Seamless Strength: The Art of Cast In-Situ Pavement Light Installation
Published: November 2025 | Leighton Buzzard, UK
When heritage meets heavy loads, cast in-situ pavement lights are the gold standard. Unlike precast panels, these are poured on-site over live vaults, delivering seamless integration, unmatched durability, and perfect historical accuracy.
At The Pavement Light Company Ltd, we’re one of just five UK specialists – and fewer worldwide – with the expertise to cast reinforced concrete pavement lights directly on your basement. From Mayfair townhouses to West End theatres, we rebuild what time has worn away.
Why Cast In-Situ? The Advantages That Matter
- Perfect for complex shapes – sloped pavements, irregular spans, curved vaults
- Heritage compliance – no removal of original iron frames or bearings
- Maximum load capacity – up to 75 kN concentrated load (BRE certified)
- Zero cold joints – monolithic pour prevents leaks
- Faster on-site completion – no transport delays, immediate curing
Explore precast vs in-situ options →
Our 5-Phase In-Situ Casting Process
1. Controlled Demolition & Waste Management
We cut and lift old panels section by section, using licensed waste carriers and dust-suppressed tools. Debris never enters your basement.
2. Precision Formwork & Lens Layout
Bearings are torch-dried and level-checked. We install custom formwork using original moulds to match historic lens sizes:
- 100mm × 100mm (standard concrete)
- 117mm half-shell (for paver integration)
- 93mm prismatic (repair inserts)
3. Hand-Cast Reinforced Concrete
We pour C40-grade concrete with embedded steel reinforcement, hand-troweled to exact falls. Lenses are aligned to ±2mm tolerance.
4. Heritage-Grade Sealing & Finishing
- Hot-pour bitumen joints or 45° mastic asphalt seals
- Carborundum grain topping for slip resistance
- Natural, coloured, or exposed aggregate finish to blend with surrounding paving
5. BRE Certification & Handover
Every panel is load-tested and issued a BRE certificate for fire, thermal, and structural compliance.
Walkable in 24–48 hours. Certified for life.
Weather-Smart Scheduling: When to Cast
Concrete cures best in spring and summer (3°C and rising, dry conditions).
In winter, we use:
- Insulated tarpaulins
- Hessian blankets
- Low-heat curing systems
Pro Tip: Book early – winter leak repairs spike demand.
Leak Prevention Built In
In-situ panels eliminate joint failures – the #1 cause of basement flooding.
For existing leaks, we offer:
- Emergency resealing with torch-applied bitumen
- Full waterproof membrane upgrades
Stop leaks before they start → Resealing & Waterproofing
Accreditations That Protect You
- BRE Certified – Fire, load, and thermal performance
- NRSWA Accredited – Full street works compliance
- Licensed Waste Carriers – Environment Agency approved
- Council Licence Support – We handle hoarding permits
Need a pavement light licence? → Start here
Iconic Projects, Flawless Results
- Selfridges, Oxford Street – Full vault light replacement over live retail
- Royal Court Theatre – Sloped in-situ panels with damp-proofing
- Levi’s Flagship, Regent Street – 93mm lens integration
- Stella McCartney, Old Bond Street – Discreet heritage restoration
- Peter Pan Estate, W14 – Structural reinforcement + lens renewal
Frequently Asked Questions
Can you cast over a live basement?
Yes – with full propping and zero disruption to occupants.
How long before it’s walkable?
24–48 hours with standard curing; accelerated options available.
Do you match original lens patterns?
Yes – using original moulds for 100mm, 117mm, and heritage sizes.
What’s the maximum span?
Up to 4.4 metres with distributed loads to 20 kN/m².
Start Your In-Situ Project Today
From survey to certification, we manage every detail.
The Pavement Light Company Ltd
46 Westside, Dogget Street, Leighton Buzzard, LU7 1BE
📞 [01525 377513 – In-Situ Specialist Line]
📧 Request a free site survey
🕒 Open: Mon–Fri 9am–5pm | Sat by appointment
Built on site. Built to last. Built for London.
Explore Related Services:
Cast In-Situ Pavement Lights →
Heritage Glass Lens Replacement →
Emergency Resealing Services →
Victorian Cast Iron Restoration →
Pavement Light Licensing Help →
Full Service Overview →
What Are Pavement Lights? →
The Pavement Light Company Ltd – In-situ excellence. Heritage precision. London trusted.
Company No: 10749794 | Copyright © 2017–2025
