EC&M - June 2025

THE TOP 40

We rank this year’s industry leaders in electrical design. Read more on pg. 14

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GROUNDING GOTCHAS

Video In this video, filmed at the NETA PowerTest 25 show, Ellen Parson interviews Lee Howard and Jacob Rioux with Hood Patterson & Dewar about “grounding gotchas.” ecmweb.com/55286324

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Gaining an AI Edge in Electrical Design

By Ellen Parson, Editor-in-Chief

One year ago this month, I wrote my viewpoint on the “ever-evolving world” of electrical design in recognition of our annual Top 40 Electrical Design Firms rankings and special report, trying to make sense of the ways in which the emergence of artificial intelligence (AI) could transform the electrical design profession. Looking back, what a difference a year makes. In my opinion, it seems almost impossible to grasp all of the ways (and extent to which) AI has been implemented in the last 12 months — both in our personal and professional lives — and early adoption in our industry is just scratching the surface of what “could be.”

Although we’ve tracked survey data on the Top 40 for many years regarding their level of adoption with augmented reality (AR) and virtual reality (VR) technologies, 2024 was the first survey in which we specifically asked how long respondents expect it will take for AI to become a “viable component” of electrical design work. Last year, 43% indicated they were “already using” AI. This year, that number jumped up 10 percentage points, and more than 30% of respondents reported that they plan to implement it in the next one to two years. How are electrical design firms currently using AI to their advantage? The top two responses this year were marketing and promotions (70%) and optimizing processes/improving efficiency (56%).

No longer a theoretical concept, AI is a practical tool that’s increasingly becoming embedded in the workflows of top consulting specifying engineers. Despite this momentum, AI’s rise in the electrical design realm — and the greater construction industry as a whole — remains somewhat tempered. According to its first annual “Construction Intelligence Study,” Slate Technologies recently surveyed senior leaders across the construction ecosystem to gauge key pain points. This research revealed that while the construction industry recognizes the strategic value of digital transformation and AI, the actual adoption of advanced technologies (such as predictive analytics) remains limited. Per the report: “This is hindered by a cautious investment mindset and persistent operational challenges, including rising material costs and unreliable forecasting tools, highlighting a significant gap between technological awareness and practical implementation. While many acknowledge the value of intelligent automation, the majority have yet to integrate tools such as predictive analytics or real-time forecasting into their planning workflows.” Uncovering some key technology gaps, the survey found that 65% of respondents had not adopted AI or predictive analytics tools for project planning or decision-making.

From the research I’ve seen so far, AI is not poised to replace engineering expertise but rather to enhance and augment it, streamlining repetitive tasks, supporting design decisions/options, and enabling a range of capabilities that have yet to be discovered. I had the opportunity to interview Chris Campbell, Vice President of Data Center Execution at Eaton Corp., at the PowerTest 25 conference hosted by NETA in March, gaining perspective and key takeaways from a panel discussion he served on as a subject matter expert related to “AI Learning — Improving Operational Efficiency and Workforce Safety.” Insisting there has never been a more exciting time to be in the electrical power industry, Campbell emphasized the need for extensive training and education surrounding AI adoption, implementation, and execution. “The training piece is critical. We have employees coming up with great use cases for artificial intelligence that we’re learning from,” he said. “So we want to have that element, but we also have to have the proper controls in place to make sure it’s not being used in a manner that it’s not intended. I personally believe that the benefits outweigh the risks, but we still have to effectively manage the risks associated with it.”

The panel discussed at length a tiered approach to AI implementation that includes having controls in place to manage such risks. “If I’m using AI to help write a performance review, it’s not as high of a risk as using AI to help troubleshoot a fault in a power distribution system,” he added. “So making sure we’re leveraging the technology and managing the risk at different tiers is going to be critical. There’s an element within electrical power services — safety is critical — but speed and creativity are too. The speed and creativity that can come from the right leverage of artificial intelligence is absolutely a competitive advantage, and the companies that figure that out and adopt the proper use of it the best are going to find that as a competitive advantage in the market.” Watch the full six-minute video interview with Campbell at ecmweb.com/55286331 for more details.

Although the future of AI is obviously yet to be fully realized, let alone fully imagined, as adoption grows — and trust in the tools improves — I think we can expect broader and deeper integration into the full life cycle of electrical system design and delivery.

Making Change Management Simple

Tools for navigating construction project change orders with ease

By Sydney Parvin and Jennifer Daneshgari, MCA, Inc.

Managing a construction project is like navigating a road trip with detours, bad weather, and a destination that changes mid-route. You know the direction you need to go, but constant changes must be addressed.

When you are on the job site, you may feel like you are the sole navigator, dealing with the roadblocks and new requests from the general contractor (GC) as they come up. But this is usually not the case. You have project team members to support your efforts. Open communication with your project team is critical, so when you do need to pivot, you can make an informed decision that lets you remain in control of your project.

Clinical research done by MCA, Inc. indicates that a typical construction project will see 30% change orders. Gaps in visibility depend on your level in the company and your ability to anticipate change orders.

Managing money, manpower, and material can be challenging when it comes to change orders. Some may be fairly obvious, depending on who you are, where you’re working, and how they’re communicated. The link between work and money is not always connected and easily managed. While you may know it’s different “work,” are you able to bill for it? Conversely, sometimes there are change orders that you have funds for that may not match the work that needs to be done.

VISIBILITY OF CHANGE ORDERS

If you’re on the money side, when do you find out? You might be the last to know. It depends on your internal processes for managing change orders. It could be:

• When an input change is pending (i.e., the project team has sent it out for a quote).

• When it’s approved (i.e., when the customer sends the official change order back).

• When the job has unusual behavior (typically a fade), which prompts the team to think through whether they should put in change orders to cover the fading material or labor estimate.

If you’re a project manager or work in the office, you may hear about change orders in a few different ways and usually when your GC/customer needs something officially.

• Receiving a proposed change order (PCO) — customer/ external request.

• Other communications, such as a verbal request, RFI, construction bulletin, or supplemental instructions.

• Weekly job review meetings.

In the field, your foremen/lead may see or hear based on impacts and fast items that they’re adapting to at the job site, such as:

• Revision of a print or answer to an RFI.

• Customer is talking with them (e.g., GC, owner’s rep).

• Project manager talking to field lead throughout the week (phone call, text, email), letting them know what they’re hearing.

• Weekly job review meetings — when you see that there is a productivity loss that can’t be explained within the current work scope.

• Updating observed percent complete, and realizing there is missing work, or extra work not in the original plan.

ID 17220729 © Sculpies | Dreamstime.com

JOB-SITE INTELLIGENCE

• Other trades (hear of a change that was sent to someone else, but you haven’t gotten it yet, or they’re back in a place that you thought was done).

These change orders can be the most difficult to capture in the office as the field teams are making many decisions each day to keep the jobs moving forward, and, in many cases, the office has no idea, according to Dr. Heather Moore’s 2013 dissertation, “Exploring Information Generation and Propagation from the Point of Installation on Construction Jobsites: An SNA/ABM Hybrid Approach.” Tack on those things that happen that you may not connect to an official change order. Sometimes it’s the things you DON’T see that you’d like to know about in advance and get documented. Key areas of scope creep or change orders needed include:

• Trade stacking — leading to delays.

• Schedule impacts — requiring work changes.

• Temporary power — adjustments not in the initial scope.

• Out-of-sequence work (less effective manpower plan, working over finishes, etc.).

• Multiple passes (go-backs) for a variety of reasons.

• Changes to job-site logistics (parking, lay-down, lifts, etc.).

WE HEAR OF THE CHANGES, BUT WHAT CAN WE DO ABOUT THEM?

The key is to get things out of your head and into an easily accessible single point of entry log. Thinking about change orders as a change in money and scope that you let the field know is coming is different than thinking about changes in work that need to be followed up with money for the defined scope. Two-way communication is key.

If you are leaning on products that use the ASTM Standard for Job Productivity Measurement, like Agile Construction® tools and/or JPAC®, you may look out for dips in productivity (lasting longer than one to two weeks), which can result from work completion that is not accounted for in the existing work breakdown structure (WBS). An example of a work breakdown structure for fire alarm installation is shown

This shows an example of a work breakdown structure (WBS) with an added fire alarm installation.

in the Photo above and discussed in a recent EC&M article, “Planning Job-Site Lighting Installations.” With your WBS as a reference, you can ask, “What are we doing that’s not in the base scope?”

During your weekly job review meetings, or observed percentage complete updates if the field lead on the job finds there is work that is not in the WBS to score, this is another indication that either scope was added since

the original plan was created, or that we missed breaking down the work in the WBS. If you didn’t initially create a WBS, start one from wherever you’re at, and document what work is left to do. Make a work plan that the team can refer to and discuss. Explicit plans can be easier to review.

Having a way to quickly document changes from all of the sources listed above, to make things visible for action,

Work Breakdown Structure: Added Fire Alarm Installation

© MCA, Inc.

is what’s needed. It needs to be simple, fast, and immediately captured. Electronic capture is best in a system that can log and categorize for future use. Whether you decide to bill for the changes or use them in negotiations and discussions, having data at your fingertips is key. Noting it in real time will save you time down the road.

