Investment scale and status of the PSE plans

The development plan of Polskie Sieci Elektroenergetyczne for 2025–2034, approved by the President of Poland’s Energy Regulatory Office, provides for PLN 66 billion of investment, approximately 4,700 km of new 400 kV circuits, 28 new substations and the extension or modernisation of around 110 existing sites. The document was approved in December 2024 and remained the binding plan at the reporting date. [2]

The next edition, presented on 2 February 2026 as the “Development plan for meeting present and future electricity demand for 2027–2036”, also assumes approximately PLN 66 billion. It covers 5,000 km of new 400 kV circuits, 30 new substations and the extension or modernisation of 110 existing sites. Circuit kilometres should not automatically be treated as route kilometres, particularly for multi-circuit lines. [1]

The scale of the plans does not mean that PLN 66 billion will flow to transformer manufacturers, still less to suppliers of tanks, frames and enclosures. The budgets cover the complete investment process: property acquisition, engineering, foundations and buildings, conductors and cables, primary equipment, automation, telecommunications, installation, commissioning and services. For metalworking companies, the relevant factor is the recurring substation programme and the pressure on equipment producers to expand capacity or establish alternative sources.

Market and order segmentation

The market for electricity-network equipment and components is not a single, easily measurable segment. It includes the 400 kV and 220 kV transmission network, 110 kV distribution networks, medium- and low-voltage networks, complete transformers and switchgear, substation automation and a broad range of welded structures, enclosures and machined parts. Voltage level, equipment type, technical responsibility and procurement route all matter.

Market segments and demand characteristics

Public statistics do not separately report the value of outsourced tank and enclosure manufacturing. Global transformer, switchgear and automation producers compete in the final-equipment segment, while the market for metal components is distributed among specialist fabricators, manufacturers retaining some processes in-house and subcontractors for special processes.

Participants in the metal-component supply chain

Multi-year investment cycle

Transmission demand is being driven by new 400 kV corridors, power evacuation from northern Poland, connections for offshore wind farms and the nuclear power plant, a planned north–south HVDC link and the modernisation of older substations. PSE reports that 53% of overhead lines and 61% of substations are more than 40 years old. Equipment replacement is therefore driven both by the changing geography of generation and by the age of existing assets. [1] [3]

Distribution investment is more dispersed. It includes 110 kV networks, primary substations, MV/LV substations, line cabling, automation, voltage-regulation systems and smart meters. The agreed plans of the five largest distribution system operators for 2023–2028 increased from PLN 42 billion to approximately PLN 72 billion compared with the preceding perspective. [2]

Capital expenditure by the five largest distribution system operators

The increase is not caused solely by renewable-energy connections. Networks must also serve energy storage, industrial electrification, new residential development, charging infrastructure and data centres. Stoen Operator reported that connected and planned data centres in Warsaw require almost 500 MW and that demand may at least double within a decade. This is the operator’s forecast for its own service area, not a national statistic. [8]

Programmes with financing, completed work or a confirmed project portfolio

TAURON reported that in 2025 it built 2,432 km of new lines, modernised 692 km, constructed 447 MV/LV substations and modernised 425. It also connected more than 700 MW of renewable generation and 100 MW of battery storage. These are implementation results rather than plans. The procurement schedule for the second half of 2026 included the Wysoki Brzeg, Rębielice, Halemba, Górka, Kędzierzyn, Blachownia and Domasław substations, among others. This does not mean that the operator will purchase a tank or frame separately; such components are normally included in the equipment manufacturer’s or substation contractor’s package. [6]

ABB is an example of a manufacturer expanding European medium-voltage equipment capacity. The programme announced on 11 May 2026 covers approximately USD 200 million over three years, including the Przasnysz plant and the production of switchgear, vacuum circuit breakers, relays and automation solutions. The announcement confirms capacity expansion but contains no commitment to increase purchases from specific Polish subcontractors. [9]

Technological change is illustrated by Stoen Operator’s contract with Siemens Energy for a 123 kV indoor switchgear installation without SF₆ at the Batory primary substation. Orders of this type may require enclosures, mechanisms, interfaces and assembly processes to be adapted to new generations of equipment. [18]

How an order reaches a metal-fabrication company

The network operator defines the functional and acceptance requirements for the substation and equipment. The main contractor delivers the site, the integrator combines supply packages, and the transformer or switchgear manufacturer remains responsible for the complete device. A metalworking company may be a direct supplier to the equipment manufacturer, a subcontractor to an integrator or a provider of one special process.

