Full Electrical Installation – New Build Industrial Unit Client

Project Overview

We were appointed to deliver the full electrical installation for a new-build industrial unit designed to accommodate the production and distribution operations of a leading UK-based hosiery manufacturer. The client required a future-proof, high-performance electrical system capable of supporting intensive manufacturing processes, large-scale distribution logistics, and modern office facilities within the same building.

Working closely with the main contractor from the early design stages through to final commissioning, our team provided a turnkey electrical solution with energy efficiency, scalability, and safety at the forefront.

Objectives

  • Provide a full electrical installation to support both industrial machinery and office facilities.
  • Deliver high-reliability three-phase and single-phase power distribution.
  • Install intelligent lighting and control systems to maximise energy efficiency.
  • Ensure compliance with all current BS7671 (18th Edition) electrical standards and industrial building regulations.
  • Integrate fire alarm, security, and data infrastructure across warehouse and office zones.

Scope of Works

Distribution & Power Systems

  • Main LV Distribution: Installation of main intake switchgear and sub-distribution boards across factory floor, mezzanine, and office areas.
  • Three-Phase Power: Provision of multiple three-phase outlets to serve knitting machines, compressors, and auxiliary plant.
  • Containment: Galvanised trunking, ladder rack, traywork, and conduit systems for segregation of power, lighting, and data routes.

Lighting & Emergency Lighting

  • Warehouse Lighting: High-level LED linear fittings with motion detection and daylight harvesting to reduce energy usage.
  • Office Lighting: Recessed LED panel lighting with DALI dimming controls.
  • Emergency Lighting: Fully compliant system with self-test luminaires, strategically placed to ensure safe evacuation routes.

Fire & Security Systems

  • Fire Alarm: Addressable fire alarm system installed to BS 5839-1, with optical detectors and sounder coverage throughout.
  • Security & Access Control: CCTV system installed internally and externally, along with intercom access and fob-controlled door entry points.

Project Challenges

The project had to be delivered within a tight programme, as the hosiery company required the unit to be operational by a fixed manufacturing start date. To meet this deadline, we carefully sequenced works to overlap with structural and mechanical trades, ensuring smooth coordination and early energisation of essential plant.

Another challenge was accommodating the client’s high-load equipment, which demanded close collaboration with equipment suppliers to design and install protective devices and distribution paths that would handle large starting currents without nuisance tripping. Additionally, the office and warehouse areas needed to remain adaptable for future growth, so we incorporated flexible containment systems and additional board capacity to support later expansion.

OUTCOME

We successfully delivered a scalable, and energy-efficient electrical infrastructure tailored to the operational demands of a growing hosiery manufacturer. The completed installation supports 24/7 production with optimal lighting, secure access, and efficient energy use, all delivered on budget and ahead of schedule.