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Insights EMAL aluminum smelter | Supporting the UAE’s future

The UAE’s landmark, Emirates Aluminium Smelter Complex (EMAL), is situated at Khalifa Port Industrial zone in Abu Dhabi. The largest industrial project outside of UAE’S oil and gas sector, EMAL supports the country’s economic diversification agenda. This mega plant is now the largest single-site aluminum smelter in the world, producing 750,000 tons of aluminum a year. It is meeting growing production demands for this lightweight and more environmentally friendly metal.

Our teams’ surpassing achievements

We were selected by Mubadala Investment Company and Investment Corporation of Dubai to provide engineering, procurement and construction management (EPCM) services for EMAL Phase 1. Our team’s successful delivery of complex projects for DUBAL since 2004, was a key factor in being awarded the contract.

Our mandate on Phase 1 included building the mega smelter with its 2,000 MW thermal power plant. Our teams completed the works on budget and three months ahead of schedule, exceeding all expectations. Following this success, our client asked us to complete the front-end engineering design study for Phase 2, and the Phase 1 upgrade.

Record breaking builds

After being awarded both contracts, our teams began work in 2011. The scope included adding 1,000 MW of generating capacity to the power plant, constructing the world’s highest rated rectifier transformer, and building a 1.6 km pot line – the longest ever built.

Prioritizing safety

With 18,000 personnel at the peak of Phase 1 and 13,000 at the peak of Phase 2, we successfully delivered our mandates without compromising our world class safety standards. As part of our safety strategy, our teams held 15 mass crew meetings, sharing health and safety best practices. And we achieved 42 million-person hours on Phase 2, without a single lost time incident.

Preserving the UAE’s future

Our work on Phase 2 broke new ground by establishing the UAE’s first carbon contaminated soil treatment facility. Our environmental team restored more than 180 tonnes of polluted soil, which we reused in lay down areas and roads.

The team also preserved the area’s desert species by moving them to suitable habitats. We sourced specialized travel containers, which minimized their stress in transit. In total, we safely relocated 902 animals, including a number of rare wonder geckos.

Building career excellence

Collaborating across the disciplines, through this project’s entire lifecycle, our teams enjoyed many challenging, career defining opportunities. We’re proud of their commitment to excellence and for earning the following accolades:

2015 MEED Quality Awards 
UAE Industrial Project of the Year – EMAL Phase 2

2012 MEED Quality Awards 
GCC Industrial Project of the Year – EMAL Phase 1

Shortlisted for 2011 PMI Project of the Year Award
EMAL Phase 1

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