record-breaking 1,395 tonnes of material laid in one night

The Background

The M1 Smart Motorways (J32-J35A) resurfacing scheme is within the Highways England programme of upgrading the M1 into a Smart Motorway all-lane running motorway.

The Problem

In order to alleviate driver disruption as much as possible, the challenge was to plane and surface 1400tonnes in one night, between junctions 33 and 32, during a full South-bound closure.

The Solution

Aggregate Industries’ Northern Director, Richard Needham’s approach was to collaborate as early as possible with Highways England, Costain and Tripod Crest - its cold milling partner, in order to ensure a meticulous approach to achieve a maximum possible output within the restricted time frame (10pm - 5am).

Richard said: “This method of lean deployment is one of the new approaches that we are implementing on the Highways England network. The aim is to drive efficiency, reduce network occupancy and disruption to road users. This will ultimately support Highways England in achieving its aim of generating £300m of efficiency through its pavement packages, as part of £1.2b efficiency savings required by 2020.”

In order to maximise the paving window Aggregate Industries’ Contracting team used three planers in echelon to plane depth of 45mm across two lanes, down the length of motorway; whilst two planer addressed the plug joints at the start of the works, moving onto those further down the area. Equally innovative, Aggregate Industries used one of its 8.5metre extended pavers paired with the MT300-2i Powerfeeder to allow simultaneous paving of two lanes. When used together with an increased capacity paver hopper continuous material can be fed and increased outputs can be achieved. The paver screed extensions were pre-rigged at Aggregate Industries’ Tinsley Depot saving an additional hour of the possession,

A lean approach to onsite vehicle management was also paramount. An exceptional vehicle movement order was obtained to transport the pre-rigged paver to site. Over 100 lorries were used to remove planings and deliver fresh asphalt. Fortunately, Aggregate Industries’ unique approach reduced lorry discharge times to just three minutes per lorry, further increasing paving lay rates.

With the job successfully completed in full and on deadline. Due to Aggregate Industries Contracting team’s renowned high quality standard, the end result is a new record for planing and surfacing with a single paver and crew in one shift.