Major Boiler Overhaul for ArcelorMittal Newcastle
Comprehensive Maintenance on 150-Ton Industrial Boilers
At Elinem Construction, we pride ourselves on delivering specialized, high-quality boiler services to South Africa’s leading industrial operations. One of our standout projects to date was the complete overhaul of 150-ton boilers at the ArcelorMittal Newcastle plant—an essential part of one of the largest steel production facilities in the Southern Hemisphere.
This complex project required deep technical knowledge, meticulous planning, and uncompromising attention to safety and quality. Our experienced team, led by founder Frik and supported by a strong project and technical crew, delivered a successful outcome with minimal downtime and maximum performance gains.
Project Scope and Key Services Delivered:
Full Tube Replacement
A complete tube bank replacement was undertaken to restore boiler efficiency and eliminate potential failure points. All fabrication and installation were carried out in line with pressure vessel compliance standards.
Lagging and Refractory Replacement
We replaced worn refractory linings and lagging materials to enhance thermal insulation and protect the structural integrity of the boilers. These upgrades contribute to better energy efficiency and longer operational life.
Non-Destructive Testing (NDT)
In collaboration with certified testing partners, we conducted a series of rigorous NDT procedures including:
- X-ray testing
- Magnetic Particle Inspection (MPI)
- Replica metallography
- Wall thickness testing
This comprehensive assessment ensured the structural soundness and safety of the pressure components.
Soot Blower Reconditioning
The soot blowers were overhauled to restore optimal cleaning functionality, reducing soot build-up and improving overall heat transfer efficiency inside the boiler system.
Drum Repairs – Mud Drum and Steam Drum
Critical internal repairs were carried out on both the mud drum and steam drum, targeting corrosion, fatigue, and previous weld failures. Our work ensured restored pressure integrity and extended service life.
Skin Casing Replacement
We replaced damaged and corroded outer skin casings to improve insulation performance and ensure compliance with plant safety protocols.
Boiler Valve Replacement
Old and malfunctioning boiler valves were replaced with new, pressure-rated units to improve control, safety, and system responsiveness.
Project Outcomes
This comprehensive boiler overhaul project was delivered:
- On time and within budget
- In full compliance with industry regulations
- Without compromising on plant operations or safety
The upgrades have significantly improved the reliability, efficiency, and safety of ArcelorMittal’s boiler systems, supporting the plant’s continuous production demands.
Partnering for Industrial Reliability
This project demonstrates Elinem Construction’s capabilities in handling large-scale, mission-critical boiler overhauls for major industrial clients. With decades of experience in pressure systems and a hands-on approach to quality, our team ensures every component is restored or replaced to meet or exceed original performance specifications.
If you’re looking for a dependable partner for your next boiler maintenance, repair, or overhaul project—Elinem Construction is ready to deliver.
