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Project Summary
Lean Project Name
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Unique ID
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Lean Project Description
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Lean Project Summary
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Kier’s A585 project required cropping 336 piles to meet tight tolerances for movement joint installation. To avoid programme delays and meet strict design criteria, the team trialled methods to ensure correct orientation, position, and verticality. Real-time data from surveys and daily records were shared via Power BI, supporting collaborative decision-making. Limited site space meant phased working instead of using two piling rigs. The trial identified rotational tolerance issues with the guide frame, enabling method and safety improvements before permanent works. Successes included quick frame set-up and a workable concrete mix design. Ongoing monitoring and collaborative planning reduced risks and disruption, delivering efficient outcomes and insights to benefit future projects. This practice has been shared and encouraged throughout the company.
Lean Project Benefits Summary
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The trial of the movement joint piles on Kier’s A585 project delivered significant benefits. By proactively identifying and resolving quality issues before the main works, the team avoided costly errors, resulting in £123,400 saved by preventing movement joint problems and potential pile rejections. The trial also ensured piles met strict tolerances, minimised risk, and upheld programme timelines by reducing delays. Brextor has removed 182 person-days of HAVS (Hand-Arm Vibration Syndrome) from the scheme by eliminating breaking activities, meeting the requirements of National Highways Raising the Bar 24 to use mechanical means. Real-time data monitoring and collaborative planning further improved efficiency and supported informed, rapid decision-making. Overall, this approach enhanced quality, reduced disruption for stakeholders, and fostered continuous improvement and knowledge sharing across future projects
Roads Period Efficiency Reported
RP1 2015-2020
RP2 2020-2025
RP3 2025-2030
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Efficiency Value Assured
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Efficiency Register ID
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Lean Construction Development Programme (LCDP) Project
Lean Construction Development Programme (LCDP) Project
No
Lean Construction Development Programme (LCDP) Project
Yes
Supplier
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Contact Email
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Stakeholders involved in project
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Stakeholders Involved - Other
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Problem Solving Strategy (DMAICT)
Define
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The A585 Windy Harbour project has 336 piles, all of which must be cropped once the specified concrete strength has been achieved. Due to the requirements set by the designer—such as the stringent tolerances for the orientation, position, and verticality of the movement joint embedded within the concrete pile—it was imperative that the team explored methods to ensure these tolerances could be met with the proposed approach. If the piles failed to meet the criteria, this could lead to substantial delays, impacting subsequent project activities. Key factors included monitoring each pile’s profile and data to ensure compliance with the specifications, as well as confirming the required concrete strength prior to cropping the piles. Effective management of these elements was essential to maintain the project’s programme and meet design requirements.
Measure
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Traditional methods such as surveys, paper drawings, forms, and diaries are used to gather information about the permanent works and constructed elements. Engineers compile this data and discuss it in Piling Progress Meetings, which inform decisions regarding progress targets, forthcoming activities, and opportunities. Specific metric methods include daily piling records, which are entered into Power BI to visualise trends. These records provide detailed insights into the progress and compliance of each pile, enabling the team to monitor and ensure that all piles meet the design specifications and project programme effectively.
Analyse
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Lean methodologies such as Value Stream Mapping (VSM) helped identify inefficiencies in the process, highlighting areas where delays and constraints were occurring. The movement joint pile design was bespoke and had never been installed by Kier or our piling contractors, which led to uncertainty. Without a trial, installing a movement joint out of tolerance could jeopardise the design. Although the use of two piling rigs was proposed to increase production, this was considered unsuitable due to restricted space and safety concerns. The work programme required the phased removal of existing roads and utilities, which further limited available space. Additionally, the secant wall was not constructed in a straight line due to delays in installing the movement joints, further constraining space.
Improve
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Due to the tight tolerances required for the movement joint embedded within the concrete pile, a trial was essential to ensure the constructability of the A585 design and to identify potential risks. The guide frame allowed for more rotation and movement than anticipated, making it challenging to achieve the rotational tolerances set by the client’s designers. The trial proved beneficial for health and safety, allowing amendments to the method statement and risk assessment prior to installing the actual movement joints. Following the trial, operatives discussed their insights, and adjustments were made based on their feedback.
Control
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The trial successfully identified issues such as insufficient resistance from the depth and frame to keep the movement joint in position, allowing mitigation measures to be implemented prior to the main works. Positive outcomes included the cage vibrator driving the joint without refusal, quick and accurate frame set-up, and a concrete mix design that remained workable for three hours. Daily production is monitored and recorded, with collaborative planning to avoid clashes with other disciplines within the central reserve work area. Data collected is input into Power BI to display trends and inform decision-making.
Transfer
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Get Involved in Trials – This was the first use of the Trial Movement Joint Pile on this type of project. The requirement for the trial pile was to ensure the buildability of the permanent works design, as the design detail is specific to the A585 and there are potential areas of risk that must be identified before progressing to the permanent works structure. The trial was successful in highlighting issues ahead of the main works, enabling mitigation measures to be implemented to prevent future problems. This practice has been shared and encouraged throughout the company.
What Lean Tools & Methodologies were used for your Lean Project?
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Other Project Benefits
Meeting the needs of all users
Meeting the needs of all users - Other
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Improving safety, health & wellbeing for all
Improving safety, health & wellbeing for all-Other
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Delivering better environmental outcomes
Delivering better environmental outcomes - Other
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Sustain a well-maintained and resilient network
Sustain well-maintained & resilient network- Other
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Providing fast and reliable journeys
Providing fast and reliable journeys - Other
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Achieve efficient delivery
Achieve efficient delivery - Other
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Project Detail
National Highways Directorates involved in project
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Division
Scheme Name
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Scheme PIN
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Was a Departure Required?
Was a Departure Required?
No
Was a Departure Required?
Yes
DAS Reference
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