Overview
The Romford bus garage project was a dynamic and rewarding initiative, where we at CX Energy successfully delivered a state-of-the-art electric vehicle (EV) charging network to support the site’s transition to a greener, more sustainable future.
Scope of work
We began by installing a new 3200 A low-voltage (LV) feeder pillar, directly connected to the transformer and equipped with outgoing breakers suited to the chargers. Situated within a newly constructed fenced outdoor substation compound, this feeder pillar formed the backbone of the EV charging network. The construction of its concrete foundation and the subsequent installation of LV cabling within the substation compound were completed with precision, ensuring compliance with safety and operational standards.
Low- and high-level containment systems were installed to distribute power throughout the site, connecting the LV feeder pillar to power units and charger locations, and LV AC power cables were laid from the feeder pillar to the power units and stand-alone chargers. Additionally, LV DC cables were installed to connect the power units to a mix of ceiling-mounted, wall-mounted and floor-mounted chargers.
We installed a diverse range of chargers to meet the site’s requirements, including:
- 3 x 600 kW DC power units
- 2 x 150 kW DC stand-alone floor-mounted chargers
- 9 x 75 kW DC ceiling-mounted satellite chargers
- 11 x 75 kW DC wall-mounted satellite chargers
- 2 x 150 kW DC floor-mounted satellite chargers.
All chargers and power units were delivered free-issued by the client and offloaded using a HIAB lorry loader or forklift, depending on site conditions. For the external units, concrete bases were constructed to ensure stable, long-lasting foundations.
Two 63 A commando sockets were supplied and installed to accommodate portable chargers. We laid CAT5e data cables from the LV feeder pillar to each charger, with the cables housed in flexible ducting for protection and ease of maintenance. To safeguard the chargers and power units, we installed up to 31 bollards and wheel stops across the site. These robust protections were implemented to reduce potential damage from vehicular impact.
Our team carried out trenching from the site boundary to the new distribution network operator (DNO) substation position, building concrete foundations for the DNO substation, including an earth nest, and a GRP enclosure was installed to house the meter and emergency power off system.
We witnessed the commissioning of all chargers by the manufacturer, ensuring that each unit performed optimally. Once it was energised, we handed over a fully operational EV network, complete with all necessary test certificates and documentation.
Challenges and solutions
A key challenge was coordinating the installation of various charger types, each with unique mounting requirements. To address this, we worked closely with the client and manufacturer, ensuring that all mounting bases, both steel and concrete, were precisely tailored to the equipment. Additionally, managing a high volume of containment and cabling works across a complex site required detailed planning and phased execution. This approach ensured that all tasks were completed on time and with minimal disruption to ongoing operations at the bus garage.
Outcome
The project was a resounding success. The Romford bus garage now boasts cutting-edge EV charging infrastructure capable of supporting its fleet’s immediate and future needs. By delivering this project, we reinforced our reputation as a leader in EV infrastructure development, driving the shift toward sustainable transportation in the UK.