The Figure above depicts how this information should flow between the field and office for change orders when there is a system in place to ensure timely communication. The project manager passes along change orders from the customer to the field, and the field passes along work requests as they are presented on the job site.

This two-way communication between your office and the field is critical. It’s also key between you and the other trades and the GC.

Here are some suggestions on how to use the information:

• Keep talking to the GC (it may take more than once, and likely will require backup).

• Keep talking to the other trades, sharing what you know, and appreciating the situation you’re all in.

• Don’t do the requested work immediately; meet with the GC to arrange for a separate team to handle the task, so the core team can stay focused on their work.

• Begin highlighting potential issues early on. Emphasize that any impact on electrical will affect all trades (adopt a positive approach).

To effectively deal with those change orders that will come, you have to:

• Recognize that small changes add up.

• Document them quickly in a single point of entry log.

• Know that small PCOs add up (>3 hours at a time).

• Catch items as early as possible, and report that there is a possible impact on drawings/contract documents.

• Put “potential” change orders on the log.

• Use the information to decide how to approach your customer.

Sydney Parvin is associate data analyst at MCA, Inc., Grand Blanc, Mich. She can be reached at sparvin@mca.net.

Jennifer Daneshgari is the vice president of financial

at MCA, Inc. She can be reached at jennifer@mca.net.

Capturing

By Tom Zind, Freelance Writer

This year’s Top 40 Electrical Design Firms see revenues spike again as demand grows for electrical work.

Even as a cloud of uncertainty — rivaling the one spawned by the Covid pandemic — descended on the U.S. economy this spring, the nation’s leading electrical design firms are largely refusing to succumb to pessimism about prospects for 2025.

Questions on the course of interest rates, taxes, regulations, and tariffs — and their possible economic repercussions — abound. But firms don’t seem overly worried, at

least for the near term. And maybe for good reason: Many had a blockbuster year in 2024 and perhaps can’t shake the feeling, or the hope, that these good times have legs.

Answering EC&M’s annual survey on business conditions in March, many of the 40 firms whose reported 2024 revenues qualify them for a spot in the EC&M Top 40 Electrical Design Firms for 2025 expressed some level of business concern about what’s happening on the policy front in Washington, D.C. Yet

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

Top 40 Electrical Design Firms

List based on proprietary survey. To get on the list to receive the survey for next year, please contact Editor-in-Chief Ellen Parson at eparson@ endeavorb2b.com or call (816) 560-6448.

NL - Not listed. This company did not appear in last year’s electrical design services revenue listing.

NA - Not available.

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

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most see a strong 2025 unfolding in which revenues and backlog continue to grow, hiring is still a priority, technology continues to exert a positive impact on their business, and demand for their services blossoms as infrastructure projects that incorporate ever more electrical backbone move ahead, though haltingly. Although uncertainty might hang in the air, design firms seem willing to see through it.

A BANNER YEAR

That might be a natural response coming off a year like 2024, which 78% of respondents said delivered a strong business climate for their firms (Fig. 1). That inched up from last year, when 76% of respondents said the 2023 business climate was strong. The recent high on that measure was reached the year before, when 91% judged the 2022 business climate as strong.

Though only one component of a business climate, revenues came in hot for this year’s Top 40. Their combined reported electrical design revenues of $5.223 billion in 2024 (the full year in which the 2025 survey results are based)

The 2024 Business Climate (N=37)

Fig. 1. The number of firms characterizing the current business climate as “strong” in last year’s survey was nearly 80%. This year, that number dropped slightly to 78%. Revenue

Fig. 2. Similar to last year’s survey results, 54% of respondents (compared to 58% last year) indicated that they had exceeded revenue expectations in 2024. set a record for this annual list (see 2025 Rankings Table on page 16). That was almost 18% higher than that reported by the 2024 Top 40, whose revenues were 13% higher than those of the prior year’s top firms. In the year prior, Top 40 collective revenues grew 22%.

For more than half of firms, final numbers for last year were a pleasant surprise. Fifty-four percent said revenues exceeded expectations (Fig. 2), little changed from last year’s survey.

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

2024 Backlog (N=36)

By

What Percentage Did Your Backlog Change?

More than a 10% decrease

to 9% decrease

or less decrease Stayed the same 5% or less increase 6% to 9% increase

to 14% increase

More than a 15% increase

(N=36)

Fig. 3. The numbers remained steady for the last several years when it comes to change in backlog. A total of 81% of firms reported an increase in backlog for 2023 compared to 86% in 2024.

The balance of firms mostly said they met expectations.

On another key metric, backlog growth was the rule. Eighty-six percent of firms said it increased last year ( Fig. 3 ), a five-percentage point

Fig. 4. Last year, two-thirds of respondents reported an increase in backlog of 5% or more in 2023. For 2024, that number approached 75%.

increase from the prior year’s Top 40. In terms of magnitude, almost three-quarters of firms said backlog increased (Fig. 4) at least 5%. But 20% reported a decline, up notably from the prior survey.

At Burns & McDonnell (No. 1), Kansas City, Mo., revenues were up almost 23% to $1.339 billion, a healthy boost attributed partly to better positioning. Mandy Olson, vice president of engineering, says an expanded electrical

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design team opened the door to more complex work that could be handled more efficiently with improved design automation and digital workflow tools.

“Clients are now seeing tangible schedule and cost benefits from the technology investment, which feeds a cycle of repeat business and referrals,” Olson says.

Backlog grew again for the firm, aided by federal and state infrastructure program business and bolstered by continued private sector investments in energy and manufacturing.

“With solid bookings across multiple business lines, we’re carrying healthy, diversified work into 2025,” says Keegan Odle, vice president of ascending business.

Salas O’Brien (No. 6), Irvine, Calif., boosted revenues 58% to $205 million, a result of scorching demand that fed strong organic growth coupled with more revenue that was booked to the firm through mergers.

“We’re working in some critical market sectors which have seen strong tailwinds

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

The Honickman Center in Philadelphia is envisioned as a bridge between home and health care, offering amenities that make it more a destination than just an ambulatory care center. The building features two levels of amenity space engaged with Chestnut Street, and amenities include a large cafe, event spaces, a large-scale lounge area, and a wearable technology bar.

and good prospects for the near-term future,” says Darin Anderson, chairman and CEO. “It’s the result of choosing the right markets and delivering to our clients.”

Heavily invested in the data center and health care markets, the firm is reaping benefits from being focused on delivering designs that address key concerns in the areas of backup power resiliency, clean power integration, and reduced electrical construction costs.

One focus, he says, is on producing innovative solutions on the design side that have long been delivered by product manufacturers. Team members have developed a patented electrical system design that reduces the amount of rigid conduit needed and labor to install it, potentially “saving millions in construction and long-term energy costs.” The company has also innovated in the area of backup power using alternative fuels, getting clients away from the heavy sunk cost for traditional diesel backup generators.

DATA CENTER, POWER MARKETS SHINE

Salas O’Brien’s focus on data centers and health care is on trend. Those two electrical design markets were judged by more respondents than any others as two

of their hottest three (Table 1) in 2024, garnering mentions from 43% each. Both data centers and power moved up dramatically from last year, when 22% and 30%, respectively, named it. Rounding out this year’s list of active markets for

the prior year were power/utilities/T&D, government, manufacturing, education, water/wastewater, and aviation.

On the ledger’s cooler side for 2024 (Table 2) were private office, hospitality, retail, oil/gas, housing, water/wastewater,

Table 1. Data centers and health care tied for the No. 1 spot as the hottest market in 2024, followed by power, government, education, and manufacturing. Interestingly, manufacturing was on the coolest market list for last year’s survey results.

Coolest Market Segments

Table 2. Again this year, private office took

by hospitality, retail, and housing.

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

and pharmaceuticals. The only big movers from last year’s list were oil/gas (moving from 7% to 21%), water (from 3% to 17%), and pharmaceutical (from 7% to 17%).

Jaros, Baum & Bolles (No. 28), New York, continued to tap the health care and surging data center market, where growing computing power needs pose ever more complex electrical design challenges, but also saw stirrings in the moribund office space.

“A growing push to rethink the traditional office environment is driving both space refreshes and new office developments,” says John Koch, a JB&B partner.

Electrical infrastructure is central to those projects, he says, because both environmental sustainability and user-friendliness — think heat pumps and improved lighting — are primary considerations. That’s especially true in many New York City building projects that must conform to new electrification mandates. That often occasions top-to-bottom building infrastructure replacements that demand a holistic design approach fusing electrical, mechanical, and plumbing teams.

“Rather than design each separately, there’s a big, coordinated package put together to make sure the right design solution is being delivered, and electrical and mechanical systems are upgraded and optimized for energy consumption,” Koch says.

Office, along with retail, another sector that has lagged, showed signs of life in markets PBS Engineers, Inc. (No. 38), San Dimas, Calif., serves. But aviation and health care were the firm’s strongest markets last year — areas where sheer scale of power demand require rigorous design.

