How Extreme Weather Events & Seasonal Power Surges Cause Electrical Failures in Commercial Buildings

Residential buildings are often designed with simple electrical systems that can be supported by a few solar panels or gas-powered generators when power goes out. For commercial spaces and industrial spaces, the story is different. In 2024, hurricanes alone caused an average of 11 hours of power outage for customers.

When power surges in a commercial setting like a bakery, ovens can stop working, or electrical panels can fry circuits. In a larger setting with sub-panels and higher voltage, it can lead to arc flashes and serious fire concerns. Even in a small-population state like Maine, weather-related events account for 58% of power outages.

Commercial buildings now support much more modern, electricity-dependent machinery than they did a few decades ago. Distribution networks, panels, and electrical rooms all require precision electrical design to avoid power surges that can lead to failures. Knowing that need is crucial to any operations manager, and we at Dreiym Engineering want to offer some experienced advice to help.

Why Weather-Driven Electrical Failures Are Increasing

Commercial electrical systems require much tighter tolerances than a typical residence. Most business facilities or manufacturing centers need more consistent power quality. That is necessary due to refrigerated inventory, broader oversight, and safety regulations, as well as to maintain productivity or IT infrastructure. When there are sudden load changes, all those connected systems are at risk of failure.

Seasonal weather amplifies the stresses on the electrical system. A 120-degree heat wave in Arizona can raise the temperature of conductors and the internal panel temperature. A -25-degree cold front in Idaho forces insulation contraction, leading to more brittle components. In all these instances, restarting the electrical system also introduces high inrush currents.

Then you have storms. Electrical storms, haboobs, heavy rains, Nor’easters, hurricanes, and tornadoes all create rapid utility switching events. The voltages get disturbed, quickly propagating deep into your commercial facility’s electrical infrastructure. When you consider that 68% of the national inventory of office buildings were built before 2000, and more than 70% in gateway cities (major hub for entry/exit ports) are over 30 years old, the stress from storms and power surges only increases.

The more volatile the climate, the more facilities in need of updating, the more power failures, long business downtime, and elevated safety exposure.

How Seasonal Weather Patterns Stress Commercial Electrical Systems

The other problem is that seasonal weather changes and storms are not just related to heat and cold. Yes, heat waves increase electrical demand as people run ACs a bit longer than they should, and deep cold causes much more wear and tear on infrastructure and its protective devices. However, the real danger is when power returns.

For example, insulation from a cold snap tends to be more vulnerable to cracking. While there are some materials electrical engineers can recommend to avoid such cracking, the colder the weather, the greater the risk. Then there is moisture. Hot and cold temperatures can cause a lot of moisture to get into places you do not want it. These naturally cause freeze-thaw cycles that can enter enclosures, accelerating corrosion.

Then there is wind. Intense storms with winds over 25 mph can and will damage the electrical infrastructure that commercial buildings rely on. Debris is sent into the air, heavy rain compromises seals, lightning and grid switching introduce voltage transients, and lines are pulled down by falling branches. Without proper preparation, a summer windstorm with even a little rain can spell disaster for a business mid-production.

Power Surges and Internal Failure Points

One of our primary goals at Dreiym Engineering when we’re called in for an electrical load analysis, is to account for power surges. Weather events and seasonal power changes are directly linked to surges. When a lightning strike hits the ground, it creates a high-energy voltage spike that travels along conductors at near-light speed. The same is true for utility recloser operations, downed lines, and grid restoration. If your building is “in the pathway” of these spikes, you will see a surge.

Surges love to find the path of least resistance. They look for transformers, switchgears, panels, and control circuits that they can travel through. If your facility has piecemeal upgrades or protection that isn’t even across the infrastructure, you will see failure from a surge.

When a surge occurs, insulation degrades, terminals loosen, and internal components get weaker. You may not even notice the damage until months later when a breaker suddenly trips or a panel overheats. Delayed failures caused by surges are dangerous because they are so hard to diagnose. What can be easily explained as “aging equipment” may be weather-driven electrical stress and is likely to occur the next time the Weather Channel issues an alert.

Electrical Load Behavior, Warning Signs, and What They Mean

So, the question becomes, how do you protect your commercial facility from weather events and seasonal power surges? First and foremost, you should have a professional electrical design or electrical load analysis performed by experienced, licensed electrical engineers. That will be your best “heads up” as to anything that may be at risk should a sudden hurricane, blizzard, or rainstorm come your way.

Next, consider how old your system is. Outdated systems can experience imbalance or nuisance tripping, and older protective devices can operate outside their intended use. All of these issues will cause additional downtime and an increased risk of fire. Some reasonable warnings before major failures you should be on the lookout for in your commercial building include:

• Lights that flicker or dim during lighter storms or seasonal changes
• Breakers that unexpectedly trip without any apparent cause
• Panels that are warm to the touch or switchgears that buzz at odd hours
• Unusual burning smells or odors coming from electrical systems
• Equipment behaving inconsistently, especially after a weather event or outage
• Equipment restarting or resetting following power disturbances
• Motors, drives, and HVAC systems run louder than normal
• Frequent alarms or fault codes
• Visible damage, corrosion, or moisture intrusion

In most cases, you can conduct a visual inspection of your infrastructure to identify the cause of the damage, but hiring an expert team will almost always lead to a better risk analysis for the future.

Operational and Business Risks Facility Managers Must Address

An electrical failure in your commercial space due to a weather event will lead to costly repairs. It can be cost-prohibitive to purchase a new auto lift for your shop when the power goes out and damages the device’s internal machinery. The same is true for production lines, heavy filtration systems, and water treatment facilities.

Then there is the downtime. A power surge caused by a storm will lead to hours of production downtime in your facility. That is lost revenue and resource management that can take weeks, months, or years to recover from, especially if your competition is ready to swoop in and pick up the slack.

Another overlooked risk of a weather event causing a power surge and electrical failure is inventory loss. Refrigerated pharmaceuticals, meats, cheeses, and even flowers can spoil if power is out for even a few hours.

We often work with insurance providers to assess current commercial electrical designs or conduct post-event forensic analysis to determine what could have been avoided. When you are unable to demonstrate that your facility took proactive maintenance or evaluations, you can end up paying a lot more in premiums and repairs.

Reducing Risk Before the Next Weather Event

To avoid downtime and reduce the risk of damage to your equipment, inventory, building, and employees, schedule regular electrical load analysis or infrastructure inspections at least once per year. Hire teams with experienced electrical engineers and not just electricians. That way, you get more insight into the correct design and documentation that hold up well in legal disputes or insurance claims.

At Dreiym Engineering, we have over 30 years of experience performing electrical design and load analyses for clients ranging from small mom-and-pop coffee shops to industrial settings on the coast of Texas. Our team of professional, licensed electrical engineers can help you avoid common power failures and surges caused by weather events, so when the next big storm comes your way, you’ll be well prepared.

If your facility has had repeated outages or unexplained electrical events post-storm or during seasonal weather changes, it’s time to act. Waiting will lead to greater risk. Contact Dreiym Engineering today and let’s get started.