DJI FlyCart 30 drone accelerates overhead line installation

• Aureos Energy Ltd has deployed the DJI FlyCart 30 to benefit the construction of a new overhead line on the Western Isles, in Scotland;

• The heavy-lift drone has enabled the installation of bond rope for conductor work in one flight - a significant milestone;

• Benefits include enhanced efficiency, improved safety, and reduced environmental impact;

• heliguy™ has supported Aureos, providing product supply and full regulatory assistance to enable the company to obtain an OSC to operate FlyCart 30.

A project to install a new overhead line (OHL) between Harris and Stornoway, in Scotland, has achieved a major milestone by using the DJI FlyCart 30 to install bond rope for conductor work in a single flight – showcasing innovation that accelerates construction while reducing environmental impact.

The heavy-lift drone, combined with advanced systems from Aureos Energy Ltd, efficiently installs high-capacity pilot ropes which, once flown, are used to directly pull the conductor, allowing for immediate installation.

This new method:

• Significantly reduces disruption to sensitive peatlands and protects fragile habitats on the Isle of Lewis.

• Shortens installation time from days to hours.

• Enhances safety by decreasing the number of personnel and vehicles required on challenging terrain.

"Using drone technology for conductor installation has been a game-changer for this project. By streamlining this stage of construction, we’re able to deliver the new line much more quickly, while limiting the need for vehicles and personnel to cross some of the most UK’s most sensitive peatland."

– Andrew Ewing, Project Manager for SSEN Transmission

This initiative marks a key milestone in SSEN Transmission’s construction of the new 58 km, 132 kV OHL between the Harris and Stornoway Grid Supply Points. By replacing infrastructure dating from 1990, it will improve resilience and strengthen energy security across the Western Isles.

Thanks to the swift progress enabled by the drone deployment, half of the new line is set to be energised in the coming months, with full energisation due later this year.

Aureos, which is contracted to deliver the installation of a section of the line, has been working for some years on new and innovative ways to deliver work like this, particularly in challenging environments.

Supported by heliguy™’s product expertise and supply, operational training and regulatory support to obtain a heavy-lift Operational Safety Case (OSC), the project represents a significant advancement in modern powerline construction.

Key takeaways

• Project: Creation of the new 132kV Harris–Stornoway overhead line, commissioned by SSEN Transmission. Aureos is responsible for installing approximately 28km of overhead line infrastructure, including conductor installation, temporary works, and the removal of the legacy line.

• Challenge: Deep peat (83% of work zones), fragile habitats, protected species, restricted access, and environmental constraints that make traditional rope-running methods high-risk and disruptive.

• Innovation: Aureos has used the FlyCart 30 to aerially install a high-strength line capable of completing both the pilot stage and the conductor pull — streamlining the process.

• Impact: Fewer vehicle movements, reduced ground disturbance, reduced carbon emissions, improved safety, and major time efficiencies.

• Support: Aureos has leveraged support from heliguy™, including assistance from the in-house regulatory team to obtain an OSC to operate the heavy-lift drone.

Expert insight

“We are optimistic about the transformative potential of heavy-lift drones to enhance safety and efficiency in construction. Together with our valued partners and clients, we aim to establish new standards for the industry that will benefit all stakeholders.”

— Gordon Cranston, Aureos Energy’s Head of Drone Services – Transmission

Site challenges — Why the project needed the DJI FlyCart 30

The Isle of Lewis and Harris represents one of the UK’s most environmentally sensitive work environments, where traditional access methods are impractical or environmentally damaging.

Challenges include:

• Deep peat covering 83% of Aureos’ work zones.

• More than 125 structure locations on peat deeper than 2m.

• Protected habitats and Schedule 1 bird species.

• Traditional access vehicles risk rutting, compaction, drainage disturbance, and large-scale peat degradation.

• Harsh weather and remote terrain.

How the DJI FlyCart 30 helped

Using the DJI FlyCart enabled the team to tackle the complex landscape.

It provided the following benefits:

• Speed and efficiency.

