Federal Pacific Panel Upgrade | Shaffer Construction Los Angeles

Introduction

If your Los Angeles home or business was built between the 1950s and 1980s, there's a significant chance you have a Federal Pacific Electric (FPE) panel. These panels were once commonplace across residential and commercial properties, but today they represent one of the most serious electrical hazards facing property owners. At Shaffer Construction, Inc., we encounter Federal Pacific panels regularly, and we understand the critical safety concerns they pose. Whether you need a panel upgrade or complete replacement, understanding your options is the first step toward ensuring your electrical system is safe, reliable, and capable of powering modern electrical demands.

The Federal Pacific Panel Crisis: A Decades-Long Safety Concern

Federal Pacific Electric panels have been at the center of electrical safety concerns for over forty years. These panels, manufactured primarily between 1950 and 1986, contain circuit breakers that have a documented history of failing to trip when they should. This means that during an electrical overload or short circuit—situations where the breaker should immediately cut power—the FPE breaker may simply remain closed, allowing dangerous electrical current to continue flowing through the circuit.

Research conducted by Jesse Aronstein, an independent electrical engineer, found that Federal Pacific Panels failed to trip in overload or short circuit conditions up to 60% of the time. This is not a minor defect; it's a fundamental design flaw that creates an extraordinarily high fire risk. When circuit breakers fail to function properly, wires can overheat and ignite, leading to potentially devastating residential fires. Insurance companies have taken this threat so seriously that some have refused to insure homes with FPE panels, and many require immediate replacement as a condition of coverage.

The Consumer Product Safety Commission (CPSC) has investigated Federal Pacific panels multiple times since the 1980s, and while the panels were ultimately taken off the market, millions remain in homes across the United States, including throughout Los Angeles. Shaffer Construction, Inc. recommends that any Los Angeles property owner with a Federal Pacific panel have it evaluated by a licensed electrician immediately.

Modern Electrical Demands: Why Your 1970s Panel Can't Cut It

Even if your Federal Pacific panel were perfectly safe—which it isn't—it would still likely be inadequate for modern electrical needs. The electrical demands of homes and businesses have changed dramatically since these panels were installed. In 1970, a typical American home used around 5,000-10,000 kilowatt-hours annually. Today, that number has more than doubled. Modern homes now feature air conditioning systems, high-powered water heaters, multiple refrigerators, sophisticated entertainment systems, and dozens of other devices that draw significant electrical power continuously.

Los Angeles homes face unique electrical challenges. The hot climate means air conditioning runs nearly year-round, dramatically increasing electrical demand. Many Los Angeles properties are upgrading to solar panels, requiring modern electrical infrastructure. And increasingly, Los Angeles homeowners are installing electric vehicle chargers—a major electrical upgrade that often necessitates panel work. As we discussed in our comprehensive guide to EV charger installation in Los Angeles, many homes built before 2000 simply cannot support level 2 EV chargers without significant electrical upgrades.

An older panel rated for 100 or even 150 amps may be completely inadequate for today's usage patterns. Modern electrical codes typically recommend 200-amp service for new residential construction. If your panel can't deliver adequate power, you'll experience frequent breaker trips, flickering lights, and you may not be able to use high-powered appliances simultaneously. For businesses and multi-family properties in Los Angeles, this can mean lost productivity and customer dissatisfaction. Shaffer Construction has helped hundreds of Los Angeles property owners upgrade their electrical systems to handle modern demands.

Upgrade Versus Replacement: Making the Right Decision for Your Property

When you discover you have a Federal Pacific panel, your first question will likely be: does it need to be upgraded or replaced? The answer depends on several factors that Shaffer Construction evaluates during a professional electrical inspection.

A panel upgrade typically involves keeping the existing enclosure while replacing the internal circuit breakers with modern, code-compliant breakers. This approach is less expensive and less disruptive than a complete replacement. However, FPE panels present a unique challenge: even replacing the breakers may not fully address the safety concerns because the main bus bars and other internal components may have design flaws. Additionally, finding modern replacement breakers that fit older FPE panels can be difficult, as FPE stopped manufacturing replacement parts decades ago.

A complete panel replacement involves removing the old Federal Pacific panel entirely and installing a new modern panel in its place. This is a more involved process, but it provides the most comprehensive solution. With a new panel, you get a complete upgrade to modern electrical standards, increased capacity (typically to 200 amps or more), and the assurance that your electrical system meets current building codes. For Los Angeles properties, panel replacement often includes running new conduit, upgrading grounding systems, and integrating new components like load study analysis for future electrical capacity.

