THAMES TIDEWAY TUNNEL Tarmac Capability
DELIVERY PARTNERS
West Section
Central Section
East section
CONTENTS
INTRODUCTION TARMAC CAPABILITIES FOR THAMES TIDEWAY TUNNEL MATERIAL SUPPLY OPTIONS PRE-CONSTRUCTION SOLUTIONS ADDING VALUE
5 6
36
16
PEOPLE
38
CEMENT SOLUTIONS
18
PLANET
40
MARINE SOLUTIONS
20
PERFORMANCE
41
LOGISTICS
22
SOLUTIONS
42
TRANSPORT FLEET
22
HEALTH & SAFETY
44
RAIL & WHARF NETWORK
24
TRANSPORT STANDARDS
26
INNOVATION
46
TRANSPORT SAFETY
28
TRANSPORT INNOVATION
30
CASE STUDIES
32
8 10 11
SOLUTIONS
12
AGGREGATE SOLUTIONS
12
BUILDING PRODUCT SOLUTIONS
SUSTAINABILITY
READYMIX CONCRETE SOLUTIONS
14
COMMITMENT TO RESEARCH & DEVELOPMENT 49 OUR BUSINESS AT A GLANCE 50
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4
Thames Tideway Tunnel
INTRODUCTION
At 25 kilometres long, up to 65 metres deep, and more than seven metres in diameter, the Thames Tideway Tunnel will be the biggest infrastructure project ever undertaken by the UK water industry. Thames Tideway Tunnel will be built by worldclass contractors using the best innovative techniques to offer the most sustainable and cost-effective methods of construction. Tarmac are committed to becoming a strategic supply chain partner working collaboratively with the delivery partners to support preconstruction activity, project delivery and an enduring legacy for what is undoubtedly London’s most significant construction project over the next 8 years. Tarmac are pleased to offer support to the delivery partners in the supply strategy around bulk materials for the Thames Tideway Tunnel. This capability document
will be the start of that process as we hope it demonstrates we are best placed to support you as a supply chain partner during all delivery stages of the project. Moreover and for your benefit, we would be delighted to offer you our allocated project team whom are all available to support your pre construction activity during the ECI stage 1 in order to support the design development and construction planning processes to achieve the Client’s target price.
In summary, the enclosed is designed to give you an insight into our business offerings; all of which have considered the envisaged material volumes and associated logistics. Additionally we have measured the options surrounding Value Engineering through our technical and logistical specialists. We firmly believe we have alternative proposals that provide considerable cost savings as well as positive impacts to the overall construction programme.
Local knowledge and previous project experience have been key in considering the optimal solutions. Direct project experience in the region coupled with our planning time allocated to the development of this capability document will provide you with a strategy that will add value, save money and help mitigate risks associated the project.
Damon Holmes National Major Projects Manager damon.holmes@tarmac.com 07725 142020
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TARMAC CAPABILITIES FOR THAMES TIDEWAY TUNNEL KINGS CROSS PARK ROYAL
PADDINGTON
120m3
SILVERTOWN 70m
3
EUROMIX SILVERTOWN
80m3
MULBERRY 40m3
120m3
23
50m3
24 15 14
1
16 2
3
7
4
18
11 12
EUROMIX GREENWICH
8
5
80m3
6
22
17
13
10 9
BRENTFORD
21
19
CHARLTON
20
GREENWICH WHARF
ERITH
BATTERSEA 90m3
WEST SECTION
CENTRAL SECTION
EAST SECTION
Acton Storm Tanks 2 Hammersmith Pumping Station 3 Barn Elms 4 Putney Embankment Foreshore 5 Dormay Street 6 King George’s Park 7 Carnwath Road Riverside
Falconbrook Pumping Station 9 Cremorne Wharf Depot 10 Chelsea Embankment Foreshore 11 Kirtling Street 12 Heathwall Pumping Station 13 Albert Embankment Foreshore 14 Victoria Embankment Foreshore 15 Blackfriars Bridge Foreshore 16 Shad Thames Pumping Station
Chambers Wharf Earl Pumping Station 19 Deptford Church Street 20 Greenwich Pumping Station 21 King Edward Memorial Park Foreshore 22 Bekesbourne Street 23 Abbey Mills Pumping Station 24 Beckton Sewage Treatment Works
1
6
50m3
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8
17
18
MAJOR PROJECTS SUPPLIED Project Name
Solution
Value
A11 Fiveways to Thetford
Aggregates and Surfacing
£17m
M25 Managed Motorways J23-J17
Aggregates, Surfacing and Readymix Concrete
£15m
C411 & C412 Bond Street Station
Readymix Concrete
£10m
Tottenham Court Road Station Upgrade
