Highway Ducting

Contract Investor:

G Osborne

Contract Location:

Essex, UK

Contract Value:


Surface Area:


The Project

A recent development saw Ally Structures design manufacture and install highway ducting for the M25 Junction 28 Brook street roundabout signal improvement works.


This was a new product for the team but called on the experiences already gained over years of producing and installing aluminium fabricated products.


The Product

The product consisted of welded aluminium brackets that would be attached to the side on the bridge over the A12 and Brentwood in Essex. A folded aluminium trough was secured to the brackets to allow 4 x 100mm ducting pipes to be laid.


The highway ducting was separated by nylon spacers and tied together. A Light line was passed through the ducting to allow the next contractor to pull the required cables through the ducting.


The trough and the ducting were sealed with an inner aluminium sheet for protection and then and profiled shroud was fitted for added vandalism and weather protection.

All the operations were completed during short night shift lane closures by our own staff. There were difficult access issues particularly the steep embankments either side of the carriage way. These were easily overcome by using our “AllyBeam” system to span from the verge to the top of the bank. This proved to be a very quick and cost effective solution. The use of cherry pickers and over bridge access systems were considered, however the logistic and cost implications meant a simpler system was required.


The Solution

Ally Structures used its experience in site installation to quickly grasp the requirements of working in a highways environment, particularly understanding the unique health and safety issues that come with working close to live traffic at night.


The highway ducting was principally for traffic signalling cables but capacity was added for future street light cables.


Our recent efforts to align our procedures with BS 1090 allowed us to produce works for permanent structural installations. The procedures give control and satisfaction that a high quality product has been produced.


The principal contractor George Osborne commented ” It was a pleasure to work and deal with Ally Structures” G Forest, Site Manager.

Other Case Studies

Looking for an innovative solution for your difficult access problem?