In the busy, competitive environment of construction in the UAE, electrical contractors are always managing the pressures of deadlines, physical budgets, and required quality. When the project comes down to something critical, like switchgear, the initial price point is often the primary talk point. However, experienced project managers and foreman know that the true cost of an installation is the cost over the duration of that project – and beyond.
True cost containment is a strategic calculation – by this, you are minimizing costly delays on site, mitigating the risk of rework, preventing failures, and confirming dependable operation far into the future. A well orchestrated plan and execution of the switchgear installation works together to protect your margins, improve your reputation, and lead to future work with that single client.
Along with this paper, here are 10 proven methodologies for achieving true cost-saves in your upcoming installation of switchgear projects, from planning, to turnover.
1. The Blueprint for Savings: Invest in Pre-Installation Planning & Design Review
The Tip: Treat the planning phase as your most valuable project asset. A meticulous review of design documents and site conditions before equipment arrives is your primary defense against budget overruns.
- Why It’s Inexpensive: Recognizing a design conflict, not enough means of egress, or the lack of a piece of equipment while looking at the drawings costs a small fortune, or not cost at all. Correcting that same issue while you are on site, will lead to costly change orders, lost production time, or not meeting the project milestone.
- Advice in Action:
- Have the client, consultant, and their key on site supervisors attend a “pre-install” meeting. During this meeting, visually walk through the installation using the layout drawings, outwardly reviewing everything; structure or floor load, widths of doors and hallways, crane lift paths, cable trench location, etc.
- Trust your experience and knowledge and make suggestions for value-engineering options. This is a great time to initiate in-line switchgear and other equipment if it will provide adequate performance while saving space and materials.
2. Partner for Performance: Choose the Right Supplier, Not Just the Lowest Price
The Advice: Your switchgear vendor should be considered a partner instead of a supplier. Look out for electrical switchgear vendors with a good reputation in quality standards, local certification, and reliable technical support.
- Why it’s Cost Effective: The hidden costs of using uncertified or poor-quality switchgear is significant. Consider early failure of components, spare part sourcing difficulties, non-compliance with local regulations (i.e. DEWA/ADDC/FEWA) and the consequential downtime for the end-user. The costs mentioned account for more than the slightly lower purchase price of an uncertified unit.
- Recommended action:
- Investigate suppliers like switchgear.ae that have a track record of certification to International Standards (IEC) and a proven track record in the GCC.
- Ensure they have a local warehouse for critical spare parts and dedicated technical support for the design lifespan of the switchgear and the commissioning.
3. Master the Move: Prioritize Proper Logistics and Material Handling
The Advice: Schedule the delivery, unloading and assembly of the switchgear as if you were planning a military operation.
- Why it’s a good investment: A dented panel or a damaged Busbar Chamber from mishandling is a direct monetary loss. It could have you waiting weeks for repair or replacement, and equally frightening, one could have an incident (safety) which could have been avoided. It is imperative to use the right equipment during this transportation phase (e.g., scissor lifts, pallet jacks, and spreader bars for lifting).
- Your Actionable Advice:
- Identify the truck type and delivery time. Patrol the access route to confirm it is clear, level, and sound based on structure loading requirements.
- Have the appropriate tools and a trained crew waiting on standby when the truck arrives to unload. It is critical to understand you are only lifting the assembly using manufactured designated points—do not use instrument transformer hooks to lift the entire assembly.
4. Just-in-Time Delivery: Optimize Your Site Logistics
The Tip: Work with your supplier to have it delivered as close to installation date as possible.
- Why it’s Cost-Effective: Keeping switchgear on-site for weeks consumes security costs, protected storage for switchgear, and likely is taking valuable space which other trades need to use. Also, the longer it is on-site, the greater the chance of damaging the switchgear due to dust, humidity or other construction activities.
- Actionable Advice: Embed your in-depth installation schedule with the supplier logistics team delivering the switchgear. A trusted partner will accommodate a ‘just in time’ delivery and ensure the switchgear arrives on the exact date you are ready to install it.
5. Build in Flexibility: Standardize on Modular and Scalable Designs
The Tip: Advocate for modular switchgear designs Where appropriate to the project scope.
