More and more industrial builders choose to rely on their electrical contractor for total design/build responsibility. General contractors, construction managers and owners prefer dealing with one supplier for both electrical design and construction because they have greater input and control. And they like the convenience of one contractor having total responsibility so it takes just one call to complete your project.
As a design/build electrical contractor, we like being able to provide the maximum impact on electrical system quality, efficiency and economy. So we continue to develop our staff of engineers, designers and technicians, and the CAD systems that facilitate design/build work.
The systems and components we design can include power, lighting, automation, low voltage controls, fire alarm, telephone, and data systems, depending on the specific job. When we're satisfied with the initial design our job foreman meets with the designer to provide field input. The result is a more efficient, economical way to accomplish the intent of the design, and reduces the number of changes needed during construction. The result is the most economical solution that meets the owners needs.
MetalTek Greatly Speeds Production with High-Tech Addition to Investment Foundry
MetalTek Investcast Division has built an addition to its Watertown investment foundry featuring a large and unique robotic system producing ceramic shells (molds). The shells are now produced in 24 hours as opposed to a process that had taken up to 10 days.
The 29,000 sq. ft. addition is attached to the original 40,000 sq. ft. plant. MetalTek Investcast produces specialized alloy, high-definition, tight-tolerance parts used as-cast with little or no machining. The parts are used in high-heat, abrasive or corrosive environments.
Roman Electric was originally hired to install just the electrical service for the addition. But as Roman VP Phil Rose, project manager Greg Cottone and foreman Fred Freeman worked with general contractor Link & Associates, Roman's participation grew into a sizable $800,000 design/build project.
Roman removed the old overhead primary service, and installed a new 3000 KVA transformer and high-voltage switchgear with an underground feed to the new 4000 amp 480/277 volt transformer. Roman electricians added a new electrical system to the existing plant and re-lighted the building. In the addition, Roman wired the new building, wired and helped relocate existing equipment, and powered the new production equipment.
At MetalTek's request, the primary switchgear used was recycled, then tested, certified, repainted and now serves as a cost-effective fully capable power component.
Bill Dossett, business development director for Link & Associates, said, "Roman did a fantastic job! They met very tight, very stringent time constraints thanks to their great planning and coordination. We'd take equipment down Friday night and Roman would have it up and running Tuesday morning. They had all the needed material on hand and even did pre-wiring to speed hookups. Things went really, really smooth and everyone was happy.
"Roman's a great company to work with. They're number one in service and always helped the other trades with power requirements. The Associated Building Contractors chose this job as an Industrial Project of Distinction and will present awards to us and Roman."
Dave Kirmse, engineering manager at MetalTek Investcast, said, "Roman was very responsive They did a lot of things above and beyond the call of duty whenever I needed help." Larry Koltz was also pleased with Roman's performance. VP of quality assurance and engineering services for Wisconsin Centrifugal, another MetalTek Division, he was part of the project development team. "Roman brought a lot of expertise to the job. We had to increase the power available and Roman did the engineering and installation. They did a very good job and did it expeditiously."
Nitto Americas Builds 180,000 Sq. Ft. Manufacturing, Office and Warehouse Facility
Nitto Americas, a unit of Nitto Denko, Osaka, Japan, the world-wide leader in manufacturing tapes and adhesives for a variety of commercial applications, is building a new 180,000 sq. ft. facility in Pleasant Prairie. The company chose the Lakeview Business Park location, a Wispark Development, to benefit from the area's central location, several good technical colleges nearby, relatively low-priced electrical and gas rates, and the Midwest work ethic.
Nitto Americas owns 87 acres in the Business Park and plans to build more manufacturing, warehousing, R&D, and headquarters structures. The $200 million seven-building campus will house its U.S. headquarters, now located in New Jersey.
Roman Electric is handling design/build of the electrical system for general contractor Berghammer Corp. Roman crews installed a 24.9KV primary substation, the distribution system, lighting, branch power, and the fire alarm network. To achieve electric service redundancy, the electrical system's four transformers can receive power from each of two primary switches.
Roman also had separate contracts with two suppliers of manufacturing systems to install wiring for coating line ovens, an oxidizer and process equipment.
