Client: Boliden

Project cost: Approximately EUR 850 million

Time: January 2021 – ongoing

The project

Boliden is expanding the world's most climate-efficient zinc smelter in Odda in southern Norway. The expansion will make it possible to almost double the production capacity for zinc, while reducing carbon dioxide intensity by 15 percent from an already world-leading level. Most production facilities are being expanded, processes are being modernized with increased digitalization and automation, and Boliden's unique solution for waste management is being further developed. The project includes new industrial and process facilities, expanded electricity supply with a new 66 kV transformer station and landfalls for new submarine cables, new administration buildings, a new deep-water quay, new roads and tunnels, and rock caverns for storage. In order to accommodate everyone working on the project, a quay has been built and three residential barges with accommodation modules have been put into use. GZO 4.0 is one of the largest industrial projects currently being implemented in Norway, and around 130 people work full-time in the project organization.

Our mission

Since the start of the project, Novaform has provided the project with key personnel, both through dedicated assignments and hiring. All of our services have been delivered within the project administration and client function. Our consultants have had the role of Construction Manager, with overall responsibility for the construction activities and direct reporting to the project director, and as Package Owners, with responsibility for cost, time, quality, contracts and interfaces in larger contract packages. We have also contributed with an Area Supervisor who coordinated the project's work with the ongoing production, construction managers in both plant and building construction, an ASOC responsible for HSE coordination, specialists in mechanical completion (Mechanical Completion) and commissioning, and a person responsible for surface treatment and corrosion protection. The role titles are in English because English is the official language of the project and the roles follow international standards from offshore and heavy industry. In the preparatory phase of the project, two of our consultants have also had project and construction management responsibility for the underground rock facilities. The works included two new rock caverns with a total volume of approximately 800,000 m³, approximately 1,350 meters of new tunnels and the extension of three existing tunnels by approximately 600 meters. In addition, a new cut-off trench was added as additional protection against pollution, extensive pipe, pump and electrical work, approximately 3,000 meters of fiber optic cable, a new 1,600 kVA transformer and the removal of rock masses by sea by barge.

Challenges

As a listed company on Nasdaq Stockholm, Boliden places high demands on schedule, cost control and reporting, and the project has been implemented under significant pressure from the market situation and investment commitments. It requires a flexible organization that can continuously adapt plans, resources and implementation strategy. The contract structure is complex, with a combination of Norwegian and international contract standards in several contract packages and disciplines. The facility is located far from Norway's major population centers, the area is limited and the existing smelter must be in operation throughout the construction period. The project also has many stakeholders and interfaces, including road authorities, Statnett, Statkraft, NVE, the county council and the municipality. Many of the specialist skills needed are not available locally. Novaform has therefore worked with resource planning and forecasts, targeted recruitment in its own network and among partners, and obtained skills from related industries such as heavy construction, offshore and public infrastructure, and where necessary from abroad. Even before the project started, we allocated resources to help Boliden recruit key people, and a special onboarding function ensures that new employees quickly get started.