A52 Holme House to RSPCA, Nottinghamshire
Client: Highways Agency / AmScott (MAC7)
Value: £1.2 million
Duration: 9 weeks
Completion: December 2007
A ProjectBrief included a requirement to remove
bound material containing tar. Tarmac suggested this
be processed into cold lay FoamMaster and enabled the
client to save over £125,000 in disposal costs..
Tarmac was required to re-surface 400m of both carriageways of the dual A52 in Gamston. The scheme
design had identified a 180mm layer of tarbound material that would cost £110 per tonne to safely dispose of.
Based on advice given by Tarmac's in-house technical team, it was agreed to excavate, recycle and re-use
the material as a lower layer FoamMaster base..
Tarmac have been assisting with MAC 7 scheme designs 2002
Tarmac has been undertaking over 50 schemes per annum on behalf of AmScott, the Highways Agency's
MAC Operator, since their initial award of the contract in July 2002. At an early stage of each Works Order
we are involved in the scheme design and responsible for procuring the requisite supply chain to ensure
a best value package is agreed.
Comment:
"Using FoamMaster means fewer lorry movements,
so the job is completed quicker, with less disruption
to local residents and motorists. It also saves material
ending up in landfill sites, saving money and helping the environment."
Andy Butler Schemes Manager, AmScott
As a specialist supply chain partner, Tarmac supply and lay
all surfacing work up to a value of £500,000, with schemes
ranging from footpath surfacing to bridge deck
re-waterproofing and night time remedial works on the
M1 motorway. Other in-house capabilities that are regularly
used include cold milling (NRP) safety fencing and electrical
works. Tarmac's contract is worth £4m per annum and is
due for completion in June 2009.
Such is AmScott's confidence in Tarmac's abilities that this
particular scheme involved three separate Works Orders
issued in tandem, with initial discussions having being held
some eight weeks prior to start of the scheme.
5,000 miles of transport movements and 100 tonnes of CO2 emissions were saved
by using FoamMaster
NRP removed 5,820 tonnes of the existing carriageway surfacing by cold milling to a depth of 380mm with all arisings taken to Hoveringham Quarry, less than 18km from site.
Arisings from the lower 180 mm comprised tarbound material
(1,160 tonnes) that were stored separately from the other
planings on an impervious (concrete) surface and kept sheeted.
100% of the tarbound arisings were crushed, screened and graded prior to mixing and processing into FoamMaster. By adding in a percentage of the other planings a total of
2,316 tonnes of FoamMaster, at a depth of 280mm, was relaid in three equal layers.
FoamMaster
Tarmac's cold lay FoamMaster product is essentially 88% highway arisings, 7% pulverised fuel ash,
2% cement and 3% bitumen, with an addition of water to meet the optimum water content target.
This system's primary advantages over conventional surfacing techniques are that it is an energy efficient
manufacturing process that reduces site transport movements and conserves local aggregate resources.
Strict testing regime ensured a Quality Product
As part of Tarmac's quality assurance, the recycled mix was tested
to ensure it met the performance requirement for stiffness and
standards specified in TRL 611, 2004, which provides a guide
to the use and specification of cold lay recycled materials.
Comment:
"Excellent site staff with excellent backup from commercial team. Good use of quality supply chain"
Richard Acklam Project Manager, AmScott
Successful recent experience of tarbound materials was a factor in promoting the scheme
70,000 tonnes of carriageway arisings were recycled into
FoamMaster during the A38 Peartree to Drybridge renewal scheme in Devon, which Tarmac completed in March 2006
on behalf of the Highways Agency (HA). This included
5,816 tonnes of Tarbound material that was discovered after works had started. Having gained both Environment Agency and HA approval the material was planed out
and then incorporated and encapsulated back into the
permanent works (in the same 2km stretch from which
it was removed), thus saving approx. £400,000 of
tipping costs at Swindon, the nearest licenced tip,
over 140 miles away.
Tarbound carriageway planings have also been incorporated
into FoamMaster on the A38 Trerulefoot in Cornwall
(6,882 tonnes, Jan/Feb 2007) and on side roads during the
widening of the M1, Junction 6A to 10 (560 tonnes, Oct. 2007).
In both instances this option was chosen to prevent the materials
going to landfill.
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