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Project Summary

Lean Project Name

Unique ID

Lean Project Description

Lean Project Summary

Specify warm mix asphalt rather than hot mix asphalt.

Lean Project Benefits Summary

Carbon savings: 2,653.41 TCO2e
Cost savings: £805,249

Roads Period Efficiency Reported

Efficiency Value Assured

Efficiency Register ID

Image

Lean Construction Development Programme (LCDP) Project

NoYes

Supplier

Contact Email

Stakeholders involved in project

Stakeholders Involved - Other

Problem Solving Strategy (DMAICT)

Define

The M54-M6 link is approx 2.5km of new dual carriageway which includes 12 slip Roads and 4 roundabouts.
Asphalt layers have high embodied carbon and carbon emissions during pavement production/ installation are damaging the environment, our global carbon footprint and our sustainable commitments. The scale of the problem could stop the project.
The design specification can influence the choice of materials and therein the amount of embodied carbon.
Review of the pavement design on M54-M6 link to look for reductions in carbon whilst considering cost.

Measure

The team created a current state spreadsheet to collate data on depths of pavement, area, volume and tonnage. Costs for each operation were also captured and carbon figures calculated for each layer. This created a baseline for the project.

Analyse

A SIPOC chart was used to understand the customers in the design of pavement process. The baseline data was used to analyse which elements of the pavement build up generated the highest levels of carbon. The base course was identified as a key area for improvement due to its high carbon content. The hot mix asphalt also had a high carbon rate due to the energy involved to reach 170 degrees Celsius

Improve

Negative brainstorming was used to generate ideas for improvement. The ideas were then transferred to an ease benefit matrix to identify some easy to implement options. A cause and effect diagram was also used to visualise the problem. Improvements made were: 
Specify warm mix asphalt rather than hot mix asphalt.
Specify the use of EME2 on both binder and base course layers allowed for stronger layers but with less overall tonnage and associated carbon.
Use of recycled aggregates and actual data from Tarmac’s local plant allowed for more accurate assessment of carbon

Control

A series of one to one sessions with Aecom and Tarmac were set up to check the values on the current and future state spreadsheets. These two spreadsheets were then presented to BAM's commercial representative to sense check and validate.

Transfer

An A3 report was produced. A powerpoint presentation was also prepared and used to share the lean project with other BAM sites. Benefits realised were:
Carbon savings: 2,653.41 TCO2e
Cost savings: £805,249
As part of Lean Construction Development Programme (LCDP) efficiencies under National Highways Efficiency Register ID 1075
Other benefits: Faster curing time for warm mix asphalt, reduced material movement, reduced people plant interface and promoting use of recycled aggregates

What Lean Tools & Methodologies were used for your Lean Project?

If Other, please specify

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

Division

Scheme Name

Scheme PIN

Was a Departure Required?

NoYes

DAS Reference

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