Customer

Large IOU

Location

Zirconia, NC

Highlights

  • Restored power infrastructure in storm-damaged, high-risk terrain
  • Eliminated inaccessible transformer through innovative redesign
  • Replaced aging and damaged underground cable network
  • • Delivered project safely within 2 months despite environmental hazards

Distribution Project: Overcoming Terrain and Storm Damage with Smart Engineering

The Challenge

Following Hurricane Helene, significant erosion caused the transformer bank to become unstable and nearly inaccessible. The situation exposed underground (UG) primary and secondary cables, creating safety risks and service reliability concerns. The steep terrain, combined with compromised ground conditions, made traditional repair and restoration approaches difficult and hazardous.  

Root Cause Analysis

Severe weather-induced soil erosion led to the collapse of the supporting bank structure, exposing aging underground cables. Ground shifting further damaged existing infrastructure, increasing the risk of outages and safety incidents.

The Solution

Think Power Solutions conducted a detailed pre-construction meeting with the client, engineers, and stakeholders to evaluate terrain constraints and identify the most effective solution. The customer constructed a retaining wall to stabilize the roadway and prevent further erosion. Our field crew then used a line truck to safely remove the transformer from the inaccessible location. Instead of reinstalling the transformer, the team redesigned the distribution approach by boring a new secondary line downhill to directly feed the home and boathouse. Additionally, all primary cables in the affected area were replaced due to age and storm-related damage. This approach not only resolved accessibility challenges but also improved long-term system reliability. Throughout execution, crews navigated steep elevation, slip hazards, and wildlife risks while maintaining strict safety protocols.

Key Benefits

  • Improved Safety:  Eliminated hazardous transformer access and reduced risk from exposed cables.
  • Enhanced Reliability:  Replaced aging and damaged primary cables to ensure stable power distribution.
  • Optimized Design:  Redesigned distribution layout to better suit challenging terrain conditions.
  • Project Efficiency:  Completed within 2 months despite environmental and logistical challenges.
  • Collaborative Planning:  On-site pre-construction coordination ensured alignment between client, engineers, and field teams.

The Results

The project was successfully completed on time and within budget, exceeding client expectations. By eliminating the inaccessible transformer and installing a new bored secondary line, Think Power Solutions delivered a safer, more reliable, and terrain-adapted distribution system. The upgraded infrastructure now supports consistent power delivery to the subdivision, home, and boathouse while mitigating future risks associated with erosion and ground instability.

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