Dudley Council's Custom Hexagonal Bollards
Dudley Council needed durable, UK-made hexagonal steel bollards after imported options kept failing. Aremco Barriers solved the problem locally by laser cutting and precision-bending the panels in-house using our Keytona press brake, producing a stronger, long-lasting galvanised solution.
Turning a Global Supply Challenge into a Local Fabrication Success
The Challenge: Durability, Cost, and Availability
Dudley Council approached us with a significant maintenance challenge. They were struggling with a fleet of existing bollards, originally manufactured from recycled materials, that were proving excessively fragile and expensive to replace due to frequent damage. The high costs and constant need for replacement were draining maintenance budgets.
The Council sought a solution that offered superior durability and a specific aesthetic: a robust, built-in, hexagonal (six-sided) bollard.
The problem? After initial searches, it became clear that this specific design was virtually impossible to source locally, with supply chains pointing exclusively to overseas manufacturers in China. Importing meant lengthy lead times, higher freight costs, and minimal quality control—a risky proposition for a critical public infrastructure item.
The Solution: UK Fabrication Ingenuity
Rather than accepting the limitations of global supply, we proposed a revolutionary local manufacturing solution, leveraging our in-house expertise and advanced machinery. Our talented fabricator devised an ingenious method to replicate the highly specific hexagonal design:
- Precision Laser Cutting: The top caps and the six individual side panels were precisely laser cut, ensuring perfect geometric conformity and minimal material waste.
- Advanced Bending: The six flat side panels were then masterfully bent into the required shape using our Keytona press brake, delivering crisp, uniform corners essential for the hexagonal structure.
- Structural Welding: All components were meticulously welded together to create a seamless, high-strength unitary structure.
- Integrated Anchoring: Two robust 30mm diameter steel bars were strategically incorporated through holes at the base, creating a secure, built-in anchoring system for maximum stability upon installation.
The Result: Galvanised Strength and Local Value
The final product is a 1030mm high, six-sided built-in bollard that far surpasses the durability and longevity of the recycled plastic units they replace.
The non-negotiable final step was the hot-dip galvanised finish. This crucial layer of zinc provides exceptional corrosion resistance, guaranteeing that these bollards will withstand harsh weather and repeated impact for decades, significantly reducing the long-term maintenance burden for Dudley Council.
Fast turnaround, superior quality control, local supply.
This project is a prime example of how bespoke fabrication can beat off-the-shelf limitations. We delivered a stronger, more cost-effective, and locally sourced solution that solved Dudley Council's recurring problem and demonstrated our technical leadership in complex metal fabrication.
Do You Have a Custom Fabrication Challenge?
If you are struggling to find a durable or cost-effective solution for bespoke metalwork, don't rely on expensive imports or fragile materials. Partner with a fabricator who can custom-engineer the perfect solution, built to last right here in the UK.