Xstrata 60,000sf mining complex to be completed
in a short 7 months using off-site construction

Driven by the need for a much shorter project completion schedule and reduced impact from on-site construction activity, Xstrata Nickel, in conjunction with architect Lemay Associé of Montreal, Quebec, and its EPCM provider, Hatch-McIntosh, explored the current trends and technology available with permanent modular construction as an alternative to conventional means when faced with building a 60,000sf facility.

The decision to switch project delivery methods from traditional "on-site" construction to modular "off-site" construction was reached toward the end of 2007 when it became apparent this was the only possible way to hit the critical completion date of January 2009, while significantly reducing the amount of disruptive construction activity at an active mine site. Lemay Associé worked with Xstrata to convert the original site-build plans, created by Yallowega Belanger, into modular plans.

With the project well underway, this is a design-build facility, engineered and constructed by NRB Inc., in Grimsby, Ontario. Constructed under controlled conditions, and using engineered structural steel framing with poured concrete floors, the building was up to 85% completed in most areas with many of the building systems, fixtures and finishes installed prior to leaving NRB's plant. The structure was built completely together for precision fit and finish at the plant, and so that systems' testing could be done in advance. It was then disassembled in the three phases, and a total of 120 three-dimensional building modules of varying sizes were transported 300 miles north. The modules had to be stopped at staging areas off the site, and then moved up to the mine site in a safe, controlled and choreographed flow allowing them to be continuously crane set, until all three phases of the facility are erected and then site finished.

The entire process, from start of construction to substantial completion takes about seven months, with a slated completion date in January 2009.

In 2007 it became apparent that modular construction was the only possible way to hit the critical completion date of January 2009, and at the same time, significantly reduce the amount of disruptive construction activity at an active mine site.

Laurie Robert, NRB-Inc.

The LEED (Leadership in Energy and Environmental Design) level design reflects the owner's commitment to environmental responsibility. Xstrata's Sustainable Development Policy reflects their commitment to the environment. "Our aim is to preserve the long-term health, function and viability of the natural environments affected by our operations."

The new construction at the Nickel Rim South site has been registered to be a LEED certified project. The entire project site and the building with all of its materials and systems have been designed and built to the highest performance and sustainability standards possible. Design strategies included optimal energy efficiencies realized through innovative mechanical/electrical designs and improved thermal protection; the maximum possible uses of recycled and regional materials; careful attention to indoor environmental qualities through the use of low emitting materials and control of contaminants and moisture during and after construction, and the adoption of many water conservation features and strategies.

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