Here at Marathon Electric we are proud to have great owners and managers that enable us and challenge us to use our minds and abilities to think "outside of the box". Thus we have something no other electrical contractor in our region has; a Prefab Shop.
In our Prefab Shop we are diverse with projects we take on and this lets us support our jobsites with many different ways to help them save labor, time and money. This also forces us to do much more up front concerning planning and scheduling which also helps our jobsites in the long run.
Here is a list of some of our services offered to our jobsites:
Temporary Power Systems
* * Trailer Mounted Services 480 volt 3 phase 800 Amp with 225A (75 KVA) Transformer and panel for powering job trailers, equipment, temp. 120 Volt outlets etc. Trailers have outriggers for securing. Also some 3 phase 208/120 volt units some trailers are 800 Amp, some 400, some 1200Amp.
* * Power Distribution Unit (PDU’s)
This is a 480 volt 3 phase 75 KVA transformer with a main line power (feed) disconnect which is 100 Amp 3 phase. It is mounted on an angle iron frame with castors and shackles for lifting with a crane or forklift. The transformer feeds a 3 phase 225 Amp 208/120 volt load center which has 4 circuits (16 outlets) of GFI power, 4-20A circuits of lighting power, 1-30 A/2 pole circuit for concrete saws etc., and 3-50 A 2 pole pigtail with twist-lock end caps for feeding power to up to 6 soldiers (temp. power stands) They also have spare circuits.
* * Temporary Power Stands (Soldiers)
These units are stand mounted 125 Amp single phase 208/120 volts load centers with 4 circuits (16 outlets) of GFT power for personnel, 4-20A non GFI lighting circuits, 1-30 A/2 pole circuit for concrete saw etc. They have 50 Amp 6-4 pigtail cords with twist lock end caps to provide a plug in feed and a feed for another soldier downstream. They also have spare circuits.
* * 50 Amp 6-4 so type cords to tie between PDU units and soldiers and from soldier to soldier. We sometimes provide these cords with only one end cap so you can tie one end into a panel existing on site or other applications. These cords have 50 Amp twist lock end caps. The standard lengths are 25’ 50’ or 100’ but other lengths are available.
* * Notes on temporary equipment
1. All equipment is 3R (Raintite) so it can be used anywhere indoors or outdoors.
2. All PDU’s and soldiers are provided with GFI check list sheets inside weatherproof box with 6
months ( 24 weekly) of cards in each unit so you can have a record to provide OSHA upon request.
We provide offsets, 90s”, kicks or any degree bend required in EMT, IMC, or Rigid pipe from 1-1/4” to 4”. These bends will be done in a timely fashion and done correctly the first time.
We custom make rigid nipples any size from ½’ through 4’ especially the odd lengths they don’t sell at the supply houses.
We cut and thread 3/8” fixture stems that need modification from factory lengths.
We cut any quantity or length of strut or other metal items quickly with our cold cut metal cutting saw that provides a square cut and is 10 times faster than a band saw.
We preassemble trapeze hangers to width required complete with all rods and hardware you will need.
We cut to desired length pipe sleeves to go in concrete pours. These can be any diameter and length and recently we had a request for some 5’ inside diameter sleeves that had to be made for rigid steel and we found some pipe that fit the requirements for 1/3 the price of rigid conduit. We also can make these of PVC if it is acceptable for the jobsite.
Telephone and Equipment Backboards
We provide backboards painted with 2 coats of fire retardant paint or we have had to provide fire treated plywood painted with normal latex paint. We will cut to special sizes if needed.
Transformer and Generator Pads
We will build the wooden forms to any size you need from 4’ thick to 2’ or more if required. These will include the leave outs in the middle for line and load side conduits. They also will have chamfered edges if required. We also tie the steel mats to go in the concrete pour and provide the ground loop of copper wire tied to the mat to specification.
The Fab Shop will make your pole base complete where all you need is a hole in the ground and some concrete. These bases have the steel rebar cage tied to drawing specifications with the sonotube form cut to length required and attached to the rebar cage as one unit. The sonotube will have a 45 degree chamfered edge on the inside lip so that no grinding is required after the pour. We also install the ground wire that will bond the pole to the ground rod. The last thing is we provide a wooden template to sit on top of the sonotube that centers and holds the anchor bolts in the correct bolt circle pattern. We also set the projection of the anchor bolts so you don’t have to measure each one on the jobsite.
