People first: The human side of heat stress prevention

Aluminium Bahrain B.S.C. (Alba)’s outstanding achievements in safety and health are all the more noteworthy given the temperature challenges it has to contend with, as Jane Warren reports.

Nestled between the golden sands of the Sakhir desert and the turquoise seas of the Arabian Gulf, the temperature in the Kingdom of Bahrain regularly soars above 45°C in the summer months. And by 10am, the searing heat has already begun to shimmer off the tarmac at Aluminium Bahrain B.S.C.(Alba) – the world’s largest aluminium smelter on one site.

Combine that with the extreme heat generated by six lines of aluminium production, and the result is one of the most challenging industrial environments on Earth.

Yet, inside this vast ten-hectare site, an extraordinary safety culture thrives. A record-breaking 34 million safe working hours without a lost time injury (LTI), achieved in April 2025, stands testament to this commitment.

“It’s not just a number,” says Alba’s CEO Ali Al Baqali. “It signifies the care we have for every single person on this site. Safety is not a regulation here—it’s a way of life and we know that the people on the shop floor are the experts. They are dealing with danger every day. For management, it is about being there, supporting them and facilitating their needs.”

That such physically punishing, inherently dangerous work could be done with an outstanding safety record — including eight consecutive summers without a single heat-related incident — might seem improbable. Yet Alba has made it routine after five decades building a world-class safety culture alongside their world-class industrial operation.

At the centre is an unwavering commitment to health and safety, spearheaded by visionary leadership and powered by a partnership with RoSPA that is redefining what is possible in high-risk environments — and doing so in one of the world’s most unforgiving climates.

Safety culture

Alba generates its own electricity through a gas-fed power station and even operates its own marine terminal – a rare infrastructure advantage in the global smelting industry. But its most important asset isn’t technical, it is cultural.

“We live by three safety principles,” says Al Baqali. “Ownership of safety and the environment is everyone’s responsibility. Working safely as one team is a condition of employment. And all work-related injuries and illnesses are preventable.”

This ethos is more than a mantra; it underpins every action at the company. Safety is embedded into the workday from the very first moment.

Each morning, before a shift gets underway, every department pauses for a five-minute safety briefing. It's a small ritual with a powerful impact—setting the tone for the day and reminding all 3,200 employees that at Alba, safety isn't an afterthought. It's the foundation.

And now, through its partnership with RoSPA and its role as an ambassador for the RoSPA Awards, ALBA is helping to shape the safety practices of not only its workforce, but also those of its contractors and global peers.

Founded in 1971, Alba is Bahrain’s industrial crown jewel. Producing more than 1.62 million metric tonnes of aluminium per annum, it plays a crucial role in both the national economy and the global aluminium market. But behind its success lies a steadfast philosophy: that safety and productivity are not in conflict—they are mutually inclusive.

From the moment you set foot inside the sprawling industrial complex, the ethos “Safety First, Safety Always” is palpable. Hard hats aren’t just worn — they’re worn with pride. Safety briefings aren’t routine — they’re respected rituals.

Pioneering leadership

This cultural shift has been orchestrated under the steady leadership of CEO Ali Al Baqali, a Forbes-recognised industry figure whose hands-on approach has set a new standard in the region, and whose impact is felt far beyond the boardroom where every board meeting starts with a ‘Safety Share’ presentation from each department.

“Safety is our licence,” says Al Baqali. “If we can’t do it safely, we don’t do it at all.”

In a culture where top-down hierarchy has traditionally prevailed, the CEO’s presence on the shop floor, clad in full PPE, side-by-side with frontline workers, is deeply symbolic. “You won’t find him in a suit,” says one team member. “He’s out there wearing overalls, checking on people, showing he’s not above safety—he’s a part of it. His ultimate dream is to have zero injuries of any type. Working safety as one team is a condition of employment here.”

This visibility is not performative. It’s habitual. Executives routinely walk the factory floor during the weekly “Safety Hour”, visiting different departments to listen, encourage, and model the behaviours they expect to see. “It’s about approachability,” says Director of Safety & Health, Mohd Khalil Saeed. “When leadership shows up, when they live what they preach, trust grows.”

“Ali Al Baqali embodies the safety-first ethos as much as any leader I have met," says Andrea Sims, Head of Strategic Partnerships at RoSPA. “He has created an empowered culture where each employee actively participates in continually driving down accident rates. Even in the most difficult conditions, Alba has proven that accidents don’t have to happen. Their mindset is clear — zero tolerance for risk, zero excuses.”

Says Mohd Khalil Saeed: “When the CEO was promoted in 2019, he said two things: When it comes to safety there is no hierarchy, and that he will not stop any capital expenditure to make our people safe. It’s an aluminium plant, it’s not like a school or a newspaper, there are inherent risks and a completely different risk profile, and that is why there is no compromise on safety.”

Heat stress innovation

At the core of Alba’s safety strategy is its pioneering work on heat-stress prevention — an area that, given Bahrain’s harsh climate, is not just important but vital. Few industrial operations demand more from their workforce than aluminium smelting in the Gulf. The humidity alone is intense.

