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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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Steps eliminated cleaning down, transportation and storage of formwork post pour
Lean Project Benefits Summary
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Improved productivity: 38% improvement in time and saving £25,740
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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As part of the lessons learned from the M40/M42 Interchange, construction of the foundations for the bifurcations for the central reserve concrete barrier were identified as an area for improvement. The DHS M42 J4-7 scheme had a similar work scope and the team was keen to address the previous bottlenecks in production. The bmJV team worked with CR Civil Engineering to look for improvement opportunities.
Measure
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The traditional method of in situ concrete foundation construction is to use temporary steel road forms. These are secured by driving steel pins into the formation. If the formation is hard such as existing concrete then holes must be pre-drilled. CR Civil Engineering gathered data from the previous M40/M42 scheme in 2023 which used the steel road form methodology. Timesheets were collected for a similar sized concrete pour on DHS M42 J4-7.
Analyse
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The use of 3m long steel Road forms is a standardised approach to creating concrete foundations and the system is very durable with interchangeable parts. The formwork height is fixed and so level control is achieved by either reducing formation level or by use of shims to pack up. If the formation is hard then an additional step of pre-drilling is required which is time consuming and requires permit to break ground and Hand Arm Vibration Syndrome (HAVS) controls. The steel road forms are limited to bay lengths and use a hit and miss pour methodology so that expansion joints can be formed.
Improve
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CR Civil Engineering introduced use of permanent formwork eliminating the support activities of drilling, striking, cleaning and transport off site. Simple to cut to length on-site, it features pre-drilled holes for positioning dowel bars in the vertical section if required. With four pairs of twin holes in the base section for anchoring to the ground on mortar beds, this screed rail is for poured concrete with a thickness of 150mm to 225mm. The product was used for the formation of concrete foundations in the bifurcation areas totalling 1100 linear metres.
Control
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The system was first trialled at the bifurcations at Chainage 14340-14395 and then quickly confidence in the benefits of the system grew and it was repeated in 7 other key areas plus multiple infills. It was ideal for tying into existing areas as the permanent formwork could be cut to length easily whereas Road forms are a fixed 3m length so require an alternative make up piece.
Transfer
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The works were just off the critical path but a time improvement of 38% helped de-risk the activity. No pins required, no drilling and thus Hand Arm Vibration Syndrome (HAVS) HAVS risk reduced & reduction in manual handling. Easy to cut to size and set to level with good finish. Separate wear strip can be removed once concrete is set to enable joint sealing. uPVC profile with built-in expansion joint. Allows adjoining bays to be poured consecutively. No cleaning down, transportation and storage of formwork post pour. The Digital Efficiency reference is 6437.
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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