Masaic’s new potash mine was designed and constructed with state-of-the-art modularization techniques and a focus on imporved execution and operation efficiency. Hatch, who managed the engineering and construction of the shafts, headframes, and hoisting systems, developed solutions that would minimize construction timelines. The south shaft headframe structure, with over 342 embedded plates, 43 block-outs, and 3 million lbs of rebar, was one of the most complex slipforms ever performed. Every hour, over 2.5 tons of reinforcement was installed, and every day, 24 hours a day, over 225 m3 of concrete was poured. The team had to execute the construction during the pandemic, coordinating the mobilization of expertise from key resources across closed international borders. In comparison to conventional stick-built construction, the project modularization and innovative approaches provided important safety and production advantages, including: a significant reduction of direct hours working at height; a reduced risk for falling objects; over 12 months of scheduling savings; and significant execution costs savings.
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