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FABRICATION SOLUTIONS

FABRICATION SOLUTIONS

Facility Information

Ponoka

  • 50 Acres
  • 240 mods +/- per year (as per Alberta maximum legal limits)
  • 12,500 FDI/wk/single shift
  • 18,400 sq. ft. shop
  • 260 tonnes/mo. steel
  • 8m High Line corridor
  • 150 – 300 FTE’s

Fort Saskatchewan

  • 3.5 Acres
  • 30 mods +/- per year
  • 2,000 FDI/wk/single shift
  • 5,400 sq. ft. shop
  • 50 tonnes/mo. steel
  • Ultimate High Line corridor
  • 3D robotic steel detailer
  • 20 – 30 FTE’s

Both facilities have the following abilities: Well pads, assembly of modules, utility and off-plot packages, pipe racks, E-Houses and equipment modules, and general structural and pipe rack fabrication.

Procurement

Gemini has a dedicated procurement team for fabrication and construction to ensure on time delivery of materials. Gemini utilizes an in house materials management system for material control throughout the construction lifecycle that begins at project estimating and expedites at various stages of construction including purchasing, receiving, production, testing and shipping or final installation.

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Receiving

Gemini uses fabrication facilities as the material marshaling point. Once the material is received, traceability is established. Bag and tag is performed five days in advance of production for fabrication activities or earlier if time allows. For any construction operations, bag and tag is performed 30 days in advance.

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Fabrication

Gemini details its own steel in house to avoid schedule delays typically experienced by the use of stand-alone detailers. We own a 7-axis robotic CNC machine that reduces both the cost of detailing and scheduled delivery. In order to reduce cycle times to fabrication, Gemini drafts and/or engineers its own steel. We currently have 30 welding stations, allowing welding productivity to average 100 FDI/day or 10/FDI per hour. Our repair rate is < 1% on a rolling 12 month basis. Gemini has 78 weld procedures, including carbon steel, stainless steel, Inconel, hastelloy, high nickel, chrome-moly, and other exotics. We can utilize stick, sub-arc, flux-core, STT and TIG welding processes.

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Staging

Gemini’s main fabrication facility has a footprint of 52.5 acres, 20 acres currently developed, and can site 50 modules simultaneously. Our facility contains 15 acres available for marshaling purposes. Gemini has 18,000 square feet of fabrication space under cover and under hook. We also have paint and blast facilities as well as a 5,000 square foot climate controlled material storage facility.

Gemini is currently expanding the Ponoka facility and developing our remaining footprint. A 10,000 square foot fabrication building is in the planning stage.

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Beam Profiler

Located in Gemini’s fabrication shop in Fort Saskatchewan, the new 3D robotic steel detailer, or beam profiler, allows Gemini to control its own schedule for detailed steel in support of client module fabrication projects. In addition, the profiler enables Gemini to commence producing custom products in support of the Industry and other Fabricators. This high definition plasma cutter provides a quality finish the first time, while the automated system eliminates human error associated with design document handling, providing quick turnaround for customer projects. The profiler is the latest addition to Gemini’s integrated solution service offering. In addition to the profiler, Gemini also offers detailed structural steel engineering capability, full welding shop services, in-house coating capabilities, assembly services and customized supply solutions.

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