Installing 2,600 metres of steel barrier within a single night requires precise planning and execution. Hill & Smith Infrastructure delivered this on the M5, installing a Zoneguard System 2 temporary vehicle restraint system (TVRS) during a full carriageway closure. Meanwhile, on the M4, the company deployed approximately 2,400 metres of Varioguard TVRS in just six hours overnight.
Six hours, 2,400 metres
Both schemes demanded complex installation in narrow overnight windows. The M5 scheme involved a full closure and required installing steel barriers with N2 containment, ensuring resistance against a 2.5-tonne vehicle impact, and a W2 working width, meaning the barrier protrudes no more than 0.75 metres into the carriageway.
Night working introduces challenges such as reduced visibility, changing weather, and greater safety risks. Hill & Smith managed these by maintaining strict safety oversight, innovative supervision, and welfare facilities designed to reduce fatigue and vibration exposure to workers.
Planning for precision
Early contractor involvement was central. Hill & Smith contributed to planning phases, improving resource allocation and methodologies. Their integrated management system holds ISO 9001, ISO 14001 and ISO 45001 certifications. These cover quality, environmental management, and occupational health and safety, reinforcing compliance and workforce protection.
The company aligns operations with National Highways’ Net Zero roadmap, targeting net zero emissions by 2040. Multiple barrier storage locations across the UK allow mobilisation from the closest depot, reducing transport distances. For example, switching a 200km haul to a nearer depot saves around 100kg of CO₂ emissions per articulated lorry trip, amounting to about one tonne per five deliveries. Their logistics system is FORS Gold accredited, applying eco-driving and minimising vehicle idling.
Faster, safer installation
Hill & Smith combines cranes with side loaders during installation. This integrated method cuts handling time and site disruption compared to crane-only approaches. It also lowers incident risk by reducing manual barrier handling.
The company uses an Asset Drilling Rig (ADR) to mechanise piling. The ADR completes anchoring faster than manual drilling. It reduces manual handling, fatigue, and exposure to Hand-Arm Vibration Syndrome (HAVS). The rig’s vacuum system collects drilling debris onsite, preventing contamination of carriageways and the environment. Waste is safely disposed of at depots or designated onsite areas.
Keeping roads moving
Both projects completed within the allocated overnight windows and avoided additional closures. The M5 reopened after a single night shift, the M4 after six hours. This reduced traffic management costs and shortened plant running times.
Rapid TVRS deployment protected workers and road users alike. The approach minimises disruption, maintains safety in complex environments, and contributes to lower emissions. Training also supports this. All installation teams hold LANTRA NHSS 10B accreditation with ongoing development to maintain high standards.
Setting the standard in UK highways
Hill & Smith Infrastructure’s recent work underlines its capacity to deliver large-scale, complex TVRS projects with reliability and safety. Its proven systems and equipment ensure that challenging programmes complete on time without compromising quality.
This approach supports contractors and local authorities working on UK strategic roads, including the M4 and M5. It balances time pressure, operational risks, safety regulations such as NRSWA and the Traffic Management Act, and environmental responsibilities.
More on Hill & Smith Infrastructure’s TVRS systems can be found at https://hillandsmithinfrastructure.com/temporary-road-safety-barriers/
