5 Stages of Residential Electrical Construction

5 Stages of Residential Electrical Construction

The Basic process of constructing a new house, in America, from an Electrician's viewpoint. (120/240 volt) 

As a Residential Electrician, it is helpful to understand how a house is built and the timing of when you are expected to begin installing the electrical system. The more you understand about the practices of other trades the better you will be as an Electrician. For example, if you know that the furnace duct work runs straight up into the attic, then you will learn not to run your wires through space above a furnace that is not yet installed. 

Observe a new house under construction and you will see different construction trades arrive, complete their task and leave. Each trade is a separate "contractor" or company, hired by the builder to perform a specific task. As an electrician, you work for an electrical contractor. The builder manages the whole construction process and is the one responsible for hiring or firing the electrical contractor (company) that you work for. Some contractors, like a garage door installer, work on the house for one day. Others, like framing carpenters, might be there for months.

There are times when nobody is working on the house and other days when 4 different contracting companies all show up at the same time. You might go to work one day and have the whole house to yourself, just you and your fellow electricians. The next day you might find yourself working with plumbers, carpet layers, security installers and the heat and aircrew. Each trade trying to get their job complete without getting in the way of each other.

Builders divide the construction process into 2 phases;

    1) The wet phase    and    2) The dry phase 

The wet phase is when the interior of the house gets wet because it is not yet protected from rain or snow.

The dry phase is when the interior is protected from rain and snow although not from temperatures. Most electrical work is done during the dry phase. 

Electricians, plumbers, HVAC, media, security and central vacuum trades have a different division of 2 phases based on when the walls are finished,

     1) The Rough In    and      2)  The Finish

They install items in the walls before sheetrock (an electrical box with wiring) and finish the installation after the walls are finished (a switch and switch plate)

Here is a general timeline that builders follow when constructing a house. Notice the times, highlighted in bold print, when the electricians arrive to do their job.

The Wet Phase

Excavation. The ground is dug out to prepare for concrete.

Footing. A wide slab of concrete is poured to lay below the load bearing walls and posts.

It is below the ground and not a good place to drive a ground rod.

Underground Plumbing, is laid in the ground where ever a concrete floor will be poured.

 ✔ Temporary and underground electric (Electrical Stage 1)   Provide the construction site with a temporary electrical power pole. Electrical conduit for floor receptacles (and plumbing for drains) is laid in the ground before any concrete floor slab is poured. In northern winter climates, the slab is poured after the house is dried in and heated. 

Foundation walls and floor are poured.

Framing carpentry The wood and metal skeleton frame of the house is built including rough floors, roof sheets, and exterior framing. 

After the framing is  Roofing shingles     Windows & exterior doors   Garage doors 

Wells      Swimming pools      Septic Systems

The Dry Phase 

HVAC or Heating, ventilation & air conditioning. Metal and flexible duct work is installed.

Plumbing rough in The plumbing pipes is run throughout the house. One piece tub/shower units are set in place before electrical wiring is in the walls because some wall studs may have to be temporarily removed in order to get the large tub units into place. 

✔ Electrical "Rough In" (Electrical Stage 2) Can light, exhaust fans, panels, and outlet boxes are nailed up. Holes are drilled, circuit wiring is run through the wall studs and into boxes where electrical connections are made. 

Exterior soffits The finished surface of the roof's overhang is installed. If you have lights in the soffit you will have to get them up fast

Exterior siding brick, stucco is applied. It is best that any nailing of exterior siding is completed before the electrical wiring is installed to avoid any damage to the wires.

Fireplace inserts Prefabricated metal fireplace inserts, the flue, and any control wiring are installed.

Systems   Entertainment system wiring, security system wiring and central vacuum pipes and wiring are installed. 

Insulation

Sheet Rock 

  After the sheetrock is installed our electrical installation process now changes. Adding electrical wiring or moving electrical items becomes more difficult because the sheet rock is blocking access to the framing where the wiring is routed and electrical items are mounted.

✔ More Temporary Electrical (Electrical Stage 3) New furnaces are connected for heat and AC, some temporary receptacles, lighting, and switches are installed. "Temporary" because they will be damaged by paint and sheet rock mud. 

Cabinets

Carpentry-finish  Trim, interior doors, locks, stairs, railings.