Airport projects are growing more abundant and complex, says President and CEO Kunal Shah, because more facilities are aging and replacements and upgrades are more technologically sprawling and demanding of resiliency. A trend is toward more decentralized terminal power that involves individual airline operations having access to their own backup power.

“There’s a tremendous amount of electrical work in these projects, partly because there’s a major focus on making sure there’s reliable power,” Shah says. “Airport projects haven’t

What Kind of Change in Revenue is Your Firm Forecasting for 2025?

More than a 10% decrease 6% to 9% decrease

or less decrease Will stay the same

or less increase 6% to 9% increase

than a 10% increase

Fig. 5. Nearly 40% of Top 40 firms expect an increase in revenues this year of 10% or more. Another 22% anticipate a 6% to 9% improvement while only 14% expect more than a 10% decline in 2025.

wanted to do anything more than the bare minimum on resiliency, but that’s now shifted 180 degrees. Our designs have to account for the requisite capacity and infrastructure to support automated backup systems.”

BANKING ON NO LETUP

Opportunities like that are certain to continue into 2025, a year most design firms see as promising. In fact, more than three-quarters of respondents expect revenue increases, many forecasting 10% (Fig. 5) or higher. That’s 11 percentage points more optimism for the year in progress than last year’s respondents showed. And a higher percentage see backlog increasing (Fig. 6). But, similar to last year, almost half see only modest backlog growth (Fig. 7 on page 30) no higher than 9%. Still, substantially more (21%) see a decrease; last year decrease predictions totaled 6%.

With solid footing in multiple elements of the surging data center market, the 2025 landscape for Faith Technologies Incorporated (No. 17), Menasha, Wis., looks good, says Rob Messina, executive vice president. Design of both electrical systems and products it manufactures for data center integration work it and customers perform is

Fig. 6. The number of firms forecasting an increase in backlog for the current year held steady — from 74% in last year’s survey to 75% this year.

core to its business, which may prove impervious to economic headwinds that could kick up this year. Worries about the impact of heightened uncertainty and sticky high interest rates on construction spending are real, he says, but the company’s design niche might prove resilient.

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

data centers through at least 2030,” says Messina. “We can see some ebb and flow, but there is predicted to be pretty steady growth in that vertical.”

A decision post-Covid to focus on the foundation and realign staff to “allow people to do what they do best,” is paying growth momentum dividends for Smith Seckman Reid (No. 31), Nashville, Tenn., says Jim Dolezal, electrical technical leader. Electrical revenues were ahead of schedule in the first quarter as the firm continued its pursuit of health care, sports, and entertainment megaprojects, “a ton of ongoing smaller stuff” in areas like water and transportation, and delved into more industrial process design work in food/beverage, power systems, and data security infrastructure studies across business units.

“Electrical touches on so many things that affect our business,” Dolezal says. “Our electrical teams are working closely alongside our other internal groups and also industrial clients.”

Increased infrastructure spending, aided by federal and state dollars, could be a sustained source of more trickledown business for electrical design firms. But the future course of that spending is currently up for grabs. The Trump Administration has halted funding for many projects birthed through Bidenera legislation, including some requiring significant electrical design input, such as EV charging infrastructure, grid updates, and renewable energy expansion.

Top 40 firms, though, largely aren’t disconcerted. Only 3% of firms predict the Infrastructure Investment and Jobs Act (IIJA) will have a significant impact (Fig. 8) on their business in 2025, down from 12% who expected that for 2024. Expectations for current-year new project revenue tied to federal infrastructure funds also have declined. Almost half last year expected such funding to pad 2024 revenues by 6% to 29%; only one-third of this year’s group (Fig. 9) expect that. Two-thirds expect no more than a 5% boost, compared with 52% last year.

POLICY TRICKLE DOWN WORRIES

Yet Trump’s “Unleashing American Energy” executive order — effectively

By What Percentage Do You Expect Your Backlog to Change?

Fig. 7. Last year, nearly half of respondents expected an increase in backlog of 5% to 15%. This year, that number rose slightly to 54% for the year ending 2024.

Impact Infrastructure Investment and Jobs Act Will Have on Business in 2025 (N=32)

Projected Revenue Increase Directly from Federal Infrastructure Projects (N=30)

Fig. 8. Similar to last year’s results, more than 75% of Top 40 firms expect infrastructure legislation to have a “minor” or “moderate” positive impact on their business while close to 20% expect no impact.

halting disbursement of IIJA and Inflation Reduction Act funds — is seen by many as a clear threat to federal construction projects this year and next. While only 11% (Fig. 10 on page 32) see a significant negative impact, almost two-thirds expect a moderate or minor impact.

Fig. 9. Even more than last year (55%), 67% of survey respondents anticipate no more than a 5% revenue increase in new project revenue tied to federal infrastructure funds this year.

The federal policy upheaval has left many firms feeling uncertain — not a rare condition in the current climate. Almost 70% concurred that the IIJA, which authorized $1.2 trillion for transportation and infrastructure spending, could be repealed (Fig. 11). That

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

How Do You Think the Executive Order President Trump Signed in January 2025 Will Affect Federal Construction Projects in 2025 and 2026?

Moderate positive economic impact

Minor positive economic impact No impact

Minor negative economic impact

Moderate negative economic impact

Significant negative economic impact

Fig. 10. When asked how they think the executive order President Trump signed in January 2025 (dubbed “Unleashing American Energy”), which halted federal agencies from disbursing Infrastructure Investment and Jobs Act (IIJA) and Inflation Reduction Act (IRA) funding will affect federal construction projects in 2025 and 2026, nearly three-quarters expect a negative economic impact, ranging from minor to moderate to significant.

Now That the Federal Infrastructure Funds Have Been Frozen/Paused, Do You Believe the Infrastructure Investment and Jobs Act is in Danger of Being Repealed by the Current Administration?

of respondents

Fig. 11. Now that President Trump has federal frozen funds (via executive order) from the Infrastructure Investment and Jobs Act (IIJA), which authorized $1.2 trillion for transportation and infrastructure spending from 2022 through 2026, nearly 70% of respondents believe the IIJA is potentially in danger of being repealed while 14% answered no.

uncertainty leaves firms with exposure to infrastructure projects little choice but to watch and wait.

Federal funding is important for some infrastructure projects CDM Smith (No. 24), Boston, works on, but it may not prove essential to viability, says Matt Goss, MEP practice leader. Cutbacks are a concern, and the pace of projects going to bid could slow, but state and private sector funding could endure.

“There’s a need for energy-related infrastructure improvement, and critical things will continue to move forward, but the pace may slow — and

they may have to take a different path forward,” he says.

Salas O’Brien is monitoring the effects of closer federal review of IIJA funding on its business, says Anderson, but the consequences aren’t clear. He expects some projects won’t survive the cuts, but that Salas O’Brien and specific federal client projects that are more mission critical in nature will.

“Some decarbonization projects are being canceled, but we haven’t seen many resiliency projects affected yet,” he says.

Should that happen, some firms heavily invested in infrastructure design

work could feel the pinch. And some, like Burns & McDonnell, are hedging their bets. VP Odle says federal and state infrastructure programs continue to generate demand, but other markets could fill any gap that emerges.

“Power industry work, especially transmission protection and grid modernization design, remains our largest slice,” Odle says. “But mission-critical facilities have become one of our fastest growing sectors.”

Tariffs are another Washington, D.C. worry for firms. Almost 85% said tariffs on China, Mexico, and Canada would

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

Faith Technologies Incorporated (FTI) recently completed the installation of a 4.3MW solar array on the roof of the Excellerate facility in Little Chute, Wis. This cutting-edge system is designed to generate as much electrical energy as the facility consumes annually, reinforcing Excellerate’s commitment to sustainability and energy efficiency.

How Much of an Effect Do You Expect the New Tariffs Will Have on Your Firm’s Business in the Electrical Market?

The tariffs will have a major negative impact on my business

The tariffs will somewhat impact my business in a negative way

The tariffs will not impact my business at all

Fig. 12. At the time this survey went out, President Donald Trump’s 25% tariffs on goods imported from Mexico and Canada took effect on March 4 and then were paused until April 2. Since that time, President Trump rolled out a new set of reciprocal tariffs to match the duties other countries have put on the United States. It is yet to be seen if any of these levies will be negotiated down. However, at the time of this survey, more than 85% of respondents anticipate that the new tariffs will impact their business in a negative way.

have some negative impact (Fig. 12) on their business in the form of materials price increases and shortages that could alter the math for many building projects. All expect them to increase prices (Fig. 13) but are equally split on the magnitude.

Carollo Engineers (No. 10), Walnut Creek, Calif., specializes in water/wastewater projects that have been surging recently. Instrumentation Engineer Ron Burdick sees a chance for higher tariffs to “hit hard on the construction side, which will affect our bottom line.”

They’ll contribute to higher costs that could shelve some projects because overseas suppliers are key sources of

How Do You Think These Tariffs Will Affect Material Prices in the Electrical Market in 2025?

