Kier A417 Missing Link Project
Project Savings
833,689
Carbon Savings (kg of CO2e)
270,574
Fuel Savings (litres)
638,180
Cost Savings
The A417 Missing Link Project
The A417 is a vital transport link connecting Gloucester and Swindon, serving as a key route between the Midlands/North and the South of England. It provides an alternative to the M5/M4 corridor via Bristol, making it essential for regional connectivity and economic activity.
A critical three-mile stretch – known as the “Missing Link” – between the Brockworth Bypass and Cowley Roundabout in Gloucestershire has long been a bottleneck. This single-lane carriageway leads to frequent and unpredictable congestion, causing many motorists to divert onto unsuitable local roads. As a result, nearby communities face increased traffic, noise, and road safety concerns. Additionally, poor visibility and road design contribute to a high incidence of serious accidents.
To resolve these issues, a comprehensive improvement scheme is underway. Key enhancements include:
- 4 miles of new dual carriageway, seamlessly linking the A417 Brockworth Bypass with the existing dual carriageway south of Cowley.
- A reconfigured route west of the Air Balloon roundabout, following the current A417 corridor, while a new section to the south and east of the roundabout will be built offline, away from the existing road.
- A new junction at Shab Hill, improving access between the A417, the A436 (towards Oxford), and Birdlip.
- A new junction near Cowley, replacing the existing Cowley Roundabout for smoother traffic flow.
- Repurposing the existing A417 between Air Balloon and Cowley Roundabout – some sections will be transformed into dedicated routes for walkers, cyclists, and horse riders, while others will be retained for local access for residents.
By addressing long-standing challenges, this scheme will enhance safety, improve traffic flow, and create a more reliable route for both local and long-distance travel.
In Collaboration with Kier – Prolectric Powers a Sustainable Solution for the A417 ‘Missing Link’ Scheme
Kier and Prolectric collaborated to address the environmental and wildlife considerations of the A417 ‘Missing Link’ project, located within the sensitive Cotswolds Natural Landscape. Given the site’s ecological significance, Kier sought sustainable and cost-effective alternatives to traditional diesel generators and tower lighting.
To explore the viability of solar-powered solutions, Kier initially trialled Prolectric’s solar site lighting across key areas of the site. The trial proved successful, leading to a large-scale deployment of solar-powered lighting solutions, tailored to different applications:
- Patented Solar Site Lights with autonomous adaptive lighting were installed on active areas, including roads, roundabouts, and operational zones requiring reliable illumination for tasks.
- Solar Street Lights on moveable concrete blocks were positioned along walkways within site compounds.
- Permanent Solar Street Lights were installed in staff car parks, providing long-term, maintenance-free lighting.
Expanding the Use of Solar Hybrid Power
Following the success of the solar lighting rollout, Kier explored the potential of solar hybrid power to further reduce reliance on diesel generators. An initial deployment of a ProPower Solar Hybrid Generator in place of a traditional 24/7 diesel unit demonstrated fuel savings of over 75% within a month. This led to a broader shift toward hybrid power across the site:
- An 8-Panel Solar Hybrid Generator replaced a diesel unit previously used for site overnight accommodation (bunker bins). The system reliably powered three accommodation units while eliminating the noise and emissions of a continuously running diesel generator. To ensure uninterrupted operation, Prolectric developed an adaptive mode where the integrated diesel backup would charge the batteries before 5pm if the state of charge was low, ensuring silent operation throughout the night.
- Four additional Solar Hybrid Generators were deployed to replace diesel generators powering security huts around the Missing Link site. These generators efficiently provided lighting, heating, and power for laptops, significantly reducing fuel use by matching power output to the actual load requirements. Previously, large diesel generators ran 24/7 despite low energy demand.
- A ProCharge 3-Phase Solar Battery Energy Storage System (BESS) was introduced to site to support a large cabin setup, leading to substantial fuel and carbon savings. At its peak, this system saved over £200 per day in fuel costs, in addition to cutting operational and maintenance expenses.
Results & Impact
By adopting Prolectric’s solar lighting and hybrid power solutions, Kier achieved:
- Significant fuel and carbon savings, reducing emissions in a sensitive environmental location.
- Lower operational costs, cutting unnecessary diesel consumption and generator maintenance.
- Improved site conditions, eliminating noise pollution from diesel generators, particularly in accommodation areas.
