well equipped to meet your futureneeds.

CAPABILITIES

Genrec capabilities include but are not limited to:

• Total Project Management• Design, Detailing & Shop Drawings• Planning & Programming• Light, Medium & Heavy Structural Fabrication• Heavy Machining• Blasting, Painting• Trial & Pre-Assembly• Logistics & Transport• Site Services (Workshop / Modifications / Engineering

/ Site Logisitics)• Erection• Steel Track & Trace • QC Control, Inspection Services

Total Project ManagementCAPITAL EXPENDITURE PROGRAMME

Genrec Engineering has empowered and developed its

employees, contributing to the improvement and

upliftment of the Structural Steel Industry, through In-

House Training and Formal School for Draughting,

giving employees both technical education and

practical experience.

Genrec’s core values are to work with Care, Honesty

and Integrity, Respect, Accountability and Commitment

and Ubuntu and is committed to the delivering of quality

products on time, to standard and within budget.

The Genrec Engineering team comprises of the

following disciplines and resource levels:

Engineering Team

Chief EngineerProfessional EngineersTechnical SpecialistsEngineersGraduate Engineers

Detailing Team

Drawing Office ManagerSection LeadersLead Detailers (15 years experience)Senior Detailers (10 years experience)Detailers (5 years experience)Junior DetailersTrainee DetailersTechnical Support Clerks

Technical Registry Team

Consisting of Senior Document Controllers andDocument Controllers

SHOP DETAILING DELIVERABLES

The drawing content and presentation is standardised,

using good quality industry norm practices, which will

be agreed with the client prior to commencement of the

project, creating the opportunity to both share our

capabilities and understand your requirements.

DELIVERABLES INCLUDE:

• Assembly drawings

• 2D single component drawings

• Erection general arrangement drawings with piece

marks and section sizes

• Floor covering General Arrangements

• NC files Cam – for nesting plates and cutting

sections

• Dstv – for nesting plates and cutting sections

• Full-size plate DXF’s (templates) – for manual

cutting of plates

• Struwalker – for location of item in the 3D model

• Fabtrol documentation

• Engineer approved drawings

• Full Size Originals

REPORTS - FABRICATOR & ERECTOR:

• Full 3D modelling progress tracking system

• Assembly lists

• Parts lists

• Material Lists

• Drawing Registers

• Integrated revision control

• Bolts lists

• Procurement lists

• BIM Information

Site ServicesGenrec has experienced site teams capable of carrying

out the following types of site activities:

• Erection of Steel Structures both Heavy and Normal

Structural Steel

• Modifications to Erected steel on site

• Logistics Support and Management in the form of

Electronic Track & Trace, receipt and issue of steel

components and all necessary BIM reporting.

• Site Quality Services including:

- inspection of existing structures

- structural integrity inspection and reporting, and

- connection certification

• Plant and Shutdown Maintenance for Industrial

Plant, Power Station, Mining Structures, etc.,

specialising in compressed program shutdowns

involving steel component replacement,

strengthening and repair. Professional Engineering

inspection of structures as required by the

Occupational Health & Safety Act, 1993 (Act No. 85 of

1993), Construction Regulations Clause 9(4) Annual

structure inspection.

• End of Life Refurbishment of Industrial Steel Plant

and Structures, including corroded and damaged

steel replacement and repair.

• Hire of high capacity craneage to selected

construction sites.

Structural Steel ManufactureGenrec was awarded Overall Winner at the SAISC SteelAwards in 2013 for excellence in the use of structuralsteel in the Main Frame and Boiler Grid Support at theMedupi Power Station. Details of the Structural SteelManufacturing facility are as follows:

FACILITY

Structural Bays:5 x 175m long, 19m wide (9m under crane hook)

Preparation Bays:5 x 125m long, 19m wide (9m under crane hook)

Paint Bays:5 x 72m long, 19m wide (7m under crane hook)

CRANEAGE

Structural Bays / Preparation Bays / Paint Bays:• 5 x 20 ton overhead gantry cranes• 17 x 10 ton overhead gantry cranes• 2 x 10 ton semi portal cranes • 17 x 5 ton overhead gantry cranes• 6 x 5 ton semi portal cranes• 12 x 2 ton semi portal cranes

EQUIPMENT

Plate processing:• 3 x Plate stripping machines (Oxy fuel)• 2 x Plate profile CNC machines (Oxy fuel and Plasma)• 2 x Plate profile drill and punch CNC machines (Oxy

fuel and Plasma)

