Problem: By the end of the 2024 concrete season, KLAW Industries needed to increase production capacity to meet growing customer demand. However, the electrical service at our factory had become the bottleneck, preventing further expansion.

Solution: Upgrade the factory's electrical service to support increased production capacity. The challenge was completing the upgrade at minimal cost and before the start of the 2025 concrete season. To do this, I learned how to bend conduit, size industrial circuits, pull wires, and wrangle master electricians, NYSEG inspectors, and lineman crews.

In the end, we paid ~$75,000 for the electrical upgrade and had it complete by January.

Steps Taken

1) Select and Manage Contractors- Negotiated pricing and terms with electrical contractors, replacing an underperforming electrician to prevent further delays and keep the project on schedule.

2) Coordinate with Utilities and Inspectors- Worked closely with NYSEG, the master electrician, and local inspectors to navigate the complex permitting, approval, and installation process for a new electrical service.

3) Complete Excavation and Concrete Work In-House- Coordinated our internal team to perform all excavation and concrete work, reducing contractor costs and maintaining control over the project schedule.

4) Install Internal Electrical- Designed the concrete foundation myself and coordinated our internal team to prepare and pour the pad, reducing contractor costs.

5) Procure and Install Equipment- Hired specialized contractors for the transformer and main electrical panel installation while completing all internal wiring and conduit installation in-house.

6) Replace old service- Disconnected the old electrical service and installed an internal High-Leg Delta transformer to maintain compatibility with legacy electrical equipment on the new service.