How can power distribution make or break your construction project?

Without reliable electricity, you won’t be able to power things like tower cranes, elevators, cabins, heating and lights, not to mention all the tools and machinery used by workers.

But how do you create a safe, dependable, and efficient electricity system to see you through from day one to completion?

Before you do anything else, you need to answer two key questions:

What power sources are available?

The easiest option is usually to hook up to the main electrical grid to guarantee you a steady stream of power. However, this depends on the location of the site and if there are utility poles nearby. You’ll also need to liaise with the electric company - if your construction site has particularly heavy power demands, this may be too much for the local grid to handle.

Solar panel installations are an alternative option, and can be great to help you reduce carbon emissions and lower fossil fuel consumption. But they are challenges over generators, and if the construction work is largely happening at night, their effectiveness will be further reduced.

Generators can be powered by diesel or gas and come in a range of different sizes depending on your power usage requirements. This brings us nicely to question number two.

How much power do you need?

Before you settle on your power source it’s crucial to create a plan of all the equipment that will be used and when, and how much power each item requires. Don’t forget to consult any partners and contractors who will be sharing your power source.

Once you have this data you should know how much power you will require at any one time, which will inform your decision on the best power source. If you are able to hook up to the local grid, the electricity company will need to see your plan to confirm they are happy with the power loads and the work they need to carry out to make it feasible. Alternatively, you can arrange for the necessary solar panels or generators to meet all your power needs.

Once you have identified your power requirements and power source, you can move on to the next stage of your plan.

Step 1: Design the power distribution for your site

You know how much power you need and where it will come from, but you also need to understand exactly how each component, system or tool joins up and connects to your main power supply. This means paying close attention to details such as grounding, bonding, input/output connections, electrical insulation, corrosion protection, over-current protection, enclosures, enclosure performance, and the capacities of any parts that carry a current.

You should also consider the temperature range that your equipment and electrical setup can work within, strain relief, icing and gaskets, waterproofing and other exposure to the elements, required thickness for metallic coating, clamped joint temperature, and dielectric voltage withstands tests.

And when you’re finalizing your plan, you must ensure the design is fully in line with all local rules and regulations.

Step 2: Coordinate with local utilities or temporary power providers

Whether you are using the main grid or temporary generators, it’s important to go through your detailed distribution plans and anticipated power loads with your power provider. If you are hooking up to the local grid the electricity company will need to plan for the surge in demand, and both types of providers should arrange pre-construction meetings to identify potential issues and help your project run as smoothly as possible.

Step 3: Prioritize safety

Did you know that US construction workers are four times more likely to be electrocuted than workers in all other industries combined?

People working with electrical tools are at risk on a construction site, but so are other workers who could trip on cabling or be electrocuted by open live wires. Between 5-10% of annual construction fatalities are caused by electrocution and a further 40% are caused by falls.

Not only is electrical safety crucial to protect the health of your workers, but it will also prevent expensive delays, damaged equipment, or even fines if things go wrong.

To minimize risk and prioritize safety on your site, follow this checklist carefully:

• Be sure to keep to all OSHA and electrical safety standards
• Keep all raised equipment at least 10 feet away from overhead power lines
• Mark buried cables clearly, as well as the position of underground power lines, to prevent accidental contact
• Use cable protectors so that passersby don’t trip or injure themselves on dangerous voltages
• Double-insulate or properly ground all electrical equipment
• Use ground-fault circuit interrupters to automatically shut off power with as little as 1/40 of a second
• De-energize circuits before servicing equipment, using lockout, tag out procedures Ensure that temporary cables used for power distribution are protected with shock-resistant barriers
• Avoid overloading normal-duty extension cords when connected to temporary power and position them where they will keep dry
• Regularly check cabling and power cords for wear and tear

Step 4: Anticipate problems

What’s the best way to avoid unplanned, costly outages?

Identify and address potential issues before they cause any problems.

You should run predictive maintenance before work starts, and throughout the project, to test critical parts of the distribution system, check voltages are correct, conduct ultrasonic analysis or thermography, and test wiring and connections.

And because even the best-laid plans can be thwarted by the unexpected, be sure to have a watertight plan in place should the worst happen.

Plan for success

When it comes to power distribution, comprehensive planning is critical. A little more time spent at this stage can save inordinate amounts of stress and money, and even lives, further down the line. So don’t be afraid to get an expert to look over your distribution design, or reach out to your power provider to schedule additional pre-construction meetings if you have any doubts. A small delay to the start of the project is much better than a longer, costly delay halfway through.

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