The schedule for the Kemi bioproduct mill challenged the builders – DC Works doubled the number of workers and completed the instrumentation and automation installations on time

Metsä Fibre’s bioproduct mill in Kemi is the most efficient wood processing plant in the northern hemisphere and one of Finland’s most significant industrial projects in recent years. It manufactures pulp and other bioproducts and produces renewable electricity for the national grid. The energy, material, and environmental efficiency of this modern bioproduct mill are world-class, and its complex processes operate entirely without fossil fuels. The mill started up in September 2023.

DC Works, which specialises in challenging industrial installations, worked at more than ten facilities, seven of which the company carried out all automation and instrumentation installations.

“The collaboration worked well from the outset. DC Works’ experts familiarised themselves thoroughly with the site and took responsibility. They also took safety issues seriously,” says Markku Savolainen, Project Manager at Metsä Fiber.

Plans were flexible at critical moments

In some facilities, the work schedule changed radically. This required flexibility and the ability to modify plans quickly from our partners, as every delay and mistake carried a high risk of compounding problems.

“DC Works adapted very well to the changing schedules of the project. For example, they were able to allocate the right people to the right place at the right time. On the other hand, when they had less work agreed with them, DC Works employees helped other contractors,” Savolainen praises.

When the automation and instrumentation installations got underway in earnest, more workers than planned were needed on site. In practice, DC Works’ work was carried out by 55 men in the final stage instead of the planned 30, sometimes working up to 84 hours a week.

“We managed to catch up on the schedule delays caused by previous work types by adjusting the schedules of our other projects to free up staff. We have agreed on working conditions with our experts in a local agreement, which allows for overtime work. In addition, we have an extensive network of partners and subcontractors,” says Marko Husu, CEO of DC Works.

In the plants where work started the latest, the work plan had to be changed and most of the work had to be done in three months.

“Our management reviewed the plans and identified the tasks that were critical for the completion and start-up of the entire plant. In the end, we completed our part of the project on schedule. Since the plant started up, we have been doing follow-up work in other areas and small maintenance projects,” says Husu.

Open communication ensured success

Savolainen from Metsä Fiber considers open and regular communication with DC Works to be important for the success of the project. Matters were taken forward in a spirit of cooperation, and neither side shied away from difficult topics in their discussions.

“At DC Works, the quality of work and commitment were spot on. They genuinely wanted to succeed and get things done, and they listened to how we saw the situation,” Savolainen says.

Participating in and succeeding in a giant construction project requires contractors to have foresight and be prepared to take on significant risks. Marko Husu sees winning the contract as a major vote of confidence from a large forestry company in a small business.

“Previously, we have focused on data centers and oil refineries, but our new venture into the forest industry has been a success. We can only express our gratitude for the trust placed in us,” Husu says.