Canadian Gypsum Company Inc. (CGC) is a leading manufacturer and distributor of gypsum wallboard products, interior finishing materials and suspended acoustical ceilings in Canada. CGC engaged Ausenco to provide detailed design engineering services for the No.1 Kettle Replacement project at their Hagersville Plant.
To support this project, we assembled a team of engineers and designers experienced in industrial site assessments, process plant design, material handling, and project management.
Client requirements
CGC planned to replace their existing aging Kettle No. 1, which had been in operation for over 50 years, with four smaller, high-efficiency kettles, while maintaining ongoing plant production. The replacement was executed through a carefully sequenced process involving equipment relocation, demolition, installation, and commissioning to minimise disruptions to operations and ensure a smooth transition to the upgraded system.
Project solutions and approach
Ausenco was selected for our proven expertise in industrial plant design and our ability to seamlessly integrate our local Ontario professional engineers with CGC’s multidiscipline team providing support from Chicago. Our scope of work included structural engineering and design services.
The project was delivered in two phases: first, a new building extension was constructed (pictured) to house two of the new modern and energy-efficient kettles. After decommissioning the original unit, the existing space was retrofitted to install the remaining two units.
Our local team collaborated closely with CGC’s engineers, working under tight timelines using platforms like Microsoft Teams and Navisworks to streamline communications and designs. The project also occurred during the COVID-19 pandemic, requiring a temporary pause and the implementation of strict safety protocols upon resumption.
While working on the existing building, we responded quickly to contractor requests, developed solutions that kept the project on schedule, and addressed safety needs such as temporary bracing and handrails.
Our experts also overcame the site’s unique challenges, including, equipment coordination in tight spaces, integration with existing multi-level structures and existing foundations, and the installation of new machinery. In addition, we efficiently managed cross-discipline scope items, delivering added value while navigating project changes.
Outcomes and achievements
Our collaboration with the client on this project was built on the foundation of earlier, smaller-scope initiatives that gave our team initial exposure to their operations. This project further deepened our operational understanding and strengthened our familiarity with the Hagersville plant and workflows.
Despite the challenges of working within an active plant and during the COVID-19 pandemic, our experts worked in close partnership with the Chicago-based engineering team to fulfill provincial requirements, maintain project timelines, and support CGC’s transition to a more modern, efficient production system.