Aspen Pharmacare – Gqeberha

May 2025

Electrical first-fix: cable-tray & wire-way installation

Client: Aspen Pharmacare (Sterile-manufacturing campus)
Scope: LV power, control & earthing for new 17 MWR ammonia refrigeration plant
Phase: First-fix cable management – hot-dip-galvanised ladder, tray & wire-mesh routes; preliminary equipment mounting (condensers & fan motors)

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Project Summary

Our team is delivering the electrical backbone for Aspen’s new cooling-as-a-service ammonia plant, a project expected to cut site energy consumption by ≈ 40 %.
The current phase focuses on installing nearly 700 m of cable ladder and tray, earth-bonded to IEC 61537 / SANS 10142, plus dedicated wire-mesh baskets to keep noisy VSD motor feeds away from low-level instrumentation.

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Engineering Scope (First-Fix)

• 100–600 mm HDG ladder & tray on M10 threaded-rod trapeze frames (≤ 1,5 m centres)
• Segmented 90° sweeps to preserve bend radius and reduce pulling tension
• Wire-mesh baskets for ETHERNET & control signals (segregated routes)
• ABB System-Pro E MCCs positioned and stubbed for future expansion
• IP68-glanded tails to evaporative condenser fan motors (GMP wash-down area)

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Challenges & Solutions

Challenge	Mitigation
Congested ceiling below GMP walk-on panels	Layered routes: power ladder top, control tray mid-level, mesh basket bottom
50 kA short-circuit capacity at MCC	75 mm side-wall ladder with 6 mm splice bars, earth studs every 3 m
GMP cleanability	All supports chamfer-ground & lacquer-sealed; no dust-harbouring shelves

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Progress Gallery

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Next Milestones

1. Pull 240 mm² XLPE feeders to compressors (Week 22) (Soft starters)
2. Pull 240mm² TOPFLEX®-EMV-3-PLUS-2YSLCY-J transparent screen cable (VSD)
3. Site earthing & bonding test – target < 0,2 Ω network (Week 24)
4. Baseline thermal-imaging survey before energising (July)
5. Loop-check & I/O mapping with OEM control vendor (July)

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Why It Matters

Every radius, earth lug and IP68 gland installed now safeguards Aspen’s GMP production from unplanned downtime later.
By getting the “invisible” infrastructure right first time, we’re helping Aspen realise its sustainability targets without compromising regulatory compliance.

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Need similar large-scale refrigeration or GMP-grade electrical work?
Contact the CSES team – we’ll keep the cool chain running.