South America’s urbanization process continues to accelerate, leading to a growing number of large-scale buildings such as commercial complexes, shopping malls, office buildings, hotels, logistics centers, and data centers. As building scales expand, electrical loads from air conditioning systems, elevators, intelligent lighting, charging facilities, and information equipment are also continuously increasing. Commercial buildings are placing higher requirements on the reliability, safety, and space efficiency of power supply systems.

Traditional building power distribution solutions usually require the construction of independent substation rooms, which occupy significant building space and involve longer construction periods. Against the background of rising land costs and increasingly compact architectural designs, the prefabricated substation has gradually become an important choice for power distribution systems in South American commercial buildings due to its modular design, easy installation, and small footprint.

During its participation in the supporting projects of multiple commercial buildings in South America, Zisheng Electric has observed that many projects focus heavily on the selection of main electrical equipment during the early design stage, while key aspects of prefabricated substations—such as protection level, heat dissipation design, and internal layout—often receive insufficient attention. After commissioning, problems such as moisture ingress during the rainy season, overload during high-temperature periods, and insufficient maintenance space gradually emerge.

This article summarizes Zisheng Electric’s practical experience in applying prefabricated substations in South American commercial building projects. It provides a systematic analysis from load characteristics and equipment selection to environmental adaptation and project implementation, helping engineers and project owners better understand the key considerations for successful application.

1.Power Consumption Characteristics and Distribution Requirements of Commercial Buildings in South America

The power demand of commercial buildings in South America is undergoing significant changes, mainly reflected in the following aspects:

Continuous growth of electrical loads. Modern commercial buildings are no longer limited to basic lighting and conventional power loads. The integration of new equipment such as central air-conditioning systems, elevators and escalators, data center equipment, commercial cold-chain facilities, electric vehicle charging stations, and intelligent control systems has significantly increased the total electricity demand compared with traditional commercial buildings. Relevant studies indicate that electricity demand in the South American building sector will continue to grow, and the level of commercial electrification will further increase.

Higher requirements for power supply continuity. Shopping malls, office buildings, hotels, and other commercial facilities are highly sensitive to power interruptions. A power outage can not only affect business operations but also lead to food safety issues (cold-chain equipment), data loss (data centers), or safety risks (passengers trapped in elevators). Therefore, commercial building power distribution systems must provide high reliability and rapid recovery capabilities.

More compact space utilization. In major South American cities such as São Paulo, Santiago, Lima, and Bogotá, commercial real estate development is placing increasing emphasis on space efficiency. Traditional substations require dedicated building space, longer construction periods, and professional civil engineering support, making them difficult to implement in high-value commercial areas where land resources are limited. Prefabricated substations adopt a factory-built approach, integrating transformers, high-voltage switchgear, and low-voltage distribution systems into a single enclosure. This significantly reduces on-site construction work and better meets the requirements of rapid commercial building development.

Stricter energy efficiency and environmental requirements. Commercial building investors are increasingly focused on equipment energy consumption and long-term operating costs. For power distribution equipment, reducing transformer losses, improving operating efficiency, and lowering maintenance costs have become important considerations in commercial project design.

II. Main Application Scenarios of Prefabricated Substations in Commercial Buildings

Power Supply Systems for Commercial Shopping Centers

Large shopping centers typically include numerous retail stores, restaurants, entertainment facilities, and public lighting systems. A typical configuration consists of 10kV/20kV/33kV high-voltage input, which is stepped down through distribution transformers to 400V or 415V and connected to the building’s power distribution system. Prefabricated substations can be installed in landscaped areas around the building, underground parking areas, or dedicated equipment zones, minimizing their impact on commercial spaces.

Application experience of Zisheng Electric in a commercial complex project in Santiago, Chile:
The project had a total building area of approximately 120,000 square meters and was located in a coastal environment with salt mist exposure. The owner initially planned to place all prefabricated substations in the equipment area at the rear of the building. After conducting an on-site survey, Zisheng Electric recommended a dual power distribution layout—installing one 1600kVA prefabricated substation for the commercial area and another for the catering and entertainment area, with the two units positioned on opposite sides of the building.

The advantages of this approach were significant: the power supply radius was reduced by half, and by optimizing the power distribution zones and substation locations, voltage drop at the terminal loads was significantly improved, meeting design requirements. In addition, reducing the capacity of each individual unit resulted in smaller enclosure dimensions, providing much greater flexibility in installation location selection.