Significant price increase

Moderate price increase

Minor price increase

Fig. 13. Remarkably, 100% of respondents were in agreement when it comes to how they believe tariffs will affect material prices in the electrical market in 2025 — they anticipate anywhere from minor (31%) to moderate (38%) to significant (31%) price increases. Percentage of respondents

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Factors Having the Most Negative Impact on the Growth of Your Business

Economic

conditions

Difficulty finding and retaining quality employees

Stagnant or retracting market segments

Project cancellations

Supply chain disruptions

Fig. 14. Overwhelmingly similar to the last three years, Top 40 firms listed “difficulty finding and retaining quality employees” as the single most challenging task they were facing on an annual basis.

Is Your Firm Having Difficulty Filling Open Job Positions?

Employee Trends in 2024 (N=37)

Projected Employee Trends in 2025

Fig. 15. On par with last year’s results, the number of respondents experiencing staffing issues remained high at 89% — up slightly from 86% the previous year.

components like instrumentation packages, he says.

Tariff uncertainty will almost surely complicate the design process, says CDM Smith’s Goss. Projects could stall out with a lack of clarity on materials prices, what items will be hit, and what the price hike will be.

“As you bid, something might not have a tariff on it but could be applied later,” he says, “so we’re asking contractors what they think could be impacted and to let us know. Those are the conversations we’re having.”

With Washington, D.C. intrigue complicating the economic picture, the

Fig. 16. Up slightly from last year’s results, the number of Top 40 firms adding headcount in 2024 came in at 89% — up from 86% the previous year.

course of the economy is on the Top 40’s mind. More than a quarter chose economic conditions that could foreshadow a recession as their top worry from a business growth standpoint (Fig. 14). That’s up from 19% last year.

STAFFING CONCERNS PERSIST

But more worrisome, by far, is finding and keeping good talent. No surprise there, as that’s topped the list every survey in recent years. That was the top choice of 62%, up a bit from last year.

Digging deeper, the survey found evidence of growing worries about being able to fill open positions. Eighty-nine

Fig. 17. Last year, 92% of firms indicated they planned to add headcount in 2023. This year, that number decreased to 89% as nearly 3% revealed plans to reduce headcount. Lay off 3%

percent said they were having difficulties (Fig. 15). That’s tough because firms are again in hiring mode; employees were added last year by 89% of firms (Fig. 16), and the same share say they plan to add again this year (Fig. 17). As shown in Fig. 18 on page 38, more said the three hardest jobs to fill were project, supervising, and design engineers.

Engineers are more in demand at Faith Technologies Incorporated (FTI), but more on the product development side, says Messina. As the firm moves more into designing products its electrical contracting business integrates for clients,

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

product engineer is the hotter commodity. Over the next two years, he says, design staff could grow 20% to 30%, but hiring success will partly depend on making the sale to candidates.

“Our industry is not the typical landing space for a graduating engineer,” he says. “You won’t be developing the next iPhone if you’re in the electrical contracting or design world, but the industry has evolved to demand a higher level of expertise.”

After adding staff last year, PBS Engineers is now looking to trim. But that doesn’t mean the hiring challenge has gone away. Shah says he’ll forge a net reduction in design staff this year to help bring expenses more in line with expected revenue. Yet a tricky balance must be struck: selecting staff fat to cut and finding talent for roles that are becoming more essential as the business evolves.

“We’ll have to make some staff reductions a bit larger than we had thought,” he says. “But overall, that will be good for us because we’ll be leaner and more judicious on hiring, finding the right individuals with special talent.”

With a growing backlog, Carollo Engineers needs to fill slots, notably the design engineer role, Burdick says. And they ideally need to double duty as de facto leaders and mentors to take up the slack from an exit of more senior staff, some leaving for the client side or the industry entirely, he says. The 10- to 12-year veteran is the target, but they’re hard to find. That leaves new grads, who may not come fully prepared. Both options present challenges.

“A lot has to happen to turn them into power engineers,” he says. “And consulting — what we do — can be a tough gig.”

TRAINING FOR NEW CHALLENGES

Indeed, training is a top priority for design firms, especially as electrical’s scope in projects grows. Whether it’s informal mentorship and job shadowing or subject matter deep dives training is key, especially as more green talent comes on board. Once again, power systems analysis, electrical design software, and building management/automation systems rank high on the support need list (Table 3 on page

Fig. 18. For the fifth year in a row, “project engineer” earned the title of “most difficult job title to fill” for Top 40 firms followed by “supervising engineer” and “design

40). But some other new choices offered this year, reflecting clear trends, scored many mentions, including energy storage, AI, and DC power systems.

As client needs evolve and industry trends shift, JB&B is placing greater emphasis on training that extends beyond traditional project design. The firm is expanding its role by offering ongoing engineering and professional services that support clients throughout

the entire life cycle of their facilities— not just during design and construction. This continued support helps clients adapt and optimize their infrastructure systems as they evolve over time.

And as grid level battery storage demand grows, the company is positioning itself to incorporate these design elements. “We’ll have to build upon our current knowledge base to address rapid expansion in that area,” says JB&B’s Koch.

Tied with health care for the hottest market sector for Top 40 firms in 2024, data centers continue to experience a construction boom as high power demands for AI drive the market.

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

Areas in Which Employees Need the Most Training

5 (tie)

5 (tie)

5 (tie)

8 (tie) 4

8 (tie) 4 Bonding and grounding

Table 3. Again this year, Top 40 firms reported the need for training in various areas, but especially emphasized power system analysis. However, energy storage and artificial intelligence emerged as new in-demand training categories.

New demands and opportunities are also driving Carollo Engineers to train staff in new subject matter, Burdick says. Its water-focused business is incorporating more green energy and renewables, for instance, so some knowledge in that area exists. But as more co-generation and solar project opportunities emerge, he adds, the company might look to build, partly through more focused training, a group to tackle that more intensely.

AI ADDS TO TECH TOOLBOX

But, he says, “the most impactful thing we can do” in the training realm, might be around AI. Others echo Burdick, pointing to AI as a technology component that must be explored, understood, and deployed in their businesses.

More than half, though, say they’re already using AI in electrical design work (Fig. 19), up 13 percentage points from last year. Drilling down, 35% say they’re using (Fig. 20 on page 42) it to perform specific design tasks, up from 13% last year. Various other possible applications drew mentions, including marketing/promotions work and process improvement, which each tallied more than “generating, analyzing and optimizing designs.”

An “emerging technology council” at Smith Seckman Reid spearheaded the launch of an AI chatbot this year to help design teams to reach deeper into the firm’s project archives.

How Long Will It Take for AI to Become a Viable Component of Design Work?

(N=32)

Fig. 19. Whereas AR and VR enhance real-world objects on a virtual platform to create immersive environments, artificial intelligence (AI) enables computer applications to mimic human-like intelligence and resolve problems, make predictions, and provide solutions. When asked when they expected AI to become a viable component of electrical design work, 43% of respondents last year indicated they were “already using” it. This year, that number jumped to 53%.

“We want to develop better tools for our design engineers, knowledgebased design guidelines that can help them write specs, narratives, reports, size conductors properly, etc.,” Dolezal says. “Some of that information can be hard to find, so AI will help us bridge that gap.”

But AI isn’t risk free. It does raise concerns about data security, Dolezal says, a sensitive issue for the firm because it does some federal government work. “There’s caution about our

information getting out or bad information getting in,” he says.

Similar concerns have caused CDM Smith to go slow with AI. For now, it’s “more on the softer side of things, supporting RFP responses and speeding up technical research and investigation,” and less on the design side, Goss says. QA/QC are concerns as are ethical, legal and insurance-related worries and, he added, “I’m not sure those are particularly clear now.”

While AI emerges other designrelated technology tools are gaining a

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

Ways Firms Plan to Incorporate AI into Their Business

Generate, analyze, and optimize electrical designs/BIM

Human resources/employee recruitment

Marketing/promotions

Diagnostics and troubleshooting

Optimize processes/improve efficiency

Gather intelligence data on electrical equipment

Improve profitability/cost estimating

Labor management

Predictive maintenance

Energy management

Autonomous systems/robots/drones

Finance/accounting

Creating multiple outcome scenarios/solutions for clients on the same project

Other

Percentage of respondents

Fig. 20. How do Top 40 firms plan to harness the power of AI going forward? Similar to last year’s results, the greatest number of survey respondents noted plans to use AI to “optimize proccesses/improve efficiency” and for “marketing/promotions.”

firmer foothold. Reported augmented and virtual reality (AR/VR) usage grew appreciably. Around 60% said they’re now using both AR and VR (Fig. 21 and Fig. 22 on page 44), up from 40% and 48%, respectively, last year.

Firms looking to use AR and VR in their business in coming years say (Fig. 23 and 24 on page 44) they’re primarily eyeing them to generally enhance collaboration, modify designs, and plan in the pre-construction phase. Specific current electrical design uses, respondents say, include virtual walkthroughs; development of models for O&M manuals, performance monitoring and work orders; space planning and owner coordination; product development and site placement; conflict resolution; and generating images,

How Long Will It Take for Augmented Reality to Become a Viable Component of Design Work?

