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Operation carried out over three days in Riyadh required continuous coordination between teams, vehicles, and equipment to maintain uninterrupted concrete pouring and establish a record recognized by the Guinness World Records.
During the construction of the Kaheel Project in Riyadh, Saudi Arabia, a large-scale operation mobilized about 9,000 workers, 6,500 trucks, and 87 concrete pumps to pour approximately 70,000 cubic meters of material.
Executed over 72 consecutive hours, the service was recognized by the Guinness World Records as the largest continuous concrete pour in history, carried out in a single operational cycle without interruptions in the pouring process.
To sustain this pace, the companies involved had to coordinate the production of the mix, the movement of vehicles, the arrival of loads at the site, and the simultaneous operation of pumps installed around the foundation.
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According to information released by Mohammed Al-Habib Real Estate, responsible for the project, all trucks accessed the area through a single entrance, a condition that increased logistical complexity and required strict control of internal circulation.
In addition to reaching 70,000 cubic meters, the operation surpassed the previous record of 32,000 cubic meters, according to data presented by the companies participating in the construction and supply of products used in the concrete pouring.
Foundation of the Kaheel Project received concrete without interruption
Located in the Al Sedra region, in the Saudi capital, the foundation of Kaheel is about 1.5 meters deep and needed to receive concrete continuously to meet the specifications established in the structural planning.
A prolonged stoppage could create discontinuity points between the material already poured and the loads dumped later, reducing the uniformity of the base and increasing the technical difficulties faced by the teams on site.
To avoid this problem, the supply was organized so that new trucks arrived while the pumps remained in operation, preserving the service sequence and the appropriate conditions for concrete application.
The location of the construction also added challenges to the operation, as the site is near the airport area and commercial centers in Riyadh, such as Riyadh Front and Business Gate, where there is heavy vehicle traffic.
As the transportation depended on a busy urban route, those responsible needed to control schedules, routes, and intervals between the trucks to prevent congestion at the site entrance and delays in material supply.
The concreting began on a Thursday night, a period that coincides with the start of the Saudi weekend, a circumstance considered in the organization of displacements and in the planning of the heavy vehicle flow through the city.
Additives maintained the fluidity of the concrete
Before reaching the foundation, each load needed to maintain adequate conditions to pass through the pumps and fill the structure, as extended waiting periods could reduce the workability of the mixture and compromise the continuous pace of the pour.
To minimize this risk, DCP, a supplier of construction chemicals, applied high-performance superplasticizer additives to almost half of the volume used during the operation carried out in the residential project.
Added during the preparation of the concrete, these compounds prolonged the retention of fluidity without decreasing the expected strength, allowing the material to withstand transportation, controlled waiting, and pumping over the 72 hours.
Among the products reported by the company were Hyperplast PC313M, Hyperplast PC318, and Flocrete RPC20, used to control consistency from production to technical evaluation and final pouring into the foundation.
At the same time, specialized teams remained on-site to monitor the behavior of the loads and assist the different suppliers, as the participation of various concrete companies required compatibility between the batches poured into the same base.
More than increasing the number of trucks and pumps, the concreting depended on the coordinated operation of all stages, because delays in manufacturing, transportation, or release of the loads could interrupt the planned sequence.
Logistics involved thousands of workers and vehicles
During the three days of operation, the continuous arrival of mixer trucks needed to keep up with the simultaneous operation of the 87 concrete pumps, preventing any section of the foundation from missing material during the scheduled period.
The concentration of thousands of workers, drivers, and operators required task division, technical monitoring, and constant communication between the teams responsible for production, transportation, and pumping of the concrete.
As all vehicles used the same access to the site, each entry needed to occur within a defined schedule, reducing the risk of queues, internal blockages, or prolonged waiting periods before unloading.
This synchronization allowed the material to be distributed across different points of the foundation, while workers monitored the regularity of the filling and the performance of the pumps positioned around the structure.
Residential complex will have 1,492 units in Riyadh
Developed by Mohammed Al-Habib Real Estate, the Kaheel occupies approximately 96.8 thousand square meters and plans the construction of 1,492 residential units in the Al Sedra region, an area of urban expansion in the Saudi capital.
In addition to the residences, the complex’s planning includes green areas, an internal park, a mosque, a sports club, a supermarket, and pathways for pedestrians, while the landscaped surface is expected to exceed 30 thousand square meters.
The size of the project helps explain the dimensions of the foundation and the high volume of concrete used, as the base was designed to support an extensive structure, consisting of residential spaces and community areas.
Before the start of the launch, suppliers and technical teams coordinated workers, machines, routes, and control procedures, establishing an operational chain capable of remaining active for three consecutive days.
The record achieved in Riyadh shows that concreting of this magnitude depends not only on the number of available equipment but also on urban logistics, material control, engineering monitoring, and integration between different suppliers.
Even with thousands of professionals and vehicles mobilized, the record was only possible because production, transportation, and pumping maintained a coordinated sequence for 72 hours, preserving the necessary conditions for continuous launching.
After an operation that moved about 70 thousand cubic meters of concrete in just 72 hours, what will be the technical and logistical limit of the next major engineering projects?