In most cases where a Federal Pacific panel is discovered, Shaffer Construction recommends complete replacement rather than upgrade. This eliminates all risk from the existing panel design and provides the opportunity to modernize your entire electrical infrastructure.

The Panel Replacement Process: What to Expect

Understanding the panel replacement process helps you plan for the project and prepare your property. The process is complex and must be handled by a licensed electrician who understands Los Angeles electrical codes and permitting requirements.

The first step is obtaining a building permit from the City of Los Angeles or your local jurisdiction. This requires submitting electrical plans that show the new panel specifications, the scope of work, and how the new system will meet current code requirements. Shaffer Construction handles all permit paperwork and inspections. Next, our licensed electricians will schedule the work and arrange for power company coordination. Depending on your situation, the power company may need to disconnect service before we can begin work.

During the actual replacement, electricians will carefully disconnect the existing panel, noting which circuits go where so nothing is lost in the transfer. The old panel is removed, and a new one is installed in the same location or a new location if necessary. All circuits are transferred to the new panel, tested for proper operation, and labeled clearly. The main breaker is installed, the grounding system is verified to meet code, and all connections are checked for safety.

Finally, inspectors from the city will verify that the new panel installation meets all electrical codes and safety standards. Once approved, you have a fully functional, modern electrical system capable of powering your Los Angeles home or business safely for decades to come. The entire process typically takes 2-5 days depending on the complexity and permitting timeline.

The EV Charger Connection: Why Panel Upgrades Often Lead to Home Electrification

Many Los Angeles property owners discover they need panel upgrades specifically when they decide to install an electric vehicle charger. A Level 2 EV charger requires significant electrical capacity—typically a 40-60 amp circuit for residential installations. Older panels, especially Federal Pacific panels, simply don't have the available capacity. This is where panel upgrades become essential.

However, adding an EV charger often reveals a larger opportunity: if you're upgrading your panel anyway, this is the perfect time to plan for other electrical improvements. As detailed in our article on planning EV charger infrastructure in Los Angeles, a comprehensive approach to modernizing your electrical system is more cost-effective than piecemeal upgrades. With a modern panel, you can install solar panels, add Level 2 EV chargers for multiple vehicles, upgrade to modern HVAC systems, or install sophisticated home automation systems.

At Shaffer Construction, our residential EV charger installation services always include a thorough electrical system evaluation. If your panel is inadequate or unsafe, we'll recommend the appropriate upgrade and provide transparent pricing and timeline estimates. Our licensed electricians will coordinate all aspects of the upgrade, from permitting through final inspection, ensuring that your Los Angeles home is ready for electric vehicles and modern electrical demands.

Safety First: Why Professional Evaluation is Non-Negotiable

Federal Pacific panel replacement is not a DIY project and should never be attempted by anyone without proper licensing and training. Working with electrical panels involves high-voltage hazards that can cause serious injury or death. Additionally, improper installation creates fire hazards and violates building codes.

Los Angeles electrical work requires a state-licensed contractor and must comply with the California Electrical Code, the National Electrical Code (NEC), and local City of Los Angeles requirements. Permits must be obtained, and inspections must be passed. Shaffer Construction, Inc. is fully licensed and insured for all electrical work in Los Angeles. We maintain current knowledge of all code requirements and work seamlessly with city inspectors to ensure your project meets all safety and legal standards.

Conclusion

Federal Pacific panels represent an unacceptable safety risk for any Los Angeles property owner. Whether you discovered the problem through a home inspection, an insurance requirement, or a need for panel capacity to support modern electrical demands, taking action is essential. A professional evaluation by a licensed electrician will determine whether your panel needs upgrading or replacement and will provide transparent guidance on the best path forward for your specific situation.

For expert electrical panel evaluation, replacement, EV charger installation, and all other electrical services in Los Angeles, trust Shaffer Construction, Inc. Our team of licensed electricians has extensive experience with Federal Pacific panels and understands the complete spectrum of electrical needs for Los Angeles homeowners and businesses. Call us today at 323-642-8509 or email hello@shaffercon.com to schedule a professional electrical evaluation. Visit shaffercon.com to learn more about our comprehensive electrical services throughout Los Angeles. Your safety is our priority.