Infrared Thermography for Electrical Systems

A Mandated Risk Control That Protects Property and Profitability

Electrical system failures remain one of the leading causes of property damage and business interruption across commercial and industrial facilities. Infrared thermography is a powerful, preventive diagnostic tool—and now, more than ever, it’s becoming a mandated best practice for insurers, building owners, and facility managers.

In this post, we explore the scale of the problem, the role infrared thermography plays in mitigating it, and why insurers and loss control professionals should consider this technology a baseline requirement.

The Problem: Electrical Failures Drive Massive Losses

Electrical distribution issues are responsible for a significant share of commercial property fires and explosions. According to claims data from FM Global and Allianz, fire and explosion account for 45–55% of large commercial losses. Of those, electrical faults are among the top ignition sources.

The NFPA (National Fire Protection Association) further reports that 13% of structure fires in industrial facilities stem from electrical distribution and lighting equipment—typically in energized, concealed systems where failures are both hard to detect and potentially catastrophic.

Bottom line: These losses are predictable, preventable, and disproportionately expensive.

The Solution: Why Infrared Thermography for Electrical Systems Works

Infrared (IR) thermography offers a non-intrusive, highly effective method for identifying hidden electrical risks—before failure or fire occurs. It detects:

• Overheating conductors

• Loose or corroded connections

• Imbalanced electrical loads

• Failing electrical components

The 2023 revision of NFPA 70B formally recognizes condition-based maintenance as the gold standard—and infrared thermography as a core strategy for electrical preventive maintenance.

Facilities with IR inspection programs experience up to 80% fewer unexpected electrical failures, according to EPRI and IEEE reliability studies.

Why Insurers Should Care

From an insurance and loss control perspective, infrared thermography offers exceptional return on investment:

• Cost of IR inspection: $2,000–$10,000 per facility per year

• Average insured loss from an electrical fire: Over $1M, plus extensive business interruption

• ROI: Studies by Hartford Steam Boiler (HSB) and NFPA show a 4–10x return through avoided losses

Portfolio-wide impact: Each avoided million-dollar claim saves the insurer far more than indemnity—think reduced litigation, lower claims handling costs, and improved reinsurance positioning.

Industry Alignment: NFPA, OSHA, FM Global

This is not just a good idea—it’s becoming industry standard:

• NFPA 70B (2023): Establishes annual IR inspections as baseline practice

• NFPA 70E & OSHA: Allow IR scans under energized conditions using windows or barriers—reducing worker exposure while ensuring compliance

• FM Global: Strongly supports condition-based maintenance and diagnostic technologies like thermography

For insurers and building owners, implementing or requiring IR scanning is no longer “innovative”—it’s simply aligning with modern best practices. By requiring annual infrared scans of your insureds’ electrical systems, you dramatically reduce one of the most expensive property loss exposures in your portfolio. Electrical fires are preventable, and NFPA 70B gives you the framework to act. You’re not just promoting safety—you’re preserving profit.

Call to Action

• Insurers & Underwriters: Make annual IR scans part of your risk improvement plans or offer premium credits for compliance.

• Facility & Risk Managers: Adopt infrared thermography as a core element of your electrical maintenance program.

• Brokers: Present IR as a win-win—fewer claims, lower risk, safer facilities, and potentially reduced premiums.

Final Word: Prevention Pays

At Assured NDT, we specialize in professional infrared thermography inspections aligned with NFPA 70B, helping businesses, insurers, and facilities identify and mitigate electrical risk before it becomes loss.

Infrared thermography for electrical systems is the single most cost-effective step your business or portfolio can take to prevent fire, explosion, and business interruption.

Frequently Asked Questions: Infrared Thermography for Electrical Systems

1) What is infrared thermography for electrical systems?

Infrared thermography uses specialized cameras to detect heat signatures and temperature variations in electrical components. It helps identify abnormal conditions—like loose connections, overloads, or insulation breakdowns—before they lead to costly failures or downtime.

2) Why is infrared thermography important for electrical maintenance?

It’s a proactive, non-contact inspection method that reveals hidden faults in energized systems without interrupting operations. Regular thermographic inspections significantly improve reliability, extend equipment life, and prevent safety hazards such as electrical fires.

3) What types of electrical equipment should be inspected?

Infrared thermography should be used on switchgear, transformers, MCCs, panels, breakers, bus ducts, disconnects, and other energized electrical components that can develop excessive heat due to resistance or load imbalance.

4) How does infrared thermography improve safety and compliance?

Thermal imaging identifies risk areas before they escalate into dangerous failures, helping organizations comply with NFPA 70B, NFPA 70E, and OSHA electrical safety requirements while reducing insurance exposure.

5) How often should electrical infrared inspections be performed?

According to NFPA 70B (2023), annual infrared thermography inspections are now required for energized electrical systems. More frequent inspections are recommended for mission-critical facilities or high-load environments.

6) Does infrared thermography require shutdowns or disruptions?

No. Thermography is completely non-invasive and can be performed while systems are energized and fully operational—making it ideal for manufacturing, healthcare, data centers, and commercial buildings.

7) What are the typical signs of electrical faults found through thermography?

Common findings include hot spots, phase imbalance, loose lugs or terminations, overloaded circuits, corroded contacts, and deteriorating insulation—all of which can be corrected before a major failure occurs.

8) Why choose Assured NDT for infrared thermography?

Assured NDT’s certified Level II and Level III thermographers use advanced thermal imaging technology and NFPA 70B-compliant inspection protocols to deliver clear, actionable reports—helping you make data-driven maintenance decisions and improve electrical safety.