1. Manchester Smart Motorways The Traffic Management Switch David Procter, Project Manager, Carillion Civil Engineering

2. The Problem
‘‘…our plans to make your jour­neys more reli­able… includes adding more than 240 miles (480 lane miles) of extra capac­ity through smart motorways.’’ Highways England

3. Contents Manchester Smart Motorways The traffic switch project
The benefits delivered
Our lean journey

4. Manchester Smart Motorways

5. Manchester Smart Motorways
£295m Smart Motorway M60 J8 to M62 J20.
26km long, 12 complex junctions, 3 interchanges.
4 way Joint Venture with 5 delivery partners.
20km of central reservation reconstruction.
Daily preliminary costs >£70,000 per day.
600 strong workforce across day and night shifts.
Estimated benefit to the economy on completion up to £1.5m per week.

6. Manchester Smart Motorways Verge Phase

7. Manchester Smart Motorways Verge Phase

8. Manchester Smart Motorways Verge Phase

9. Manchester Smart Motorways Centre Phase

10. Manchester Smart Motorways Centre Phase

11. The Traffic Switch Aim and deliverables
To safely realign traffic from Lane 1, 2 & 3, to the H/S, Lane 1 & 2.
To create a work area for the central reserve works to commence.
16km of temporary barrier to be moved
48km of traffic lining to be removed and reinstalled

12. Verge Phase – the hard shoulder is closed off
Verge Work Area
Central Reserve Phase – Traffic runs in the Hard Shoulder
New road marking
New barrier position
Centre Work Area

13. Verge layout
Centre layout

14. Capturing and sharing our progress

15. The Original Plan (how it has always been done)
Remove all temporary barrier
10 nights
Switch narrow lanes
4 nights
Re-install temporary barrier
10 nights
24 nights overall programme !

16. It can’t be done! ‘‘It’s not safe’’. ‘‘There’s not enough time’’.
‘‘We’ve always done it this way’’
‘‘They won’t do that’’.
‘‘This wouldn’t work’’

17. The Lean Method
to close motorway (Agreed closure times 22:00hrs – 06:00hrs)
to laterally move temporary barrier to offside to allow lining works
to switch road marking detail from current phase to new phase
to move temporary barrier to new position
to remove TM and open motorway on completion of switch
Critical aspect of this process is moving the barrier from nearside to offside on the same night, thus removing the need to take barrier of site whilst still allowing time for lining to be switched.
Install temp
TM & Close C’way
Switch
barrier
Switch lining
Install perm TM
where needed
Remove temp TM &
re-open c’way

18. Actual Progress 14 nights overall programme!!!
Night 1 - Switch Barrier & Lining 2.5km J19 to J20
Night 2 - Switch Barrier & Lining 2.5km J19 to J20
Night 3 - Switch Barrier & Lining 2.5km J20 to J19
Night 4 - Switch Barrier & Lining 2.5km J20 to J19
Night 5 - Switch Barrier & Lining 2.5km J19 to J18
Night 6 - Switch Barrier & Lining 2.5km J19 to J18
Night 7 - Switch Barrier & Lining 2.5km J19 to J18
Night 8 - Switch Barrier & Lining 2.5km J19 to J18
Night 9 - Switch Barrier & Lining 2.5km J18 to J19
Night 10 – Prep 2.5km J18 to J19
Night 11 Prep 2.5km J18 to J19
Night 12 - Switch Barrier & Lining 2.5km J18 to J19
Night 13 - Switch Barrier & Lining 2.5km J18 to J19
Night 14 - Switch Barrier & Lining 2.5km J18 to J19
14 nights overall programme!!!

19. The Switch - Achievements
>5000 incident free hours worked.
>1000 hiab lifts eliminated.
>50,000 HGV miles eliminated.
10 less TM closures to put people at risk and disrupt the road user.
Over £200,000 savings by starting critical path works earlier.

20. The Switch – Sharing our learnings

21. Our Lean Journey on Manchester Smart Motorways
Part 2
Our Lean Journey on Manchester Smart Motorways

22. Our MSM Lean Journey Investment in people. Collaborative planning.
Spending to save £££.
Embedding a culture.
Identifying opportunities.
Starting our projects early.

23. Our MSM Lean Journey
Sharing our learnings across the scheme and client knowledge banks through Knowledge Transfer Packs

24. Our MSM Lean Journey
Scale Models - do things differently

25. Our Lean Journey – visibility and emphasis

26. Our Lean Journey – Planned Vs Actual

27. Our Lean Journey
Early Contractor Involvement (Suppliers, Design and Client) – Investing £ early

28. Our Lean Journey – Opportunity and Risk
TM switch
Switch TM across carriageway rather than remove
Site clearance - safety barrier
saw cutting around gullies (machine removed gullies before the rockwheel arrived)
Shears to remove the barrier
Manhole mods
Cored the rings, layout of the site - quick decision on going all the way down to the benching
Split shifting i.e. working grabs longer
Logistics
bringing material into the yard on Saturdays
Filter drain -
improved output by removing the idea of shuttering and built up in layers
Kilstra
pre-cast manholes
Box cut and excavation
Sub-base and capping
using improved machines e.g.
reducing dig depths & wet use of wet lean (knuckle boom and hydraulic tilt bucket)
targeting weekends when weather is good
Concrete deliveries
used volumetrics
Pavement
basically patching work - where the pavers worked very closely behind other trades

29. Quality Management – Prevention

30. Our Lean Journey
Joint lean studies with the supply chain

31. Conclusion Early investment across different disciplines.
Challenge the status quo.
Task the enthusiastic and committed.
Bring key people together early.
Celebrate and share your success.

32. Thank you
David Procter, Carillion, October 2017