WSH INNOVATION AWARD 2016€¦ · WSH INNOVATION AWARD 2016: LIAN SOON iDRAIN(THE DURABLE-REUSABLE...

LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)

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WSH INNOVATION AWARD 2016

Lian Soon Innovative Drain Project

“iDrain - The Durable-Reusable ECM Drain”

Presented by:

Lian Soon Construction Pte Ltd


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Lian Soon Construction iTeam

Steering Committee Executive Director KC Lee

Project Director Gary Tan

Facilitator HOD EHS Ariola Ruel Penaflor

Director Yuen Sik Weng*

Members Senior Project Manager Wong Chin Boom

WSH Officer T P Ramachandran

WSH Coordinator K. Balamurugan

Site Manager Tan Yong Keng

* Affiliated company (Greenleaf Industries Pte Ltd – in-charge in fabrication)


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CONTENT

� Background of the Project

� Identification of the Root Causes of the Problem using Fish-Bone Analysis

� Introduction of iDrain

� Notable Comparisons – Environmental, Health, Safety & Financial Aspect

� Tangible & Intangible Results

� Continual Improvement thru PDCA Cycle

� Q&A


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Background of the Project

ECM Drainage system is a legal requirement by PUB before any earthworks can commence.

This is considered fixed-temporary structure.

Needed to be demolished at certain stage of the project or at the tail end of the project.

ECM Drainage installation is normally constructed using C7 concrete channel.


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Conventional C7 ECM Drain:

� Easy to break during raged handling

� Heavy to carry using manual labor

� Bulky to store, require more space

� Challenging to install due to it’s weight

� Require excavator to lift and install

� Require more manpower

� Require Lifting Plan & Lifting Team

� Require breaker to demolish


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Background of the Project

C7 Concrete Channel ECM Drain is prone to damaged due to raged handling.

Pure Expense – minimum recovery.

High recurring cost (install/demolish at certain stage)RECURRING

COST WITHOUT

RECOVERY


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C7 Drain is costly &

Minimum RecoveryMATERIALS

Minimum recovery

Heavy Weight

Bulky to store

METHOD

High recurring Cost

(Install/Demolish)

MACHINERY

Raged handling

Prone to damage

MANPOWER

Poor handling

Need more man to carry

Bulky & heavy

Analysis of the ProblemUse of Conventional C7 Concrete Channel


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C7 Drain is costly &

Minimum RecoveryMATERIALS

Minimum Recovery

Heavy Weight

Bulky to store

METHOD

High recurring cost

(Install/Demolish)

MACHINERY

Raged handling

Prone to damage

MANPOWER

Poor handling

Need more man to carry

Bulky & Heavy

Analysis of the Problem: Root CausesUse of Conventional C7 Concrete Channel


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Analysis of the Problem: Finding Solutions

Areas of Improvement Problem Identified

(C7 Drain)

Approach

Materials Minimum recovery Substitute an alternative material that is

durable, light weight and stackableHeavy weight

Bulky to store

Method Use of Excavator Elimination the use of heavy machinery by

employing manual laborExposed to heavy

machinery

Recovery Minimum recovery after

demolition

Substitute to reusable material


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Areas of Improvement Problem Identified Proposed Solution

Disposal Mixed waste Substitute to recyclable material – therefore

no need for disposal

Manpower Licensed Excavator Operator Elimination the requirement of heavy

machineryRigger man/Signalman

Tradesman Maintain manual labor for installation and

recoveryGeneral Worker

Work Sequence High recurring cost Substitute to reusable and recyclable

material to reduce cost

Analysis of the Problem: Finding Solutions


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Project Objective:

To innovate an alternative to conventional C7 Concrete Drain

Strategies:

1) To find an alternative durable/reusable material

2) To design an innovative and practical equivalent of C7

concrete channel

3) To reduce risk exposure of workers


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Parameters Option 1 Option 2 Option 3

Material Plastic* Aluminum** Mild Steel

Characteristics (20%) Very Light Light & Durable Moderately Light &

Very Durable

Reusable (20%) Yes Yes Yes

Recyclable (20%) Yes Yes Yes

Environmental Friendly (20%) No Yes Yes

Cost Effective (20%) No No Yes

Overall Score 60% 80% 100%

1) Finding a Durable-Reusable Material

Legend:

*Customized size & Plastics are non-biodegradable

**Aluminum sheet is very expensive. 40% more expensive that mild steel.


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2) Designing an innovative & practical C7 equivalent

810mm

280mm

495mm


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3) Reduce Risk Exposure to workers

C7 Drain Installation of ECM Drain iDrain

High Excavation using Excavator Reduced

High Installation using Excavator * Eliminated

High Exposure to Hot Weather Reduced

High Heavy Load Eliminated

Reduce to ALARP

2 High Risk

Eliminated

2 High Risk

Reduced

Legend:

*Excavator with Lifting Machine (LM) Certificate.

RL = Risk Level


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3) Reduce Risk Exposure to workers

C7 Drain (RL) Demolition of ECM Drain iDrain (RL)

High Hacking Works Eliminated

High Hacking using Excavator Eliminated

High Exposure to Hot Weather Reduced

Legend:

RL = Risk Level

Reduce to ALARP

2 High Risk

Eliminated

1 High Risk

Reduced

Results of the 3 Strategies were collected.


