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Commenting on the challenges associated with the project, Vail says: “With a clean slate, the boundaries are removed, so you have to look at your existing facilities and ask that if you had to do it again, what could you do better?”
Some improvements to be introduced at Ducab HV Cable Systems are the introduction of skylights to allow more natural light in, and the use of ambient heating for some of the processes. The cooling water needed will be circulated in a closed system to increase efficiency, while wastewater will be collected and reused for irrigation purposes. In addition, condensate water from the factory roof will also be collected and reused. “We have a dedicated engineering team working on all the ‘green’ aspects, which also include fittings, lights and taps,” says Vail.
Commenting on the new facility’s business plan, Vail says that although it is designed specifically for high-voltage cables, it can make smaller sizes as well. “We will need to keep the factory busy with the 66 kV to 132 kV range, which are the bigger volumes and do not require the one-year test. The high-voltage side will be project-driven by DEWA and ADWEA, which will grow their offtake gradually. The utilities are key customers of Ducab, and have been for many years.”
As for when the first cable will emerge from the new facility, Vail says: “I expect to be able to fully make and test cable from the new facility by Q1 next year.” The first step in this process is to get the insulation line running, which is critical in terms of the overall quality of the cable. “We have the advantage of being able to get conductor from the existing Ducab facility next door, run it through the new insulation line, make a cable and test it until that process is right.”
In terms of logistics, Vail says the new facility will simply tap into Ducab’s existing supply-chain operation. “Where we have specialised requirements, such as for these particularly big cable reels and their handling, we may appoint some external experts.”
In terms of the overall management team for the new facility, Vail says he is the first appointee.
“We will start to recruit later in the year. At the moment we have a Ducab team of about 30 working on the project. Overall we will create about 100 jobs when the new facility is fully up and running.”
Story continues below 
In Numbers
20 000 t structural steel and rebar
30 000 m³ concrete
120 000 m³ backfill
Professional team
Consultant/Design: Hyder/Holfords
Project Manager: Derek King, AECOM
Civil contractor: Khansaheb
Piling: Dutco Balfour Beatty
MEP contractor: MACAir
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