NAL origin series:
The story behind solving your controller cabinet installation challenges
Listening to the problems our customers face in the field is a critical part of the NAL product development process. Time and again, direct feedback from engineers, designers, and installers has helped us improve and evolve our infrastructure solutions.
One of the clearest examples of this approach is the development of the NAL controller cabinet base.
You can trace this product back to when the NAL Retention Socket transformed the traffic signal sector. While maintenance teams reaped the benefits of pole removal post-knockdown, it became clear that other pain points remained when replacing cables.
These discussions led to the development of our controller cabinet base, and now, over a decade later, it is an integral part of the NAL portfolio and a key component of a fully ducted system.
Here’s the origin story of a product born from industry challenges, and shaped entirely by your real-world input.
Identifying the problem
Back in 2009, clients raised concerns about the traditional controller cabinet installation method. The repeated use of a carcinogenic base seal not only posed health risks, but also created practical issues in the field:
- Difficult and messy to install and remove
- Risk of gas build-up and condensation
- Vermin and slug ingress
- Complications during re-cabling or maintenance
- BT access delays requiring signal engineer presence
This feedback gave us a clear mandate: eliminate the base seal and resolve the wider ecosystem of related issues.
Rethinking cabinet base installation: safer, smarter, simpler
After 18 months of R&D, NAL launched a completely reimagined cabinet base. Key innovations included:
- A pre-drilled gland tray to eliminate the need for carcinogenic base sealant
- Air vents to prevent gas build-up and condensation
- Sealing grommets for unused cable entries
- Compatibility with ducted systems to improve future cabling
Initial trials were met with enthusiasm from maintenance teams, who saw reduced time on-site. Armed with these reactions, as well as constructive feedback from installers, we had everything we needed to progress and refine.
Responding to real-world needs: the development timeline
-
2011 – Temporary controller cabinet base
Enabled surface-mounted installation during temporary works.
-
2012 – Enhanced gland tray
Deeper tray and wider holes to accommodate 20-core armoured cables.
-
2014 – Low-level cabinet base
Developed for The Mall, London, after TfL flagged visibility concerns near Buckingham Palace.
-
2015 – BT access door
A segregated access point gave BT engineers independent access, removing the need for coordination with traffic signal teams.
-
2015 – Multi cabinet base
Created to house multiple UPS cabinets with a reduced footprint and ducting, specified by Slough Borough Council.
Field insight as the foundation of progress
Field feedback is the catalyst for better, safer, and more efficient infrastructure. The NAL controller cabinet base is now used not only across the traffic signals industry but also in motorway comms, where installation time has dropped from 16 hours to just 4.5.
By listening to engineers, designers, and maintenance teams, NAL has turned everyday challenges into sector-wide solutions. We’ll continue to do so. Ultimately, smarter infrastructure starts with the people who build and maintain it.
Contact us to specify the NAL controller cabinet base for your next project – or to share your project pain points. We might just be able to help.