The rapid rollout of ultra-rapid charging
In 2024 a UK retailer launched an ambitious rollout, working alongside a major CPO.
This service provides convenient customer access to ultra-rapid 150kW EV charging points. While visitors shop in-store, these chargers can deliver a full charge to their parked and wating vehicles in as little as 30 minutes.
Within just over a year, this project has established over 500 charging points in over 60 sites throughout the UK. This ultra-rapid rollout was made possible by the infrastructure beneath the surface.
Here’s a look at how, with NAL’s help, 500+ EV chargers were deployed ~12 months.
The infrastructure you don’t see
When it comes to EV hub delivery, two priorities are consistently front of mind: • Future-proofing • Speed of installation
For CPOs, the investment in EV infrastructure must be resilient to future technology shifts. At the same time, deploying on live retail sites demands minimal disruption to customers and store operations – making the swift completion of groundworks critical.
Dispenser foundations
Groundworks are typically the longest and most complex phase of EV hub installation. For this project, each site includes five Kempower satellite dispensers, each requiring its own foundation. So, to support this dispenser roll-out, we delivered our Universal EV Foundation – ensuring the systems can be built-up quickly and precisely. The system consists of:
- The STAKKAbox™ Modula access chamber – allowing swift assembly via stackable ring sections
- The NAL Retention Socket – head mounted to the chamber once positioned
This setup accommodates the bend radius of high-capacity power cables, while securely housing the dispenser with an OEM-specific adapter plate.
Our solution is also prime for future-readiness. For example, unused foundations can be pre-installed and sealed with socket plugs. These idle foundations can later be reopened and cabled when additional capacity is needed – without revisiting groundworks.
Plus, adapter plates are fully interchangeable. If a CPO opts for a different OEM or an upgrade to the latest hardware, this easy interchangeability allows them to swap dispensers without additional groundworks.
Power solutions
As well as dispensers, the project uses:
- Kempower power units – a modular, scalable cabinet system distributing power to dispensers
- NAL’s modular EV cabinet base system to support these units
Like the Universal Foundation, NAL’s EV Cabinet Base incorporates the ever-flexible STAKKAbox™ chamber. In this application, however:
- The Ultima Connect system takes the much greater loadings associated with power cabinets
- Assembled ring sections form the spacious underground chamber
- Steel modules are secured to the surface to hold and secure the cabinets
- Composite access covers allow easy entry for cable routing and connections
Together, this system gives electrical contractors a larger working space to pull cables and connect to cabinet internals. And, as with the dispenser foundations, the modular approach allows for future expansion by adding cabinets without disturbing the existing footprint.
Vulnerable site furniture
Visibility and protection are critical at EV hub sites. So:
- Signage must be clear and positioned for maximum visibility
- Bollards play an essential role as the first line to defence, protecting equipment against impacts
Traditionally, damage to this street furniture would result in costly repairs and further excavation. By mounting bollards and signage using NAL’s Retention Sockets, damaged items can be removed and replaced in a matter of minutes. (With obvious payoffs in terms of maintenance costs and minimised disruption.)
The customer has further optimised this efficiency by integrating signage into their bollards. Using a shared foundation not only reduces installation time, but also maximises usable space onsite.
EV expansion, engineered right
By recognising the key considerations of EV hub construction methods and investing in NAL’s EV infrastructure solutions, the customers hubs are protected against:
- Evolving technology
- Contract renewals
- Uptake in future demand
All the while, our customer is incurring significant savings in time and maintenance costs.
The key takeaway? This rollout demonstrates how thoughtful infrastructure choices —like NAL’s smart foundations — can accelerate EV charger deployment while preparing for the demands of tomorrow.
