Heavy Haul Waad Al Shamaal Railway Project (CTW 320)

Client: Saudi Railway Company (SAR) / Public Investment Fund (via Al-Ayuni Investment & Contracting Co.)

Location: Northern Saudi Arabia (Waad Al Shamaal mineral corridor)

Period: 2015–2018

Narrative & Background

Al-Ayuni Investment & Contracting Co. (AICC) was awarded CTW320, their first major rail contract as Main Contractor. Previously, AICC had only acted as a civil contractor in joint venture with a Chinese rail contractor. The tender was submitted with W.O. Trackworks (WOT) as subcontractor. During negotiations with SAR, WOT was approached to identify potential savings, and proposed a framework to build internal capacity and skills for AICC to become a leading rail contractor within 5 years. CTW320 was designated as the pilot project for this programme. Ultimately WOT provided technical skills ex‑South Africa, with 56 expatriates supervising the works. AICC provided the labour and on‑track plant. WOT sourced and facilitated procurement, managed logistics globally, and executed remedial and modification works on the on‑track plant. WOT was further responsible for ongoing maintenance and operation of the plant throughout CTW320.

Scope of Works

• Construction of 190 km of new heavy-haul standard gauge track (1435mm).

• Installation of 84 No. turnouts.

• Ballast distribution, tamping and destressing.

• Flash Butt Welding of rails into 250m lengths.

• Interfaces with civil structures (bridges, culverts, yards) while retaining full responsibility for track superstructure.

Key Challenges

• Harsh climatic conditions (extreme desert heat and sandstorms).

• Remote, logistically complex work environment requiring full self-sufficiency.

• Stakeholder delays in 2014–2015 which shifted the mainline construction start into 2016.

• Mobilisation and management of a multinational workforce in a foreign jurisdiction.

• Coordination of plant, equipment, and supply chain ex-South Africa & Australia into Saudi Arabia.

Solutions & Innovations

• Capacity-building approach, with WOT transferring skills and technical expertise to AICC as part of a 5‑year development framework.

Full deployment of WOT’s technical supervisors (56 expatriates) to guide, train and oversee AICC labour resources.

• WOT facilitated global procurement, remedial works, and modification of on‑track plant, ensuring plant availability and performance.

• Implementation of SAR and AREMA heavy-haul standards, with QA/QC processes including CWR stressing, turnout geometry and weld NDT verification.

• Leadership structure combining South African core team with multinational workforce, ensuring productivity and knowledge transfer.

• Proactive stakeholder engagement to unlock programme delays and protect operational milestones.

Outcome & Benefits

• Successfully constructed and accepted into beneficial use by SAR prior to final handover, with construction peaking at 1.5 km track constructed per day.

• Works delivered within agreed budget parameters despite cross-border complexities.

• Project recognised as a key enabler in Saudi Arabia’s rail expansion strategy, connecting phosphate mines to the national network.

• Strengthened WOT’s reputation as a specialist international heavy-haul rail contractor, capable of delivering large-scale infrastructure in extreme environments.

• AICC, through the capacity-building framework implemented on CTW320, has since become one of the leading Saudi Arabian rail contractors.

• Due to the success of CTW320, WOT went on to construct the SFTCH Rail Intermodal Yard for SAR in Hail under AICC in 2019.