Prefabricated wiring completes the circuit

A new pluggable wiring solution is expected to revolutionise electrical installation practice in the MEP sector. Prime Electrical Manufacturing (PEM) engineering and business development manager Darren Harper highlights the benefits for contractors.

Harper says the pluggable system from Apex Wiring Solutions of the UK “has been demonstrated locally to save at least 70% of the installation time on-site.”

MEP contractor BK Gulf has already deployed the system successfully at Al Zeina, a precinct of Aldar’s Al Raha Beach development in Abu Dhabi.

PEM is now in talks with local and international MEP contractors for hospitals, hotels, residential and commercial developments within the region.

PEM’s advantage is that it already understands manufacturing and the integrated project management required to effectively provide this type of Solution.

“We already manufacture the supporting systems such as switchgear, MCCs and control systems, so when the opportunity arose to introduce a pre-manufactured wiring solution to our portfolio, it made perfect sense. The Apex Wiring system is a natural progression for us, as well as the Middle East construction industry. We manufacture all of the products locally to ensure adequate product lead time to actively support our clients.”

Harper says the system has already garnered all the necessary Abu Dhabi Distribution Company (ADDC) approvals and complies with DEWA regulations. The systems have already been successfully implemented in Dubai and Abu Dhabi on a number of projects. “We are currently looking to increase the roll out in these regions, and will be expanding into Al Ain with Saudi Arabia close behind.”

So how does the system work? In terms of traditional wiring installed in any type of building, be it a villa or high-rise complex, single-core cables are pulled through PVC or metallic conduits and terminated at the distribution board (DB), sockets and switches.

This requires a significant amount of labour onsite to complete the tasks within the required programme. There is also major material waste due to unused off-cuts, theft and loss. “The Apex system negates all of this due to the manufacturing and installation process used,” says Harper.

PEM provides a fully pluggable solution from DB to final connection

“We make all the wiring accessories and light fittings pluggable, as they are assembled away from site in our purpose-made manufacturing facility. Pre-wired, flexible, pluggable conduit (available in PVC and metal) is also made to specific lengths, and facilitates the connection between the wiring accessories and the DB. Once materials are on-site, the system is installed quickly and simply plugs together. In a single visit, both cable and conduit is installed, and the final connection is made by simply pushing two connectors together. No tools; no waste; no mess; no damage,” stresses Harper.

The reduction in on-site labour inherently reduces the cost of installation. This is achieved by reducing the number of workers required to install the product, therefore reducing the amount of supervision, and whilst the obvious benefit would be the reduction in wages, Harper highlights the additional cascade benefits to the client.

“Whilst salaries is a significant saving, do not forget the additional costs of daily travel, housing and welfare of the site workers. Couple this to the rising visa costs and the real shortage of true skilled workers, and the argument against this system becomes very weak. We are all aware that the perceived cost of labour in the UAE is very low, but when we consider the actual productivity achieved, we can demonstrate that the actual rate is in line with most other European countries.

“When considering the commercial benefits, it is very easy to lose sight of the other advantages our solutions provide. Do not underestimate the safety, efficiency and programme benefits we offer, all of which contribute to a better building,” argues Harper.

“This market is historically based on ‘best price’ materials, which causes some confusion when proposing a prefabricated solution, as the cost of a pre-engineered, designed and manufactured Apex system cannot easily be compared to traditional conduit and cable costs. The costs only become comparable when you consider a fully-installed system

Communicating such concepts is a new approach within the UAE, but in the downturn contractors are realising the effects and burdens and lack of efficiency that often prevails with over-supply of labour is affecting the out-turn cost of projects.

We must remember that the fundamental design of the electrical layout does not change, only the method of installation; therefore the same-size cables are connected to the specified accessories, light fittings and distribution boards as detailed in the original design.

“The system is designed to help everyone in the supply chain from client to consultant to MEP contractor by simplifying the electrical installation process. The system is not limited to mains-only applications, and can be used for control circuits, allowing the single installation to cater for all client needs.”

Harper adds that the Apex Wiring solution greatly reduces a contractor’s and client’s exposure to risk. “These can be due to various factors which are generally outside of the MEP contractor’s control, but normally come at a cost to their business. Remember that time is a risk; unproductive labour is a risk; the incorrect use of tools is a risk; an incorrect installation is a risk; and all of these lead to the biggest risk of all, which is cost. The Apex system reduces, and can indeed eliminate, all of these if deployed correctly.

Harper concludes: “Locally we have been demonstrating an average 20% cost-saving overall and installations some 70% quicker than traditional methods. The material costs are greater than that of traditional material, but the overall savings are significant and clear for all to see. It is often not until a client initiates and completes an installation that they appreciate and accept the scale of the direct and indirect benefits that can be realised.”

Labour benefits
First and second fix completed in one visit at worst case 15m / hour, allowing succeeding trades quicker access

• Pluggable connections between cables, DB and all spur units, AC fan coil’s, sockets, light fittings and other final connections means a fully integrated and pluggable system on site
• Third fix visit always takes place after room fit-out. The wiring solution comprises factory-manufactured accessories, therefore no dirty trades or tools are required in the furniture, soft furnishings, plastering and painting are completed, eliminating the possibility of any damage during this process.
• DB termination (third fix) completed in nor more than 1 hour
• General termination (third fix) is simply pushing two plugs together