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America races to rebuild its aging power grid before demand overwhelms it

America races to rebuild its aging power grid before demand overwhelms it

Built World
By Newzino Staff |

Decades of underinvestment meet surging electricity demand from data centers, AI, and electrification

6 days ago: DOE launches $1.9 billion SPARK reconductoring program

Overview

Seventy percent of America's power lines and transformers are over 25 years old, and nearly a third of transmission infrastructure has passed its useful life. Now electricity demand is rising at its fastest pace in decades, driven by data centers powering artificial intelligence, electric vehicles, and reshored manufacturing. The Department of Energy just committed $1.9 billion to a program called SPARK that funds a deceptively simple fix: swapping old wires on existing towers for advanced conductors that can carry up to double the electricity, without the decade-long permitting fights required for new power lines.

In This Story

2 People
Chris Wright Catherine (Katie) Jereza
3 Orgs
DE
DOE Grid Deployment Office Federal Energy Regulatory Commission (FERC)
10 Events
6 Key Stats
$1.9B
4 Scenarios
Reconductoring becomes the fast lane for grid expansion
3 Context
Rural Electrification Act and the TVA (1935-1952)

Key Indicators

$1.9B
SPARK program funding
Federal investment specifically for reconductoring and advanced transmission technology upgrades
70%
Grid infrastructure over 25 years old
Share of U.S. power lines and transformers deployed more than 25 years ago
2x
Capacity gain from reconductoring
Advanced conductors can up to double power transfer capacity within existing rights of way
D+
ASCE energy infrastructure grade
The American Society of Civil Engineers downgraded the grid from C- to D+ in its 2025 report card
2,300 GW
Interconnection queue backlog
Generation and storage capacity waiting for grid connection as of late 2024, with typical waits of five-plus years
10-15 yrs
New transmission line timeline
Average time to permit and build a new power line, making reconductoring's speed a significant advantage

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People Involved

Chris Wright
Chris Wright
In office since February 2025
 Catherine (Katie) Jereza
Catherine (Katie) Jereza
Leading the Office of Electricity since October 2025

Organizations Involved

DE
U.S. Department of Energy, Office of Electricity
Federal Agency
Administering the SPARK program

The DOE office responsible for research, development, and deployment programs that strengthen, modernize, and protect the nation's electricity delivery system.
DOE Grid Deployment Office
DOE Grid Deployment Office
Federal Agency
Distributing over $26 billion in grid investments

Created under the Bipartisan Infrastructure Law to invest more than $26 billion in expanding and modernizing the electric grid.
Federal Energy Regulatory Commission (FERC)
Federal Energy Regulatory Commission (FERC)
Independent Federal Agency
Implementing Order 1920 transmission planning reforms

The independent agency that regulates interstate transmission of electricity, natural gas, and oil, and oversees wholesale electricity market rules.

Timeline

  1. DOE launches $1.9 billion SPARK reconductoring program

    Funding

    The Office of Electricity announced the SPARK funding opportunity to replace aging power lines with advanced conductors that can double capacity, targeting projects that use existing rights of way to bypass lengthy permitting. Concept papers are due April 1, full applications May 19, with selections expected in summer 2026.

  2. ASCE downgrades energy grid to D+

    Assessment

    The American Society of Civil Engineers dropped the energy sector's grade from C- to D+ in its 2025 infrastructure report card, citing transformer shortages, weather vulnerability, and insufficient transmission capacity.

  3. New Energy Secretary orders grid reliability push

    Policy

    Secretary Chris Wright issued his first secretarial order prioritizing grid reliability, permitting reform, and energy infrastructure modernization under the banner of "American energy dominance."

  4. DOE announces $4.2 billion in second-round GRIP projects

    Funding

    The second round of GRIP funding selected 46 projects across 47 states, bringing total GRIP commitments to $7.6 billion across 105 projects in all 50 states.

  5. FERC issues landmark transmission planning rule

    Regulatory

    Order 1920 required utilities to adopt 20-year planning horizons and consider advanced transmission technologies including reconductoring for the first time in over a decade of transmission policy updates.

  6. DOE selects $3.46 billion in GRIP projects

    Funding

    The first round of Grid Resilience and Innovation Partnerships funding selected 58 projects across 44 states to strengthen grid reliability.

  7. FERC issues interconnection queue reform

    Regulatory

    The Federal Energy Regulatory Commission issued Order 2023 to address the backlog of over 2,000 gigawatts of generation projects waiting years for grid connection.

  8. DOE creates Grid Deployment Office

    Institutional

    The Department of Energy established a new office to manage over $26 billion in grid investments authorized by the infrastructure law.

  9. Bipartisan Infrastructure Law signed

    Legislation

    President Biden signed the Infrastructure Investment and Jobs Act, allocating $73 billion for grid modernization over five years, the largest federal investment in electricity infrastructure in American history.

  10. Texas grid collapses during Winter Storm Uri

    Crisis

    The largest manually controlled load-shedding event in U.S. history left 69% of Texans without power, killing at least 246 people and causing up to $300 billion in damage. The failure exposed critical vulnerabilities in aging, weather-unprepared infrastructure.

Scenarios

1

Reconductoring becomes the fast lane for grid expansion

Discussed by: GridLab, the Goldman Sachs 2035 report, and Berkeley energy researchers who model transmission buildout scenarios

If SPARK-funded projects demonstrate that advanced conductors reliably double capacity at half the cost of new lines, the approach could spread rapidly. Eighteen states have already introduced legislation encouraging grid-enhancing technologies, and FERC Order 1920 requires utilities to consider them. In this scenario, reconductoring becomes the default first option for utilities facing capacity shortfalls, significantly compressing the timeline between identifying a bottleneck and resolving it from over a decade to two or three years. The $1.9 billion in federal seed money triggers a much larger wave of utility and state spending.

