From the Ground Up:

How HC Matcon brings
Value Through Innovation

Integrating streamlined operations greatly strengthens the firm’s project’s foundations, ensuring a rock-solid start to finish.

Since its founding in 2001, HC Matcon has carved out a distinguished identity as a specialized shoring and deep foundation and ground improvement contractor. With a substantial portfolio that includes monitoring and design services to TTC, Metrolinx, and many leading real estate developers, HC Matcon has become synonymous with providing full Design-Build shoring, deep foundation, ground improvement, and bespoke foundation solutions across Canada. Executive Vice President Ken Clark and Project Manager Dawson Ham join us to discuss HCM’s Design-Build approach, and the firm’s use of innovation technologies that enhances project execution.

BC: How does HCM define an efficient design, and what factors contribute to achieving this efficiency in your projects?

Dawson Ham:  At HCM, the way that we’re most eco-friendly is through our efficient designs and the way to achieve that is combining best engineering practices with real life experience.  We envision a design that is optimized, and not over-designed.  We are aware of what is needed on site as opposed to what is simply shown on paper – if we see designs coming in from other companies that have certain steel sections that are too heavy, or concrete strengths that may not be required in that application, we can redefine and optimize these plans while keeping everyone safe.

Ken Clark: What we see often are designs that are very conservative, whether they’re from young engineers or just people taking conservative approaches.  Since we’re closer to the pulse of the project, we look for the opportunities where we can create efficiencies with design, and reduce our carbon footprint while still observing all safety requirements. 

BC: What advantages does HCM’s Design-Build approach offer clients in terms of cost efficiency, schedule adherence, and quality that align with each project’s unique requirements?

Ken Clark: We look at all projects through a holistic lens. Even though we are the shoring and foundation guy, we review the entire super structure, make reviews and recommendations based on what type of loading is going to applied to the soils and foundations.

Dawson Ham: I think it’s important to understand what’s best for the project isn’t always best for a single scope, so we try to approach project design and execution with consideration of downstream scopes because there’s schedule savings to be had all along the way. We have a decent understanding of what happens for the trades that follow us, and we try to augment our design and execution accordingly that allows overlap and continuity of work.

BC: What is it that separates HC Matcon shoring techniques from others?

Ken Clark: A big advantage at HCM is what we bring to the table, and what we can deliver to clients. We’re well versed in many shoring and deep foundation systems; whereas, our competitors focus only on a limited selection.  HC Matcon was one of the first companies in Ontario to implement shotcrete shoring with results that match the performance of caisson wall systems next to buildings.

Dawson Ham: Our design advantage is important in distinguishing HCM from our competitors. Through our design advantage we were awarded the NextStar electric vehicle battery plant in Windsor which is a joint venture between LG Energy Solution and Stellantis. We redesigned the foundations completely, steering it from caissons to driven piles and because of the size of that project we had to rapidly tool up our fleet for schedule adherence and the size of the scope.

Ken Clark: We design and construct a wide range of deep foundation systems, including driven piles, caissons, micropiles, and helical piles. This versatility gives us a distinct advantage over competitors who specialize in only one or two methods. We often develop hybrid foundation solutions that combine multiple systems to deliver the most efficient and cost-effective results. Complementing this, a growing area of focus for us is ground improvement systems. Leveraging our extensive experience with deep foundations, we’ve successfully expanded our offerings to include increasing the existing soil bearing capacity. With several proven methodologies available, we’re well-versed in selecting and implementing the most effective approach for each unique site condition.

BC: Are there any methods of construction that possession of new technology has enabled you to undertake?

Dawson Ham: A project that comes to mind that pertains to new tech would be in the form of a technique as opposed to technology. In Ontario, and Canada, our current paradigm of infrastructure is onerous, slow, and negatively effects the commuter that the project is ultimately being built to serve.  We are always looking for ways that we can contribute to the commuters through construction without impacting their current experience. An example of this would be our contributions to the Port Credit Go Station.

HCM worked alongside the Mobilinx team at the Port Credit GO Station project to complete the design and installation of shoring for a 14m deep excavation, as well tied-back anchors for a thrust block system. This was the first time that a push-box was used in Ontario to complete the construction of a tunnel under existing rail lines. This approach minimized disruption to active railway traffic and of the four rail lines.

Building Partners

BC:  What projects would you like to highlight? What purpose do they serve the community? 

Dawson Ham: We execute so many unique projects that serve Canadians in all aspects of their lives. One of which was the shotcrete rehabilitation that we performed on the Gardiner Expressway. We shot in excess of 70m3 of dry-mix shotcrete placed over 135 patch locations on the existing bridge elements while the highway was in service. 

Dawson Ham: HCM not only gives extended life to existing infrastructure, but we also investigate and contribute to crucial traffic arteries that are yet to be built and are in design phases. One case of this was the deep foundation load tests for the twinning QEW Garden City Skyway that HCM performed. The Garden City Skyway is a critical transportation corridor connecting St. Catharines and Niagara-on-the-Lake. Our scope at this site included the deep foundations testing program, QVE & instrumentation, installation on execution, site soil stratigraphy, load testing results both axial and lateral capacity were tested.

Ken Clark: Another project that we did to contribute to critical infrastructure in Canada was for a new sewage pumping station in Kitchener, Ontario. We used sheet piles for the shoring to manage water infiltration. The sheet piles were supported by one level of bracing which consisted of face walers and struts. The design we employed allowed the construction manager to sequence the pour breaks of the structure, which in turn allowed for the removal of bracing as foundation walls were constructed to eliminate formwork boxouts. The pumping station needed to be watertight, and formwork boxouts were problematic.

Dawson Ham: At a time when there hasn’t been that much private investment in Ontario and we’re seeing a lot of that coming back with what seems to be this new wave of EV plants.  We’re actively trying to pursue some investments like a synthetic graphite production facility in St. Thomas and Volkswagen’s Power Co facility in St. Thomas, which is on track to become Canada’s largest electric vehicle (EV) battery plant.