This CO2 stunning expansion was completed in September 2015 for Maple Leaf Foods in Brandon, Manitoba, Canada.  Jeremy was the design/build Construction/Project Manager for the facility responsible for bringing in the project on schedule and on budget. 

The expansion was approximately 7,300 SF. This expansion is located in a courtyard area bounded by existing structures on three sides: the kill floor to the west, the restrainer/lead-up area to the north, and the existing livestock barn to the east. These logistical complexities, tight schedule and the food grade materials required for this facility made the contract value $8M CAD or $1,095/sqft.

Project challenges included construction in a very tight logistical area and working around the existing production schedule of the operational plant.  The project consisted of drilling secant piles into the courtyard soil to underpin and support the existing foundation.  

The piles then had wailing installed and welded to support tabs to brace the piles as the center was dug out for the future stunning pits. 

Once the interior of the pile shoring was excavated the (2) 35' deep pits were formed up to be poured.  Because the stunning equipment sits on the pits and lowers carousels into the pits a tolerance in/out of plumb over the 35' distance was limited to 1/4". 

Once all the equipment and mill work was installed and tested on temporary power the team needed to make a final change over from the main line.  This consisted of: Cutting openings through the plan wall IMP panels, demolishing 250LF of concrete wall, pouring new concrete flooring between the adjacent slabs, pouring 250LF of high early concrete curved walls, making all final MEP connections to the equipment, installation of miscellaneous gates and lights, final testing and commissioning of the equipment, final clean and CFIA inspection of the addition for full production to begin.  

This process occurred over a 3 day weekend with crews working 24/7.  The plant employed 1,200 people and processes over 10,000 hogs per day so any down time is unacceptable.  As such Jeremy and his team developed and implemented a detailed schedule by the hour and were able to turn the plant over with time to spare Tuesday morning for full production.