Paint   

Wallpaper A missing outlet might be behind some wallpaper 

Countertops

Tile/granite Floors, showers, counter tops, and backsplashes are covered with tile or granite.

✔ Electrical Finish (Electrical Stage 4)  Time to install items like switches, receptacles, lights and ceiling fans. This might take 1 to 4 days on a small house and 1 to 4 weeks in a large mansion.

Plumbing finish. Sinks, toilets, water heaters, dishwashers, and disposals are installed.

HVAC finish. Vent covers and thermostats are installed.

Flooring Wood floors and the carpet is installed. >Misc; shelving, mirrors, towel bars, gutters

Landscaping  Gardens, grass, fences, patios, sprinkler systems  

Driveway 

Cleaning 

Move in day

Builder's Warranty Work 

✔ Electrical Modifications and Warranty Work (Electrical Stage 5)  Fix switches that are miswired, add a receptacle up high for a wall mount TV. 

   

So the builders are thinking wet/dry and electricians are thinking rough/finish

Notice how electrical installation methods change after sheetrock is installed.

For example, a box that is easily nailed in place before sheetrock will have to be cut into the sheetrock using a retrofit style box after sheetrock is installed. 

  

Also, notice that there are ✔5 different stages when the electricians are scheduled to arrive. 

Residential Electricians spend most of their time on just 2 of these; 

   "The Rough In" Stage 2, when the house is "dried in" but before sheet rock and 

   "The Finish" Stage 4, after sheet rock and some time after the paint is finished. 

             

  The 5 Stages of Residential Electrical Construction   

Stage 1 Temporary electric and underground conduit

Stage 2 The Rough-in 

Stage 3 More temporary needs 

Stage 4 The Finish 

Stage 5 Modifications and Warranty 

Electrical construction on a new house comes in 5 stages. When a stage is complete, the electricians leave the job site and do not return until the house is ready for the next stage. The larger the house is, the greater the time it will take for your electrical team to complete the stage and the greater the time between stages when you and your fellow electricians are away on other projects. 

   The "Rough In" Stage 2 and the "Finish" Stage 4 take a long time to complete and are explained in more detail below. The other stages are completed quickly and may not even exist in your local area. 

   Stages 1 and 3 deal mostly with temporary electrical needs. Some builders would rather save the cost of your services and provide their own temporary electrical needs. They might use an extension cord from the house next door or generators, portable heaters, and flood lights. 

   Other builders will order allot of temporary electrical needs. They will have your company set up a temporary power pole before construction begins. Later on, after the sheetrock is installed, they will have you energized the house panel and install several temporary lights and receptacles. They might also want the furnace and air conditioner to be connected. 

   The Warranty work in Stage 5 is often done after the owners have moved in which will require an appointment time so you are not locked out. It might be as simple as showing the owners how to reset a GFI receptacle or installing a switch and light in the attic that was forgotten. 

Here is a summary of the 5 Stages of Residential Electrical Construction; 

   Stage 1 Temporary electric and underground conduit   

Provide the job site with a temporary electrical power pole.

Start time; After the concrete footing and base, gravel is set and before the concrete floor is poured and the framing carpenters arrive.

Total time; 1-8 hours 

   Normally, this power pole is constructed with an outdoor weatherproof panel and breakers, GFI protected receptacles and a meter box mounted on a 6-foot post. The temporary pole comes in an overhead style or an underground style. Both styles are normally set in a 2-foot hole and held upright by attaching 3 2x4 braces like a tripod that is staked to the ground. Some electrical supply stores sell the pole already assembled. Visit a local construction site and notice their temporary power pole. Some companies require the use of portable generators that eliminate the need for a temporary power pole. 

   Install conduit under the concrete slab if required. If a house has receptacles on a concrete floor, the electrical conduit has to be laid on the ground before the concrete slab is poured. Typically 3/4 inch PVC conduit is glued together and buried in the gravel from a concrete style floor box to a nearby framed wall. The box and the other end of the 3/4 conduit, have to be set above the finished floor and covered to prevent concrete from entering the conduit.

   Some electrical contractors install the underground service conduit during this Stage 1, although it is best to wait until the meter is mounted on Stage 2. PVC electrical conduit is buried from the underground utility transformer (or junction box) to the area where the meter will be. The conduit is left sticking out of the ground close to the foundation until the house is framed and a meter can be mounted and connected to the conduit. 

