Construction Power Design, Installation & Control Considerations for a Large
Industrial Construction Project
ESW2015-09
Scott Mitchell
Cianbro Corporation
PO Box 1000
Pittsfield, ME 04967
smitchell@cianbro.com
Abstract- Provisions for Construction Power
often present many unique electrical safety
challenges both in logistics and in hazard miti-
gation, which must be addressed.[1] An aware-
ness and familiarization of the regulations and
standards that govern electrical safety require-
ments can be challenging.[2] It is often the re-
sponsibility of electrical supervisory personnel
whom in many cases do not have an engineer-
ing background, but are familiar with assessing
needs and components used to meet those
needs. One consideration is the variety of
equipment needed and the types of loads that
they introduce to the supply system. As the
project progresses there may be a need for ad-
ditional specialized equipment so it is necessary
to allow for increase in demand. The complexity
of the construction power scheme must be suf-
ficient to safely meet the needs of the project.
I. Introduction
This paper will demonstrate some of what a
contractor should consider in the design, instal-
lation and control of construction power for a
large industrial project.
978-1-4799-4782-9/15/$31.00©2015 IEEE
Mark Cross
TIC Southern
785 Greens Parkway
Houston, TX 77067
mark.cross@ticus.com
With any electrical supply there are hazards
related to electrical shocks and arcs. It is a
common misconception that temporary wiring
represents a lower standard than that of other
wiring. Per NFPA 70, the same rules of work-
manship, ampacity and overcurrent protection
apply to temporary installations as to others.
“Except as specifically modified in this article, all
other requirements of this Code for permanent
wiring shall apply to temporary wiring installa-
tions”.[3] Due to the nature of construction ac-
tivities on projects exposure to damage must be
carefully analyzed.
The level of risk to electrical hazards can be
affected by many variables including but not
limited to the following:
• Safety culture
• Project leadership
• Type of construction activity
• Location / environment
• System design
• Availability of equipment
• Condition of equipment
• Project schedule
• Documentation and Control
II. Safety Culture / Project Leadership
 What is the safety culture of your organiza-
tion? Has the value of a properly designed elec-
trical system been agreed upon? Does the
budget carry the cost? Does the safety culture
of your organization support the value of a sys-
tem that will stand up to the needs of the
project? What type of conversations should the
electrical leaders have with project leaders?
What does project management need to under-
stand so they will support the cost and installa-
tion of a system that meets or exceeds all appli-
cable codes and safety standards? Are company
policies and procedures in alignment with NFPA
70E? [4]
III. Type of construction activity
The type of activity and how the activity will
be accomplished is important for everyone to
understand from the project estimators at the
bid phase, through the commissioning phase of
turn over to the owner.
There are always needs for electrical services
in addition to accomplishing the direct work
activities. The field offices, lunchrooms, ware-
housing, onsite equipment maintenance, fuel
storage, site lighting security gates, cameras,
warning systems, communications, weather
stations, internet needs , environmental and
sanitary needs are all areas that should be con-
sidered in the overall construction power plan-
ning and design. The projects of today have be-
come more complex with additional but neces-
sary considerations from just a few years ago.
Welding is the primary method of attach-
ment with Industrial work. Knowing that the
managers will want to use fueled welding ma-
chines or rectified electric machines is critical.
Experience has taught that the majority of
welding will be from electrical sources. If there
will be pre heat and post weld treatment re-
quirements for the project, it will be paramount
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to understand the work plan for this in the be-
ginning. This post weld heat treatment (PWHT)
requirement could be the biggest electrical load
to consider. These PWHT loads are resistive
loads that will draw steady current for a length
of time. The loss of this circuit during the treat-
ment phase will cause the weld to be cut out
and started all over. This is not what any man-
ager wants to see happen.
Many projects require cranes to supply lifts
to complete the work and consideration for
mobile cranes verses tower cranes can be cru-
cial to a properly sized electrical distribution
system. Physical space on a site could be a rea-
son to use electric tower cranes. If so, and de-
pending on their size, these electrical loads will
also take special consideration. If at all possible
these loads should have dedicated circuits.
Usually in the hoist down travel mode these
cranes will have dynamic braking and can have
a regenerative effect on the electrical system.
These loads will draw more current than some
may anticipate or plan for.
Specialty equipment and electrical needs will
arise throughout the project. Some could in-
clude machining for valve repair, bolt heaters,
sky climbers and preservation power needs
such as de-humidifiers, climate controls anti
condensation heaters etc. Use of dewatering
equipment, where water tables require this ac-
tivity, can introduce substantial electrical load
on a construction power system.