Office Buildings and Mixed-Use Complex Projects

Modern office buildings have high requirements for power stability, particularly in IT equipment areas, server rooms, intelligent office systems, and security systems, all of which require a stable power supply. By properly configuring high-voltage switchgear, protection devices, low-voltage distribution panels, and intelligent monitoring systems, prefabricated substations can achieve more reliable building energy management.

Hotels and Tourism Facilities

With the continuous development of the tourism industry in South America, hotel projects have increasingly high requirements for power supply reliability. Major hotel loads include air-conditioning systems, kitchen equipment, hot water systems, lighting systems, and guest room facilities. Prefabricated substations offer outdoor installation capabilities and can adapt to complex operating environments such as high temperatures, high humidity, and coastal salt mist conditions.

Data Centers and High-Load Commercial Facilities

With the development of the digital economy, the construction of data centers and communication infrastructure is increasing. These projects require power supply systems with high reliability, continuous operation capability, and rapid expansion capacity. Prefabricated substations can serve as external power nodes for data centers, providing a fast power supply solution from grid input to prefabricated substations, then to low-voltage distribution systems, and finally to IT equipment.

III. Advantages of Prefabricated Substation Selection in Commercial Projects

Compared with traditional substations, prefabricated substations offer the following advantages in commercial projects:

Specifically:

Modular design improves project construction efficiency.
Prefabricated substations are manufactured using a factory-based production approach. Equipment installation and commissioning are completed in the factory before the entire unit is transported to the project site. Only foundation construction and cable connections are required on-site before commissioning. Compared with traditional substations, this approach significantly reduces installation time, lowers construction complexity, and shortens the project schedule, allowing commercial projects to be put into operation more quickly.

Saving building space.
Prefabricated substations feature compact structures, small footprints, flexible installation methods, and outdoor installation capabilities. For commercial real estate projects where land value is high, this advantage is particularly significant.

Adaptation to complex environments in South America.
South America has significant climatic differences across regions: some areas of Brazil experience high temperatures and high humidity, coastal areas of Chile are affected by severe salt mist, certain regions of Peru are dry and dusty, and many areas of Colombia have hot and humid conditions. Therefore, power distribution equipment used in commercial buildings must have corrosion-resistant designs, dust and moisture protection capabilities, and effective heat dissipation performance.

Zisheng Electric can customize enclosure protection levels, materials, anti-corrosion processes, and internal configurations according to specific project environmental conditions, ensuring long-term stable operation of equipment in complex environments.

IV. Capacity and Layout Selection Should Be Based on Actual Operating Conditions

The power load of commercial buildings is not a straight line—it is usually higher during daytime business hours and lower after closing at night. Air-conditioning loads also vary depending on seasonal changes and ambient temperatures. Therefore, when selecting capacity, it is not enough to simply focus on the transformer’s rated capacity. The actual load profile must be taken into consideration.

How Should Load Calculation Be Performed?

There are two commonly used calculation methods for commercial projects in South America:

The unit area power density method is suitable for the preliminary design stage. For commercial complexes, the typical range is 80–120VA/m², with the specific value depending on the business type. For example, department stores and supermarkets have different load densities, while catering areas generally have significantly higher power demand than ordinary retail stores.

The demand factor method is commonly used during the detailed construction drawing design stage. All electrical equipment is categorized and its installed capacity is calculated, then multiplied by the corresponding demand factors and diversity factors to determine the calculated load. When selecting transformer capacity, an appropriate margin should also be considered. It is recommended to reserve at least 15%–20% above the calculated load to allow for future capacity expansion.

Application experience of Zisheng Electric in an office building project in São Paulo, Brazil:
The load list provided by the owner only included three major categories: lighting, air conditioning, and elevators. During the on-site review, Zisheng Electric discovered that the reserved capacity for 60 underground parking charging points had not been included.

If this factor had been ignored, a 1000kVA transformer would have been barely sufficient according to the original load list, but the capacity would have become inadequate once the charging stations were installed. Zisheng Electric ultimately recommended a 1250kVA configuration. During installation, the transformer itself was supplied at 1250kVA, while the high-voltage switchgear and low-voltage busbar systems were designed according to 1600kVA specifications to reserve additional capacity.

The additional investment was limited, but it provided the owner with sufficient expansion capability for future development—avoiding secondary power outages and modification work.

How Should the Installation Method Be Selected?

Outdoor Installation

Outdoor installation is the most economical option, where the prefabricated substation is directly installed around the building perimeter or on the rooftop. Many shopping centers in Brazil place prefabricated substations in outdoor parking areas, avoiding the use of valuable indoor building space.

However, temperature rise control must be specially verified. In Brazil, outdoor temperatures can be high during summer, and the heat generated by transformers and switchgear inside the enclosure can become significant. If ventilation design is insufficient, frequent over-temperature alarms may occur during hot seasons.

