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Project Summary

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Lean Project Description

Lean Project Summary

Kier’s A417 team reviewed traditional temporary haul road construction methods used during enabling works and identified opportunities to reduce time, carbon emissions and material use. Working with Soil Science Limited, a reversible soil stabilisation approach was adopted, allowing existing site materials to be treated in situ to form stable haul road surfaces. This removed the need for large volumes of imported aggregate and asphalt while maintaining performance requirements. The solution supported programme delivery, reduced environmental impact and improved construction efficiency across multiple haul road locations.

Lean Project Benefits Summary

The revised haul road construction approach delivered clear programme, carbon, cost and efficiency benefits for the A417 project. Construction time was reduced by 81%, enabling faster delivery of enabling works and reducing programme risk. Greenhouse gas emissions reduced by 39% due to lower transport requirements and reduced waste generation. Vehicle movements to site reduced by 81%, equating to approximately 838 fewer movements, improving safety and reducing disruption. Imported aggregate demand reduced by 78% (approximately 15,091 tonnes), while installation costs reduced by 28%, delivering measurable efficiency and cost savings.

Roads Period Efficiency Reported

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Lean Construction Development Programme (LCDP) Project

NoYes

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Stakeholders Involved - Other

Problem Solving Strategy (DMAICT)

Define

The A417 project required extensive temporary haul roads to support enabling works. Traditional construction methods relied on large volumes of imported aggregate and asphalt, leading to high construction time, carbon emissions, vehicle movements and material waste. There was a risk that this approach would increase programme duration, cost, and environmental impact, particularly within the sensitive Cotswolds landscape. The project needed a compliant, lower-impact haul road solution that maintained performance while reducing time, carbon and material use.

Measure

Baseline performance was established using traditional haul road construction assumptions, including quantities of imported aggregate, vehicle movements, construction duration and associated carbon emissions. Programme durations, material volumes and transport movements were reviewed to understand the scale of time, cost and carbon impact. These baselines were used to compare alternative construction approaches and quantify potential reductions in construction time, imported materials, vehicle movements and greenhouse gas emissions.

Analyse

The team reviewed haul road construction requirements, ground conditions and programme constraints to understand the drivers of time, carbon and material impacts. Production control principles were applied to assess planned versus actual construction activities, sequencing, and resource demand across the enabling works programme. Collaborative planning workshops involving construction, environmental and supply chain stakeholders were used to review options, challenge assumptions and assess constraints. This analysis identified that traditional imported aggregate solutions created unnecessary transport, waste and programme inefficiency.

Improve

A reversible soil stabilisation solution was implemented in collaboration with Soil Science Limited. Existing site materials were treated in situ to form stable haul road surfaces, significantly reducing the need for imported aggregate and asphalt. The approach reduced construction time, vehicle movements and carbon emissions while maintaining required performance. The approach was successfully applied across multiple haul road locations, supporting programme delivery and reducing environmental impact.

Control

Controls were established through agreed construction methods, quality assurance testing and environmental management measures. Haul road performance and material behaviour were monitored throughout use to ensure compliance with specification and safety requirements. Environmental constraints and approvals were embedded into delivery, ensuring works remained compliant throughout the enabling phase.

Transfer

The project demonstrates that reversible soil stabilisation can provide a reliable, lower-impact alternative to traditional haul road construction on large infrastructure schemes. The approach can be transferred to future projects where temporary access roads are required, enabling reductions in construction time, carbon emissions, vehicle movements and material consumption while maintaining performance and compliance.

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Other Project Benefits

Meeting the needs of all users

Meeting the needs of all users - Other

Improving safety, health & wellbeing for all

Improving safety, health & wellbeing for all-Other

Delivering better environmental outcomes

Delivering better environmental outcomes - Other

Sustain a well-maintained and resilient network

Sustain well-maintained & resilient network- Other

Providing fast and reliable journeys

Providing fast and reliable journeys - Other

Achieve efficient delivery

Achieve efficient delivery - Other

Project Detail

National Highways Directorates involved in project

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