Vaughn Industries has been installing and maintaining substations for many years, earning our reputation as one of the Midwest’s top substation contractors. We have the resources and experience to costruct a new facility from the ground up, providing everything from foundation installation to transformer dress out, and installation of control buildings. From start to finish, Vaughn Industries is dedicated to providing top-quality service, no matter the size or scope of the project. Not only do we specialize in installing substations, but we also provide many maintenance and repair services for already-existing facilities.

As you can see in our list of services below, Vaughn Industries can be your “one call” contractor of choice. Let us meet all of your high voltage needs.



New Construction

  • Site clearing, grading, and foundation installation
  • Installation of the complete grounding systems
  • Steel structure erection
  • Complete electrical equipment installation
  • Overhead Bus installation
  • Transformer dress-out and installation
  • Installation and connection of control wiring and battery systems
  • Installation of control buildings


  • Site restoration, foundation repairs, and replacement
  • Oil Containment installation
  • Electrical equipment repairs and cleaning
  • Transformer replacement
  • Breaker repairs and service
  • Routine schedule maintenance




More and more people are demanding to convert their overhead electrical systems to underground, and Vaughn Industries has helped many industrial and commercial customers make the switch. Underground systems have many advantages – less chance of losing electricity due to power outages and no more hassle of trimming tree branches to avoid power-lines. Vaughn Industries has always prided itself in staying up to date with the industry’s recent technological developments, and underground systems are no different. We are here to meet our customer’s demands with top quality work and professional technicians, while always meeting budget requirements.
We can construct brand-new underground systems, both trenchless and open-trench, installing all of the cables and pipes necessary. We have experience in the maintenance of already existing underground systems, able to replace or repair any malfunctioning components. We have installed street lighting systems as well as airport lighting, and we can even construct confined space entry systems, allowing our customers to easily access areas with constricted spaces. Even high voltage cable installation presents no trouble for us – we can easily work with cabling up to 138 kilovolts.

Browse through the list of Underground services that Vaughn Industries offers, and discover why we are Ohio’s premier underground contractor. Let us meet your needs.


New Construction

  • Trenchless underground utilities and open trench installation
  • Utility backbone (power cable, communication cable, duct bank, manhole and gas pipe) installation
  • Transformer and switchgear installation
  • Street light installation
  • Complete airport lighting
  • Confined space entry
  • Cable installation and termination, including 138 KV cabling
  • Riser pole framing and connection


  • Utility backbone replacement
  • Transformer repairs and replacement
  • Lead cable repairs and replacement
  • Hy-Pot maintenance testing of existing cables



Construction Support Services

The construction industry is always evolving. The techniques being used to improve the safety and well-being of workers and to improve efficiency are constantly being studied and administered throughout the industry. Vaughn Industries’ substation division strives to continuously improve and broaden its services by administering techniques and technological advancements to provide top notch projects for our customers. Within our substation division, a construction support team has been created to assist in the recognition and implementation of new ways to improve safety, efficiency and construction schedule improvements. For years, other parts of the construction industry have made technological advances and have proven such techniques improve projects all around. Within Vaughn Industries, we have extensive experience with some of these technological advancements and we are now implementing such advancements in the substation utility industry that we serve.

Services we now provide in substation, that make use of these advancements, include Building Information Modeling (BIM), 3D Scanning, and Prefabrication. As each project differs from the next and has its own challenges, the support team works closely with the Project Manger’s and field crew to determine if such service can improve the safety, quality and efficiency of a project. Many times we are able to reduce or eliminate outages with the use of this technology.



Building Information Modeling (BIM)

Building Information Modeling (BIM) is the process of taking traditional 2D drawings and converting them into a 3D model. Information is also then embedded into the 3D model to aid with the construction of a project and then turned over to the owner at the completion of a project to improve Operations and Management (O&M) tasks. With the use of the 3D model, Vaughn’s has improved aspects of our projects which include:

  • Improved Safety

  • Improved accuracy of Bill of Materials (BOM)

  • Identification of potential issues prior the start of work and crew mobilizing to site

3D Scanning

Due to the complexity of certain projects and the success of such technology in other industries, Vaughn’s has also incorporated 3D scanning into our line of services. 3D scanning allows us to get true to life dimensions of job sites, which reduces the possibility of human error that can be found on As-Built drawings, and minimizes the risk to our work force and customers. Scans are taken from the safety of the ground eliminating the need for specialized equipment or outages to gain the measurements. The scan can then be viewed on a computer, and used to obtain measurements, get up to date site information, or incorporate into a 3D model.


Vaughn Industries has a climate controlled facility that we currently conduct all of our fabrication in. We also have our satellite office in Lewis Center with warehouse storage space that gives us the additional capability of offering just in time delivery for Northern and Central Ohio.

To help ensure all dimensions are accurate, models are completed for the assemblies that are to be prefabricated. Fabrication can take place either at our Carey facility, on the job site at ground level, or a combination of the two. Prefabrication can range from jumpers between equipment, hard bus, and components to larger assemblies. Each job will be evaluated individually to see what is most cost effective.

As technology continues to improve for use in the construction industry, the capability of completing prefabrication work increase with it. The use of 3D scanners and Building Information Modeling (BIM) have led to an increase in assemblies being prefabricated off site with incredible accuracy. Having this capability available to us has led to significant benefits including:

  • Improved Safety
  • Shorter Construction Schedules
  • Reduced Project Cost



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