Terex Corporation

Case Studies

Terex Corporation

About Terex Corporation

Terex Corporation is a global manufacturer of lifting and material processing products and services that deliver lifecycle solutions to maximize customer return on investment. The Company reports in two business segments: Aerial Work Platforms and Materials Processing. Terex delivers lifecycle solutions to a broad range of industries, including the construction, infrastructure, manufacturing, shipping, transportation, refining, energy, utility, quarrying and mining industries.


Electrical Safety UK were requested to carry out an Arc Flash Risk Assessment Study at the Terex, Coalville site. We carried out a free of charge, on site pre-assessment to agree the scope of work with Terex and to determine the size of their electrical network. We provided Terex with a fixed price proposal for an arc flash study.


Electrical Safety UK were contracted to undertake the Arc Flash Study at the Terex, Coalville site in compliance with UK/European Legislation using the benchmark IEEE 1584 and NFPA 70E Standards. We were subsequently asked to deliver arc flash awareness training to staff and contractors and to carry out task based risk assessments on the high incident energy equipment identified during the study. The project was fixed price and scheduled to take 5 months.


ESUK agreed the scope and strategy with site management in Coalville. ESUK’s standard Windows based software tool, EasyPower® was used to model the electrical systems. ESUK supply, free of charge, a copy of EasyPower® with every completed Arc Flash Study.

ESUK carried out the discovery phase of the work, gathering information on the electrical distribution system by comprehensively surveying the site’s electrical systems. The surveying was done using a tablet and the EasyPower® Onsite software.  The data collected during the discovery phase of the project was downloaded into our EasyPower® modelling software. We analysed Terex’s electrical system including:

  • short circuit analysis
  • simple protective device co-ordination
  • arc flash incident energy
  • arc flash boundary distance

Any instances where the 3-phase prospective short circuit current exceeded the breaking capacity of protective devices was highlighted in the report. Protection curves showing any instances of miscoordination were provided. Incident energy levels and arc flash boundary distances were listed for all equipment included in the scope of the study.  Up-to-date, single line diagrams for the electrical network were provided to Terex. Incident energy hazard reduction analysis was then carried out and preferred options and order of magnitude costs were given for the reduction of the incident energy where it was above 8 cals/cm2.  We also provided guidance on the “As Low As Reasonably Practicable” requirements of UK Legislation.

Arc flash equipment labels were sent to the Coalville site once the design was approved by site personnel. Arc flash PPE guidance was included in the report and our strategic partner JK Ross were asked to help Terex with their arc flash PPE requirements. We will shortly be completing the task based equipment risk assessments for Terex. Where for high incident energy pieces of equipment we will be considering what tasks could potentially expose personnel to an arc flash. Where personnel could be exposed to high incident energy we will be advising on whether PPE should be worn and what PPE should be worn for those tasks.  Finally, electrical personnel on-site will be receiving arc flash awareness training. This training shall include content from the arc flash study we have carried out at the Coalville site, as well as reviewing the task-based risk assessments we will be carrying out.

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