Located in one of the world’s most significant manganese mining regions, the project played a critical role in enhancing the transportation of this metal given the rise in demand as manganese is a key element in the manufacturing of lithium-ion batteries, such as those used in electrical backup systems and electric vehicles.

What set Project Raptor apart from the outset was WSP's innovative tender strategy. The team, led by Dr Terence Milne, Managing Director: Transport & Infrastructure for WSP in Africa, proposed a future-ready, digital-first approach that introduced 3D modelling, BIM-based project controls, and 4D and 5D execution – significantly elevating the project’s technical complexity and precision.

Combining innovation with sustainability

From design to execution, Project Raptor was digitally driven. The team employed advanced technologies such as drone measurement for real-time construction tracking and Autodesk Construction Cloud (ACC) for paperless construction monitoring. This enabled the creation of a digital twin of the project, where bi-weekly drone imagery was converted into 3D models, allowing WSP and South 32 to assess progress against the design with unsurpassed accuracy.

“By integrating a paperless, 3D design methodology from the beginning, we ensured the project's sustainability, efficiency, and scalability. This digitally advanced approach reduced traditional on-site errors and provided a fully transparent platform for collaboration between stakeholders, including project contractors,” says Milne.

Community engagement

WSP’s commitment to local community development was a cornerstone of the project. In collaboration with South 32, Project Raptor supported a sizeable number of women from the local area in obtaining training certificates in heavy plant operation, thereby promoting local employment opportunities and fostering long-term skills development.

“Project Raptor not only delivered on its technical promises but also uplifted the surrounding community,” says Milne. “We were able to create real, tangible opportunities for local workers, many of whom will continue to contribute to South Africa’s infrastructure and industrial development for years to come.”

Overcoming challenges

While the project encountered typical large-scale construction challenges, such as tight timelines and logistical constraints, WSP’s innovative use of real-time, digital monitoring helped mitigate associated risks. The project’s safety management protocols, enabled by ACC, were so robust that South 32 is now considering adopting them as standard practice across its operations.

With the success of Project Raptor, WSP has set a new benchmark for excellence in the engineering industry. The project has already generated future opportunities, including major infrastructure bids like the Simandou bulk earthworks project and Transnet port expansions.

“Project Raptor is a testament to our technical ingenuity, dedication to client satisfaction, and Future Ready approach to engineering. This will serve as a blueprint for future major infrastructure projects, proving that digital transformation can enhance not only technical outcomes but also community impact,” concludes Milne.

WSP in Africa is hiring! To find out more about available opportunities, check out the Careers page on our website or look out for updates on our LinkedIn page, @WSPinAfrica.