Industrial buyers assess total cost and supply risk, not only the price per kilogram of fabrication. The decision is affected by material, welding labour, post-weld machining, surface protection, inspection, documentation, packaging, oversized transport, lead time and the cost of a possible non-conformity. Procurement is primarily business-to-business through approved supplier lists and competitive RFQs.

A company seeking a place in this supply chain should not begin by claiming that it can manufacture “all structures”. Buyers need specific data: the largest part that can pass through the hall and paint shop, crane capacity, methods for controlling distortion and tightness, responsibility for welding technology, material traceability, the ability to machine datums after welding and the language of acceptance documentation.

A starting point for building a longlist is the Metal Navigator directory of Polish metalworking suppliers. Search results do not replace an audit: declared processes, certificates, dimensions and capabilities must be confirmed on the shop floor and in documentation.

Components and entry barriers

For Polish metalworking companies, two entry routes are most realistic. The first covers frames, bases, platforms, supports, mounting plates, cable trays, covers, smaller enclosures and machined parts. The second is a gradual move towards larger welded assemblies after an audit, first-article manufacture and approval of special processes.

Metal components, requirements and accessibility for SMEs

A lower barrier does not mean an absence of requirements. An incorrect hole pattern in a serial bracket can stop the assembly of a complete switchgear bay. For simple parts, competitive advantage comes from repeatability, drawing-revision control, batch marking, coating condition after transport and delivery in the required assembly sequence.

A transformer tank is not an ordinary vessel

The tank carries the loads of the active part, oil, accessories, lifting points and transport. Its walls may be subjected to vacuum during manufacturing, pressure changes in service and transport loads. The applicable conditions depend on the transformer design. A tank should not automatically be treated as a conventional pressure vessel or assigned one universal test procedure.

Surfaces for the cover, bushings, valves, radiators and active-part components must remain within tolerance after welding. If datum surfaces or holes require machining, the operation should be planned after welding and straightening, taking account of machine load capacity, fixturing and maximum travel.

The inspection plan should cover incoming material, plate identification, joint preparation, welding, repairs, dimensional inspection, non-destructive testing, tightness, cleanliness, surface preparation, coating and protection for transport.

Minimum acceptance-documentation package

• material certificates and batch traceability,
• welder list and welding procedure specifications,
• dimensional inspection records,
• NDT and leak-test reports,
• surface-preparation and coating reports,
• register of non-conformities, concessions and repairs,
• photographic documentation where required by the customer,
• statement of conformity with drawings and the approved specification.

The documentation scope must always follow the contract. A package from another product should not be copied mechanically, and no single test method should be presented as appropriate for every transformer tank.

Example process chains

Switchgear enclosure

A typical process may include laser cutting or punching, bending, welding of corners and reinforcements, grinding, surface preparation, powder coating, installation of hinges, locks, seals and mounting plates, dimensional inspection and packaging. The manufacturer of the empty enclosure is responsible for conformity with the drawings but should not independently declare the internal-arc classification or temperature-rise performance of the complete switchgear assembly.

Transformer frame

The process includes cutting profiles and plate, edge preparation, assembly in a fixture, welding, diagonal inspection, straightening, machining of datum surfaces and industrial coating. Lifting points, surfaces for wheels or skids and alignment of interfaces with the tank are critical.

Substation bracket

A bracket can be produced from profiles or plate by cutting, drilling, welding, marking and galvanising. Simple geometry does not remove the need to inspect holes and distortion or to consider how vent and drain holes affect safe galvanising.

