Providing infrastructure for the Moma mineral-sands project

Providing the infrastructure required to install and run a modern minerals-processing plant has been a critical component of the success of the Moma mineral-sands project in Mozambique, given the remote and undeveloped area in which it is located.

The USD250 million lump-sum turnkey project, which is nearing completion, is being carried out in joint venture by Bateman Engineering and Multiplex Ltd of Australia for Kenmare Resources P.L.C., Ireland. The project is located at the village of Tupuito, approximately 50 km from Moma in the Nampula Province, Northern Mozambique.

Like the rest of the project, the infrastructure had to be constructed under adverse conditions including an extremely hot and humid climate with daytime temperatures reaching 45°C, health hazards such as malaria and heat stroke, as well as possible mine fields and discarded munitions from the civil war. The entire servitude for the 170 km overhead-transmission line had to be swept for mines before construction commenced.

The budget to provide the infrastructure was USD20 million. This covered the cost of the air-strip upgrade, landing jetty on the beach, earth works, roads, aggregate crushing and screening plant, cast-in-situ and second-hand houses, dormitories, clinic, medical and kitchen equipment and security fencing.

Physical access by air, land and sea had to be greatly improved. A tarmac surface and lighting was provided for the 1.6 km compacted sandy-clay airstrip built by Kenmare during the project’s exploration phase. Most items, however, are brought in by land and sea.

The ‘national’ road to the nearest major town, Nampula, is 240 km of dirt road in poor condition. All the major bridges are of the Bailey type used by the military with an uncertain load-bearing capability. Two bridges collapsed under overloaded trucks. Collapsed bridges usually took many months to repair and alternative routes usually required upgrade before heavy loads could pass. The 20 km from the national road to site was along a sand track that had to be upgraded completely.

The really heavy bulk equipment, such as the wet- and dry-processing plants acquired from Australia, had to be imported by barge direct to Tupuito beach. A jetty was constructed on the beach to accommodate barges shuttling between Durban in South Africa and Maputo, Nacala and Angoshe in Mozambique. Cargo on ships from other parts of the world is transferred onto the barges at these harbours and the barge beach landed at Tupuito where the load is then discharged. A road was provided from the beach to the site.

The initial tent camp was replaced by 48 single rooms for personnel of small contractors. Eight dormitories were built for larger contractors, sleeping 40 junior staff per dormitory. These were constructed using local materials, building methods and labour.

Thin-walled shuttered concrete was used to provide single-quarter accommodation for skilled and management staff. The permanent kitchen, dining and recreational facilities, laundry and a clinic were also constructed utilising the thin-walled concrete.

Second-hand houses from two other projects were re-erected at Moma to provide accommodation for senior construction management and will eventually be used by the plant’s operating management.
Until the 170 km overhead-transmission line reached the site, electric power was provided by a total of 10 generators that required expert, 24-hours a day attention to ensure continued supply.

There was no communications infrastructure, with the closest telephone link 240 km away. Initially satellite systems were used, then two cell-phone companies provided services and now land-line connections provide telephonic, facsimile and email facilities.

Water, fit for human consumption, is available in abundance. The water is pumped from a drill hole at the foot of the hill to a 75,000 l water-storage facility next to the plant. A water-purification system has been installed and is operating satisfactorily.

A septic-tank system was used until the sewerage treatment plant was constructed. Solid waste is deposited in a fenced landfill area and immediately covered by a layer of sand to discourage scavenging.

The new infrastructure has also proved to be an important benefit to the local community and provided local labour opportunities during construction. The plant is expected to be commissioned in January 2007 and, when fully operational, will produce 701,000 t/yr of ilmenite, 60,000 t/yr of zircon and 17,000 t/yr of rutile.

More detail may be obtained from Freddie Dickason, Bateman Engineering Functional Manager – Construction on +27-11-899-9111 or email industrial.minerals@BatemanEngineering.com.