HV Cable Replacement

MAG appointed Bethell to deliver a complex HV cable replacement project at East Midlands Airport (EMA). We assembled a dedicated site team with the correct experience and competencies in directional drilling, vacuum excavation, and cable installation.

Early engagement with the EMA operations team, Swissport Cargo, and FedEx ensured the site set-up and sequencing would minimise disruption to day-to-day cargo yard operations. Clear lines of responsibility were established from the outset, and a daily briefing routine was implemented to align all staff and subcontractors with the programme and safety requirements.

The project required our proposal for the most suitable engineering solution to replace the existing 11kV cable between Substation N (within the Swissport yard) and Substation S (adjacent to the CP fence). Instead of a traditional open-cut trench, our design incorporated an innovative directional drilling solution, reducing the impact on surrounding operations, safeguarding critical yard access, and reducing delivery time. Launch and reception pits were established at agreed locations, supported by vacuum excavation, to protect buried services.

250m of ductwork was installed using directional drilling to link three intermediate pits. Each substation interface was completed using short open-cut hand-dig trenches to achieve the correct entry depth and angle. Works were carefully sequenced to avoid peak operational times in the Swissport yard. The risk of unknown services was mitigated by accurately mapping buried infrastructure using GPR surveys and service tracking. Traffic management was coordinated with stakeholders to ensure uninterrupted cargo movements.

The works were delivered within four weeks, with no defects, safety incidents or operational disruption. Following successful cable pull-through and testing, all ducts, pits, and reinstatements were handed over with full as-built documentation. A defects inspection was carried out jointly with the client, confirming high-quality reinstatement to both the CP fence area and the Swissport yard.

Collaboration was central to success. Early engagement with FedEx and Swissport ensured operational continuity, while the airport’s engineering team supported technical approvals. Directional drilling represented a joint value-engineered outcome, delivering cost savings and minimising operational disturbance. Regular progress meetings and open communication built strong client confidence and trust throughout the project.

The project was highly received by MAG, with the following feedback received by our team on site:

“I wanted to formally acknowledge the excellent performance of Bethell on the recent project at East Midlands Airport. In my time at EMA, Bethell has been one of the most professional and efficient contractors I have had the pleasure of working with. The team demonstrated a high level of competence, commitment, and integrity. Communication was open and transparent from day one, fostering a collaborative working environment and ensuring that the project progressed smoothly throughout."

"The works were delivered ahead of programme, and without any significant issues. Any issues were reported immediately through the appropriate channels and resolved on the spot. This reflects the team’s proactive approach to health, safety and quality assurance, further demonstrating the professionalism embedded in Bethell’s way of working. I’d like to commend Cyril Gazay, Mike O’Connor and Alastair Jewell for their exemplary conduct and engagement throughout the project. Their responsiveness, technical expertise and cooperative attitude made them a pleasure to work with, and I sincerely hope to collaborate with them again on future projects.” – Oluwanifesimi Akinwumi, Project Manager

“It was a pleasure working with Bethell on this high-risk project. The level of professionalism shown throughout was outstanding, and clear communication was absolutely key to its success. A special mention goes to Site Manager Alistair, whose leadership and commitment played a brilliant part in keeping everything on track. From Contracts Manager Mike to Project Manager Cyril, it was truly a great team effort from everyone involved. I look forward to the opportunity to work with you all in the future.” – Wilson Crowson, Assistant Project Manager