EMAL Aluminium Smelter

Our success on the EMAL project demonstrates how we can exceed client expectations while protecting workers and the environment.

For more than a decade, the United Arab Emirates (UAE) has relied on our expertise to successfully deliver projects in its aluminum industry. When EMAL decided to build the world’s largest single-site aluminum smelter in Abu Dhabi, they chose us to provide engineering, procurement and construction management (EPCM) services for EMAL I, the project’s first phase. This included a 750,000-tonne-per-year mega-smelter and a 2,000-MW thermal power plant.

Following the success of EMAL I, we were called back to complete the front-end engineering design study for EMAL II. We were awarded the full EPCM contract in 2011. EMAL II included the addition of 1,000 MW of generating capacity to the power plant, a 1.6-kilometre potline, the longest ever built, and the highest-rated rectifier transformer. Efficient work on both phases advanced the overall schedule by more than six months.

Industry-leading safety and environmental performance

Delivering a project early is only valuable if the work is done safely. We held mass crew meetings with all contractor employees and implemented other proactive health and safety initiatives to achieve nearly 42 million person-hours without a lost-time incident.

EMAL II was also an innovator on the environmental front, resulting in the first soil treatment facility in the UAE. Our environmental team treated more than 180 tonnes of contaminated soil, which was reused in the construction. We also made a concerted effort to relocate desert species from the area. Captured animals were transported to their new home in specialized travel containers to minimize their stress. A total of 902 animals, including quite a few wonder geckos, were safely relocated to new homes.

 Sustainability achievements:
  • Proactive health and safety initiatives led to nearly 42 million person-hours without a lost-time incident.
  • SNC-Lavalin treated 180 tonnes of contaminated soil, which was reused in construction.
  • A total of 902 animals were safely relocated away from the construction site.
  • Our efficient work plans helped advance the project schedule by more than six months.

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