Draco Group successfully completed one of South Africa’s most technically challenging demolition projects: the controlled blasting and toppling of a structurally compromised 107-metre concrete converter stack at Palabora Mining Company (PMC).

The reinforced concrete stack, built in 1960 and refurbished in the late 1980s, had reached the end of its serviceable life. By early 2025, a structural assessment by consulting engineers Knight Piésold revealed alarming signs of instability. The structure was leaning six degrees with a 600 mm off-centre deflection, exceeding national SANS 10160 serviceability limits. This raised the risk of a sudden collapse. Situated at the heart of PMC’s live smelter operation – and within the boundaries of the Kruger National Park – the stack posed significant safety, environmental, and operational risks.

Conventional dismantling methods such as scaffolding or a top-down demolition were ruled out due to instability and limited space. The smelter plant surrounded the stack on 340° of its perimeter, leaving only a narrow 20° corridor for a safe fall zone. Further complicating the project, three live railway lines crossed the designated drop area and had to be dismantled and within a 48-hour timeframe to avoid production delays.

Draco Group’s engineers developed a solution that combined demolition expertise with advanced technology. More than 400 precision-drilled blast holes created a controlled failure plane, while diamond rope cutting introduced a hinge line to guide the toppling direction, and reinforcement bracing was installed to stabilise weak points. Sophisticated surveying methods mapped over 1,000 data points across the structure, informing digital models and refining the blast design. On the day of the blast, drones equipped with thermal imaging surveyed the 300-metre exclusion zone to detect any wildlife or human presence, confirming the area was clear.

At precisely 12:00 on 17 June 2025, the blast was executed. The stack fell exactly within the planned corridor, crossing the three railway lines with a margin of less than 20 metres. Surrounding infrastructure remained intact, and smelter operations resumed immediately once the rail lines were reinstated.

Safety was the cornerstone of the project. The Department of Mineral Resources approved the blast plan, and strict safety procedures were enforced. A 300-metre exclusion zone was cleared and monitored, while daily safety briefings and PPE checks ensured compliance. The project concluded with zero incidents, zero injuries, and zero damage to adjacent plant assets.

Environmental protection was equally critical, given the project’s location inside the Kruger National Park. Measures included dust suppression, blast blankets, and strict debris containment. Within 48 hours, rubble was removed to a designated mine landfill site, with reinforcing steel recycled. Post-blast monitoring confirmed no contamination of soil or water and no disturbance to wildlife.

Community and stakeholder engagement also played a role. Public notices were issued in local newspapers, and collaboration with the Palabora Foundation, PMC’s CSI arm, ensured transparency. Local subcontractors were employed for post-blast clean-up, creating jobs and skills development opportunities.

“This project was about more than toppling a structure – it was about protecting lives, safeguarding critical infrastructure, and ensuring environmental responsibility,” said Teddy Habib, CEO of Draco Group. “We are proud to have delivered a project of this scale and complexity without incident, and to have set a new benchmark for specialist demolition in South Africa and across the continent.”

The demolition of the converter stack represents a milestone for both Draco Group and the wider industry. It is the tallest stack of its kind ever demolished in South Africa and the first time a structure of such severe instability has been safely brought down in a live smelting environment.

For more information about Draco Group and their full turnkey solutions, visit the website: https://dracogroup.co.za/ and join the conversations on Facebook and LinkedIn.