The most productive plant for continuous basalt fiber
(CBF) and BFRP rebars in the Middle East has been
handed over to the Customer.
(CBF) and BFRP rebars in the Middle East has been
handed over to the Customer.
How it was…
EPMICS | BLOG
The Largest Basalt Fibre Production Facility
The most productive plant for continuous basalt fiber (CBF) and BFRP rebars in the Middle East has been handed over to the Customer. This is the story of how a sophisticated industrial landmark was raised in the rugged heart of Fujairah, the challenges of building “in the middle of nowhere,” and why this project remains the beating heart of our professional journey. We tell it with pride from ourselves, those engineers and managers who worked for the EPC contractor from the first centerline in the very first drawing to handing over the keys to the Plant Operator.
Because it’s also the story of our rebirth as EPMICS. The page has been closed... New tales are coming up...
Because it’s also the story of our rebirth as EPMICS. The page has been closed... New tales are coming up...
In December 2024, the silence of the Fujairah mountains was replaced by the echoes of a celebration. The Largest Basalt Fibre/Rebar Production Facility in the Middle East was inaugurated with the distinguished presence of His Highness Sheikh Hamad bin Mohammed Al Sharqi the Ruller of Fujairah. It wasn’t just a ribbon-cutting ceremony; it was the birth of a new industrial sector for the UAE. With an impressive production capacity of 5,000 tonnes of basalt fibre and 7,000 tonnes of basalt rebar annually, this state-of- the-art facility stands as a milestone in the region’s industrial and sustainable development. We didn’t just build a factory; we introduced a sustainable alternative to steel in a region where corrosion is the silent killer of infrastructure.
The Architects of Innovation
Every ambitious project requires a symphony of players. The success of this facility was the result of a coordinated effort between visionary investor, Arab Mining Company –Fujairah LLC, an Arab Mining Co subsidiary incorporated in Emirate of Fujairah, its contractual representative and conductor of the orchestra, Pioneer International Projects Management Consultant LLC, Fujairah government bodies, and… the technical pioneers.
The Architects of Innovation
Every ambitious project requires a symphony of players. The success of this facility was the result of a coordinated effort between visionary investor, Arab Mining Company –Fujairah LLC, an Arab Mining Co subsidiary incorporated in Emirate of Fujairah, its contractual representative and conductor of the orchestra, Pioneer International Projects Management Consultant LLC, Fujairah government bodies, and… the technical pioneers.
The plant itself was engineered and realized by BTUK ME building contracting LLC (BTUK-ME), a Special Purpose Vehicle (SPV) founded by British shareholders—veterans of the basalt composite industry, BasTech UK Ltd, specifically to develop the Project. That’s where the aforementioned technological pioneers gathered, we humbly note, which has integrated the process solutions of Basalt Technologies into fully coordinated workflow...
It’s also worth noting other key players in the process: Mozoon Engineering Consultancy, the project consultant, which verified that engineering solutions met UAE regulatory requirements and acted as a liaison between the construction site and the Fujairah Municipality. And, of course, National Building Contracting, the main construction subcontractor, which carried out most of the construction work. In total, over a hundred contractors and suppliers under BTUK ME were involved in the project.
All parties brought with them decades of specialized knowledge, but more importantly, an international dream team of experts was assembled within BTUK ME. This team managed the entire lifecycle: from scaling the rocky mountains and study raw geological samples to the final engineering handshake that brought the production lines to life.
It’s also worth noting other key players in the process: Mozoon Engineering Consultancy, the project consultant, which verified that engineering solutions met UAE regulatory requirements and acted as a liaison between the construction site and the Fujairah Municipality. And, of course, National Building Contracting, the main construction subcontractor, which carried out most of the construction work. In total, over a hundred contractors and suppliers under BTUK ME were involved in the project.
All parties brought with them decades of specialized knowledge, but more importantly, an international dream team of experts was assembled within BTUK ME. This team managed the entire lifecycle: from scaling the rocky mountains and study raw geological samples to the final engineering handshake that brought the production lines to life.
From Camels to Composites: Building from Zero
To say we built in a “prime location” would be a bit of a stretch. When we first arrived at the site in the heart of Fujairah, we found “the center of nothing.” It was a valley where the only residents were the local Bedouins and their camels, who watched us with a mixture of curiosity and skepticism.
Usually such projects are called “greenfield”... In this case, it’s a bit of fun, it sounds like an oxymoron. Building a high-tech facility in such an environment meant more than just pouring concrete; it meant bringing life, power, and logistics to a wasteland. We weren’t just engineers; we were pioneers in a landscape that had remained unchanged for centuries.
To say we built in a “prime location” would be a bit of a stretch. When we first arrived at the site in the heart of Fujairah, we found “the center of nothing.” It was a valley where the only residents were the local Bedouins and their camels, who watched us with a mixture of curiosity and skepticism.
Usually such projects are called “greenfield”... In this case, it’s a bit of fun, it sounds like an oxymoron. Building a high-tech facility in such an environment meant more than just pouring concrete; it meant bringing life, power, and logistics to a wasteland. We weren’t just engineers; we were pioneers in a landscape that had remained unchanged for centuries.
Technical Prowess & Innovation
The plant isn’t just new; it’s a technical masterpiece.
