On Line Widening of the N7 Naas RoadOn Line Widening of the N7 Naas RoadIntegrating Design and ConstructionIntegrating Design and Construction

PresentationPresentation

By By

Jim ThorpeJim Thorpe BS Di l E CE MIEI MICEBS Di l E CE MIEI MICEJim ThorpeJim Thorpe BSc, Dipl Eng, CEng, MIEI, MICEBSc, Dipl Eng, CEng, MIEI, MICE

Project ManagerProject Manager

Roughan & O’Donovan Roughan & O’Donovan –– Faber Maunsell AllianceFaber Maunsell Alliance

Contractor’s Designer forContractor’s Designer for

ClonmelClonmel --Laing O’Rourke JVLaing O’Rourke JV

On Line Widening of the N7 Naas RoadOn Line Widening of the N7 Naas RoadIntegrating Design and ConstructionIntegrating Design and Construction

•• Scheme Description and BackgroundScheme Description and Background

•• Tender Design PrioritiesTender Design Priorities

•• Integrated ProgrammingIntegrated Programming

•• Integrating Pavement and AlignmentIntegrating Pavement and Alignment

•• Integrating Structures into Construction PlanningIntegrating Structures into Construction Planning

•• DiscussionDiscussion

Scheme DescriptionScheme Description

•• 14km of N7 widened from dual 2 to dual 3 from 14km of N7 widened from dual 2 to dual 3 from R th l tR th l t M dliM dliRathcoole to Rathcoole to MaudlinsMaudlins

•• 4 new grade separated junctions, Johnstown,4 new grade separated junctions, Johnstown,Kill, Kill, CastlewardenCastlewarden and and SteelstownSteelstown

•• MaudlinsMaudlins and Rathcoole junctions upgradedand Rathcoole junctions upgradedMaudlinsMaudlins and Rathcoole junctions upgradedand Rathcoole junctions upgraded

•• 14km new side road and interchange links14km new side road and interchange links

•• 2 Footbridges, 12 Culverts, 17 Sign Gantries2 Footbridges, 12 Culverts, 17 Sign Gantries

•• New Streetscapes and Traffic Calming in Johnstown andNew Streetscapes and Traffic Calming in Johnstown and•• New Streetscapes and Traffic Calming in Johnstown and New Streetscapes and Traffic Calming in Johnstown and Kill villagesKill villages

Background Background Originally two separate schemes:Originally two separate schemes:

Kildare County CouncilKildare County CouncilKildare County CouncilKildare County Council

High quality dual with local access High quality dual with local access segregated on parallel local roadssegregated on parallel local roads

Statutory Approval 2002Statutory Approval 2002

South Dublin South Dublin -- HalcrowHalcrow BarryBarry

All purpose road with left in left out local road All purpose road with left in left out local road junctions and private accessesjunctions and private accesses

Statutory Approval 2003Statutory Approval 2003

KildareKildare

South Dublin South Dublin

Design and Build Contract Design and Build Contract Merged into single D+B scheme August 2003 with tenders Merged into single D+B scheme August 2003 with tenders submitted in April 2004submitted in April 2004pp

Scheme to maintain a flow of 62,000 vehicle per day Scheme to maintain a flow of 62,000 vehicle per day through the sitethrough the site

Lowest Comparative Tender won by CELOR taking Lowest Comparative Tender won by CELOR taking p y gp y gaccount of Site Occupation and Lane Rental chargesaccount of Site Occupation and Lane Rental charges

Maintain 2 lanes in each direction and minimise hard Maintain 2 lanes in each direction and minimise hard shoulder closuresshoulder closures

PrePre--tender Programme of 30 months reduced to 22 tender Programme of 30 months reduced to 22 months in CELOR tendermonths in CELOR tender

Tender Design Priorities Tender Design Priorities •• Maximise reMaximise re--use of existing pavement use of existing pavement

constructionconstruction

•• Minimise volume of materials to be transported Minimise volume of materials to be transported through congested sitethrough congested site

•• Minimise excavationMinimise excavation

•• Minimise utility diversionsMinimise utility diversions

•• Minimise culvert construction under mainlineMinimise culvert construction under mainline

•• Integrate traffic management phasing into alignment Integrate traffic management phasing into alignment

