In a milestone achievement for South Africa’s renewable energy sector, Concor has taken full control of the Balance of Plant (BoP) scope on the TotalEnergies Renewables De Aar 2 South Wind Energy Facility in the Northern Cape. This marks the first time the company is delivering a fully wrapped BoP contract under its own direct engineering and construction management. Not only is Concor the main contractor for the 25 turbine project spread across five farms near Philipstown, but it is also responsible for both the Civil BoP (CBoP) and Electrical BoP (EBoP) – from design and engineering through to execution including the Eskom Distribution self-build scope. This comprehensive self-perform approach represents a bold departure from traditional contracting models and signals Concor’s evolution into a truly turnkey BoP provider.

“With over 13 years of experience in renewable energy infrastructure, more than 10 wind farms successfully completed since 2012 and a further six wind farms currently in various phases of construction, Concor is no stranger to the demands of this sector,” says Stephan Venter, Contract Director at Concor. “But this project sets a new benchmark. By taking full ownership of both the engineering and construction elements, we are reducing interfaces, improving accountability and de-risking the process for our clients.”

This strategic shift positions Concor at the forefront of renewable project delivery in South Africa, offering clients a streamlined single-source BoP solution that enhances coordination and ensures delivery certainty.

The 5,473 hectare facility is on a fast track programme, with early works launched in November 2024 and completion expected by Q3 of 2026. The company’s scope includes 54 km of gravel road infrastructure, starting with the realignment and upgrading of 15 km of the existing Kranskop district road to accommodate heavy turbine components. Additionally, 41 km of new internal access roads are being constructed, supported by extensive blasting and cut-and-fill earthworks to adapt to the local terrain.

A major innovation lies in Concor’s design of the turbine foundations. A unique central pit, 7 metres in diameter and filled with G7 material, has been incorporated to address the region’s geological challenges, reducing stress on the 22 metre diameter concrete bases. Each foundation uses 600 m³ of specially designed readymix concrete, batched on-site making use of two brand new modified 45 m³/hr Karoo plants to ensure consistency and quality. Smart rock sensors embedded in the foundations monitor internal temperatures, allowing real-time adjustments to mitigate the risk of thermal cracking.

As part of the Electrical Balance of Plant (EBoP), Concor is responsible for trenching and laying 13km of 33kV medium voltage cabling from each turbine’s Power Transformer Kiosk (PTK) to a termination overhead line (OHL) structure. This is linked via an extensive 80km 33kV OHL network to the IPP substation, which steps up the voltage to 132kV utilising a 165 MVA power transformer. The project also includes the construction of a new adjacent Eskom Distribution 132kV Switching Station (SWS) and an extension of a 132kV OHL to an upstream Eskom Main Transmission Substation (MTS).

The project has not been without challenges. A high water table impacted 11 of the 25 turbine bases, requiring the installation of subsoil drainage systems. In addition, heavy seasonal rainfall necessitated robust stormwater management to protect both access and internal roads.

Environmental compliance has remained central to Concor’s operations, guided by the Environmental Management Programme Report (EMPR). Teams receive regular training to uphold environmental protocols and safeguard heritage and biodiversity in this sensitive landscape.

“Our execution reflects Concor’s depth of experience in remote, large-scale projects,” says Concor Project Manager Gideon Niemand. “We are delivering to the highest standards, with environmental responsibility and engineering excellence at the core of everything we do.”

Through innovative engineering, efficient planning, and environmental stewardship, Concor is helping shape a more sustainable energy future – one turbine at a time.

Concor has embarked on its first fully wrapped Balance of Plant (BoP) contract – covering both civil and electrical scopes – at the De Aar 2 South Wind Energy Facility, showcasing its turnkey engineering and construction capabilities.

Clearing and grubbing activities underway on the De Aar 2 South Wind Energy Facility project, forming part of the initial site establishment and earthworks phase.

Cut-to-fill activities in progress on the De Aar 2 South Wind Energy Facility project, optimising on-site material use for road construction and turbine platform preparation.

Load and haul activities underway on the De Aar 2 South Wind Energy Facility project, supporting bulk earthworks for roadbeds and turbine platform development.

Construction of the roadbed progressing on one of the access roadways at the De Aar 2 South Wind Energy Facility, forming a key part of the site’s civil infrastructure development.

Environmental management includes dedicated search and rescue operations for indigenous flora, ensuring protected plant species are identified, carefully relocated and preserved ahead of construction activities.

Drilling is underway on a wind turbine base at the De Aar 2 South Wind Energy Facility project, marking a key step in the foundation preparation process.

Load and haul activities taking place around a wind turbine base under construction at the De Aar 2 South Wind Energy Facility, supporting foundation works and material placement.

Base cleaning underway on a wind turbine foundation at the De Aar 2 South Wind Energy Facility, preparing the surface for the next phase of construction.