Zisheng Electric’s solution for high-temperature environments:
The enclosure adopts a double-layer insulated roof structure, with thermal insulation materials installed on the top and a ventilation gap maintained between the inner and outer layers. At the same time, the internal temperature rise of the prefabricated substation is recalculated based on the extreme summer temperature of the project location.

Standard prefabricated substation designs are typically based on an ambient temperature of 35°C. However, temperatures in northeastern Brazil can reach 42°C during summer, reducing the available temperature rise margin by 7K. Therefore, the ventilation area must be increased accordingly.

In the Recife project, Zisheng Electric increased the ventilation louver area on both sides by 30% compared with the standard design and installed two forced exhaust fans on the roof. As a result, the internal temperature remained within acceptable limits.

Basement Installation

Basement installation is very common, especially in city centers where land resources are limited. However, underground spaces usually have poor ventilation and difficult heat dissipation conditions. Therefore, dry-type transformers must be used, together with mechanical ventilation systems.

Application experience of Zisheng Electric in a São Paulo office building project:
The project adopted dry-type transformers, an enclosure protection level of IP43, and dedicated ventilation ducts inside the electrical room to ensure controlled operating temperatures during summer conditions.

Important note:
For underground installation, transportation access dimensions must be confirmed at an early stage. Some projects encounter problems when the prefabricated substation arrives on-site and cannot be moved into the basement.

Zisheng Electric encountered a similar situation in a project in Bogotá: the basement entrance had a height limit of 2.8 meters, while the standard prefabricated substation height was 2.9 meters, making installation impossible.

Zisheng Electric’s solution: Before equipment production, the team obtains complete information regarding transportation routes, access dimensions, and turning radius requirements. If obstacles are identified, a sectional design is adopted, allowing the transformer and switchgear compartments to be transported separately and assembled on-site.

For this project, the equipment was divided into three sections for underground transportation. After assembly, the overall dimensions and technical performance remained unaffected, enabling successful delivery and commissioning.

Building-Integrated Installation

Building-integrated installation is suitable for renovation projects or sites with extremely limited space. The enclosure is directly integrated into the building façade or equipment layer without requiring additional space.

However, this solution requires higher standards for fire protection, noise control, and heat dissipation, and therefore must be coordinated with architectural design teams at an early project stage.

V. Environmental Adaptability: South America Has Diverse Climates, and Protection Cannot Follow a One-Size-Fits-All Approach

A prefabricated substation is installed outdoors, meaning the enclosure is continuously exposed to natural environmental conditions. The enclosure protection level, corrosion resistance, heat dissipation design, and sealing performance directly determine the equipment’s service life and operational reliability.

Climate Zoning and Protection Strategies

Specific selection recommendations:

1. Corrosion Protection

For coastal projects, it is recommended that the enclosure adopts a hot-dip galvanizing + polyurethane topcoat process, with a total dry film thickness of no less than 240μm, achieving C5-M level corrosion protection. Stainless steel fasteners should be used, and sealing components should be made of EPDM or silicone rubber.

Zisheng Electric’s corrosion protection solution for a hotel project in Lima, Peru:
The hotel was located in the coastal area of Lima, where salt mist concentration is high. Zisheng Electric considered conventional C4-level corrosion protection insufficient for long-term reliability. After discussion with the owner, the protection level was upgraded to C5-M.

The enclosure was first treated with hot-dip galvanizing, achieving a zinc coating thickness of 85μm, followed by a three-layer coating system:

• Zinc-rich epoxy primer: 80μm

• Epoxy micaceous intermediate coating: 80μm

• Polyurethane topcoat: 80μm

The total dry film thickness reached 240μm. All exposed fasteners were made of A4-80 stainless steel, and EPDM sealing components were applied.

During an on-site inspection three years after commissioning, no obvious corrosion was found on the enclosure surface, demonstrating good long-term protection performance in the coastal environment.

2. Protection Ratin

For outdoor installation, a protection level of IP54 or above is recommended as the minimum requirement. In areas with severe dust conditions, IP55 should be considered. For humid underground environments, enhanced anti-condensation measures should be incorporated into the enclosure design.

3. Heat Dissipation Design

Excessive internal temperature inside the enclosure can directly affect equipment service life and operational reliability. The main measures include:

• Increasing ventilation area

• Using forced ventilation systems

• Adding thermal insulation layers on the roof

• Selecting high-temperature-resistant insulation materials

For regions with consistently high temperatures, such as northeastern Brazil, it is recommended to provide additional transformer capacity margin to ensure reliable operation under extreme conditions.

