Services: Welding & Fabrication

WELDING & FABRICATION

Industrial facilities depend on the quality of their fabricated assets and welded joints to ensure safe, reliable, and efficient operation. Whether transporting water through high-pressure pipelines, supporting process equipment through structural steelwork, fabricating pressure vessels, or constructing critical infrastructure, the integrity of every weld directly impacts operational performance, safety, and asset life.

Thwalokuhle provides specialist welding, fabrication, and mechanical installation services across the power generation, water treatment, mining, manufacturing, petrochemical, municipal, and industrial sectors. Our capabilities extend from engineering detailing and workshop fabrication through site installation, quality assurance, testing, commissioning, and ongoing maintenance support.

Our fabrication teams are experienced in working with carbon steel, stainless steel, duplex stainless steel, galvanised steel, aluminium, and HDPE piping systems. We fabricate process pipework, pressure piping systems, tanks, filtration vessels, structural steelwork, platforms, access structures, pump skids, pipe supports, equipment supports, and customised engineered solutions designed to meet specific operational requirements.

Quality remains central to every fabrication project we undertake. Through qualified welding procedures, competent personnel, material traceability, non-destructive testing programmes, and stringent quality control systems, Thwalokuhle delivers fabrication solutions that meet the demanding requirements of Eskom, municipalities, mining houses, industrial manufacturers, and utility operators.

Our approach combines engineering expertise, workmanship excellence, internationally recognised quality standards, and rigorous inspection processes to ensure that every fabricated component performs reliably throughout its intended service life.

02 STANDARDS

REGULATORY STANDARDS

Standard 01

ISO 3834 – Quality Requirements for Fusion Welding of Metallic Materials

ISO 3834 is the internationally recognised quality standard governing the fusion welding of metallic materials. The standard establishes comprehensive requirements for welding procedures, welder qualifications, inspection processes, testing requirements, material traceability, and fabrication documentation.

Standard 02

Eskom Welding Quality Requirements

Power generation facilities operate under demanding conditions where welded structures, pressure systems, piping systems, and process equipment must perform reliably over extended periods. Eskom therefore imposes strict quality requirements governing welding activities, quality control, inspection, documentation, and material management.

Standard 03

Thwalokuhle Fabrication Quality System

Thwalokuhle implements fabrication quality systems aligned with ISO 3834 principles to ensure consistent workmanship and repeatable quality outcomes. Our fabrication activities incorporate controlled welding procedures, documented inspection plans, qualified personnel, and comprehensive quality records that provide confidence in the integrity of fabricated assets.

Standard 04

ISO 9606 – Qualification Testing of Welders

ISO 9606 establishes the requirements for qualifying welders performing fusion welding on metallic materials. The standard verifies a welder’s ability to consistently produce sound welds in accordance with approved welding procedures.

Standard 05

ASME Section IX – Welding and Brazing Qualifications

ASME Section IX governs the qualification of welding procedures and personnel for pressure-retaining systems and critical process equipment applications.

Standard 06

PD 5500 – Unfired Fusion Welded Pressure Vessels

PD 5500 provides requirements for the design, fabrication, inspection, testing, certification, and maintenance of unfired fusion welded pressure vessels. Thwalokuhle supports clients through design and fabrication in accordance with recognised engineering codes.

Standard 07

SANS 347 – Pressure Equipment Regulations

Pressure equipment operating under elevated pressure conditions is regulated under South Africa’s Pressure Equipment Regulations. Thwalokuhle supports compliance through controlled fabrication practices, quality assurance, and testing.

Standard 08

Occupational Health and Safety Act (OHSA)

Safety is integrated into every stage of our operations through risk assessments, permit systems, safe work procedures, toolbox talks, and ongoing workforce training.

Standard 09

ISO 9712 – Non-Destructive Testing Personnel Qualification

Thwalokuhle utilises qualified NDT personnel and recognised testing methodologies to verify fabrication quality and ensure compliance with project specifications and client requirements.

3. Services

Thwalokuhle fabricates and installs carbon steel, stainless steel, and specialised alloy piping systems for municipal, mining, utility, and industrial applications. Services include spool fabrication, site installation, testing, commissioning, and quality documentation.

We fabricate pressure vessels, filtration vessels, activated carbon filters, multimedia filters, ion exchange vessels, compressed air receivers, and process tanks in accordance with recognised engineering standards and project specifications.

We fabricate tanks, pipework, process skids, platforms, handrails, and custom-engineered stainless steel components designed to meet demanding operational requirements.

Services include structural detailing, fabrication, corrosion protection, erection, and final commissioning of structural systems such as platforms, walkways, and pipe supports.

Thwalokuhle fabricates and installs process tanks, storage vessels, chemical tanks, sludge tanks, and associated equipment designed to client specifications and operational requirements.

We provide site installation services including mechanical erection, pipe installation, equipment alignment, pressure testing, commissioning, shutdown fabrication support, and rapid-response teams for outages.

Our refurbishment services include equipment repairs, piping replacements, structural modifications, corrosion repairs, vessel refurbishments, and plant upgrades to restore reliability and extend asset life.

04OUR TECH

Technology

TIG

TIG Welding (GTAW)

TIG welding provides exceptional weld quality, precision, and cleanliness, ideal for stainless steel, thin-wall piping, hygienic process applications, and pressure-retaining systems.

MIG

MIG Welding (GMAW)

MIG welding offers high productivity and consistent weld quality across structural steel, process piping and equipment fabrication.

MMA

MMA Welding (Shielded Metal Arc Welding)

MMA welding is versatile and ideal for site-based fabrication, repairs, and maintenance activities.

Orbital

Orbital Welding

Orbital welding provides automated, repeatable welds for critical piping systems and high-purity applications.

CNC

CNC Plasma and Profile Cutting

Computer-controlled cutting systems improve accuracy, productivity, and repeatability during fabrication activities.

Rolling

Pipe Rolling and Forming

Pipe and plate rolling technologies allow the fabrication of specialised components including tanks, vessels, and cones with improved quality and reduced waste.

Hydrotest

Hydrostatic Testing

Hydrostatic testing verifies the integrity of fabricated piping systems and pressure-retaining equipment before commissioning.

NDT

Non-Destructive Testing (NDT)

NDT techniques such as visual inspection, dye penetrant, magnetic particle, ultrasonic testing, and radiography provide assurance that fabricated components meet quality requirements.

5. Maintenance

Thwalokuhle provides specialist weld repair services that restore structural integrity and operational performance while minimising downtime and extending asset life.

Our teams undertake inspections, repairs, replacements, and protective coating programmes designed to extend asset life and reduce maintenance costs.

We provide dedicated fabrication teams, quality control personnel, and project supervision to support outage execution while maintaining quality and safety standards.

Thwalokuhle provides vessel inspections, repair services, nozzle replacements, shell repairs, internal refurbishment, hydrostatic testing, and integrity assessments.

Our assessment programmes evaluate piping systems, structural components, tanks, pressure vessels, and mechanical equipment to identify risks and prioritise maintenance activities.

Thwalokuhle offers structured maintenance agreements tailored to client operational requirements, including routine inspections, preventative maintenance, fabrication support, emergency response services, condition reporting, and long-term asset management recommendations.

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