Acklea and Fusion Processing to automate Impact Protection Vehicles

Fusion’s Automated Drive System, CAVstar to be used in feasibility study and ultimately fitted to trucks that protect road workers

Fusion Processing Ltd, a leader in autonomous drive technology, is conducting a technical feasibility study to trial systems that would automate an on-highway Impact Protection Vehicle (IPV). The aim is to remove the need for a driver in the cab during live roadworks, significantly improving safety for road maintenance crews.

Enabled by Fusion’s CAVstar® automated drive system, the IPV will operate at SAE Level 4 autonomy. The initiative is part of a feasibility study funded by Innovate UK and delivered in collaboration with highway maintenance companies Ringway and Colas with expertise from TRL and IPV specialist Acklea. The study will explore how Connected and Autonomous Vehicle (CAV) technologies can be applied to remove drivers from one of the most dangerous positions in road maintenance.

IPVs are typically used to shield road workers during short-duration mobile works on live carriageways. Despite their high-visibility markings and energy-absorbing crash cushions, collisions remain frequent. It’s estimated that around 1,500 Impact Protection Vehicles (IPVs) are currently in operation across the UK’s Strategic Road Network. Between 2019 and 2024, 105 IPV collisions were reported, all with a driver in the cab at the time. Many of these incidents resulted in physical or psychological harm to the driver, with investigations revealing that some have suffered from Post-Traumatic Stress Disorder (PTSD) as a result.

By automating the IPV, Fusion Processing and its partners plan to remove the driver entirely, eliminating the risk of injury or trauma from rear-end collisions. This will be achieved without compromising the IPV’s protective role or the safety of other road users.

“Our mission at Fusion Processing is to deploy autonomous technologies where they can make a real-world impact,” said Jim Hutchinson, CEO of Fusion Processing. “Through this project, we plan to demonstrate that automating the IPV is not only possible, but also one of the most immediate and meaningful ways we can use autonomy to protect lives.”

The vehicle will be designed to operate in both Manual and Autonomous Mode (No Driver In Cab)offering flexibility across a variety of maintenance operations.

Philip Reid, Head of Innovation and Transformation at Ringway, commented: “Every year, IPV drivers are exposed to unacceptable risk while protecting the rest of the workforce. By taking the driver out of the danger zone, this project could transform how we approach safety on our roads. I hope that this is the first of many such applications of automation in highway maintenance vehicles.”

“We are proud to support Ringway and the wider project team with our technical vehicle expertise as we explore the feasibility of an autonomous IPV. It’s a privilege to help shape a safer and smarter future for traffic management, to explore how we can improve road safety for workers and those using our roads,” said Clive Brocklehurst, Product Manager at Acklea.

David Hynd, Principal Consultant, TRL, said: “TRL is developing a detailed understanding of the Operational Design Domain (ODD) to support the evaluation of the system’s technical and operational feasibility. As part of this work, we will assess the operational and ODD risks to ensure the system is suitable for real-world deployment. We are also leading on the regulatory feasibility, assessing how the system aligns with existing regulations and identifying any gaps that may need to be addressed. Ultimately, our goal is to reduce the risk to the workers who help maintain our roads, by leveraging automation to enable safer and more efficient outcomes”

Funded by the UK Government through the CAM Pathfinder Feasibility Studies (FS) Competition, this project will also assess the potential for adapting this technology across a wider range of highway maintenance vehicles, opening the door to broader industry adoption of CAV technologies.