Carnell and specialist barrier supplier Versco have been recognised with the National Highways Asset Community East (ACE) Better Together 2025-26 Innovation of the Year Award for the development and successful deployment of an innovative hydraulic beam former system on the A421 Noise Barrier Replacement Scheme in Bedfordshire.
The innovation was developed to overcome significant construction challenges encountered during the replacement of more than 1.5 kilometres of roadside noise barriers. Faced with difficult ground conditions, existing buried infrastructure constraints and programme pressures, the project team collaborated to create a reinforced concrete beam foundation using hydraulic formers designed and manufactured by Versco.
The reusable hydraulic formers transformed delivery of the scheme, replacing traditional timber shuttering with a safer, faster and more efficient construction method. Using a cast-one, miss-one approach, the project team was able to achieve production rates of up to five six-metre foundation bays within a single night shift, dramatically reducing programme durations and labour requirements.
By minimising excavation requirements and reducing the risk of clashes with buried services, the solution improved workforce safety while maintaining construction quality through accurate reinforcement positioning and consistent concrete cover. In addition, the reusable steel formers significantly reduced material waste compared with conventional timber formwork.
The innovation was implemented as part of the A421 Noise Barrier Replacement Scheme, which delivered 1,571 metres of replacement noise barrier across three locations, incorporating 525 new posts and more than 4,900 square metres of acoustic screening. The completed scheme protects nearby communities from traffic noise generated by approximately 55,000 vehicles per day.
The project showcased the value of collaboration by National Highways and their supply chain, with Carnell, Versco and Atkins Réalis working together to develop, trial and refine the solution. Lessons learned from the first installation were successfully applied across subsequent phases of the project, driving continuous improvements in constructability and productivity.
Shaun Moseley, Asset Needs Manager at National Highways, said: “The introduction of the innovative beam former did not just speed up the construction of the noise barrier, it redefined what our team believed was possible. By turning a complex, delay-prone process into a seamless flow of precision and progress, we proved that bold thinking and smart engineering can elevate both performance and ambition.”
Versco have refurbished the beam formers for use on future projects, ensuring that the benefits of the innovation continue to be realised across the wider UK infrastructure sector. The success of the A421 project demonstrates how collaborative innovation can solve complex delivery challenges while improving safety, efficiency and value for the client and taxpayer.
(Image – Carnell)
LCRIG shares news, announcements, and press releases from our member organisations. Content remains the responsibility of the issuing organisation and does not necessarily reflect the views or endorsement of LCRIG.