Spartan Composites 2000-Amp Service Upgrade

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Year:
2023
Location:
Rockledge, FL
Summary:
  • Engineer and execute a major service upgrade
  • Boost their incoming power capacity to 2000 Amps
  • Coordinated service requirements with the local utility
  • Installed upgraded service entrance equipment
  • Installed switchgear and distribution infrastructure
  • Ensured proper load balancing and future expansion capacity

Project Gallery

Spartan Composites Electrical Service Upgrade

For more than 14 years, Spartan Composites has been a driving force in American manufacturing, producing heavy-duty and light-duty composite access mats from their headquarters in Rockledge, Florida. In February 2024, they took a strategic step forward by acquiring FODS LLC, a company known for its innovative track-out control mats that help contractors meet SWPPP environmental compliance requirements. This acquisition expanded Spartan Composites’ product portfolio and strengthened distribution capabilities across all 50 states, further cementing their leadership in the industry.

When Spartan Composites ramped up production to meet increasing demand, their existing electrical infrastructure simply could not keep pace with the requirements of a new, high-output manufacturing line. That’s when Core Electric was brought in to provide a complete solution. Our team engineered and executed a major service upgrade designed to increase incoming power capacity to 2000 amps, ensuring the facility could handle both current and future loads with confidence.

We began by working closely with the local utility to design and secure approval for the expanded service requirements. Coordinating with utility engineers is a critical step in projects like this, and we made sure every element—from service sizing to equipment selection—met stringent safety, reliability, and operational standards. Once the plan was approved, we installed upgraded service entrance equipment, new switchgear, and a reinforced distribution infrastructure capable of supporting continuous heavy-duty manufacturing.

Load balancing was a major focus of our work. We calculated and configured the system to distribute power efficiently, reducing stress on components and improving overall performance. At the same time, we designed the electrical backbone with expansion in mind, giving Spartan Composites the flexibility to add machinery or increase production without requiring another major service overhaul.

One of the project’s biggest challenges was executing the upgrade without interrupting Spartan’s day-to-day manufacturing operations. Our team worked in phases, scheduling critical tie-ins and equipment changes during low-impact windows to minimize downtime. This careful planning ensured that Spartan could maintain productivity while we brought their electrical systems to a new level of capability.

In the end, we delivered a robust, future-ready electrical infrastructure that now powers Spartan Composites’ advanced composite mat production line. More importantly, the upgrade gives them the headroom to grow—supporting their continued expansion and allowing their manufacturing floor to operate at peak performance every single day.

At Core Electric, we take pride in being more than just an installer. We’re a partner in growth, providing the expertise and precision needed to help companies like Spartan Composites meet their goals, overcome infrastructure challenges, and prepare for the demands of tomorrow.

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