Warehouse & Light-Industrial TI Electrical

The most important question on many industrial electrical projects is:

What equipment is actually being installed?

OTC reviews available equipment information such as:

• Nameplate voltage

• Amperage

• Phase

• Horsepower

• Manufacturer requirements

• Disconnect requirements

• Starting characteristics

• Equipment location

The electrical design should follow the equipment requirements rather than assuming the existing building power will work.

A building may have three-phase electrical service and still not have the correct power available where a new machine is being installed.

Equipment may require:

• 208V three-phase

• 480V three-phase

• 120/208V distribution

• 277/480V distribution

• A dedicated transformer

• A new feeder

• A local disconnect

OTC verifies the actual building voltage and distribution before planning the equipment connection.

480V distribution is common in larger commercial and industrial facilities because it allows significant loads to be served efficiently.

OTC can install and modify systems involving:

• 480V feeders

• Three-phase panels

• Disconnects

• Equipment circuits

• Transformers

• Distribution equipment

Higher-voltage distribution can also allow power to be carried closer to the load before stepping down to 208Y/120V where needed.

Transformers are often needed when the building voltage does not match the equipment or tenant requirements.

A common commercial configuration is:

480V distribution → Transformer → 208Y/120V distribution

Transformers may serve:

• Office areas

• Receptacles

• Lighting

• Equipment

• Local panels

• Specialty loads

OTC evaluates transformer size, location, ventilation, feeder requirements, and downstream distribution as part of the overall system.

Large equipment should not be powered by simply extending the nearest available circuit.

Industrial and warehouse equipment may require:

• Dedicated feeders

• Local disconnects

• Motor circuits

• New panelboards

• Larger conductors

• New conduit pathways

• Transformers

OTC sizes and routes the electrical infrastructure around the actual equipment requirements.

Light-industrial tenants may operate equipment such as:

• CNC machines

• Compressors

• Production equipment

• Packaging equipment

• Pumps

• Motors

• Conveyor systems

• Welding equipment

• Specialty manufacturing machinery

Some of these loads can significantly change the electrical requirements of the building.

That is why the equipment package should be reviewed before major electrical construction begins.

Adding production equipment can quickly consume the available capacity of an existing facility.

OTC evaluates:

• Existing service size

• Panel capacity

• Feeder capacity

• Transformer capacity

• Existing building load

• Proposed new equipment

If the available electrical system cannot support the new tenant, the project may require:

• Larger panels

• Additional distribution

• New transformers

• New switchgear

• A commercial service upgrade

Identifying that early is critical because major service equipment can affect engineering, permitting, utility coordination, cost, and schedule.

Large warehouse spaces can benefit from placing electrical distribution closer to the equipment being served.

A new subpanel may reduce the need for multiple long branch circuits and provide room for future expansion.

OTC can install local distribution for:

• Production areas

• Warehouse equipment

• Office build-outs

• Battery chargers

• Mechanical equipment

• Future machinery

The decision depends on available upstream capacity and the layout of the facility.

Warehouse buildings can create long distances between the electrical room and the equipment.

Long feeder runs require consideration of:

• Conductor size

• Voltage drop

• Conduit routing

• Equipment load

• Installation access

OTC plans these runs around both electrical requirements and the physical building.

In larger facilities, locating distribution closer to the load can sometimes provide a cleaner solution than repeatedly running circuits across the entire warehouse.

Warehouse tenant improvements often include lighting modifications or full lighting upgrades.

OTC can install:

• LED high-bay fixtures

• Linear high-bays

• UFO high-bays

• Aisle lighting

• Work-area lighting

• Emergency lighting

• Occupancy controls

Fixture layout should account for ceiling height, racking, aisle locations, and how the space is used.

Lighting should support the warehouse operation rather than simply provide a high overall light level.

Large warehouses may not need every fixture operating at full output all day.

OTC can install controls including:

• Occupancy sensors

• 0–10V dimming

• Zoned controls

• Daylight controls

• Time-based controls

Different aisles, storage areas, and work zones can be controlled independently depending on facility use.

Warehouses may also require power for:

• Forklift chargers

• Battery chargers

• Maintenance equipment

• Material-handling equipment

• Specialty charging systems

These loads should be reviewed before installation because larger charging systems can create meaningful demand on the electrical system.

Many warehouse tenant improvements also include office space.

That may require separate electrical systems for:

• Workstations

• Conference rooms

• Breakrooms

• Lighting

• Receptacles

• IT equipment

• HVAC

The office and warehouse portions of the project should be coordinated as one electrical system even though they use power differently.

Existing warehouses frequently contain electrical systems left behind by previous tenants.

OTC may find:

• Old machinery circuits

• Abandoned disconnects

• Unused feeders

• Existing transformers

• Incorrect panel schedules

• Empty conduits

• Previous tenant modifications

Some of this infrastructure may be useful.

Some may no longer be appropriate for the new tenant.

OTC verifies what is actually installed before deciding what can be reused.

Existing:

• Feeders

• Panels

• Transformers

• Disconnects

• Conduit

• Lighting

• Equipment circuits

may sometimes be reused if the ratings, condition, location, and capacity work for the new equipment.

Reusing the correct infrastructure can save substantial time and cost.

Reusing the wrong infrastructure because it is already there can create a much bigger problem later.

Many warehouse and light-industrial electrical projects happen while the facility remains operational.

OTC can coordinate around:

• Production schedules

• Forklift traffic

• Loading areas

• Equipment shutdowns

• Shift changes

• Active warehouse aisles

Work can be phased by area or scheduled during planned downtime when necessary.

Industrial facilities change.

Equipment gets added.

Production expands.

Tenants change processes.

Where practical, OTC considers reasonable future growth when planning:

• Panels

• Feeders

• Conduit

• Transformer capacity

• Distribution locations

A small amount of planning during the original build-out can make the next equipment addition significantly easier.

A complete warehouse or light-industrial TI electrical scope may include:

• Electrical demolition

• Existing circuit tracing

• New service or distribution

• Switchgear

• Transformers

• Subpanels

• Equipment feeders

• Disconnects

• Three-phase circuits

• Machinery connections

• Forklift or equipment chargers

• High-bay lighting

• Lighting controls

• Office electrical

• Emergency lighting

• Exterior electrical

• Testing

• Panel labeling

• Punch-list corrections

OTC coordinates these systems around the complete operation rather than treating the warehouse as a collection of individual circuits.