Case Study

Enabling eHGV Fleet Charging Through Private HV Network Integration

The Project

For organisations operating large utility fleets, electrification is rapidly becoming a strategic and operational priority, driven by the need for greater cost transparency, long-term fleet resilience and measurable, reportable progress toward environmental commitments.

However, it’s essential that organisations structure fleet electrification as a programme, ensuring the underlying electrical infrastructure can safely and compliantly support significant new demand without compromising operational performance, and only then integrate the charging technology.

From Decarbonisation Commitment to Infrastructure Reality

Our client, an extensive utilities fleet operator based in Manchester, decided to introduce eHGV charging infrastructure to support its fleet of electric heavy goods vehicles. The site was already supplied by a private high-voltage network, meaning the introduction of additional load required careful engineering, regulatory compliance, and controlled integration into the existing infrastructure.

What the client required was not standalone chargers, but a fully designed and delivered HV-to-LV infrastructure solution that could enable fleet electrification without compromising network integrity or site operations.

We were appointed as Principal Designer and Contractor to deliver the integrated infrastructure solution, providing complete project assurance from design through to energisation.

Project Challenges and Solutions

Introducing New Supply Without Increasing Risk

Integrating eHGV charging into a private HV network poses a greater technical challenge than standard EV deployment, requiring careful protection coordination and capacity planning.

The project required:

Breaking on to an existing HV circuit
Introducing a significant additional electrical supply
Designing and constructing a new HV-to-LV substation
Delivering associated civils and ducting across mixed landscapes

All works were undertaken within a live operational site in a major city location, with sensitivity required to the surrounding meadow environment adjacent to an existing car park.

The real challenge was not installation — it was ensuring network stability, safety and compliance while enabling a step change in fleet capability.

Assured HV Infrastructure Delivery

After feasibility assessments, we ensured a robust design package was developed to assess load requirements, the HV integration strategy, and the substation configuration before works were authorised.

As specialists in HV and LV electrical delivery, we evaluated the best way to introduce the additional demand into the private network while maintaining operational certainty.

The project progressed from HV design approval through to full civils and electrical build, including:

Construction of new HV and LV infrastructure
Installation of substation and RMU equipment
Construction of plinths, ducting and landscape-sensitive works
Final connection to supply power to the eHGV charging solution

James Burnett, Head of EV at Clarke Connect, commented on the project:

By maintaining single-source accountability across design, civils and electrical disciplines, we ensured coordination, compliance and technical assurance at every stage, mitigating risk throughout the programme.

Close collaboration with the site and project stakeholders meant the works were delivered while maintaining environmental sensitivity, with reinstatement undertaken to preserve as much of the surrounding meadow as possible following installation.

Powering Low-Carbon Fleet Operations With Confidence

Fleet electrification at eHGV scale depends on resilient, compliant and future-ready power infrastructure.

The completed project provides:

A reliable charging platform for eHGV deployment
Secure integration within the existing private network
A scalable electrical foundation for future low-carbon expansion
Confidence that electrification has been delivered without compromising network integrity

More than a charging installation, this project demonstrates how specialist HV capability, integrated delivery and assurance-led EV project management enable organisations to meet environmental commitments while safeguarding essential operational infrastructure.

Operational Confidence Secured

As a result of this project, the organisation now operates a purpose-built eHGV charging platform fully integrated within its existing electrical infrastructure, providing the capacity and stability required to support heavy-duty fleet electrification at scale.

By embracing eHGV technology and investing in the necessary HV and LV infrastructure, the organisation has taken a forward-thinking step toward reducing operational emissions while strengthening long-term fleet resilience and cost transparency.

The site is now equipped with an electrical foundation that supports continued fleet transition without compromising network integrity or operational reliability, enabling low-carbon progress within a major city environment where resilience and compliance are essential.