THE Eastern Cape has been a priority province for wind energy generation in South Africa for over a decade and continues to play a key role in advancing the country’s renewable energy production. Nordex Energy South Africa (Nordex) has invested in the Eastern Cape since 2013 and now boasts a significant footprint in the province, including its head office, a warehouse in Gqeberha and 573 MW of installed capacity across five operational wind power plants; this is in addition to the new concrete tower manufacturing facility and cluster of wind farms currently under construction.
In November, Nordex announced that the casting of the 1,425 keystones required for the construction of a wind farm cluster near the Impofu Dam in the Eastern Cape had successfully commenced at its manufacturing facility, marking a key milestone in the project’s development. Production is expected to ramp up significantly in the coming months to meet the demands of this large-scale renewable energy initiative, with additional keystones scheduled for delivery to the site next month.
“This custom-built factory, located 52 kilometres from the wind farm site, is a key investment in the region’s renewable energy infrastructure and we are pleased to be able to announce that the facility is ready to ramp up in line with the construction milestones,” explained David Moncasi Hortet, head of sales for Africa at Nordex Energy South Africa.
Each of the wind turbine concrete towers comprises 25 individual keystones, with the heaviest keystone cast to date weighing over 57 tonnes, measuring 20 metres in length and over 5 metres in width. In addition to concrete, rebar is a crucial structural component, ensuring the strength of the keystones by absorbing tensile forces that concrete cannot withstand on its own. Rebar installation is completed in one day, followed by a 4-5 hour casting process, and the keystones are cured for 7-10 days to achieve the necessary strength for transport.
“Considering the local content contribution, including steel rebar, concrete, and aggregate – all sourced locally – the production of the towers not only supports job creation but also provides an additional boost to the South African economy,” added Moncasi Hortet.
Given the size and weight of the keystones, 13 of the 25 required for each turbine tower will need police escorts for transportation. With the factory’s proximity to the wind farm site, the logistical process is streamlined, ensuring smooth delivery of these essential components.
Developed as part of a broader strategy to stimulate the local economy, the facility is creating approximately 350 ongoing jobs and spans nearly 10 hectares. Its strategic location near the Port of Ngqura supports efficient logistics for both the manufacturing and transport of the keystones, further cementing the Eastern Cape as a renewable energy hub.
This cluster of wind farms is a significant milestone in South Africa’s renewable energy efforts, with the casting of the first keystone marking a crucial step in the project’s construction progress.
Nordex currently commands over 32% of the country’s market share, operating 1.1 GW across the Eastern, Northern and Western Cape provinces, with 631 MW currently under construction in the Eastern and Northern Cape.
Nordex believes its new production hub may enhance its competitiveness in future bidding processes, while also demonstrating the versatility and proven technology of its in-house concrete towers.
Wind energy on a growth trajectory
In scenarios presented by the Department of Mineral Resources and Energy during recent Integrated Resource Plan 2024 stakeholder engagement workshops, wind energy was allocated no less than 69 GW and up to 76 GW. In the current Draft IRP 2023, wind energy is allocated far less, at 4,5 G W.
The South African Wind Energy Association (Sawea) has welcomed the increase but notes that the draft still has to go through the process of policy adjustment. Sawea says it expects the policy adjusted IRP to still retain this trajectory even if the actual capacity is adjusted.
