The transition to GFRP in Saudi construction

Saudi Arabia

Abdullah Hammoud, general manager of Industrial Control Solutions Company (ICSC), talks to The Energy Year about the advantages of using glass-fibre reinforced polymer (GFRP) relative to steel and the use of GFRP rebar in Saudi Arabia. ICSC was established in 2020 in partnership with Dextra to manufacture GFRP in Saudi Arabia.

What are the key advantages of using GFRP as opposed to steel?
There are many advantages and benefits of GFRP compared to steel. For example, GFRP is lighter, non-corrosive and more economical to produce and install. It’s also an environmentally friendly material and an energy saver during the production process.
Fibreglass reinforcement bars (rebar) are becoming very important in the construction industry, where it is important to have a more economical, lighter and durable product to work with. The whole world is experiencing growth in the use of non-metallic materials for all types of construction due to their sustainability.
Here are some quick examples: fibreglass can be used in tanks; manhole covers and pipelines. In fact, any steel part of an oil and gas facility can be replaced by fibreglass. As rebar is an essential item in any large-scale construction, as it is used in concrete and all ground structures, GFRP rebar could replace steel rebar and therefore save a lot on concrete maintenance costs.
Corrosion is the main factor in cracking concrete structures and a major driver of maintenance. It also has an impact on the required maintenance of the concrete structure and necessary costs to renovate equipment. GFRP can last for 100 years without corrosion, which translates into savings and reduced maintenance and equipment costs.

To what extent has GFRP rebar penetrated the market in Saudi Arabia?
When Aramco asked us to localise GFRP rebar manufacturing in Saudi Arabia, they projected an annual demand of 20 million linear metres of rebar. Although this projection hasn’t been reached yet, I’m confident that it will materialise soon.
In 2023, GFRP utilisation is approximately around 10-20%. However, in 2024 we are expecting a significant increase in demand since our fibreglass rebar has already been approved by Saudi Aramco and the Royal Commission for Jubail and Yanbu. The Ministry of Energy’s Oil Sustainability Program has a very dynamic agenda for increasing the rate of fibreglass use across the whole energy supply chain and in construction.
The selling price for 1 metre of GFRP currently costs approximately 4 to 5 SAR [USD 1.05 and 1.35], depending on the type of GFRP. Manufacturing costs are continually decreasing and will decrease even further once GFRP is fully manufactured in-kingdom. The ICSC manufacturing plant is one of two certified suppliers in Saudi Arabia that is fully operational.

How has ICSC/Dextra evolved over the past couple of years?
ICSC/Dextra was established in 2020 with our partner Dextra, the global leader in GFRP manufacturing, to create a hub for non-metallic manufacturing in Saudi Arabia. Our R&D team is continuously working on how to make further non-metallic products. We plan to create a new manufacturing line for fibreglass cable trays using a USD 3.5-million investment. The resin we use to manufacture rebar can also be utilised to produce cable trays as well.

How are you working to increase GFRP’s market penetration?
Unlike other suppliers that only provide the product, we provide a fully integrated design service for our customers. For example, we design the structural changes required to replace steel with GFRP.
In addition to providing GFRP and a fully integrated design service for our clients, we have also taken it upon ourselves to provide seminars to teach our clients how to use GFRP. For instance, ICSC can also design rigs, and we have approached rig operators to show them the durability and cost savings of building their rigs with GFRP and how it compares to steel.

What have been your flagship projects, and what projects are you targeting next?
One of ICSC/Dextra’s greatest accomplishments came in Q1 2023 when we installed GFRP to replace all the existing steel at Salman Energy Park’s dry port. We have also supplied projects at the Jizan refinery and the Royal Commission for Jubail and Yanbu. We are currently working on a project with the Saudi Electricity Company.
NEOM would be an exciting future project to work on due to its mission of sustainability and its building of relationships based on core principles. ICSC is ready and willing to support and provide NEOM with the product to achieve sustainability. We have been invited to open a new facility in NEOM.
We have also approached Ceer, Saudi Arabia’s electric car company, to construct their manufacturing facility using GFRP. Lastly, we have approached many warehouse builders and constructors of structures such as manholes and channels.

What kind of opportunity does the Jafurah unconventional gas project present with respect to fibreglass use?
There are many areas in Jafurah that need concrete paving, and in the past, the concrete was being reinforced with steel. Aramco is now transitioning from reinforced concrete to using GFRP. We are moving forward alongside Aramco to replace steel in many places in Jafurah with GFRP.

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