The 203 building is 205,000 square feet of manufacturing and office space with the major portion being manufacturing.

Shoffner electrical division was awarded this project in December 2006 with a completion date for the plant of October 2007  and the office area was scheduled for January 2008. In late June of 2007 the owner decided they wanted the plant area a month early because of new contracts they received. This meant that we had to have power on, light fixtures hung and all major feeders to the office area as we could not get back in the plant area after Denso started setting equipment. This was made more difficult because the plant floor has a special coating that required two weeks of preparation and installation which did not allow us access for our work. Our crew took on the challenge of completing this project and was very successful; we had power on August 17 and turned the plant over before September and got the certificate of occupancy for the entire building by December 14.

The main power source is two sets of 13.2 KV service conductors that feed three 2500 kva substations with three 4000 amp 277/480 volt switchboards. Emergency power is supplied by a 400 kW diesel generator. Power distribution for this project consisted of 1800 feet bus duct, 2590 feet of cable tray, 10,000 feet of tray cable and approximately 54 miles of branch and feeder wire. The light level in the plant area is over 100 foot candles, we installed 1039-8’ six lamp tandem fluorescent fixtures suspended on a Unistrut wiring system. The office area is lighted by over a 1000 standard lay-in and recessed can lights. The parking area has 47 pole lights with 150 and 400 watt metal halide fixtures.

We installed a 4/0 perimeter ground grid and a lightning protection system which consisted of over 7000 feet buried ground cable, 94- ¾”x10’ copper ground rods, 11,000 lightning protection cable and over 300 air terminals. We provided feeder circuits and connections for three 500 ton chillers, two 600 amp air compressors, four 20 horse power and seven 60 horse power pumps. There were over a dozen rooftop HVAC units, approximately 75 VAV air distribution boxes, eight steam generators and various other pumps and water heaters that required power.

This project started at less than 2 million dollars and with change orders ended up at 2.6 million and more than 28,000 man hours estimated. We were able to accomplish all this work with 24 men sometimes working seven 12 hour shifts. The project came in under budget and ahead of schedule.

Maryville, Tennessee         $2,714,877.00