Cutting-Edge Civil & MEP Solutions for Industrial Manufacturing
Large-scale manufacturing facilities require robust infrastructure, advanced climate control, and specialized mechanical systems to support high-performance production processes, energy efficiency, and regulatory compliance. As a leading Civil & MEP contractor in Saudi Arabia, Saudi ProTech was awarded the design and build contract for Ravago Factory in Al-Jubail Royal Commission, delivering integrated infrastructure, HVAC, air treatment, water treatment, and mechanical utilities.
Completed in 2017 under RADICON Consulting & Engineering, this project covered a 65,000 m² facility, incorporating state-of-the-art cooling, ventilation, compressed air, and environmental treatment systems to ensure sustainable and high-efficiency operations.
Project Overview
Project Details
- Project Name: Ravago Factory
- Location: Al-Jubail Royal Commission, Saudi Arabia
- Year: 2017
- Owner: Ravago Middle East
- Consultant: RADICON Consulting & Engineering
- Project Status: Handed Over
- Scope of Work:
- Civil Works (Steel Structure & Concrete Foundations)
- HVAC System (Chilled Water System & Process Cooling)
- Air Treatment & Ventilation Systems
- Compressed Air System Installation
- Water Treatment System Setup
- Chiller Plant Management (CPM) System Installation
- Testing & Commissioning
Project Objectives
Saudi ProTech was responsible for:
- Designing and constructing durable industrial infrastructure to support heavy-duty production.
- Providing energy-efficient cooling solutions through a chilled water system and air handling units (AHUs).
- Enhancing air quality with dust and fume extraction systems.
- Installing a high-capacity compressed air system for manufacturing processes.
- Implementing an advanced water treatment system to optimize resource usage.
- Ensuring seamless project execution while complying with safety and environmental regulations.
Project Challenges
- Constructing a high-strength warehouse to accommodate mechanical utilities and chiller plants.
- Integrating dust and fume extraction to maintain clean air quality in the factory.
- Managing large-scale HVAC and ventilation requirements for a 65,000 m² facility.
- Implementing advanced water treatment processes for environmental sustainability.
Scope of Work: Civil & MEP Implementation
1. Civil Works: Steel Structure & Concrete Foundations
A strong industrial foundation is essential for heavy machinery and production facilities.
A. Structural & Infrastructure Development
- Designed and built a steel structure warehouse for mechanical utilities and chiller plant.
- Constructed underground concrete tanks for the water treatment system.
- Installed underground concrete trenches for piping and cabling networks.
Key Benefits:
Heavy-Duty Load Bearing: Designed to support industrial equipment.
Optimized Layout: Efficient space utilization for utilities and plant operations.
Durable & Corrosion-Resistant: Concrete structures ensure long-term reliability.
2. HVAC System: Chilled Water & Process Cooling
Efficient cooling is critical for industrial production and environmental control.
A. Chilled Water System Installation
- 4 high-capacity chillers with a total cooling capacity of 2,000 TR.
- Primary and secondary loops for optimized cooling distribution.
- 9 Air Handling Units (AHUs) for large-scale ventilation and temperature control.
- Process cooling points installed across the production zones.
Key Benefits:
Consistent Temperature Control: Maintains stable cooling for factory operations.
Energy Efficiency: Reduces operational costs through optimized chiller performance.
Scalable System: Can handle future production expansions.
3. Air Treatment & Ventilation System: Clean Air Solutions
Maintaining clean air quality is essential for manufacturing safety and compliance.
A. Dust & Fume Extraction System
- Installed a Donaldson Technologies dust and fume extraction system for clean air filtration.
B. Ventilation System Installation
- Installed exhaust and fresh air fans for continuous air circulation.
Key Benefits:
Health & Safety Compliance: Reduces air pollutants and ensures worker safety.
Energy-Efficient Ventilation: Fresh air circulation maintains indoor air quality.
Minimized Airborne Contaminants: Prevents production contamination.
4. Compressed Air System: Industrial Pneumatic Power
Compressed air is essential for powering manufacturing tools and equipment.
A. High-Performance Compressed Air System
- Designed and installed an industrial compressed air distribution system.
Key Benefits:
Consistent Airflow for Machinery: Ensures uninterrupted production operations.
Energy-Efficient Compressed Air Usage: Reduces waste and optimizes performance.
Long-Term Reliability: Designed for continuous heavy-duty usage.
5. Water Treatment System: Sustainable Resource Management
Industrial water usage requires advanced treatment and recycling for efficiency.
A. Water Treatment System Installation
- Installed underground concrete water tanks for treatment and storage.
- Integrated filtration and chemical treatment units for process water recycling.
Key Benefits:
Environmental Compliance: Reduces wastewater discharge.
Cost Savings on Water Usage: Enables reuse of treated process water.
Safe Water Handling: Ensures high-quality water for industrial applications.
6. Chiller Plant Management (CPM) System: Smart Cooling Automation
A chiller plant management (CPM) system was installed to automate and optimize HVAC performance.
Key Benefits:
Automated Cooling Adjustments: Reduces energy consumption based on real-time data.
Smart System Monitoring: Tracks chiller performance and efficiency.
Minimized Maintenance Costs: Predictive analytics prevent unexpected breakdowns.
Testing, Commissioning & Handover
Saudi ProTech conducted detailed testing and commissioning to ensure full system functionality.
A. HVAC & Ventilation Testing
- Verified cooling efficiency and temperature regulation.
- Ensured proper ventilation balance for clean air circulation.
B. Electrical & Water System Validation
- Load testing for electrical circuits to ensure safety and stability.
- Water treatment system performance testing for compliance.
Successfully handed over a fully functional and optimized facility to Ravago Middle East.
Key Benefits of the Ravago Factory Project
1. Future-Proof Industrial Infrastructure
- Reinforced civil structures ensure long-term durability.
2. Energy-Efficient Cooling & Ventilation
- Chilled water system & smart CPM optimize cooling performance.
3. Sustainable Water Treatment & Resource Management
- Water treatment solutions reduce environmental impact.
Conclusion: A Benchmark in Industrial Civil & MEP Excellence
The Ravago Factory Civil & MEP Project in Al-Jubail showcases Saudi ProTech’s expertise in designing and executing high-efficiency, scalable, and sustainable industrial solutions.
📞 Contact us today for turnkey Civil & MEP solutions for your industrial facility!
