Electrical Control Panel Design and Build Services
Is your existing control panel outdated, unreliable, or no longer fit for purpose? Whether you’re managing ageing hardware that’s causing downtime, integrating new machinery into an older system, or upgrading a legacy panel to meet current compliance standards, DB Site Services provides complete control panel design and build solutions across London and the UK.
We work with facilities managers, maintenance engineers, and operations teams who need a reliable, fully compliant control panel designed from scratch or rebuilt around your existing infrastructure.
Our bespoke panels are built, tested, and installed by accredited electrical engineers, and every project is delivered to ISO 9001 and BS EN 61439 standards.
Many of our clients come to us because their current panels are:
- Causing unexplained downtime — older relay-based systems fail without warning, and replacement parts are increasingly hard to source
- No longer compliant — regulations change; panels installed 10–15 years ago may not meet current BS EN 61439 or IEC standards
- Unable to scale — businesses adding new equipment, production lines, or automation find their existing panels can’t handle the load
- Lacking visibility — modern PLC and SCADA integration gives real-time monitoring that legacy systems simply can’t offer
- Expensive to maintain — reactive repair on outdated hardware costs far more over time than a planned panel upgrade
A new or upgraded control panel doesn’t just solve today’s problems — it reduces long-term operational costs and prepares your systems for future expansion.
We recently completed a bespoke ATS generator control panel design and build for a security centre and newspaper print facility in Central London. View the case study →
Our Control Panel Design & Build Process
1. Site Survey & Consultation
We start by understanding your current setup — what’s working, what isn’t, and what your system needs to do in the next 5–10 years. For upgrades, we assess the existing panel, identify obsolete components, and flag any compliance gaps before a single cable is touched.
2. CAD Design & Engineering
Our engineers produce detailed CAD drawings for your approval before any build begins. This includes panel layout, wiring schematics, component schedules, and PLC logic where required. You see exactly what you’re getting — no surprises.
3. Workshop Build
Panels are built in our controlled workshop environment using premium components from manufacturers including Siemens, Schneider Electric, ABB, and Honeywell. Every panel is wired, labelled, and documented to your specification.
4. Testing & Quality Assurance
Before leaving our workshop, every panel undergoes full functional, safety, and compliance testing — including insulation resistance testing, load testing, and where applicable, type-tested assembly verification to BS EN 61439.
5. On-Site Installation & Commissioning
Our engineers install and commission the panel on-site, managing the changeover to minimise disruption to your operations. For upgrades, we plan the switchover carefully to keep downtime to an absolute minimum.
6. Documentation & Handover
You receive a full documentation pack — as-built drawings, test certificates, component datasheets, and operation & maintenance manuals — ensuring your team and any future engineers can work with the system confidently.
7. Ongoing Support & Maintenance
We offer preventative maintenance programmes, fault finding, and thermographic inspections to keep your panels operating at peak performance long after installation.
Project Examples
Project: Generator Control Panel Design, Build & Distribution Upgrade
Client type: Commercial Client, London
The Problem: The client was experiencing an electrical fault traced back to years of poor maintenance, a loose connection on the neutral bar had gone undetected, creating a dangerous and unreliable installation. The existing setup used two separate distribution boards to handle lighting and power loads, adding unnecessary complexity and making the system harder to manage and maintain. A scheduled thermographic inspection would have identified the fault early; without one, it had been allowed to develop into a more serious issue.
What We Did: DB Site Services designed and built a new generator control panel incorporating a Deep Sea Electronics (DSE) generator set controller, providing reliable automatic control and monitoring of the generator. We also rationalised the distribution by combining the two existing boards into a single distribution board capable of handling both lighting and power loads, simplifying the installation, reducing potential failure points, and making ongoing maintenance significantly easier.
Result: A compliant, reliable, and consolidating solution that resolved the immediate fault and future-proofed the installation. The client now has a single, well-documented system with clear visibility over their generator and distribution — and a thermographic inspection schedule in place to catch any issues early going forward.
Smart Electrical Planning For Your Commercial Control Panel Build
At DB Site Services, we specialise in the design and build of bespoke electrical and instrument control panels. In addition, we provide solutions for a wide range of industries.
Industrial control panel assembly
PLC and automation integration
Fault finding and repair of control systems
Preventative maintenance programs
Thermographic scanning for early fault detection
Companies such as Siemens, Schneider Electric, ABB, and Honeywell set the benchmark for quality and reliability in automation, building management, and industrial control, and our electrical engineers use the best components to guarantee the same level of precision and compliance to every project we deliver.
Industries We Serve
Our fully designed and compliant control panels are trusted across a wide variety of sectors, including:
Manufacturing & Production Facilities
Water Treatment & Pumping Stations
HVAC & Building Management Systems (BMS)
Food & Beverage Processing
Commercial & Retail Developments
Renewable Energy & Utilities
No matter the industry, we provide industrial control panels and automation solutions designed to improve efficiency, reduce downtime, and support safe, reliable operations. All panels are designed and tested to ISO 9001 standards, ensuring compliance and reliability for industrial operations.
Frequently Asked Questions
What is included in a control panel design and build service?
Our service covers consultation, CAD design, panel assembly, PLC integration, testing, on-site installation, documentation, and ongoing maintenance.
How often should industrial control panels be inspected?
We recommend at least one thorough inspection per year, including thermographic scans and preventative maintenance, to prevent faults and downtime.
Can you upgrade or refurbish our existing control panel?
Yes — refurbishment and upgrade is one of our most common services. We assess your current panel, identify what can be retained and what must be replaced, and provide a phased solution that minimises cost and operational disruption. In many cases, a targeted upgrade is significantly more cost-effective than a full replacement.
Are your control panels compliant with UK standards?
All panels are designed and built to BS EN 61439 and tested to ISO 9001 standards. We provide full test certification and documentation on completion.
What brands and components do you use?
We work with leading manufacturers including Siemens, Schneider Electric, ABB, and Honeywell, ensuring components are reliable, supportable, and available long-term.
Do thermographic scans prevent electrical failures?
Thermographic scans detect hotspots and early faults before they cause system failure, helping to avoid costly downtime and improve safety.