Electric Forklift Charging Infrastructure Installation for a Large UK Manufacturer
Industrial Forklift Charging Infrastructure Upgrade
A leading UK building products manufacturer partnered with us to deliver a complete electrical infrastructure upgrade to support the transition from fuel-powered forklifts to a fully electric fleet.
The project required high-capacity power distribution from the site LV substation, dedicated charging distribution systems with integrated emergency shutdown functionality, and the installation of industrial-grade forklift chargers designed for demanding warehouse environments.
The works were delivered as part of our wider Electrical Building Services capability, supporting manufacturing and industrial clients with safe, scalable and future-ready electrical infrastructure.
Project Objectives
- Enable full transition to electric forklifts
- Install a robust, high-capacity supply network
- Integrate enhanced emergency shutdown capability
- Maintain safe pedestrian and vehicle movement
- Ensure full compliance and future-proofing
- Utilise best-in-class industrial charging technology
Our Electrical Solution: Design & Installation
High Capacity Sub-Main Infrastructure
To support multiple high-demand forklift chargers, we installed approximately 150 metres of 95mm² 4-core XLPE/SWA cabling from the site LV substation.
High-level containment systems were implemented to ensure safe routing above operational zones, maintaining clear working areas and minimising disruption to warehouse activity.
This formed the backbone of a scalable power distribution network designed for future expansion.
Dedicated Distribution & Emergency Safety Controls
A custom distribution board was installed specifically for the forklift charging system.
The board incorporated an MCCB main switch with shunt-trip functionality, enabling remote emergency stop activation — a critical safety requirement within busy industrial environments.
This ensured compliance with site safety protocols while providing rapid isolation capability if required.
Industrial Forklift Charger Installation
A custom distribution board was installed specifically for the forklift charging system.
The board incorporated an MCCB main switch with shunt-trip functionality, enabling remote emergency stop activation — a critical safety requirement within busy industrial environments.
This ensured compliance with site safety protocols while providing rapid isolation capability if required.
Overhead Cable Management & Compliance
To maintain safe pedestrian and vehicle movement within the warehouse, we constructed a bespoke Unistrut overhead framework to manage charging cables.
This prevented obstruction across walkways and ensured compliance with onsite safety standards, supporting both operational efficiency and workforce safety.
Project Gallery
Results: Safe, Scalable Electric Forklift Charging Infrastructure
The completed installation delivered:
- Reliable power infrastructure for a fully electric forklift fleet
- Reduced fuel and ongoing maintenance costs
- Improved onsite operational safety
- Lower operational emissions
- A scalable electrical backbone ready for future expansion
The manufacturer successfully transitioned to electric material handling equipment with minimal disruption and a future-proof electrical platform in place.
Delivered Under Our Electrical Building Services
This project was delivered as part of our comprehensive Electrical Building Services offering for industrial and commercial environments.
From substation distribution and high-capacity cabling to specialist equipment integration and safety system design, we provide turnkey electrical solutions tailored to complex operational sites.
If you are planning an electrification programme, infrastructure upgrade or expansion project, our team can design and install a system that supports long-term performance and compliance.
This project demonstrates our capability in delivering complex industrial power infrastructure as part of our wider Electrical Building Services offering for manufacturing and warehouse environments.
Why Manufacturers Choose Us
This project demonstrates our ability to combine:
- Industrial electrical engineering expertise
- Integration of premium technology solutions
- Practical design for complex operational environments
- Safety-led installation and compliance
- Scalable infrastructure planning
We work in partnership with manufacturers and warehouse operators to deliver robust, future-ready electrical systems that support operational growth.