Already using it

One year

Two years

Three years

Four years

Five years or more

Fig. 21. When it comes to augmented reality (AR) adoption, Top 40 firms have consistently reported participation. While 42% of Top 40 firms said they were “already using” AR last year, this year that number grew to 59%.

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THE 2025 TOP 40 ELECTRICAL DESIGN FIRMS

renderings, and videos of design concepts and completed installations.

Having utilized 3D modeling to generate construction plans, JB&B has been accelerating the use of VR to walk owners and contractors through models it develops, Koch says. The next frontier is AR, leveraging it to work with architectural and project planning partners to “help end users better understand the space.”

At Salas O’Brien AR/VR has so far benefited non-electrical elements of the practice more, Anderson says, but the opportunity is there. It could find a place alongside BIM and others as a tech tool ensuring better design coordination and efficiency, reducing repetitive tasks and aligning with “our feverish efforts to improve the quality of our product delivery, communicate better and faster and have better outcomes.”

Editor’s Note: At press time (in early June), the U.S. tariff situation continues to be fluid; however, many of the Trump Administration’s harshest tariffs have been paused (and some exemptions have been made). As of June 1, a 10% universal tariff, 25% on cars and auto parts (with some exceptions), 30% tariff on Chinese imports (with some exceptions), and 25% tariffs on goods from Canada and Mexico not covered in the United States-Mexico-Canada Agreement (USMCA) were all active. On May 28, however, a U.S. trade court blocked most of the tariffs in a ruling that found the President had overstepped his authority by imposing across-the-board duties on imports from U.S. trading partners. On May 29, a federal appeals court temporarily paused this ruling, allowing the tariffs to remain in effect until the government’s appeal is considered (the Administration must respond by June 9). These developments all occurred after this survey was sent out. However, the questions about tariffs are geared toward determining if electrical design firms expect tariffs (in any form) will have an impact on their firm’s business in 2025 and 2026.

Tom Zind is a freelance writer based in Lee’s Summit, Mo. He can be reached at tomzind@att.net.

How Long Will It Take for Virtual Reality to Become a Viable Component of Design Work?

Already using it

One year

Two years

Three years

Four years

Five years or more

Fig. 22. Virtual reality adoption stayed about the same as the past two year’s of survey results — rising from 52% in 2024 to 63% this year among firms saying that they’re “already using” the technology.

Key Areas Firms Plan to Incorporate AR into Their Business

with other

Fig. 23. As has been the case for the past many years, Top 40 firms already using this technology overwhelmingly indicated they plan to use AR for “collaboration with their own clients.”

Key Areas Firms Plan to Incorporate VR into Their

Fig. 24. Mirroring last year’s responses, Top 40 firms that are already using this technology overwhelmingly indicated they plan to use VR for “collaboration with their own clients.”

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How to Eliminate Ground Loops in Building Electrical Systems

Easy to create and hard to detect, ground loops can only be prevented through proactive design and strict NEC compliance.

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a parallel path for neutral current on the grounding conductor. This connection is a typical source of a ground loop.

two or more points in an electrical system that are nominally at ground potential are connected by a conducting path such that either or both points are not at the same ground potential.”

Under normal conditions, neutral current arises from load unbalance in 3-phase, 4-wire systems or from electrical circuit harmonics. While grounded (neutral) conductors are designed to carry current, grounding conductors are not. If a grounded conductor is improperly grounded at multiple points, neutral current may flow through unintended parallel paths, such as grounding conductors and the overall grounding system, creating a ground loop.

Figure 1 illustrates an example of a system with a ground loop problem. In the one-line diagram, neutral current is brought to the grounding system through a second bonding jumper, which violates National Electrical Code (NEC) Sec. 250.30(A)(1). Please note that all figures in this article use generic symbols to represent current and are based on the 2023 edition of the NEC. Refer to the symbol list in Fig. 1 for clarification. Not all connections are depicted in the diagrams. None of the figures in the article should be used for any real project, which grounding system shall be designed and constructed per applicable code and standards. The primary intent is to identify

potential ground loop problems within the systems rather than to analyze the exact flow or quantity of current in detail.

NEC GUIDELINES FOR GROUND LOOP PREVENTION

Although the 2023 NEC doesn’t explicitly define ground loops, Art. 250 outlines methods to prevent them:

• Section 250.6 mandates that “the grounding and bonding of electrical systems, circuit conductors, surge arresters, surge-protective devices, and conductive normally non-current-carrying metal parts of equipment shall be installed and arranged in a manner that will prevent objectionable current.” Objectionable current refers to unwanted current, such as neutral current, flowing through grounding and bonding conductors, which are not designed for current-carrying under normal conditions. “Currents resulting from abnormal conditions such as ground faults, and from currents resulting from required grounding and bonding connections shall not be classified as objectionable current,” as noted in Sec. 250.6(C).

• Section 250.30(A)(1) restricts grounding and bonding to a single point for separately derived systems to prevent parallel paths for neutral current.

Fig. 1. The second bonding jumper at the branch panelboard creates

•

•

or

stud, and position the

Next bend the strap at the foldline (centerline). Fold the strap over the cables and insert the locking tab in the opening as shown to hold

Fig. 2A. This one-line diagram with a grounding electrode connection at the source meets the Code requirements for a separately derived system. The figure is similar to NEC Exhibit 250.14.

Fig. 2B. This one-line diagram with a grounding electrode connection at the first disconnect means meets the Code requirements for a separately derived system. The figure is similar to NEC Exhibit 250.15.

• Section 250.142 prohibits using a grounded conductor for grounding load-side equipment to avoid creating objectionable current.

In the following paragraphs, several NEC-related scenarios will be reviewed where potential Code violations should be carefully considered during design and construction.

SCENARIO #1: SINGLE SEPARATELY DERIVED SYSTEM

Let’s start with a single separately derived system, which is defined as “an electrical power supply output, other than a

service, having no direct connection(s) to circuit conductors of any other electrical source other than those established by grounding and bonding connections,” as noted in Art. 100.

Sections 250.30(A)(1) and (5) require the neutral conductor to be grounded and connected to the grounding electrode system at a common point between the source terminal and the first disconnect means. “A grounding electrode conductor connection for a single separately derived system shall be made at the same point where the system bonding jumper is connected,” [Sec. 250.30(A)(5)]. This ensures that objectionable current does not flow through the grounding system.

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Fig. 3. This one-line diagram for an outdoor transformer (either service transformer or separately derived system) serving a single building shows a grounding electrode connection at the first disconnect means.

Exhibits 250.14 and 250.15 in the NEC illustrate these requirements. Figures 2A and 2B (similar to NEC exhibits) show line current (Iø) and neutral current (In) flow under normal conditions. From the figures, no parallel path is created when the separately derived system is grounded and bonded at a single point. No closed circuit forms between the neutral and grounding conductors, so no neutral current (In) flows through the grounding system (In1 = 0A as indicated in the figures).

SCENARIO #2: OUTDOOR TRANSFORMERS

For outdoor service transformers, except those with impedance-grounded neutral systems, Sec. 250.24(A)(2) requires at least one additional connection from neutral to a grounding electrode at the transformer or elsewhere outside the building. This outdoor grounding connection helps mitigate the effects of lightning, line surges, or accidental primary-to-secondary crossovers on the interior portion of the premises wiring system. So, a bonding jumper is required and is typically installed at the exterior service transformer besides a main bonding jumper inside the building, usually at the indoor main switchboard.

For exterior transformers serving as separately derived systems but not as electrical services, Sec. 250.30(A)(1), Exception No. 2 allows “a system bonding jumper at both the source and the first disconnect means shall be permitted if doing so does not establish a parallel path for the grounding conductor.”

Therefore, for exterior transformers, an additional grounding point at each service transformer is required [Sec. 250.24(A) (2)], or an additional system bonding jumper is permitted [Sec. 250.30(A)(1), Exception No. 2] for a separately derived system (Fig. 3). The electrical system is grounded and bonded at two different locations, which could potentially lead to a ground loop problem. However, the resistance of the earth between these two grounding and bonding points is typically high enough that any objectionable current flowing through it is insignificant, which mitigates ground loops in most cases. This is why Exception No. 2 of Sec. 250.30(A)(1) clarifies that “for the purposes of this

exception, connection through the earth shall not be considered as providing a parallel path” for neutral current.

Here, two terms need to be clarified for their difference: main bonding jumper and system bonding jumper. Both serve a similar function — providing connections between a grounded circuit conductor and an equipment grounding conductor — to complete a ground fault current path back to the source. However, a main bonding jumper is used at the service entrance, while a system bonding jumper is used in a separately derived system.

SCENARIO #3: SINGLE OUTDOOR TRANSFORMER FEEDING MULTIPLE BUILDINGS

Figure 3 illustrates a scenario where an additional grounding connection is required at an outdoor service transformer feeding a single building. But what if it supplies multiple buildings? Can the neutrals still be grounded at both the outdoor transformer and each building’s main disconnect? The answer varies by configuration. Figure 4 on page 53 provides an example of an exterior transformer feeding two separate buildings, highlighting how grounding requirements can differ.

