Bechtel extended its long heritage of megaprojects in Saudi Arabia by managing construction of the world’s largest aluminum smelter—and Saudi Arabia’s first. The smelter is the cornerstone of Ras Al Khair Industrial City, which is fast becoming the country’s aluminum and phosphate center, 56 miles (90 kilometers) north of Al Jubail.
The Ras Al Khair effort—delivered safely, ahead of schedule, and under budget—included the construction of two high-amperage potlines that use Pechiney technology to produce 740,000 metric tons of aluminum per year.
The project included construction of
A rail line transports bauxite feedstock from a mine at Al Ba’itha. The bauxite is refined at Ras Al Khair to yield alumina for smelting.
The project reached mechanical completion in 2013 by Bechtel’s Mining & Metals global business unit. Over 35,000 people worked more than 78 million job hours on the project, achieving an outstanding lost-workday case rate of 0.01. The project team worked two extraordinary stretches without a single workday lost to safety incidents: 32 million hours and 29 million hours.
Key facts about the Ras Al Khair project: