In Situ Casting of Pavement Lights

Precision-Cast In-situ Pavement Light Panels

We’re among the elite five UK specialists (and a handful globally) casting concrete in-situ panels over live vaults and basements. Our process delivers like-for-like replacements, preserving historic loading and design while meeting modern safety standards. Perfect for heritage and listed buildings.

The In-situ Process: Demolition to Certification

Demolition & Removal: Cut and remove old panels section by section, safely disposing of debris as licensed waste carriers.
Preparation & Formwork: Torch-dry bearings, install precise formwork with historic moulds and glass size matches (100mm x 100mm or 117mm lenses).
Casting & Reinforcement: Pour reinforced hand made C40 concrete on-site, embedding lens alignment To agreed levels and falls.
Sealing & Waterproofing: Seal joints with bitumen or mastic asphalt, adding carborundum for slip resistance.
Finishing & Certification: Finish with natural or colored concrete, issuing BRE certificates.

Cast In-situ Pavement Lights

Pavement Light in-situ table

Why Choose Cast In-situ Panels

Ideal for large openings, sloped pavements, or custom shapes.
Perfect for heritage sites where frames can’t be removed.
Faster curing with minimal disruption.
Seamless finish blending with surroundings.

Weather & Seasonal Tips

Concrete casting is weather-dependent. Schedule spring/summer works when temperatures are 3°C and rising with dry conditions. In colder months, we use tarpaulins, hessian, and heating to protect curing concrete. Book early to avoid winter surges.

Leak Repairs & Resealing

Defective seals cause basement leaks. We offer re-sealing, leak diagnosis, and bitumen/asphalt torch sealing. See our Waterproofing & Resealing Page for details.