HVDC Transformers Facility in Stafford – GE Vernova.
The Challenge.
ACS Construction Group were appointed Principal Contractor by GE Vernova for a major infrastructure expansion at its Stafford HVDC Transformers facility, part of the company’s drive to support global decarbonisation through advanced transformer technology.
The Solution.
ACS commenced with the Test Supply Building work in September 2024 and were recently further awarded the main Expansion Project works starting in Summer 2025.
Our scope encompasses the construction of a new 42-metre-high HVDC Test Facility, covering approximately 2,200 square metres -designed to support increased production capacity for large-scale electrical transformers, as well as several associated buildings and infrastructure improvements across the site.
All construction activities are being carried out within a live site environment, requiring close coordination with GE Vernova’s ongoing manufacturing operations.
The Solution.
ACS is working to strict interface controls to ensure minimal disruption, allowing transformer production to continue seamlessly throughout the transformation programme.
Once operational, this facility will allow GE Vernova to build and test some of the largest transformers in the world, reinforcing GE Vernova’s role in delivering the critical grid infrastructure needed for net zero. The building will also feature an integrated Faraday cage enclosure to ensure safe and precise high-voltage testing in a controlled electromagnetic environment.
Supporting this main facility is a new Test Supply Building, currently under construction. Spanning approximately 1,200 square metres, it will provide critical power infrastructure to the HVDC testing operations, housing high-voltage equipment and advanced control systems.
The Wider Project.
- Construction of a new Dispatch Building to streamline logistics and transformer dispatch.
- A Connecting Building linking the existing factory to the new HVDC Transformers Test Facility for operational continuity.
- Building services and equipment.
- Installation of approximately 1,700 piles and placement of over 15,000 cubic metres of reinforced concrete across the development.
- Internal alterations to the existing production space to integrate new infrastructure.
- Installation of new below-ground drainage, cable routing, and earthing systems to support the upgraded facility.
- Full utility diversions across the site to maintain uninterrupted service during works.
- Demolition of an existing four-storey office building (80 metres wide by 15 metres high) to clear space for new construction.
The Result
The project is being delivered under strict environmental and safety standards. Prior to the main works, ACS completed extensive remediation works, including the safe removal of waste in line with Local Authority expectations and Environment Agency legislation.
In close collaboration with GE Vernova and environmental consultants, our teams managed complex utility diversions, established robust environmental controls, and implemented a tailored Construction Environmental Management Plan to protect surrounding ecosystems and groundwater quality.
This project goes beyond expanding a facility—it’s about delivering the infrastructure required for the next generation of clean energy transmission. We’re proud to support GE Vernova in advancing their global energy mission.