About the Client
H+H is recognised as the UK’s largest manufacturer of aircrete products, operating multiple production facilities and producing the widely established Celcon Blocks range. With a strong reputation for innovation, including the development of the Thin-Joint building system and the adoption of energy-efficient, environmentally responsible manufacturing methods, H+H continues to invest in safer, more efficient operations across its sites.
As a high-output manufacturer, H+H sites run around the clock to maintain a continuous supply chain. This operational pace requires large volumes of finished product to be moved from the end of production into storage and then onto vehicles for nationwide distribution. To support this workflow efficiently, H+H deploys specialist Konecranes forklifts capable of moving up to four pallets at a time. While this significantly improves productivity and reduces waiting times for outward deliveries, it also increases the frequency of vehicle movements across the site, creating additional risk exposure in areas where pedestrians and plant vehicles operate in proximity.
The challenge
With forklifts transporting heavy loads across multiple zones throughout the day, H+H required a safety solution that could enhance pedestrian awareness of moving vehicles without disrupting operations.
High-risk areas included:
- The end of the production line, where visibility can be limited, and activity is concentrated
- Storage and loading zones adjacent to large stacks of blocks
- Shared work areas with cross-traffic from employees, contractors, and visitors
- Manoeuvring spaces where vehicle layout or site infrastructure can restrict sightlines
To support its safety commitments, H+H sought an integrated approach combining real-time hazard detection, clear driver alerting, and reliable recording to support incident review and continuous improvement.
The solution delivered by TrafficAngel
Following a site assessment, TrafficAngel specified an integrated package combining a plant safety system and an HFR camera system to improve pedestrian detection and driver awareness across key operational zones. This resulted in H+H opting for our PlantShield 360 System. The solution was designed to provide real-time alerts, strengthen visibility around blind spots, and ensure high-quality video evidence was available for review and training where required.
The proposed PlantShield 360 System comprised:
- Four external AI cameras, which are configured to monitor pedestrians in high-risk areas
- Un ECU to process detection events and support system integration
- GPS and gyroscope inputs (GPS/GYRO) to provide operational context
- Un in-cab LED display to deliver clear, immediate driver alerts
This configuration was selected to enhance awareness around pedestrians near the vehicle, particularly in zones where frequent manoeuvring occurs near production outputs and stacked materials.
Video recording and internal coverage
To ensure comprehensive recording and incident traceability, TrafficAngel paired the PlantShield360 System with:
Together, these components enabled recording across six cameras, supporting both external situational coverage and internal visibility for operational review.
HFR Camera System Support (Driver Monitoring)
To strengthen behavioural safety and support consistent driving standards, the specification also included a driver monitoring capability. Used appropriately, this enables structured review of predefined driver behaviour indicators, helping managers identify coaching opportunities and reduce recurring warnings or unsafe habits.
Installation and implementation
The vehicle’s layout introduced constraints requiring careful planning and a high standard of installation.
Internally, limited available space meant the DVR and PlantSafe ECU had to be mounted with precision to ensure secure fitment while maintaining appropriate access and reliability. Connectivity hardware, including GPS, 4G and Wi-Fi antennae, was installed discreetly to preserve a clean cab environment. Cable routing also presented a challenge due to the fine headlining and restricted access pathways. To ensure a durable and professional finish, multiple interior panels were removed so cabling could be run neatly and safely, minimising exposure and improving long-term serviceability.
Externally, camera placement was optimised for detection performance. Two side cameras were mounted high using specially designed brackets positioned beneath existing floodlights, providing an improved vantage point for pedestrian detection. The front camera installation required careful positioning due to limited usable mounting space, while the rear camera was installed using a purpose-built bracket aligned with another floodlight to strengthen rear coverage.
Outcome for H+H
By implementing the PlantShield 360 System and HFR camera system as a unified detection, alerting, and recording solution, H+H enhanced pedestrian safety controls around high-activity areas while supporting operational efficiency. The result is improved driver awareness, strengthened visibility around heavy loads and blind spots, and reliable footage to support investigations, audits, and continuous improvement initiatives.
Testimonial from H+H
Following is the testimonial from Ian Hunter, Logistics Specialist, H+H UK Ltd
El sistema PlantShield 360 y el sistema de cámaras HFR han supuesto una mejora notable en la seguridad y la visibilidad operativa en nuestras instalaciones. Debido al intenso movimiento de carretillas elevadoras y a la presencia de múltiples zonas peatonales de alto riesgo, necesitábamos una solución robusta que mejorara la visibilidad, redujera los puntos ciegos y respaldara nuestro compromiso con la seguridad y la eficiencia operativa.
El sistema integrado de cámaras con inteligencia artificial, combinado con alertas para el conductor en tiempo real y grabación de vídeo de alta calidad, ha mejorado significativamente la forma en que nuestros operarios gestionan la proximidad de los peatones, especialmente en zonas de producción concurridas, materiales apilados y áreas de visibilidad reducida. Las cámaras externas detectan de forma fiable a los peatones en zonas de alto riesgo, mientras que el sistema de monitorización interna ayuda a reforzar las buenas prácticas de conducción y facilita la formación específica cuando sea necesario.
The installation quality was exceptional. Despite space limitations in the vehicle cab and challenging cable‑routing pathways, the TrafficAngel team delivered a clean, professional fit with optimised camera placement, precise ECU and DVR mounting, and secure antenna positioning. Their attention to detail resulted in a reliable, durable system that integrates seamlessly with our daily operations.
Since implementation, we have seen enhanced driver confidence, improved pedestrian safety, and clearer visibility around heavy loads and blind spots. The recorded footage has already proven valuable for incident review, training, and continuous improvement. The PlantShield 360 System has become a key part of our risk‑reduction strategy and is a solution we would strongly recommend to any high‑activity industrial operation looking to strengthen its safety performance.
El sistema de cámaras PlantShield 360 y HFR ha transformado la seguridad en nuestras instalaciones. La detección de peatones mediante IA, las alertas claras para los conductores y la grabación de vídeo de alta calidad han mejorado notablemente la visibilidad en puntos ciegos y zonas de alto riesgo. La instalación fue excepcionalmente profesional y el sistema se integra a la perfección con nuestras operaciones diarias. Es una solución de seguridad fiable e inteligente que aporta un valor real desde el primer día.
Get your own PlantShield 360
To explore how a similar approach could strengthen safety across your operation, TrafficAngel can provide a tailored assessment and recommendation based on your site layout, vehicle types, and risk profile. Contact TrafficAngel to discuss PlantShield 360 and how its AI-driven detection and in-cab alerting can help reduce risk around moving vehicles and pedestrians, supporting safer, more confident day-to-day operations.
