The reconstruction presented significant technical challenges. The original roof structure, designed as a single-span wood truss system, could not be replicated using the same materials while meeting current structural safety factors for the 26m (85-foot) span.

A revised structural approach was developed through collaboration between the structural engineers and N53 Architecture. The final design incorporated a large steel truss, supported by strategically placed columns and beams, which reduced the span of the wood trusses. This solution maintained the required overhead clearance for the bridge crane to remain operational and unobstructed.

During the course of the design process, the project team identified several significant Building Code non-conformances in the original building. Despite being constructed within the last decade, the building exceeded the maximum allowable size for a non-sprinklered structure. Additionally, exiting provisions were inadequate, poorly located, or absent, and numerous required fire separations and ratings were missing. Several mezzanines had also been constructed contrary to Code requirements.

Given the rural location of the facility and the absence of a municipal water supply, installing a sprinkler system was not feasible. To address this, the reconstruction included the conversion of the existing insulated concrete form (ICF) perimeter walls around the main shop areas into firewalls, providing the necessary fire-resistance ratings for compliance. A redesign to provide proper exiting and extensive upgrade of fire ratings was also implemented.

This project required a coordinated approach to resolve both the structural rebuilding and the life safety deficiencies identified during the design process.