January 12, 2026 Charging Arizona: Successfully Delivering Battery Storage in Arizona
Sturgeon Electric successfully delivers Sierra Estrella, the largest standalone BESS in the Grand Canyon State
It would be one of the largest battery energy storage projects (BESS) Sturgeon Electric Company had ever undertaken.
By the time it was complete, Sierra Estrella would be a 250MW/1,000MWh facility with 276 BESS units making it the largest standalone battery storage facility in Arizona when it came online in 2024.
The project would be a huge success, beating scope, schedule and budget.
But first they would have to build it and that would be no easy feat.
In 2023, an engineering firm awarded Sturgeon Electric all the electrical construction services for the large BESS facility and the associated 230kV/34.5kV greenfield substation in Avondale, Ariz.
Sturgeon Electric was responsible for much of the electrical material procurement and for performing all below and above grade electrical construction in the BESS yard including conduit, grounding, batteries, transformers, wiring and connections.
Their work would need to be accomplished under a compressed schedule and sequenced to meet set milestones required to meet already scheduled battery testing dates. A similar milestone was set for the substation to be constructed and ready to energize and backfeed for testing.
Sudden Materials Cancellation Threatens the Schedule
Sturgeon Electric’s construction work began in 2024, but with extremely long lead times for some essential electrical components, they began placing orders well in advance. They ordered more than 400 required T-bodies (also called dead-end bodies) in 2023 due to their 16-week lead times.
However, just six weeks before the T-bodies should have begun arriving, the team was notified that the manufacturer’s product line had gone down and wouldn’t be able to fulfill any of the orders.
This situation threatened not only schedule milestones, but the company’s reputation. The Sturgeon Electric team acted fast, immediately coordinating with their vendor to identify an alternate supplier while working with the customer to get the new supplier approved.
Although the new supplier had a similar long lead time, Sturgeon Electric worked out a creative solution. They developed a plan to incrementally fill the order with 25 percent in about four weeks, another 25 percent at eight weeks, and the remainder closer to 16 weeks out. This kept the work on schedule to meet all the milestones associated with the T-bodies.
Innovative BESS Installations
Delays in the battery yard outside of Sturgeon Electric’s work scope also presented a schedule challenge. But the team remained proactive, engaging their partners to identify alternative work and continue moving the project forward.
Although foundations were delayed, the team tracked, reviewed and scheduled BESS installations based on the completed foundations.
Efficiency was key. Sturgeon Electric implemented an efficient production line for receiving the 276 BESS units and used an innovative method for installations.
By using a 300-ton track mounted crane, they established a highly efficient tempo of receiving and setting eight BESS units and four transformers per day, avoiding double handling and storage. This enabled them to stay on track to meet or beat schedule milestones and elicited positive feedback from the customer.
A Successful Finish
Sturgeon Electric overcame those challenges and more during the construction of Sierra Estrella through determination, creative problem-solving, and innovation.
Ultimately, they beat multiple schedule milestones and completed the bulk of electrical construction of the BESS yard and new substation in less than five months – a tremendous accomplishment given its size and complexity. Substantial completion was also reached nearly a month early and the system was placed online in April 2024.
The team also went above and beyond the original scope by taking on scope additions and identifying and proposing solutions to scope gaps while still delivering the project under budget.
“We executed all scope within our baseline contract and change orders; and when the opportunity presented itself, we did more for the customer than we were asked to do,” said Project Manager Troy Scott.
Regional Vice President Matt Patterson was the Phoenix district manager for Sturgeon Electric during Sierra Estrella’s construction.
“Our selection as a construction partner for the Sierra Estrella BESS project, Arizona’s largest energy storage facility was a privilege,” Patterson said. “This landmark achievement showcased our deep capabilities and solution-focused approach to complex project execution. We are proud of our team’s persistence and excellence, which ensured the project’s success and contributes to the region’s reliable clean energy future.”
Project Details: Sierra Estrella Battery Energy Storage