Custom Fabrication

Custom Fabrication

Gemini can bring your custom projects to life, utilizing our large welding bays and talented staff to minimize your risk on any product.

  • Shop fabrication of any custom spooling, modifications, maintenance
  • Shop fabrication of any custom site steel structures and support

Community

Community

Gemini Values

"We'd like to share our gratitude for the continued support we receive from our Ponoka community."

Gemini does more than manufacturing steel products for the oil & gas industry. We create jobs and opportunities for the surrounding communities in Alberta. But our economic contribution would not be possible without the continued support of the town of Ponoka. We are proud to be members of this community, and we do anything we can to give back. 

Ways Gemini takes part or gives back to our communty 

 

  • Ponoka Stampede- Sponsor

  • Ponoka Hockey Team – Donor

  • Ponoka Hockey Rink - Sponsor

  • Central Alberta Minor Hockey Association - Sponsor/Coach

  • Central Alberta Minor Baseball Association - Sponsor/Coach

  • Calgary Stampede - Sponsor

  • In From the Cold - Volunteer

To seek Gemini sponsorships or community activities please contact our team.

Quality

Quality

Gemini Values

Quality is Ingrained in our DNA

Gemini upholds a reputation for exemplary emphasis on quality. We apply an unparalleled attention to detail, which allows us to consistently deliver products you can trust and display with pride. We achieve this through our buttom up approach to quality assurance, and thorough employee training programs. This level of quality is a company wide shared value that is ingrained in the DNA of every employee. 


Gemini Certifications:

Facility

Facility

About Gemini

Module Fabrication Capabilities

Gemini Fabrication has a strong reputation for providing high quality fabrication services to the Western Canadian Energy Industry. Our fabrication facility, located in Ponoka, AB, is equipped with the following abilities: wellpads, fabrication & assembly of modules, MCC buildings, pipe racks, meter skids, pipe spools, pump houses, and utility packages among others. Gemini Fabrication's integrated approach allows for the ability to self-perform almost all aspects of the build in-house. This vertical integration allows for schedule and cost certainty other facilities cannot offer due to their high level of subcontract activities. All module fabrication and assembly activities take place at Gemini Fabrication's Ponoka Facility. Gemini Fabrication is situated on the Alberta Highline Corridor and has no restrictions with module size and weight.

Download More information about the High Load Corridor

Total Area:

Laydown Area:

Shop Area:

Indoor storage:

Area under roof:

Painting facility:

54 Acres

15 Acres

18,400 sqft

9,200 sqft

25,400 sqft

12,000 sqft

Our shop offers complete flexibility and capability with 97 different weld procedures including carbon steel, stainless steel, inconel, hastelloy, high nickel, chrome-moly, monel, and other exotics. Duplex and Super duplex.

Currently, we have sufficient available space to house up to 50 standing, full sized Alberta modules, at various stages of completion. 

Capacity:

Modules:

Spooling:

Average Welding:

Repair Rate:

150 units/year

12,500 FDI/wk/shift

10 FDI/Man /HR

<1.00%

Pipe fabrication is housed within our 18,400 sq ft shop. This space can be increased by adding up to an additional 24 outdoor stations. Our average welding productivity is 100 FDI/day/welder or 10/FDI per hour, and our repair rate is < 1% on a rolling 12 month basis.

Pipe Fabrication

Gemini produces 100 FDI/welder at <1% repair rate

This allows for an intimate understanding of both the trade and code requirements governing our work. Our Quality department prides itself on working collaboratively with our client’s inspectors in a joint effort toward a successful project.

Gemini has 97 weld procedures, including: carbon steel, stainless steel, inconel, hastelloy, high nickel, chrome-moly, monel, and other exotics. We are one of the only fabricators capable of this type of technically challenging alloy welding. We can utilize stick, sub-arc, flux-core, STT and TIG welding processes.

Gemini Fabrication employs a rigorous Quality Management System (QMS) for all fabrication activities. Our QMS is approved for regional jurisdictions, including Alberta (ABSA), British Columbia (BCSA), and the CWB, Saskatchewan (TSAK) the National Board of Boiler and Pressure Vessel Inspectors and the American Society of Mechanical Engineers (ASME). Project-specific Quality Management Plans are established at time of award to identify the project specific requirements based on scope of supply. Our Quality Team of Inspectors are Certified in accordance with CSA W178.2 as Level I or Level II, and composed primarily of Red Seal Journeymen, who have attained other industry certifications (API 510/570).