Panel Prefab with Homeruns
We can prewire panels such as one going into a condo unit or motel room etc. That will have all the home run cables cut to desired lengths and rolled up above the panel and labeled to be ready to roll out and route to the specific circuit or piece of equipment. The entire panel will be wired up and the only thing needed will be the feeders to be tied in. We also install metal track on the sides of the panel that will fit over the studs and screw off to the stud for easy installation. A cardboard temporary cover is installed over the face of the panel for protection during construction.
Panel board Prefab for Electrical Rooms
We can prewire multi-section panel boards with all of the interconnecting wiring installed between sections. We also can prewire all circuit breakers to a gutter mounted above or below the panels with a terminal strip for connecting all the hot wires; full size neutrals without double lugging; and ground bars, and even isolated ground bars if required. This unit will be mounted on a unistrut frame ready to bolt to the wall or structure and on a temporary frame with castors to facilitate transporting from the delivery truck to desired location in the building. We also prewire 480 volt panels or disconnects feeding a transformer with all the interconnecting wiring installed. We provide all lugs installed, a ground bar for grounding terminations, and the neutral bonded. This unit is also mounted on a frame with castors for transporting all covers are on panels with labels and circuit directories provided. The benefits of the gutter includes being able to turn off the circuit breakers to terminate circuits and thus No PPE special equipment is required because you aren’t working on a live panel.
In Wall Rough In
We will review blueprints with the P.M. and job foreman to determine what extent of the wall rough in we can do then sometimes rework circuitry to make it more user friendly to install. Then after getting measurements from the field we cut m/c cables to length to go between outlets or fixtures. They are labeled and color coded along with circuits on the drawings to make installation easy. Each room or circuit is boxed up separately and delivered to jobsite when needed. The outlet boxes will have all mounting brackets attached with the devices already installed and a temporary metal cover attached to the device where the sheetrock can be hung over it. We also do the lighting circuits. Everything needed to rough in each room is there with no searching the jobsite for pieces and parts. We can take it one step further and prebox all covers fixtures etc. needed for trim out.
Box Assembly for in Wall
Some jobs may only want the outlet boxes assembled with mounting brackets, plaster rings and ground stinger installed. This will work for a conduit job.
Box Assembly for Masonry Walls
These boxes can be put together with short conduit nipples attached with a coupling already on each piece of pipe. Then we will cut sections of conduit and bundle together to use to extend conduit up to top of wall as required. Boxes will be duct taped up to keep mortar and concrete out.
We can precut the conduit (rigid or EMT) to length required to go between the light mounting boxes, have wires already in the conduit lengths with boxes mounted on one end and push in wire connectors installed ready to accept the wires in the next section. Ground stingers will also be installed inside of boxes. These conduits will be bundled by rows or circuits whichever is required.
Exit Light Assembly
Recently we had a job that had 125 exit lights that needed ½” pipe stems painted white and cut to 27” long. We made the stems painted them then assembled the exit light together with a cover on the end of the stem to mount to an outlet box in the ceiling. The unit was pre-wired with 3 wires protruding out of the stem with push in wire connectors attached for quick installation.
Last year we had 150-1500 watt sports lighters that needed to be installed at a High School stadium under a very tight time schedule. We were able to meet this deadline by bringing the catwalks to the shop and mounting the lights to them and pre-wiring all the lights along with a panel on the middle catwalk feeding all the lights. We provided a conduit cut to correct length and bent to fit between catwalks. Then we had all wiring boxed up with all required hardware so when they got to the job site all that was required was for the catwalk to be bolted to the pole and tied together with one conduit and the feeder tied into the panel. Cut on the lights and have a ball game.
Precut Wire Lengths
We have been cutting wire to length required and re-spooling 3 phases onto 1 reel with dividers for easy setup and quick wire pulling. Most of this wire was obtained from the warehouse left over from other jobs. We are doing this manually now but hope to get a machine for this to re-spool from spool to spool and from spool to a coil if the length is not too long.