Overview
We designed, constructed and managed the implementation of a private electrical network (PEN) to support new electric vehicle (EV) charging infrastructure at the largest ultra-rapid charging superhub in the south of England. This project played a crucial role in advancing sustainable transportation, providing a state–of–the–art charging facility to accommodate a growing number of EVs.
Scope of works
We undertook a comprehensive scope of works, delivering a fully integrated solution.
- Electrical infrastructure installation
We supplied and installed single-core low-voltage (LV) cables from the air circuit breaker (ACB) to the adjacent LV feeder pillar, including all necessary terminations. - Feeder pillar deployment
We installed one feeder pillar with a main incoming breaker and outgoing breakers designed to support the chargers, additional feeder pillars, battery energy storage systems (BESS) and solar connections. Spare outgoing breakers were available as optional upgrades. - LV cable distribution
Approximately 2950 m of LV power cable was installed from the LV feeder pillars to 44 chargers, ensuring optimal power delivery to each charging unit. - Charger installation
We successfully installed 44 chargers, with all charging equipment free-issued by the client. - Communications infrastructure
CAT5e data cabling was installed from the LV feeder pillars to each charger, supporting seamless network integration. - Ancillary electrical supply
We installed a 200 A feeder pillar to support essential site infrastructure, including streetlighting; vacuum, air and water stations; CCTV; ANPR; and other services. - Streetlight and signage power supply
Approximately 975 m of LV cable was installed from the feeder pillar to power 95 streetlights and entrance signage, with the streetlight fixtures supplied and installed by others. - Additional facility power connections
- 20 m of LV cable installed to supply the pumping station
- 20 m of LV cable installed to supply toilet facilities
- Three runs of 45 m LV cable installed to supply air, vacuum and water stations
- 20 m of LV cable installed to supply a defibrillator unit
- 25 m of LV cable installed from a spare ACB to supply the restaurant, including all terminations
- A 400 A heavy duty cut out (HDCO) and current transformer (CT) metering system installed for the restaurant
- GRP enclosures and fibre connectivity
Two GRP enclosures were installed for the communications infrastructure, along with fibre cabling between the central communications cabinet and the BT intake position. - Grid connection compliance
We carried out a G100 scheme to ensure regulatory compliance.
Additionally, the project required extensive off-site works.
- HV cable installation
- 2.1 km of trench excavation and reinstatement within public highways, including footways and carriageways, from the point of connection to the site boundary
- Installation of approximately 2.1 km of 11 kV high-voltage (HV) mains cable from the point of connection to the on-site substation
- Direct laying within the footway, verge and ducting within the carriageway, with additional ducting for road crossings
- Substation construction
- Concrete foundation constructed for the substation
- Installation of a package substation, including a GRP enclosure
- Installation of GRP gratings, earthing arrangements and small power and lighting within the substation
- LV cable installed from the transformer substation’s LV ACB to the adjacent LV feeder pillar
Challenges and solutions
A key challenge involved coordinating extensive trenching and cabling work within the public highway, while minimising disruption. We worked closely with local authorities to ensure efficient traffic management and compliance with Section 50 regulations. Additionally, we leveraged existing ducting, where possible, to reduce costs and streamline installation.
Another challenge was optimising power distribution to multiple facilities on-site, including EV chargers, streetlighting and ancillary services. To address this, we designed a robust feeder pillar system with flexible upgrade options, ensuring scalability for future expansion.
Outcome
The project was successfully delivered on time and to specification, providing a fully operational ultra-rapid charging superhub with robust power distribution and communications infrastructure. The installation supports our and the client’s commitment to expanding high-speed EV charging networks, enabling a seamless charging experience for EV users.
Our expertise in electrical infrastructure and renewable energy solutions was instrumental in the success of this project. By integrating engineering excellence with sustainable energy solutions, we helped the client take a significant step toward a low-carbon transportation future.