AUTOMOTIVE

E.S. Fox Ltd. has successfully completed major contracts for automotive manufacturers, such as: Chrysler Canada Limited, Ford Motor Company of Canada, Ford Motor Company, Dearborn, Michigan; General Motors of Canada, Honda of Canada Inc., Toyota Motor Canada, and G.M./ Suzuki (Cami Inc.).

These contracts have been diverse and have included the supply and installation of various equipment ranging from complete heating and ventilating systems spread over 52 acres of building, complete paint systems comprised of E-Coat and Phosphate Process Systems, a Climatic Wind Tunnel, 4500 sq. m. of steel mezzanine deck, to the installation of robotics for the automation of a Crankshaft line.

In addition, E.S. Fox has undertaken numerous 'fast track' projects for the Automotive Industry, with many of the contracts completed during shutdown periods to avoid disruption and loss of production.

ENERGY RELATED PROJECTS

E.S. Fox Ltd.'s track record in the energy related field dates back to early involvement in Ontario Hydro/Ontario Power Generation projects and it continues through to the present with the development of turnkey cogeneration projects.

Our experience ranges from Hydro (water generated) through Nuclear, natural gas fired cogeneration to the utilization of gas generated by landfills as a method of producing electrical power.

A cross-section of our customers is as follows:

• Ontario Power Generation
• Bruce Power Inc.
• AECL (Atomic Energy Corporation Limited)
• Boise Cascade
• Dupont Canada
• Korean Electric Power Corporation
• New Brunswick Power
• National Research Council of Canada
• Pacific Nuclear
• NPM (Nuclear Project Management)
• CFFTP (Canadian Fusion Fuels Technology Projects)
• E.B. Eddy
• Enercogen Limited
• Solar Turbines Incorporated
• TransAlta Energy Corporation
• Hamilton Health Sciences

Projects range from the complete turnkey design and construction of cogeneration plants such as a 4 MW unit for the National Research Council of Canada to the development of a 5 MW electrical generation facility operating on "landfill gas" at the 10.5 million ton Beare Road landfill in Toronto.

Major projects for the Nuclear industry are as diverse as 2 1/2 miles of SF6 aluminum bus duct for the Darlington Nuclear Generating Station, the fabrication of specialized cabinets for the Korean Electric Power Corporation and Transfer Casks for the retubing of the Bruce Nuclear Generating Station, to the design and construction of a new Radioactive Waste Processing and Storage Facility and installation of a new RadWaste Incinerator for Ontario Power Generation at the Bruce Nuclear Generating Station, the Restart of 1652 MW of shutdown Nuclear Units (3 and 4) for Bruce Power at the same location and the construction of the 550 MW Gas-fired Sarnia Regional Cogeneration Plant for TransAlta Energy Corporation of Calgary, Alberta.

Water generating projects include the fabrication and installation of penstock facilities such as those for the E.B. Eddy Hydro Power Project in Espanola, to the Magpie River Hydro Project in Northern Ontario.

Quality, on-time delivery, the completion of work within budget and safety have played an important part in the development of this segment of our industry.

E.S. Fox Ltd. has the capability of developing and managing total turnkey projects, and offers fully integrated construction and fabrication services all as described further herein.

Top

EQUIPMENT INSTALLATION

E.S. Fox Ltd. field construction forces have compiled a comprehensive list of projects representing many different segments of the market place.

These projects range from Automotive through Chemical, Paper, Metal and Nuclear with customers such as:

This "track record" has been built on customer satisfaction which in turn is a direct result of precision installation carried out by qualified field construction forces who are part of an integrated multi-disciplined construction organization.

We have endeavored to develop a team approach working closely with owners and equipment manufacturers to ensure that the equipment will fit when it arrives and such matters as tolerances, centre line criteria, trial assembly and field installation techniques are known and understood in advance so as to minimize installation time and prevent problems before they occur. This allows commissioning and start-up to proceed smoothly and quickly brings the equipment "on line" for owner operation.

Our precision optical alignment group is well known and we routinely get requests to accept specialized assignments, such as problem solving, in the very early stages of project development.

Our equipment installation group uses a fully integrated computerized planning and scheduling system with schedules provided on a weekly basis (daily if needed) to all interested parties and has the full 24-hour support of:

• A computerized central tool crib with $10 Million of company owned equipment.
• A fully equipped 45,000+ square foot fabrication facility.
• Quality Assurance Group.
• A fully integrated field erection construction group.