2

Investment wave falls short as demand outpaces upgrades

Discussed by: The PJM Interconnection capacity market analysis, Bank of America grid research, and ASCE infrastructure assessments

Even with SPARK and GRIP combined, total federal grid funding represents a fraction of the estimated $720 billion Goldman Sachs says is needed through 2030. If permitting reform stalls, if utility capital plans hit supply chain bottlenecks for transformers and advanced conductors, or if AI-driven electricity demand grows faster than projected, the grid could face reliability crises in high-demand regions. PJM already projects a six-gigawatt capacity shortfall by 2027. In this scenario, rolling blackouts or emergency orders become more frequent, forcing costlier emergency measures.

3

Political headwinds redirect or slow grid spending

Discussed by: E&E News and Latitude Media, which track DOE budget politics and energy policy shifts between administrations

Federal grid programs draw from Bipartisan Infrastructure Law funds that were authorized under a different administration. If fiscal priorities shift, appropriations are redirected, or program implementation slows during administrative transitions, projects could face delays or cancellations. SPARK's application timeline extends into summer 2026, and actual construction would begin later, leaving a window for policy changes. However, grid reliability is a bipartisan concern and the current administration has publicly championed the SPARK program, reducing but not eliminating this risk.

4

Grid modernization becomes a sustained multi-decade national priority

Discussed by: Morningstar DBRS utility analysts projecting a capital expenditure "super-cycle," and Apollo infrastructure investment outlook

Rising demand from AI, electrification, and reshoring locks in a structural increase in grid investment that persists regardless of which party holds power. Utilities are already on pace to spend $208 billion in 2025 alone, and private capital flows into grid infrastructure accelerate. Federal programs like SPARK prove the technology, states mandate adoption, and the utility "super-cycle" sustains itself through the 2030s. In this scenario, the current moment marks the beginning of an infrastructure transformation comparable in scale to the interstate highway era, with grid capacity expanding to match 21st-century demand.

Historical Context

Rural Electrification Act and the TVA (1935-1952)

1935-1952

What Happened

In 1935, only about 10% of rural Americans had electricity. President Franklin Roosevelt's Rural Electrification Administration provided federal loans to farmer cooperatives to build distribution lines, while the Tennessee Valley Authority built dams and generation capacity across the Southeast. By 1942, nearly half of American farms were electrified; by 1952, nearly all were.

Outcome

Short Term

Rural communities gained access to refrigeration, lighting, and powered machinery, transforming agricultural productivity and quality of life within a single generation.

Long Term

The model of federal funding catalyzing infrastructure that private markets had failed to build became a template for subsequent national infrastructure programs.

Why It's Relevant Today

Like the 1930s electrification gap, today's grid challenge involves federal investment addressing infrastructure that private utilities have underbuilt for decades. SPARK's use of federal dollars to catalyze a technology shift mirrors how REA loans enabled rural cooperatives to extend the grid where investor-owned utilities would not.

Federal-Aid Highway Act (1956)

June 1956

What Happened

President Eisenhower signed the $25 billion Federal-Aid Highway Act, the largest public works project in American history at the time (equivalent to roughly $220 billion in 2025 dollars). The law created the Highway Trust Fund and authorized 41,000 miles of interstate highways, with the federal government covering 90% of construction costs.

Outcome

Short Term

Tens of thousands of construction jobs were created and existing roads were rapidly upgraded, reducing cross-country travel times dramatically.

Long Term

The interstate system reshaped American commerce, enabled suburbanization, and generated an estimated $2 in economic output for every $1 invested. It also created path dependencies that persisted for decades.

Why It's Relevant Today

The current grid investment push shares structural similarities: a federal government using large-scale funding to upgrade infrastructure that individual states and private entities were building too slowly. The utility investment "super-cycle" projected at $1.1 trillion through 2030 echoes the scale of the highway era, though this time private capital leads and federal funding provides the catalyst.

2003 Northeast blackout

August 2003

What Happened

On August 14, 2003, a software bug at an Ohio utility and overgrown trees touching a high-voltage line triggered a cascading failure that shut off power to 55 million people across eight U.S. states and Ontario, Canada. It was the largest blackout in North American history, lasting up to two days in some areas.

Outcome

Short Term

At least 11 deaths were attributed to the blackout, with economic losses estimated at $6 billion. The joint U.S.-Canada investigation identified aging infrastructure and inadequate monitoring as root causes.

Long Term

Congress passed the Energy Policy Act of 2005, which made compliance with reliability standards mandatory rather than voluntary, and established the North American Electric Reliability Corporation as the enforcement body.

Why It's Relevant Today

The 2003 blackout demonstrated how aging grid infrastructure creates cascading failure risks that cross state and national borders. Two decades later, the grid is older and more stressed. Programs like SPARK aim to address the same underlying vulnerability: transmission lines operating at or beyond their designed capacity on deteriorating hardware.

Sources

(12)
+6
U.S. Department of Energy Investing.com / Reuters E&E News by POLITICO Fortune Utility Dive Federal Energy Regulatory Commission American Society of Civil Engineers IEEE Spectrum NPR U.S. Department of Energy U.S. Department of Energy Utility Dive