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It is a bold claim indeed to say that a South African manufacturer has the most advanced range of industrial enclosures in the world.

While there is no enclosure world cup for the players to square off and prove such claims there are some features built into the DNA of this nations only homegrown range of Enclosures that would arguably make it worthy of holding up such a trophy if it existed.

Not Steel
The vast majority of electrical enclosures used in South Africa are coated mild steel. Standard off the shelf sizes used to be locally manufactured but the tide of low cost imported steel products has almost completely displaced local steel manufacture in this sector. 
The probability that there is any local content in the boxes that are bought from stock from any electrical wholesaler in South Afruca is close to zero.

Allbrox enclosures are not made from steel. Allbro compounds a special version of Glass Reinforced Polyester (GRP) known as SMC (Sheet Moulding Compound). This material is a well known composite material that is used in the manufacture of critical structural parts used on Jet Skis, manhole covers, truck body parts, car parts and many consumer products that require durability in excess of what steel can provide.

SMC enclosures have historically been about 3 times more expensive than steel enclosures. Allbro has changed the price position of SMC enclosures. Local mould manufacture, local raw material sourcing and compounding local labour and local energy costs when combined make Allbrox the only SMC composite enclosure that can compete with cheap steel imports on price.

It goes without saying that the benefits of using SMC over steel are profound when end users are able to justify paying three times more for the benefits that SMC provides. In most aplications however the vast price difference has been the driving force for accepting and standardising on inferior steel enclosures. Such compromise is no longer required for end users and equipment manufacturers in South Africa. The vastly superior SMC technology is now generally cheaper than steel.

Allbrox is without question the most durable SMC enclosure available worldwide. A unique coating process allows the enclosure to withstand decades of the harshest weather conditions. 
It is important to remember that the material underneath the coating is also able to endure decades of abuse from the elements. There is no enclosure in the world that will last as long as Allbrox. 

Over the last 5 years the range has grown to include 19 Part numbers covering a broad range of sizes. Industry in South Africa is rapidly recognising the benefits of this home grown solution and more and more specifications are being changed to support the introduction of Allbrox as a plant standard. 

The local support base for this breakthrough is a fundamental aspect for the success of the product range on a competitive world stage. 

Its business includes not only the manufacture of products, but also the design and manufacture of the actual tools that are used to mould the various parts. ‘Rapid advances in Camera and CCTV technology have left the supporting physical infrastructure, including the enclosures, in what seems like the dark ages’, says a company spokesperson. Most installers must grapple with general purpose electrical boxes in an attempt to create a mounting or connection setup that is respectable’. Allbro says it has solved this problem with the launch of the very first camera enclosure of its kind. Designed and made in South Africa, the product is patented worldwide and addresses the unique challenges of this application in a manner that has never been done before. Upon first seeing the company’s new Camera Nest it becomes difficult to even call the new invention a camera box. The first major difference is the way that the installer works with the box. A small mounting bracket is easily installed with two screws. The camera is mounted to the Camera Nest and then the entire assembly is mounted to the bracket with one screw. The open connection housing on the side is now available for cabling and also for testing with the camera in place. This has many advantages, but the primary one is that a test harness can be used to align the camera as the leads remain accessible. Camera Nest is not made from ordinary plastic. Glass reinforced plastic (GRP) is the material of choice that Allbro has been using for 40 years. This resin-based fiberglass material lasts for decades in direct exposure and will last for multiple generations of cameras. The ingress protection (IP) level of the enclosure is IP66 which means that it will keep dust and water out. The way that the unit is mounted means that this IP level is not compromised when mounting the screws. The company believes that the concept is a breakthrough idea that will forever change the way cameras are installed.

PSO1 – Stealth
Whilst Camera Nest is the latest arrival for Allbro, the product is only one of a host of new innovations that  Allbro has brought to the market over the past 40 years. Allbro is in almost every South African home with their outdoor weather-proof socket boxes known by the trade as PSO1 and PSO2. A few months back, Allbro launched the PSO1- Stealth. Whilst the product serves the same function as its famous predecessor, it has dramatically improved performance and design. The same durable GRP material is used in the construction so the expected lifespan of this new range of product will also be measured in decades. One of the most appreciated features of the new socket outlet box is that it is designed to be installed into the wall.

“Allbro is one of the companies in South Africa that is proving world- class innovation and manufacturing is still very much alive in SA.”

Slab Box
Launched early in 2018, the new Slab Box by Allbro is the first new product to be introduced for this application since the inception of downlighters. The old method of using traditional galvanized steel boxes has never changed and the contractor community has found ways to adjust for the alignment and installation challenges that came with installing downlighters in poured concrete slabs. Allbro says it has solved this problem. The new concept uses the same GRP material as the other products but for a different reason. Obviously, these boxes are not exposed to UV sunlight. They are, however, exposed to vast temperature range fluctuations as they house a variety of LED lamps. GRP does not burn or melt like normal plastic and is also safe for use in electrical installations where a faulty cable connection can create temperatures much higher than any LED lamp ever could.

