McCain Foods

French Fry Production in Coaldale

Sealand Delivers 250,000 SF Processing Facility for McCain Foods

In 1999, McCain Foods set out to build a state-of-the-art processing facility in Coaldale, Alberta, designed to handle various stages of French fry production. The facility, located on a 60-acre site that would serve as a future campus, features everything from potato receiving and processing to packaging and cold storage, ensuring the efficient production and distribution of French fries across the region.

Sealand’s role as the design-build contractor ensured that the project stayed on track, meeting the Owner’s tight timeline.

Sealand oversaw the building site, civil works, and construction of the building shell, while McCain Foods managed the specialized mechanical and electrical systems. The facility’s design features a steel frame wrapped in insulated metal panels, with cold storage and process areas engineered to meet CFIA standards. With varying building heights across the facility, Sealand’s expertise ensured smooth integration of all elements, from the glycol subfloor heating system in cold storage to the walk-on ceiling in process areas, allowing for easy access to mechanical systems.

This advanced facility marks a significant investment in Alberta’s food production infrastructure.

Despite a fast-paced timeline, Sealand efficiently mobilized the greenfield site in May 1999, beginning foundation work by June and fully erecting the building by December. By the end of the year, 60% of the floor slabs were placed, keeping the project on schedule. The facility was ready for French fry production by May 2000, less than a year after work began.

Key Features

• Cold Storage and Dock Areas: The facility’s cold storage was designed with a glycol subfloor heating system, ensuring long-term durability and temperature control.
• Process and Packaging Areas: The processing areas were designed to accommodate specialized equipment, with a suspended walk-on ceiling to house mechanical and electrical systems.
• Office and Operations Areas: Commercial-grade spaces include offices, locker rooms, washrooms, a QC lab, and training rooms, providing a comprehensive workplace for employees.

Sealand self-performed several critical tasks, including installing insulated panels, constructing insulated floors, and completing rough carpentry and concrete work, ensuring that the project met high standards of quality and efficiency.

Overcoming Challenges
The key challenge was the aggressive schedule. Sealand’s rapid mobilization and efficient construction approach allowed the facility to be weather-tight by December, ensuring the timeline stayed on course. By May 2000, the facility was fully operational, ready to process and distribute French fries across the region.

Project Details

Client: McCain Foods (Canada)

Location: Coaldale, Alberta, Canada

Project Type: Design Build Lump Sum

Building Area: 250,000 SF

Budget: $15 Million

Project Duration: 12 months

Number of Trades: 40