Before sunrise, the desert is still.
Then the wind shifts. The temperature begins to climb. And work begins across one of Saudi Arabia’s most important energy infrastructure projects.
At the Zuluf Onshore Oil Facilities in Saudi Arabia’s Eastern Province, KAEFER Saudi Arabia is contributing to the construction of a large oil processing facility. Once completed, the plant will be capable of processing up to 600,000 barrels of heavy crude oil per day – roughly equivalent to filling around 95 million litres daily, enough to supply millions of households with energy products.
The project forms part of Saudi Arabia’s long-term strategy to secure and stabilise energy supply as global demand continues, while modernising infrastructure under Vision 2030.
The project was exceptional in both scale and complexity, requiring careful coordination, strong engineering expertise and consistent execution standards.
A mega-project with strategic impact
Located approximately 260 kilometres north of Dhahran, the Zuluf Central Processing Facility (ZCPF) forms part of one of the world’s largest offshore oilfields, with a production capacity estimated between 550,000 and 600,000 barrels per day.
The facility integrates complex in-plant systems for aquifer water treatment and reinjection, creating a highly engineered, multi-discipline construction environment where structural steel erection, piping, mechanical works and installations progressed in parallel.
For KAEFER, one thing was clear: Without safe and timely access, nothing else could move forward.
Scaffolding played a central role in enabling structural steel erection, piping and mechanical works, allowing multiple contractors to operate safely and efficiently – often simultaneously and at height.
Engineering first: scaffold designing for complexity
Long before the first tube was lifted on site, the project began in the design office.
KAEFER Saudi Arabia developed and engineered a total of 34 dedicated scaffold designs specifically for Zuluf’s structural steel supports, pipe racks, vessels and elevated work fronts. Our team achieved a milestone by erecting 200,000+ square metres of suspended scaffolding approx in a year – the largest Piperack quantity ever executed by the company. This accomplishment included elevated structures up to 36.5 metres high, demanding advanced structural calculations, specialised configurations, and reinforced safety controls for work at height.
What made the scaffold design scope at Zuluf particularly special was not only its scale – but also the introduction of innovative design approaches.
For the first time on a project of this magnitude in Saudi Arabia, several scaffold designs were developed using 3D modelling, making Zuluf one of the early projects where KAEFER began implementing advanced 3D modelling practices in the region. This approach enabled the creation of highly accurate, detailed representations of complex scaffolding structures before physical erection began.
As the only GBS scaffolding contractor offering this 3D modelling capability, KAEFER was able to enhance precision, improve clash detection and support more efficient planning across multiple work fronts.
This was not standard catalogue scaffolding. Each design required:
Multiple stakeholders were involved in reviewing and approving designs, including ARAMCO PMT, LPD and CSD departments, client construction management and safety teams, as well as KAEFER representatives from design through to execution.
Continuous coordination and open communication with Saudi ARAMCO significantly influenced the approval process. Comments and technical feedback were addressed promptly, helping to streamline subsequent submissions once the first design had been approved. The initial approval process took approximately six weeks. The primary challenge was ensuring full compliance with ARAMCO’s stringent standards, including the thorough verification of every material used within the scaffold systems.
Alignment did not end with approval. Design and site execution teams ensured 100% compliance through approved drawings, detailed method statements and continuous inspections. Inspectors verified that every scaffold was erected exactly according to approved designs, safeguarding structural integrity and quality at every stage.
Engineering and execution were fully integrated – and that integration became one of the project’s defining strengths.
Planning at scale: the right scaffold, at the right time
By mid-morning, multiple work fronts were active across the greenfield site. Pipe racks, vessels, confined spaces and elevated platforms required tailored access solutions, carefully sequenced to match structural steel erection and neighbouring project activities supporting our contractors.
Scaffolding did not simply support the construction schedule – it directly influenced it. Any delay in access would have affected multiple downstream contractors.
At peak deployment, the project achieved:
This positioned Zuluf as one of the most significant scaffolding scopes delivered by KAEFER Saudi Arabia. Planning precision was essential. Access had to be available exactly when required – no earlier, no later.
Matching a demanding environment with Health & Safety
Delivering access solutions at this scale meant operating in one of the region’s most challenging environments. Summer temperatures on site reached 48-50°C, with additional radiant heat from steel structures increasing perceived temperatures at working elevations. Scaffolding structures rose to heights of up to 36.5 metres, while multiple contractors operated simultaneously across an evolving greenfield site.
The biggest health and safety challenges included:
Safety was therefore integrated directly into planning – not treated as a separate activity. At Zuluf, safety began before the heat.
Every shift opened with toolbox talks covering:
- Working at height
- Dropped object prevention
- Heat stress management
- Permit-to-work compliance
- Tagging and load classification
Inspection routines, clearly defined material storage rules, unobstructed walkways and strict tagging systems were enforced daily to maintain safe and orderly work areas. Rigorous permit systems, strict scaffold inspection protocols and continuous supervision ensured that work only progressed once all safety requirements were met.
The heat in particular posed one of the biggest challenges for the KAEFER Team. However, it was addressed through structured and preventive measures.
Concrete actions included:
- Regulated work-rest cycles
- Shaded rest areas and hydration stations
- Electrolyte distribution
- Mandatory cooling breaks
- Heat stress monitoring
- Manpower rotation
- Adjusted work schedules to minimise exposure during peak heat hours
But heat was not the only environmental factor. Working in the desert also meant preparing for sandstorms. When sandstorms occurred, work at height was temporarily suspended and additional inspections were conducted before reoccupation. Scaffold stability was ensured through reinforced anchoring, additional tie-ins and post-storm structural checks. Wind and weather monitoring, alongside safety alerts, were integrated into daily planning routines.
Safety, scale and shared success
A strong “Safety First” culture was reinforced through leadership commitment, stop-work authority for all personnel and strict compliance with ARAMCO standards to ensure productivity never overruled safety. Performance metrics prioritised safety over output – and no activity proceeded without approved permits and safety verification.
Targeted behavioural safety campaigns were implemented to reinforce safe working practices across the site. These initiatives placed particular emphasis on working safely at height, ensuring the correct and consistent use of harnesses, preventing dropped objects, and strengthening awareness around fatigue and heat stress. Regular Mass Toolbox Talks strengthened hazard awareness and reinforced consistent safe behaviours across all crews.
The result:
Zero LTI.
Zero major incidents.
Full client confidence.
For KAEFER, Zuluf represents more than a successfully delivered scope.
It demonstrates our ability to integrate engineering and execution seamlessly, operate at scale under extreme environmental conditions and deliver high-volume access solutions without compromising safety.In environments where complexity, pressure and scale converge, disciplined execution makes the difference.
At Zuluf, that difference was built – tube by tube, shift by shift – by a KAEFER Team committed to doing it right.
Note: Written by humans – with a little help from GenAI. This article combines human understanding and intelligent digital tools to bring KAEFER stories to life.