In this example, if there is no continuous metallic path between Building No. 1 and Building No. 2, the neutral-toground connection is allowed in each building. However, if the continuous metallic path exists and is bonded to the building grounding system, it may create a ground loop. Inter-building metallic connections, such as telecom outside plant copper backbone cable and metallic water/gas pipes, are common in multi-building facilities. In these cases, a system or main bonding jumper should not be installed at both buildings’ main switchboards to prevent ground loops through the metallic paths.

With ground loops, neutrals can unintentionally serve as ground fault return paths — a condition recognized and generally prohibited by the NEC with limited exceptions. Section 250.32(B)(1), Exception No. 1 permits the

Fig. 4. This electrical schematic shows a typical bonding and grounding arrangement for an outdoor transformer serving multiple buildings.

MCB1 TIE CB MCB2 (CLOSED) (OPEN) (CLOSED)

TO LOAD TO LOAD

EQUAL POTENTIAL BETWEEN TERMINAL BARS AND "G" BAR DUE TO BONDING CONNECTION BETWEEN THEM, SO NO CURRENT FLOW THROUGH THIS (In11 = 0 AND In21 = 0).

TERMINAL BAR

In11 = 0

In21 = 0

SINGLE GROUNDING ELECTRODE

CONDUCTOR CONNECTION TO THE TIE POINT OF THE GROUNDED CONDUCTORS FROM EACH POWER

SOURCE IS PERMITTED, PER 250.24(A)(3) OR PER 250.30.(A)(6)

NEUTRAL CURRENT FLOWS BACK TO POWER SOURCE THROUGH SINGLE PATH SO NO GROUND LOOP IS CREATED.

Fig. 5A. This one-line diagram shows a double-ended substation arrangement with a single grounding electrode connection.

FIGURE 5A - DOUBLE-ENDED SUBSTATION WITH A SINGLE GROUNDING

grounded conductor to serve as the ground fault return path for a feeder to a separate building/structure, but only for existing installations that comply with the 2002 NEC or earlier, and that meets all three listed conditions, including

“no continuous metallic paths bonded to the grounding system in each building or structure involved. ” In such cases, an equipment grounding conductor may not be permitted in the related feeder.

Fig. 5B. This one-line diagram shows a double-ended substation arrangement with multiple grounding electrode connections. Note: Transformers T1 and T2 are not in close proximity.

Fig. 6A. As this one-line diagram shows, a ground loop may form if both switchboards are connected to ground and feed a 3-pole transfer switch with a solid neutral. Note: Some bonding & grounding conductors are not shown.

Per UL 891, switchboards used as service equipment shall be marked “suitable for use as service equipment” and include a bonding jumper connecting the neutral to the enclosure and ground bus. NEC Sec. 408.3(C) also requires “each switchboard, switchgear, or panelboard, if used as service equipment, shall be provided with a main bonding jumper ”. If the main bonding jumper is omitted, as in Fig. 4 to avoid ground loops, the switchboard may no longer qualify as service entrance-rated equipment. In this case, coordination with the electric utility or local AHJ is required, and a field evaluation and UL recertification may be necessary.

SCENARIO #4: SINGLE BUILDING FED BY MULTIPLE FEEDERS/SERVICES (DOUBLE-ENDED SECONDARY SUBSTATION)

For multiple separately derived systems feeding a single building, “a common grounding electrode conductor for multiple separately derived systems shall be permitted This connection shall be made at the same point on the separately derived system where the system bonding jumper is connected ” [Sec. 250.30(A)(6)] For dual-fed electrical services, the single grounding electrode conductor is also permitted to connect to the tie point of grounded conductors from each power source, if both services are “in a common enclosure or grouped together in separate enclosures, and employing a secondary tie,” [Sec. 250.24(A)(3)]. A double-ended substation with main-tie-main

configuration is a typical example. As shown in Fig. 5A on page 53, the switchboard is supplied by two power sources with two main breakers and a tie breaker, all grounded at a common point. In this setup, neutral current returns to the source through a single path, avoiding any ground loop.

However, “if the power sources are not in close proximity, a common ground point is not recommended. The impedance in the neutral bus connection may become large enough to prevent effectively grounding the neutral of the source at the remote location. The interconnect may inadvertently become open, allowing the transformer to operate ungrounded ” [IEEE Standard 142-2007, Section 1.6.6] In dual-fed (doubleended) substations, where transformers are located remotely from the switchboard, each transformer must be individually grounded at its location (Fig. 5B on page 54). If the connection between GEC1 and GEC2 forms an effective path for current (indicated as dashed line in Fig. 5B), such as through the building grounding system, a parallel path for neutral current may be created, potentially resulting in a ground loop. When multiple grounding and bonding connections cause objectionable current, Sec. 250.6(B) lists four permitted alterations to eliminate or minimize such currents.

With Fig. 5A, a traditional ground fault sensing scheme, such as differential ground fault protection, can be used for a double-ended substation with a common permissible ground shared by multiple power sources. However, in Fig. 5B, where

Fig. 6B. As this one-line diagram shows, no ground loop will form if both switchboards are connected to ground and feed a 4-pole transfer switch with a switched neutral. Note: Some bonding & grounding conductors are not shown.

neutrals are grounded at multiple locations, ground fault currents may return through various paths, depending on fault conditions. In this case, a modified differential ground fault protection scheme is recommended to capture and sum up ground fault current through all varied paths. This ensures reliable system protection, even when multiple ground-fault current paths exist during a fault, as noted in the whitepaper, “Modified Differential Ground Fault Protection for Systems Having Multiple Sources and Grounds,” by David L. Swindler and Carl J. Fredericks.

SCENARIO #5: ELECTRICAL SYSTEM WITH TRANSFER SWITCHES

For buildings supplied by alternate power sources, such as generators in addition to electric utility power, transfer switches are used to transfer power between sources. Proper bonding of the grounded conductor is essential to avoid ground loops. Figures 6A (on page 54) and 6B illustrate a system fed by two medium-voltage transformers — one from the electric utility and the other from generators. Main or system bonding jumpers are provided at both the normal and emergency power switchboards.

The system in Fig. 6B, using a 4-pole transfer switch with a switched neutral, is acceptable. However, if both switchboards

feed a 3-pole transfer switch with a solid neutral, as shown in Fig. 6A, a ground loop may form.

In California, as noted in its Electrical Guide for Health Facilities Review 2022, the Department of Health Care Access and Information (HCAI) requires 4-pole transfer switches for separately derived Emergency Power Systems (EPSs) — that is, systems with generator-side grounding and neutral-to-ground bond — for hospital projects.

CONCLUSION

Ground loop issues often result from overlooked design flaws or improper installations. To minimize risk, it’s essential to carefully follow NEC guidelines, ensure correct bonding, select appropriate grounding points, and remain aware of potential parallel current paths. While ground loops are easy to create, they can be extremely difficult to diagnose and fix, making proactive prevention vital for safe and reliable electrical systems.

Hua Yan, P.E., LC, RCDD is a Principal Electrical Engineer with Stantec, Irvine, Calif. He has 30 years of design experience across multiple sectors, including mission-critical facilities, aviation, industrial, commercial, and more. He can be reached at Hua.Yan@stantec.com.

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CODE BASICS

NEC Requirements for Feeders

Do you know the requirements for feeder conductor ampacity and circuit protection?

By Mike Holt, NEC Consultant

Article 215 covers the installation, conductor sizing, and overcurrent protection requirements for feeder conductors not over 1,000VAC or 1,500VDC (Fig. 1).

Feeders are the conductors between the service disconnect, a separately derived system, or other power supply, and the final branch-circuit OCPD [Art. 100].

CONDUCTOR SIZING

Feeder conductors must be sized to have an ampacity not less than the largest of the calculations in Sec. 215.2(1) or (2).

(1) Without conductor ampacity correction/adjustment. The ampacity must be at least 125% of the continuous loads, plus 100% of the noncontinuous loads, based on the temperature rating of equipment per Sec. 110.14(C)(1) and Table 310.16, before conductor ampacity correction and/or adjustment.

(2) With conductor ampacity correction/adjustment. The ampacity must be at least 100% of the total load after conductor ampacity correction and/or adjustment per Table 310.15(B)(1)(1) and Table 310.15(C)(1).

Example without conductor ampacity adjustment

Question: What size conductors are required for a 100A continuous load and 100A noncontinuous load where the equipment is rated for 75°C conductors?

(a) 1/0 AWG (c) 3/0 AWG

(b) 2/0 AWG (d) 4/0 AWG

Solution:

Step 1: Determine the minimum conductor ampacity.

Minimum conductor ampacity = (100A × 125%) + 100A = 225A

Step 2: Determine the conductor size. 4/0 AWG rated 230A at 75°C column [Table 310.16].

Answer: (d) 4/0 AWG

Fig. 1. Article 215 covers the installation, conductor sizing, and overcurrent protection requirements for feeder conductors not over 1,000VAC or 1,500VDC.

Example with conductor ampacity adjustment

Question: What size conductors rated 90°C are required for four currentcarrying conductors supplying a 180A continuous load in an ambient temperature of 100°F, where the equipment is rated for 75°C conductors?

