Case Study: Solar Lights at EKFB sites
- EKFB
- Apr 22
- 3 min read
EKFB’s Traffic Management operations, delivered alongside supply chain partner HW Martin, spans the entire 80km of the C23 sections of the HS2 programme.
The operations include 30 to 40 operational plant crossings, and around 20 to 30 other sites requiring portable lights in remote, rural areas, making it one of the largest traffic management schemes of its kind in the UK.
The Challenge
Temporary traffic lights present a unique set of challenges, particularly surrounding the batteries. Each week, approximately 1,500 individual battery changes are required, stretched thinly across a limited resource of 4,500 batteries that are in circulation.
The frequent battery changes lead to numerous further challenges; changing batteries in a live environment where numerous unpredictable factors are present is dangerous for operatives, while the weight and location of the batteries (up to 25kg) also creates a risk of manual handling injuries. Frequent journeys from the HW Martin depot in Coventry to replace used batteries also increases our carbon emissions due to continuous car journeys to and from sites.
The instability of the traffic light batteries means potential traffic light outages, which poses another critical issue, with potential consequences such as complaints and traffic congestion on both public and internal roads when signals have to be switched off.
The Solution
The solution to the challenges of managing temporary traffic lights has been found in the form of Solar Traffic Lights. Specifically, the Nissen LZA550 Solar lights, which are the leading portable solar-powered lights in the UK, have been rolled out for temporary and portable systems.
These lights come with built-in Energy Management systems, fold and tilt solar panels, and an industry-leading communications system to reduce communications failures. They also feature an Intelligent Light system named AMOS (Automated Man on Site) and are compatible with the Haul Route Programme and Solar Pedestrian systems. In addition, all solar units are fitted with trackers that can be accessed via an app from a laptop, phone, tablet, etc. This allows for remote viewing of location, performance, and battery levels, fostering a proactive rather than reactive maintenance regime.
As of the end of February 2025, all of our sites have successfully installed these solar lights, with a mix of temporary and portable units, marking a significant step towards sustainable and efficient traffic management.
The Results
EKFB have seen numerous benefits since implementing the solar traffic lights. There have been 0 battery failures and 0 battery changes, meaning we have avoided 1,311 individual battery changes. This, in turn, has meant that an estimated 594 working hours from undertaking battery changes has been saved, equivalent to 50 working shifts[1]. This has also increased safety for the workers due to the manual handling and vehicle interface risks being drastically reduced.
Furthermore, this initiative has resulted in a considerable reduction of CO2 emissions from fuel alone, by 123.14 tonnes as of the end of February 2025[2]. This is equivalent to planting 5,864 trees per year for carbon offsetting, or to 1,324 hours of flying time for one passenger. These results underscore the transformative potential of the solar traffic lights in promoting sustainability and operational efficiency.
[1] Assuming the worker takes a two hour round trip from the Coventry depot to the light that needs to be changed
