Sasol Secunda Annual Structural Inspections

Project Overview

For three consecutive financial years (FY24, FY25 and FY26), Robust Consulting Engineers was appointed by Sasol Secunda Operations to undertake annual structural inspections of civil and structural assets across one of the world’s largest integrated petrochemical production facilities. The appointment forms part of Sasol’s asset integrity management programme, which is aimed at ensuring that critical infrastructure remains safe, reliable and fit for purpose throughout its operational life.

The inspections covered a diverse range of operational facilities, including process plants, structural steel pipe racks, workshops, control buildings, cooling towers, storage facilities and utility plants. By providing comprehensive structural condition assessments and engineering recommendations, Robust Engineers supports Sasol in maintaining the integrity of infrastructure that is critical to continuous production.

The Challenge

The Sasol Secunda complex contains thousands of structural assets operating in an aggressive industrial environment characterised by elevated temperatures, chemical exposure, vibration, corrosion and continuous mechanical loading. These conditions can accelerate the deterioration of structural steelwork and reinforced concrete structures if not identified and managed proactively.

The client required a structured inspection programme capable of assessing the condition of numerous facilities spread across the operation while maintaining consistent engineering standards and reporting methodologies. The challenge extended beyond identifying visible defects—it required engineering judgement to evaluate structural risks, prioritise repairs and provide practical recommendations that could be incorporated into Sasol’s maintenance and shutdown planning.

Given the scale of the operation, inspections had to be completed efficiently with minimal disruption to production while ensuring that every asset received a thorough engineering assessment.

Our Engineering Solution

Robust Engineers developed and implemented a systematic structural inspection methodology tailored to Sasol’s operational requirements and asset integrity standards.

Each inspection involved a detailed visual assessment of structural steelwork, reinforced concrete elements, pipe racks, industrial buildings, cooling towers, access structures and process support infrastructure. The inspections focused on identifying deterioration mechanisms such as corrosion, deformation, cracking, settlement, damaged protective coatings, loose connections, overstressing and other structural defects that could affect the long-term performance of the assets.

Every identified defect was documented, photographed and evaluated according to its potential impact on structural integrity, operational reliability and personnel safety. Engineering recommendations were then prioritised to enable Sasol to plan maintenance interventions based on technical risk rather than reactive repairs.

Over the three-year appointment, Robust Engineers successfully inspected infrastructure across numerous operational units, including hydrogen production plants, gas cooling plants, catalytic cracker plants, supply chain integration facilities, propylene purification plants, boiler feed water treatment plants, cooling towers, dispatch facilities, structural steel pipe rack networks, workshops, office buildings and control rooms. The inspections also covered specialised Market Process Integration (MPI) pipe rack systems that form a critical component of Sasol’s production process.

Comprehensive inspection reports were produced following each inspection, providing condition assessments, photographic records, engineering evaluations and practical recommendations for repair, refurbishment or continued monitoring.

Value Delivered

Robust Engineers plays an important role in supporting Sasol’s proactive asset management strategy by identifying structural risks before they impact production, safety or operational reliability. Our inspection programme enables maintenance teams to focus resources where they are most needed, reducing the likelihood of unplanned shutdowns and extending the service life of valuable infrastructure.

The consistency of our inspection methodology over multiple years also allows Sasol to monitor deterioration trends across its facilities, providing valuable data for long-term maintenance planning and capital investment decisions. This proactive approach improves infrastructure reliability while reducing lifecycle costs and enhancing plant safety.

Through detailed engineering assessments and practical recommendations, Robust Engineers contributes to the continued safe operation of one of South Africa’s most important industrial facilities.

Project Outcome

The annual structural inspection programme has become an integral part of Sasol Secunda’s infrastructure integrity management system. Over three consecutive years, Robust Engineers has successfully inspected hundreds of critical structural assets, providing the engineering insight required to support safe operations, informed maintenance planning and long-term asset sustainability.

The project demonstrates our specialist capability in industrial structural inspections, asset integrity management and condition assessments for large-scale petrochemical and industrial facilities. It also reflects the confidence placed in Robust Engineers to provide technically sound engineering services within one of the most demanding industrial environments in Africa.