A new 18,000m² distribution centre on the western edge of Bedford was nearing practical completion when the LV distribution package needed delivering at pace. Forty dock leveller positions, charging bays for warehouse trucks, and the office block sub-main all hung off the same LV switchgear room.
We were brought in to pull, joint and terminate the LV distribution from the main switchroom to every demand point, with the building services contractor handling final connections.
What the job involved
- Approx. 1,400m of LV cable (35mm² to 240mm²) pulled across rooftop trays and underground duct routes.
- Twelve in-line joints at the junction boxes between zones.
- Forty dock-leveller circuits terminated to manufacturer's spec.
- Charging room sub-main installed and tested separately.
- Cable schedule, test sheets and as-builts handed over electronically.
Key challenges
- Forklift trial runs began before the LV install was finished — temporary protection over live areas.
- Roof tray spans of up to 80m required careful tension and support spacing.
- Tenant move-in date held firm — programme had no slack.
Outcome
- All forty dock positions energised one day ahead of programme.
- Charging room handed over with full battery-bay test certificates.
- Operator added us to their national framework for future depots.
Six weeks from first drum to first lorry. Numbers don't lie — and the as-builts were on my desk the day they finished.
— Project Director, Bedford, Bedfordshire
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