Infrared Inspections for Switchgear and Control Panels: What GTA Facility Managers Need to Know

Infrared Inspections for Switchgear and Control Panels: What GTA Facility Managers Need to Know

Switchgear and control panels are the nerve centres of any commercial or industrial electrical system.

They manage the distribution of power, protect downstream equipment, and keep facilities operational. When they fail, the consequences are rarely minor — unplanned downtime, equipment damage, fire risk, and significant repair costs are all on the table.

For GTA facility managers, keeping switchgear and control panels in reliable condition is not optional. It is a core operational responsibility.

Infrared thermography is the most effective non-invasive method available for detecting developing faults in these assets before failure occurs.

Key Takeaways

• Switchgear and control panels are among the highest-risk electrical assets in commercial and industrial facilities
• Thermal anomalies in these components develop weeks or months before visible failure — infrared inspection catches them early
• Inspections are conducted on energized equipment without shutdown or production interruption
• GTA facilities with aging switchgear are particularly exposed — many panels in the region are operating well beyond their designed service life
• IRIS PDM serves industrial and commercial facilities across Toronto, Mississauga, Etobicoke, North York, and the broader GTA

Why Switchgear and Control Panels Require Dedicated Attention

Switchgear and control panels operate under continuous electrical load.

Every connection point, bus bar, breaker, and conductor in these systems is subject to thermal stress over time. Loose connections develop resistance. Resistance generates heat. Heat accelerates deterioration. Deterioration leads to failure.

This progression is predictable — and preventable.

The challenge is that the early stages of this process are invisible without thermal imaging. A connection that is generating dangerous levels of heat may show no visible signs of deterioration until it is close to failure.

By then, the cost of intervention is significantly higher than if the issue had been caught during a routine thermal scan.

What Infrared Inspections Detect in Switchgear and Control Panels

When IRIS PDM technicians scan switchgear and control panels using advanced FLIR thermal imagers, they are looking for temperature differentials that indicate abnormal resistance or load imbalance.

Common findings in switchgear and control panel inspections include:

• Loose or corroded bus bar connections
• Overloaded or failing circuit breakers
• Imbalanced three-phase loads
• Deteriorating insulation on conductors and bus bars
• Failing disconnect switches
• Overheating neutral connections
• Hot spots in motor control centres (MCCs)

Each of these findings has a measurable thermal signature that appears in infrared imaging before any visible damage is present.

The Risk of Aging Switchgear in the GTA

A significant portion of commercial and industrial switchgear in the Greater Toronto Area is operating well beyond its original designed service life.

Buildings constructed in the 1970s, 1980s, and 1990s — which represent a large share of the GTA’s commercial and industrial building stock — were designed for electrical loads that have since been significantly exceeded by modern equipment, HVAC systems, and technology infrastructure.

This mismatch between original design capacity and current operational demand places additional thermal stress on switchgear components that were not engineered for these loads.

For facility managers overseeing older buildings in Toronto, Etobicoke, North York, Mississauga, and Scarborough, the risk profile of existing switchgear deserves serious attention.

Inspections Without Operational Disruption

One of the most common concerns facility managers raise about switchgear inspections is downtime.

Infrared thermography eliminates that concern.

IRIS PDM conducts all switchgear and control panel inspections on energized equipment — meaning panels remain live during the scan. There is no requirement to shut down power, interrupt production, or notify tenants.

Technicians require access to the panel enclosures only for the duration of the scan. In most cases, switchgear inspections can be completed within normal business hours without any operational impact.

What Happens After the Inspection

Following a switchgear or control panel inspection, IRIS PDM delivers a structured report that includes:

• Thermal and visual image pairing for every asset inspected
• Temperature differential measurements for all identified anomalies
• Severity classification of each finding
• Specific repair recommendations for each identified issue
• Documentation suitable for maintenance planning and insurance review

Findings are prioritized so facility managers can address critical issues immediately and schedule lower-priority repairs into planned maintenance windows.

For more on what happens after a hotspot is identified, see our post on what happens after a hotspot is found during an infrared inspection.

Frequently Asked Questions

How often should switchgear and control panels be inspected using infrared thermography?

Annual inspections are the recognized standard for most commercial and industrial facilities. Higher-load operations — manufacturing, data infrastructure, multi-tenant commercial — may benefit from semi-annual inspections. Facilities with aging switchgear operating beyond its designed service life should prioritize getting a baseline inspection completed as soon as possible.

Can infrared inspections be conducted on all types of switchgear?

IRIS PDM can inspect virtually all types of commercial and industrial switchgear, including low-voltage and medium-voltage equipment, motor control centres, distribution panels, and transfer switches. Our technicians use next-generation FLIR thermal imagers capable of detecting anomalies across a wide range of equipment types and configurations.

Do panels need to be under load during the inspection?

Yes. Infrared electrical inspections must be conducted while equipment is energized and under load. Thermal anomalies caused by resistance and load imbalance only generate detectable heat signatures when current is flowing. Inspecting de-energized equipment will not produce meaningful thermal data.

What qualifications do IRIS PDM technicians hold?

IRIS PDM technicians are certified thermographers trained in electrical systems inspection. All inspections are conducted using industry-recognized standards and advanced FLIR imaging equipment to ensure accurate, defensible results.

How do I book a switchgear inspection for my GTA facility?

Contact IRIS PDM directly to discuss your facility’s scope and schedule an inspection. We serve commercial and industrial facilities across Toronto, Mississauga, Etobicoke, North York, Scarborough, and the broader GTA.

To learn more about our infrared electrical inspection services, visit our Infrared Electrical Inspection Services page.