Khumani Iron Ore Mine Expansion, South Africa

Engineering excellence drives fast-track expansion of a major iron ore mine.

Client

Assmang

Project date

2016-2017

The Khumani iron ore mine, near Kathu in South Africa’s Northern Cape Province, required expansion to replace the ore tonnage from Assmang’s Beeshoek Mine, which had reached the end of its economic life. The project demanded a combination of precise engineering, local expertise, and careful coordination with the main EPCM contractor.

The opportunity

Assmang sought a reliable local engineering partner to support DRA Global, the Australian EPCM and managing contractor. The challenge was to deliver complex civil and infrastructure works on a tight schedule while maintaining high standards of quality, safety, and operational efficiency. Success would require foresight in design, attention to detail, and close collaboration between multiple teams.

What we did

Zutari contributed to the Khumani Expansion by delivering comprehensive engineering services that formed the backbone of the project’s success. Our team focused on:

  • Bulk earthworks and terracing: Designed and managed the construction of terraces for crusher tips, workshop areas, overland conveyors, and stacker and reclaimer bunds for run-of-mine and product load-out. These terraces provided a solid platform for downstream infrastructure, ensuring that subsequent project phases could progress without delays.

  • Water and stormwater management: Developed bulk water supply connections, stormwater canals, berms, pump stations, and attenuation dams to protect the mine infrastructure from flooding and to ensure a reliable water supply.

  • Civil engineering services: Delivered comprehensive sewer and water reticulation solutions, ensuring that all terrace and service roads were correctly designed to support operational demands and heavy traffic loads.

  • Roads and site access: Designed and engineered terrace and service roads to facilitate the safe and efficient movement of materials and personnel throughout the mine site.


The project required meticulous coordination with the main contractor and other stakeholders. Our detailed designs and timely execution ensured that all components were integrated seamlessly into the overall mine expansion plan.
The completed terraces and infrastructure create a robust foundation that supports efficient mining operations.

The outcome

Through careful planning, technical expertise, and dedicated teamwork, the Khumani Expansion was completed successfully and on schedule. The project strengthened Assmang’s operational capacity, replaced the depleted ore source from Beeshoek Mine, and reinforced the mine’s long-term sustainability. The collaboration between Zutari and the wider project team has been recognised as a benchmark for effective local and international partnerships in the mining industry.

Zutari’s involvement in the Khumani Expansion demonstrates the impact of combining local knowledge, technical expertise, and collaborative teamwork to deliver complex mining infrastructure projects efficiently and to the highest standard.

The bulk earthworks terraces created a crucial platform that enabled every subsequent stage of the project to proceed on time.

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