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CASE STUDIES

TOWER OVER-PLATING & STRUCTURAL REINFORCEMENT - 230 SITES

Project Overview:
In October 2022, TEC was approached by one of our blue-chip clients to undertake a critical and rapid-response Health & Safety project. The objective was the immediate rectification and reinforcement of 200 towers that had reached end-of-life, with an initial instruction covering 230 sites. The project involved comprehensive site surveys, installation of a new over-plating solution to support the existing tower structures, and handover of all sites, ensuring structural integrity and safety.

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Scope and Technical Solution:
The chosen solution involved installing new over-plates onto the existing tower flanges. Each tower leg comprised three plates (one back plate and two wing plates). The process included:

  • Drilling four M35 holes per leg to a depth of 600mm, for each of the three plates,

  • Installing and securing the plates with M30 anchors,

  • Resin-ing the anchors into the ground using Hilti-approved methods,

  • Applying grout within the tower substructure and beneath the newly installed plates after curing, to transfer the tower’s weight and stress from deteriorating stubs onto the new, robust steelwork.

 

Timeline & Delivery:
The project required swift delivery, with a target of completing the survey on 230 sites by Christmas. The survey work was a significant success, with all documentation completed within 48 hours of each site visit and promptly referred back to the client for design purposes.

The installation phase was planned to complete 15 sites per week. Within five weeks of project initiation, TEC formed a dedicated team of 18 engineers working across 8 regional teams. This rapid and coordinated effort enabled us to progress efficiently through the extensive site portfolio.

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Challenges & Solutions:

  • Logistics of Materials: Managing 330 kg of steelwork and over 500 kg of grout and water per site posed a massive logistical challenge. We developed a robust framework supporting the timely delivery of materials, identification and securing of key storage locations, and coordination of transportation.

  • Rapid Deployment: To ensure continuous progress, additional engineers were allocated to each team to facilitate material collection and site activity without delays.

  • Workforce Coordination: Synchronizing 8 teams across multiple regions required detailed planning, communication, and local management to streamline operations and minimize travel time between sites.

 

Innovative & Effective Approaches:

  • Templated, Modular Solutions: The use of pre-designed steel plates and standardized drilling and anchoring procedures enabled rapid deployment across all sites.

  • Regional Logistics Hubs: Establishing regional storage points allowed for quicker material distribution and reduced downtime.

  • Dynamic Workforce Management: Allocating additional personnel for material collection and site support ensured continuous workflow and kept the project ahead of schedule.

 

Safety & Quality Assurance:
Throughout the project, safety was paramount. All operations adhered strictly to health and safety standards, with specific protocols for drilling, resin installation, and grouting. Our engineers followed Hilti-approved procedures, and all activities were monitored by site supervisors. Quality control involved on-site inspection, verifying grout curing, anchoring procedures, and documentation of each step.

 

Current Status & Outcomes:
At the time of reporting, the final five sites are in progress, with the project approximately one month ahead of schedule. Our team’s disciplined approach, combined with rigorous logistics and proactive coordination, has enabled us to execute this substantial project efficiently, maintaining high safety and quality standards.

 

Lessons Learned & Future Recommendations:

  • Integrated Logistics Planning: The importance of pre-emptive logistics and regional storage can’t be overstated, especially for large-scale, rapid-response projects.

  • Detailed Scheduling & Workforce Allocation: Dynamic deployment of engineers to support logistics ensures continuous progress and mitigates delays.

  • Early Site Validation & Design: Prompt site surveys and data transfer facilitate swift design finalization, critical for rapid deployment schedules.

3UK BUY-IN PROJECT - PCN RIGGING & NETWORK UPGRADE

Project Overview:
In response to the UK government’s instruction to remove Huawei-branded equipment from telecoms networks by 2027 and from sites critical to national security by January 2023, TEC was engaged to support a major network upgrade for 3UK. The project involved the sophisticated rigging, upgrading, and reinforcement of multiple cell sites across the UK. The scope included upgrading existing towers, deploying new antennas, supporting steelwork, and integrating high-capacity bandwidths (700/800/1400/2100 & 3500 MHz), thereby delivering a high-speed, high-capacity 5G network while reinforcing existing 4G infrastructure.

