IEC 61439 & IS:8623 Standardized Workflow

Precision Engineering &
Manufacturing Lifecycle

From CAD single-line blueprints and CNC sheet fabrication to 7-tank anti-corrosion pre-treatment, 4000A primary injection testing, and CEIG turnkey handover.

Explore 6 Stages Schedule Factory Visit
Production Pipeline Hub
4 Critical Milestones
01
Phase 01 · Engineering AutoCAD & SLD
CAD Design & Thermal Sizing
General arrangement, busbar sizing & IEC clearance rules
02
Phase 02 · Fabrication <0.5mm CNC & 7-Tank
CNC Shearing & Powder Coat
14/16G CRCA steel with pure epoxy RAL 7032/7035 finish
03
Phase 03 · Integration 100kA Cu/Al Spine
Busbar & Switchgear Assembly
Electrolytic Cu/Al, torque fastening & FRLS wiring
04
Phase 04 · QA & Handover 4000A Lab & CEIG
Lab Testing & Turnkey Handover
2.5kV HV dielectric, FAT report & CEIG energization
Standard: IEC 61439 & IS:8623 Inspection: 100% FAT Certified
Step-by-Step Execution

The 6-Stage Manufacturing Pipeline

Engineered with uncompromising precision at every step — ensuring high reliability, electrical safety, and decades of operational life.

01

Engineering Design & Estimation CAD & Thermal Sizing

Our specialized electrical design engineers draft precise Single Line Diagrams (SLDs), General Arrangement (GA) drawings, control schematics, and busbar thermal calculations strictly in accordance with IEC 61439 and client site specifications.

AutoCAD Electrical Modeling Short-Circuit Withstand Calculations Form 3b / Form 4b Separation
Stage Deliverable
Approved Blueprint & BOM
Signed GA Drawing & Wiring Schematic
02

CNC Fabrication & 7-Tank Pre-Treatment 14/16 Gauge CRCA

Premium CRCA sheet steel undergoes computer-controlled shearing, turret punching, and hydraulic bending. Frames pass through our automated 7-tank chemical pre-treatment (degreasing, phosphating, passivation) before pure epoxy powder coating.

Tight CNC Tolerance (<0.5mm) 7-Tank Chemical Rust Inhibition RAL 7032 / 7035 Powder Finish
Stage Deliverable
Corrosion-Proof Enclosure
IP42 to IP55 Ingress Protection
03

Busbar Engineering & Switchgear Assembly Electrolytic Cu / Al

Electrolytic Grade high-conductivity E91E Copper or Aluminium busbars are precision-bent, routed, and insulated with heat-shrinkable color-coded PVC sleeves. OEM switchgear (ABB, Schneider, L&T, Siemens) is mounted with calibrated torque wrenches.

100kA Short-Circuit Sizing Heat-Shrinkable Color Sleeves Calibrated Torque Fastening
Stage Deliverable
Integrated Power Spine
Torque-Marked & Shrouded Busbars
04

Control Wiring & Harness Routing FRLS Multi-Strand

Control circuits, PLC automation lines, metering units, and protection relays are wired using flame-retardant low-smoke (FRLS) multi-strand copper wires. All terminations feature clear numerical cross-ferrules and neat PVC conduit routing.

FRLS Copper Wire Wiring Laser-Printed Numerical Ferrules Electrical & Mechanical Interlocks
Stage Deliverable
Fault-Isolated Harness
100% Traceable Control Circuitry
05

In-House Lab Testing & Quality Control Dielectric & Megger

Safety is paramount. Every single switchboard undergoes comprehensive routine testing in our in-house lab: 2.5kV AC High-Voltage Dielectric test, 1000V DC Megger insulation resistance, contact resistance milli-volt drop, and full functional relay simulation.

2.5kV AC HV Dielectric Test (1 min) 1000V DC Megger Insulation Primary Current Injection (Up to 4000A)
Stage Deliverable
Signed QA Test Certificate
Factory Acceptance Test (FAT) Report
06

Packaging, Logistics & CEIG Handover Turnkey Erection

Certified panels are wrapped in heavy-gauge polythene, corner-padded, and crated for secure transport. Our certified field engineers supervise on-site placement, re-torque checks, secondary injection testing, and complete statutory CEIG liaisoning.

Vibration-Damped Packaging On-Site Erection & Alignment Chief Electrical Inspectorate Approval
Stage Deliverable
CEIG Energization Pass
Final Handover & As-Built Drawings
Quality Assurance

Zero-Defect Engineering Standards

Four foundational pillars governing every manufacturing stage at our Bengaluru facility.

CNC Precision (<0.5mm)

Tight-tolerance hydraulic shearing and CNC turret bending ensuring zero misalignment and rigid structural integrity.

7-Tank Rust Prevention

Complete chemical degreasing, phosphating, and electrostatic epoxy coating tested for 500+ hours salt-spray resistance.

In-House Testing Lab

Calibrated 4000A primary injection, 2.5kV AC dielectric breakdown, and micro-ohm contact resistance verification.

CEIG Liaisoning

Turnkey drawing approvals, physical inspectorate liaisoning, and official energization certification across Karnataka.

Plant Infrastructure

Bengaluru Manufacturing & Testing Facility

Our modern manufacturing facility in Bengaluru is purpose-built for heavy-duty switchboard fabrication, automated surface preparation, switchgear integration, and rigorous high-voltage pre-commissioning.

CNC Fabrication Plant
Dedicated fabrication, assembly, and testing bays under one roof.
OEM Switchgear Stock
Direct partnership with ABB, Schneider, L&T, and Siemens.
Hydraulic Busbar Line
High-speed precision cutting, punching, and bending machinery.
FAT Staging Area
Comfortable inspection facility for client and consultant testing.
Schedule a Plant Walkthrough
KES Advanced Testing Bench and Panel Assembly
Calibrated Testing Lab Up to 4000A Primary Current Injection

Have Custom Panel Specifications?

Consult with our chief electrical engineers today. We review your Single Line Diagrams (SLDs) and deliver comprehensive technical estimates within 48 hours.

Request Engineering Quote