The Modernization Challenge
Millions of switchgear lineups across North America are reaching 30, 40, or even 50+ years of age. Many contain circuit breakers that are no longer manufactured, with replacement parts becoming increasingly scarce and expensive. Facility managers face a critical decision: retrofill the existing enclosures with modern breakers, or replace the entire lineup.
What is Retrofill?
Retrofill (also called retrofitting or backlift) involves removing obsolete circuit breakers from existing switchgear enclosures and installing modern replacements that are engineered to fit the same space. This preserves the existing bus work, enclosure, and wiring while providing modern protection and control capabilities.
Retrofill Advantages
Retrofill typically costs 40-60% less than full replacement. It can be completed in significantly less downtime — often during a weekend shutdown rather than weeks of construction. It eliminates the need for demolition, foundation work, and re-routing of cables and bus connections.
When Full Replacement is Better
Full replacement is recommended when the switchgear enclosure is physically damaged, corroded, or has experienced a significant fault event. It's also preferred when the bus ratings need to be increased, the physical configuration needs to change, or code requirements mandate specific enclosure ratings that the existing lineup cannot meet.