Khwezela Dragline Relocation

A complex dragline relocation project enabling extended coal production through innovative geotechnical and civil engineering.

Client

Anglo Operations Pty Ltd

Project date

May 2017 - October 2018

As part of Anglo American Coal South Africa’s (AACSA) Khwezela LifeEx Project, a massive dragline, nicknamed the “Pit Bull”, was relocated from the Kromdraai open cast mine to the Navigation Pit near eMalahleni. This strategic move was key to unlocking previously mined underground resources and extending the life of the Khwezela complex.
Khwezela Dragline Relocation-1

The opportunity

The Navigation Pit project bridges the production gap left by the closure of Kromdraai in 2019 and sets the stage for future operations at Clydesdale and Landau 1 and 2, ensuring coal production continues through 2035. The relocation required moving through 18.5 km of greenfield and brownfield areas, wetlands, roads, rail lines, power lines, and buried utilities, posing a unique engineering challenge.

What we did

Zutari was appointed to conduct both the pre-feasibility and feasibility studies for the dragline walkway, which spanned approximately 18.5 km across greenfield and brownfield terrain. The scope included:

  • Civil and electrical design of the temporary walkway and energising infrastructure

  • Geotechnical investigations to assess subgrade conditions and ground risks

  • Rotary core drilling, Shelby tube sampling, and SPT testing

  • Laboratory analysis of soil and rock samples

  • Advanced Plaxis and 3D modelling to simulate dragline movement and soil-structure interaction

  • Risk-based design adjustments to accommodate real-time site conditions


The walkway crossed major infrastructure, including the N4 highway, provincial roads, a Transnet Freight Rail line, Eskom power lines, and buried utilities. After the relocation, the walkway was dismantled and the land rehabilitated.
The 18.5 km dragline walkway crossed diverse terrain and critical infrastructure, requiring precise geotechnical modelling and adaptive engineering.

The outcome

Zutari’s innovative approach ensured the dragline’s safe passage while minimising environmental impact and infrastructure disruption. The temporary walkway and supporting infrastructure were removed post-relocation, and all areas were rehabilitated, enabling AACSA to continue operations efficiently and safely.

The Khwezela Dragline Relocation project exemplifies how engineering innovation can unlock strategic resource potential. Zutari’s expertise in geotechnical modelling, civil design, and risk-based decision-making helped AACSA move a mining giant across a complex landscape, safely, efficiently, and sustainably.
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By combining advanced geotechnical studies, innovative modelling, and risk-based design, we turned a logistical challenge into a precision-engineered solution.

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