VI. How Should the Internal Configuration Be Designed? The Key Is to Properly Coordinate These Layers of the System

A prefabricated substation is not simply a matter of placing transformers and switchgear inside a metal enclosure. The rationality of the internal configuration directly affects long-term operational reliability and maintenance convenience.

High-Voltage Side: Configuration Based on Grid Connection Conditions

High-voltage connection voltages vary among South American countries:

• Brazil commonly uses 13.8kV and 34.5kV

• Chile commonly uses 23kV

• Peru commonly uses 10kV and 22.9kV

• Colombia commonly uses 13.2kV and 34.5kV

The selection of high-voltage switchgear must match the local grid short-circuit capacity and grounding system.

A common solution is the load switch-fuse combination unit, which is suitable for commercial projects with relatively small capacities. It features a simple structure, lower cost, and reliable protection.

For projects with larger capacities or higher requirements for power supply reliability, circuit breaker panels can be selected to provide more comprehensive protection functions and reclosing capabilities.

Transformer Selection: Oil-Immersed or Dry-Type Based on Installation Location

For outdoor standalone prefabricated substations, oil-immersed transformers offer better economic performance and stronger overload capability, making them suitable for large-capacity applications. Many shopping centers in Brazil install outdoor prefabricated substations equipped with oil-immersed transformers, provided that sufficient safety distances are maintained from buildings.

For basement installations or locations close to densely occupied areas, dry-type transformers are recommended due to their superior fire safety performance and the fact that they do not require oil pits or oil collection facilities.

Cast resin dry-type transformers are widely used in South American commercial projects. They typically feature H-class insulation, high protection levels, and strong adaptability to humid and hot environments.

Zisheng Electric’s solution for a São Paulo, Brazil project:
The equipment room was located on the second basement level of an office building. Due to fire safety requirements, oil-immersed equipment was not permitted.

Zisheng Electric selected an SCB13 epoxy resin cast dry-type transformer, rated at 1000kVA, with H-class insulation and a forced air cooling system.

Noise reduction measures were also implemented inside the enclosure. Since dry-type transformers generally produce more operating noise than oil-immersed transformers, sound insulation materials and vibration damping pads were added. The operating noise level was controlled below 55dB, allowing the project to pass owner acceptance on the first inspection.

Low-Voltage Side: Reserve Sufficient Outgoing Circuits

Commercial buildings typically require many low-voltage outgoing circuits, including:

• Lighting systems

• Air-conditioning systems

• Elevators

• Fire protection systems

• EV charging stations

• Information technology equipment

Each circuit requires independent protection and metering. Therefore, low-voltage distribution panels must reserve sufficient spare circuits to avoid rewiring or reconstruction during future expansion.

Zisheng Electric’s standard practice:
At least 20% spare space is reserved for outgoing circuits. Instead of installing unnecessary breakers, installation space and busbar interfaces are reserved in advance.

Meanwhile, each major outgoing circuit is equipped with an intelligent meter supporting RS485 or Ethernet communication.

In a logistics center project in Colombia, the owner initially considered the additional spare circuits unnecessary because they increased cabinet dimensions. Later, when a cold-chain storage area was added, the reserved circuits were directly connected and energized without replacing cabinets or carrying out power interruption modifications. The owner later recognized the value of this design approach.

Intelligent Configuration: Gradually Becoming Standard

Intelligent monitoring devices with communication interfaces can monitor voltage, current, power, temperature, and other parameters in real time.

For chain commercial projects, headquarters often needs unified management of electricity consumption across different locations. Remote monitoring functions provide significant operational advantages.

VII. South American Project Experience: Several Cases Demonstrating Critical Details

Commercial Complex Project in Santiago, Chile

The project was located in Santiago, Chile, and was a large commercial complex with a total building area of approximately 120,000 square meters. Located near the coast, the project needed to withstand a salt mist environment.

Zisheng Electric’s approach during the early project stage:
The team first obtained local meteorological data and grid parameters before developing the technical solution.

Santiago is relatively close to the sea, with annual average humidity exceeding 70%. Therefore, the prefabricated substations were designed with C5-M corrosion protection.

The local grounding system was also reviewed. Chilean distribution networks commonly use the TN-S system, with the neutral point directly grounded, which differs from IT systems used in some projects. Zisheng Electric adjusted the high-voltage protection settings and grounding configuration accordingly, avoiding modifications after equipment arrival on-site.

Final supply:

• 2 units of 33kV/0.415kV prefabricated substations

• Capacity: 1600kVA per unit

• C5-M corrosion-resistant coating

• IP54 protection level

• Outdoor installation on the east side of the building equipment area

After commissioning, the equipment operated stably and effectively ensured reliable power supply for the commercial complex.

