Brackmore and ArcelorMittal collaborate on long-life Magnelis^® road barriers across UK national highways infrastructure

Brackmore (formerly Hill & Smith VRS) has partnered with ArcelorMittal to co-engineer a new highly durable road barrier system for the UK’s national highways infrastructure. Magnelis^® is ArcelorMittal’s innovative pre-galvanised, self-healing steel, offering much greater corrosion resistance to installations in harsh environments while protecting cut edges. The new offering significantly extends the lifespan of road barriers compared to traditional hot-dipped galvanised products, thereby substantially reducing associated lifecycle carbon emissions, and the frequency of repairs, maintenance and replacement.

Brackmore's business dates back to 1824, and with over 200 years of experience, it now provides total solutions in Vehicle Restraint Systems (VRS) to assist the world in returning home safely at the end of every day. The company offers a wide range of permanent safety barriers, vehicle and pedestrian parapets, and passive safety solutions for both on and off highway applications, which are tested to international standards and quality engineered giving them global recognition.

A more sustainable and lower maintenance solution

Brackmore Barriers, a division of Brackmore, has worked closely with its steel supplier and long-time customer of ArcelorMittal, Sebden Steel Service Centres, over several years to develop a more sustainable and lower maintenance solution for the UK’s road network. In particular there has been a focus on supporting the industry’s move towards lower full lifecycle carbon impacts. Magnelis^®’s impressive longevity in harsh environments, lasting up to three times longer than conventional hot-dipped products, is a major factor in reducing overall maintenance, costs and lifecycle carbon emissions. Approval has required detailed technical analysis by independent structural engineers and certification from the UK’s National Highways public body.

Independent SCI review

Independent review of Magnelis^® ZM310 and ZM430 corrosion performance by the UK’s Steel Construction Institute (SCI) endorsed ArcelorMittal’s findings on Magnelis^®’s longevity and durability. Highway infrastructure is often subject to extreme environmental conditions, together with high salinity from winter road treatment.

A study to compare the performance of samples of Magnelis^® and batch galvanised steel samples was conducted by ArcelorMittal at a site in Dunkirk, France. The exposure conditions were classified as a marine environment. The samples were positioned at an inclination of 45° to the horizontal and facing south. The mean consumed coating thickness was measured annually. After 5 years of exposure the mean consumed coating thickness was 1.4 μm for Magnelis^® and 7.5 μm for the batch galvanised coating. The average yearly coating consumption over the exposure period and the resulting coating life were calculated assuming linear performance over time as shown in the table above. The study was reviewed and endorsed by the SCI.

Products and partnerships that last

Brackmore has commenced the rollout of its corrugated beam barriers across the UK, including 4 km on Scotland’s busiest motorway, the M8, connecting Edinburgh and Glasgow, where the system was installed by BEAR Scotland. Other notable projects include the A428 Black Cat to Caxton where 32 km of Brackmore’s proprietary N2 Dudley VRS is being supplied in pre-galvanised steel and installed by HW Martins. This offers savings in overall lifecycle costs due to increased lifespan and reduced maintenance requirements as well as offering lower embodied carbon.

Brackmore’s double-sided H2 W4 corrugated beam barrier manufactured from Magnelis^® steel and installed on the M8 motorway, Scotland [Copyright: Brackmore]

In addition, Brackmore is supporting Amey Highways by supplying 1.5 km of pre-galvanised corrugated beams for use in a range of maintenance and repair schemes involving legacy vehicle restraint systems. Amey said: “By reducing maintenance needs and improving long-term performance, the solution will help keep roads open for longer, supporting more consistent journeys for road users.”

“This represents a major step change for our industry - the biggest innovation in barriers for over 60 years,” says Martin Hall, Head of Sales and Commercial, Brackmore. “Partnering with Sebden Steel Service Centres and ArcelorMittal has combined our barrier engineering expertise with their deep knowledge of pre-galvanised steel applications. It has enabled us to develop a solution that dramatically reduces whole life costs, minimises maintenance and road disruption, and supports our customers’ net zero commitments - a pre-galvanised solution that is stronger, more durable and more sustainable than anything else currently on the market.”

Detailed technical insight

William Butler, Chief Engineer, Brackmore, added: “Building up to the transition to Magnelis^® has been an exciting engineering challenge. ArcelorMittal has supported us along the way with detailed technical insight and the strong performance data from their trials, along with our own analysis and material reviews. It's a major advance for guard rails and barriers, where material grade and coatings have not moved forward for a very long time.”

Magnelis^®’s advantages include that it requires no major changes in installation procedures compared to traditional galvanised steel, and offers its own unique self-healing properties both for cutting and fabrication, as well as for incidental damage during its lifetime. It uses the same forming techniques as for galvanised steel, and can be arc, laser, brazed or induction welded. Magnelis^® uses less zinc than batch galvanised steel, and as a result substantially reduces zinc runoff into the environment.

Magnelis^®: edge protection with self-healing effect

Protecting people and the planet

“The expansion of our product portfolio to include pre-galvanised solutions marks an important step forward in our sustainability strategy,” said Brad John, Product Manager at Brackmore. “By offering products that support reduced environmental impact without compromising impact performance, we are strengthening our commitment to creating more sustainable road infrastructure. This enhanced offering not only differentiates us within the industry, but also positions us at the forefront of driving positive change across the industry.

The response from installers has also been very positive, with many describing the product as superior in terms of handling, aesthetics and long-term durability when compared with traditional alternatives. This feedback reinforces our confidence that pre-galvanised solutions can deliver benefits across the entire supply chain, from manufacture and installation through to in-service performance. A big thank you to ArcelorMittal and Sebden Steel Service Centres for their support on this collaboration.”