Established in 1990, Polysafe combined modern materials with the ‘Bomac’ design that had dominated the Level Crossings market in the UK since the mid 1970’s.

The result was a Level Crossing system that key stakeholders.

The same qualities are in demand today with much higher volumes and speeds of road and rail traffic and the Polysafe system continues to meet this demand. Using the latest in Polymer Concrete technology and a design that eliminates problems associated with systems that are supported by sleepers and/or ballast, the Polysafe system has evolved to meet today’s demands.

And because Polysafe is a UK-based company, manufacturing their own product in the UK, turnaround times are quick and flexible to meet the needs of our clients.


A quality product is critical, and the following accreditations held by Polysafe ensure the highest standards are maintained:

  • Network Rail approved supplier – the UK rail system is vast, and inevitably the standards required to be an approved supplier are stringent.
  • BS EN ISO 9001: 2015 – the internationally recognised sign of high quality has been held for many years.

RISQS verified supplier – assurance that you are dealing with a company of high integrity and standards

Safety is Critical

Numerous safety features are built into the Polysafe system including:

  • High grip – even in the wet. The surface of the panels has the same or higher skid resistance as that found on road surfaces. In the wet, when the risk of skid-related accidents is at its highest, Polysafe units do not lose the high skid resistance they achieve in the dry, helping to avoid delays and the knock-on costs of an accident.
  • Visible road markings – White lines / yellow hatching are designed to increase safety. As Polysafe level crossing decks have a similar surface to that of a road, these can be applied easily and do not wear off readily (which according to some rail engineers does happen on timber or rubber systems).
  • High strength and durability – Polysafe systems are renowned for this and are capable of consistently taking loads that other systems are incapable of handling.
  • No gaps – in addition to the weight of the system itself, heavy duty end restraints prevent dangerous gaps appearing even under the severest conditions, meaning ongoing safe passage for motorists and pedestrians alike.
  • No damage to rail infrastructure – the design of a Polysafe system means it fits around Pandrol clips and is supported by the strength of the rails (in the same area that supports the train weight) meaning it doesn’t need to be full depth. A key safety advantage of the gap beneath is that it allows water to drain away rather than sitting around Pandrol clips and the rail – both potential sources of rot.

Real costs

A level crossing is designed to be a long term solution to keep road and rail traffic moving, and the features of a Polysafe system are geared towards this:

  • Life span – Concrete panels can be expected to last at least 15 years, while the polymer version can be expected to last longer. Other systems do not offer the same long-life expectations. Viewed over a period of 25 years or so, this can eliminate one complete level crossing replacement – a huge cost saving in materials, not to mention the inconvenience of road/rail closure during installation. This may seem a long term to look at – but given that there are thousands of level crossings in the UK alone, the potential for long term saving is immense.
  • Installation – although installation costs are unavoidable, with targets to satisfy and government and passenger requirements, there is a fine balance to achieve. It is vital that the installation of a level crossing is made as simple and quick as possible without compromising the safety of the system involved. A Polysafe system can be installed overnight, making use of the quietest and least disruptive night-time hours.
  • Maintenance – to maximise the life of any type of crossing, Network Rail acknowledges maintenance is essential for ongoing safety, with inspections taking place regularly. Although some cost is unavoidable, the design of the system can help keep costs to a minimum.

Polysafe panels do not rely on ballast/sleepers for support, have a gap beneath the system for drainage, Pandrol clips can be viewed without panel removal, and insulation by special rubber wedges prevents track circuiting. These features lead to a relatively low maintenance regime and minimal downtime for both road and rail – in turn leading to minimal maintenance cost. When routine inspection is required, individual concrete / polymer panels can easily be accessed and removed without the need for major panel removal.

Our services

Whatever your need, Polysafe offers the following services to help you:

  • Site visits to assess/ discuss your needs.
  • Quotations for both new projects and maintenance needs.
  • Design service (e.g. if unusual shape panels are required).
  • Full range of spares and maintenance items – individual panels, full level crossing decks, panel lifters, end restraints. All Bomac and Polysafe compatible and available at short notice.
  • Associated concrete products – we can help if you require other pre-cast concrete products to complete your project.

What our customers say…