Motorway Construction, Project Execution Plan

Details of how a Motorway is constructed, and how the progress, safety and quality will be monitored and controlled. Also the measures to
ensure that the site is environmentally friendly.
David H Moloney
Nov 2016

Brief Description

The purpose of this presentation is to give an

understanding of the Methods, Plant and
Sequence to construct a Motorway.

This presentation can be used to engage

Stakeholders and to get the Site Teams
commitment to the programme. Also can be
used for Induction Training and as a way to
capture and share knowledge.

Project Execution Plan (PEP) details how a

project will be executed, monitored and
controlled.

High in Educational Value and easily understood.

Recommended for Continuing Professional
Development (CPD)
Contents

ⓒ David H Moloney
 Earthworks

Includes
Earthworks

Excavations, filling, compaction, disposal and landscaping.

Cut through hills

Fill in low areas

Strip Vegetation &Topsoil

 Mass Haul Diagram
The mass haul diagram shows the fill and excavation volumes plotted against chainage along a road. It is
used to provide an indication of the haul distances and to ensure that haul distances are minimised.
Earthworks
Earthworks
Outputs - Excavate & Load, Cart, Tip & Return

Brief Description 7 minutes

Cycle Time for 7km haulage distance

using an Excavator 45 tonne weight
and Dumper with a 40 tonne capacity,
the cycle time is 34 minutes

7 km

14 minutes 7 km 14 minutes

3 minutes
Earthworks
Outputs for Excavate & Load, Cart, Tip & Return
Rock - Excavability

The excavability of rock depends mainly on the rock strength and the layer thickness.
This diagram shows excavation methods for rock of various strengths and thicknesses,
with a free face.

ⓒ David H Moloney
Earthworks
Outputs for Rock breaking
Earthworks
Rock Cut
Health, Safety & Environment
Trench - Safety Measures
 Existing Underground Utilities
Health, Safety & Environment

Brief Description

Before digging establish the

location and route of
underground utilities.

Locator to find Utilities

Spray Paint to mark pavement ⓒ David H Moloney
 Roads & Pavings
Roads & Pavings

Includes
Sub-base, base and surfacing, kerbs, footpaths, traffic signs and markings.

Signs & Markings

Asphalt pavement

Basecourse

Median Barrier
Roads
CABC ( Crushed aggregate base course )
Earthworks
CABC ( Crushed aggregate base course )

Testing Compaction

Mixing Plant
Site Trial
 Crushed Aggregate Basecourse
Paving

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 Asphalt Paving
Paving

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 Asphalt Paving
Paving

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 Insitu Concrete Barrier

Slipform central median barrier, the

Paving

moving formwork allow for the

simultaneous extrusion and finishing
of the concrete. Powerful vibrators
compact the semi-dry concrete.

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 Steel Traffic Safety Barrier
The barriers are designed to keep vehicles
within their roadway and prevent vehicles from
Paving

colliding with dangerous obstacles such as

bridges, buildings, walls or large storm drains.

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 Pavement Marking
Paving

Road surface markings are used on paved roadways to

provide guidance and information to drivers and
pedestrians. They can be used to delineate traffic lanes.
 Road Signs
Paving

Road signs are signs erected at the side of or

above roads to give instructions or provide
information to road users.

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 Bridges
Bridges
 Bridge Construction
Concrete

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 Bridge Construction
Concrete

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 Reinforced Wall Construction Sequence
Concrete

Brief Description

The sequence to construct a reinforced concrete wall is as

follows:
Tie the reinforcement.
Erect stop-ends and the wall shutters.
Pour and vibrate the concrete mix.
Remove the shutters after the concrete has hardened.