 

Scope & Location:
Over several months, teams undertook upgrades on numerous sites spanning from easy-to-access greenfield locations to highly remote and challenging sites requiring specialist transportation. The extensive geographic scope required meticulous planning and regional deployment strategies to ensure timely delivery.

 

Technical Deployment & Challenges:
The roll-out enabled 3UK to expand its 5G coverage network-wide, significantly improving data speeds, capacity, and network resilience. Many sites featured new antenna arrays mounted on newly fabricated supporting steelwork to accommodate larger antennas. Engineers faced challenges due to the size of the supporting structures, with some sites in remote locations requiring adaptation of transport machinery such as ATVs and 4x4s. Handling equipment safely was critical, especially on difficult-to-access sites, which necessitated the use of electric track barrows and specialized handling equipment.

Specially designed, fabricated derricks were deployed to handle the larger antenna arrays. These derricks overcame height restrictions that prevented traditional rigging methods, ensuring safe and efficient installation without risking tower structural integrity. This innovative approach was a key enabler of the project, allowing for consistent and safe deployment despite site-specific constraints.

 

Logistical & Operational Solutions:
To support the large-scale deployment, TEC established a robust logistical framework. Approximately five teams of two engineers each operated across all regions of the UK, working concurrently to meet demanding timelines. We procured open-ended RF jumpers in bulk, which offered several benefits:

  • Cost savings through bulk purchase of universally compatible jumpers

  • Eliminated delays caused by incorrect or missing jumper sizes

  • Improved aesthetics and professional appearance of the installation

This approach minimized project delays and reduced costs, ensuring that deployment targets remained achievable.

 

Major Achievements:

  • Designed and deployed custom fabricated derricks that enabled safe, effective rigging of larger antennas in restricted spaces—a key technical breakthrough.

  • Development of tailored logistics, including regional storage solutions and efficient material handling, supporting rapid and seamless deployment across the UK.

  • Positive client feedback, with all stakeholders praising the open, transparent communication and fluid project management. Clients appreciated our proactive approach, ensuring a clear understanding of progress and issues throughout.

 

Safety & Quality Assurance:
Throughout the project, safety was paramount. We adhered strictly to health and safety protocols, especially during complex rigging and handling operations. Engineers employed specialist safety measures while working at height and in remote locations. Regular quality checks, inspections, and documentation ensured that standards were maintained across all sites.

 

Outcomes & Lessons Learned:
The project demonstrated our capability to manage large-scale, complex network upgrades across diverse geographic and logistical challenges efficiently. The use of custom fabricated equipment, innovative rigging techniques, and an emphasis on communication and safety resulted in a successful deployment, one month ahead of schedule.

Key lessons included the importance of flexible logistics planning for remote site access and the benefit of bulk purchasing standardized components to reduce costs and delays. The project also reinforced the value of engineering innovation in overcoming site-specific constraints, ensuring safe and effective deployment.

TELECOMS CIVILS BUILD - SITE ID 93133

Project Overview:

This project involved a comprehensive site upgrade on a business estate in Cardiff. The scope included installing a new concrete foundation for a 30m high Swann CS5SP tower, extending and installing a new compound fence, laying tx and power ducts for new cabinets, and establishing cable containment systems. The site was initially cleared of vegetation and graded to facilitate access and construction, with the primary goal of enabling the installation of telecommunications infrastructure efficiently and safely.

 

Timeline and Duration:

Construction commenced on 28th April 2025, with a three-week window allocated for the concrete pour, followed by a two-week curing period. The project was scheduled meticulously to meet the client’s deadlines and operational needs, ensuring minimal disruption.

