Steinmüller Africa achieves 51 000 X-ray quality butt welds in power generation milestone

Steinmüller Africa has once again demonstrated its industry-leading fabrication expertise. Through its specialised welding capabilities, the company has completed over 51 000 pressure-containing butt welds – all to X-ray quality standards – under Eskom’s boiler service contract.

With a current total of over 60 000 butt welds across all contracts, Steinmüller Africa remains unmatched in the scale and quality of its output.

The volume statistics achieved represent consistent delivery recorded this year under demanding conditions and tight deadlines.

Key to this performance is the strategic deployment of welders and the rotational use of experienced artisans across critical boiler zones, ensuring both efficiency and quality control.

Steinmüller Africa employs up to 350 welders at peak outage periods to meet production targets across multiple power stations, including Kendal, Kriel, Hendrina, and Kusile power stations.

Traditionally, welders are expected to produce between eight and ten butt welds per shift. However, Steinmüller Africa’s welders have been completing 20 or more per day – a testament to the high-performance culture embedded in the company.

“This milestone is not just a number; it reflects a level of operational excellence and skilled craftsmanship unmatched in the industry,” said Orifuna Netshifamadi, Senior Welding Engineer, Steinmüller Africa, “Our teams are not only delivering volume, but they are also maintaining stringent quality standards under immense pressure – both literally and figuratively.”

Quality assured by innovation and simulation

Steinmüller Africa's training and quality assurance processes are at the heart of this success. Each year, the company’s training centre in Bethal produces a new generation of artisans who are rigorously trained using custom-built boiler simulators. These simulators replicate real working conditions for different boiler types, enabling welders to perfect their technique in a controlled, high-fidelity environment.

“The simulator programme is not just training; it's a continuous revival of the welder’s craft,” noted Netshifamadi. “Welding is an art. Like any artist, practice is essential.  Our systems ensure they’re ready when critical projects go live.”

In addition to training, Steinmüller Africa implements intensive quality assurance protocols. Even a single repair is thoroughly investigated, with every weld undergoing strict examination – including X-ray inspection – to ensure compliance with pressure containment requirements.

Inspiring confidence through capability

This level of performance has solidified Steinmüller Africa’s reputation as the leading boiler maintenance contractor in the region. The company continues to be awarded strategic contracts by Eskom based on its proven reliability and results-driven culture.

Future-ready with vision and grit

Looking ahead, Steinmüller Africa aims to maintain its high-volume production while reducing the average Weld Repair Rate (WRR) below 2% at each site. A strong focus remains on mentoring and gradually integrating newly qualified welders into the production workflow, ensuring sustainable talent development and industry longevity.

“There is no manufacturing team with grit like Steinmüller Africa’s when it comes to high-intensity, high-quality production,” concluded Netshifamadi. “In power generation, time is of the essence – so are results. Our team delivers both consistently.”