Assmang and Hotazel Manganese Mines (HMM) embarked on a joint effort to refurbish and upgrade the capacity of the existing 10 km private railway line between Black Rock Mine Operations (BRMO) and Hotazel Station from a 20 ton axle load (TAL) to a 30 TAL railway line inclusive of a new railway bridge crossing the Gamagara River.

The existing private railway siding, including the Gamagara River railway 

bridge structure, are more than 50 years old and as such have been designed for 20 TAL and not intended to accommodate 125 wagon trains, heavier wagons nor for the current and future anticipated increased rail capacity.

The purpose of the refurbishment and upgrade of the existing private railway line siding and bridge structure were to operate a safe, reliable and efficient rail-

way line; mitigate the increased maintenance costs of the existing railway line; maximise the throughput volumes and 

align the performance to both partner’s long-term plans. 

Zutari was appointed by Assmang in July 2022 to provide EPCM services for the Black Rock Private Rail Siding Project (BR RSP). The project was executed in conjunction with an Assmang Owner’s team and constant interface with HMM engineering and project management team. 

All detailed designs were approved by Transnet Freight Rail (TFR), the Rail Safety Regulator (RSR) and BRMO.

The existing Transnet Rail Infrastructure Manager (TRIM) railway line between Hotazel station and Kathu/Khumani area, is in the process to be refurbished and upgraded to 26/30 TAL.

Construction Management 

The project was implemented in collaboration with Stefanutti Stocks (Pty) Ltd, ERB Technologies (Pty) Ltd, Makali Plant and Construction (Pty) Ltd and WO Trackworks (Pty) Ltd with continual liaison with the neighbouring mines, alignment and communication with TFR, RSR and the community at large which contributed to the success of the project. The major rail tie-ins into the existing private railway line were conducted during TFR’s Cape Corridor annual shutdown from November 12, 2024 to November 21, 2024.

The new 30 TAL private railway line complete with all the associated infrastructure was hot commissioned on November 22, 2024; while the final handover of the new private Rail Siding Project from Assmang Project team was conducted on January 30, 2025.

The BR RSP consistently upheld an exemplary safety performance, recording zero lost time injuries (LTIs) during the period from July 25, 2022 to January 30, 2025.

The project further created 180 local job opportunities of which 18 local employees were trained, assessed and found competent in different job categories such as track masters and equipment operators.

The success of the project is a true reflection that collaboration between industry players in conjunction with government departments yields excellent results for both the mining sector and the country at large, says Andre Joubert, Chairman of the Assmang Exco.