Developed in parallel with a mirror facility in Western Australia, this project meets ATCO’s ambition to be a leader in the modular construction industry. The facility has been designed to their high-volume production program, which delivers large-scale structures for the mining and construction sectors, including worker accommodation, and mess halls for remote mining camps. The design allows for the ability to fabricate a 4-room accommodation unit every hour, with the column free, clear-span production area (50x30m) with a 16m internal height, and a structural grid at 18m centres. The programming of the factory floor has been rigorously considered;

• Dual 18m-wide, 100m-long assembly lines with materials staged at the perimeter, for a seamless
• Integration into ATCO’s construction program
• Rail dollies on inlaid tracks and overhead cranes enable efficient movement of modules along the
• Production line, minimising manual handling and accelerating build times.
•20m articulated vehicle access through the building for internal laydown and direct loading of
• Completed modular units, reducing turnaround times.
• A 70,000 sqm hardstand area constructed with interlocking pavers supports the movement of 40-Tonne forklifts and semi-trailers, enhancing site durability under heavy loads.

The design co-locates a 19,000sqm production facility with a 2,000sqm workplace, with a focus on a structure that meets the functional and sustainability ambitions of the business. Natural daylighting and high-bay LED lighting reduce energy consumption and create a well-lit, safe working environment. Water-sensitive urban design (WSUD) and a low-dust concrete surface ensure site resilience and minimize environmental impact.

Additionally, the project incorporates separate buildings for welding bays and flammable storage, reducing fire load risks and ensuring compliance with building classifications. This strategic separation enhances safety while maintaining workflow efficiency.

Overall the facility provides ATCO with a way to deliver further efficiencies in their rapid construction approach, and facility that will remain resilient and well equipped to evolve as construction methodologies advance, and their workforce requirements evolve.