Material Handling
Your operation depends on throughput. We help keep it moving.
built to scale.
Power distribution
Power distribution design for distribution centers and fulfillment centers — service entrance, switchgear, MCCs, and panel layouts sized for conveyor, sortation, and ASRS loads.
-
Service Entrance & Switchgear Design
Utility service entrance, switchgear, and MCC design sized for facility peak load.
-
Conveyor & ASRS Power Design
Power distribution engineered for conveyor, sortation, and automated storage and retrieval loads.
-
Load & Short-Circuit Studies
Load flow, short-circuit, and arc flash studies for distribution and fulfillment center electrical systems.
-
Expansion-Ready Design
Panel and distribution design engineered for phased build-outs and future capacity.
-
Lighting & Life-Safety Design
Lighting, emergency power, and life-safety electrical design integrated with the facility scope.
built end-to-end.
Distribution centers,
Distribution and fulfillment center electrical construction — from service entrance through final device hookup — self-performed by Spark crews on live and greenfield sites.
-
Greenfield DC Electrical Build
Full electrical construction for new-build distribution and fulfillment centers.
-
Brownfield Live-Site Construction
Electrical construction sequenced around live picking, packing, and shipping operations.
-
Power Distribution Install
Switchgear, MCCs, transformers, panels, and conduit installed by Spark crews.
-
Lighting & Life-Safety Install
Lighting, emergency power, and life-safety systems installed to code across the facility.
-
Prime Contractor Safety
COR-certified Canadian operations and Prime Contractor accountability on every build.
wired to run.
Conveyor, sortation
Power and controls installation for conveyor, sortation, and ASRS systems — wired, terminated, and integrated with plant SCADA by Spark crews.
-
Conveyor Power & Controls
Power and controls wiring for overland, in-plant, and sortation conveyor systems.
-
ASRS Electrical Integration
Power distribution and controls wiring for automated storage and retrieval systems.
-
Motor & VFD Terminations
Motor and VFD terminations at production scale across conveyor and sortation lines.
-
Multi-Vendor Equipment Coordination
Installation coordinated across multiple material handling equipment vendors on one schedule.
-
Commissioning Handoff
Installed systems handed off ready for PLC, HMI, and SCADA commissioning.
one integration.
PLC, HMI & SCADA,
PLC programming, HMI design, and SCADA integration for conveyor, sortation, and ASRS systems. Vendor-neutral and integrated with the facility’s existing controls.
-
PLC Programming
Allen-Bradley, Siemens, and other platforms programmed for conveyor and sortation controls.
-
HMI Design
Operator-facing HMI design tailored to material handling workflows.
-
SCADA & Fieldbus Integration
SCADA and fieldbus network integration across multi-vendor equipment.
-
MiddleWare
PLC and WMS integration through Ignition Middleware.
-
Multi-Vendor Controls Coordination
Controls integration coordinated across conveyor, sortation, and ASRS OEMs on one platform.
-
Commissioning-Ready Documentation
Control narratives and I/O documentation delivered ahead of system testing.
built for speed.
System commissioning,
Functional testing, integrated systems testing, and commissioning for conveyor, sortation, and ASRS systems — electrical testing included, so nothing waits on a second visit.
-
Functional & Integrated Testing
Device-level and system-level functional testing before go-live.
-
NETA ATS Acceptance Testing
Acceptance testing to NETA ATS standards for facility electrical equipment.
-
Multi-Vendor System Testing
Integrated testing across conveyor, sortation, and ASRS equipment from multiple vendors.
-
Punch-List & Go-Live Support
On-site support through go-live and initial ramp-up.
-
Audit-Ready Documentation
Test results and as-commissioned documentation delivered at handover.
built in-house.
Custom control panels
VFD, PLC, RTU, SCADA, and motor control panels designed, programmed, built, and tested inside Spark’s three CSA/UL-certified panel shops.
-
Three CSA/UL Panel Shops
Calgary, AB; Hamilton, ON; Fresno, CA.