Readymix Concrete
£4m
London Bridge Station Redevelopment
Readymix Concrete
£2m
THURROCK
TILBURY
GREENHITHE NORTHFLEET RIDHAM
DELIVERY METHOD HGV Rail Ship
PRODUCT Aggregate RMX m3 per hour Cement
Screed Grout Mortar
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PLATIN NORTHFLEET
TUNSTEAD
LIMERICK
THURROCK NORTHFLEET BRENTFORD PARK ROYAL PADDINGTON KINGS CROSS BATTERSEA
NORTHFLEET
COOLMORE NORTHFLEET
MATERIAL SUPPLY OPTIONS Rail Ship Cement Limestone Granite
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Destination Thames Tideway Tunnel
MOUNTSORREL NORTHFLEET BRENTFORD PARK ROYAL PADDINGTON KINGS CROSS BATTERSEA
PADDINGTON
KINGS CROSS
PARK ROYAL
THURROCK
BRENTFORD BATTERSEA
NORTHFLEET
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PRE-CONSTRUCTION SOLUTIONS At Tarmac we don’t just think two heads are better than one, we believe the more heads the better. That’s why collaboration is at the heart of our business. We believe that collaboration leading up to the start of construction is critical to the success of a project. In response to the challenges and opportunities offered by Thames Tideway Tunnel, Tarmac has created a dedicated multidisciplinary team. The team will develop an understanding of both Thames Tideway Tunnel and consortias’ strategic priorities. By doing this we can work collaboratively to develop integrated plans during the preconstruction phase. We can provide guidance on selection of materials, equipment, logistics and methods of project delivery. We will evaluate and make recommendations on the availability of materials and labour, time requirements, manufacturing, installation and factors related to cost, including but not limited to, the cost of alternative designs or materials. 10
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During preconstruction, the project will be fully programmed from all aspects of budgeting and pricing to schedule and project execution. It is during this phase that the plan is developed and during construction where it is executed. Tarmac can provide key services including: Value management, providing practical recommendations for constructability including analysing building systems, materials, finishes and equipment Innovative developments to improve quality Pricing for labour and materials today and for the project duration Project management including milestone, critical path and critical decision points Assessment of construction feasibility, ease and speed of construction and use of laboursaving, off-site fabrication or preassembled building systems Site logistics planning to optimise the flow of workers, materials and equipment to and from the construction site, with a strong
emphasis on safety and minimum impact to on-going site or area operations Development of safety programmes, planning for temporary project facilities, equipment, materials and services for common use
Tarmac can provide the assessments and recommendations necessary to make timely, informed and data-driven business decisions that better serve the interests of Thames Tideway Tunnel through relevant suggestions and hands-on partnership with Clients and Tier 1 Contractors. We can help you achieve the 10 Thames Tideway Tunnel Legacy Objectives. We take a holistic approach throughout the preconstruction process and our proactive approach enables informed and timely decisions to be made.
ADDING VALUE
FEASIBILITY STUDIES
PLANNING & PROGRAMMING
DEVELOPMENT APPRAISALS
CONSTRUCTION LOGISTICS
RISK ASSESSMENTS
LIFE CYCLE COST ANALYSIS
VALUE ENGINEERING
TARGET VALUE DESIGN
PROJECT SPECIFIC SAFETY PLANNING
BIM DATA IDENTIFICATION
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AGGREGATE SOLUTIONS
AGGREGATES IN LONDON
EUROPE’S LARGEST
MARINE AGGREGATE WHARF
7
THAMES FRONTED WHARVES
4
DEEP WATER WHARVES
3
2
WHARVES WITH POTENTIAL FOR A PRECAST FACILITY
5
WHARVES WITH ON SITE READYMIX CONCRETE
RAIL CONNECTED WHARVES
4.3
12
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8.4
MILLION TONNES
MILLION TONNES
CRUSHED ROCK
SAND & GRAVEL
Solutions
AGGREGATES IN THE SOUTH Marine Wharves serviced by our 4 company dredgers with access to a number of licenses in the Thames Estuary and North Sea. Strong relationships with external shipping companies to allow us to bring in materials from assets in Ireland.
