Ironwork in Highways -Whole Life Cost Perspective. Reducing cost through collaboration

Transcription

1 Ironwork in Highways -Whole Life Cost Perspective Reducing cost through collaboration

2 About Instarmac... Instarmac The Company Quality Systems ISO 9001 Environmental Systems ISO Preferred Supplier Registered Supplier Market Leader

3 About Saint Gobain... The global brand of the pipelines division

4 A changing environment As traffic speed and intensity increases the solutions and methods used to install and maintain street ironwork needs to evolve in order to provide a resilient and reliable network Typically c. 200m is spent on replacing or reinstating ironwork each year

5 What do you say about Street Ironwork? need to provide reliable & resilient systems minimum failure frequency under routine conditions long term assets need to be right first time Increasing failure frequency & costs avoid disruption and the costs arising from it good specifications & solutions if not policed, improved or enforced are wasted

6 The cost of failed repairs

7 The causes of Ironwork Failure Failure of Bedding and Jointing Mortar Sunken Cover and Frame Contributing Factors: Poor workmanship Incorrect product selection Support system failure Bedding Mortar Failure Quick fix solutions Where is the bedding mortar?

8 How can failure be avoided? Each element is part of a system that combines; Quality & design of the casting Use of high performance bedding materials Stable and robust substructure Robust & definitive specifications Reinstatement to recognised standards

9 What does the industry need? Consistent and Robust Specifications Annual maintenance bill SROH Code of Practice 3 rd Edition Apr 2010

10 Ironwork Selection Select application specific solutions, Where possible select high performance solutions for problem installations Preference should be given to those products that include features that aid stability and durability Frame, seating profiles, low frame bearing pressure, large footprint Add on any client/operator specific requirements H&S, Security, Frequent Inspection, Absorption

11 Collaboration Supply Chain Stakeholder engagement Specification

12 Total Cost of Installation and the reduction of premature failures Openreach instigated stakeholder survey of a 1000 installations which determined a 10% failure/re-work rate Issues identified as mainly reinstatement & installation defects Estimated annual to cost BT of c. 1m Brownhills, near Walsall

13 Openreach undertook a full review of installation process The study concluded that a full review of the installation specification and methodology was required including; Openreach client documentation, specifications, method statements, assessment criteria of chamber condition, preparation, materials, installation protocol etc. Supply Chain Collaborative Working Group

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15 Envirobed Flowable Developed in partnership with BT Can be used in wet weather Accommodates variable depths in a single pour Ensures intimate contact and maximum bond with frame Contains recycled glass Can be used at temperatures as low as 1 C Environmentally friendly: no requirement for hazardous waste disposal or pungent fumes Conforms to the Department of Transport Design for Roads & Bridges: Mortars for Bedding Ironwork, HA104/09 Early tensile strengths provide significant resistance to heavy trafficking

16 Full Systems Materials That Form A System Will Reduce Split Liability Give Compatibility and Longevity

17 Full Systems (PCSM) Permanent Cold Lay Surface Macadam Rapid Set Bedding Mortar Cover Frame Rapid Set Backfill Concrete Class B Engineering Bricks

18 Bedding Mortar Selection Polyester Resin System Cement Based System

19 Polyester Resin Mortar Compressive strength 85N/mm 2 Tensile strength 9.91N/mm 2 (at 20 0 C after 28 days) Workability 5 10 minutes Set time 15 minutes HA104/02 Compliant Can be applied at 0 0 C Open to traffic within 45 minutes Ideal for use with Composite Materials Recommended applications are for installing ductile ironwork, kerbs, street furniture in heavily trafficked areas available as a stiff consistent mortar and a flowable grout

20 Cementitious Bedding Mortar Bag & Bottle System 50N/mm² Compressive Strength In 3 Hours 5.8N/mm² Tensile Strength In 3 Hours 9.8N/mm² Flexural Strength In 3 Hours Workability 15 Minutes Set Time 30 Minutes

21 Rapid Strength Concrete Compressive strength 50N/mm 2 Workability 5 10 minutes Setting time 15 minutes Shrinkage compensated Versatile No independent curing required Backfilling concrete for installation of ironwork Post & barrier erection Recommended applications are for backfilling ironwork surrounds, and also barrier and sign erection

22 Vertically Seal Spray Cold Joint Sealant Ozone friendly Prevents water ingress instantly Clean and efficient use Simple and economical to apply Recommended applications are for applying to reinstatements to prevent water ingress

23 Surfacing & Compaction PCSM for permanent repairs, 10mm & 6mm grades for footways, cycle tracks and class 3 & 4 carriageways Compact in accordance with Appendix 8, specification for the Reinstatement of Openings in Highways 1992 Open to traffic instantly

24 SUPPORT & TRAINING Material Awareness Days Tailored Workshops Site Support & Best Practice Training Specification Input & Product Selection

25 Whole Life Benefits of a System Based Solution Using a BBA/HAPAS Ironwork Reinstatement System Will: 5 Year Service Life Independent Assessment Providing Confidence in the System Full System No split Liability Using a High Performance Casting... Extend the life of the installation Offers consistent safe performance for longer Avoids premature failure and the cost of repeat reinstatement Reduce whole life costs

26 Helping Achieve This Avoiding This