Flare Stack Rope Access at 154m – AIMMS in Ruwais, UAE

Scaling New Heights: Flare Stack Installation by Rope Access at BOROUGE 4

At AIMMS, we believe that height should never be a hurdle to precision, safety, and engineering excellence. Our recent milestone at the BOROUGE 4 – EPC Package 4 U&O Unit in Ruwais, UAE stands as a testament to that belief.

The Project Challenge

The task: Install and align a demountable flare support structure towering over 150 meters — safely and precisely — within a tight window of 30–40 days. The complexity? A multi-module structure (Modules A to D) to be installed at various elevations, requiring flawless interconnection, alignment, and bolting… all while suspended at height.

Why Rope Access?

Unlike traditional scaffolding or crane basket methods, rope access offers:

• Speed and flexibility at complex elevations.

• Minimal site disruption during critical shutdowns.

• Superior access to challenging bolting and bracing points.

For this project, AIMMS deployed a 12-member IRATA-certified rope access crew, comprising:

• 2x Level 3 Supervisors

• 6x Level 2 Technicians

• 4x Level 1 Technicians

Our Scope of Work

• Module Interconnection at elevations from +31.3m to +154.0m

• Precise Bolt Insertion and Torqueing using calibrated tools

• Diagonal Bracing Installation across Modules B, C, and D

• Raiser Rail Installation during interconnection phases

• Rigging and De-rigging for all rope access activities

• Safety Supervision and Rescue Readiness at all times

Each module (B, C, D) was pre-rigged on the ground, lifted to the required elevation, then:

1. Aligned using spike bars and aid climbing

2. Bolted and torqued in sequence, following a cross-pattern to 70% torque before final tightening

3. Braced using chain blocks installed mid-elevation

4. Verified for alignment accuracy using level-checking tools

Safety at the Core

We operate under stringent HSE protocols:

• Dual-rope attachment with anchors rated >15kN (EN 795/BS 7883)

• Equipment redundancy and anti-drop measures

• Real-time communication via 2-way radios

• On-site rescue kits and standby Level 3 supervisors

Every operation was backed by a risk-assessed work permit system, ensuring full compliance with ADNOC and project-specific HSE mandates.

The Result

Despite the complex module-to-module interconnections and extreme heights, the AIMMS team:

• Completed each stage on schedule

• Maintained zero incidents or near misses

• Delivered alignment and torqueing within design tolerance

Final Thoughts

Projects like these aren’t just about steel and bolts — they’re about trust. At AIMMS, we’re proud to be the rope access partner trusted for mission-critical flare stack installations in the oil & gas sector.

Whether it’s a 150m flare in the UAE or a remote offshore rig, we go where others can’t — and deliver what others won’t.