Project Principles and Objectives
Ryebridge was awarded the contract for the installation of 1.8km of 5 x 160mm Class 2 High Voltage rigid ducts for Associated British Ports and DP World within a live operational port environment. These were to provide power to four new container quayside cranes for DP World.
The cranes, which weigh more than 2,000 tonnes each, are capable of performing quad lifts, moving two 40ft containers at the same time from ship to yard in a single move, drastically reducing the time taken to load and unload large container vessels.
Designed to service the largest ships currently in operation, including 24,000 TEU megaships, they require the necessary power capacity to run them.
Ryebridge stripped out existing cycle footpaths at Dock Gate 20, digging down between one to 1.5 metres and installing five new electric ducts and one 100ml data duct.
Spanning 1.8km at their maximum length, the ducts include a straddle corridor charging point half way along their length.
Project Works
The works involved the installation of HV ducting within existing port roads and footpaths in a heavily trafficked operational area.
Due to the high volume of HGV movements and continuous port operations, the project presented significant logistical and traffic management challenges. To minimise disruption to port users and maintain programme, Ryebridge carried out substantial portions of the works during evenings, weekends, and night shifts.
The programme duration was particularly challenging due to the fixed delivery schedule of the new container cranes, with no allowance for programme overrun. The works required careful coordination around existing buried services, operational restrictions, obstructions, and live traffic routes.
Ryebridge proactively mitigated delays through resequencing of works, extended working hours, and close coordination with the client and stakeholders to ensure the programme milestones were maintained.
Despite the constraints, all duct installations and cable pulls were completed on programme.
The HV infrastructure will supply power to DP World’s new cranes, which will be among the largest cranes in Europe upon installation. Due to the length of cable pulls, approximately 300m between joint pits, installation accuracy was critical to ensure successful cable installation.
To achieve this, Ryebridge maintained strict tolerances throughout the duct installation works. Duct spacers were utilised to ensure the ducts remained straight, level, and evenly spaced across the full route.
This reduced friction and drag during cable installation and ensured compliance with the required cable pulling parameters.
A 5.5-ton cable winch was utilised during the cable installation process; however, due to the quality and alignment of the installed ducting, only a 700kg pulling load was required to install the cables, demonstrating the high standard of workmanship achieved.
Best Practice
Southern Voltage Services, who were contracted to carry out the cable installation works, provided the following feedback regarding the project: “A message from the cable pullers commending Ryebridge on the quality of the ducting install throughout the entire run, it has definitely made installation a lot smoother.”
This project demonstrates Ryebridge’s capability to successfully deliver technically demanding utility infrastructure works within live operational port environments while maintaining programme certainty, quality standards, and safe operational interfaces.
