FWS Group was commissioned by Grande Cache Coal Corporation to upgrade the raw crushing and conveyor system at its facility in Grande Cache, Alberta. This project aimed to enhance the facility's infrastructure, improve the material handling processes, and optimize the efficiency of raw material processing operations.

The key objectives of the project were:

• To replace and upgrade the existing raw crushing and conveyor systems.
• To improve the structural stability of the facility, ensuring it could support the new equipment.
• To optimize the material flow from the mine truck dump area to the processing system.
• To ensure the upgraded systems could handle the heavy operational demands of coal processing.

The project incorporated several advanced construction techniques and systems:

• Demolition and Removal of Existing Infrastructure: Dismantling and clearing old coal conveying systems and concrete silos, making way for new equipment and more efficient processes.
• Mechanically Stabilized Wall (MSE Wall): The construction of a new MSE wall to provide support for the surrounding area, helping manage soil pressure and maintaining the integrity of the system.
• Foundations for New Equipment: New foundations for the primary crusher and conveyor systems, designed to support heavy machinery and ensure smooth operation.
• Approach Slab with Steel Wing Walls: Designed to facilitate efficient truck access for material dumping, improving the flow of raw materials into the processing system.
• Piling Pile Caps and Mass Concrete Raft Foundations: The use of piling pile caps and mass concrete raft foundations to distribute loads evenly and maintain long-term stability for the new infrastructure.

The project resulted in several key improvements:

• Enhanced Material Handling: The new systems significantly increased the efficiency and capacity of raw material processing.
• Structural Stability: The addition of an MSE wall and upgraded foundations ensured the facility could support the new equipment while withstanding heavy operational loads.
• Optimized Flow: The approach slab and steel wing walls streamlined material dumping and transportation, leading to smoother operations.
• Long-Term Reliability: The new foundations and structural upgrades provided long-term operational stability, reducing maintenance costs and downtime.