Specialist industrial services contractor KAEFER has been in continuous service of State-owned power utility Eskom for 30 years.

KAEFER South Africa MD Jayson Cleaver says the relationship with Eskom spans the breadth of the utility’s generation fleet, from conventional coal-fired power stations to the country’s only nuclear facility at Koeberg. Rather than operating as a single-trade contractor, KAEFER deploys complementary specialist services within a single project scope: access solutions; insulation; surface protection; and passive fire protection.

“Limiting contractor interfaces reduces operational and safety risk and allows for faster turnaround,” Cleaver notes, adding that in a live-plant environment, that level of coordination is crucial.

Nuclear Capability

At Koeberg, KAEFER’s involvement “carries particular technical weight”.

Cleaver notes that the company’s Nuclear Centre of Competence, based in France, has built its knowledge through a decades-long partnership with the French nuclear utility, with hands-on experience in access, insulation and coatings on the same three-loop PWR Framatome Generation II reactor type as Koeberg, spanning close to 50 years. KAEFER’s involvement at the station dates back to its original construction in the 1970s and has continued through the plant’s life extension and steam generator replacement projects.

A technically differentiated capability KAEFER brings to the nuclear environment is its role as an original-equipment manufacturer (OEM) supplier of Reflective Metal Insulation (RMI). Unlike conventional insulation systems, which work by reducing heat conduction, RMI blocks radiant heat through reflection.

Hundreds of specially designed prefabricated metal cassettes, filled with reflective elements, are precision-assembled around specialised equipment.

“The system is capital intensive, but it delivers strong thermal insulation performance, allows rapid access for inspection and maintenance, and is entirely fibre-free and reusable. These properties address a range of practical and regulatory requirements specific to the nuclear environment, including the need to minimise contamination risk and support frequent access for inspection.

“While insulation is not a primary structural component, maintaining high-integrity insulation within the containment area is essential to ensure the plant operates as intended and remains safe. Having a reputable and capable service provider on hand to deal with issues as they arise during maintenance is critical. Delays are not an option, and neither is leaving problems to be resolved after the fact,” Cleaver explains.

The high-salinity coastal environment at Koeberg presents its own challenges beyond the containment building, with Cleaver noting that the environment “wreaks havoc” with metallic structures and corrosion needs to be aggressively managed over the long term, especially in the cooling water intake and screening areas.

KAEFER states that its international nuclear experience reinforces its local capability. The company’s UK operation is currently executing scope at Hinkley Point C, the largest active nuclear construction site in Europe, involving the latest Generation III+ EPR reactor, with hundreds of KAEFER personnel on site. Other recent international nuclear projects include Olkiluoto in Finland and Flamanville in France.

Working closely with the OEM across twin sites in France, through both ongoing maintenance and major projects, further ensures the company is well placed to access the required knowledge and “deliver consistently on quality, safety and performance, whatever circumstances may arise”.

Data as a Competitive Tool

Across both its nuclear and conventional power work, KAEFER is investing in digital tools to improve how projects are planned, executed and reported.

As clients increasingly move toward unit-rate contract forms in pursuit of risk transfer and cost containment, data becomes “the critical ingredient, ensuring the project remains commercially viable for the service provider while generating the insights needed to continuously improve value for customers,” Cleaver states.

He cites KAEFER’s proprietary DPMS, or Digital Project Management Solution, which has proved successful with customers both locally and internationally.

Robotics and digitalisation are also playing a growing role in how industrial services are delivered, enabling repeatable, high-quality execution at lower deployment costs. KAEFER adds that its corporate innovation laboratories, supported by partnerships with leading global technology suppliers, allow it to develop and fine-tune specialised solutions before deploying them in the field.

Building Local Capacity

Beyond technical delivery, KAEFER has invested deliberately in developing local contractors and suppliers throughout its decades of Eskom service. Skills transfer, subcontractor development, and the inclusion of local businesses in its supply chain have been “consistent priorities”.

“Supporting and building local business is also a key priority for our customers, and we have a strong track record of developing local capacity through deliberate investment in skills and opportunity,” Cleaver says.

Looking ahead, the prospect of nuclear new build and the emerging Small Modular Reactor space, in the context of South Africa’s Integrated Resource Plan 2025 ambitions, make a resilient and capable local supply chain an imperative. “We know that a collaborative approach with communities, industry, and our customers is imperative in securing long-term energy sustainability, and we are excited about what lies ahead,” Cleaver concludes.