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Introduction of iDrain (The Durable-Resuable ECM Drain)

� Durable

� Light-weight

� Easy to install

� Eliminates use of heavy machinery

� Reduce manpower requirement

� Eliminate lifting requirement

� Stackable – save space for storage

� Easy to recover and re-usable


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Introduction of iDrain – The Durable-Reusable ECM Drain

� 3mm thick (S275 Mild steel)

� 9mm flat bar stiffener along its perimeter

and center section

� Weep hole provisions

� Galvanized coated to prevent rapid corrosion

iDrain specifications:

Length: 1220mm

Width: 580mm

Weight: 38 kg


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Designing an innovative & practical C7 equivalent


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Designing an innovative & practical C7 equivalent

� Corrosion protection (Galvanized Coated)

� Eliminate connection joint sealing (Overlapping joints)

� Improved flow* (MS plate is more fluid in terms of water flow)

� Reusable to >5 cycle years (100% ROI after 2nd use)

* Manning’s coefficient of roughness in average velocity flow in open channel


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Notable Comparisons (C7 Drains vs iDrain)

C7 Drain Physical Comparison iDrain

70kg Weight 38 kg (72% Wt. Reduction)

600mm Length 1220 mm

810mm Section 580mm

495mm Depth 470mm

Notes:

iDrain is 2x length of the C7 Drain.

iDrain is easier to maintain & clean.

iDrain cross section A=0.2m2 (thinner)

C7 Drain cross section A=0.2m2

Manning’s coefficient of roughness:

C7 Drain = 0.025 iDRAIN = 0.012


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C7 Drain Cost Comparison iDrain

$10.60 Market Price Unit Price Fabrication Cost $106.00

167 100m run (qty) 84

$1,910.20 Material Cost $ 9,754.00

$720.00 Manpower Cost $120.00

$840.00 Machinery Rental $280.00

$800.00 Hacking Cost $120.00

$350.00 Disposal Cost $0.00

$46.20 Unit Rate per 100m run $102.74

0 Cycle to break even 2.2

Notes:

100m = C7 Drain = 3 days to complete = 2 Workers + 1 Rigger/Signalman + 1 Excavator Operator

100m = iDrain = 1 day to complete = 2 Workers

Please refer to the detailed costing comparison for details.


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C7 Drain Safety iDrain

High Exposure to heavy machinery* Eliminated

Moderate Exposure to heavy manual lifting Eliminated

Notes:

The change in material equate to safer methodology.

Total elimination of hazards associated to heavy machinery.

Eliminate manual lifting of heavy material.

* Excavator with Lifting Machine Certificate (LM)


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C7 Drain Health iDrain

Moderate Exposure to Noise (Hacking) None (Elimination)

Long Exposure to hot weather

(during Installation)

Reduced (Substitution)

High Exposure to Dust (Hacking) Low (Substitution)

Moderate Productivity* Very HighNotes*:

C7 installation rate at 100m = 2-3 days.

iDrain installation rate at 100m = 1 day (Reduction of 67%)

Resulting to shorter exposure to hot weather = faster to complete.

No need to seal the connection joints. Overlapping method.


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C7 Drain Environmental iDrain

Minimum recovery Sustainability Reusable

Mixed Waste Disposal Recyclable

Notes:

iDrain is made of superior material (mild steel) – equating to longer life cycle to reuse.

Use of iDrain will result in the reduction of the amount of waste to be dispose.

Environmental friendly – recycle after the reusable life of 5 years.

Disposed as scrap metal – cost recovery.


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Tangible Results:

� Cost savings on material cost (iDrain is reusable for >5 years)

� Cost savings of manpower (Reduction of manpower requirement)

� Cost savings on disposal cost (iDrain is recyclable)

� Cost savings on recovery cost (Disposed as scrap metal)

� Reduced storage space (Stackable)


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Intangible Results:

� Safer, Faster & Efficient as compared to C7 concrete drain

� Higher Productivity (+67%) as it requires lesser manpower & zero

heavy machinery

� Sustainable as iDrain is Reusable for 5 years

� Green Product as iDrain is Recyclable


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Continual Improvement using PDCA Cycle

• Check effectiveness

• Adopt/adjust new design/new material

• Fabricate new sections

• Introduce shorter/new sections

Plan Develop

CheckAct

Future Improvements:

Introduction of smaller size and corner

sections for challenging

terrain/curvatures profiles

� iDrain 600mm length

� iDrain 300mm lenght

� iTraps (Silt Traps)

� 90/45 Degree Sections

This PDCA cycle will be use to continuously

improve this product and review it’s

effectiveness

� Earthing provision as enhanced

safety measure


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Use 2 manpower to install - overlapping. Complete installation.

Two-man carry – moderately light weight. Stacking of iDrain for storage.

Application of iDrain at Project 1: ST. JOSEPH INSTITUTION A&A PROJECT


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Regular cleaning of iDrain.

Two-man carry – moderately light weight.

Stacking of iDrain for storage.

Application of iDrain at Project 2: NUS RVA Project


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Impact of iDrain to Construction Industry

iDrain is offered as an alternative option

for C7 Concrete Channel Drain

Make a smart switch -

Use iDrain in your next project


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WSH INNOVATION AWARD 2016

Lian Soon Innovative Drain Project

“iDrain - The Durable-Reusable ECM Drain”

Presented by:

Lian Soon Construction Pte Ltd

End of Presentation. Safe Regards.

WSH INNOVATION AWARD 2016€¦ · WSH INNOVATION AWARD 2016: LIAN SOON iDRAIN(THE DURABLE-REUSABLE...

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