Large tank

The process chain is substantially longer: material preparation, prefabrication of walls and stiffeners, assembly of sections, welding in a defined sequence, continuous geometry control, installation of nozzles, straightening, machining of datums and holes, weld examination, leak testing, internal cleaning, abrasive blasting, application of the coating system, final inspection and transport protection.

ISO 3834, EN 1090 and surface protection

ISO 3834: welding-quality requirements, not proof of product capability

ISO 3834 specifies quality requirements for fusion welding of metallic materials. Part 1 supports selection between ISO 3834-2, ISO 3834-3 and ISO 3834-4. The standard can be applied in workshops and on site, but it is not a general management system for the entire company. The certificate alone does not demonstrate the ability to manufacture a large leak-tight tank. [13]

An audit should verify the actual certification scope, materials, welding processes, procedure qualifications, welder qualifications, welding coordination, storage of consumables, equipment control and handling of repairs. A plant may operate a valid ISO 3834 system but still lack the crane capacity, test station or experience required to control distortion in a large transformer tank.

EN 1090: application depends on product function

EN 1090 does not automatically apply to every tank, cabinet or enclosure. The decisive factors include whether the product is a load-bearing structural component in a construction works, how it is placed on the market and the project documentation. Guidance from Poland’s General Office of Building Control indicates that even the assessment of a guardrail requires its structural function to be determined; resemblance to a steel component alone does not establish the standard’s scope. The execution class should follow the design and the component’s responsibility. [14]

C4 and C5 are not complete paint specifications

C4 and C5 define environmental corrosivity categories under ISO 12944-2. They are not complete coating systems and do not state durability. An order should define surface preparation, cleanliness grade, profile, coating system, number of coats, nominal dry-film thickness, expected durability, application conditions, inspection and repair. ISO 12944-5 links system selection to the environment, surface preparation and expected durability, while laboratory tests under Part 6 support selection but do not provide an exact service-life prediction. [15]

Hot-dip galvanising, paint systems and duplex systems are not freely interchangeable. Galvanising requires suitable process holes and consideration of distortion risk. Painting provides greater control over appearance and local repair but requires disciplined preparation and application conditions. A duplex system can provide additional protection but increases the number of operations and quality interfaces.

The enclosure and the complete switchgear assembly

A metal enclosure is one part of the equipment. The integrator of the complete switchgear assembly is responsible for apparatus configuration, busbars, connections, earthing, insulation, heat dissipation and testing. The empty-enclosure manufacturer can guarantee dimensions, material, coating, doors, seals and conductive components in accordance with the drawings, but should not automatically declare the performance of the complete assembly.

The IP rating or IK impact resistance may depend on the final configuration, penetrations, ventilation, locks and assembly. Internal-arc classification concerns the switchgear’s behaviour during a defined arcing fault, not merely the strength of the sheet metal. Temperature rise depends on currents, busbars, apparatus and ventilation. IEC TR 60890 describes a calculation method for temperature-rise verification in low-voltage switchgear and controlgear assemblies and is linked to IEC 61439 requirements, illustrating the dependence between enclosure and installed equipment. [17]

EU Regulation 2024/573 restricts the commissioning of new electrical switchgear using fluorinated greenhouse gases. The prohibition for medium-voltage equipment up to 24 kV applies from 1 January 2026; for equipment above 24 kV up to 52 kV it is intended to apply from 2030; and for certain high-voltage equipment above 52 kV up to 145 kV from 2028, subject to the exceptions in the regulation. The change strengthens demand for new equipment architectures but does not determine whether enclosures will be larger, smaller or easier to manufacture. [16]

Qualification of a Polish supplier

The process should begin by defining a product family, not by asking generally about “available capacity”. The buyer first defines dimensions, weight, material, responsibility level, processes, coating, documentation and volume. Only then should potential plants be identified, an NDA signed and RFQ documentation released.

1. Define the component and requirements

   Specify function, dimensions, weight, materials, tolerances, special processes, testing, coating, documentation and volume.