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Challenges and Solutions:

A significant issue emerged during the mass fill phase when an underground sewer line, previously unidentified during the design stage, was discovered passing through the site. The pile works, organized by the client’s third-party contractor, had to be aborted due to restrictions on working near the sewer. We responded swiftly by collaborating closely with the client to map the sewer’s precise location and depth using sondes, receivers, and CCTV surveys. This data allowed us to avoid intrusive excavation beneath ground level and preserve the existing infrastructure.

Instead, we adopted an innovative mass fill approach - excavating a larger area with heavy plant to create a large concrete slab capable of safely distributing loads, thus eliminating the need for deep groundworks near the sewer line. This approach minimized delays, reduced environmental risks, and maintained project schedule integrity.

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Innovative Methods and Techniques:

  • Use of non-intrusive underground mapping techniques (sonde transmitters and CCTV) to accurately locate and assess the sewer line, eliminating the need for intrusive excavation.

  • Adoption of a mass fill approach, involving substantial earthworks and concrete placement, to bypass underground restrictions safely.

  • Enhancement of safety measures through site access restriction to authorized personnel, use of ground-shoring to prevent collapses, and adjustments to plant size to ensure safe excavation.

 

Health, Safety, and Quality Management:

Strict safety protocols were enforced throughout the works. The excavated area was restricted to authorized personnel to prevent falls, and larger plant was deployed to perform excavation at a safe distance from the sewer and unstable ground. Ground-shoring was installed to prevent collapse of the excavated areas.

Quality assurance included compaction testing to verify fill stability, installation of Cellcore HXB above the sewer to facilitate load spread and earth stability, and cube testing on concrete batches to ensure appropriate compressive strength. Regular site meetings with management and clients ensured continuous monitoring, issue resolution, and compliance with standards.

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Client Coordination and Communication:

The project maintained constant communication through Teams and WhatsApp to ensure real-time updates on progress, hazards, and issues. Daily toolbox talks were conducted, documented, and shared to promote safety and transparency. This high level of engagement fostered trust and effective collaboration throughout the project.

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Project Outcomes:

Despite encountering unforeseen underground utilities, our flexible manpower, innovative problem-solving, and strategic planning enabled us to complete the project on time and within budget. The use of non-intrusive surveys and mass fill techniques preserved existing utilities, minimized delays, and ensured infrastructure integrity. The project met all client specifications, safety standards, and quality expectations, culminating in a successful site upgrade.

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Lessons Learned and Recommendations:

A key lesson from this project is the importance of early and detailed site investigations. We recommend that future projects include requesting comprehensive surveys, utility plans, and geotechnical reports from clients during tendering or prior to site attendance. Such data can facilitate better planning, risk mitigation, and cost efficiency by foreseeing potential underground issues, reducing costly delays, and informing more accurate project designs.

DEPLOYMENT OF OUTDOOR TRANSMISSION CABINET - SITE ID BRF037

Overview:
Site ID BRF037 was designated as a trial site to evaluate the efficacy of deploying an Outdoor Transmission Cabinet (OTC) for future telecommunications expansion and relocation projects. A trial site serves as a testing ground to determine whether a proposed solution is fit for purpose, easily deployable, and suitable for operational deployment.

 

Objectives:
The primary objectives of this project were:

  • To deliver the OTC to the designated site

  • To land, fix, and secure the cabinet in position

  • To install electrical supplies, grounding systems, and manage cable routing

 

Execution:
The deployment commenced with the delivery of the OTC via a hiab-equipped trailer. However, due to site restrictions posed by restrictive bollards, access to the final installation location was not possible using the trailer. As a result, the team adapted by transporting the cabinet to the site via an electric track barrow, demonstrating flexibility in overcoming logistical challenges.

 

The installation process included:

  • Precise placement and fixing of the OTC in the designated location

  • Electrical installation designed and constructed in accordance with BS7671 standards, ensuring compliance with safety and quality requirements

  • Setup of grounding systems to facilitate a safe and reliable electrical connection

  • Cable management to facilitate future expansion and maintenance

The entire installation was conducted under supervision and was observed by the MBNL design team, the cabinet manufacturer representatives, and other MBNL management personnel to ensure compliance with design and safety standards.

