Manufacturing plant electrical refurbishment
0
Every maintenance window was handed back on time. Zero unplanned production stoppages across an 8-month refurbishment programme.
8mo
Out-of-hours and weekend working across 8 months, fully integrated into the client's production schedule without disruption.
4
Four independent production zones refurbished sequentially, each with a zone-by-zone commissioning and handover process.
The Challenge
Refurbishing the electrical infrastructure of a continuously operating manufacturing facility is one of the most logistically demanding projects in the sector. Every intervention must be planned around production, validated against live process requirements and fully reversed within a working shift window.
Zero Downtime Planning
Our engineers worked alongside the client's facilities and production teams to identify safe working windows — typically nights and weekend shutdowns — and plan each phase of work against the production schedule. All temporary supplies and diversions were pre-made and tested off-site before installation, minimising on-site intervention time.
Heavy-Current Distribution
The refurbishment covered busbar replacement, motor control centre upgrades and distribution board replacement across four production zones. All new equipment was rated to the client's process specification and tested under full load conditions before handover of each zone.
“Zero unplanned downtime across an 8-month programme. Every maintenance window was handed back on time — without exception.”
— Con-Tec Lead Project Engineer
The Result
Four production zones refurbished with upgraded infrastructure rated for the next 25 years. Full EICR documentation and updated circuit schedules were passed to the client's FM team, with a commissioning-to-handover period of under three days per zone.
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