•• Optimise Construction ProgrammeOptimise Construction Programmedesigndesign

Tender Design Approach Tender Design Approach Realign horizontally to maximise reRealign horizontally to maximise re--use of pavementuse of pavement

MaudlinsMaudlins JunctionJunctionMaudlinsMaudlins JunctionJunction

Tender Design Approach Tender Design Approach Realign Vertically, initially to a nominal 200mm above Realign Vertically, initially to a nominal 200mm above existing pavementexisting pavementexisting pavementexisting pavement

Specimen DesignSpecimen DesignSpecimen DesignSpecimen Design

Tender DesignTender DesignTender DesignTender Design

Tender Design Approach Tender Design Approach Refine horizontal alignment to facilitate traffic Refine horizontal alignment to facilitate traffic

managementmanagementmanagementmanagement

Tender Design Approach Tender Design Approach Design Interchanges to permit temporary diversion of the Design Interchanges to permit temporary diversion of the N7 flowsN7 flows

•• Alignments through roundaboutsAlignments through roundabouts

•• Widths and pavements of link roadsWidths and pavements of link roads

Tender Design Approach Tender Design Approach ReRe--Design of Design of CastlewardenCastlewarden Interchange as Compact, with Interchange as Compact, with straight Bridgestraight Bridge

Programme Integration Programme Integration Design and Construction Process Mapping Design and Construction Process Mapping

Cross team understanding of roles and interfaces, Cross team understanding of roles and interfaces, EgEg::--

Precast culvert procurementPrecast culvert procurement

Requires early sizingRequires early sizingRequires early sizing Requires early sizing

Requires critical approvalsRequires critical approvals

Requires detailed topographic surveyRequires detailed topographic survey

Requires early traffic management andRequires early traffic management andRequires early traffic management and Requires early traffic management and procurementprocurement

Programme Integration Programme Integration

Process Programming Process Programming –– Ideal worldIdeal world

Integration of Design and Construction Integration of Design and Construction ProgrammesProgrammes

I t h l f TMI t h l f TM

g gg g

Interchanges early for TMInterchanges early for TM

Mainline priorities to match TMMainline priorities to match TM

Priority StructuresPriority Structures

P i i i f T SP i i i f T SPriorities for Topo SurveyPriorities for Topo Survey

Programme Integration Programme Integration

Revised Construction ProgrammeRevised Construction Programme

Trade Construction float ease Trade Construction float ease design peaksdesign peaks

Delay construction start untilDelay construction start untilDelay construction start until Delay construction start until design lead establisheddesign lead established

Thereby minimise site possession and Thereby minimise site possession and traffic disruption traffic disruption

Programme Integration Programme Integration

Resource Balancing Resource Balancing Resource loading by disciplineResource loading by discipline

Identify unrealistic peaksIdentify unrealistic peaks

Breakdown into smaller elements Breakdown into smaller elements

ReRe--programme to address more specific programme to address more specific prioritiespriorities

RR li tli t d t ffi it h t fd t ffi it h t fReRe--alignment alignment -- reduce traffic switches to free reduce traffic switches to free programme constraintprogramme constraint

Programme Integration Programme Integration Project FlowProject Flow

Weekly team meetings between Design and Weekly team meetings between Design and construction team leadersconstruction team leaders

Review progress and commit to the next week’s Review progress and commit to the next week’s programme programme -- at micro level of agreed process mapat micro level of agreed process map

Clear and immediate understanding of effects of delays Clear and immediate understanding of effects of delays -- full team buy in to overcoming these together full team buy in to overcoming these together

Similar procedures followed on site on a daily basis toSimilar procedures followed on site on a daily basis toSimilar procedures followed on site on a daily basis to Similar procedures followed on site on a daily basis to plan and manage constructionplan and manage construction

Programme Integration Programme Integration

Integrated Pavement and Alignment Integrated Pavement and Alignment Existing PavementsExisting Pavements

•• Kildare section fully flexibleKildare section fully flexible

•• South Dublin rigid concrete with thin bituminous South Dublin rigid concrete with thin bituminous overlayoverlay

•• Rathcoole Interchange recently upgraded by slabRathcoole Interchange recently upgraded by slabRathcoole Interchange recently upgraded by slab Rathcoole Interchange recently upgraded by slab stabilisation and major overlaystabilisation and major overlay