2. Identify suitable plants

   Build a longlist based on actual processes, infrastructure, experience and location without treating a directory listing as proof of capability.

3. Verify dimensions, weight and material flow

   Check crane capacities, door dimensions, assembly space, ability to rotate the product, internal transport and removal from the hall.

4. NDA and documentation

   Release drawings, models, bills of materials and specifications in a controlled manner with an unambiguous revision status.

5. Assess feasibility and quotation

   The supplier should identify manufacturing observations, risks, fixture needs, external processes and assumptions affecting price and lead time.

6. Plant audit

   Assess processes, personnel, quality system, traceability, welding coordination, measuring equipment, documentation and subcontractors.

7. Sample or first article

   Manufacture the component using the target or agreed process, including dimensional inspection, tests and the complete document package.

8. Approval and controlled ramp-up

   Approve after reviewing the results and increase the share of the new source only after further conforming batches rather than moving the entire volume after one sample.

9. Monitor quality and delivery

   Continuously assess non-conformities, on-time delivery, documentation changes, capability of critical processes and effectiveness of corrective action.

Audit questions, expected evidence and warning signs

RFQ and second sourcing

How to prepare the RFQ

External dimensions and quantity are insufficient for a reliable quotation. The supplier needs drawings, three-dimensional models, a bill of materials, grades and thicknesses, tolerances, welding requirements, NDT scope, leak-test criteria, post-weld machining, corrosion-protection system, cleanliness requirements, documentation and schedule.

The buyer should also state batch size, delivery location, packaging method, first-article requirements and responsibility for tooling. For transformer tanks, the documentation should clarify design responsibility, permitted manufacturing changes, repair procedure and conditions for customer witness during testing.

Frequently omitted information includes product weight, centre of gravity, post-coating tolerances, unpainted surfaces, closure of openings, documentation language, record-retention period and the concession-approval procedure.

Where a second source is most realistic

An alternative source is easiest to establish for parts with complete documentation and stable interfaces: plates, brackets, trays, covers, frames, smaller enclosures and CNC parts. Larger structures require fixtures, trial production and geometry comparison. For a transformer tank, qualification may take many months because it covers welding technology, testing, coating, transport and integration with the complete transformer.

The buyer should establish ownership of documentation and tooling, allow a period of parallel deliveries and define the point at which the new plant’s share will increase. Moving the entire volume after one positive sample creates unnecessary risk. A safer approach is to divide orders and expand scope gradually after further conforming batches.

Opportunities, SWOT and risks

SWOT of Polish energy-sector subcontractors

The International Energy Agency indicates that procurement of a large transformer may now take up to four years, approximately twice as long as in 2021, while prices of large transformers have increased by around 75% in real terms since 2019. These figures refer to the international market and advanced economies, but they increase pressure on European manufacturers and their supply chains. [10]

European manufacturers of transmission and distribution equipment have announced multi-billion-euro investments in capacity. A joint initiative by ENTSO-E, DSO Entity, Europacable and T&D Europe reported in 2025 more than EUR 9 billion of publicly announced investment by T&D Europe members and more than EUR 4 billion by the cable industry. The European Investment Bank also described a EUR 250 million guarantee mechanism intended to support up to EUR 2 billion of investment by grid-equipment manufacturers. [11] [12]

The difference between plans and implementation

The principal market risk is the movement of projects between years. PSE implemented 64.7% of planned capital expenditure in 2024, while the five largest DSOs achieved approximately 97% of plan. Delays in permits, engineering and outages can postpone demand even when the long-term investment need remains. [3]

Risks for the manufacturer

The supplier is responsible for leaks, incorrect material, distortion, coating quality and delivery. Testing, documentation, witnessed acceptance and repairs increase quality cost. In large structures, one non-conformity can occupy a workstation for weeks and disrupt the complete production schedule.

Dependence on external processes is significant. A galvaniser or paint shop may use the correct technology but have insufficient dimensions or a long queue. Transport between plants increases the risk of damage, flash rust and loss of schedule control.

