Not all switchgear quotes are created equal. In fact, most quotes you’ll get from general contractors or service firms leave out critical elements—engineering design, testing, certification, and long-term reliability. That can lead to major cost overruns, delayed installs, and worst of all, non-compliant equipment that puts people and infrastructure at risk.
Here’s the issue: most electrical contractors and testing companies attempting switchgear upgrades rely on NEC (National Electrical Code) guidelines. While NEC governs general installation practices, it does not apply to switchgear retrofit engineering. Retrofitting and modifying medium voltage switchgear must adhere to IEEE standards and be verified through a Nationally Recognized Testing Laboratory (NRTL)—standards that manufacturers like Spike Electric are trained and certified to follow. Contractors, even experienced ones, are not trained or authorized to certify that a retrofit meets these high-level design and testing standards.
One of the biggest red flags is when a quote simply includes the price of a new breaker and labor—without evaluating the compatibility of that breaker with the existing gear. Compartment compatibility, mechanical racking interfaces, arc flash reanalysis, and UL/NRTL requirements are often not even mentioned. Without these, you may be buying an incomplete or invalid solution.
Even more dangerously, some quotes will include language like “arc-resistant upgrade” without any mention of IEEE C37.20.7 arc flash testing or validation. That’s a major compliance issue—arc-resistant gear must undergo full type testing at an NRTL lab to retain or claim that designation. Making those claims without supporting data is not only misleading—it’s unsafe and non-compliant.**
Because many firms quote without considering compatibility, engineering, testing, or certification. Spike Electric provides complete, standards-based quotes so you’re not left paying for mistakes down the line.
What’s included in a complete upgrade quote?
A true upgrade quote includes engineering, design verification, documentation, installation, testing, and NRTL coordination. Spike Electric provides all of these as part of our turnkey offering.
Should a retrofit include design verification?
Absolutely. IEEE C37.59 requires it. Without design testing, your upgraded gear is not considered compliant—even if it functions.
What’s missing in most switchgear quotes?
Design validation, arc flash analysis, certification support, and field documentation. Spike Electric includes all of these.
How much does a compliant switchgear conversion cost?
It depends on the gear, breaker model, footprint, and standards required. While our quotes may not be the cheapest, they reflect real, compliant, and safe solutions—not shortcuts that cost more in the long run.
Many industrial facilities operate with switchgear that was installed 20, 30, or even 40 years ago—gear that may have been safe and compliant when installed but no longer meets today’s safety standards. While these systems may still function, aging equipment combined with modern loads and regulatory expectations introduces serious risk.
One of the biggest misconceptions in the field is that functioning equipment equals compliant equipment. In reality, any modification—like installing a new breaker, replacing a relay, or upgrading controls—can void your gear’s original UL or NRTL certification. According to industry best practices and IEEE C37.59, any change that affects design, electrical clearances, or operational safety requires new design verification and documentation.
Meanwhile, standards from OSHA, the National Electrical Code (NEC), and NFPA 70E evolve regularly. They now require:
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- Verified arc flash studies
- Updated labeling and hazard boundaries
- Proof of maintenance on protective devices
- Documentation for employee training and PPE policies
Failing to align with these expectations can result in:
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- Fines and violations from OSHA
- Insurance claim denials
- Increased liability for injuries or outages
- Delayed inspections and permit issues
Spike Electric performs full safety audits and compliance assessments for facilities across Texas and beyond. Whether you’re looking to modernize your gear or just confirm that your legacy equipment is safe to operate, our engineering team will:
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- Review existing equipment and modifications
- Check for expired UL/NRTL labels or voided certifications
- Evaluate breaker compatibility and dielectric integrity
- Verify arc flash boundaries and update labels
- Provide a prioritized punch list for upgrades or mitigation
Integrated questions — answered:
Is my switchgear OSHA compliant?
Compliance depends on your current condition, documentation, and retrofit history. OSHA 1910 requires arc flash labeling, hazard training, and safe operating procedures. Spike Electric will audit your gear and give you a clear compliance roadmap.
What standards apply to medium voltage switchgear?
IEEE C37.20, C37.59, NFPA 70E, NEC Article 110, and OSHA 1910 Subpart S are most relevant. These govern design, testing, labeling, and safe work practices.
How do I test old gear for modern requirements?
Testing includes insulation resistance, contact resistance, timing, racking force measurements, and more. Spike Electric combines field testing with engineering reviews to determine retrofit needs.
Can I add breakers without voiding certifications?
Only if the new breakers are installed through a manufacturer-backed process that includes UL/NRTL verification. Otherwise, the original gear’s certification is void. We help preserve or re-certify these installations.
What is IEEE C37.59 and why does it matter?
It’s the industry standard that defines how modified switchgear must be design-tested and documented to be considered compliant. It’s critical for maintaining safety, insurance validity, and UL listings.