Top

FIELD ERECTION

E. S. Fox Limited maintains an average of six to eight hundred workmen (has been as high as 2,000 during major projects) in field construction throughout Canada and in doing so deals with 98 different union locals. These forces are well experienced and equipped and include tradesmen of all industrial construction disciplines including:

Our field construction work is planned, scheduled, and monitored via a sophisticated computer management system developed by Fox over many years. Our clientele consisting of well known corporate names will attest to our field construction abilities as described below:

Top

MILLWRIGHTING & RIGGING

The millwrighting division specializes in the complete installation of new equipment and the relocation, modification and servicing of existing facilities for the heavy industrial, power, automotive, manufacturing and food processing industries.

Utilizing the latest precision instruments, our millwrights can work to the most demanding tolerance requirements, and have undertaken such diverse projects as the installation of 2,000 ton stamping presses for automotive plants; electric arc furnaces and vacuum degassers for steel mills; Banbury mixers and Calender presses for the rubber industry; an entire winery, from presses to bottling line; the installation of Oriented Strand Board facilities, involving over 200 individual pieces of equipment; a complete paper mill from log yard through to packaging and shipping of paper rolls; and the installation of 3 x 110 MW Gas Turbines, Steam turbine and balance of plant mechanical and electrical systems for a 550 MW Cogeneration Plant.

Our plant shutdown capabilities are universally acknowledged in the industry. Typically, we have undertaken the rehabilitation and modification of an entire paper machine and auxiliaries. Careful management of the project resulted in the 220-man crew successfully completing this assignment well within strict owner-imposed time and monetary parameters.

Top

INDUSTRIAL PROCESS PIPING

E.S. Fox Ltd. field crews have successfully completed a wide variety of new and plant shutdown assignments in chemical plants, refineries, smelters and industrial waste treatment complexes for the mining, pulp and paper, and food and beverage industries.

Our pipefitters are specialists, and excel in the cutting, welding and stringent cleaning and testing of the most sophisticated process piping. The Company's personnel are experienced in working with all materials including carbon steel, stainless, aluminum, titanium, nickel, copper, fiberglass, plastic and glass.

The E.S. Fox Ltd. industrial piping division has built up an enviable reputation for work of the highest calibre, which has made us an acknowledged leader in this specialized field. A broad range of past and present E.S. Fox Ltd. clients can attest to this expertise.

Top

PLUMBING

This division works in the traditional industrial, commercial and institutional fields, and has successfully completed such diverse projects as automotive, chemical, steel and metal processing plants; office, hotels and apartment buildings; universities and hospitals; correctional facilities; sewage and water treatment plants; and casinos.

With over 70 years of experience, E.S. Fox Ltd. is exceptionally strong in the plumbing field and has maintained its strong position in the industry through the successful completion of thousands of projects.

Top

ELECTRICAL

This E.S. Fox Ltd. division has undertaken complete electrical installations on major projects in the industrial, commercial, institutional and marine fields.

In the industrial sector, we have the resources and experience to design and install any phase of high and low voltage work; from power source, to secondary, to machine connection and commissioning. Our work has ranged from heavy power wiring for electric arc furnaces, to hazardous chemical plants, grain elevators and mines, to intricate electronic systems for metal rolling mills, automotive plants and OSB and paper mills.

Top

SHEET METAL & HVAC

In total, the E.S. Fox Ltd. branch operations throughout the province provide in excess of 20,000 sq. ft. of sheet metal fabrication space.

Each shop utilizes the latest equipment up-to-date fabrication techniques, thus providing our clients with a local contractor capable of fulfilling the most specialized shop and field sheet metal requirements. The fabrication and installation of dust collection systems, ovens, heavy industrial and high pressure duct systems, fermenters, sound suppression enclosures, pneumatic conveying and material handling systems, all reflect the broad scope of our abilities.

E.S. Fox Ltd. shops work in all materials, from galvanized sheet and carbon steel for industrial applications, to the highest quality stainless steel and copper requirements for the food and beverage industries.

Top

INSTRUMENTATION

Our instrumentation division is staffed with experienced technical specialists, capable of accomplishing the most complex tasks in all types of electronic and pneumatic control systems. Our experience extends from petro-chemical and power plants, steel and paper mills, to the food and drug industries.

The instrumentation and control aspects of projects complement, and are easily integrated with, the other strengths of E.S. Fox Ltd.

Clients receive highly individualized service, tailored to their diverse requirements.

Top

IRONWORKING

The erection of a pipe bridge, or structural steel work for a building; the rigging and setting of a 200 ton vessel; the construction of a calcium kiln; the erection of large electric reduction furnaces; these are indicative of the range of projects successfully undertaken by the E.S. Fox Ltd. ironworking division.

