To power a new industrial manufacturing facility built for Haas Automation’s heavy machinery CNC machine production in Henderson, Nev., an electrical contractor was tasked with designing and installing a large-scale power distribution system requiring 22,000 feet of electrical conduit.

Challenge

The medium-voltage distribution system for the 2.5 million sq. ft. facility required 22,000 feet of conduit across 165 acres, putting immense pressure on the installation timeline. The electrical contractor found that conventional options presented a triple threat to efficiency:

• Labor and safety: Galvanized rigid conduit (GRC) was too heavy, with a 6-inch elbow weighing up to 200 pounds, slowing down installation crews and increasing safety risks.
• Corrosion and taping: The notoriously acidic Nevada soil would require extensive, time- consuming taping of metal conduit to prevent corrosion.
• Burn-through risk: Lightweight PVC conduit was ruled out due to its susceptibility to burn-through during long-distance wire pulls, risking costly project delays and rework.

The electrical contractor needed a durable, cost-effective solution that could resist corrosion, eliminate burn-through and drastically shorten installation time.

Solution

Champion Duct® conduit emerged as the clear solution. A major benefit of fiberglass conduit is its lighter weight. One 6-inch 90-degree elbow of rigid steel conduit can weigh up to 200 pounds, while fiberglass weighs only 20 pounds, reducing labor costs and allowing for easy on-site handling and installation. It offers equal durability and corrosion resistance, eliminating the need for gluing or taping conduit. Additionally, fiberglass conduit elbows do not burn-through.

The electrical contractor fully BIM-modeled the project ahead of install, creating a 3D visualization of all bends and transitions across the system. Champion Duct (20-foot lengths of 4- and 6-inch) would be installed underground, with vaults approximately 1,000 feet apart to account for splicing.

Results

With Champion Fiberglass® conduit, the electrical contractor has seen faster and easier installation, substantial labor savings and reduced overall costs. Champion Duct’s lighter weight allowed for installation of 20 feet per hour, resulting in a 33% pickup on install time. It also helped reduce transport and material costs while increasing project efficiency, supporting the contractor ahead of the facility’s grand opening.

Contact Champion Fiberglass

PROJECT NAME

Haas Automation Manufacturing Facility

APPLICATION

Industrial

CHAMPION FIBERGLASS PRODUCT(S)

Champion Duct®

BENEFITS

> 33% pickup on install efficiency

> Lighter weight conduit = reduced installation costs