Warrington · industrial and logistics

Power and distribution for a new automated line

  • £250k to £350k
  • Distribution and containment
  • 10 weeks, two weekend shutdowns
  • Completed November 2025

The project

A long distribution centre aisle of high pallet racking and conveyors under rows of new LED high-bay lights, cable tray running overhead.

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Client
A third-party logistics operator
Main contractor
Direct for the operator, alongside its automation integrator
Consultant
The integrator's electrical designer
Location
Warrington
Contract value
£250k to £350k
Programme
10 weeks, two weekend shutdowns
Floor area
18,000 m² warehouse
Form of contract
NEC4 Engineering and Construction Contract
Our role
Principal electrical contractor
Completed
November 2025
Occupied throughout
Yes: the site picked and shipped 24 hours a day
Safety
0 lost-time incidents in 1,900 hours at height
Services

The result in numbers

  • 0lost shifts
  • 2weekend shutdowns, both finished early
  • 1,600 ALV switchboard installed and commissioned
  • 1.2 kmof cable ladder installed at height
  • 0lost-time incidents

The brief

A logistics operator was installing an automated picking line and needed new power to it, in a distribution centre that never closes.

What we worked around

  • The site operated 24 hours a day, seven days a week, throughout
  • All work at height from MEWPs inside daily exclusion zones
  • Only two weekend shutdowns available, booked eight weeks ahead

Our solution

Every cable went in at height from MEWPs inside exclusion zones agreed each morning with the shift manager. The switchboard was fitted over the first of two planned weekend shutdowns, so the second was needed only to connect the line.

Two electricians in Marlow & Reed hi-vis on a scissor lift pulling cable through trays above warehouse racking, a third watching from behind barriers.
Cable pulled onto ladder at height, zone below

What we installed

  • A new 1,600 A LV switchboard and sub-mains to the automation panels
  • 1.2 km of cable ladder along the roof steelwork
  • High-bay LED lighting with presence control in the new aisles
  • Thermographic survey of the existing switchgear before connection
A new grey low-voltage switchboard along a plant room wall, cables dropping into it from trays overhead and a rubber safety mat in front.
The new LV switchboard in the plant room

Programme

Ten weeks, with the two weekend shutdowns booked eight weeks ahead and the integrator's commissioning dates fixed from the start.

The result

The automation was powered and tested on the date the integrator had planned around, with both shutdowns finished early and not one lost shift.

Handover

An as-fitted single-line diagram, the switchboard's test results, a thermographic baseline of the new switchgear and the O&M manual.

INCOMING SUPPLY · 1600 A TP&N · 400 V MAIN SWITCH 1600 A BUSBAR 100 A 4c 70mm² SWA DB-AEXTERNAL 125 A 4c 25mm² SWA DB-BDATA ROOM 63 A 4c 120mm² SWA DB-CEV CHARGING 125 A 4c 120mm² SWA DB-DMECHANICAL 160 A 4c 120mm² SWA DB-EAUTOMATION CIRCUIT BREAKERBUSBAR POWER AND DISTRIBUTION FOR A NEW AUTOMAT DRG MR-8969-E-113 ILLUSTRATIVE ONLY SCALE NTS REV C
Illustrative drawing generated for this record, not the client's building.

Two shutdowns, both finished early, and not one lost shift.

Engineering manager, logistics operator

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