Key parameters include:
Total project area: 40,173 m²
Annual Production: at least 5,000 tons of the continuous basal fiber, the capacity of the plant in terms of output, i.e. BFRP re-bars is average 7,000 tons per year. The technological process consists of the following stages:
The plant isn’t just new; it’s a technical masterpiece.
Key parameters include:
Total project area: 40,173 m²
Annual Production: at least 5,000 tons of the continuous basal fiber, the capacity of the plant in terms of output, i.e. BFRP re-bars is average 7,000 tons per year. The technological process consists of the following stages:
- delivery and unloading of basalt crushed rock to the
- warehouse;
- incoming control of raw materials;
- screening and washing;
- loading basalt crushed rock into the 12 furnace;
- melting basalt;
- production of continuous fiber in the form of a filament;
- drying,
- rewinding of filaments and obtaining roving with a given linear
- density value;
- drying the roving at a temperature of 120...160°C for 12 hours;
- quality control of roving;
- transportation to finished product warehouse.
Sustainability: Drastically lower CO2 footprint compared to traditional steel reinforcement.
Corrosion Resistance: 100% immunity to salt-laden coastal environments.
We didn’t just follow the book; we wrote a few new chapters. The innovative solutions involved unique cooling systems adapted for the grueling Middle Eastern heat and proprietary melting furnace technologies that maximized energy efficiency— a crucial factor when turning rock into liquid silk.
The Human Element: The Real "Secret Sauce" If you look at the blueprints, you see lines and measurements. If you look at the factory today, you see working machines, furnaces and comprehensive engineering systems working together. But if you look at the process, you see the team. It was the shared sweat, the midnight problem-solving sessions, and the unwavering belief that "it can be done" that turned a dusty valley into an industrial titan. That synergy is the most valuable asset we ever possessed.
Throughout its lifecycle, the project weathered a fair share of storms and unwelcome surprises—starting with the global collapse brought on by the pandemic, followed by tectonic geopolitical shifts that often forced us to reinvent our procurement strategies on the fly. And perhaps, not everything came together quite as swiftly as our optimism had hoped.
By the time the lead partners reached the mutual decision to hand the newly minted plant over to the Operator, Arab Basalt Fiber Company, commissioning was still very much in its boisterous prime. Finalizing it became the new "challenge" for the Operator— a team that had gathered quite a collection of brilliant experts under its wing, making their eventual success less a question of "if" and more a simple matter of time
Throughout its lifecycle, the project weathered a fair share of storms and unwelcome surprises—starting with the global collapse brought on by the pandemic, followed by tectonic geopolitical shifts that often forced us to reinvent our procurement strategies on the fly. And perhaps, not everything came together quite as swiftly as our optimism had hoped.
By the time the lead partners reached the mutual decision to hand the newly minted plant over to the Operator, Arab Basalt Fiber Company, commissioning was still very much in its boisterous prime. Finalizing it became the new "challenge" for the Operator— a team that had gathered quite a collection of brilliant experts under its wing, making their eventual success less a question of "if" and more a simple matter of time
The Birth of EPMICS
As the project concluded, the team that designed and built the factory reached a crossroads. We realized that while the project was finished, our collective potential was just beginning. The most precious thing in engineering isn’t the steel or the fiber—it’s the people and their accumulated wisdom and skills.
We decided to stay together. Today, we are EPMICS—a full-cycle multidisciplinary engineering company. While we look toward new horizons, we will always look back at the Fujairah plant with pride. It wasn’t just a contract; we poured our souls and years of our lives into those furnaces. The plant has now been handed over to the operator, ABFC (Arabian Basalt Fiber Company). It is in safe, capable hands. Over the past few months, they have already achieved staggering results, pushing production limits and maintaining the high standards we set during design. They are skilled, they are driven, and we believe in their future success completely. And, by the way, we haven’t gone far, we’ll always be happy to help if anything... Well, you know... The page is closed... New tales are coming up...
As the project concluded, the team that designed and built the factory reached a crossroads. We realized that while the project was finished, our collective potential was just beginning. The most precious thing in engineering isn’t the steel or the fiber—it’s the people and their accumulated wisdom and skills.
We decided to stay together. Today, we are EPMICS—a full-cycle multidisciplinary engineering company. While we look toward new horizons, we will always look back at the Fujairah plant with pride. It wasn’t just a contract; we poured our souls and years of our lives into those furnaces. The plant has now been handed over to the operator, ABFC (Arabian Basalt Fiber Company). It is in safe, capable hands. Over the past few months, they have already achieved staggering results, pushing production limits and maintaining the high standards we set during design. They are skilled, they are driven, and we believe in their future success completely. And, by the way, we haven’t gone far, we’ll always be happy to help if anything... Well, you know... The page is closed... New tales are coming up...
Legal Disclaimer: EPMICS-Engineering FZ LLC was established as a separate legal entity in the Creative City Fujairah Free Zone by the lead engineers and management employees of the original EPC contractor involved in construction of the Basalt fiber plant in Fujairah. It is not affiliated with, nor legally connected (directly or indirectly) to BTUK ME. EPMICS-Engineering FZ LLC and its employees operate independently as a distinct legal entity from its registration..