The existing Admin & Maintenance Complex (AMC) for Elk Valley Resources coal mine near Sparwood, BC, was nearing its end of life, which led to the design and construction of new buildings that would not only upgrade the mine’s operation’s efficiency for years to come, but also unlock new reserves of coal under the existing facility, extending the viability of the mining operations in the area.

Located on a spill pile at a recently mined site, the new $580M facility includes several buildings: an 11,000 m2 administration building, 11,000m2 warehouse and maintenance facility, a 12-bay heavy vehicle repair shop, heavy and small vehicle wash buildings, a potable water treatment plant, wastewater treatment plant, fuel depot, and a lube oil storage building. The buildings, with high-performing envelopes, were designed to minimize construction time while improving safety, human comfort, ease and flexibility of use, and durability. The buildings were primarily constructed using a steel structure and insulated metal cladding (IMP).

Given the inherent dangers of working with such large machinery and in a potentially harsh mountainous environment, Stantec extensively explored ways to improve the safety of staff using and maintaining the new complex. The design team embraced Elk Valley Resources’ Courageous Safety Leadership program in the design.

Stantec, in partnership with PCL, worked collaboratively with the client on this progressive design-build project through a fast-tracked process to iteratively price the design throughout each design milestone to optimize the cost of this new facility. This process of early collaboration also helped ensure all of the client’s operational needs were met.

Stantec’s approach to engineering required thoughtful and innovative solutions to complete the project on an accelerated schedule. The new building features high-damage-grade structures with long spans and towering heights, reaching up to eight stories without floors. Designed to support 400–500-ton vehicles, it incorporates fully welded steel plates for floor reinforcement. To optimize the timeline, the foundation and floor slab were poured as a single concrete placement. The structure was completed in 18 months, with full project completion in under three years.

Built on an active mining site with significant waste soil, the facility was constructed atop a backfilled, monitored foundation. Engineers ensured the compacted fill—ranging from 3 to 9 metres in depth—was stable before laying a 1.2-metre thick concrete slab foundation.

The workshops were designed for flexibility, allowing operations to occur anywhere without fixed locations. Ventilation supports any process, ensuring adaptability.

The facility is net-zero ready, with systems designed for future electrification. Sustainability features include a heated radiant slab, heat recovery, and water-source heat pumps. The electrical design includes redundancies for reliability, generator backup for critical functions, and UPS for lighting to meet safety standards. Stantec’s design extends from the substation to individual receptacles, ensuring a reliable, future-proofed system for long-term operations.

The project was completed in under three years, with the structure built in 18 months. Sitting on a compacted waste fill foundation with a 1.2-metre concrete slab, it supports 400–500-ton vehicles with welded steel plate flooring and. The workshop is Net-zero ready and features optimized ventilation, a heated slab, heat recovery, and water-source heat pumps. Redundant electrical systems, backup generators, and UPS ensure resilience, while future-proofed infrastructure supports long-term growth.