The Alrode expansion adds a further 1,600 m² of dedicated production space under roof, equipped with two 63 ton gantry cranes operating at a clearance height of 18.5 metres, according to Alandré van Vuuren, Integrated Supply Chain Director at Weir. This strategic upgrade was driven by a landmark £53 million contract awarded to Weir by the Reko Diq copper-gold project in Pakistan, which includes the supply of fine grinding, separation, and tailings solutions.

“The advanced technological capability and rigorous quality assurance at our Alrode plant - together with our robust local and regional supply chain - enabled us to manufacture the first two ENDURON® Elite screens even before completion of the expansion,” says Van Vuuren. “We already had the specialised expertise and equipment in place, including a laser facility capable of cutting the massive 12 m by 5 m side plates. In parallel, we ran a targeted supplier development programme to further strengthen and empower our local supply partners.”

The outcomes of this process were rigorously assessed and audited by both an independent third party and Weir’s own technical team, clearing the way for the expansion which commenced in early 2025.

Construction has required substantial earthworks and piling, with excavations reaching two storeys below ground to accommodate the concrete and steel structure of a 1,000 ton plinth. This specialised plinth is engineered to absorb the intense vibration forces generated by the exciters during product testing.

The expansion has created two dedicated assembly stations for the high capacity double deck ENDURON® Elite screens – each weighing nearly 50 tonnes, with deck dimensions of up to 4.3 m wide by 8.5 m long.

“This expansion marks a significant boost to South Africa’s manufacturing capacity,” he says. “Facilities with heavy engineering capability and crane clearance at these heights are rare in the country, yet they are essential to support the ambitious manufacturing plans we are rolling out at Alrode.”

The upgraded facility enables the safe and efficient assembly of large screen components such as the subframe, screen body, screen deck and exciters, with completed units reaching heights of over 15 metres, Van Vuuren notes.

The new production bays will have the capacity to manufacture at least two ENDURON® Elite screens per month - without disrupting Alrode’s ongoing output of small, medium and large screens across the broader ENDURON® range.

“Our production for the first half of 2026 will be dedicated to fulfilling the Reko Diq contract, but market interest in our larger ENDURON® Elite screens is already strong,” he says. “We anticipate ramping up production soon and have deliberately designed the facility to accommodate future capacity upgrades as demand grows.”

Weir is advancing the development of its Alrode plant in line with its strong sustainability commitments, with the expanded facility serving as one of the company’s pilot sites for water-based paint application. This shift helps lower carbon emissions across both the production process and supply chain, he notes, supporting Weir’s global target of reducing carbon emissions by 50% by 2030.

“The facility is running entirely on renewable energy from a solar power generation system - with the only exception being the variable speed drive used to start up the screens,” he says. Van Vuuren emphasises the broader economic benefits of the expansion, from boosting local procurement and export earnings to creating jobs and developing skills. While most of the ENDURON® Elite screens produced at Alrode will be destined for export, nearly all components and materials are sourced locally.

“The expansion opened up around 40 new technical positions at Alrode, including roles in screen assembly, hand-lining and painting,” Van Vuuren explains. “We upskilled some of our current employees as assemblers and fitters - giving them a path into formal trades and supporting career growth from within. At the same time, we are creating opportunities for new entrants in lower-skilled roles, with a focus on developing their potential over time.”