Electrical problems in commercial and industrial construction projects are not the same as those found in residential construction. Industrial job sites come with tighter timelines, greater coordination demands, and more demanding electrical systems. Mistakes can lead to equipment failures, inspection delays, safety hazards, and costly downtime.
That’s why trained electricians play such a crucial role in keeping large-scale projects on track. In this post, we’ll explore the most common electrical problems encountered on big construction sites—what causes them, why they matter, and how skilled tradespeople are trained to troubleshoot and prevent them.
TABLE OF CONTENTS
- Why Electrical Issues are Common in Large-Scale Builds
- Problem #1: Circuit Overload in New Buildings
- Problem #2: Code Violations and Compliance Mistakes
- Problem #3: Grounding Issues
- Problem #4: Large-Scale Lighting System Challenges
- Problem #5: Safety Hazards on Active Construction Sites
WHY ELECTRICAL ISSUES ARE COMMON IN LARGE-SCALE BUILDS
Electrical systems in industrial construction projects are far more complex than those found in residential homes. While a house might require a few circuits to power lights, appliances, and HVAC systems, an industrial facility could be running heavy machinery, multi-phase motors, control panels, automation systems, and high-voltage distribution networks—all at once.
Plus, industrial projects often operate under tight timelines dictated by production demands or contract penalties. When delays happen or trades overlap, electrical installations may be rushed, and mistakes may be made.
Another factor is the skill level of the contractors. Not everyone has the same level of experience, especially with industrial-grade systems. Inconsistent workmanship, outdated methods, or poor documentation can lead to costly mistakes and safety risks.
PROBLEM #1: CIRCUIT OVERLOAD IN NEW BUILDINGS
Every circuit has a limit based on the wire size, breaker capacity, and overall design. When that limit is exceeded, the system can overheat, trip breakers, damage equipment, or even start an electrical fire. Warning signs of an overload include flickering lights, warm outlets, tripped circuit breakers, or the smell of burning plastic.
Imagine you’re working on the construction of a large manufacturing facility. During the build-out phase, temporary power is routed from a main panel to various work zones using extension cords and temporary panels.
A crew sets up several high-draw power tools to the same temporary 30-amp circuit. Each tool pulls around 20 amps on its own, and when multiple tools run simultaneously, the total demand far exceeds the circuit’s rating.
So what happens? The excess energy causes the breaker to trip repeatedly, disrupting work. If the breaker doesn’t trip fast enough, wires can overheat, risking insulation damage. Expensive tools may get damaged from inconsistent voltage.
Overloaded circuits can lead to big problems
To prevent this, electricians are taught to:
- Calculate electrical load accurately before installation
- Design circuits with buffer capacity to handle startup surges or additional tools
- Use dedicated circuits for high-draw equipment
- Install temporary distribution panels with the right amperage and grounding
PROBLEM #2: CODE VIOLATIONS AND COMPLIANCE MISTAKES
On commercial and industrial job sites, code violations and compliance mistakes can lead to serious consequences, such as failed inspections, equipment damage, or worker injury. Common issues include:
Improper wire sizing: Undersized wiring can overheat under load, creating an electrical fire hazard
Inadequate working space around panels: When space is too tight due to poor layout planning, electricians may not have safe access to perform work
Improper grounding [link] and bonding: Failing to properly ground electrical equipment or bond metal parts can lead to shock hazards or system instability—especially critical in facilities with sensitive electronics or explosive environments
Overfilled conduits: Packing too many wires into a conduit can cause overheating
Use of non-rated materials: Using residential-grade materials or fixtures in an industrial environment can be a major violation and poses a significant safety risk
To prevent such issues, electricians are taught to:
- Read and interpret the most recent version of the electrical code
- Spot code violations before they become expensive problems
- Work with inspectors and engineers to ensure installations pass from the start
- Understand environmental ratings for hazardous or wet areas
PROBLEM #3: GROUNDING ISSUES
Grounding provides a safe path for electricity to return to the earth in the event of a fault. When done incorrectly, risks can include:
- Electric shock hazards for workers
- Nuisance tripping of breakers or ground fault interrupters
- Damage to sensitive electronic controls or automation systems
- Voltage fluctuations or erratic electrical equipment behaviour
For example, take a chemical processing plant project. A motor control centre (MCC) is installed to power large pumps and agitators. But the grounding conductor installed from the MCC back to the main panel is undersized and improperly terminated on a nearby steel beam—not on the main grounding bus.
When one of the pump motors develops a fault, the breaker fails to trip because the fault can’t return to ground properly. The excess energy causes the motor to overheat and catch fire, causing thousands in equipment damage and halting production.
To prevent this, electricians are taught to:
- Size and install grounding electrode conductors properly
- Ensure all metallic components are bonded together
- Use grounding bushings, lugs, and bars correctly
- Test and verify the continuity and resistance of grounding systems
- Apply specialized grounding methods for environments with moisture, vibration, or explosive gases
PROBLEM #4: LARGE-SCALE LIGHTING SYSTEM CHALLENGES
Designing and installing lighting for multi-level buildings, warehouses, or outdoor spaces presents unique challenges.
Lighting must be planned for multiple levels, zones, and functions, such as offices, stairwells, storage areas, and loading docks. Each area has different lighting needs and regulations. For example, outdoor areas like parking lots and walkways require weather-rated fixtures.
Outdoor lighting fixtures need to be weather-rated
Plus, running wire safely and efficiently over hundreds of feet, often through steel framing, drop ceilings, and mechanical chases, takes careful planning to avoid voltage drop, interference, and safety risks.
To prevent these issues, electricians are trained to:
- Interpret lighting layout plans and control wiring diagrams
- Understand load calculations for lighting panels
- Select and install the right fixtures, sensors, and controls for different environments
- Work with lighting designers and energy consultants to meet efficiency targets
PROBLEM #5: SAFETY HAZARDS ON ACTIVE CONSTRUCTION SITES
With dozens of tradespeople working simultaneously, temporary setups in use, and systems still in progress, electrical hazards are everywhere on active construction sites. Common problems include:
- Exposed wiring and open panels
- Ungrounded cords or missing GFCIs
- Wet conditions raising the risk of shock or electrocution
- Arc flashes from faulty connectors or leads
- Confusion over which circuits are live or incomplete
To prevent these issues, electricians are taught to:
- Inspect the job site daily for hazards
- Follow lockout/tagout procedures
- Use PPE like gloves, insulated tools, and arc-rated clothing
- Follow site-specific safety protocols
LEARN HOW TO HANDLE COMMON ELECTRICAL PROBLEMS IN COMMERCIAL BUILDINGS
At Herzing College, we equip future electricians with the skills and confidence to thrive on commercial and industrial job sites. Our 24-week pre-apprenticeship electrician training includes:
- Hands-on training with real-world electrical equipment and tools
- In-depth instruction on the latest codes, safety practices, and troubleshooting methods
- Problem-solving simulations based on common construction challenges
Click below to get full program details and chat live with an admissions advisor. We’re here to help!