Office Building Distribution Project in São Paulo, Brazil

The project was located in central São Paulo, where available space was extremely limited. The equipment area was located on the second basement level, with a transportation height restriction of 2.6 meters, preventing installation of a standard prefabricated substation.

Zisheng Electric’s solution:
Sectional transportation and on-site assembly.

The transformer and switchgear were packaged separately and transported to the basement using freight elevators. The enclosure was also divided into sections, transported underground, and assembled on-site.

A complete transportation and installation plan was prepared one month in advance. The actual installation process took only five days, which was faster than installing a fully assembled prefabricated substation.

Final supply:

• 1 unit of 13.8kV/0.415kV prefabricated substation

• Capacity: 1000kVA

• Dry-type transformer solution

• No independent oil pit required

• Fully compliant with underground fire protection and space requirements

Logistics Center Project in Bogotá, Colombia

The project was located near Bogotá at an altitude of 2640 meters. High altitude affects equipment in two major ways:

1. Reduced air insulation strength

2. Reduced heat dissipation capability

Zisheng Electric’s adjustment strategy for high-altitude projects:

• Increase insulation distances according to altitude correction factors

• Increase external insulation creepage distance beyond standard requirements

• Apply altitude correction during transformer capacity selection

A 2000kVA transformer does not provide the same usable output capacity at high altitude as under standard cooling conditions. The actual available capacity may decrease by approximately 10%.

Zisheng Electric’s approach:
Instead of allowing output capacity reduction, the company directly selected a higher-capacity transformer.

For a required actual output of 2000kVA, a 2250kVA transformer was supplied to ensure full performance under high-altitude conditions.

Final supply:

• 34.5kV/0.415kV prefabricated substation

• Capacity: 2000kVA

• IP55 enclosure protection

• Dust filters installed on air inlets

Hotel Project in Lima, Peru

The project was located in the coastal area of Lima, where salt mist and humidity created demanding protection requirements.

Zisheng Electric developed a fully sealed solution specifically for coastal projects:

• All enclosure joints treated with sealing strips

• Cable entries equipped with cable sealing modules

• Internal electrical components coated with conformal protective coating

• Control cabinet equipped with anti-condensation heaters to prevent internal moisture during nighttime temperature drops

Final supply:

• 1 unit of 10kV/0.4kV prefabricated substation

• Capacity: 800kVA

• Fully sealed structure

• C5-M corrosion protection

After three years of operation in the coastal environment, inspection showed no significant corrosion on the enclosure surface, and internal electrical components remained in good condition.

VIII. Selection Checklist: A Practical Verification List for Commercial Projects

Based on actual requirements of South American commercial projects, the following items should be confirmed during the selection stage:

IX. Conclusion

For commercial building projects in South America, prefabricated substations are not merely electrical equipment; they are essential infrastructure that ensures the safe and reliable operation of buildings. From shopping centers and office complexes to hotel projects and data centers, selecting the right prefabricated substation solution can effectively improve power supply reliability, optimize space utilization, and reduce long-term operating costs.

Zisheng Electric’s approach in the South American market is not simply to provide equipment, but to help customers address the entire process—from equipment selection and environmental adaptation to delivery and maintenance—by considering potential challenges in advance.

Accurately understanding environmental conditions and load characteristics at the early design stage can significantly reduce later modifications and operational issues. The more detailed the planning is at the beginning, the fewer problems will occur during operation.

Spending more time refining the solution in the early stage ultimately creates greater value throughout the project lifecycle.

Zisheng Electric specializes in the research, development, and manufacturing of power equipment. Its product portfolio includes prefabricated substations, oil-immersed transformers, dry-type transformers, amorphous alloy transformers, and related switchgear equipment.

Technical Capabilities Include:

• Capacity range: 315kVA to 2500kVA and above

• Voltage levels: 10kV, 13.8kV, 23kV, 34.5kV / 0.4kV, 0.415kV

• Protection levels: IP54 to IP65

• Corrosion protection grades: C4 to C5-M (ISO 12944)

• Manufacturing standards: IEC 60076, IEC 62271

• Transformer types: Oil-immersed and dry-type options available

For prefabricated substation selection solutions, technical specifications, or procurement support for commercial building projects in South America, please send your project details through Zisheng Electric’s official channels to receive professional technical assistance.

You may also directly provide basic project information, including project location, building type, required capacity, and installation method. Zisheng Electric’s engineering team will provide preliminary recommendations based on the actual application conditions.