Based on our success working with Glencore on their Process Gas Project, PCL expanded its contract to include additional buildings that make up the Sudbury Integrated Nickel Operations (Sudbury INO) Smelter site. The next facility requiring upgrades: a fabric tent structure that reached its safety lifespan. The 10,428 square-foot building rested on concrete LEGO-style blocks. These blocks were removed and replaced with a perimeter-grade beam. The old fabric tent was quickly demolished and replaced with a pre-engineered metal building that measured 66 by 155 feet.

On site, the PCL team managed excavation/backfill and foundations, followed by the construction of a pre-engineered steel warehouse, complete with siding and the installation of a new overhead door. Through value engineering and discussions with our supplier and trade partners, PCL was able to lower the cost of the structure by reducing the number of column bays. 

Located in a high-traffic area neighboring rail lines and office space busy with warehouse deliveries, equipment and trucks, this project demanded meticulous coordination and scheduling of staff, subtrades, and materials to meet timelines and budgetary obligations. Recognizing the challenges posed by these conditions, the owner opted to rent offsite storage for material that was initially housed in the warehouse. The PCL team worked efficiently, enabling the client to bring the material back to the project site.

A firewall was added to the scope of work to meet the city’s building codes. Installing the steel and siding was challenging as they required working with aerial platforms. The work also happened near the smelter activities, where there was a lot of heavy equipment and machinery.

Due to the strong safety culture of both PCL and Glencore, the project was completed without any incidents, including the demolition and installation phases.

The early 2020s were a difficult time for the construction industry – steel market prices and the COVID-19 pandemic created a lot of stress on keeping projects within budget. For this project, PCL leveraged its buying power to order the pre-engineered metal building in 2021 and secure the supply. This helped reduce the effect on the yearly budget when the project began in April 2022.

Despite these challenges, the team learned from the experience and improved their processes and relationships with all parties involved.  The PCL team successfully completed the project on time and on budget.