IV. Location / Environment
When a project is spread out to cover offic-
es, parking areas, warehousing, etc. there may
be need for multiple power sources. In all loca-
tions, consideration for where the source will
come from, where it will be distributed to, and
a need for a locale that will not have to be dis-
turbed later for any construction activity should
be planned. Access for operability, protection
from traffic, grading, flooding, corrosion and
environmental concerns are all important con-
siderations.
The NEMA rating of the distribution equip-
ment must be suitable for its environment. [5].
One of the major environmental concerns is
moisture, as it not only has a negative effect on
electrical equipment, but also increases risk of
electrical hazards. Whether the construction
activity takes place on land and the concern is
precipitation related, or marine based activities
which could include corrosive salt water expo-
sure, all wet environments offer unique chal-
lenges.
Many safety procedures and training re-
quirements have been introduced and added to
company policies due to the complications of
work in wet locations. Specific training must
target those workers who do not have an un-
derstanding of electricity and yet depend on it
to support their construction activities. These
workers are likely to make dangerous choices in
order to complete their tasks without realizing
the increased risk. For example, portable GFCI’s
could be removed when work is being per-
formed in particularly wet locations due to what
is perceived as nuisance tripping. Making and
breaking power cord connections above
125/250V single phase, is an at-risk activity for
untrained workers, as these are not required to
be GFCI protected.[6].
Hazard awareness training which fosters an
understanding of how protective devices oper-
ate and why special procedures are mandated
will improve compliance with written policies.
V. System Design
Consider coordinating construction power
system design with project engineered design
to support facility critical power systems such as
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lighting, communications, and battery systems,
without energizing facility permanent power
systems. This can avoid the perceived need to
have energized permanent plant electrical
equipment scattered throughout the facility
before construction is substantially complete.
Provisions to have construction activities per-
formed in electrically safe conditions will reduce
risk of injury to the workers.
It is very likely that many local distribution
boxes will be used to minimize the number of
small power cords and related voltage drop is-
sues. These boxes should always be positioned
close to activities which they serve and in a rela-
tively dry and safe location. Routing feeder
cords and extension cords overhead will elimi-
nate both tripping hazards for workers and risk
of physical damage to the cords. Often it is
worth constructing temporary supports to ac-
complish this. Cords should always be sup-
ported using nonconductive ties. If overhead
activities such as crane use make overhead
routing infeasible, cords routed on walking and
working surfaces should be guarded with run-
ning boards on either side or other suitable pro-
tection.
Cord connections should be minimal to avoid
increased risk to workers from connecting and
disconnecting as well as problems related to
environment and physical damage such as loose
blades, cracked housings, and loose connec-
tions. Connections when needed should be
made with approved listed devices suitable for
the application and should always be kept dry.
System design should include large frame
feeder breakers with adjustable trip settings.
Ground fault, short circuit, over current, short-
time and long-time settings should all be part of
the scheme.
VI. Availability of equipment:
In the development of the overall construc-
tion power scheme one must consider the type
and availability of electrical equipment to be
used on the project. From the main distribution
equipment supplying feeders out to areas, sub
feeders, panels and branches to end of the line
outlets, all need to be sized and properly pro-
tected as in any designed system. The equip-
ment used may be engineered and manufac-
tured switchgear mixed with specifically con-
structed equipment on the project similar to
the “Bang Board” approach of distribution.
Many times your specific needs drive the deci-
sion to buy, build or rent. In some coastal areas,
depending on season, rental electrical distribu-
tion gear can be very hard to acquire. Rentals in
Florida during hurricane season may be in stock
but unavailable for possible emergency needs.
VII. Condition of equipment:
All electrical equipment should be cleaned,
tested, torqued, bonded and grounded as part
of the installation procedure. Whether it is
called temporary power, construction power or
permanent power is irrelevant. The physics of
electricity are unaltered. The equipment may
have been used several times before, used in
harsh environments, shipped long distances,
damaged in removal, transit, or installation.
Even new equipment fails from time to time.
Our policies are to treat construction power
provision as any other power provision. Quality
Control and Assurance should be completed on
each component of the system as if it were a
permanent system.
The nature of electrical accidents from un-
safe equipment and installations can be due to:
• Faulty insulation
• Improper Grounding
• Loose connections
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• Defective parts
• Ground faults
• Unguarded live parts
• Corrosion
VIII. Project schedule:
Every project schedule has construction de-
lays. Schedules are living documents that need
to be updated and managed within themselves.
Equipment and material deliveries, weather,
manpower, holidays, and sequence of events
will affect a schedule. Construction managers
are always reviewing and trying to make the
best progress forward with the current condi-
tions.