Angle and flat section processing:• 2 x Angle and flat section profile CNC lines

I beam/section processing lines:• 2 x Beam drill lines (CNC)• 4 x Band saws, miter and straight (CNC)• 1 x Beam lay out marking machine (CNC)

Surface preparation/Blasting:• 3 x Pre blasting machines (Wheelabrators)

WELDING EQUIPMENT:

• 2 x 12 ton beam rotators• 2 x 15 ton beam rotators• Boom welder (2 heads, 1000A per head)• Gantry welder (2 heads, 1000A per head)• 8 x submerged arc tractors• 2 x squirt welders• Numerous MIG, ARC, TIG welding machines• Manipulators and rotators

Heavy Steel ManufactureEQUIPMENT

Plate Rolls:• 1 x 150mm thick x 3m wide

• 1 x 40mm thick x 3m wide

Plate processing:• 3 x Plate stripping machines (Oxy fuel)

• 2 x Plate profile CNC machine (Oxy fuel and Plasma)

• 2 x Plate profile drill and punch CNC machine (Oxy

fuel and Plasma)

PLATE GIRDER ASSEMBLY LINES:

• 4 x manual plate girder assembly lines

• 1 x automated plate girder assembly line (4 x 1000A

submerged arc, tandem welding process)

Genrec’s Heavy Steel Manufacture Facility typicallymanufactures products such as Stacker Reclaimers andDraglines. This facility comprises:

FACILITY

Heavy Bay:305m long, 31m wide (21m under crane hook)

CRANEAGE

Heavy Bay:• 2 x 100 ton overhead gantry cranes

• 1 x 35 ton overhead gantry crane

• 3 x 20 ton overhead gantry cranes

• 4 x 10 ton semi portal cranes

Plate Yards:• 2 x 20 ton overhead gantry cranes

• 2 x 10 ton overhead gantry cranes

Machining

Typical Projects Completed:Crusher – Machining of bores and facesGirth Gears – Machining of faces, outer diameter and inside diameterRiding Rings – Machining of outer diameter, inside diameter and facesCrusher – Machining of bores and facesImpeller – Machining of centre bore, recesses and facesWinder Brake Disc – Machining of brake disc internal diameter andfacesWinder Drum Assembly – Machining of winder drum and discassembliesTrunnions – Machining of faces

Typical Projects Completed:

Impeller – Machining of centre bore, recesses and facesWinder Brake Disc – Machining of brake disc internal diameter andfacesWinder Drum Assembly – Machining of winder drum and discassembliesCast Iron Ladle – Machining of facesTippler End Rings – Machining of rings and railsGirth Gears – Machining of faces, outer diameter and inside diameterRiding Rings – Machining of outer diameter, inside diameter and facesTrunnions – Machining of facesHP & LP Valves – Machining of bores and faces

CRAVEN VERTICAL BORING MILL:Specifications:Table Load 40 TonTable Diameter (mm) 5 500Max. Swing Diameter (mm) 5 300Max. Height Under Cross Slide (mm) 2 600Distance Between Columns (mm) 6 400Vertical Travel of Cross Slides (mm) 2 750Horizontal Travel of Cross Rails (mm) 2 200 x 2Taper Of Main Ram 30ºTable Speed (RPM) 0.45 - 18Min. Bore Diameter (mm) 300Max. Chucking Diameter (mm) 5 500Side Box Details 2m up/downSide Box Taper 60º inclusiveAchievable Tolerance (mm) 0.05

SCHIESS DEFRIES – VERTICAL BORING MILL:Specifications:Table Load 65 TonTable Diameter (mm) 8 000Max. Swing Diameter (mm) 8 200Max. Turning Height below Tool (mm) 3 700Distance Between Columns (mm) 8 200Vertical Travel of Cross Rails (mm) 4 200Horizontal Travel of Cross Rails (mm) 4 500 x 2Taper Of Main Ram 30ºTable Speed (RPM) 0 - 7Drive Power 127Kw

AC MotorMin. Bore Diameter (mm) 450Max. Chucking Diameter (mm) 8 000Main Ram Details 1,8m up & down travelAchievable Tolerance (mm) 0.05

Genrec is well known for its heavy machining capabilities and has successfully machined products such as WinderDrums and Brakes over the past 60 years. Some of the workshop equipment and equipment capabilities are listed below:

BORING MILLS:

Vertical • Schiess: Chuck Dia: 7,860mm, Swing Dia: 8,300mm, Height: 4,600mm

Horizontal • Schiess: Long Travel: 9,300mm, Height: 4,300mm, Spindle Travel: 2,200mm• Union: Long Travel: 8,300mm, Height: 2,800mm, Spindle Travel: 900mm• Crovel: Long Travel: 5,000mm, Height: 5 ,500mm, Spindle Travel: 2,700mm• Ki Heuls: Long Travel: 10,000mm, Height: 3,800mm, Spindle Travel: 600mm

MachiningTypical Projects Completed:

Medupi & Kusile & Structural Steel Columns –Machining and drillingof facesWinder Brake Disc Segments – Machining of faces and key slotsContainer Cranes - Machining of bores, faces and bogeysGirth Gear Half Sections - Butt facing and joint holes

Typical Projects Completed:

Medupi & Kusile & Structural Steel Columns - Machining and drilling

of facesContainer Cranes - Machining of bores, faces and bogeysGirth Gear Half Sections - Butt facing and joint holesTransnet Bogies - Machining of faces, spigots and bores

Typical Projects Completed:

Cast Iron Ladle - Machining of facesCutter Booms - Machining of bores, faces and recessesCrusher - Machining of bores and facesTippler Rings - Machining of pads and butt facing of rail segmentsWinder Brake Disc - Machining of disc segment faces and key slotsDrag & Hoist Gearbox Base - Machining of bores and facesTrunnions - Machining of facesHP & LP Valves - Machining of bores and facesRotor Cores - Machining of facesMedupi & Kusile Structural Steel Columns - Machining & drilling offacesContainer Cranes - Machining of bores, faces and bogeysGirth Gear Half Sections – Butt facing and joint holes

UNION HORIZONTAL BORING MILL:Specifications:Max. Vertical Travel of Headstock (mm) 2 700Max. Traverse of Column (mm) 8 500Max. Boring Depth (mm) 1 300Spindle Diameter (mm) 150Distance from Table - Top Spindle min: 675Centre (mm) max: 2 700Bed Size Length (mm) 10 500Bed Size Width (mm) 4 000Spindle Speeds (RPM) belt: 2.8 - 560

gears: 2.8 -112Feed Range (mm/min) boring: 0.05 - 48

KI HEUNG CNC HORIZONTAL BORING MILL:Specifications:Long Travel (mm) 11 000Column Height (mm) 3 200Spindle Length (mm) 1 500Table Length (mm) 9 000Table Width (mm) 2 000Table Depth (mm) 400Motor Power (Kw) 28/38Speed Variation 0 - 1 000

1 000 - 4 000Fast Feed x 15m/min;

y,z 10m/minRapid Feed Rate x 10m/min;

y,z 5m/minAngle Head rotation 360°Achievable Tolerance (mm) 0.02

SCHIESS - HORIZONTAL BORING MILL:Specifications:Max. Vertical Travel of Headstock (mm) 4 500Max. Traverse of Column (mm) 9 300Max. Boring Depth (mm) 1 500Spindle Diameter (mm) 190Quill Diameter (mm) 800Distance from Table - Top Spindle min 1 100Centre (mm) max: 4 500Bed Size Length (mm) 11 800Bed Size Width (mm) 500Spindle Speeds (RPM) belt 200 - 380

gears 1.7 - 266Feed Range (mm/min) low 0 - 35

high 0 - 1 000Achievable Tolerance (mm) 0.02

MOBILE DRILLING MACHINE:Specifications:Direction X, Y, ZMax. Drill Diameter (mm) 5

Markets and Clients

GRDMinprocC O N C O RLimited

MARKETS

Genrec specialises in the manufacture of

structures and equipment in diversified

markets such as:

• Power Generation

• Mining

• Petrochemical

• Mineral Beneficiation

• Infrastructure, Oil and Gas, and Industrial

CLIENTS

Our clients include highly respected companies such as:

• January 2012 – SABS Certification of Recognition20 Years of Loyalty, Commitment & Compliance toSABS Quality Management System CertificationScheme

• June 2013 - Sasol HSE Work Team of the MonthHSE, Work Team of the Month, WRG Secunda

• SAISC Steel Awards 2013 – Overall Winnerfor excellence in the use of structural steel - MedupiPower Station