In conjunction with our engineering department and fabrication facilities, the Company's ironworkers form a highly experienced team with the resources and equipment to carry out all phases of construction, repair and modification work. In the case of an industrial plant, E.S. Fox Ltd. ironworkers can handle every aspect of construction, from the structure itself to the individual pieces of equipment it contains.

Top

BOILERMAKING

The expertise of the E.S. Fox Ltd. boilermaking division has been utilized by our clients in every area of this particular trade's jurisdiction.

Large storage tanks, complex dust collection systems, stacks and scrubbers, large diameter flues for oil refineries and high storage tanks are some of the installation activities successfully carried out by the Company's boilermakers.

The division's mobility, tools and equipment, engineering backup and fabrication facilities, make it a natural choice for both maintenance and new installation applications.

Top

REFRIGERATION

Our refrigeration division has undertaken assignments ranging from walk-in coolers for convenience stress, to complete ammonia systems for the food processing and beverage industries.

Working in conjunction with other E.S. Fox divisions for electrical and mechanical requirements, we design and install complete refrigeration systems for hotels, warehouses, sports arenas and process industries.

From drawing board to finished product, we have the unique ability to pre-fabricate custom refrigeration packages to our clients' specialized requirements.

Top

MAINTENANCE AND SERVICE

Our maintenance and service division provides E.S. Fox Ltd. clients with a single source solution, capable of providing either a totally comprehensive preventative maintenance and service program, or as-required, 24-hour emergency service.

Preventative maintenance programs are individually designed to the specific requirements of each client, be it a large or small industrial plant, or an institutional or commercial building. A systematic, qualified program of inspection and maintenance can minimize a client's problems before they force the expense and disruption of an emergency shutdown.

The Company's service division maintains a large fleet of service vehicles on 24-hour standby, 365 days a year. Each is a mobile service center, fully equipped with the finest diagnostic equipment and a large inventory of parts, enabling our service technicians to correct your emergency without delay.

Major areas of service include: process refrigeration, piping, instrumentation, heating, ventilating, air conditioning, plumbing, electrical and alarm systems, for the industrial, commercial, institutional and marine fields. This service is available throughout the province, simply by contacting any branch of E.S. Fox Ltd.

Top

FABRICATION

Our main facility in Port Robinson exceeds 45,000 square feet of production space dedicated to serving our clients with the highest possible quality standards in complex sheet metal, pipe, module and pressure vessel fabrication.

This facility is the epitome of the term "state of the art" and is readily accessible by road, rail and water. Our computerized business system encompasses estimating, planning, scheduling and quality assurance monitoring. We also feature computerized design and transmission of component shapes to NC machines such as punches and plasma plate burners. Most significantly, our experienced, dedicated workforce is well trained for this sophisticated environment ensuring precise components which facilitate assembly and produce products of superior quality.

E.S. Fox Ltd. boasts quality products in all materials, including mild and stainless steel, nickel, titanium, inconel, chrome-moly, aluminum and clad, varying in thickness from gauge to multiple inches. Product design codes include ASME B31.1, B31.3, B31.5 & Z305.1, ASME Section I, S & PP, ASME Section VIII, Division I, U & R, and ASME Section III, Division I,2,3,4 & 6, A.P.I. 620, 650 & 653. Our reputation is envied in everything from the fabrication of aluminum specialty products to the exacting tolerances we achieve. Our overall welding expertise, exemplified by keyhole plasma welding for instance, allows us to provide a unique service to clients who require fabricated products of extreme quality and precision.

Our finely tuned Quality Assurance Program, (approved to the standards of ISO 9001-2000, CSAZ299.2, 3, 4), in combination with the continuous upgrading of equipment and personnel skills, ensures our clients of the highest quality product available. In this way, E.S. Fox Ltd. continues to remain a leader in the field of plate and pressure vessel fabrication.

All modes of transportation are available as our Port Robinson facility has ready access to road, rail, air and water for finished products.

Nearby docking facilities on the Welland Canal are accessible to ships and seagoing vessels for shipment of equipment that is too large for road or rail transport, or for products destined for overseas. Fox has utilized water shipment to transport both oversized (25' dia. X 80' long) vessels and overweight (325 ton) shop fabricated units.

Top

PIPE FABRICATION

Our main pipe fabrication shops, located in Port Robinson and Kingston are equipped for the fabrication and testing of pipe of any size or material.

The unique feature that separates E.S. Fox Ltd. from other pipe shops, is our ability to "fabricate" pipe from sheet steel, in conjunction with our plate shop. Utilizing a variety of ASME welding procedures, we fabricate ASME approved pipe to customer's specifications and every piece carries a UA label, signifying it is union made.

