Overview
We were asked to extend the existing electric vehicle (EV) network at one of our client’s logistics sites in Milton Keynes as part of Phase 1 operations. The project involved installing four new 360 kW DC E-Truck chargers to support the client’s ongoing commitment to sustainable logistics.
Scope of work
We approached the project systematically, ensuring each phase aligned with the client’s operational and sustainability goals.
We began by designing the layout and performing detailed cable calculations to ensure the network extension would integrate seamlessly with the existing infrastructure. Our team then installed low-level overground cable containment from the existing transformer low-voltage (LV) cabinet to the designated charger locations. We then laid LV AC single-core power cables from the existing transformer LV cabinet to three of the new chargers, terminating them at the 630 A circuit breakers within the cabinet and at each charger. For the fourth charger, we installed power cables to a proposed future transformer LV cabinet position, leaving one end of the cable ready for connection during Phase 2.
We also supplied and installed CAT6 data cables to each charger, routing them through flexible ducting and the containment system, ensuring efficient communication between the chargers and the network. Concrete foundations were constructed to support the chargers, with short underground ducting sections for cable entry. We landed and installed the four chargers using a HIAB offload from the delivery vehicle, placing them directly onto the prepared bases.
To ensure safe operations, we installed four wheel stops and eight bollards, matching the existing site specifications. Additionally, we completed line painting for three of the four new truck bays and three existing lorry bays, marking a total of six bays. The fourth bay’s painting was scheduled for Phase 2.
We oversaw the charger commissioning, performed by a third party, and provided test certificates and an operations and maintenance pack. Once all systems were verified, we energised the chargers and handed over the completed network extension to the client.
Challenges and solutions
One of the challenges was coordinating the installation of the fourth charger, which relied on a future transformer position. To address this, we prepared the necessary cabling and infrastructure for a smooth connection in Phase 2, minimising disruption and ensuring scalability.
Outcome
The project was successfully delivered on time and met all performance requirements. Our ability to integrate the new infrastructure seamlessly with the existing network demonstrated our expertise in renewable energy and EV solutions. This project exemplified our commitment to enabling a low-carbon future and fostering long-term partnerships with forward-thinking organisations such as our client.