• Contractor of the Quarter at the Water RecoveryGrowth Project, Sasol Secunda

AWARDS RECEIVED

• 2002 / 2003 – 2nd Place International Project (Strucad Award) for Abu Dhabi Zayed Cricket Stadium

• 2004 / 2005 – 1st Place International Project (Strucad Award) for Khalifa Sports Hall

• September 2006 – SAISC Steel Awards - OverallWinner for excellence in the use of structural steel -Khalifa Indoor Sports Hall

• 2010 / 2011 – 1st Place International Project (Strucad Award) for Medupi Power Station

Successfully Completed Projectsand AwardsProject Name: El Abra Copper MineLocation: ChileClient: BechtelMass: 3 300tDuration: 12 Months

Project Name: Burj Al Arab HotelLocation: Dubai - UAEClient: M&R and Fletcher JVMass: 11 000tDuration: 24 Months

Project Name: Emirates TowersLocation: Dubai - UAEClient: Besix & MultiplexMass: 800tDuration: 24 Months

Project Name: CMT Spinning MillLocation: MauritiusClient: Construction Management

& Allied ServicesMass: 1730tDuration: 14 Months

Project Name: Khalifa Sports ComplexLocation: Qatar - UAEClient: SNC LavalinMass: 2 795tDuration: 14 Months

Project Name: Sheik Zayed Cricket Stadium

Location: Dubai - UAEClient: Abu Dhabi Cricket AuthorityMass: 800tDuration: 12 Months

Project Name: Muskeg River Oil SandsProject

Location: CanadaClient: Shell, Chevron, Marathon OilMass: 800tDuration: 18 Months

Project Name: Carnival CityLocation: RSA (JHB East)Client: WBHOMass: 700tDuration: 14 Months

Project Name: Jacket - MossgasLocation: RSAClient: Camfil - FarMass: 2 551tDuration: 14 Months

Project Name: Mopani Winder HouseLocation: Kitwe, ZambiaClient: Mopani Copper Mines PLCMass: 220tScope: Detailing, Fabrication,

Delivery to site & Erection (Concor)

• Ekurhuleni: Hand-in hand with Ekurhuleni’s job

creation initiative, Genrec has engaged the services

of 15 students on a learner program for a one year

period. These students are gaining experience in the

fields of Safety, HR, Quality Control, Production

Planning and other disciplines. The experience

gained will ensure high probability for future

employment and make them valuable employees to

any employer. Genrec is proud to be in a position to

assist the Ekurhuleni Council in this initiative.

Training and development is a crucial part of any

business and not only does it benefit your employees,

but it also benefits the overall motivation, efficiency,

capacity and innovation of our company.

The importance of training can thus never be

overemphasised, especially when considering the

dynamic nature of the business world and changing

technologies. By creating a culture of “training and

development” at Genrec, we will stay competitive in the

global market by ensuring that our people are abreast

of changes in the industry, especially in terms of new

technology, work practices and competitive strategies

therefore ensuring the satisfaction of our clients and

fulfilling their expectations.

Training and Skills DevelopmentTHE IMPORTANCE OF ONGOING TRAINING

Genrec believes in the importance of ongoing training,

ensuring that our people have the ability to achieve

their full potential, delivering our future and ensuring

the fulfillment of our client’s needs.

While it is well recognised that South Africa struggles

to meet the demand of skills required in the

Engineering Sector, Genrec has risen to this challenge

at a number of levels:

• Apprentices - Genrec’s Apprentice Artisans form

part of the Manufacturing Production Teams and

apply their learning in the day-to-day fabrication

work they produce. Over the past 4 years, Genrec

has trained and qualified 11 apprentices.

• In-House Artisan Training – the AATP undergo an

18 month intensive on-the-job and institutionalised

training in respective Trades. 187 people have

successfully completed this programme since 2009.

• Supervisors are selected from the existing

workforce on appropriate role fit, through a rigid

assessment and training process.

• Graduates form part of the Murray & Roberts

graduate program, while under the mentorship of

in-house professionals.

• Specific training is given to Specialists once they

have shown commitment to the business.

Cnr Dekema & Niemann Roads, Wadeville, 1428, Johannesburg, South AfricaTel: +27 11 876 2300 I Fax: +27 11 827 1733 | Email: sales@genreceng.co.za www.genreceng.co.za

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