Technical proof, not promises
Every project here shipped, installed, and validated for mission critical reliability.
Case Studies
Mission-Critical UPS Bypass in an 80-Inch Footprint
How PowerStream adapted its PowerPass Tile architecture to deliver a custom, Made-in-America UPS bypass solution in just 12 weeks. 80" Maximum Width | 12 Weeks to Ship | 2 Lineups | Mission-Critical Data Center
The Challenge
A mission-critical data center required a custom UPS bypass solution on an accelerated project schedule. Speed, however, was only part of the challenge.The equipment also had to fit within a strict 80-inch maximum footprint while incorporating an integrated load-bank breaker, Scheme 39 and Scheme 29 SKRU interlocking, two output feeder breakers, and the functionality required to support UPS maintenance and downstream distribution.The challenge was clear: deliver the required functionality within a highly constrained footprint without compromising the project schedule.
The PowerStream Solution
PowerStream used its PowerPass Tile architecture as the foundation for the design, adapting the modular platform specifically for the customer's single-UPS application.The final design incorporated:
- Modular Tile architecture configured for a single-UPS application
- Compact 80-inch-wide lineup
- Integrated load-bank breaker
- Scheme 39 and Scheme 29 SKRU interlocking
- Two output feeder breakers
- Made-in-America compliant constructionBy starting with a flexible architecture and engineering around the application, PowerStream was able to deliver a highly customized solution while maintaining the speed and repeatability of a modular platform.
The Result
PowerStream manufactured, assembled, tested, and shipped two complete lineups in just 12 weeks, meeting both the customer's accelerated schedule and strict footprint requirement.
The project demonstrates the philosophy behind PowerPass: standardize the architecture without limiting the application.Rather than forcing the customer's requirements into a fixed product, PowerStream adapted the platform around the needs of the data center, delivering the required functionality, footprint, and schedule in one solution.
Application-Driven Engineering. Schedule-Driven Execution.
4000A Power Distribution In an 84-Inch Footprint
How PowerStream deployed a high-density 4000A switchboard design for seamless integration into a prefabricated eHouse in just 12 weeks. 4000A Main | 84" Maximum Width | 4 × 1000A Feeders | 12 Weeks to Deploy
The Challenge
A semiconductor customer required two 4000A main switchboards for installation within a prefabricated eHouse.Each switchboard needed to incorporate a 4000A main and four 1000A, 100%-rated feeder breakers while fitting within a strict 84-inch maximum width.Because the switchboards were being integrated into a prefabricated structure, equipment footprint was a critical design constraint. The solution needed to deliver the required ampacity and feeder capacity while integrating seamlessly into the eHouse design and maintaining an accelerated project schedule.
The PowerStream Solution
PowerStream had already identified the need for higher-density switchboard designs in prefabricated and modular applications. Our engineering team was actively developing a compact 4000A architecture specifically for applications like this one.When the project requirements arrived, the application aligned directly with that work.PowerStream deployed the design around the customer's requirements, delivering each switchboard with:
- 4000A main
- Four 1000A, 100%-rated feeder breakers
- Compact 84-inch maximum width
- High-density architecture designed for prefabricated applications
- Configuration engineered for integration within the customer's eHouseBy combining an application-driven design with an architecture already under development, PowerStream was able to move quickly from project requirements to production.
The Result
PowerStream engineered, manufactured, assembled, tested, and delivered two complete 4000A switchboards in 12 weeks.
The compact 84-inch-wide design integrated seamlessly into the prefabricated eHouse while providing the full 4000A distribution capacity and four 1000A feeder circuits required by the application.The project demonstrates the value of designing ahead of the market. By anticipating the increasing power-density and footprint requirements of prefabricated electrical systems, PowerStream was able to deploy an application-ready solution when the customer needed it.
Dense by Design. Built for Integration. Delivered on Schedule.
38 Sections. Seven Weeks. Delivered.
How PowerStream combined vertical integration, manufacturing capacity, and schedule-driven execution to deliver a 38-section switchboard project on an accelerated timeline. 38 Sections | 7 Weeks | Accelerated Schedule | Complete In-House Execution
The Challenge
A customer needed a large switchboard project delivered on an exceptionally aggressive schedule.The project consisted of 38 sections of custom low-voltage switchgear, with only seven weeks available to manufacture, assemble, test, and prepare the complete project for shipment.At this scale, speed alone isn’t enough. Engineering, material availability, fabrication, assembly, wiring, testing, and project management all have to remain aligned throughout the manufacturing process.The challenge was to execute quickly without allowing the size of the project to compromise quality or schedule certainty.
The PowerStream Solution
PowerStream built its manufacturing model around controlling the activities that have the greatest impact on project schedules.With engineering, steel fabrication, bus fabrication, assembly, wiring, and testing managed within PowerStream’s manufacturing operation, the team was able to coordinate the project as a single production effort rather than relying on multiple external handoffs.That control allowed engineering, procurement, fabrication, and production activities to move in parallel while the team closely managed the project against the required delivery date.As production progressed, sections moved continuously through fabrication, assembly, wiring, and testing—allowing PowerStream to maintain the pace required to execute a project of this size within the available window.
The Result
PowerStream completed all 38 sections in just seven weeks.The project demonstrated something beyond the ability to build equipment quickly. It demonstrated the ability to maintain speed at scale.
Large accelerated projects require more than manufacturing capacity. They require engineering alignment, material coordination, production planning, and disciplined execution across the entire organization.PowerStream’s vertically integrated manufacturing model provides the control necessary to bring those activities together—helping customers compress equipment schedules when time matters most.
38 Sections. Seven Weeks. One Team. One Process. Full Accountability.
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