- Enhanced sustainability, aligning the A417 Missing Link project with Kier’s environmental commitments and the project’s AONB requirements.
Prolectric’s off-grid renewable technology has demonstrated the practicality and financial benefits of transitioning to solar and hybrid power on large-scale infrastructure projects – helping Kier deliver a more sustainable and cost-efficient construction site.
Measurable Success & Key Benefits
By integrating Prolectric’s solar lighting and hybrid power solutions, Kier achieved a range of efficiencies and operational improvements, including:
Fuel & Carbon Savings
- Over 75% fuel savings from switching to solar hybrid power, significantly reducing operational costs.
- Substantial carbon emission reductions, aligning with sustainability commitments for the AONB project.
Improved Operational Efficiencies
- Reduced generator maintenance due to fewer moving parts and lower operational strain.
- Less frequent refuelling, cutting both costs and logistical demands.
- Portal access for remote monitoring, allowing real-time management of performance and energy usage.
Enhanced Team Wellbeing & Site Conditions
- Eliminated noise pollution in accommodation areas by replacing diesel generators with silent hybrid units.
- Improved air quality on-site, benefiting workers and surrounding communities.
- User confidence built through comprehensive training and live performance data, reinforcing trust in solar technology.
Seamless Transition to Sustainability
- Kier’s commitment to moving away from diesel was reinforced through successful trials, demonstrating that solar solutions could meet performance needs without compromise.
- A collaborative approach between Prolectric and Kier ensured tailored support, from site assessments to product selection and training.
- Regular engagement with Prolectric specialists provided ongoing assistance, ensuring smooth integration of renewable technology.
Impact on Project Delivery
By reducing fuel consumption, emissions, and maintenance needs, Prolectric’s solutions enhanced the efficiency, cost-effectiveness, and sustainability of the A417 ‘Missing Link’ scheme. The confidence gained through real-time data tracking, hands-on training, and expert support enabled a smooth transition from diesel to solar, without disrupting site operations.
The success of this collaboration sets a benchmark for future infrastructure projects looking to adopt off-grid renewable solutions for a more sustainable, low-carbon construction approach.
What We Have Learned
The A417 ‘Missing Link’ project has demonstrated that transitioning from diesel to solar and hybrid power can be both highly effective and straightforward. Key takeaways from this experience can help other infrastructure projects make similar sustainable shifts:
Proven Performance & Cost Savings
- Hybrid generators reduced diesel costs by 75%, delivering substantial financial and carbon savings without any loss of power reliability.
- Solar lighting towers require no refuelling or manual intervention, operating autonomously and ensuring consistent all-night illumination.
- Remote monitoring and control enable real-time adjustments, such as turning off lights without visiting the site, improving efficiency.
Enhanced Site Conditions & Workforce Wellbeing
- Lower noise and emissions from diesel alternatives have improved working conditions for site operatives and reduced disruption to local wildlife.
- Solar streetlights eliminated the need for costly mains power installation, saving tens of thousands of pounds in infrastructure costs.
Steps to Implement This Approach on Other Projects
- Start with a trial – Small-scale deployments help validate performance, build confidence, and refine operational integration.
- Use real-time data tracking – Monitor fuel savings and efficiency improvements to make data-driven decisions.
- Engage stakeholders early – Collaboration between sustainability teams, procurement, and site managers ensures seamless adoption.
- Leverage remote technology – Remote monitoring reduces maintenance demands and allows for greater control over energy use.
- Consider a phased transition – Introducing hybrid solutions gradually allows for a smooth switch from diesel without disrupting site operations.
The success of this approach on the A417 project demonstrates that solar and hybrid power are not just viable alternatives – they are superior solutions in terms of cost, efficiency, and environmental impact. By taking a proactive approach, other projects can replicate these benefits, reducing emissions, lowering costs, and improving on-site conditions.
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What our clients have to say
Working with Prolectric has transformed the A417 ‘Missing Link’ project. Their innovative, sustainable solutions exceeded expectations, delivering cost savings and reducing our carbon footprint. Remote monitoring improved efficiency, and reduced noise and emissions created a better environment. With projected annual savings of £638k and CO2e cuts of 800,000 kg. Their support made the transition effortless and their solutions have set a new standard for powering major infrastructure projects.
Gavin Jones
Project Manager, Kier Transportation | Highways Major Projects
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