Challenge
Highway maintenance teams needed a large sliding light arrow that could be deployed from either side of a service vehicle during road closures. The system had to extend to 3.5 metres, withstand strong wind loading, cope with uneven road gradients and collapse safely in the event of a collision at speeds up to 70 mph.
On top of this, the entire structure needed to fold compactly enough to fit within the footprint of a small lorry without overhangs, be simple to deploy by operators on site and be robust enough for constant daily use in harsh outdoor conditions. Existing solutions in the public domain were not suitable, either lacking the flexibility, collision behaviour or compactness required for this application.
How Amtek Tackled It
Amtek began by analysing the deployment paths, allowable vehicle envelope and collision requirements. This informed the geometry, joint locations and mechanical sequencing needed for the system to extend smoothly and fold into a compact, transportable form.
A series of parallel linkages and vertical hinges were developed to create a stable, extendable frame that allowed the arrow to move more than 3.5 metres from the vehicle while maintaining structural stability. The linkage system was refined through iterative modelling, testing and hinge sequencing studies, ensuring it could deploy cleanly to both sides without interference, snagging or excessive operator input.
Ensuring safe collision behaviour, the frame needed to absorb and redirect energy in the event of an impact. Amtek carried out structural simulations, including finite element analysis, to evaluate deformation patterns, hinge performance and strength under various collision scenarios. Material grades and hinge configurations were optimised to deliver controlled retraction behaviour without compromising normal operation.
Overcoming installation and clearance constraints, space on the small lorry bed was extremely limited, so the system had to fold into a minimal footprint while avoiding clashes with powerpacks, electrical systems and other equipment. Through iterative design and prototyping, Amtek produced a hinge and linkage arrangement that allowed the arrow to nest tightly within its storage space while still being simple to deploy on site.
The Solution and Its Impact
The final system was a rugged, collision tolerant sliding light arrow capable of reliable two sided deployment, safe energy absorption and compact stowage within the required vehicle dimensions.
The customer gained:
- 5 metre extendable arrow Capable of deploying left or right from the same vehicle.
- Compact, foldable frame Met all space and transport constraints.
- Hinge and linkage system Engineered for stability, repeatability and long-term field use.
- Verified collision performance Achieved through detailed modelling and material optimisation.
- Quick and confident deployment Designed so operators could set up safely on live road networks.
The project demonstrated how Amtek applied advanced engineering and practical field awareness to create a system that improved roadside safety, reduced operator workload and met stringent dimensional and performance demands.
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