Construction RequirementsConstruction Requirements•• Concrete slabs to be removedConcrete slabs to be removed•• Concrete slabs to be removedConcrete slabs to be removed

•• RathcooleRathcoole -- replace wearing course replace wearing course

Integrated Pavement and Alignment Integrated Pavement and Alignment

•• Detailed Level SurveyDetailed Level SurveySurveysSurveys

yy

•• Full video condition surveyFull video condition survey

•• Full Radar SurveyFull Radar Survey

•• Calibration coresCalibration coresCalibration coresCalibration cores

•• Falling Weight Falling Weight DeflectometerDeflectometer

Initial DesignInitial DesignA l ti l d i f i i l i tA l ti l d i f i i l i t•• Analytical design of minimum overlay requirements Analytical design of minimum overlay requirements by chainage for each laneby chainage for each lane

Integrated Pavement and Alignment Integrated Pavement and Alignment Vertical Alignment OptimisationVertical Alignment Optimisation

Seek to match minimum pavement depthsSeek to match minimum pavement depthsSeek to match minimum pavement depthsSeek to match minimum pavement depths

Rationalise pavement types to suitRationalise pavement types to suit

RubblisingRubblising of Concrete Pavement of Concrete Pavement

•• Crack and Seat asCrack and Seat asCrack and Seat as Crack and Seat as subsub--base rejectedbase rejected

•• RubblisingRubblising with with controlled breakercontrolled breaker

•• Plate load tests to Plate load tests to prove foundationprove foundation

•• Saves removal Saves removal and cappingand capping

Integrating Structures into Construction Integrating Structures into Construction

CulvertsCulvertsCulvertsCulverts•• Detailed Condition SurveysDetailed Condition Surveys

•• Sophisticated analysis to maximise reSophisticated analysis to maximise re--use of use of existing structuresexisting structures

•• ReRe--alignment to keep square to traffic lanes alignment to keep square to traffic lanes to align to align joints with TM phasesjoints with TM phases

•• New culverts precast for speedNew culverts precast for speed

Integrating Structures into Construction Integrating Structures into Construction

FootbridgesFootbridges

•• Requirement for single spanRequirement for single span

•• One night closure for liftOne night closure for lift

•• Specimen and Tender designs in Steel Specimen and Tender designs in Steel

Additional gantries put pressure on steel fabricators Additional gantries put pressure on steel fabricators --Precast ConcretePrecast Concrete

Integrating Structures into Construction Integrating Structures into Construction

FootbridgesFootbridges

Longest beams to Longest beams to date at 43mdate at 43m

Heaviest Lift with Heaviest Lift with deck and parapetsdeck and parapets

Integrating Structures into Construction Integrating Structures into Construction OverbridgesOverbridges

•• Bank Seats on Spread FootingsBank Seats on Spread Footings

•• Special fill achieves 1:1.5 slopeSpecial fill achieves 1:1.5 slope

•• Standardise spans to suit Precast Beams Standardise spans to suit Precast Beams

Integrating Structures into Construction Integrating Structures into Construction OverbridgesOverbridges

•• Designed as lost Designed as lost diaphragms diaphragms

•• Beams supported on Beams supported on Temporary Trestles Temporary Trestles

Integrating Structures into Construction Integrating Structures into Construction OverbridgesOverbridgesTemporary WorksTemporary WorksTemporary Works Temporary Works Failure on M1 Failure on M1 DundalkDundalk

Introduced Introduced Landing shelfLanding shelf

Sound base Sound base within original within original design envelopedesign envelope

Landing shelf Landing shelf

Plus proppingPlus propping

On Line Widening of the N7 Naas RoadOn Line Widening of the N7 Naas RoadIntegrating Design and ConstructionIntegrating Design and Construction

SummarySummary

•• Aligned to minimise time and materials within TMAligned to minimise time and materials within TM•• Complex scheme with critical live trafficComplex scheme with critical live traffic

•• Integrated Programming to minimise on site timeIntegrated Programming to minimise on site timeIntegrated Programming to minimise on site time Integrated Programming to minimise on site time

•• Refined pavement and alignment designRefined pavement and alignment design•• Structures designed to integrate with construction Structures designed to integrate with construction

programme and Traffic Managementprogramme and Traffic Management

QUESTIONS?QUESTIONS?