21 SAND & GRAVEL QUARRIES
11
MARINE AGGREGATE WHARFS
3 CRUSHED ROCK QUARRIES
19
21
RECYCLING DEPOTS RAILHEADS
9
JV BUSINESSES
Plant developments at these marine wharves mean that we will be able to load out on to river going vessels.
Long term relationships with 3 leading barge providers on the Thames, gives us the opportunity to form partnerships and service those sites that require material delivery by river.
Direct rail access into London from some of the UK’s largest Limestone and Granite quarries
5
DREDGERS
400
Largest private aggregate mover by rail
We have the ability to partner with our extended supply chain in order to further expand our rail capabilities.
2 state of the art aggregate and asphalt testing facilities in the London area, supported by the UK’s leading technical R&D centre in Wolverhampton.
Currently provide aggregates to all major concrete producers in the London area
Have a long standing agreement with Tata steel to bring Slag in for production of sustainable concrete
We have the facility, at our three London landfill sites, to accept both inert and demolition waste, these landfills currently have a combined annual void space of 750kt, with plans to further increase this capacity before the start of Thames Tideway Tunnel.
TRUCKS
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BUILDING PRODUCT SOLUTIONS ANNULUS GROUTING
ANTI-WASHOUT GROUT A polymer modified to improve resistance to flowing water for structural work in river and/or marine environments.
CONCRETE REPAIRS
An interface between the tunnel segments and the substrate being bored through, Annulus grout would ensure any voids are filled and complete contact is made to give the tunnel its integrity and ensure any water is displaced.
HIGHWAY REPAIRS
COMPENSATION GROUT
Our comprehensive range features over 300 premium cementitious solutions and has seen Tarmac supply major projects with
UNDERGROUND GROUTS CONSTRUCTION GROUTS
WATER BAR SEALS SCREEDS & PLASTERS
The process stabilizes the substrate between the surface and the structure protecting overlying properties and may be an option for Thames Tideway Tunnel given the 25km route below a densely populated city.
CONSTRUCTION GROUT Used for the placement of heavy machinery (e.g. pumping equipment) and sets to extremely high strengths (typically 80N/mm2 after 28 days).
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FISSURE GROUT A grout modified to achieve long distance pumping and enhanced penetration.
SPRAYED CONCRETE Used to stabilise rock faces and for tunnel/structural repairs.
PRECAST SOLUTIONS Tarmac can source, install, commission and operate a variety of different mobile plants. With an experienced Precast facility in Tallington we are ideally positioned to supply for this end use and have already started working with London based manufacturers to review the opportunities for this project.
HYDROTITE Offers a wide variety of hydrophilic rubber joint sealing materials (water bars) with excellent longterm durability and good chemical resistance (this may be adopted as an alternative to the EPDM gasket design). All of these solutions can be modified for use in jet grouting processes and environmentally sensitive areas such as water abstraction zones. Due to the requirement for 90% of materials to be shipped by water our Tilbury plant is ideally located to load materials for shipment to site where they can be delivered via silo, in bulk bags or smaller if required. Limestone may be substituted for PFA in areas where water abstraction takes place. The dry product can be blended with filtered river water ready for application.
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READYMIX CONCRETE SOLUTIONS Tarmac are positioned to offer a complete solution based package in support of constructing the Thames Tideway Tunnel. We have recently worked with a variety of tunnelling contractors developing bespoke readymix concrete solutions specifically for this end use and we would be happy to work with your designers and materials engineers to produce the most suitable solution.
TUNNEL SECONDARY LINING SOLUTIONS
FLOATING MOBILE PLANT SOLUTIONS
Shotcrete or reinforced concrete can be supplied using our Mobile Plant Solutions and on site batching. Similar products can also be supplied from our fixed assets within the capital.
CONSTRUCTION SITE SOLUTIONS
A low heat self compacting product can be supplied either manufactured on or off site.
Due to the targets of this project for at least 90% of all materials to be delivered by river, Tarmac have started discussions with both barge operating companies and manufacturers of floating pontoons to assess our capability of siting a batching plant on the Thames which could receive aggregates by barge and operate off a floating structure. This option would also help with a mobile readymix concrete strategy with a number of construction sites material requirements being staggered. We have engaged with the Port of London Authority to investigate the use of such structures and build solutions around any constraints
Tarmac have 8 fixed plants in London and a mobile fleet of 12 plants including an Ultra Mobile solution capable of producing 60m3 p/h. These can provide a high level of flexibility to meet the varying production demands of Thames Tideway Tunnel at different points of construction.
