Modular wiring systems
Perceptions and methodologies hard-wired into the electrical contracting industry have resulted in a slow and reluctant uptake of such ‘modern’ trends as modular wiring systems. MEP Middle East speaks to Middle East Electricity 2009 exhibitor Marshall-Tufflex International about the latest developments.
Modular systems, particularly in terms of lighting, have been around for a number of years, and are becoming increasingly sophisticated, with a growing range of applications and benefits. But what does ‘modular’ mean precisely, and exactly how does it relate to the day-to-day work carried out by your run-of-the-mill electrical contractor?
Quite simply, a modular wiring system is prefabricated off-site – for example, pre-wired lighting units, power connection systems, floor boxes or desk units with the tap-off fully tested. Such systems were developed to reduce the quantity of work needed to be done on-site. Rather than collating the individual components for a particular task and assigning an electrician to assemble them, the electrical contractor purchases the finished unit, and in theory recouping the extra cost of the component in time saved on-site.
Not only does this way of working offer time- and cost-savings, it is also perfectly geared to installations that need to be carried out quickly – for example, contracts in schools, healthcare facilities, retail outlets and offices where minimising downtime is an absolute necessity. Modular systems really do have the ability to relieve some of the time pressure from on-site work, and make installing the electrical infrastructure easier and quicker.
Faster build process
Systems are prepped off-site and delivered ready to connect together, speeding up the build process and helping to ensure the project remains on schedule and does not incur penalty charges for over-running. They are also brilliant for repetitive work, such as commercial projects and buildings with common footprints, including modular buildings, hotel rooms, offices, shops and even residential developments like housing.
Indeed, specialist electrical contractors well-versed in installing modular systems may wish to consider requesting a deviation from the specification on projects where modular wiring has the potential to deliver significant cost-savings – which is a benefit for both the contractor and the client, especially given that a modular system has the ability to be reconfigured at a later date.
In short, contractors now have access to modular wiring systems that deliver tool-free, fast-track installation of complete cabling runs from power source to final outlet. There is no on-site wiring required, allowing installers to simply click it together, circuit test and sign-off. Depending upon the system used, installation times can be reduced by up to 80%, with overall cost savings of up to 50% possible.
‘Eureka!’ moment
“There is a ‘Eureka!’ moment when specifiers realise the huge potential such systems offer in reducing on-site installation times,” argues Marshall-Tufflex International sales director Tracy Masters. For example, research has shown that an accessory box wiring installation that previously took 20 minutes can be reduced to five minutes or less. And because the best systems are ‘plug-and-play’, the keyed connectors cannot be installed incorrectly.
Modern modular wiring systems have been borne out of the drive to prefabricate an increasing number of components within the construction process in order to speed it up and simultaneously reduce errors. Prefabrication has infiltrated all aspects of the building industry, with manufacturers devising new and innovative ways of adding value to and extending their product ranges.
But while great strides were made in fast-tracking many construction tasks, simplifying the installation of electricity proved a harder nut to crack, and the need to address the swift provision of power became increasingly critical. Buildings could go up in double quick time, but fitting out power requirements took just as long as previously.
Manufacturers began researching ways of solving this problem, and modular wiring systems were developed and refined. Now they can be sourced for a wide range of applications, from commercial to domestic, taking power from source and delivering it to final outlets via plug-in connectors. On the commercial side, flexible cabling systems can take power via trunking to a ‘plug-and-play’ connection in pre-wired, pre-tested accessory boxes.
In addition, underfloor boxes can be supplied pre-wired and pre-tested. Power is fed from the distribution unit or powertrack via flexible conduit leads. This system is particularly suited to irregular lay-outs, or where power has to be delivered over a wide area to a large number of outlets (for example, such specialised applications as call centres or trading floors).
For the domestic market, there are pre-wired and assembled dry-lining sockets, switches and pendants for use in new-build or domestic refurbishment projects, and surface-mounted sockets and switch boxes for use in new-build or refurbishment projects. So, although the electrical industry may not have been the first to embrace the movement to off-site production, it is catching up fast.
Modular systems are now accepted as not only being quicker to install when compared to traditional methods of hard wiring, but also safer, since many are factory-tested and keyed to ensure correct installation. What is more – and unlike traditional wiring – they can be reconfigured (during office moves), stripped out (during refurbishments) and re-used, thereby providing even more benefits for price-conscious clients and those wishing to reduce construction waste.
However, the cost of a modular system may appear higher when compared with a hard-wired system. Thus there is a great temptation to value engineer a product like modular wiring out without looking at the whole life-costing implication of such a decision. This raises two important, highly valid points:
• When price comparisons are carried out between modular and hard-wired systems, it is imperative to include installation time on-site. To simply compare product costs, without taking labour into account, is not comparing ‘like with like’. Modular wiring can reduce installation times significantly (and therefore labour costs), and this saving has to be factored into the overall equation.
• Modular wiring systems can help ‘future-proof’ installations by allowing easier, and therefore cheaper, reconfiguration and upgrading of the electrical system. Achieving the comparable result with a hard-wired installation could involve the expense and subsequent disruption of a complete re-wiring.
Research carried out by Marshall-Tufflex International has shown that specifiers and installers rate ‘plug-and-play’ a more practical consideration than environmental performance. This means it can be unclipped and re-used, which is an important benefit in terms of efficiency and cost-savings. Modular buildings equipped with modular wiring are ultimately a safer and quicker solution.
Local tradesmen simply click the electrical system together before circuit-testing, thereby removing any uncertainty associated with hard wiring. However, some electrical contractors argue that the modular approach is reducing the demand for their skills.
What they fail to realise is that a qualified electrician is still required not only to circuit test and sign off, but also to oversee the project. All modular wiring systems require installation by qualified electricians to ensure they are fitted in accordance with the necessary regulations and specifications.
“Modular wiring systems eliminate the need for labour-intensive component assembly on-site. Not only does this reduce site time and have the potential to boost profit margins, it removes any element of installer error, delivering ‘right first time’ installations more quickly.
“There is no doubt that, for modern commercial projects and buildings with common footprints, such systems provide massive benefits. However, they also have much to offer right across the electrical installation sector,” concludes Masters.
What is modular wiring?
Construction programmes dictate that electrical installations are undertaken efficiently and in the least possible time. With technology changing constantly, installations need to be readily adaptable and offer a high degree of flexibility.
Traditional fixed installations are labour intensive, offer little in flexibility and remain costly. Modular wiring is a rapid and easily installed, modular sub-circuit distribution system prefabricated off-site. A complete installation is achieved, from the distribution board to the furthest point of a circuit, by simply connecting the system components together.
A range of metal-clad cables is also available to complement the system. Total modular wiring design support can be provided, including AutoCAD layout designs, voltage drop calculations and record drawings. There are various systems available, depending on the application:
• Armoured: A lightweight armoured system to give strength and protection where needed. Suitable for both lighting and power applications, with armoured polycarbonate plugs.
• Unarmoured: Where mechanical protection is not a requirement.
• Branch cabling: Sub-mains distribution cable. Suitable for risers, corridors, tunnels, bridges etc.
More about Marshall-Tufflex
Marshall-Tufflex is the UK market leader in cable-management systems. It has been operating in the Gulf for more than 30 years, and has been specified on virtually every major project in the region. SnakeWay, a steel support system for cabling that is hand-bendable and faster to install than traditional wire basket or tray systems, was a big hit at the recent Middle East Electricity 2009.
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