(a) 4/0 AWG (c) 500kcmil

(b) 300kcmil (d) 600kcmil

Solution:

Determine the feeder conductor size by the larger of Sec. 215.2(A)(1) or (2) [Sec. 215.2(A)].

Step 1: The circuit conductors must have an ampacity of 180A after conductor ampacity temperature correction [Table 310.15(B)(1)(1)] and adjustment [Table 310.15(C)(1)], based on the conductor’s insulation rating of 90°C. One way to find the conductor size is to determine

the conductor ampacity required to supply a 180A continuous load at 100% after correction and adjustment.

Conductor ampacity at 90°C = continuous load at 100% ÷ (correction × adjustment)

Continuous load = 180A

Correction [Table 310.15(B)(1)(1)] = 91% (100°F ambient temperature with 90°C conductor)

Adjustment [Table 310.15(C)(1)] = 80% (four current-carrying conductors)

Conductor ampacity at 90°C column = 180A ÷ (91% × 80%) = 180A ÷ 73% = 247A

Step 2: Select the conductors from the 90°C column of Table 310.16 [Sec. 110.14(C)(1)(b)(2)].

4/0 AWG THWN-2 is suitable because it has an ampacity of 260A at 90°C before any correction and adjustment.

Determine the feeder conductor size by the larger of Sec. 215.2(A)(1) or (2) [Sec. 215.2(A)]. In this case, based on the conditions specified in this example, 4/0 AWG is the minimum size conductor.

Answer: (a) 4/0 AWG

Note 2: The NEC recommends that feeder conductors be sized to prevent a voltage drop of not more than 3%. It also recommends that the total voltage drop on both feeders and branch circuits not exceed 5%.

NEUTRAL CONDUCTOR SIZE

The neutral conductor must be sized to carry the maximum unbalanced load per Sec. 220.61, but must not be smaller than the equipment grounding conductor (EGC) per Sec. 250.122 [Sec. 215.2(B)], as shown in Fig. 2.

Example

Question: What size neutral conductor is required for a feeder consisting of 3/0 AWG phase conductors and one neutral conductor protected by a 200A OCPD when the unbalanced load is 30A and the equipment is rated for 75°C conductor?

(a) 3 AWG (c) 6 AWG

(b) 4 AWG (d) 8 AWG

Solution: Section 220.61 and Table 310.16 permit a 10 AWG neutral conductor rated 30A at 75°C [Sec. 110.14(C)(1) and Table 310.16] to carry the 30A unbalanced load, but must not be smaller than the 6 AWG EGC per Sec. 250.122.

Answer: (c) 6 AWG

OVERCURRENT PROTECTION SIZING

Feeder OCPDs must have an ampere rating of not less than 125% of the continuous loads, plus 100% of the noncontinuous loads [Sec. 215.3].

Example

Question: What size feeder overcurrent protection is required for a 100A continuous load and a 100A noncontinuous load?

(a) 200A (c) 250A

(b) 225A (d) 300A

Solution:

(100A continuous load × 125% continuous load) + 100A noncontinuous load = 225A [Sec. 240.6(A)]

Answer: (b) 225A

Exception No. 1: Where the assembly,

Fig. 2. The neutral conductor must be sized to carry the maximum unbalanced load per Sec. 220.61 but must not be smaller than the equipment grounding conductor, per Sec. 250.122.

including the OCPDs protecting the feeder(s) is listed for operation at 100% of its rating, the ampere rating of the OCPD can be sized at 100% of the continuous and noncontinuous loads.

MUST HAVES

A feeder must have an equipment grounding conductor [Sec. 215.6].

Each feeder disconnect rated 1,000A or more supplied by a 4-wire, 3-phase, 277V/480V wye-connected system must have ground-fault protection of equipment per Sec. 230.95 and Sec. 240.13 [Sec. 215.10].

Exception No. 2: This Section does not apply if ground fault protection of equipment (GFPE) is provided on the service per Sec. 230.95.

IDENTIFICATION

The feeder neutral conductor must be identified per Sec. 200.6 [Sec. 215.6(A)].

EGCs can be bare, covered, or insulated. Insulated EGCs 6 AWG and smaller must have a continuous outer finish — either green or green with one or more yellow stripes [Sec. 250.119(A)] [Sec. 215.6(B)]

Insulated EGCs 4 AWG and larger can be permanently reidentified with

green marking at the time of installation, where accessible [Sec. 250.119(B)].

Where premises wiring is supplied from more than one nominal voltage system, phase conductors must be identified by phase or line, and by system at termination, connection, and splice points [Sec. 215.12(C)(1)].

Identification of the phase conductors can be by color coding, marking tape, tagging, or other means approved by the authority having jurisdiction. The method of identification must be readily available or permanently posted at each branch-circuit panelboard. It must be sufficiently durable to withstand the environment involved, and not be handwritten.

When a premises has more than one voltage system supplying branch circuits, the phase conductors must be identified by phase and system. This can be done by permanently posting an identification legend that describes the method used, such as color-coded marking tape or color-coded insulation.

The NEC does not require a specific color code for phase conductors. Whatever color scheme is used, make it consistent wherever phase conductors are terminated or accessible throughout

CODE BASICS

CodeWatch

This e-newsletter, published four times per month, is dedicated to coverage of the National Electrical Code. The content items are developed by well-known Code experts.

CodeWatch promises to:

• Explain how to properly apply the Code

• Test your knowledge of the Code

• Provide information on upcoming Code-related seminars and shows

• Offer Code quizzes and real-world Code violations

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See all of our EC&M e-newsletters at www.ecmweb.com

the entire premises. This is especially important when identifying different system voltages and neutrals (Fig. 3).

Barriers must be placed such that no energized phase busbar or terminal is exposed in equipment supplied by:

• A feeder tap [Sec. 240.21(B)] when the OCPD into which the feeder taps terminate is in the open position [Sec. 215.15].

• Transformer secondary conductors [Sec. 240.21(C)] when the OCPD into which the secondary conductors terminate is in the open position [Sec. 215.15].

SURGE PROTECTION

Where a feeder supplies any of the following occupancies, a surge-protective device (SPD) must be provided:

(1) Dwelling units.

(2) Dormitory units.

(3) Guest rooms and guest suites of hotels and motels.

(4) Areas of nursing homes and limited care facilities used exclusively as patient sleeping rooms [Sec. 215.18].

The SPD must be installed in or adjacent to distribution equipment that contains the branch-circuit OCPD(s).

Surge protection is most effective when closest to the branch circuit. Surges can be generated from multiple

sources, including lightning, the electric utility, or utilization equipment.

The SPD must be either Type 1 or Type 2. The distribution SPDs must have a nominal discharge current rating (In) of at least 10kA.

Where the distribution equipment supplied by the feeder is replaced, all the requirements of Sec. 215.18 apply.

AVOIDING CONFUSION

Feeders have specific requirements that differ from those of branch circuits. You can think of them as being the main arteries in a city street layout, as opposed to side streets. They handle more traffic at higher speeds and thus are designed and built differently.

As with main arteries, feeders also have destinations other than side streets. For example, a fire pump is supplied by a feeder, not a branch circuit. So, how do you tell these circuits apart? The origin of a feeder is a service disconnect, a separately derived system, or other power supply. The origin of a branch circuit is a panel supplied by a feeder.

These materials are provided by Mike Holt Enterprises in Leesburg, Fla. To view Code training materials offered by this company, visit www.mikeholt.com/code.

Fig. 3. Whatever color scheme is used, make it consistent wherever phase conductors are terminated or accessible throughout the entire premises.

CODE QUIZ OF THE MONTH

Test Your Code IQ

How much do you know about the National Electrical Code?

By Mike Holt, NEC Consultant

All questions and answers are based on the 2023 NEC.

Q1: When judging equipment, considerations such as cybersecurity for network-connected to address its ability to withstand unauthorized updates and malicious attacks while continuing to perform its intended safety functionality shall be evaluated.

a) normal equipment

b) emergency equipment

c) standby power equipment

d) life safety equipment

Q2: An insulated or covered conductor and larger is permitted, at the time of installation, to be permanently identified as an equipment grounding conductor at each end and at every point where the conductor is accessible.

a) 8 AWG

b) 6 AWG

c) 4 AWG

d) 1/0 AWG

Q3: All single-phase receptacles rated 150V to ground or less, 50A or less and 3-phase receptacles rated 150V to ground or less, or less installed in locker rooms with associated showering facilities shall be GFCI protected.

a) 60A c) 100A

b) 75A d) 125A

Q4: Metal cable trays containing only non-power conductors (such as communications, data, and signaling conductors and cables) shall be electrically continuous through approved connections or the use of a(an)

a) grounding electrode conductor

b) bonding jumper

c) equipment grounding conductor

d) any of these

Q5: When replacing a non-groundingtype receptacle where attachment to an

equipment grounding conductor does not exist in the receptacle enclosure, a(an) can be used as the replacement.

a) non-grounding-type receptacle

b) grounding receptacle

c) AFCI-type receptacle

d) tamper-resistant receptacle

Q6: Where a feeder supplies branch circuits in which equipment grounding conductors are required, the feeder shall include a(an) , to which the equipment grounding conductors of the branch circuits shall be connected.

a) equipment grounding conductor

b) grounding conductor

c) bonding conductor

d) grounded conductor

See the answers to these Code questions online at ecmweb.com/55292469.

