Green Light for Traffic Group Signals’ New Battery Charging Solution

We’ve designed and delivered a bespoke battery charging solution for Traffic Group Signals to provide a safe space to charge its lead acid batteries at its new site, with safety being the main priority.

The Customer

Part of The Traffic Group, a collective of specialist technology innovators focused on improving traffic and travel systems, Traffic Group Signals is a manufacturer of temporary and permanent traffic management solutions used across the UK. The business designs and supplies traffic signal equipment for roadworks, infrastructure projects, and local authority networks, where reliability and safety are critical.

Operating within a highly regulated environment, Traffic Group Signals requires robust, compliant facilities to support the manufacture, testing, and maintenance of its battery-powered systems.

Interior of a containerised electrical control room with open steel doors, displaying mounted control panels, isolators and electrical distribution equipment for battery storage applications.

The Challenge

Traffic Group Signals wanted to incorporate a lead acid battery charging facilitywithin its new building to house the VRLA (Valve-Regulated Lead-Acid) batteries which power its traffic light units. However, due to the potential risk of fire and explosion of hydrogen gas during the charging process it wasn’t possible to secure appropriate buildings insurance. The team needed a specialist containerised storage and charging solution which could be located well away from the main building and would contain any fire and provide adequate access for emergency services.

All works were completed within the guidelines outlined by BS EN IEC 62485-2: 2018 Safety Requirements for Secondary Batteries and Battery Installation. Using projected hydrogen emission calculations, the team created a ventilation system using an ATEX Zone 1 lighting and ATEX Zone 1 fan forced air solution. An additional safety factor fan was also incorporated into the ventilation design to ensure that concentrations of hydrogen in air within the container battery compartment would never reach their explosion limit even if one of the two installed ATEX fans failed. Power to the ATEX fan ventilation circuits is designed to switch on automatically and run continually when any one of the 48 battery chargers is switched on.

Roof-mounted ducted ATEX-rated extraction fan installed on a containerised battery storage unit, designed for safe ventilation of hazardous gases in industrial environments.

What The Traffic Group Had to Say

“The design and construction of a bespoke battery charging facility was new ground for Traffic Group Signals. S Jones provided us with advice on the design and technical aspects of our proposed unit, having listened to our original requirements. They guided us through the options available to us, to arrive at a design that not only fulfilled our needs but complied to all the relevant safety standards. They involved us throughout the process and completed the unit to the agreed schedule.”  – Mark Hutchinson, Director at The Traffic Group.

Close-up of industrial battery charger connections mounted on orange steel racking, showing numbered charging points inside a containerised battery charging container.

Need a Safe, Compliant Solution for Battery Charging or Storage?

We design and deliver bespoke containerised battery charging and storage solutions engineered to manage fire, gas, and electrical risks. Built to meet relevant safety standards and located away from occupied buildings, our container conversions provide secure, controlled environments for critical battery operations.

Learn more about our container conversion capabilities or contact us today to discuss your project.