- Why it is good to do: Modular, compartmentalized units are faster and easier to install and align, allowing for labor hours to be saved. The flexibility in design also allows for easy future expansions or modifications, which minimizes disruption on the job site and leads the client to view your company as the logical choice for future modifications or upgrades.
- What to do: When reviewing designs, discuss the benefits of modular switchgear with the client and their consultant regarding long-term operations, as well as a reduced lifetime cost.
6. The Foundation of Success: Don’t Cut Corners on the Base
The Tip: A level, stiff, and code-compliant foundation or base frame is the key to an efficient install.
- Cost-Effective Solutions: An uneven base quickly converts what should be a simple panel alignment into a frustrating and prolonged ordeal, and more importantly, mechanically stresses busbars and the primary components, creating hot spots and failures. The few hours you save rushing your base work will be lost ten times over aligning the project, and can cost you significantly in repairs down the line.
- Actionable Tips: Use high-precision laser levels for installation, and check stationary foundation anchor bolts for good placement; otherwise, regular shims can be used (do not use materials that can be compressed).
7. Off-Site Fabrication: Leverage Pre-Fabricated Busbar and Cable Kits
The Tip: Investigate whether your supplier has pre-engineered busbar systems and/or pre-cut, pre-terminated cable kits.
- Why it is Cost Effective: This process moves complex, labor-intensive tasks off the busy and often hectic construction site and into a whole different level of provided controlled environment in the factory. This process eliminates measurement errors, reduces on-site waste, and dramatically speeds the interconnect process. As a result, this will lead to a faster, cleaner, and more dependable installation.
- Actionable Advice: When requesting a quote, be specific and ask the supplier if they provide pre-fab busbar and cable kits as a value-added service. The small amount increase in material costs are almost always well worth the trial savings on labor time.
8. Knowledge is Power: Train Your Crew on the Specific Product
The Tip: A familiar crew is an efficient crew. Ensure your team is briefed on the specific make and model of the switchgear they will be installing.
- Why it’s Cost-Effective: A team that understands the specific interlocks, assembly sequence, and torque settings for the equipment will work faster and with more confidence. This prevents accidental damage from improper handling, which can void warranties and create costly delays.
- Actionable Advice: Request installation manuals, videos, or even a brief on-site training session from your supplier before the installation begins. This small time investment pays for itself in improved productivity and fewer errors.
9. Test to Avoid Costly Failures: Integrate Thorough Pre-Energization Checks
The Tip: Never treat testing as an optional extra. It is a critical, non-negotiable phase of the installation process.
- Why it’s Cost-Effective: Discovering a wiring error, a high-resistance connection, or a misconfigured protection relay before energization is a simple fix. Discovering the same fault after energization can lead to catastrophic equipment damage, tripping of the entire system, and immense reputational harm. Testing is the cheapest insurance policy you can buy.
- Actionable Advice: Mandate a suite of tests including Insulation Resistance (IR), contact resistance (Ductor), and primary injection testing for protection relays. Use calibrated equipment and document every result for the handover package.
10. The Professional Finish: Document Everything for a Smooth Handover
The Note: Detailed documentation is the last step in an economical project for any Switchgear Company in UAE.
- Why It Is Economical: A complete and professional handover package (including as-built drawings, test reports, manufacturer manuals, warranty certificates, etc.) will speed up your project sign-off and final payment. It shows extreme competence, and it is a clear reference point for any future service. As a result, your company will be the obvious choice to pursue an ongoing maintenance contract.
- Tip to Action: You should have someone on your team throughout the project compile the handover package and not wait until then end. That can include marking up any field changes on the single-line diagrams.
Conclusion: Building a Reputation, One Installation at a Time
In the challenging challenges of construction in the UAE, cutting-edge switchgear installation is a trademark of a competent, forward-thinking contractor. This is a mentality that values long-term value and workflow over independent, superficial immediate savings.
By using these ten principles, from strategic partnerships and project planning to acceptance testing and documentation, you will do more than just save money on a single project. You will build a brand and reputation of “quality and reliability” which you will be able to rely on for many years.
Are you ready for your next switchgear installation project to be safer, more efficient, reliable, and profitable? The switchgear.ae team stands ready to EXPLORE high-quality, certified equipment and high-quality technical support from design to commissioning. Would you push the contact form and send us a request today for a consultation and let’s begin a dialogue about building a safer, more reliable electrical infrastructure together?