When is Ampacity Not Really Ampacity?

How the ampacity requirements to feeder conductors demonstrate definitions don’t seem to matter as much as the intent of the wording in the NEC.

By Russ LeBlanc, NEC Consultant

The term “ampacity” is used hundreds of times throughout the Code and is defined in Art. 100 as “the maximum current, in amperes, that a conductor can carry continuously under the conditions of use without exceeding its temperature rating.” Based on this definition, I think it’s accurate to say the conditions of use would include any adjustments for current-carrying

conductors or corrections for ambient temperature.

The conductor ampacities in Table 310.16 are based on not more than three current-carrying conductors and wiring installed in an 86°F ambient temperature. The adjustment factors in Table 310.15(C)(1) are applied when there are more than three current-carrying conductors, and the correction factors in Table 310.15(B)(1) are applied when the

ambient temperature is other than 86°F. So, one would assume, anytime the Code requires us to calculate a minimum conductor ampacity, we should include the ambient temperature correction factors and current-carrying adjustment factors too. This is true for sizing conductors as specified in Secs. 240.21(B), 240.21(C), 334.80, 409.20, 424.4(B), 430.22, 430.24, 460.8(A), 630.11(A), and virtually every other time the Code establishes a minimum conductor ampacity.

This makes sense and aligns with the definition of “ampacity.” However, when applying the requirements to feeder conductors as specified in Sec. 215.2(A), definitions don’t seem to matter as much as the intent of the wording.

I would like to say thank you to instructor Jeremy Weed for the following example showing us why. In this scenario, the feeder has four current-carrying conductors and is installed in an ambient temperature of 125°F. The load includes 75A of noncontinuous load and 119A of continuous load. The copper THHN conductors are protected by a 225A breaker. For Sec. 215.2(A)(1), the intent is to size the conductor to not less than 125% of the continuous load, but excluding any corrections or adjustments. The intent here is to keep the conductor/equipment terminal connection from overheating.

For our example, (119A x 125%) + 75A = 223.75A minimum. The intent is for us to choose the wire directly from Table 310.16 to correlate with the equipment terminals, but without applying any corrections or adjustments. A 4/0 conductor in the 75°C

column of Table 310.16 is rated for 230A and satisfies this requirement. This method, however, does not align with the literal definition of ampacity because the conditions of use for the example installation are different than those specified in Table 310.16. If we apply the definition of ampacity here — and include corrections for the 125°F ambient temperature and adjustments for four current-carrying conductors — the conductor will need an ampacity of 223.75A. That would require a 400kcmil THHN, which would have an ampacity of 231.04A under the specified conditions of use. (380A x .76 x .8 = 231.04A).

Which conductor size is correct? Well, as Jeremy pointed out, based on Example D3(a) in Annex D, the 4/0 THHN would apparently satisfy Sec. 215.2(A)(1). But there is another piece to this puzzle we must find before we choose our wire. Section 215.2(A)(2) requires the feeder conductors to have “an ampacity not less than the maximum

load to be served after the application of any adjustment or correction factor in accordance with Sec. 310.14”. Why bother stating “after the application of any adjustment or correction factor” when the definition of ampacity already includes that? It seems a little redundant and unnecessary, but this is the clue we needed to explain that Sec. 215.2(A)(1) should be calculated excluding any adjustments or corrections despite the seemingly incorrect usage of the term “ampacity” in Sec. 215.2(A)(1). The actual load is 194A (119A + 75A = 194A), and, for our example, the 400kcmil conductor had an ampacity of 231.04A and would satisfy both Sec. 215.2(A)(2) and Sec. 215.2(A)(1). The 4/0, however, would have an ampacity of only 139.84A (230A x .76 x .8 = 139.84A) and would not satisfy Sec. 215.2(A)(2).

Jeremy pointed out that a 350kcmil THHN would satisfy Sec. 215.2(A)(1) if we ignore the true definition of

ampacity and instead follow the intent rather than the literal wording, since it’s ampacity in the 75°C column of Table 310.16 is 310A. That 350kcmil THHN would also satisfy Sec. 215.2(A)(2), since its ampacity after applying corrections and adjustments would be 212.8A (350A x .76 x.8 = 212.8A).

Section 215.2(A) requires feeder conductors to have an ampacity no less than the greater of Sec. 215.2(A)(1) or Sec. 215.2(A)(2). This means both of these calculations must be done to choose the correct wire size. You will just need to decide how closely you want to adhere to the meaning of clearly defined terms and literal wording versus the intent of the words. In the case of Sec. 215.2(A), ampacity may not mean “ampacity” when it comes to sizing conductors for continuous loads. By the way, we could probably discuss the same issues in Sec. 210.19 for branch-circuit conductors and Sec. 230.42(A) for service entrance conductors, too.

CODE VIOLATIONS

Illustrated Catastrophes

By Russ LeBlanc, NEC Consultant

All references are based on the 2023 edition of the NEC.

SUNSCREEN WON’T HELP THESE CABLES

Sunlight has taken its toll on these cables. The jacket has cracked and crumbled off, leaving the insulated conductors exposed directly to the sun, rain, snow, and ice. This type of damage certainly did not happen overnight. These cables were most likely installed before the 2023 Code, but it is a great example of the damage that can happen from long-term exposure to the sun. For power-limited cables installed in corrosive, damp, or wet locations, Sec. 722.3(J) requires power-limited cables to comply with the applicable requirements in Secs. 110.11, 300.5(B), 300.6, 300.9, and 310.10(F). Section 110.11 would apply to this outdoor wet location and prohibits conductors and equipment from being located in damp or wet locations unless identified for use in the operating environment.

Section 300.6 is also applicable and requires cable sheathing, fittings, supports, and support hardware (among several other items) to be made of materials suitable for the environment in which they are installed. Where nonmetallic cable jackets and other nonmetallic equipment are exposed to sunlight, Sec. 300.6(C)(1) requires the materials to be identified as sunlight resistant or listed as sunlight resistant. Lastly, Sec. 722.179(A)(11) requires nonmetallic cables used in wet locations to be listed for use in wet locations and marked either “wet” or “wet location.”

IMPROPER USE OF EMT AND FLEXIBLE CORD

Electrical metallic tubing (EMT) cannot be used to support boxes. Period. End of story.

Section 358.12(2) prohibits EMT from being used for the support of luminaires or any other equipment except a conduit body no larger than the trade size of the EMT. Whomever installed the wiring and lights to light up this parking lot sign supported two boxes using EMT. Facing the weatherproof lampholders up to the sky is a violation of Sec. 110.3(B) as there are markings on the side stating to aim horizontally or below. In this position, they could fill up with rainwater or melting snow, causing significant damage to the equipment. Neither the round box at the end of the EMT nor the box in the middle of the I-beam is supported correctly and in accordance with any of the

requirements in Sec. 314.23(A) through (H). Using flexible cord as a permanent wiring method between two boxes is a violation of Sec. 400.12(1). Using LFMC or LFNC instead of flexible cord

would have been two other Code-compliant options. Securing the flexible cord to the EMT installed on the building is a violation of Sec. 358.12(2) as well as Sec. 300.11(C).

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CODE VIOLATIONS

By Russ LeBlanc, NEC Consultant

How well do you know the Code? Think you can spot violations the original installer either ignored or couldn’t identify? Here’s your chance to moonlight as an electrical inspector and second-guess someone else’s work from the safety of your living room

or office. Can you identify the specific Code violation(s) in this photo? Note: Submitted comments must include specific references from the 2023 NEC.

Hint: These splices are not for temporary power.

‘TELL THEM WHAT THEY’VE WON...’

Using the 2023 NEC, correctly identify the Code violation(s) in this month’s photo — in 200 words or less — and you could win a $25 Amazon gift card. E-mail your response, including your name and mailing address, to russ@russleblanc.net, and Russ will select one winner (excluding manufacturers and prior winners) at random from the correct submissions. Note that submissions without an address will not be eligible to win.

APRIL WINNER

This month’s winner is Daniel Brown, an EC&M reader from North Ridgeville, Ohio. He correctly cited some of the violations in this photo, including Sec. 406.9(B)(1), which requires 15A and 20A, 125V and 250V receptacles in wet locations to have an enclosure that is weatherproof regardless of whether an attachment plug cap is inserted or not. That same Section also requires those receptacles to be listed and identified as being the weather-resistant (WR) type. Section 210.8(B) requires these outdoor receptacles to be provided with GFCI protection. One other problem is the melted face of the top left receptacle. This has obviously been exposed to extreme heat. To provide a safer and Code-compliant installation, all of these duplex receptacles should be replaced with WR-type receptacles, and the correct type of covers should be installed along with GFCI protection if not already provided.

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