We were appointed to complete an 11kV and 33kV cable route installation at Gatwick Airport, delivering specialist electrical infrastructure works to enable the safe connection of a new power supply for an electric vehicle charging forecourt which has now been constructed and is operational.

Working in line with the project specifications and site RAMS, our team carried out the installation and pulling of multiple high-voltage cables between 5 joint bays along the route which stretched between the new on site substation and a 33kV point of connection outside of the airport perimeter.

The works included:

• Over 1,100m of trench excavation across both soft ground and hard surfaces. The was routed through land side areas of Gatwick Airport and within the West Sussex high boundary.
• Installation of 125mm and 160mm class 1 emmtelle high-voltage ducts.
• Construction of joint bays, including a loop-in loop-out HV joint bay.
• Temporary access to the POC field with a wire mesh perimeter fence and a bogmat road.
• Pulling three 500mm² 33kV cables through 160mm ducts to form a dual circuit route.
• Installation of cement bound sand and DNO specification stokboard for cable protection.
• Installing 185mm² 11kV cable through 125mm ducts, connecting the network to the new substation and connection pole.
• Setting up cable drum stands, rollers and calibrated winch equipment to ensure safe and controlled cable installation.
• Controlled winch tension cable pulling to protect the integrity of the HV cables.
• Monitoring and maintaining correct pulling tensions in line with manufacturer and network operator requirements.
• Coordinating the installation team via radio communication to maintain safety and precision during cable pulls.
• Ensuring adequate cable allowances for jointing and terminations at each end of the installation.
• Full reinstatement of excavated areas on completion.

All works were completed in accordance with DNO specifications, with strict adherence to safety procedures, permits and environmental considerations.

This project required careful planning, experienced operatives and specialist equipment to successfully install and protect critical high-voltage infrastructure within a live airport environment.