Safety

Safety

About Gemini

Health, Safety, Security, and Environment

One of Gemini Fabrication’s core values is “We have an unwavering commitment to our industry leading safety program and the security it provides.” Gemini recognizes that all workers have the right to work in a safe and healthy work environment.

We believe in safeguarding our employees and the communities where we live and work. Our policies, procedures, and programs are designed to secure the health and safety of our employees and minimize harm to the environment.

Gemini Safety Principals

  • We believe that all incidents are preventable, and our goal is to be a leader in our industry.

  • We are committed to supporting our employees with programs that will ensure their safety and minimize harm to the environment.

  • The well-being of our people begins with our employees and this safety culture is embedded throughout our entire organization.

  • Our success is measured by how well we manage the health, safety, and security of our employees and the integrity of the environment.

Gemini is strongly committed to providing excellent service without compromising the health, safety, and security of staff, clients, suppliers, or the general public. Our policies and practices, along with client requirements, are an integral part of how we conduct our business.

Gemini Safety Credentials

Mobile Services

Mobile Services

Gemini Fabrication is there when you need us. Our mobile service can help bring products to life and increase value when you need it. 

Mobile Field Crews:

  • Field maintenance
  • New installation
  • Insulation - Soft cover supply and install
  • Stainless steel cladding

Electrical and Instrumentation

Gemini offers value to our clients and their complex projects that require advanced electrical and instrumentation support. Our goal is to have the customers trust built through our project execution. We strive for excellence by consistently training and educating our staff and building a safe company culture

Function testing

EHT on area piping

Custom site cable tray supply

 

Insulation

Insulation on the move. Our insulation capabilities are mobile, and we can assit with all aspects of the insulation trade, specializing in heat conservation, Personnel protection, cold work, cryogenic, new construction, facilities maintenance, module fabrication, insulated removable blankets, utilidor boxes and buildings, vessels and towers. 

Painting

Paint & Coat

Utilizing our 13,00 sq. FT dual pay paint and blast facility Gemini is able to provide our clients with quality external coating. We provide a cost effective, safe and efficient paint service to ensure client budgets and schedules are maintained.

Specializations:

  • Commercial and external blasting and coating of fabricated pipe and steel
  • NACE inspection
  • Qualified and experienced personnel
1-paint-123

Insulation

Insulation

Gemini Fabrication, Insulation division’s goal, is to maintain customer satisfaction, by providing quality thermal insulation, in a safe and efficient manner. Drawing from a wealth of experience. Our team is driven by safety minded individuals, who take pride in executing work to the highest standards, specific to client needs and specifications. We are capable of providing professional, courteous service in any work environment, from small remote wellhead locations, compressor stations, to large industrial facilities. With a strong focus on module pipe systems, at our facility in Ponoka, Alberta.

Condensation control - we use Foam Glass insulation, which is designed to wick moisture away from the pipe we can eliminate the formation of condensation on pipework and avoid the potential for corrosion 

Heat conservation – Insulation used together with a heat medium, such as Electrical or Glycol tracing will protect critical systems from freezing and allow the piped commodity to operate with optimal viscosity.

Cryogenic/cold work- insulation can be applied to maintain temperatures as low as -163 c

Noise controls – insulation can prevent noise transfer by acting to damp the pipe wall 

Personnel Protection - pipe insulation can be used to bring surface touch temperatures into a safe range.

Materials Gemini Fabrication uses:

  • Mineral Wool
  • Calcium Silicate
  • Foam Glass
  • Aluminum cladding
  • Stainless steel cladding

We are fully capable of assisting is all aspects of the insulation trade, specializing in heat conservation, Personnel protection, cold work, cryogenic, new construction, facilities maintenance, module fabrication, insulated removable blankets, utilidor boxes and buildings, vessels and towers. Anything between the fences that you need kept warm or cold we can do it all.

Electrical & Instrumentation

Electrical & Instrumentation

Gemini offers value to our clients and their complex projects that require advanced electrical and instrumentation support. Our goal is to have the customers trust built through our project execution. We strive for excellence by consistently training and educating our staff on the most up to date industry practices, while never sacrificing safety or quality. 

Specializations:

  • Function testing
  • EHT on area piping
  • Custom site cable tray supply

Utility Packages

Utility Packages