Saudi Engineering Client – Large-Scale Mobile Oil Containment Pond System (Batch Customisation, Long-Term Cooperation)

A Saudi oilfield contractor needed ~100 reusable 25m×8m containment ponds for oily wastewater and sludge, able to resist oil/UV and support heavy equipment. We delivered a modular system: 3mm GEO geocomposite puncture barrier on sand, a heat‑seamed 1.5mm TPU sealed liner with ~30cm sidewalls, and an 8mm textured rubber working layer. 185 height‑adjustable hot‑dip galvanised steel support feet level the pond on uneven ground. The rubber surface passed on‑site tests supporting 80‑tonne crawler cranes, and the ponds have been dismantled and reused multiple times, leading to a long‑term framework agreement.

Middle East, Europe and America, Australia, Saudi Arabia

government use, engineering, factory, industrial use, oil field, mining site

Oil Spill Containment Berm

Client Background

A Saudi oilfield engineering contractor, serving national oil companies like Saudi Aramco, needed to set up large oil containment ponds at multiple oilfield sites. These ponds are used for temporary storage of oily wastewater, sludge, and other fluids generated during oil extraction. Each pond has a standard size of 25m × 8m, and the total number of ponds is close to 100 units, spread across different work sites.

The client’s key requirements were:

· The containment pond itself must be impermeable, oil-resistant, and weather-resistant.

· The system must be able to withstand heavy equipment operations (cranes, cleaning vehicles) directly on or inside the pond.

· The entire system should be dismountable, transferable, and reusable across different sites.

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Our Solution

From initial request to final delivery, we went through solution design, material selection, drawing revisions, sample testing, batch production, and on-site support. After the first pond was successfully commissioned, the client entered a long-term cooperation with us, and all subsequent ~100 ponds have adopted the same customised system.

The structure of each 25m × 8m oil containment pond (from bottom to top) is as follows:

1. Bottom layer – 3mm GEO geocomposite
Laid directly on the original sandy ground. The GEO layer acts as a separator, reinforcement and puncture barrier, preventing sharp stones or plant roots from damaging the TPU liner above. It also distributes the load evenly to avoid uneven settlement.

2. Middle layer – 1.5mm TPU (thermoplastic polyurethane) – forms the main containment body
The TPU material is heat-seamed to create a fully sealed pond body, with the side walls raised to a certain height (approx. 30cm, as required by the client). TPU offers excellent oil resistance, chemical resistance, and UV ageing resistance. Long-term contact with crude oil or oily wastewater causes no corrosion or swelling, completely eliminating leakage risks. At the same time, TPU is strong and elastic, adapting well to minor ground deformations.

3. Top layer – 8mm high-strength rubber sheet
Placed directly on top of the TPU pond bottom as the working surface. The rubber sheet withstands the point loads and impact from heavy crane tracks, cleaning equipment, and personnel walking, effectively protecting the underlying TPU liner from cuts or punctures. The rubber surface is textured for anti-slip performance, ensuring safe operation even in rainy conditions.

4. Support & levelling system – 185 carbon steel galvanised support feet
A total of 185 height-adjustable carbon steel galvanised support feet are installed either under or around the GEO layer (some partially embedded in the ground, others as detachable independent supports). These support feet level the entire containment pond system, ensuring a flat pond bottom and even stress distribution on the side walls – even if the original ground has slopes or local depressions. All support feet are hot-dip galvanised, suitable for the humid, corrosive outdoor environment of oilfields, and can be disassembled and reused.

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Project Scale & Long-Term Cooperation

· Single pond size: 25m × 8m = 200 m² effective bottom area.

· Total number of ponds: Close to 100 units, covering a total area of approximately 20,000 m².

· Load capacity: The top rubber sheet can safely support 80-tonne class lifting equipment (crawler cranes, etc.) to walk, lift and rotate directly on the pond bottom – verified by on-site load tests in Saudi Arabia.

· Reusability: Each pond can be fully dismantled – roll up the TPU liner, stack the rubber sheets, remove the support feet – and reassembled at the next site. The client has reused the system more than three times across different oilfield locations, and the TPU and rubber sheets remain in perfect condition.

· Cooperation status: After the first pond was successfully delivered and validated, the client signed a long-term framework agreement with us. Nearly 100 ponds have been delivered in batches, and the client continues to reorder. This has become a benchmark case for us in the Middle East oilfield sector.

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Client Testimonial (excerpt)

“In the past, our containment ponds were either excavated pits lined with HDPE – single use, expensive, and unable to bear heavy loads – or welded steel tanks, heavy and costly. Your solution – TPU + rubber sheet + GEO + support feet – is not only fully impermeable and able to support heavy equipment, but also reusable. From the first 25×8 pilot pond to now nearly 100 ponds delivered by you, we have made the right choice.”

— Nader, Project Manager, Saudi Engineering Company