Electrical design is at the heart of any successful construction or engineering project — whether you’re building a home, a commercial facility, or specialized structures like pole barns. A well-executed electrical design ensures safety, functionality, energy efficiency, and long-term cost savings. Yet, even seasoned professionals can fall into avoidable traps that lead to costly corrections down the line.
At Servinsky, we’ve encountered a range of projects where small oversights snowballed into significant issues. That’s why we believe in knowledge-sharing to help buyers, builders, and fellow engineers prevent these problems before they happen. In this post, let’s look at the five most common electrical design mistakes — and how you can steer clear of them.
1. Underestimating Power Load Requirements
One of the most frequent (and impactful) mistakes is failing to accurately calculate the power load requirements of a building. This includes all electrical devices, HVAC systems, lighting, and any future expansions. Inadequate load estimation can lead to overloaded circuits, tripped breakers, or even fire hazards.
How to Avoid It:
- Conduct a thorough load calculation that factors in not just current usage but potential future demands.
- Collaborate with all stakeholders early in the design process to understand real-world usage scenarios.
- Use load diversity factors and industry-standard formulas instead of guesswork.
2. Improper Placement of Electrical Panels
Convenience and accessibility often take a backseat in design discussions, especially when it comes to panel locations. However, placing electrical panels in hard-to-reach areas — like tight closets, behind doors, or near water sources — can violate codes and hinder maintenance or emergency shutdowns.
How to Avoid It:
- Familiarize yourself with NEC (National Electrical Code) or local codes regarding panel clearance and access.
- Choose locations that are central, dry, and unobstructed.
- Ensure at least 36 inches of clearance in front of the panel for safety and code compliance.
3. Neglecting Grounding and Bonding
Grounding and bonding might not be the most glamorous part of electrical design, but they’re absolutely critical. Poor grounding can result in electrical shock risks, equipment failure, or poor power quality. It’s a silent flaw that can cause major damage over time.
How to Avoid It:
- Always use proper grounding conductors and connectors as per your jurisdiction’s electrical code.
- Design a clear grounding plan that covers service entrances, panels, and all branch circuits.
- Perform ground resistance testing to ensure effectiveness.
4. Ignoring Lighting Control and Energy Efficiency
Many electrical designs still treat lighting as an afterthought — a series of switches and circuits without much integration. In today’s energy-conscious world, this is a missed opportunity. Inefficient lighting layouts and lack of controls can dramatically increase energy consumption and reduce the lifespan of your fixtures.
How to Avoid It:
- Implement LED lighting with smart control systems like dimmers, occupancy sensors, and daylight harvesting.
- Optimize fixture placement for both task and ambient lighting, minimizing glare and dark spots.
- Consult energy codes like ASHRAE 90.1 or local mandates for compliance and best practices.
5. Overlooking Coordination with Other Trades
Electrical designers don’t work in a vacuum. Failure to coordinate with plumbing, HVAC, or structural teams can lead to major conflicts — like conduit paths clashing with ductwork or insufficient clearance for wiring due to framing.
How to Avoid It:
- Schedule early coordination meetings with architects, mechanical engineers, and other stakeholders.
- Use Building Information Modeling (BIM) to detect clashes before construction begins.
- Update and review plans regularly as field conditions change.
Bonus Tips for Flawless Electrical Design
In addition to avoiding the common mistakes listed above, here are a few best practices that make a big difference:
- Label Everything: From circuit breakers to junction boxes, clear labeling reduces troubleshooting time and boosts safety.
- Plan for Expansion: Always leave room in your panels and conduits for future needs.
- Stay Up-to-Date: Electrical codes change frequently. Make continuous learning a priority.
Real-World Impact: A Case Example
Let’s say you’re building a large agricultural facility such as pole barns for storage and equipment. Improper load planning here could mean underpowered outlets, insufficient lighting, or incompatible power sources for large equipment. By engaging an experienced team from the outset, you can avoid costly redesigns and ensure your electrical system grows with your needs.
Final Thoughts
Electrical design isn’t just about laying out wires and switches — it’s about building a safe, efficient, and future-ready infrastructure. Whether you’re designing for a home, commercial space, or specialty structure, these five common mistakes can significantly impact performance and safety.
By learning from them and implementing smart solutions, you can ensure smoother installations, happier clients, and fewer callbacks.