“Stand Up” Pool Box
A challenge that every pool owner is familiar with is the setting of the pool timer. While the complexity of the timer device is well within the grasp of a technology savvy populace, the difficulty in making eye contact with the timer is the main challenge. Allbro has solved this problem with the Stand-up pool box,’ says the spokesperson. 

On-site manufacture
Allbro compounds its GRP material on-site and the enhanced development of the characteristics of this material is a core achievement of the company. More than 70% of what the company invents and does today has come about in the last six years, so the focus on innovation is proven. The company continues to invest a tremendous amount of its resources in making things to address what is often a challenging environment. These solutions are being recognised in more and more countries around the world. Allbro is one of the companies in South Africa that is proving that world- class innovation and manufacturing is still very much alive in SA.

Article by, 
Gareth Griffiths (BSc, Mat Sci)
Editor: TO BUILD MAGAZINE

The tried and tested little enclosure has proven itself in some of the harshest environments and has remained the outright industry standard in the face of numerous foreign products being offered.

While the trusty and familiar favourite PSO-1 will still be available for years to come there has been an increasing number of requests for the company to provide the option of an up market version.

Allbro has called its newest arrival -  “PSO-1 Stealth”

At first glance it is apparent that there is a dramatically different appearance. Looking more closely it becomes evident that the new product also has some noteworthy features that have been introduced.

PSO-1 Stealth has an IP level of 66 which means that it keeps the electrical socket dry with even when faced with a powerful water jet.

Stealth is also equipped with cams and a padlock point for applications that need to be secured.

The company believes that the most important feature that has been added is the “In wall mounting capability”.  By cutting the base on a cut line provided the base can be mounted precisely in the space of 2 standard bricks.

The use of GRP (Glass Reinforced Polyester) is very important because of the characteristics associated with the material. 

• Mechanical strength of GRP does not deteriorate like plastic materials that become brittle when their molecular structure is compromised by UV exposure. 
• There is also no deflection with high temperatures so the sealing of lid to base on these products remains predictable over long periods of time. 
• The material does not ignite when it comes into contact with electrical circuits so it is not a fuel source for an electrical fire. (Glow wire 960 degree)
• The impact resistance of the enclosure is IK10 so it does not break easily when bumped. 

Allbro has invested heavily in local design and toolmaking capabilities over the last 6 years. The result has been that the bulk of the company’s business now is generated from new products developed in this time. Local designs, local toolmaking, local material, and local manufacture make this product thoroughly South African. 

Often-overlooked or forgotten challenges

Vandalism: Due to the high value of enclosure content, bypassing a smart meter, disabling a surveillance system or simply stripping the contents for sale on the black market are growing global realities.

Access Control:  Ease of access for authorised personnel is often adversely affected when trying to address vandalism challenge. Monitoring and tracking of authorised personnel is important as criminal elements sometimes gain authorised status.

IP Level (water and dust): While companies do their utmost to solve new challenges the primary function of the enclosure is sometimes forgotten. Electrical systems fail because of three main factors, temperature, water and dust. The latter two are addressed by the international standard IEC61529 (SANS IEC 61529). Enclosures that are hand-made differ from each other and simply do not seal consistently.

UV resilience and weatherability: Accelerated UV testing is primarily a measure of colour degradation. However, real life exposure has to cope with temperature cycling, rain and particle rich wind. International standards do not currently exist to test this, leaving real life long-term field trials to provide the only genuine test of an enclosures’ ability to withstand the elements.

Human contact risk / shock hazard: When the solution to vandalism involves metallic materials there is a serious risk for personnel and public to come into contact with live electrical circuits. When such an enclosure is on a pole the risk for the person working at height is exaggerated.

Flammability: Some plastic materials are able to absorb impact very well. If one strikes a garden refuse bin with a hammer it just bounces off. The cautionary embossed words on the lid “No hot ash” point to a serious flaw in using such materials within an electrical network. All electrical enclosures are supposed to be non-flammable or at least self-extinguishing. Most utility companies require compliance to IEC 62208, which stipulates the parameters of glow wire testing and flammability. Using these materials specifically to address vandalism would incorrectly suppose that vandals only have access to hammers and not matches.

Weight: Whilst modern composites constantly deliver greater strength to weight performance there is no way to get around the fact that weight is added when increasing the strength of a mechanical part. Keeping this weight down to a level that allows installation and does not compromise the pole or wall structure is a real challenge.

Signal interference: Some materials create a faraday cage effect and interfere with signals that often form part of the function of the installed equipment. Antennae that are mounted outside the enclosure are a vulnerable point that also attract unwanted attention.

Announcement

Solving the above challenges is complicated and the resulting solution normally becomes costly bringing the price into question.

AllVault is the name given to the latest innovation that is officially being announced in ESI Africa – Africa’s power journal, for the first time. Experience learned while pioneering composite manhole chamber design allowed Allbro to create what we believe is the strongest composite enclosure ever to be sold commercially.

AllVault has been designed to address every one of the above challenges. The cost of lost revenue is not measured in the time and capital it takes to replace infrastructure. Systems that are bypassed or are out of order represent enormous values that can never be recovered. The financial case to be made to justify investment in this area is a very straightforward conclusion to prove.

