Full LED Lighting & Power Infrastructure for a Cheshire Logistics Facility
Portcullis Power Solutions was appointed to carry out a full commercial electrical installation at a large logistics and distribution warehouse near Chester, Cheshire. The project involved designing and installing a complete LED lighting solution across the entire facility — including the main warehouse floor, mezzanine level, and loading areas — alongside the power supply infrastructure to support the site’s operational requirements.
As a working logistics facility with stock movements ongoing throughout the project, careful planning and a structured installation programme were essential. Our team coordinated closely with site management to ensure work was carried out safely and with minimal disruption to day-to-day operations.
Scope of Works
What the Installation Involved
The scope of works covered two distinct areas — the main warehouse floor and the mezzanine level — each with different lighting and power requirements based on usage and ceiling height.
Main Warehouse Floor
The primary warehouse space required high-output LED highbay fittings capable of delivering consistent, uniform illumination across a large floor area at significant height. We specified and installed a full array of commercial LED highbays, positioned to eliminate dark spots and provide safe working light levels throughout the racking aisles and open floor areas.
Cable containment was installed throughout using galvanised steel cable tray, run neatly along the structural steelwork to keep the installation tidy, accessible for future maintenance, and compliant with current commercial wiring standards.
- LED highbay fittings throughout the main floor
- Uniform illumination across full racking and aisle areas
- Galvanised steel cable tray containment
- Full power supply distribution to lighting circuits
Mezzanine Level
The mezzanine floor presented a different set of requirements. With a lower ceiling height beneath the mezzanine deck and specific task lighting needs above, we installed commercial LED batten fittings to provide efficient, glare-free illumination suited to the working environment.
The mezzanine lighting circuits were wired back to the distribution boards as independent circuits, allowing them to be controlled and isolated separately from the main floor lighting — an important operational consideration for a site running across multiple shifts.
- LED batten fittings under and on the mezzanine level
- Independent circuit control from main warehouse
- Suitable for multi-shift operational use
- Clean, low-maintenance fitting specification
Installation Detail
Cable Containment & Power Distribution
Galvanised cable tray containment — neat, accessible, and compliant
Full LED highbay array across the main warehouse floor
LED batten fittings providing task lighting on the mezzanine level
Alongside the lighting installation, all power supply cabling was routed and contained within galvanised steel cable tray fixed to the building structure. This approach keeps all cabling organised, protected, and fully accessible for future maintenance or circuit additions — essential in a commercial environment where electrical infrastructure needs to evolve alongside the business.
The power distribution system was designed to serve both the lighting circuits and any future power requirements the facility may have, with capacity built in to accommodate expansion without the need for a full rewire.
“Good cable management isn’t just about aesthetics — in a commercial environment it’s about safety, compliance, and future-proofing the installation. Every metre of containment is planned before a single fixing goes in.”
Why LED?
The Case for LED in Commercial & Industrial Settings
For a large logistics facility like this one, the switch to LED makes compelling financial and operational sense. LED highbays and battens consume significantly less energy than their fluorescent or metal halide predecessors — typically 50–70% less — while delivering equal or superior light output. In a facility operating across long hours and multiple shifts, the energy savings compound quickly.
LED fittings also carry a far longer operational life, reducing maintenance costs and the disruption of lamp replacements at height. For a working warehouse, that means fewer call-outs, less downtime on cherry pickers, and a more consistent lighting environment for staff.
All fittings specified for this project were commercial-grade LED products selected for their output, efficiency, and longevity. Find out more about our commercial and industrial electrical services.
The Result
A Fully Operational, Compliant Commercial Installation
The completed installation provides the facility with a modern, energy-efficient lighting solution across both levels, with a clean and well-organised power distribution infrastructure capable of supporting the site’s ongoing operational needs.
All work was carried out to BS 7671 (IET Wiring Regulations 18th Edition) and full certification and compliance documentation was provided at handover. The installation was completed while the site remained operational throughout.
If you manage or operate a commercial or industrial property in Cheshire and are looking to upgrade your lighting to LED, add power supply capacity, or carry out a full electrical fit-out, we’d be happy to discuss your requirements. Take a look at our Cheshire electricians page or get in touch directly.
Need Commercial Electrical Work in Cheshire?
Portcullis Power Solutions carries out commercial and industrial electrical installations across Cheshire — from LED lighting upgrades to full fit-outs. NAPIT-accredited, CHAS-certified, and fully insured.