From June to September, during the kingdom’s peak summer months, Alba enforces strict controls on outdoor work, in line with government regulations and additional in-house protocols.

“We don’t leave it to chance,” says Mohd Khalil Saeed. “We tell workers how much water to drink—three cups per hour—when to rest, and when to stop. We’ve had summers without a single heat-related incident. Our goal is zero harm.”

Leading this work is Nezar Hameed, Alba’s Senior Safety and Health Manager, whose innovative approach has turned the company into a global exemplar in managing occupational heat stress.

Alba’s Heat Stress Management Programme is a meticulously engineered response to local climatic conditions. From misting systems and shaded walkways to air-conditioned rest zones and scheduled work-rest cycles, every detail is designed to protect employees and contractors. The company even uses Wet Bulb Globe Temperature (WBGT) calculations to determine safe exposure times based on real-time ambient temperature, humidity, and wind speed. On the hottest days, some teams work no more than 10-15 minutes per hour.

“Working in a smelter is intense at the best of times,” Nezar Hameed explains. “But in Bahrain’s summer months, the combination of ambient temperatures and radiant heat from furnaces can create an extremely high-risk environment. Our aim is to control the controllables, through planning, monitoring, education, hydration, and above all — listening to our people.”

Since 2017, Alba has had zero cases of heat exhaustion. It is a staggering achievement — and one that has earned international recognition.

Inspiring approach

Lord Jordan, RoSPA’s Life President, captured this achievement during his visit to Alba in January 2025 to present the company with RoSPA’s Life President’s Award. This prestigious accolade recognises organisations that have achieved multiple Gold Awards and maintain a strong commitment to safety, often for a decade or longer.

“In a country where summer heat can be perilous, Alba stands as a beacon,” said Lord Jordan in his speech. “This is more than a company — it is a community that cares. Their efforts contribute to a safer, healthier Bahrain, where every worker can return home safely to their families.”

What sets Alba apart is not only the infrastructure but the culture of communication that permeates the site. Safety messages reach employees through every channel imaginable: WhatsApp updates, LED screens, emails, and department meetings. Safety is discussed before every board meeting, not after.

Crucially, these messages are crafted not just to inform but to inspire.

“We believe in telling the story behind the message,” says Eline Hilal, Director of Investor Relations. “Whether it's a visual campaign during Ramadan or a fourth-season safety initiative, we bring safety to life in a way people can relate to.”

This creative, empathetic approach reflects Alba’s belief that safety isn’t about rules—it’s about people. A single lost-time injury in 2023, involving a contractor burned during power plant maintenance, prompted immediate review and system-wide learning. Every incident, no matter how minor, is analysed, understood, and used to prevent the next. The numbers speak volumes: since 2019, Alba has averaged fewer than 13 minor first-aid cases annually. Last year there were just four such incidents.

With 87 per cent of its workforce made up of Bahraini nationals, Alba invests heavily in training, development, and employee well-being. Its Alba Club, a recreational hub with tennis courts, swimming pools and family-friendly amenities, underscores the company’s belief in caring for the whole person, not just the employee.

Working with RoSPA

Alba’s journey with RoSPA began over a decade ago, with a simple submission to the RoSPA Health and Safety Awards. Today, the company is not only a perennial Gold Award winner — now boasting 11 consecutive wins — but now sponsors two of RoSPA’s Industry Sector Awards: Waste Management and Recycling (since 2021) and Renewable Energy (since 2022).

“Becoming an ambassador for the RoSPA Awards is a significant honour for Alba and validates our continuous efforts to maintain and improve standards to a global standard in fostering a safe working environment,” says Mohd Khalil Saeed, Director Safety & Health.

“The accolade reflects our unwavering commitment to health and safety, which is deeply ingrained in our culture. It validates our continuous efforts to maintain and improve internal standards and acknowledges the hard work and dedication of every member of the organisation.”

And the benefits are not just internal. “Partnering with RoSPA and becoming an ambassador has enhanced Alba’s visibility among health and safety professionals, award winners, and the wider RoSPA community,” they explain. “It has brought visibility to Alba through events, webinars, journals, newsletters, and social media. It’s a vivid platform to showcase our expertise and thought leadership in health and safety.”

There is also a reputational dividend. RoSPA’s global platform has given Alba the opportunity to showcase best practices, participate in webinars, and connect with safety professionals around the world. The partnership also reflects Alba’s own philosophy: that sharing knowledge saves lives.

“Alba is seen as a global benchmark,” says Ali Al Baqali. “That’s something we take seriously. We’re not just doing this for us—we’re doing it for the industry, for the region.”

Alba intends that its involvement with RoSPA will have a ripple effect beyond its own gates.

“We hope to inspire our contractors and suppliers to participate in the RoSPA Awards,” he adds.

“That’s how you build a culture of safety not just within your own organisation, but across your entire supply chain.”