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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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Sprayed concrete was proposed as an alternative to cladding to wing walls design
Lean Project Benefits Summary
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Carbon savings: 92.66 TCO2 Cost savings: £147,076 66 Days saving in programme, reduced work at height, reduced HAVS risk
Roads Period Efficiency Reported
RP1 2015-2020
RP2 2020-2025
RP3 2025-2030
N/A
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 M54-M6 Link scheme has 6 Retaining walls near the bridge structures at Jct 1. This project is focused on looking at an alternative to concrete cladding in front of the bored piles. The design for concrete cladding is primarily for aesthetic purposes rather than structural. Using concrete cladding increases construction risk, the amount of carbon emissions and time in the programme by at least 20%. The walls exposed are extremely high and do not easily lend themselves to the addition of concrete reinforced cladding, hence the drive to look for an alternative.
Measure
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The Retaining Walls at Jct 1 were identified as areas for improvement. Sessions were held with the Engineering Manager to understand the technical details for the concrete cladding wall to be constructed in front of the bored piles. The Retaining Walls were broken down further into Wing Walls as well as Retaining Walls. Quantities were taken from the 3D model and cross sectional detail drawings. A spreadsheet was set up to log dimensions, areas, volumes, tonnages, carbon rates and costs. This allowed an understanding of the current state concrete cladding wall proposal.
Analyse
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A workshop was held with the team to create a current state value stream map to identify waste in the process for WW1 (Wing Walls), RW (Retaining Walls) & WW2. We identified there were a lot of temporary works in the form of scaffolding access and formwork required to create the concrete cladding wall. The height of the wall dictated it be constructed in a number of lifts which introduces waiting time for concrete to cure and additional time for scaffold modifications. There is a requirement for permanent dowels and temporary formwork ties which requires a large number of holes to be drilled.
Improve
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The results of our data collection and analysis supported the proposed design improvement of using sprayed concrete as an alternative to the cladding reinforced concrete wall, which would have been constructed using formwork. This improvement project output will be used to submit a Departure from Standard when a new delivery partner is appointed for the construction of the project. The improvement is a reduction of a 750mm thick concrete wall to 200mm thick (the wall is not structural), removes the need for scaffolding, formwork, drilling and material quantities.
Control
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A series of one to one sessions with the Engineering Manager, Commercial Lead and Environmental Manager from BAM Nuttall to sense check the values on the current and future state spreadsheets, including Carbon savings. All data has been validated by the relevant SME's.
Transfer
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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: 92.66 TCO2 Cost savings: £147,076.84 Other benefits: 66 Days in the programme, reduced work at height and reduced risk to Hand Arm Vibration Syndrome (HAVS) This is due to a reduction in time exposed to the activity, smaller holes to be drilled and less scaffolding. As part of Lean Construction Development Programme (LCDP) efficiencies under National Highways Efficiency Register ID 1075
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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