Our experience has included the fabrication of bustle piping for blast furnaces and coke ovens, oxygen distillation modules, deaerator systems, chlorine dioxide modules, and piping systems for a broad range of other process and heavy industrial application. In addition we have fabrication shops at each of our other five locations, which handle small diameter pipe work for local markets.

Top

MODULAR FABRICATION

Modular fabrication is another of the highly specialized fields in which E.S. Fox Ltd. consolidates and utilizes its wealth of in-house expertise. Structural frame fabrication, piping, pressure vessels, equipment setting, electrical systems, instrumentation and testing are but a few of the fields in which we draw on proven strengths to create high quality, finished products.

We at E.S. Fox Ltd. have, with great success, completed a variety of modular contracts for delivery throughout the world. Among these are modules used for:

• air liquefaction/separation
• hydrogen purification
• chlorine dioxide
• merox
• catalyst reclamation
• oil/water purification
• ammonia
• freon
• food quality starch
• cryogenic air distillation columns for oxygen, nitrogen and argon
• process modules demanding stringent "clean room" conditions.

For instance, E.S. Fox regularly manufactures Cryogenic Cold Boxes for air separation plants. These plants operate at temperatures beyond 200F° below zero; aluminum and stainless steel are used for vessels, piping and instrumentation systems. Special materials, highly specialized welding techniques, documented quality control, and meticulous attention to detail are mandatory since the units cannot be maintained or repaired while operating.

E.S. Fox has demonstrated, time and time again throughout our many years of modular experience, the expertise to maintain maximum high quality standards. These proven standards are considered an absolute prerequisite for the successful fabrication of modular units.

Top

WELDING

E. S. Fox Limited has over 450 welding procedures registered with the T.S.S.A and over 80 registered with CWB. Our experience includes the use of the following materials:

Equipment Includes:

Top

QUALITY ASSURANCE

Every discipline within field construction and fabrication groups are fully versed with our quality assurance systems which meet C.S.A. (Canadian Standards Association) and A.S.M.E. (American Society of Mechanical Engineering) standards for vessels, pipe, modular and equipment fabrication. Our Quality Assurance system, appropriate manuals and our employees are continually being updated with the latest enhancements.

Work is regularly carried out under the following codes:

1. A.S.M.E. Section I and Section VIII, Division I, "S", "U", "R" & "PP" Shop & Field
2. C.S.A. N285.0 Class 1, 2, 3, 4, 6 Components and Parts and Supports Shop & Field ASME Section III Div I (Nuclear)
3. C.S.A. N285 Nuclear Metallic and Non-Metallic Material Supplier
4. C.S.A. B51-M1998 ASME Section I and VIII Shop & Field
5. A.S.M.E. B31.1, B31.3, B31.5 and Z305.1 (Certified by TSSA)
6. ISO 9001 - 2000 Edition
7. Canadian Welding Bureau (CWB) Certified W47.1 and W47.2
8. A.P.I. 620 and 650 & 653 (American Petroleum Institute)
9. C.S.A. Z299.2 1985 (Canadian Standards Association)
10. C.S.A. Z299.3 1985 (Canadian Standards Association)
11. C.S.A. Z299.4 1985 (Canadian Standards Association)

Top

ENGINEERING

Our in-house engineering and drafting staff are well versed in designing in accordance with a variety of standards including American Society of Mechanical Engineering (A.S.M.E.), American Petroleum Institute (A.P.I.), Canadian Welding Bureau (C.W.B.) and Underwriters Laboratory (U.L.), pressure vessels, storage vessels, piping systems, process modules, and heavy equipment.

MANAGEMENT

E. S. Fox Limited is totally committed to planning, scheduling and monitoring techniques which ensure adherence to scheduled completion dates. Our computer based management system incorporates all aspects of a properly run construction and fabrication facility including estimating, purchasing, monitoring, inventory, manufacturing and capacity planning.

Top

COMPUTER CONTROL

Computer Control consists of Sun X4200 complete with software for all functions such as accounting, estimating, purchasing, project monitoring, planning, scheduling, inventory and production. The computer is programmed and operated by our internal Computer Department utilizing the "data base" principle, a concept that has been developed especially for construction and fabrication by our computer technicians. The data base concept simply means that all information is stored in one large file, all linked together in such a manner that the information can be easily and simply retrieved in any desired format.

This system, coupled with our internal programming capability readily lends itself to program modifications and improvements, thus allowing us to keep pace with the complexity of the modern construction environment. Our system is flexible enough so that we can often adapt one or several of our reports to include for a specific customer requirement.