• Reduced environmental impact and lower carbon emissions.

• Enhanced safety, reducing human and vehicle exposure to hazardous terrain.

DJI FlyCart 30 proved to be a viable option compared to alternative methods, such as all-terrain vehicles (can damage land/be impeded by topography), helicopters (can be expensive/high emissions), and traditional drone deployment (can be a long process, involving multi-stage rope pulling).

Mr Ewing said: “Crucially, the new line will replace infrastructure that has been in place since 1990, strengthening the network and improving the reliability of power supplies for homes and businesses across the Western Isles.

"Thanks to this technology, work that once took days can now be completed in hours – meaning local communities will feel the benefits of this upgraded, more resilient network sooner.

"It demonstrates how smart, modern technology is helping us bring a more resilient electricity network to the Western Isles as swiftly and sustainably as possible."

How the DJI FlyCart 30 made it possible

The DJI FlyCart 30 is designed for industrial logistics in hostile or remote environments.

Key features include:

• Up to 30kg payload capacity — enabling the drone to carry high-strength rope.

• Dual-battery or single-battery configuration for greater flexibility.

• Long flight endurance and stable operation in challenging wind conditions.

• Advanced safety systems including ADS-B, multi-sensor positioning, and redundant flight controls.

• IP55 weather resistance, suitable for the harsh climate of the Western Isles.

heliguy™’s support: Product and regulatory expertise

heliguy™ has supported Aureos’ drone programme for the best part of a decade, helping the company scale its operations.

The FlyCart 30 project represented the next chapter for Aureos’ innovative UAS division.

Regulatory Support

Heavy-lift drones, like the FlyCart 30, often fall outside standard permissions. To fly it safely and compliantly, Aureos required an Operational Safety Case — OSC (which has now been replaced by UK SORA).

heliguy™’s regulatory specialists — experienced in securing and operating their own heavy-lift OSC — helped Aureos by:

• Guiding them through the OSC application and evidence-gathering process.

• Providing insights from heliguy™’s own OSC, including mitigations, procedures, and risk modelling.

• Helping Aureos build a compliant heavy-lift framework tailored to FlyCart 30 operations.

• Ensuring that Aureos understood the constraints, requirements, and safety expectations of FlyCart deployment.

Gordon said: "Our collaboration with heliguy™ has played a significant role in navigating regulatory frameworks, and we appreciate the mutually beneficial partnership that has allowed us to pursue this innovative endeavour."

heliguy™ also supplied Aureos with the DJI FlyCart 30.

“Aureos Energy's success with the FlyCart 30 reflects years of close collaboration – consultancy, supply, training, and shared development. It shows how powerful a long-term drone partnership can be. By growing its capability step-by-step, Aureos is delivering groundbreaking work. It is a real success story and shows what’s possible when you have a drone partner that can provide continuity, expertise, and the scale to match your ambitions.”

— Ruairi Hardman, Business Development Manager at heliguy™

The future

The Stornoway project demonstrates the capabilities of the DJI FlyCart 30 for enhancing powerline construction.

Mr Cranston said that Aureos is currently advancing its heavy-lift drone programme and exploring options to further integrate these platforms into its overhead line construction activities.

Summary

Aureos’ deployment of the DJI FlyCart 30 across the Harris–Stornoway OHL route is a significant moment for the UK utilities sector.

Deploying the heavy-lift drone to install bond rope for conductor work in a single flight delivers faster, safer and lower-impact construction, perfectly suited to the unique challenges of Lewis and Harris.

The project demonstrates how heavy-lift drones can overcome complex terrain, reduce environmental impact, enhance safety and accelerate delivery across even the most demanding environments.

With heliguy™’s product expertise and heavy-lift regulatory support, Aureos has become one of the UK’s leading adopters of drone-enabled powerline construction.

This project points to the future: Safer and more efficient infrastructure delivery powered by advanced aerial systems.

To get started with DJI heavy-lift drones, and for regulatory support and guidance, contact us.