 

Outcome & Reflection:
The successful delivery and installation of the OTC at Site BRF037 highlighted several key insights:

  • Flexibility in logistics is critical when faced with site access restrictions.

  • Adherence to BS7671 standards during electrical installation ensures safety, reliability, and future-proofing of the infrastructure.

  • Centralized oversight ensures adherence to design specifications and safety protocols.

  • The trial demonstrated that, despite logistical challenges, the proposed solution is viable and ready for scaling.

 

Conclusion:
The trial at Site BRF037 was successful in proving the deployment process and installation procedures for the OTC, including compliant electrical works as per BS7671 standards. This experience will inform future projects, ensuring smoother logistics, and confirming the solution's suitability for wider deployment.

TX MIGRATION PROJECT - "HOT CABS" INITIATIVE

Overview:
In 2022, the telecommunications team was tasked with addressing a critical issue affecting hundreds of sites across the UK: overheating of transmission (TX) equipment. This problem, identified as "Hot Cabs," posed a significant risk to ongoing site operation, often resulting in site failures and outages, thereby impacting service continuity.

 

Background & Findings:
Extensive site surveys revealed multiple contributing factors to the overheating issues:

  • Overpopulated cabinets, leading to insufficient space for cooling and airflow

  • Waste and debris within cabinets that impeded ventilation

  • Poor cooling solutions and inadequate ventilation systems

  • Blocked filters restricting airflow and heat dissipation

These root causes necessitated a comprehensive approach to mitigate overheating and ensure reliable site operation.

Objectives
 

The primary objectives of the TX Migration project were:

  • To identify and eliminate the root causes of overheating

  • To implement effective cooling solutions and capacity upgrades

  • To ensure the continued operation of transmission equipment by migrating, upgrading, or replacing existing infrastructure

  • To enhance overall network resilience and facilitate future expansion

 

Solutions Implemented:
A multi-faceted approach was undertaken:

  1. Site Surveys and Root Cause Analysis:
    Detailed investigations identified specific issues at each site, informing tailored solutions.

  2. Installation of New TX Cabinets and TX Migrations:

    • Deploying new, appropriately populated cabinets designed for better airflow

    • Migrating existing TX equipment to these new cabinets to reduce population congestion

  3. Installation of New Filters and Cooling Units:

    • Upgrading filtration systems and installing advanced cooling units to enhance heat dissipation

  4. Cabinet Extensions:

    • Expanding cabinet sizes to provide additional space, thereby reducing overcrowding

    • Facilitating subsequent TX equipment division and relocation for optimal airflow management

  5. Network Resilience & Expansion:

    • The scope of work also enabled enhanced network resilience by allowing easier deployment of additional redundancy solutions and power resilience measures

These upgrades contribute to creating a more stable and capable network with increased bandwidth

 

Implementation & Deployment:
The deployment involved careful survey planning, site-specific adaptations, and coordinated installation activities. Ensuring minimal disruption to ongoing site services was a priority. The cabinet extensions were followed by detailed TX equipment division and relocation, designed to optimize cooling and improve overall site resilience.

 

Outcome & Reflection:
The TX Migration project successfully mitigated overheating issues at targeted sites, resulting in improved reliability, reduced site outages, and increased equipment lifespan. The enhancements also reinforced network resilience and capacity, preparing the network for future expansion and ensuring a more stable, high-capacity infrastructure.

 

Conclusion:
The "Hot Cabs" initiative demonstrated the effectiveness of targeted site enhancements through TX migrations, cabinet upgrades, cooling improvements, and resilience measures. The success of this project has provided valuable insights for managing similar challenges across the network, supporting sustainable and reliable transmission infrastructure with increased capacity and redundancy.

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