Extrudakerb Concrete Barrier 

United Kingdom

In January 2005, the UK Highways Agency initiated the Smart Motorway Projects, focusing on replacing outdated steel barriers with concrete to enhance safety and reduce maintenance. Concrete barriers are more durable, safer, and cost-effective, minimizing traffic disruptions and lane closures. Extrudakerb (Maltby Engineering) Limited, a leading UK slipform concrete contractor, developed the innovative Extrudakerb Concrete Barrier (ECB) in 2018. ECB has been widely installed in major road improvement schemes, including the Smart Motorway Projects.

Loads paved per shift
Compared to 10-12 loads per shift before.


Manufacturing and installing concrete barriers is an intricate process that requires careful management and delivery to ensure a quality product is provided. Consideration of all processes and applications must be addressed, from concrete production, transportation to placement.
Concrete consistency often changes during transportation and naturally loses consistency over time, meaning it can dry out before it can be paved. When this occurs, concrete trucks arrive on site and require tempering to adjust the mix so that it can be placed through the slipform paver. Manual adjustments need to be made by adding water via the onboard supply carried by the truck. This relies on the experience of the site operatives, to add a small quantity at a time until the mix is judged suitable for use. However, without a system to monitor the water added, there was no accurate way to record the tempered water. This is a time consuming operation and causes delays to placement of the concrete once it arrives on site.

VERIFI® Expertise and Benefits:

To control the concrete inconsistencies in-transit, Extrudakerb decided to invest in VERIFI® in-transit concrete management system. This automated system encompasses cloud connected in-truck sensors, dosing equipment and data intelligence. The sensors collect real-time data about the concrete properties as the load travels to the job site, and adds water and admixture as needed so that each batch arrives on target. The data is accessible through a hub that can be accessed on phones, tablets, laptops and desktops.

The VERIFI® solution has helped Extrudakerb on several fronts. From monitoring the concrete batch consistency, to reducing rejected loads through remote insight, this tool has provided additional visibility to assist Extrudakerb’s operations.

Results and Testimonials:

The implementation of the VERIFI® system has significantly enhanced Extrudakerb’s operations:

  • Real-Time Vehicle Tracking: Allows precise monitoring of concrete truck locations and status.
  • Vehicle Status Monitoring: Enables comprehensive oversight of the delivery cycle.
  • Record Verification: Supports production records with precise data.
  • Temperature Management: Provides insights into temperature effects on concrete, ensuring compliance with standards.
  • Water/Cement Ratio Compliance: Ensures accurate recording of water additions, maintaining mix design specifications.
  • Supplier Flexibility: Enables use of any concrete supplier in the UK.

Overall, the VERIFI® system has improved operational efficiency, increased the number of loads paved per shift from 10-12 to 16-20, and enhanced product consistency. This innovative partnership has enabled Extrudakerb to exceed project timelines and advance traditional paving processes.

Verifi in-transit concrete management

Project participants

  • Extrudakerb (Maltby Engineering) Limited
Before we put VERIFI® on our trucks, we were typically paving 10-12 loads per shift. With the addition of VERIFI® as part of the overall paving process, we typically pave 16-20 loads per shift. Overall the innovative partnership has allowed Extrudakerb to push traditional boundaries, excelling against project timescales.
Extrudakerb’s Materials and Concrete Technology Manager