Each project is controlled and monitored by a number of reports issued weekly thus ensuring that we know exactly where we are, and where we are headed, on each individual project.

Top

PLANNING/SCHEDULING

We, at E.S. Fox Ltd. consider ourselves leaders in the application of computers to the construction and fabrication industries. Our desire for the greatest possible control over our projects, and the simple need to "know where we are", prompted us to be one of the first construction companies in Canada to purchase a mainframe computer over 35 years ago. Since no prepared programs were available in those days we were forced to create our own. We designed totally integrated software for everything from payroll to receivable and most importantly, programs to keep our projects on schedule and this meet commitments made to our clients.

Over the years, new generations of computers have evolved which can perform tasks once considered unthinkable. Our progress at conceiving, writing and perfecting computer-driven systems to manage our construction business has matched the evolution of computers. We have regularly traded and upgraded our computer hardware for the newest technology available and several programmers are always working to make our systems better and simpler, in other words, "user friendly" and more productive. The nature and diligence of this endeavour over many years must be unique among our competitors and must provide a superior service of our clients.

Hence, we have become a "21st Century Fox" with well-honed systems driven by powerful computers, executing vastly complex programs, making it easy to properly manage our company and its projects with the utmost confidence. Of equal importance are the many years of experience our management, from foremen on up, have with these systems. It is impossible to purchase an integrated company-wide computer system so well suited to our type of business and even if it were possible, it would take years of personnel training to implement. We at E.S. Fox Ltd. are far ahead in this respect and intend to remain so for the benefit of our clients.

Considering the nature of our business and its inherent complexities, our most basic need centres around project control.

In order to achieve this control, all projects are planned, scheduled and monitored from inception through to completion using state of the art computers to drive a scheduling system that work and is integrated with every other aspect of our business from purchasing to payroll.

Our planning methods, in part, demand that a project be broken into small, manageable components of work called "PHASES" and that a quantity of manhours be assigned to each phase. Manpower scheduling is accomplished by assigning a start date and completion date for each phase. From this basic concept of the project and our weekly payroll data, we obtain timely information incorporating both a precise history and a reliable forecast of the project. The available information includes:

• Schedules
• Manhour Requirements
• Manhour Efficiency Analysis
• Manhour Forecast
• Percent Complete Curves
• Material Costs

All of the data is automatically coalesced with regard to calendar, manhours, materials and cost. The system features a "locked-in" original schedule to compare with actual progress, as well as manual and automatic forecasting of future endeavours.

Although considerable information is readily available for a detailed, in-depth study of the many different aspects of a project, only a small portion is used on a regular basis to provide effective project control.

Through the use of these computerized systems, we are able to instantly "see" every aspect of every job at all times. Manpower can be added or removed from any phase of a project, scheduling or rescheduling can be accomplished long before "problems" occur, and thus total control is maintained. In this way, projects are completed on time and within the specified budgets. We at E.S. Fox Ltd. are proud of our leadership role within a highly complex industry and plan to maintain this lead, not by leaps and bounds but by light years.

The BARCHART incorporates features such as:

• Original schedule locked in for future reference.
• Automatic forecast adjustments for:
  
  • early starts
  • late starts
  • sequenced phases
• Manual forecast adjustments.
• % Complete by phase.
• Automatic phase sorting by start date.
• Reasons for early or late start.
• Available on a weekly or daily basis.
• Automatically co-ordinated with manpower level report.
• Customer supplied material & equipment can be scheduled.
• Available in 5 separate levels.

The MANPOWER LEVEL incorporates features such as:

• Original schedule "locked in" for future reference.
• Automatic forecast adjustments.
• Available on a weekly or daily basis.
• Manual forecast adjustments.
• Instant identification of manpower requirements.
• Automatically coordinated with barchart report.
• Available in 5 separate levels.

The HOURS REPORT incorporates features such as:

• An accurate forecast of where the project is headed.
• Total hours available by phase.
• Total hours used by phase.
• Available hours to complete the project.
• Description of each phase.
• Identification of all changes to original contract.
• Consolidation of work remaining by removing completed phases.
• Accounts for all T&M hours.
• Available on a weekly or daily basis.

Top

THE FUTURE

E.S. Fox Ltd. intends to continue enhancing its management techniques while forging ahead in the development of new markets as well as modern production methods which must necessarily include new processes, modern numerically controlled machinery, computer aided design techniques as well as new standards of quality assurance. We have been leaders in these aspects both in construction and fabrication and will continue to be. The company was established and has grown on these principles and has benefited from these core beliefs. Continual review and improvement of these management techniques will bring continued success.

Top