Emcor's manufacturing facilities are located at two plant sites, totaling 43 acres, in Rochester, Minnesota.
Our modern plants enclose more than 600,000 square feet, and house the very finest equipment for the production of high quality metal fabrications.
We supply enclosures, and the systems that ventilate, heat and cool them.
Emcor produces modular electronic enclosures for computer, test equipment, security, broadcast and military applications,
along with Electrical Enclosures which meet National Electrical Manufacturers Association requirements.
Metal Processing Equipment
• De-coiling and precision cut-to-length line.
• Capacities: 22-gauge to /16" thicknesses, 5' maximum blank width, 12' maximum blank length.
• 8 CNC controlled punch presses (Amada and Wiedemann) 15 ton through 50 ton capacity-plasma arc cutting capability.
• 2 CNC controlled laser cutters, (Mazak) - 1000 watt 4' x 8' capacity.
• 32 Press brakes - 60 ton through 600 ton capacity.
• Kamatsu, OBI mechanical press - 250 ton capacity, bed size of 37" x 106" with "SmartPac", an auto-advance control system for multi-position dies.
• 7 Straightside mechanical presses 150 ton through 750 ton capacity, bed sizes to 84"x 132".
• Straightside hydlraulic press - 1,000 ton capacity, bed size of 72" x 124".
• 24 Punch presses - 20 ton through 150 ton capacity.
• Tube bender (Eaton Leonard) to 4" round capacity, CNC controlled.
• 2 Tube benders, (Pines) - to 4" O.D. tubing capacity.
• 8 Power shears - to 1/2" capacity.
• Flame cutting machine - 6 head with template tracing, photocell control.
• 3 Production band saws, (Marvel) - 18" x 20" capacity with automatic feed.
• 29 Drilling and tapping machines - to 1 1/4" diameter capacity.
• Model Shop - complete with 56 ton and 200 ton press brakes, 5' power shear, band saw, drill presses, punch presses and welding machines.
• Fixture, Tool and Die Shop - complete with welding machines, lathes, grinders, mills and heat treating oven.
Welding/Metal Finishing
Welding operations are supported by adjacent grinding areas, and are served by traveling bridge cranes and supplementary jib cranes.
• 8 ABB robotic welders - 500 amp capacity
• 2 Motoman robotic welders - 500 amp capacity
• 2 1GM Robotic Welders - 450 amp capacity.
• 23 Resistance welders - to 200 KVA capacity.
• More than 200 Gas shielded arc welding machines - 650 amp capacity.
• 2 "Tracveyor" welding systems - each 300' in length, with (21) work stations and cart capacity of 2 tons. Each work station is served by a bridge crane with a 1 ton capacity and a jib crane with a 1/2 ton capacity.
• Overhead conveyor grindline system - with (24) work stations, inspection stations and weld repair stations.
• 2 Overhead conveyor and storage systems - A prepaint conveyor system delivers units from welding to grindline to an overhead storage area with a capacity of 135 units.
The overhead conveyor system can bypass the storage area and move the parts directly to the paint system. A pre-assembly
conveyor system delivers units from the paint area to either overhead storage with a capacity of 76 units, or from this paint
system directly to final assembly.
The grindline and the overhead conveyor and storage systems have a power and free accumulating feature which is monitored
by a computer. Like or similar units may be accumulated into efficient lot sizes, and then released to the grindline, paint system
or final assembly as required.
Painting
A state of the art Cathodic "SST" Electrocoat 18 stage dip & spray wash operation -
The system is equipped with 2 acid immersion tanks, cycles every 2 1/2 minutes including a 1 1/2 minute
immersion period with a 60 second lift and drain operation. This provides a production capacity of 24 loads per hour.
2 Conveyorized paint systems - The paint system used for heavy units has a work opening of 9' x 9' and a
carrying capacity of 1,800 lbs. per load bar. It features a 6-stage power washer and phosphatizing system equipped with a
dry-off oven. There are (5) paint booths ranging in length from 28' to 40' and 2 baking ovens along this paint line- Smaller units
are painted on a second conveyorized system which is governed by a 40' wide x 50" high work opening. This is a 2-chain system and
includes a 5-stage phosphate washer and dry-off oven. There are (12) spray booths and (3) baking ovens incorporated into this system.
Each oven is 240' long and is individually temperature controlled.
We also have a mini-paint line consisting of (2) 14' paint booths and (1) 55' baking oven for short run requirements.
9 Air compressors - (2) 60 HP, (1) 125 HP, (3) 150 HP, (2) 200 HP and (1) 350 HP units supply compressed air throughout the plants.
Assembly
Final cab assembly is accomplished on a powered floor level wood slat conveyor measuring 5' x 300' long.
Two 200' long non-powered assembly lines are utilized for the assembly of cabs with complex electrical and electro mechanical components.
Final assembly for cabinet items is accomplished along a 360' roller conveyor utilizing individual multifunctional assembly stations
that allow the operator to raise and lower the unit being assembled to optimum working conditions. Smaller units are assembled on a 30" x 60'
waist high belt conveyor.
Testing/Inspection
Testing and inspection equipment includes both magnetic particle and ultrasonic weld inspection equipment.
Dimensional measurement capabilities include a 'Fabrivision" optical comparison machine with a 48" x 72" scan surface and a
computerized Brown and Sharpe Validator with a measuring cube of 72" x 48" x 36". Two computer assisted lay-out inspection machines
with 100" x 140" surface tables and 72 'vertical measuring capacity.
Our metallurgical lab is equipped to perform the physical testing of tensile, yield, elongation, impact and hardness.
The appearance and performance of painted finishes is established and monitored in a laboratory equipped with a Data Color
computerized color analyzer, as well as salt spray, conical bend, taber abrasion, gloss, film thickness, scrape, adhesion and drop testing equipment.
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