Rolling Mill 3 of Suez Steel Company: Advancing Egypt’s Steel Industry

Nestled in the industrial hub of Suez, Rolling Mill 3 of the Suez Steel Company stands as a testament to Egypt’s growing prowess in the global steel industry. As the Project Manager for Cosmos-E Engineers & Consultants, I led the development of this state-of-the-art rebar rolling mill, which boasts an annual production capacity of 1.4 million tons. Spanning 310,000 square meters, this facility not only elevates Suez Steel’s output to 2.2 million tons of rebar annually but also positions Egypt as a key player in the regional steel market, delivering high-quality products that meet international standards.

A Milestone in Steel Production Excellence

Rolling Mill 3, inaugurated in 2021 by President Abdel Fattah El-Sisi, represents a significant leap forward for Suez Steel Company, making it the second-largest integrated steel producer in Egypt. Equipped with cutting-edge technology from Danieli, the mill produces high-grade rebar (including B500DWR) in diameters ranging from 10 mm to 40 mm, catering to both local and international construction demands. The project was completed in just one year—against an anticipated three-year timeline—highlighting a remarkable feat of engineering and project management.

As Project Manager, I oversaw the end-to-end execution of this ambitious project, coordinating with global suppliers like Danieli to ensure the timely delivery and installation of advanced rolling equipment. My role involved fostering strategic partnerships with stakeholders, streamlining workflows, and ensuring compliance with stringent safety and quality standards. Through weekly progress reports and proactive risk management, we maintained alignment with Suez Steel’s vision, delivering a facility that sets a new benchmark for steel production in the region.

Navigating Complex Challenges with Strategic Precision

Completing a project of this scale in just one year presented significant challenges. The accelerated timeline required seamless coordination with international suppliers, while the integration of advanced technology demanded precision to meet Danieli’s global standards. Additionally, operating in Suez’s industrial zone necessitated careful management of logistics to ensure a steady supply of billets from Suez Steel’s melt shops, all while adhering to strict safety protocols in a high-risk manufacturing environment.

To address these challenges, I implemented a strategic approach:

Global Coordination: I established a robust communication framework with Danieli and other suppliers, ensuring equipment delivery and installation stayed on track despite the tight schedule.
Operational Efficiency: We optimized resource allocation, leveraging data-driven scheduling to manage labor, machinery, and materials, enabling us to meet the one-year deadline without compromising quality.
Safety and Compliance: Rigorous safety audits and training programs ensured the facility met international standards, creating a secure environment for workers and operations.

These strategies enabled us to transform a complex project into a resounding success, delivering Rolling Mill 3 as a model of efficiency and innovation in steel production.

A Catalyst for Industrial and Economic Growth

Rolling Mill 3 has significantly strengthened Egypt’s steel industry since its operational launch. With its 1.4 million-ton annual capacity, the mill has increased Suez Steel’s total rebar production to 2.2 million tons, meeting the growing demands of the construction sector both domestically and regionally. The facility’s high-grade rebar, produced to international standards, supports critical infrastructure projects, contributing to Egypt’s urban development and economic growth.

Beyond production, the project has created over 1,000 job opportunities, empowering local communities in Suez with diverse roles across scientific and technical qualifications. By enhancing Egypt’s steel export capabilities, Rolling Mill 3 has positioned Suez Steel as a competitive player in the global market, reinforcing the country’s industrial leadership and supporting its Vision 2030 goals for sustainable development.

Lessons Learned: Building for Impact and Longevity

The Rolling Mill 3 project reinforced several key principles that continue to guide my work as a civil engineer and project manager:

Time as a Strategic Asset: Accelerated timelines demand meticulous planning and coordination, turning constraints into opportunities for innovation.
Technology Drives Excellence: Leveraging advanced equipment, like Danieli’s rolling technology, ensures long-term operational success and market competitiveness.
Safety First: Prioritizing safety in high-risk industrial projects is non-negotiable, ensuring sustainability for both workers and operations.

A Defining Achievement in My Journey