Cycle Time
Pour per Day

ⓒ David H Moloney
 Reinforced Wall Construction Sequence
Concrete

ⓒ David H Moloney
General Items Concrete Mix

A concrete mix contains 5 major

elements: cement, water, coarse
aggregates, fine aggregates (sand) and
air in different proportion. Additional
elements such as pozzolanic materials (fly
ash, silica fumes or slag) and chemical
admixtures can also be incorporated to
the mix to increase its properties.
 Vibrating Concrete
Concrete

ⓒ David H Moloney
 Culvert Construction
Concrete

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Piling Insitu Concrete
Piling
Piling Construction - Vertical Piles
Piling
Piling Construction - Raking Piles
Surveying & setting Out
Survey & Setting Out
Setting out & Surveying
Setting out & Surveying
 Site Facilities & Temporary Works
Site Facilities & temporary Works
Site Facilities & temporary Works
Site Facilities
General Items Welfare Facilities

Toilets – Washing

Canteen, Drying Room, Toilet & Generator

ⓒ David H Moloney
General Items
Site Hoarding examples

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 Wheel Wash Drive-through
General Items

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General Items Temporary Electricity Supply & Tower Lights
Used so construction work can continue effectively and safely in
periods of insufficient natural light.

Generators
General Items
Dewatering

Brief Description

Construction dewatering is the removal or drainage of

groundwater and or surface / rain water usually by
pumping to keep the works dry.

ⓒ David H Moloney
Concrete Batching Plant David H Moloney

ⓒ David H Moloney

Concrete batching plant comprises - concrete mixer, control cabin, silos for cement and fly ash, aggregate bins
and conveyor belt system to feed the mixer. Also aggregate storage bays and water storage tanks.
The mixing is computer controlled and has a dynamic screen display, showing the process. Material storage
capacity to match two days concrete production
General Items
Concrete Batching Plant Yard
Quarry & Aggregate Production

3D image to show Sequence, Method & Plant.

ⓒ David H Moloney
Quarry Operations
Reinforcement Cutting & Bending Yard David H Moloney

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine

Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site
ⓒ David H Moloney
Asphalt Batching Plant

The plant is used for the

manufacture of asphalt.
Aggregates, sand and a filler (such
as stone dust), in the correct
proportions, are heated, and
coated by mixing with a binder,
bitumen based. The temperature of
the finished asphalt mix must be
sufficient to be workable after
transport to the final destination.
 Health, Safety & Environmental
Health, safety & environmental
Emergency Phone Numbers & Response
 Dashboard is a single page, graphical representation of
HSE Monitoring & Reporting - Dashboard current HSE Issues and historical trends
 The purpose of safety training is to provide the knowledge necessary to
Safety Training Matrix perform a job safely
Miscellaneous
 Personal Protective Equipment (PPE)
Health, Safety & Environment

Personal protective
equipment (PPE) is
protective clothing,
helmets, goggles, or other
garments or equipment
designed to protect the
wearer from injury or
infection
Safety Precautions
Site Safety Posters examples
 Air, Noise, Water & Soil Pollution
Environmentally Friendly Site
 Hazardous Substances Symbols
Health, Safety & Environment

COSHH stands for the

Control of Substances
Hazardous to Health

Shown are the new

hazard symbols
General Items
Water Pollution Prevention
 Segregation of Waste
Health, Safety & Environment

Segregation of waste for proper disposal and

recycling. Less waste goes to landfill and
hazardous waste is treated to make it safe.

Colour Code for Skips & Bins

 Precast bases for signs and hoarding,
Putting Waste Concrete to use Precast blocks for walls.
Health, Safety & Environment

ⓒ David H Moloney
 Quality Assurance
Quality Assurance
 Dashboard is a single page, graphical representation of
Quality Assurance Dashboard current statistics and historical trends
 Laboratory
Asphalt Paving

ⓒ David H Moloney
 Administration
Administration
Organogram

Brief Description

Shown are the line and

lateral relationships
between the various team
members and their relative
position in the site
organisation.
Staff Responsibility Matrix
Staff Directory

Brief Description

List of staff and their

contact details
Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and
work activities carried out daily.
Quotations Comparison Sheet
Filing System
 Programme & Progress Monitoring
Programme & Progress Monitoring
Progress Monitoring & Reporting - Dashboard

Dashboard is a single page, graphical representation of current progress and historical trends

ⓒ David H Moloney
Histogram Charts for Resources & Outputs

Manpower per Discipline Concrete per Location

Numbers for each month of the Project Quantity for each month of the Project

ⓒ David H Moloney
Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney
 Legend
Time Chainage Diagram
Brief Description

The chart has two axis: one for time and the other for location
A legend explains meaning of the colours, symbols and line types
End