-
Conveyor & Sortation Panels
Custom panels built for conveyor, sortation, and ASRS control requirements.
-
Customer or Spark-Developed Design
Panel designs accepted from the customer or developed in-house.
-
FAT Before Delivery
Pre- and post-build acceptance testing with documentation delivered before shipment.
-
Lifecycle Service
Training and maintenance available from the same panel shop team.
for reliable performance.
Preventive maintenance
Preventive and corrective electrical maintenance for conveyor, sortation, and ASRS systems scheduled around your shipping calendar.
-
Risk-Based PM Scheduling
Preventive maintenance scheduled against equipment risk profile and shipping calendar.
-
Corrective & Same-Visit Repair
Diagnosis and repair from the same team, on the same visit.
-
Predictive Diagnostics
Infrared and vibration diagnostics to catch failure modes before they cause downtime.
-
Multi-Vendor Equipment Coverage
Maintenance coverage across conveyor, sortation, and ASRS equipment from multiple OEMs.
-
Performance Reporting
Maintenance and corrective-action tracking delivered on a recurring schedule.
built for growing demand.
Facility expansions,
Brownfield expansions and capacity upgrades sequenced around live picking, packing, and shipping operations with new equipment integrated with the systems already running.
-
Brownfield Capacity Upgrades
Expansion and capacity upgrades executed inside live distribution and fulfillment centers.
-
Phased Sequencing
Work sequenced in phases to avoid disruption to shipping and receiving schedules.
-
New-to-Existing System Integration
New conveyor, sortation, and controls integrated with systems already in production.
-
Multi-Building Campus Coordination
Expansion scopes coordinated across multi-building distribution campuses.
-
Outage & Changeover Planning
Disciplined outage coordination tied to shipping and receiving windows.
when you need it most.
Emergency response,
Crews ready for mobilization when a conveyor, sorter, or ASRS system goes down from the same team that installs and maintains the equipment that shows up to fix it.
-
24/7 Dispatch
Emergency crews dispatched from 16+ regional offices across Canada and the U.S.
-
Automation Fault Diagnostics
On-site diagnostics for conveyor, sortation, and ASRS controls faults.
-
Multi-Vendor Troubleshooting
Emergency troubleshooting across equipment from multiple material handling OEMs.
-
Post-Event Reporting
Root-cause findings and preventive recommendations documented after every event.
GAP’s Pacific Distribution Center
Major infrastructure upgrade for GAP’s 1.78M sq. ft. Pacific Distribution Center: automation-ready power, full electrical design, and a complete lighting upgrade across two connected buildings.
Canada BW
Installed emergency lighting, sump pump power, and metering for Canada BW following a negative experience with their previous contractor. Completed efficiently, ahead of schedule, and with clear communication throughout.
Automotive Distribution Conveyor System
Wired a 400,000 sq. ft. automotive distribution facility in 8 weeks with zero delays. That performance extended the work into a year-long engagement.
Real questions,
real answers
-
Yes. Engineering, procurement, construction, commissioning, and long-term maintenance live under one roof — one accountable team from drawing through energization and ongoing service.
-
Yes. Plant expansions, controls retrofits, and equipment upgrades are routinely executed inside live production environments, with disciplined outage coordination and shutdown sequencing.
-
Within 24 to 72 hours for emergency response, dispatched from 16+ regional offices across Canada and the U.S.
-
Yes. Three CSA and UL-certified panel shops in Calgary, Hamilton, and Fresno produce custom protection, control, and automation panels designed in-house or to customer drawings.
-
Yes. Many providers specialize in either identifying problems or performing labor. Spark covers both, with highly skilled technical resources for complex diagnostics and a dedicated general labor group for cost-sensitive, high-volume remediation under one engagement.
-
Engineering scopes range from system studies on existing equipment to multi-year EPC engineering on substations and BESS sites. Some of our largest engineering scopes have spanned 200+ MW BESS and 245/144 kV substation upgrades.
Let’s talk power
The form could not be loaded. Please try again later.