The remote mining operations in northern Canada present many logistical challenges for resource extraction companies. Providing long-term accommodations for rotational workers hundreds of kilometers from major population centers is no small feat. When contemplating upgrades to dated on-site housing, Ontario-based mining firm Sudbury Resources turned to modular construction specialist Lida Group to design and erect a state-of-the-art prefabricated labor camp using repurposed shipping containers.

For over 50 years, Sudbury Resources’ Birchtree Mine had relied on outdated dormitory-style lodging to house the rotating workforce necessary to keep operations running around the clock. Consisting of a series of buildings dating back to the mine’s original construction in the 1960s, the aging accommodations were in dire need of replacement. With tight living quarters, limited privacy, and dated amenities, the company recognized the outdated housing model was negatively impacting worker satisfaction, retention, and well-being.

“We had heard too many complaints about the cramped and institutional feel of the old dormitories over the years,” said Sudbury Resources CEO Jason Marshall. “It was past time for an upgrade if we wanted to attract and keep the best people in this remote region. But constructing new permanent buildings would have been cost and time prohibitive given the location. That’s when we started exploring modular or prefab options that could be assembled on-site more quickly and efficiently.”

After reviewing proposals from several modular construction specialists, Sudbury Resources selected Lida Group to oversee the labor camp replacement project based on their innovative design approach and extensive experience erecting modular structures in remote resource industry sites across Canada. Founded in 1982, Lida Group has earned a reputation as leaders in modular and prefabricated building solutions, having constructed everything from fly-in mining camps to commercial and institutional facilities.

For the Birchtree Mineworker Housing Project, Lida Group proposed a first-of-its-kind design concept — a fully self-contained modular prefabricated labor camp constructed almost entirely from recycled 20- and 40-foot shipping containers retrofitted internally as living units. According to Lida Group Project Manager Tom Wilson, “We saw an opportunity to give new life to discarded shipping containers while delivering durable, easily transportable living quarters tailored to the mine site’s needs.”

Construction of the modular labor camp began in the winter of 2020 at Lida Group’s manufacturing facility near Winnipeg, Manitoba. Master carpenters, plumbers, and electricians outfitted the shipping container shells with interior walls, floors, and meticulously designed living spaces incorporating feedback gathered from current and former Birchtree Mine employees. Fully integrated kitchenettes and bathrooms with energy efficient appliances maximized limited floor plans. Windows, insulated exterior siding, and composite decking were installed to improve aesthetics and liveability.

Modular construction allowed production to continue uninterrupted even as pandemic-related delays impacted many construction sites. By spring 2021, over 100 refurbished shipping container modules in various configurations had been completed to form multi-unit complexes for single occupants as well as larger family units. Sophisticated pre-wiring and pre-plumbing connections streamlined on-site installation.

In May 2021, a fleet of specially equipped transport trucks carried the container modules 1,200 km north to the Birchtree Mine site. Using heavy lifting equipment, the prefabricated units snapped cleanly into place like interlocking building blocks atop a concrete foundation. Community spaces and a centralized services building were also trucked-in and installed. Within just six weeks, the new 72,000 square foot modular labor camp was completed, coming in on time and under initial cost estimates.

“The modular and prefabricated approach enabled construction to continue unhindered despite restrictions, resulting in timely delivery of much-needed accommodations for our rotational workforce,” said Marshall. “The housing meets our standards for durability, liveability and energy efficiency. Most importantly, early feedback from employees indicates a dramatic improvement in satisfaction compared to the outdated facilities.”

Adopting a refurbished shipping container modular system offered several key advantages for the project. As purpose-built transportation vessels, containers are highly durable and weather resistant — ideal for withstanding the extreme climate swings in northern mining regions. Their standardized dimensions also make efficient use of space in multi-unit arrangements. Building the labor camp off-site allowed production to continue through winter months, shortening the construction period and minimizing disruptions.

Recycling discarded containers into livable modular units offered environmental benefits as well. According to Lida Group, over 2,000 metric tons of steel were diverted from landfills through the project, eliminating the energy and emissions associated with producing new building materials. Internally, the minimized building envelope resulted in highly insulate, airtight living spaces reducing ongoing heating and cooling demands.

Satisfied with the successful outcome of the Birchtree Mineworker Housing Project, Sudbury Resources is exploring replicating the model across its other remote mining operations serviced by rotational workforces. Lida Group has also received substantial interest from other resource firms seeking durable, energy efficient accommodations for remote sites. According to Tom Wilson “Repurposing shipping containers provides a sustainable modular construction solution with applications far beyond mining camps. The cost savings, design flexibility and environmental benefits will continue driving increased adoption in many industries.”

In conclusion, by selecting Lida Group’s innovative prefabricated modular housing solution constructed from repurposed shipping containers, Sudbury Resources was able to replace outdated on-site dormitories with a state-of-the-art labor camp offering spacious, dignified accommodations tailored to the unique needs of rotational mining employees. Despite challenges from the global pandemic, the off-site prefabrication approach enabled timely project delivery. Early indications of vastly improved worker satisfaction suggest the investment will help enhance recruitment and retention in the remote mining region for many years to come. Most importantly, adopting this sustainable modular system redirected thousands of tons of waste from landfills, supporting the company’s environmental stewardship goals. The success of this pioneering project is likely to influence future workforce housing decisions across Canada’s resource industries.

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