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When Kansanshi Mining expanded its processing capabilities in copper production with a new oxygen plant, the reliability of its thermal insulation system became mission-critical. KLINGER Zambia was selected to engineer and execute a complete insulation package – hot, cold, and acoustic – under strict compliance requirements and a non-negotiable schedule tied to international commissioning timelines.
The project was executed through three simultaneous purchase orders, each addressing a different core requirement:
All work aligned with internationally recognized standards, including ASTM C533/C547, ISO 12241, EN 14303, and ARI RP 521. “Our goal was simple but demanding: deliver a fully compliant insulation system that met every functional, technical, and safety requirement within an extremely tight schedule,” says Jaco Sadie, General Manager of KLINGER Zambia.
The project followed a structured workflow beginning with design reviews and material verification, ensuring correct thermal conductivity, corrosion resistance, and acoustic performance. Surface preparation prevented CUI risks (Corrosion Under Isolation), followed by the application of high-grade materials such as calcium silicate, polyurethane foam, and mineral wool. Stainless steel and aluminum jacketing provided mechanical protection and weatherproofing. Quality assurance included thermal performance testing, acoustic verification, integrity checks, customer-specific protocols, and OSHA-aligned audits (Occupational Safety and Health Administration standards).
(14) Caption: Technicians securing aluminum jacketing on insulated process piping, ensuring full compliance with international thermal performance standards.
What set the project apart was not only its technical complexity but the team behind it. Of the 33 personnel on site, 27 were Zambian professionals – 20 of them seasoned experts with more than two decades of industrial experience. Before mobilization, KLINGER Zambia conducted intensive training programs and learning schools to ensure that every team member performed at international standards. Drone-based aerial monitoring provided precise progress tracking, allowing real-time decision making and ensuring insulation was completed before the arrival of Australian commissioning engineers. “This project proved that a locally empowered team can deliver an international-grade result,” Jaco emphasizes.
Kansanshi Mining praised KLINGER Zambia for outstanding workmanship, schedule adherence, and seamless collaboration between the Zambia and South Africa teams. Seven Zambian team members of Kansanshi Mining earned performance experience certificates, strengthening local expertise for future industrial projects.
The Kansanshi Oxygen Plant insulation project was more than a technical assignment – it became a showcase of engineering precision, local capability, and KLINGER’s commitment to raising industry standards across Africa.