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SHAFTS & DIAPHRAGM WALL SOLUTIONS
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CEMENT SOLUTIONS
Tarmac has a range of costeffective and environmentally responsible solutions that offer significant benefits over traditional construction methods to the Thames Tideway Tunnel.
FERROCRETE BULK PORTLAND CEMENT CEM I 52,5 Properties/ Features
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Finely-ground Portland cement
Advantages
High early strength development
Benefits
Facilitates early demoulding, handling and use of precast units
Applications
Precast piling
PORTLAND CEMENT CEM I 52,5 Properties/ Features
Consistent strength conforming to BSEN 197-1. Compatible with admixtures and additions.
Advantages
Long experience of use
Benefits
Good early strength
Applications
Piling Diaphragm walls Sprayed concrete Soil stabilisation
MICROCEM Properties/ Features
Super-fine cement (Typical D95 20 m) with narrow particle size distribution, containing carefullyselected setregulating additives.
Advantages
Good early strength development and controlled setting, high ultimate strength, low bleed.
Benefits
Can be used with standard cement injection equipment
Applications
Injection into joints, cracks, fissures and soils to produce a watertight mass of grouted rock or soil. Sulfate-resisting applications and use in hot climates.
ASSETS
SUPPLY CHAIN
Our Northfleet depot has 6 silos storing over 50,000t of material which is brought in by sea and offloaded at the deepest wharf on the river Thames. Able to take vessels of 25,000t, Northfleet handles around 500,000t of cement product per year and has the capacity to double this given market demand. Delivered by road on bulk tanker, our fleet of 23 HGVs distribute our range of products across the capital safely and efficiently.
The construction sites would be predominantly serviced by road; to comply with the need to transport 90% of materials by river there is an opportunity to move product in either horizontal silos, or 120t storage tankers with the potential to be transported along the Thames on floating pontoons and be moored at site. Tarmac have previously supplied cement using pressurised barges to deliver material to areas in Fulham and Nine Elms.
We have a second operation on the north bank of the Thames at West Thurrock. Fed by rail, cement is brought in from our flagship plant in Buxton and finished product is supplied in both bulk and bagged quantities. Thurrock also caters for our CEMII product range by having onsite blending capability using ash.
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MARINE SOLUTIONS
5
MARINE AGGREGATE DREDGERS
5m
DREDGED PER YEAR
TONNES
20
WHARF LOCATIONS
SATELLITE NAVIGATION ACCURATE TO WITHIN
5 METRES OPERATIONAL
24/7
80
EMPLOYEES
6
CADETS IN TRAINING
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CITY OF LONDON AND CITY OF WESTMINSTER
CITY OF CARDIFF AND CITY OF CHICHESTER
These ships operate mainly off the East Coast supplying sand and gravel to the near Continent and Tarmac’s 3 wharves on the River Thames, including the rail linked Greenwich wharf, which is the busiest marine aggregate wharf in Europe with a throughput of over 1.5 million tonnes in 2013. The Thames landing points serve customers over a wide area of London and the South East. Designed for typical passages of eight to ten hours in order to reach dredging grounds in the North Sea and English Channel, the City of London has a cargo capacity of 4,800 tonnes while the City of Westminster can deliver 5,200 tonnes. Both can load and discharge in three hours in ideal conditions.
Launched in 1997 at a cost of £9.5 million each, these ships work off the South Coast and in the Bristol Channel and have been designed to meet the particular constraints of small wharves and shallow draughts. They are capable of carrying out 2 trips in a day and can load and discharge a full cargo of 2,200 tonnes of sand or gravel in under 3 hours in ideal conditions.
BRITANNIA AGGREGATES This is also a 50/50 JV between Tarmac and Brett Aggregates operating 1 ship, the Britannia Beaver. This 4,800t vessel operates along the south and east coast of England and the near continent.