The need for electrical distribution can
change and knowledge of how the priorities can
change, from day to day on a project can greatly
enhance the initial design and setup of the con-
struction power system. Always have some
room for growth and adjustment. Most times
the issue is not necessarily total KVA or load,
but rather the lack of outlets to distribute the
loads.
IX. Documentation and Control:
Begin documentation of the design with a set
of one-line drawings. Many cases require these
drawings be approved and stamped by a Pro-
fessional Engineer. This is especially helpful
when county or city permits are required. Con-
tractors should work with the engineering
group for the project to help with this design
and develop professional drawings.
Maintain and post an up to date single-line
diagram. Posting of this diagram should be in
the safety office, electrical office or conference
rooms where discussions and planning may take
place. The drawings should include protective
device details such as fuse and circuit breaker
types and ratings. The drawings should indicate
available fault currents and arc hazard incident
energy at the equipment.
Maintain and post an up to date general ar-
rangement or layout drawing along with the
one line drawing to show underground and
overhead utilities installed on site. This will aid
in locating obstacles for future excavations,
placement of cranes or equipment.
Conduct a monthly audit and action item
checklist of the construction power once it is
installed. Verify labeling and placards are in
place and correct. [7].
Check for open holes or penetrations that
should be sealed or covered and verify power
panel directories are correct and in place.
Maintain safety training records to verify that
all workers have been made aware of the ha-
zards involved and risk reducing measures.
Complete monthly continuity and grounding
checks and document as needed. Complete
checks for ground fault device operation.
X. Conclusions
A shock or arc blast from a temporary instal-
lation can be just as deadly as one from a per-
manent installation. Either type of installation is
capable of igniting a fire if the conductors over-
heat or an arc is produced by faulty wiring or
poor installation practices. It is only reasonable
that the same rules in regard to workmanship,
conductor ampacity limits and overcurrent pro-
tection should apply to both kinds of installa-
tions.
Large scale construction projects may last
more than a year. Construction Power design
should start at the beginning phases of the
project while still with Engineering. EPC con-
tracts provide a good opportunity for the con-
tractor and engineers to work together. Design
the system to be flexible.
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Documentation of the original installation
and maintenance records are key components
to a safe and effective system.
XI. Acknowledgements
Thanks to Jim Mitchem of TIC for leadership
in policy development and in training and to
Daryld Ray Crow of DRC Consulting, Ltd. for his
knowledge and support in the IEEE community.
XII. References
[1] Meeting the Electrical Safety Challenges.
Dennis Neitzel and Timothy Gauthier, ESW
2014-28
[2] CFR29-OSHA 1926.405, CFR-29-OSHA
1910.302, NECA – 200 -210, Cal OSHA 2320
[3] NFPA 70 2014 Article 590.2(A) & (B)
[4] NFPA 70E 2012 Article 105
[5] NFPA 70 2014 Article 110.28
[6] NFPA 70 2014 Article 590.6
[7] NFPA 70 2014 Article 110.16
XIII. Vito
Mark A. Cross has been in the electrical
construction industry since 1974. With more
than 35 years in the Industrial segment, Mark
has experience as a craftsman, in front-line
supervision, and for the past 25 years as
superintendent. In 30 years with TIC Industrial
Mark has constructed and managed projects
across the United States including geothermal
power, gold and copper mills and smelters,
cement plants, natural gas, mining projects,
surface and underground, fossil unit upgrades,
and many combined cycle power projects up to
1200 MW.
In his role as Superintendent, Mark is
responsible to direct the work and to meet goals
for safety, schedule, quality, and productivity.
Mark has long been passionate about electrical
safety, and conducts electrical safety training
both on his projects and in support of other
projects. Mark has been a leader within TIC in
minimizing employee exposure to electrical
hazards and building a sustainable electrical
safety culture. Mark carries various state
electrical licenses.

Scott B. Mitchell has been involved with the

electrical industry since 1980 and is currently
the Electrical Training Coordinator for Cianbro
Corporation, a general contractor headquar-
tered in Pittsfield, Maine. Beginning his career
on his tools as an electrician, Scott progressed
into various electrical leadership roles.
Scott has experience in residential, commer-
cial, and industrial wiring with 12 years as an
instructor for electrical apprentices and elec-
trical safety trainer for all Cianbro team mem-
bers. He holds Master Trainer credentials with
NCCER, and serves as a subject matter expert
assisting with electrical curriculum develop-
ment. Scott also holds OSHA outreach trainer
and American Heart Association instructor certi-
fications. Scott has become an electrical safety
resource for Cianbro and has developed specific
electrical trainings designed to increase the
skills of the electrical group and promote safe
work practices. Scott carries various state elec-
trical licenses.

978-1-4799-4782-9/15/$31.00©2015 IEEE