Case Study

Enabling First-of-its-Kind eHGV Charging Infrastructure in a Live Logistics Environment

The Project

As organisations accelerate their transition toward low-carbon operations, the electrification of heavy goods vehicle fleets presents both a strategic opportunity and a complex infrastructure challenge.

For large-scale manufacturing and distribution operations, where high volumes of materials are processed and dispatched, eHGV infrastructure must be carefully integrated within live logistics environments where operational continuity, safety and programme certainty are critical.

Gridserve

From Sustinability Ambition to Operational Deployment

Working with Gridserve, this project delivered first-of-its-kind eHGV charging infrastructure at this scale within the client’s global organisation. The complexity of the site made this a critical test case for delivering eHGV infrastructure within a live, high-demand operational environment.

More than charging equipment, this required a fully integrated, turnkey infrastructure solution. Designed, coordinated and delivered to enable immediate operational use without disruption.

Appointed to provide end-to-end delivery, we supported the client by aligning design, planning, construction and activation within a single accountable framework.

The Challenge

Infrastructure Within a High-Intensity Operational Environment

The challenge was operational — delivering substantial infrastructure works without disrupting day-to-day operations.

Operating within this live logistics environment required careful coordination to ensure works could be completed without impacting ongoing operations or compromising site safety.

Critical considerations included:

Maintaining safe working practices within a live HGV environment
Coordinating works around continuous site activity
Managing high and low voltage installation risks
Ensuring minimal disruption to distribution schedules

The Approach

Structured Delivery Within a Live Environment

Rather than applying a fixed delivery approach, the programme was structured to respond dynamically to operational conditions.

A segregated CDM construction environment was established, supported by clearly defined pedestrian routes, traffic management measures and close coordination with site operations teams.

Temporary traffic reconfigurations were implemented through clear communication and on-site coordination.

Specialist NERS-accredited partners were deployed for HV and LV works, ensuring compliant installation and safe energisation. This included safe energisation and coordination of high and low voltage infrastructure to integrate new demand within the existing operational environment.

Thomas Brooks, EV Project Manager at Clarke Connect, commented on the project:

Delivering this project within a live operational environment required precise coordination across infrastructure, power and site operations.

The result is not only a successful deployment, but a proven approach that can be applied to future eHGV infrastructure delivery across comparable operational environments.

Assured Delivery

Integrating Design, Programme and Stakeholder Alignment

Close collaboration between stakeholders was critical to maintaining alignment throughout delivery. This included the commissioning client, end customer, project consultants, DNO, delivery partners and site operations teams.

A Programme of Works was developed following detailed feasibility and survey activities, establishing clear milestones and a coordinated delivery sequence across all workstreams.

This programme acted as the central control mechanism for:

Progress tracking
Supplier coordination
Risk management
Schedule optimisation

As the project progressed, dynamic adjustments were required due to adverse weather conditions and evolving client requirements. Workstreams were reprioritised to maintain programme continuity while ensuring quality was achieved first time.

Our structured and adaptive approach ensured delivery remained aligned with operational demands, without compromising safety, quality or schedule.

Following completion, the project underwent a full stakeholder audit and was accepted without defect, reflecting the control and assurance applied throughout the delivery lifecycle.

Operational Confidence Secured

Enabling Immediate eHGV Operations with Assured Infrastructure Delivery

The project has delivered a fully operational eHGV charging infrastructure, enabling immediate deployment within a live logistics environment.

The project delivers:

A reliable and operationally integrated eHGV charging platform
Infrastructure designed for safe and compliant deployment within a live environment
Safe integration within an active distribution environment
Confidence in operational continuity during delivery

As a first-of-its-kind deployment, the project establishes a proven delivery model that can be applied across similar operational environments, supporting wider decarbonisation objectives and long-term operational planning.

From Feasibility to Deployment at Scale

By successfully delivering and integrating eHGV infrastructure within a live operational environment, the client is now positioned to move forward with electrification as a structured programme, rather than isolated EV charging installations, enabling a repeatable approach to electrification delivery with confidence.

The delivery model and coordination approach provide a clear pathway for future deployment, enabling consistent, scalable infrastructure delivery with confidence in performance, safety and operational continuity.