   In cold winter climates, under slab conduit is delayed until stage 2 when the house has roof windows, doors, and temporary heat. 

   Stage 2 The Rough-in    

Install all the electrical wiring, housings, boxes and panels before the walls and ceiling are covered with sheetrock.

Start time; After the house, framing is "Dried in" with windows, doors, exterior sheathing and shingles on the roof. 

Average Total time; On a small 1500 square foot house 2-8 days, on a large 15,000 square foot mansion 2-8 months. 

More on the "Rough In"   http://roughin.blogspot.com

The Electrical "Rough In" Article

   Stage 3 More temporary needs   

Start time; After sheetrock is installed. Total time; 1 day or less. 

Depending on the needs of the builder, this stage might be as simple as installing 1 circuit breaker in the house panel and a receptacle in the garage. 

In a large mansion the builder might require far more temporary needs; 

Temporary lights. 

Installing light bulbs hanging down from recessed can light and the switches to control them. Connect wiring at receptacles to feed power through to the switch. Use a keyless or temporary light socket in rooms without can lights. All of this to make it easier for the painters, and others, to complete their work. 

Temporary receptacles. 

Install receptacles on 20 amp circuits spread out around the house to help eliminate excessive extension cords and tripping breakers. A receptacle is installed and energized at the garage door motor so the house can be locked and entered using the garage door security code. 

Furnace and Air Conditioning connections. 

Normally installed at stage 4, permanent connections are made to the furnace and air conditioner to remove moisture from the unfinished woodwork and sheet rock mud. Builders request permanent heat and AC connections early, long before the house is finished so they can save the cost of renting temporary portable units. 

   Stage 4 The Finish   

Start time; After paint and wallpaper. Average Total time; On a small 1500 square foot house 1-8 days. On a large 15,000 square foot mansion 1-8 months. 

More on the "Finish Stage"   http://electricalfinish.blogspot.com

The Electrical "Finish" Article

   Stage 5 Modifications and Warranty   

Start time; After the house is occupied and when called upon by the builder or owner. 

Total time; 1 hour to 1 week depending on the situation. 

Modifications. 

   Often a customer will only agree to buy a house if certain changes or additions are made. 

They might want several switches changed to dimmers or a new circuit added for a hot tub out back. 

Warranty. 

   Warranty work means you have to go back to a finished house, days or weeks after the customer has moved in, to fix something that you or your company installed. Sometimes it is your fault; maybe you miswired a 4way switch and now the hall lights don't come on when the 4way is in a certain position. Other times it is the fault of a manufacturer who's ceiling fan is throwing sparks. The 4way can be rewired, the fan can be taken down and exchanged for a new one. Other problems include; stuck doorbell button damages the chime, an attic light needs a light bulb, an arc fault breaker keeps tripping because someone interconnected neutrals from 2 separate circuits inside a 2 gang switch box. 

   One difficulty about warranty work is that you just can't show up any time that you would like.

You have to arrange for an appointment so that the homeowner will be home to unlock the door.

   I remember a time when I arrived at a house to make some electrical repairs and noticed a "Home Window Repairs" truck parked in the driveway with 2 guys sitting in cab smoking. I pulled up next to them, rolled down my window and said "Good Morning" "Well it could be better" they complained. I said, "Oh, what's wrong?" They told me that they have been waiting for almost an hour for the owner to get home. Before I could get a word in they continued complaining, "The boss said someone would be here but we rang the bell several times and no one is answering. He told us to keep waiting. He thinks they went to the store and will be back soon, but we have other jobs to go to and we can't wait here much longer. These people might never come home." Finally, they asked me, "Do you need to get in there too?" "Yes," I said, "I'm here to fix the doorbell " There was a moment of silence and then we all busted out laughing. Sure enough, when we knocked on the door, the owners came to open it. 

  

   A safety note; 

► Electrical work is dangerous to both the installer and the customer, it should be done under the supervision of licensed professional. Something as simple as plugging a space heater into a rolled up extension cord that is tucked under a couch can burn a house down. It can be easy to wire up a heater circuit. The question is can you wire the heater or anything else, safely. What you don't know might hurt someone. Work with a professional.

Source: 5 Stages of Residential Electrical Construction