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Making Mondi magnificent

How does a major paper mill secure itself, protect the environment, appeal to its visitors and ensure that the local wildlife and ecosystems remain undisturbed? Mondi's Pulp and Linerboard Mill at Richards Bay is one of the company's main operations and employs around a thousand people in an area occupying 385 hectares, where pulp and white top linerboard for the fine paper, tissue products and food packaging industry are manufactured.

To enclose an area of this size requires over seven kilometres of fencing. Mondi has embarked on a three-phase instalment of different levels of security fencing to suit key pressure points. Striking a balance between providing optimum security and retaining the aesthetics of the outlying and surrounding areas was one of the main challenges.

Various other factors were also considered in the planning and implementation of the project - such as the environmental parameters, legal considerations, the overall appearance and interface between the green Nylofor fence that was erected in phase I of the project and the silver Bezinal coated high security fence that was put up in phase II.

Multiple factors to consider

Added to this were security considerations surrounding the new entrance so that access could be controlled and the integrity of the main site could be maintained at all times. There were maintenance issues surrounding the existing fenceline and civil works were required on the road being used by maintenance and security vehicles. And, of course, the wildlife and migration patterns of certain species of wildlife meant there had to be strict controls and constraints during the erection of the fence at certain stages of the project. Add to this the fact that timing and pricing issues interacted with overseas production and shipment schedules and you can understand why what seems to be a straightforward exercise needed to be split into three phases.

Multiple solutions

The solution was reached through Mondi's association with Bekaert Bastion, and involved an installation of two types of fencing - a green high security fence at the gate and access area and a green epoxy coated fence that was already Bezinal coated to give added corrosion protection and an enhanced appearance. Bi-steel posts replaced the single post design to give added stability to the fence line and all the fences were matched in the same colour green. The total contract - worth around R5 million - began in the second half of 2001, the second phase was completed between March and September 2003 and Mondi is just about to embark on Phase III of the project, when the final section will be completed leading from the garage to the Afrox site.

Another overriding and crucial consideration in all three phases of the project has been corrosion. One of the main features of Bekaert Bastion's Superior coated mesh is that it comes with a 10-year corrosion guarantee. Bekaert specially developed Bezinal - a coating process that uniquely combines a formula of zinc and aluminium - to provide a better, stronger and more durable solution and, with Bezinal, the steel wire assumes new properties. The coating does not flake with bending; it has very high corrosion resistance and is altogether less porous and less easily washed away than normally galvanised steel. The corrosion resistance is exceptional around the weld because the compounds have melting temperatures higher than the weld heat - it cannot be 'blown away'.

Mondi will incur considerably less maintenance hassle and have considerably more peace of mind as it continues its manufacturing business in a safe and aesthetically pleasing environment.

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