Volume 2 Issue 4 of Connected.
Electrical contractors continue to face ongoing challenges limiting their ability to complete a project in a timely and cost effective way. Labor shortages, quickening timelines and budget constraints all contribute to how quickly or efficiently a project can be completed. Green building initiatives are also presenting unique challenges with requirements for more environmentally friendly products and processes that focus on waste reduction.
To address these ongoing challenges, more electrical contractors are turning to prefabricated electrical solutions. Prefabrication refers to the overall action of assembling a variety of parts or components at a manufacturing site and transporting those sub-assemblies to a construction jobsite where they will be set in place to expedite construction.
WHY CONSIDER PREFAB SOLUTIONS?
According to John Galliher, Sales Representative for Eaton's Crouse-Hinds, the use of prefab solutions by electrical contractors has grown exponentially in the past 10 years. While Eaton has offered prefab components for many years, Galliher recalls earlier efforts being more accepted by contractors working on huge casinos and hotels on both coasts where a “cookie cutter” approach was needed - all rooms generally needed the same components. Customers told them what they needed, then Eaton would assemble a box for each room containing all the components — wires, fittings, receptacles, boxes, etc. — in the correct order, with instructions. The contractor would not have to leave the room once unpacked, saving time and conserving effort.
In recent years, most large contractors in Indiana have moved to owning their own prefab shops, says Galliher. Contractors will purchase some prefab components like Crouse-Hinds Quick-Lok™ outlet boxes, with fittings included, and incorporate those in their own prefab processes. “It's saving them two to three steps in their prefabrication process.”
WHY INCORPORATE PREFAB SOLUTIONS INTO PROJECTS?
Time savings - Using prefab materials decreases the amount of labor spent on a jobsite, particularly during installation. Prefab products make onsite labor more efficient, allowing electricians to make the best use of their time and skill set.
Cost savings - With prefab products enabling more efficient installation, time on the jobsite decreases, as do delays caused by harsh weather or other interruptions. This helps to calculate project costs more accurately. According to Dodge Data & Analytics' 2020 SmartMarket Report , 81 percent of firms and contractors agree that prefabrication provides significant improved cost predictability.
Quality control - Since prefab parts are manufactured in temperature-controlled facilities, they are produced to meet high quality-control standards. Also, offsite assembly lessens imperfections caused by harsh outdoor climates or other external factors.
Less environmental impact - Assembling prefab materials offsite reduces disturbance of the environment surrounding a jobsite. With more streamlined delivery of sub-assembled parts, onsite traffic is lowered, as well as fuel cost and usage. Also, scraps and other materials are more easily recycled in a contractor prefab shop or factory setting.
Jobsite safety - With prefabricated electrical products reducing installation time, less time spent on the jobsite equates to less time for accidents to occur. Workers also have decreased chances of becoming overfatigued, which can lead to accidents. With shorter project timelines, the opportunity for vandalism and theft at the jobsite decreases as well.
Eaton's Crouse-Hinds series Quick-Lok™ outlet box is a terrific example of the benefits prefab products offer electrical contractors, says Galliher. Released approximately a year ago, the Quick-Lok™ box is rapidly becoming a standard line item on a purchase order rather than ordering the separate components it incorporates. Initial objections to a higher cost have been virtually negated by the realized time and cost benefits of the product.
While competitors offer similar products, Galliher highlighted why Quick-Lok outlet boxes surpass the competition's offerings.
- The connectors are mounted on the outside of the box, allowing more cubic capacity inside the box for wire, internal fire pads and more. Pre-installed pigtails are also an option.
- The fittings are permanently secured to the box rather than snapped onto the box, preventing loose or lost fittings.
- The box features patented S-curve shaped brackets, allowing two brackets to be interlocked and mounted side by side on one stud and making installation easier.
- The box includes attached cable management brackets to hold cable in place while snapping cable into the connector, eliminating the need to attach a separate cable strapping device.
- The Quick-Lok box, when coupled with Eaton's B-Line series telescoping bracket, becomes the ultimate prefab solution. The BBT-HF telescoping bracket features auto-height adjustment of 18", offers hands-free installation and adjusts to accommodate stud widths from 14.5" to 25". The box, bracket and mounting plates can be ordered pre-assembled to save time and labor onsite.