Objectives

The primary objective of this tender is to appoint a qualified supplier with proven experience in heavy mechanical engineering work to support Foskor’s Drying and Dispatch Maintenance teams. The goal is to ensure high plant availability, reliability, and efficiency of six rotary coal-fired driers, thereby enhancing production performance and reducing unplanned plant downtime. The successful supplier will work closely with Foskor’s maintenance team, reporting to the Maintenance Engineer, and will be responsible for providing labour, executing minor works, and installing drum internals during shutdowns and emergencies. An overarching aim is to leverage plant equipment availability to improve operational efficiencies and meet international quality standards, while responding swiftly to short-notice requirements over a three-year contract period.

Scope

The scope encompasses:

• Provision of labour for the upkeep and minor works of six rotary coal-fired driers at Foskor Mine, Phalaborwa, over a three-year period.
• Managing plant availability, reliability, and efficiency during operational periods and shutdowns, including emergency responses.
• Installation of drum internals such as liners, lifter plates, rings, propeller plates, brackets, bolts, and nuts during scheduled shutdowns and on an emergency basis.
• Development and submission of welding procedures, method statements, and technical formulae for ovality and gaps, subject to Foskor’s approval.
• Supply of skilled labour trades (boilermakers, welders, fitters, assistants, safety officers, site managers, supervisors) along with general tools and PPE, ensuring compliance with Foskor’s safety and legislative standards.
• Responding promptly to very short notices, including emergency works, with flexible scheduling within normal working hours or breakdown basis.
• Adherence to Foskor’s safety, legislative, environmental, and quality management policies, including compilation of safety files and obtaining permits to work.
• Disposal of waste generated during works and ensuring site cleanliness.
• Provision of all materials, equipment, supervision, and transportation necessary for scope execution, with Foskor paying only for materials and services delivered to site.

Technical Requirements

The technical requirements include:

• Prequalification demonstrating CIDB grading of 2ME or higher, with proven experience in heavy mechanical plant maintenance, especially kilns, driers, furnaces, conveyors, and elevators.
• Provision of a dedicated, experienced team with CVs highlighting relevant expertise in rotary kiln/drier maintenance, with a minimum of five years’ experience.
• Development and submission of detailed project schedules (GANTT charts), work method statements, and technical formulae for ovality and gaps, with signed approval from Foskor’s Maintenance Engineer.
• Supply of welding procedures, quality control plans (QCP), and generic method statements for tasks outlined in scope, subject to Foskor’s approval.
• Availability of basic tools, welding equipment, PPE, electrical tools, lifting tackle, and transport, inspected and approved by Foskor prior to use.
• Compliance with all relevant South African standards, legislative requirements, and Foskor’s safety policies, including permit-to-work procedures and compilation of safety files.
• Implementation of environmental commitments, waste management, and energy conservation policies, with evidence provided by the bidder.
• Participation in safety, health, and environmental training, including HIRA, first aid, fire safety, and lock-out procedures, with certificates submitted for verification.
• Adherence to Foskor’s procurement, legal, and contractual standards, including confidentiality, intellectual property rights, and data protection in line with POPIA.
• Provision of detailed pricing schedules, including labour rates, tools, equipment, and transportation, with the understanding that Foskor will pay only for work executed and materials delivered on-site.
• Compliance with all applicable legislation, including Occupational Health and Safety Act, Labour laws, and environmental regulations.

In summary, the technical scope demands a competent, safety-compliant, and environmentally responsible contractor capable of delivering skilled labour, technical documentation, and emergency response within a structured maintenance framework, aligned with Foskor’s operational and safety standards.