What happens when you build the largest machine in the world, but it’s still not big enough? That’s the situation the North American transmission system, the grid that connects power plants to substations and the distribution system, and which by some measures is the largest machine ever constructed, finds itself in right now. After more than a century of build-out, the towers and wires that stitch together a continent-sized grid aren’t up to the task they were designed for, and that’s a huge problem for a society with a seemingly insatiable need for more electricity.

There are plenty of reasons for this burgeoning demand, including the rapid growth of data centers to support AI and other cloud services and the move to wind and solar energy as the push to decarbonize the grid proceeds. The former introduces massive new loads to the grid with millions of hungry little GPUs, while the latter increases the supply side, as wind and solar plants are often located out of reach of existing transmission lines. Add in the anticipated expansion of the manufacturing base as industry seeks to re-home factories, and the scale of the potential problem only grows.

The bottom line to all this is that the grid needs to grow to support all this growth, and while there is often no other solution than building new transmission lines, that’s not always feasible. Even when it is, the process can take decades. What’s needed is a quick win, a way to increase the capacity of the existing infrastructure without having to build new lines from the ground up. That’s exactly what reconductoring promises, and the way it gets there presents some interesting engineering challenges and opportunities.

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