Xstrata Coal

Fuel is essential to mining and coal processing, but managing its logistics is generally not a core competency for a mining entity. To secure long‑term efficiency, the company committed to a Vendor Managed Inventory (VMI) model—where fuel stock remains vendor‑owned, with guaranteed supply levels and on‑site dispensing.
To support this strategic shift, ProjectWay managed the construction of three bulk diesel and lubrication facilities across major open‑cast operations. By aligning infrastructure with future‑focused supply strategies, we ensured reliable fuel availability, streamlined operations, and strengthened out client’s commitment to productivity.

ProjectWay was appointed to manage the implementation of South Africa’s first high wall mining project—introducing advanced technology from Addcar Systems in the USA. Operations began producing coal in August 2012, powered by a Joy continuous miner, 33 conveyor cars, a launch vehicle, stacker, and a CAT 988 front‑end loader with a specialized “pizza pan” attachment.
This method proved ideally suited for extracting thin 5‑seam coal reserves with high stripping ratios. Compared to conventional board‑and‑pillar or opencast mining, the Addcar system delivered superior results. With ProjectWay’s leadership, groundbreaking mining technology was successfully deployed.

At ProjectWay, we pride ourselves in delivering project in a responsible, sustainable manner. Our expertise spans the full spectrum of water management and land rehabilitation, ensuring mines meet both operational and environmental obligations. For Xstrata Coal/Glencore, we successfully managed projects including the removal of polluted soil, construction of pollution control dams (PCDs), and the construction of clean and dirty water separation channels. Beyond infrastructure, we supported our client in the management of complex regulatory processes, such as the update of Environmental Impact Assessments (EIA), Environmental Management Plans (EMP), Integrated Water Use License Applications (IWULA), Integrated Waste Water Management Plans (IWWMP), and certified flood line studies. By combining technical excellence with regulatory compliance, ProjectWay empowers mining operations to act responsibly, safeguard natural resources, and build a sustainable legacy.

As mining progresses, certain shafts and ventilation systems no longer serve a purpose. Leaving them open poses risks such as ground instability, unauthorized access, and environmental hazards. Sealing shafts prevents accidents, protects communities, and reduces liability. It also ensures compliance with regulatory frameworks that require closure of unused mine workings. Beyond safety, closure helps restore land for future use—whether for conservation, agriculture, or development. Sinkholes and shafts can disrupt ecosystems if not properly managed. ProjectWay’s initiative with Xstrata coal/Glencore—sealing 55 shafts and sinkholes over five years—shows the scale and planning required. It’s not just about plugging holes; it’s about systematic risk reduction and long-term land stewardship.

At ProjectWay, we specialize in turning complex mining access challenges into seamless, well-executed projects. Gaining access to coal reserves requires more than just excavation—it demands strategic planning, robust infrastructure, and controlled execution. From ensuring safe access for personnel and machinery to managing water systems, material transfer, ventilation, fire protection, and reliable power supply, we deliver comprehensive solutions that keep operations running smoothly. Our proven expertise includes successfully managing the Blinkpan 4 Seam and Tweefontein 2 Seam coal access projects, effectively overseeing design and development. With ProjectWay, you don’t just get project management—you get a trusted partner committed to unlocking resources and driving operational success.

When mining development at Xstrata Coal South Africa required critical ventilation at the coal face, ProjectWay delivered. In 2007 we managed the design and construction of an up‑cast ventilation shaft and additional inlet, overseeing both surface fan installation and raise bore shaft construction.
By combining technical know‑how with disciplined project management, ProjectWay ensured safe, efficient, and timely delivery of a high‑stakes mining infrastructure project. We turn complex engineering challenges into success stories.

A coal handling and beneficiation project faced mounting risks from scope creep and construction delays. ProjectWay was appointed to audit the project, identify remedial measures, and ultimately manage the turnaround through to completion.

Our scope included critical upgrades to slurry and discard management systems: modifying conveyors, constructing a new overland conveyor and discard bin, and enhancing slurry handling. With disciplined project management and technical precision, ProjectWay transformed a high‑risk project into a success story.