Roman TechNet was also key in the construction. TechNet web site specialists set up and kept current a dedicated web site to give representatives from the owner, contractors and suppliers access to the latest job site details.
Roman TechNet cable technicians installed a redundant fiber optic ring and five telecommunications closets in the plant to service all data locations with Cat 5 cable and make sure the data system is always up and running.
In the offices, TechNet installed 125 data and 75 voice lines, a Northern Telecom telephone switch, and 4" conduit from the building under future roads to accommodate fiber lines for future buildings.
Craig Eischen, Berghammer project manager, said, "This was a unique job for Roman because they were hired by us, did work for Nitto directly, and worked for equipment suppliers. They're doing an excellent job dealing with multiple groups and different people at the same time, and satisfying each with service and manpower." Don Pirlot, Nitto Americas plant manager, was also pleased. "Roman is on time with everything. Project manager Gabe Rose and his crew are doing a great job," he said.
Other major contributors for Roman included Phil Rose, who designed the electrical system, project superintendent Len Sagan and foreman Brian Paulick.
Golden Books Constructs New 503,700 sq. ft. Manufacturing and Office Buildings
Golden Books Publishing Co. - the largest publisher of children's books in North America - broke ground in mid-July of '97 for a $39 million complex on 33 acres in Sturtevant's Renaissance Business Park. With fast-paced construction , a new 442,000 sq. ft. manufacturing plant was completed February 2nd, and the company's 61,700 sq. ft. office building will be finished in early April.
Golden Books (formerly Western Publishing) has produced books in Racine since 1907. The publisher will lease the new complex from developer First Industrial Realty Trust of Rosemont, IL. General contractor on the project is Berghammer Corp. of Butler. Roman Electric was awarded a $3.2 million contract for all the electrical work.
Roman vice president Phil Rose said, "This was a very, very fast design/build project, done in just six months. We designed the complete electrical system from power distribution to lighting." Crews of 43 electricians worked 10 hour days and Saturdays to meet the tight schedule.
Huge Power Demand The enormous facility is fed with 10.4 megawatts of electrical power capacity, enough to power 2,100 homes. The plant's primary service also has future capacity for another 14 megawatts. The distribution system includes almost two miles of high voltage cable feeding six primary transformers. Nearly 150 miles of copper cable and 2500 ft. of bus duct deliver power where needed in the plant.
The manufacturing area is lighted by 362 high-efficiency 1000 watt metal halide lamps. Offices are lighted by 5,600 fluorescent lamps. 54 million lumens of light are produced.
Lighting in the manufacturing building is controlled by a computerized energy management system. Infrared and ultrasonic occupancy sensors control lighting in the administration building. Because both systems are designed for maximum energy efficiency, total energy used for all interior and exterior lighting is only 650 kilowatts, much less than the usage allowed by the state's new energy-efficiency code.
According to Andy Justman, project manager for Berghammer, "With the size of the buildings, the amount of equipment, pads for the equipment, the large presses and the very fast pace, the speed of completion was quite a feat. We're very happy to have Roman on our team. They're doing a great job. They've met or exceeded our expectations." Berghammer supervisors on the job were Dan Nord and Scott Nord.
New Plant for The Custom Shoppe, Manufacturer of Custom Wood Furniture
One of the reasons for Roman Electric's growth to a major contractor with over 300 employees is an emphasis on service. Frank Krejci, president of The Custom shoppe, a manufacturer of custom wood furniture in Watertown, says, "We build high quality furniture and are very customer-oriented. Roman is also dedicated to customer service. They listen well, understand our needs, and come up with solutions."
Customer satisfaction is always the goal at both Roman and The Custom Shoppe. "Since our plant burned down last March," Krejci said, "we've been scrambling to satisfy our customers and build a new plant. Roman has been a big help. They've moved and rewired machinery, and delivered instant service as needed. Our new 100,000 sq. ft. plant will be ready in June and Roman supplied valuable input on a fast-track job. Like us, they're creative and provided advice and capability that helped give us a cost-effective facility."
A Crew of Highly Skilled Electricians
Continuous Training with an Emphasis on Safety
A fleet of 50 Service and Bucket Trucks
A staff of Professional Engineers, Designers and Technicians
Full Service Design/Build Capability
Wisconsin's Energy Efficiency and Renewable Energy Experts