Cable Routing for EV Infrastructure

EV charging infrastructure requires cable routes from switchboards to charge points across car parks and highways.
Cables must be protected from vehicle traffic, surface water, and accidental damage throughout their route.
Trench excavation for cable ducts crosses existing buried services requiring detection and safe digging.
Cable sizing must account for the full charge point load, voltage drop, and future expansion capacity.
Ducting must be correctly sized and sealed to allow cable pulling and prevent water ingress.
Marker tape and cable protection tiles above the duct prevent accidental damage during future excavation.
Cable pulling requires coordination between teams at each end to prevent cable damage and personnel injury.
Reinstatement of surfaces after cable installation must meet the original pavement specification.
Multiple cable routes serving a charging hub require careful coordination to avoid congested duct crossings.
As-built records of cable routes must be accurate for future maintenance and additional installations.

Buried services	Cable duct routes cross paths with gas, water, and electricity services — strikes during excavation can be fatal.
Cable damage	Incorrectly installed or unprotected cables suffer damage from vehicle loading, causing electrical faults and fire.
Future maintenance	Accurate as-built records prevent accidental damage to EV cables during future excavation and maintenance work.

Do

Don't

Locate all existing buried services using CAT, Genny, and utility plans before excavating
Obtain a permit to dig before any ground disturbance for cable duct routes
Protect cable ducts from vehicle loading using concrete surround or protective covers
Install marker tape above the duct to warn future excavators of the cable below
Size ducts to allow cable pulling without excessive friction and for future expansion
Coordinate cable pulling operations with teams at each end using radio communication
Reinstate the surface above the cable route to match the original pavement specification
Record the as-built cable route location, depth, and duct type accurately on survey drawings
Seal duct ends after cable installation to prevent water and rodent ingress
Brief the team on cable route hazards including buried services and traffic management

DON'T excavate cable duct trenches without locating existing buried services first
DON'T lay cables without protective ducting in areas subject to vehicle loading
DON'T pull cables through ducts without coordination between both ends of the route
DON'T omit marker tape and cable protection above the duct — they prevent future damage
DON'T undersize ducts — allow for cable expansion and future additional circuits
DON'T leave duct ends unsealed where water or vermin could enter the cable route
DON'T reinstate surfaces to a lower standard than the original pavement construction
DON'T skip the as-built survey — lost cable routes cause future service strikes
DON'T route cables through areas without traffic management where vehicles are present
DON'T force cables through undersized or damaged ducts — it damages the cable sheath

See also: EV Charging Electrical Installation | Below Ground Drainage Installation

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