Introduction
Upgrading an older factory to meet modern electrical codes can be a daunting and expensive task. However, with some strategic planning and smart solutions, it is possible to rewire your factory without breaking the bank. In this article, I'll walk you through the key steps and considerations for cost-effectively rewiring your factory to meet code.
Assess Your Current Electrical System
The first step is to thoroughly assess your current electrical system and identify problem areas.
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Hire a qualified electrician to conduct a full evaluation and point out any hazards, overloaded circuits, improper wiring, lack of grounding, etc.
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Request an estimate for a complete rewire. This will give you an idea of the potential cost.
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Prioritize the biggest issues - focus first on problems that pose safety risks.
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Document areas that fall short of modern codes. Know exactly what needs to be addressed.
Thorough assessment will reveal the scope of required updates and allow you to budget and plan accordingly.
Explore Your Rewiring Options
Once you've assessed the electrical issues, explore different options for addressing them:
Partial Rewires
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If your facility has distinct areas or circuits with varying needs, consider partial rewires focused on the worst sections. This reduces costs compared to a blanket rewire.
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Upgrade the most outdated or overloaded circuits first.
Phase the Project
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Given budget constraints, it may be necessary to phase the rewire over time. Coordinate with your electrician to create a multi-year plan, starting with the most critical needs.
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Rewire one section or circuit per year over several years to spread out costs.
DIY Small Jobs
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For minor upgrades like installing new switches or outlets to meet code, consider doing these yourself to save on labor costs.
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Stick to simple tasks if knowledgeable. Leave major electrical work to the professionals.
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Even small DIY jobs add up to big savings.
Alternative Materials
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Using lower-cost wiring alternatives like aluminum instead of copper can yield major material savings, so long as safety is not compromised.
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Discuss options with your electrician to see if any hazardous areas or major circuits require copper.
Leverage Incentives and Tax Credits
There are a number of incentives and tax credits available to offset rewiring costs:
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The EPAct tax credit offers a deduction of $0.30 - $0.60 per square foot for upgrades that achieve electrical savings.
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Many utility providers offer rebates for energy efficient upgrades like new lighting or machinery controls.
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Check state/local programs - for example California offers cash incentives for manufacturing efficiency improvements.
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Grants may be available. Reach out to local economic development offices.
Every little bit helps knock down the overall price tag. Be sure to tap all available resources.
Use Cost-Effective Labor
Electrical work can represent a major portion of your rewiring budget. Get creative with labor:
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Hire apprentice electricians who work under supervision at a lower hourly rate. Ensure quality work.
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Explore deals with electrical vocational schools to utilize students/trainees for portions of the work. Provides experience for them and savings for you.
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See if the manufacturer of your electrical equipment offers installation/rewiring services. Bundled packages can be cheaper.
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Ask your electrician about off-peak or volume discounts for large projects completed during slower seasons or alongside other facilities they service.
Finding affordable qualified labor will pay dividends on a tight budget.
Prioritize Safety, But Avoid Over-Engineering
Your top priority should always be safety. However, scope creep can quickly balloon costs.
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Stick to the minimum rewiring needed to meet safety codes, rather than elective improvements. Defer nice-to-have upgrades for a later date.
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Work with your electrician to find safe, cost-effective solutions. Avoid over-engineering unless absolutely required by code.
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For example, if conduit is very expensive, ask about other acceptable wiring methods like cable trays or cable buses.
Focusing on safe, code-compliant minimum requirements will maximize your budget.
Create a Realistic Budget
Cost overruns can put your entire rewiring project at risk. Create a detailed electrical upgrade budget:
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Build in adequate contingency - at least 10% more than your electrician's estimate for unforeseen issues.
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Account for all costs - materials, labor, permits, inspections, drawings, outage impacts, contingencies.
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Phase in multiple smaller budgets for a multi-year project rather than one huge budget.
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Be prepared to adjust or defer some upgrades if required to stay on budget. Keep safety as the priority.
Sticking to a well-built budget ensures you complete cost-effective upgrades without busting your bank.
Conclusion
Rewiring an outdated factory to meet modern safety codes is a big task, but also a smart investment. With good planning, phasing, cost control, and budget contingencies, it is possible to complete necessary electrical upgrades without blowing your budget. Prioritize safety, explore creative solutions with your electrical contractor, and take advantage of all available incentives and rebates. Thorough assessment, preparation, and realistic budgeting are the keys to a successful and affordable rewiring project.