Capital Karts, Star City, Birmingham

Case Study: High-Octane Infrastructure. Delivering Power and Precision for Capital Karts, Star City, Birmingham

Project Overview

When Capital Karts set out to launch their flagship indoor go-karting destination at Star City in Birmingham, they required an electrical infrastructure capable of supporting one of the UK’s longest and fastest indoor tracks. Transforming a huge, empty industrial shell into a state-of-the-art, high-voltage entertainment hub demanded exceptional engineering, precise project management, and a highly resilient power distribution system.

West Group Technical Services were appointed as the principal electrical contractor to design, install, test, and commission the entire electrical infrastructure. The project was successfully delivered on time, to budget, and in strict accordance with the latest safety standards.

Key Project Metrics

Location: Star City, Birmingham.

Client: Capital Karts.

Primary Power Supply: 1600A LV Switch Panel.

Specialist Systems: 32 x 3-Phase Fast Chargers, Addressable Fire Alarm, Mezzanine Track Lighting.

Compliance & Safety: 100% LSF (Low Smoke and Fume) Cabling, Full BS 7671 Testing.

Scope of Works

1. Heavy Power Distribution & Infrastructure

The backbone of this project required substantial incoming power to handle the combined demand of multiple distribution boards, specialised racing equipment, and high-draw kart charging networks.

• 1600A LV Switch Panel Installation: We installed a1600A main Low Voltage (LV) distribution switchboard. The primary feed from the private supply transformer was completed using single-core, Low Smoke and Fume (LSF) Aluminium Wire Armoured (AWA) cables, engineered to carry heavy current loads safely and with minimal voltage drop.

• Sub-Mains Distribution Network: From our central 1600A panel, we ran a complex web of sub-mains LSF Steel Wire Armoured (SWA) cables to feed nine dedicated distribution boards (DBs) strategically positioned across the vast industrial facility:

o             Kart Charging DB 1, 2, 3, & 4: Four heavy-duty 250A supplies dedicated entirely to the kart fleet.

o             Kitchen DB: A robust 125A supply to support the commercial-grade kitchen appliances.

o             Auxiliary Services DBs: Dedicated 63A supplies split individually across the Mechanics Bay, Toilets, Race Control, and General Lighting.

2. High-Level Containment Systems

To support thousands of metres of heavy-gauge power cabling, control wiring, and data lines across a cavernous industrial unit, we engineered an overhead pathways network.

• Heavy-Duty High-Level Containment: We installed a high-level containment network featuring heavy-duty cable ladders and trays. Given the height of the steel roof structure, our teams utilised precision drop-rod systems and custom-fabricated Unistrut bracketry to suspend the containment safely over the track and pedestrian areas.

• Secondary Containment & Life Safety: We ran dedicated secondary containment paths specifically for the life-safety networks, isolating critical fire alarm, emergency communication, and security wiring from the primary power paths to prevent electromagnetic interference.

  
  

3. Track-Side Power, Special Equipment & Kart Charging

The heart of Capital Karts is its high-performance electric fleet and its multi-level racing circuit.

• High-Capacity 3-Phase Kart Charging: We installed dedicated power supplies to 32 independent 3-phase go-kart charging units. This high-draw charging grid allows Capital Karts to rapidly charge their fleet between sessions, maximising track uptime and venue throughput.

• Mezzanine Track & Crash Barrier Lighting: To ensure racer safety and a high-velocity visual aesthetic, we wired and installed specialised track lighting running along the crash barriers across the elevated mezzanine track structure.

• Workshop & Mechanics Bay Power: Power infrastructure was delivered to the main maintenance workshop. This included dedicated radial circuits and isolators for industrial air compressors, drill presses, heavy machinery, and workbench tool chargers.

• Audio-Visual Power Infrastructure: To keep racers and spectators updated, we integrated power feeds to multiple high-definition information TV displays and race telemetry screens mounted across the spectators' paddock and main track areas.

  
  

4. General, Emergency & Amenity Installations

We delivered tailored lighting and power configurations to individual zones to ensure both operational excellence and visitor comfort.

• Contactor-Controlled Main Lighting: For seamless control over the massive venue floor, we engineered a custom control panel utilising eight 4-pole contactor switches connected to centralised master light switches. This allows staff to energise or dim large sectors of the building's high-bay lighting instantly.

• Emergency Lighting System: A fully compliant emergency lighting system was mapped and installed along all main egress routes, the track perimeter, public areas, and back-of-house zones to secure safe evacuation routes in the event of a power outage.

• Toilets & Public Amenities: We delivered functional lighting and power to the female, gents, and disabled toilets. This included wiring specialised tap control units and high-power hand dryers to meet heavy public footfall demands.

• Changing & Administrative Rooms: We designed and installed comfortable, bright lighting and convenient power grids in the visitor changing rooms, locker spaces, and managers' offices.

• Commercial Kitchen Feed: Full power and lighting infrastructure were provided to the food preparation and service areas, facilitating the operation of heavy-duty commercial kitchen utilities.

  
  

5. Life Safety, Commissioning & Client Relations

No industrial leisure project is complete without rigorous safety protocols, seamless coordination, and strict transparency.

• Fire Alarm System Integration: Our technicians completed the physical installation, secondary containment, wiring, programming, and final commissioning of an addressable fire alarm system. This system was fully integrated to interface with the venue's master trip systems to ensure safety during emergencies.

• Testing, Inspection & Certification: Upon completion, our test engineers executed full Electrical Installation Testing and Certification on every single circuit, traced all the way back to the private supply transformer. This guaranteed complete BS 7671 compliance and absolute operational safety.

• Project Management & Collaboration: We worked in lockstep with Capital Kart's designers, main contractors, and project managers. Our collaborative approach allowed us to coordinate high-level works around track-building teams, mitigating trade conflicts and keeping the project moving towards its strict grand opening deadline.

• Transparent Communication: Throughout the build, we maintained an open-book policy with the client. By holding regular progress walkthroughs and providing detailed visual status updates, we showed the client exactly what had been completed, what was actively in progress, and the timeline for remaining works.

The Result

The Star City venue successfully opened its doors, boasting a robust, safe, and incredibly efficient electrical infrastructure. By combining heavy-duty industrial engineering with highly coordinated project management, we transformed a vacant warehouse into a cutting-edge leisure landmark for Birmingham.

Capital Karts – Star City

Unit 12, Star City

Birmingham

B7 5SA

WEBSITE