Steel and energy-price volatility affects profitability where a long period separates quotation and delivery. The contract should define price validity, adjustment rules for significant material changes and responsibility for documentation changes. A fixed price without frozen documentation transfers disproportionate risk to the supplier.

Demand forecast for 2026–2030

There is insufficient data to forecast the value of the transformer-tank and enclosure market alone. The article therefore uses an index of demand for metal subcontracting, with 2025 = 100. The model is based on approved PSE plans, DSO plans, signed financing, the number of substation projects and European pressure on manufacturing capacity. [1] [2] [4] [5] [7] [10]

Scenario assumptions

Metal-subcontracting demand index, 2025 = 100

In the cautious scenario, demand remains above the 2025 level but growth is spread over a longer period. In the base scenario, growth results from implementation of the DSO portfolio, continued grid orders and moderate expansion of outsourcing. In the accelerated scenario, schedule pressure encourages manufacturers to divide packages and establish alternative supply sources.

Recommendations and limitations

Recommendations for Polish manufacturers

A company without energy-sector references should select one product family and prepare a capability sheet covering maximum dimensions, weight, materials, thicknesses, processes, tolerances, crane capacity, assembly area, machining range, coatings and tests. A general machine-list presentation is insufficient.

The most practical route is to begin with parts that have limited functional risk but require repeatability. After several conforming deliveries, the company can move towards frames and larger assemblies. A large transformer tank should become a target only after experience has been gained in leak-tight structures, distortion control and customer-witnessed acceptance.

Welding qualifications, material traceability, calibration of measuring equipment, revision control and coating documentation should be organised early. Investment in a machine makes sense only after the complete process chain has been considered: the cut part must still be bent, assembled, rotated, welded, measured, painted and shipped.

Recommendations for buyers

The first step should be to divide the portfolio into critical parts and parts that are easier to transfer. Minimum hall dimensions, weight, processes, certificates, testing and documentation should be defined for each family before a longlist is built.

The audit should follow actual material flow, not remain in a meeting room. The buyer should trace the route from plate receipt through marking, preparation, welding, measurement, surface processing and dispatch. Particular attention should be paid to operations performed outside the plant and to who has authority to approve repairs.

Several qualifications can be run in parallel for enclosures, supports, frames and machined parts. For leak-tight tanks, a staged project with a trial structure, complete inspection plan and customer-quality specialists present is more appropriate.

Interpretation limitations

Investment plans may be delayed, and the PSE draft for 2027–2036 may change during the approval process. Large packages are normally contracted through equipment manufacturers and main contractors. The operator is not required to disclose how contract value is divided among metal components.

The buyer should include the cost of audits, trials, tooling, testing, supervision and document retention. The supplier should include warranty cost, capacity buffers, complaints and the risk of unused workstations after the project.

Dependence on one customer may require dedicated tooling and personnel without a guarantee of follow-on orders. Excessive customer fragmentation, on the other hand, increases the number of standards, paint systems and documentation formats. The portfolio should be built deliberately.

Conclusions for buyers and manufacturers

Modernisation of Poland’s electricity networks creates a durable demand base, but access to orders depends on the company’s place in the supply chain. The strongest candidates are plants that can define the limits of their capabilities, take responsibility for the process and document the result. For a buyer, the decisive factor is not the number of machines but the ability to manufacture a specific component to the agreed geometry, quality and schedule.

A search for a transformer tank manufacturer in Poland should begin with requirements for dimensions, weight, distortion, tightness, cleanliness, post-weld machining and the acceptance package. For enclosures, brackets, frames and CNC parts, alternative sources can be created more quickly, provided that documentation and first-article control are managed correctly.

Target Solutions Poland can prepare a market map, identify manufacturers by product dimensions and weight, verify declared processes, ISO 3834, EN 1090 scope and coating capability, and support RFQ preparation, bid comparison and preliminary plant qualification. A typical project could involve finding two alternative manufacturers for leak-tight transformer tanks, welded bases and medium-voltage switchgear enclosures with corrosion protection and complete quality documentation.