You're diving into a fairly specialized construction method! Structural Concrete Insulated Panels (SCIPs), or 3D Panels as they're sometimes called, can offer excellent insulation and structural performance, but they definitely require a different approach to electrical work compared to standard construction.Here's a breakdown of things to consider and potential solutions for running electrical in SCIPs, particularly in a Florida environment

Understanding the Challenges:
Foam Obstruction

The primary challenge is the foam core. You can't simply run Romex through it. It's flammable, offers no protection against physical damage, and violates code.

Wire Mesh

The welded wire mesh complicates cutting pathways. You need to ensure you don't compromise the structural integrity of the mesh and also avoid creating sharp edges that could damage wiring.

Shotcrete Thickness

The shotcrete layer on each side of the panel further limits your options. You need to plan your conduit and box placements before the shotcrete is applied.

Thermal Bridging

Penetrating the insulation can create thermal bridges, reducing the energy efficiency of the panels. Minimize penetrations and consider strategies to mitigate thermal transfer.

Florida Climate

High humidity and potential for corrosion need to be factored into material selection.

Strategies and Products

Here's where your options come in, and where you can adapt European solutions for the US market:1.

Planning is Paramount



Collaboration

Work very closely with the architect, structural engineer, and the SCIP panel installer before the panels are manufactured or erected. Electrical placement must be integrated into the overall design. Reworking after the fact is extremely difficult and expensive.

Layout

Meticulously plan the location of every outlet, switch, light fixture, and electrical panel. This is not a situation where you can easily "fudge" things later.

Shop Drawings

Create detailed shop drawings showing the exact location of conduit runs and boxes within the SCIPs. Get these approved by all parties before installation begins.2.

Pre-Installation Solutions (Ideal)



Embedded Conduit

This is the best approach, but requires careful planning:

Rigid Metal Conduit (RMC) or Intermediate Metal Conduit (IMC)

These are the most robust and code-compliant options. They can be embedded within the shotcrete layer. Use corrosion-resistant coatings suitable for concrete. RMC is the more expensive, but more robust option.

PVC Conduit (Schedule 40 or Schedule 80)

Can be used if it's fully encased in concrete. PVC is less susceptible to corrosion but offers less physical protection than metal. It's crucial that the concrete provides adequate support and protection against damage. Local code variations may restrict PVC in some applications, especially in commercial construction. Check with your inspector.

Conduit Placement

Secure the conduit to the wire mesh before the shotcrete is applied. Ensure adequate concrete cover around the conduit to prevent corrosion and physical damage.

Pre-Cut Channels

Some SCIP manufacturers can pre-cut channels in the foam core to accommodate conduit runs. This simplifies the process but requires extremely accurate planning.3.

Post-Installation Solutions (Less Desirable, but Sometimes Necessary)



Surface-Mounted Conduit

The simplest solution, but it's not always aesthetically pleasing. Use rigid or EMT conduit secured to the surface of the shotcrete. This is usually only acceptable in unfinished areas (e.g., garages, utility rooms).

Chasing (Cutting Channels)

Only do this with the approval of the structural engineer. Cutting into the shotcrete and foam can weaken the panel. Use specialized tools (concrete saws or routers) to create channels for conduit or wiring. Reinforce the areas around the channels with wire mesh or fiber reinforcement before applying a patching compound. Use appropriate patching materials to restore the structural integrity and insulation value of the panel.

Box Placement



Cutouts

Use a multi-tool or oscillating saw to carefully cut out the foam core for electrical boxes.

Secure Boxes

Use construction adhesive and fasteners appropriate for concrete and foam to securely attach the boxes to the panel.

Consider Box Depth

Choose boxes that are shallow enough to fit within the shotcrete layer without protruding excessively.

Ganging

Gangable boxes are crucial to achieve desired box size.

Sealing

Seal around the boxes with a sealant to prevent air leaks and moisture intrusion.4.

Product Considerations



Conduit

As stated before, RMC/IMC or PVC is a good option.

Electrical Boxes



Concrete Boxes

Look for electrical boxes specifically designed for concrete construction. They're typically made of metal and have knockouts for conduit connections.

Plastic Boxes

Some plastic boxes are also suitable for concrete, but ensure they are UL-listed and approved for this type of application. Choose boxes with internal threads or mounting brackets for secure attachment.

Watertight Boxes

Given the Florida climate, consider using weatherproof or watertight boxes, especially for exterior applications or areas prone to moisture.

Wire/Cable



THHN/THWN

Use THHN/THWN insulated wire inside conduit. THWN is suitable for wet locations.

UF Cable

For direct burial (if allowed/necessary), use Underground Feeder (UF) cable.

Sealants/Adhesives



Polyurethane Sealant

Use a high-quality polyurethane sealant to seal around penetrations and boxes. Polyurethane is flexible, durable, and resistant to moisture.

Construction Adhesive

Use a construction adhesive specifically formulated for bonding to concrete and foam.

Fasteners



Concrete Screws

Use concrete screws (e.g., Tapcon) to attach boxes and conduit straps to the shotcrete.

Self-Drilling Screws

Self-drilling screws can be helpful for attaching to the wire mesh.

European Products and Adaptations

You're right that Europe is further ahead in SCIP construction. Here's how to adapt their solutions:

Research

Look for European manufacturers of conduit systems and electrical boxes designed for concrete construction. Download their product catalogs and technical specifications.

UL Listing

Crucially, any electrical product used in the US must be UL-listed (or equivalent, like ETL). This ensures the product has been tested and certified for safety and compliance with US electrical codes. You cannot simply import and install non-UL-listed products.

Adaptation



Conduit Systems

Even if you can't directly import a European conduit system, you can often adapt the concept. For example, if they use a specific type of conduit clip, you might be able to find a similar UL-listed clip made by a US manufacturer.

Electrical Boxes

Focus on the design of European boxes. Are they shallow? Do they have integrated mounting features? Then, search for UL-listed boxes in the US that offer similar features.

Specialty Suppliers

Look for US-based electrical suppliers that specialize in concrete construction. They may carry products that are suitable for SCIPs.

Specific Recommendations Based on Your Builder's Comment

The builder's statement, "we will have to cut the foam and flex between boxes," is a red flag. Flexible conduit (like ENT or flexible metal conduit) is not intended to be run through the foam core.

Push Back

Explain to the builder why running flex through the foam is not code-compliant and poses a safety hazard.

Suggest Alternatives

Propose the embedded conduit or pre-cut channel solutions. Emphasize the importance of planning and collaboration.

Document Everything

Get everything in writing. Clearly specify the approved methods for running electrical in the contract and shop drawings.

Important Considerations for Florida



Corrosion

Florida's humid, coastal environment accelerates corrosion. Use corrosion-resistant materials and coatings. Consider stainless steel or PVC-coated conduit for exterior applications.

Moisture Intrusion

SCIPs can be susceptible to moisture intrusion if not properly sealed. Ensure all penetrations and joints are sealed with a high-quality sealant.

Hurricane Resistance

Ensure the electrical system is designed to withstand hurricane-force winds. Secure conduit and boxes properly to prevent them from being dislodged.

Local Codes

Always check with your local building department and electrical inspector to ensure your design meets all applicable codes and regulations. Florida has its own amendments to the National Electrical Code (NEC).

In summary, working with SCIPs requires meticulous planning, collaboration, and the use of appropriate materials and methods. Don't cut corners or take shortcuts, as this can compromise the structural integrity, insulation value, and safety of the building. Be prepared to adapt European solutions to the US market by focusing on UL-listed products and code compliance. Flag for review