Supporting sustainability: KAEFER’s role in ArcelorMittal’s legacy upgrade

Steel is everywhere – from the bridges we cross, to the cars we drive, to the buildings we live in. However, the production of steel requires intense heat and a great deal of energy. So, what happens when a team sets out to make that process cleaner, safer and more efficient?

That’s exactly what KAEFER Poland did at ArcelorMittal Poland’s steelworks in Dąbrowa Górnicza. The team was tasked with complex insulation work and scaffolding for a new flue gas heat recovery system. They stepped into an environment where legacy infrastructure met modern sustainability goals – and where every action had to count.

Numbers that matter

Now that the project is complete, the results are striking: 10,000 fewer tons of coke are consumed per year, 56,000 fewer tons of CO₂ are emitted annually, and 117 GWh of energy are recovered. However, behind these figures lies a deeper story of teamwork, adaptability and shared purpose.

Team spirit in action

“Working in an active heavy industry plant means that every day brings something new and unexpected,” says Krzysztof Wójcik, KAEFER project manager.

This unpredictability has only served to strengthen the team spirit on site. Scaffolders and insulators worked in sync, quickly reconfiguring access points as new work areas opened up. There was no hesitation, just quick thinking and constant coordination. When a gas reading once triggered an emergency protocol, for example, it took just minutes for everyone to evacuate safely, and work resumed the next day without disruption. This kind of readiness comes from deep trust and daily diligence.

A robust safety culture is always the foundation: Colleagues looking out for each other, adapting in real time and staying flexible – not because they are told to, but because it is the only way forward.

Meeting challenges head-on

Every high-impact project comes with hurdles. This one was no different…

• A tight lump-sum contract left little room for budgetary adjustments.
• Fluctuating gas levels and sudden shutdowns caused constant scheduling problems.
• Limited labour availability meant that every pair of hands was needed.
• Work sequences had to be reshuffled based on what was accessible, sometimes by the hour.

Rather than slowing progress, these challenges became catalysts for ingenuity. The KAEFER team responded with constant cost optimisation, rapid decision-making and a mindset rooted in finding solutions.

Coordination and trust: a blueprint for success

One of the most unique aspects of this project was the collaboration between KAEFER, Mostostal Zabrze, E.ON and ArcelorMittal.

Rather than following rigid protocols, the team prioritised real-time dialogue. Changes were discussed and approved verbally on site, often first with ArcelorMittal, before being formalised with the general contractor. This reversal of the typical chain of command wasn’t just efficient; it signalled trust and respect.

“Success came from really listening to the client,” reflects Krzysztof. “Every change was pre-approved; nothing happened in isolation. That trust, and the way we worked closely with our scaffolders, made the difference.”

Creating value for a greener future

This wasn’t just an insulation and scaffolding job. It was a contribution to decarbonising one of the world’s most energy-intensive industries.

By recovering energy from flue gases, which were previously considered waste, this installation supports ArcelorMittal’s sustainability strategy and demonstrates the vital role insulation plays in environmental performance. For those on site, it meant being part of something bigger.

“It’s not just about insulation,” says Krzysztof. “It’s about creating value, reducing emissions and doing our part for the environment. That’s something to be proud of.”

Lessons for the road ahead

The team set a new standard for what can be achieved under pressure. Through teamwork, trust, and technical excellence, KAEFER Poland not only met expectations but also set a new benchmark for complex industrial insulation in active production settings.

This project demonstrates that progress in technology and sustainability is also driven by the hands-on work of people on site, whose work directly shapes technological and sustainable development.