Falmouth Docks
Zero Emission Vessel Infrastructure
Project Location:
Falmouth
Client Name:
APCL Group
Project Description:
The Falmouth Docks Infrastructure Upgrade was a strategically important, government-funded project aimed at enabling zeroemission operations within a site of outstanding natural beauty.
Acting as both Principal Contractor (PC) and Principal Designer (PD), IPE successfully delivered critical infrastructure upgrades under strict time constraints to meet the demonstration requirements of the Zero Emission Vessels and Infrastructure (ZEVI) scheme.
The project involved the upgrade of 8 substations, implementation of a resilient N+1 power supply, and installation of 14 Ship-to-Shore (STS) 11kV power units across the port. All works were completed with zero disruption to client operations, supporting both business continuity and national decarbonisation goals.
Key Stats:
• Installation of 14 Ship-to-Shore 11kV Power Units
• Cable and Fibre Network Deployment and integrated a fibre optic ring
• Zero Downtime implementation
1 Year
Duration
Challenge
• Complex Ground Conditions - Encountered up to 700mm of reinforced concrete and numerous historic buried services, requiring intensive excavation and service location efforts
• Poor ground bearing capacities - This necessitated engineered foundation solutions to safely support new infrastructure
• Operational Continuity - Developed and executed detailed outage planning to ensure uninterrupted customer operations, avoiding any disruption to critical site activities
• Integration with Legacy Infrastructure - Required extensive modification of historic electrical connections to ensure compatibility with modern equipment standards and operational requirements
• Spatial Constraints - Tight working conditions under dockside environments imposed limitations on equipment placement, access, and installation methodologies
• Site Dilapidation Issues - Managed infrastructure upgrades within areas affected by building subsidence and other forms of structural deterioration, necessitating additional engineering assessment and adaptive design
• Evolving Scope - Responded dynamically to scope changes arising from ongoing site assessments, maintaining project momentum while adapting to shifting requirements
Solution
• Strategic Route Selection - Our team worked closely with the GRP team to identify and implement optimal cable routing. This collaboration minimized service obstructions and mitigated the impact of thick concrete layers, reducing both cost and construction time
• Ground Load Adaptation - In response to poor ground bearing capacities, our civils design team re-engineered the foundation solution, delivering a cost-effective and structurally sound alternative without compromising project timelines
• Proactive Outage Planning - The electrical and engineering management teams meticulously planned each outage, ensuring all necessary materials, equipment, and personnel were on standby. This approach guaranteed minimal risk and maximum responsiveness to any eventuality, maintaining uninterrupted client operations
• Innovative Shore Power Integration - Facing spatial limitations at dockside locations, our engineers devised innovative placement strategies for the shore power units. The final design ensured full operational functionality while integrating seamlessly with ongoing dock operations
• Addressing Site Dilapidation - In partnership with the port authority, our team resolved structural concerns at two substations affected by subsidence. We managed the demolition of unstable masonry and implemented robust replacements using GRP enclosures and metal cladding for durability and compliance
• Multi-Project Coordination - With several concurrent projects running across the dockyards, our teams demonstrated flexibility by diversifying the original design. Through close collaboration with the client, we aligned our solutions to support broader site objectives and infrastructure developments
Outcome
• On-Time Project Energisation - The project was successfully energised within the agreed timeline, enabling the client to enter the demonstration phase on schedule and secure funding through the ZEVI (Zero Emission Vessels and Infrastructure) scheme
• Contribution to Carbon Reduction - This project played a key role in supporting the decarbonisation of port operations at a site designated as an Area of Outstanding Natural Beauty, contributing to wider environmental and sustainability goals