About the author and company

Quintin Lamprecht has held senior roles in multinational corporations and as a shareholder and managing director of Allbro Pty Ltd has led the company’s expansion into new markets. More than 50% of the company’s revenue now comes from new innovation that was not in existence five years ago. Allbro supplies key components that are used in almost every locally made transformer. Over the last three years, Allbro has invested heavily into modern non-metalic enclosure systems for international markets.

Connecting more than 12 million homes to the grid across what is often a very challenging landscape resulted in the creation of solutions that were unique and in some cases global firsts.

The additional challenge associated with many of the regions having harsh climates contributed to the development of robust and durable solutions that are different than what is typically found in Europe, where our local standards have originated from.

Split metering and pre-paid electricity were local innovations that needed housings which would address all the challenges already mentioned while also being cost effective.

Allbro is the largest producer of Ready Boards and Weatherproof pole top boxes in the world.

The latest innovation which is also a WORLD FIRST is a New Generation of expandable ready boards. The extremely basic single electricity point that was the standard over the last 20 years although effective did not allow for expansion into multiple rooms. The New Gen ready board has a port that allows for a “Room Extender” to be safely and simply deployed in a chain for up to 4 rooms where a light and 2 sockets are then available.

The room extender can be provided by the utility, or can be purchased in an after market scenario by the consumer and can be easily fitted as a sort of appliance.  

Another innovation that has captured tremendous attention since it was released at Africa utility week earlier this year is AllVault.

This “vault like” high security box that can withstand very high levels of abuse. (https://www.youtube.com/watch?v=zk35crHMKek )

As the value and complexity of equipment being deployed across vast geographical areas has increased there has been corresponding increased need to protect the function of these networks and devices. Lost revenues due to bypassing of meters amounts to vast sums of money that dwarf the cost of the physical infrastructure.

Allvault is designed to withstand high degrees of abuse.

The unique composite material was developed locally for manhole systems and is able to absorb the impact of hammers, chisels and axes among other things.

Intelligent locking systems allow the utility to monitor the behaviour of the technicians maintaining the network, further improving the integrity of the network and the security of the revenue.

Allbro employs over 800 people and has factory space of close to 20 000sqm. Competencies include:

1. Raw Material compounding - 3900 Tons of raw material produced annually
2. Design and development – Products are designed by our own team of mechanical engineers using the latest design tools.
3. Tool Making – Moulds are made on site (some as large as 8 tons)
4. Manufacturing to global quality standards ISO 9001
5. Testing – Laboratory on site to verify ongoing compliance

With more than 100 million enclosures in service for as long as 40 years we have learned much from the real world environment in which these products are expected to perform.

A South African firm that produces customised pole top metering enclosures for Kenya Power Company will soon appoint a dealer to merchandise its wares in East Africa. The Allbro Company is negotiating with an electrical wholesale outlet in Kenya to up its brand visibility in Nairobi -- the region's economic hub. Allbro Business Development Manager Chris Galloway said the firm's interest in Kenya has been energised by the country's renewed economic renaissance. "We view Nairobi as an important component in business growth in Africa, hence our desire to avail our quality products here," he said during the recent East Africa Power Investors conference in Nairobi. At the same time, Galloway decried dumping of sub-standard goods in Africa, blaming this for the failure by some firms to excel in African markets. He said the trend has given birth to the so called 'Africa syndrome' which unfortunately has found its way to some South African firms. The 'Africa syndrome' occurs when companies believe, incorrectly, that they can market substandard product into Africa because "Africans don't know the difference between a quality product and a sub-standard product". These companies can then make greater margin on the products they are exporting into Africa."I am glad we have survived in business for the last 35 years, conquering new markets all the time", says Galloway. He said the firm has been designing and manufacturing quality electrical distribution products for the growing African market. "We care about our customers' needs and we offer them more than just a product, we offer them safety and durability in our unique designs. We consistently strive to meet, and exceed our customers' expectations", he said. In 2011, Allbro acquired ABB's York enclosure business through which its association with Kenya Power began. Galloway said the current economic parameters based on consumer trends post a rosy picture for Kenya's economy despite the many challenges that face the country - attested to by relocation of many multinationals to the country such as General Electric, Coca Cola Africa and Airtel.

November 2017

At the end of 2013, the Allbro Group celebrated its 35th year in business. Specialising in the manufacture of high quality non-metallic electric enclosures, transformer accessories, locks, hinges and insulators, the company employs over 300 factory-based staff. It was decided that the year-end function would take the form of a soccer day. This caused a lot of excitement and staff formed ten soccer teams kitted out in Allbro branded shirts, sporting their team colours. Lunch hours suddenly became a hive of team discussions about match day strategies and about who posed the biggest threat on opposing sides. In the end, it came down to the “Free State Stars” and the “Pirates” in the final. It was a hotly contested battle with both teams confirming that they deserved their place in the spectacle. In the end, it was a solitary goal from Misheck Munkhonda who won it for the “Free State Stars”.