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TRANSPORT FLEET Across the UK, our extensive transport fleet and established relationships with transport operators, enables us to offer reliable and flexible material delivery options for Thames Tideway Tunnel. Strong transport links and consistent traceable high quality materials will be critical to the success of this project. • In addition to our highly professional Operational Logistics teams, we maintain a Group Logistics and Supply Chain team providing: • Logistics and Supply Chain Strategy operating model, roadmap and strategy development • Expert knowledge of Road and Rail transport • A dedicated Logistics Development Team, enabling us to develop our capabilities in this area (eg. ePoD) • Industry leading specialist Supply Optimisation (Network Modelling) capability utilising cutting edge tools and modelling software • Representation and lobbying the profession (CILT), trade bodies (MPA), government (ORR, Network Rail, Political parties), safety groups (CLOCS), road (FTA) and rail (RFG)
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MOUNT EVEREST TWICE
IN 2013 TARMAC DELIVERED
5,206,377.43 TONNES
OF AGGREGATES BY RAIL
IN 2013 THE TARMAC ROAD FLEET TRAVELLED AN AVERAGE OF
30,939,787.46 MILES
READYMIX CONCRETE BY ROAD
468,242 LOADS
ONE TARMAC CEMENT TRAIN HAULS THE EQUIVALENT OF
45 LORRIES
AND AN AGGREGATE TRAIN HAULS THE EQUIVALENT OF
Logistics
THE TARMAC FLEET STACKED END TO END WOULD BE THE EQUIVALENT HEIGHT OF
IN 2013 TARMAC DELIVERED
16,016,181.83 TONNES
OF AGGREGATES BY ROAD
65 LORRIES
IN 2013 TARMAC DELIVERED
2,715,806.10
CUBIC METRES OF READYMIX CONCRETE BY ROAD
IN 2013 TARMAC DELIVERED
7,193,631.27 TONNES
OF ASPHALT BY ROAD
AGGREGATES BY ROAD
AGGREGATES BY RAIL
IN 2013
IN 2013
787,036 LOADS
10,552 LOADS
ASPHALT BY ROAD
WE DELIVER ON AVERAGE
IN 2013
OF AGGREGATES A MINUTE
416,539 LOADS
40 TONNES
IN 2013
WE DELIVER ENOUGH TONNES OF AGGREGATE IN ONE YEAR TO BUILD
THE GREAT PYRAMID OF GIZA 3 TIMES OVER
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RAIL & WHARF NETWORK OUR RAIL OPERATIONS SPAN
85 SITES
20
NATIONWIDE
25
5
MARINE WHARVES
DREDGERS
OPERATING
TRAINS
WEEKLY -
PRIVATE SECTOR
OWNED,
USER OF RAILFREIGHT
FREIGHT &
IN THE UK
LEASED
1 CEMENT LOADED TRAIN
1 AGGREGATE LOADED TRAIN IS THE EQUIVALENT OF
IS THE EQUIVALENT OF
45 LORRIES
9
65 LORRIES
2
MILLION TONNES
MILLION TONNES
TONNES
OF MATERIALS TRANSPORTED
DREDGED INTO THE THAMES
DREDGED INTO THE
BY RAIL ANNUALLY
ESTUARY PER YEAR
SOUTH COAST
TRAINS CAPABLE OF AT LEAST
CURRENT AVERAGE
60MPH 25MPH JOURNEY SPEEDS OF
AVERAGE LOAD SIZE
AGGREGATE RAIL CONNECTION CEMENT RAIL CONNECTION AGGREGATE & CEMENT RAIL CONNECTION JV AGGREGATE RAIL CONNECTION WHARVES
.
OF MATERIALS ARE TRANSPORTED FROM TUNSTEAD AND MOUNTSORREL ANNUALLY
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TRANSPORT STANDARDS
HAULIER STANDARDS In addition to Tarmac’s own fleet, all of our hauliers have completed a VRU DCPC course and MPQC Driver Skills Training; a safety related DCPC which is industry recognised. In addition all drivers and hauliers have undergone an induction covering safety information as well practical day to day information. Contract Hauliers are all trained to the same high standard as our own drivers and we do not see them as any different when it comes to safety training and incident reporting.
SUBCONTRACTOR STANDARDS Subcontractors are held accountable to the same high standard. We are rolling out inductions and over the next 2 years we expect subcontractors entering our sites or delivering on our behalf to have completed an induction.
LOW EMISSION ZONE STANDARDS All our hauliers meet the Low Emission Zone standards in London and we are increasing the number of Euro 6 compliant trucks we have across our national fleet as we update our fleet for both safety and emission improvements.
APPRENTICE STANDARDS We recognise that we have a role to play as a leading logistics supplier in the industry, to increase the number of younger people joining the industry in all areas. We have begun a new apprenticeship scheme with ten new readymix concrete driver apprentices being taken from car licence through to Class 2 HGV through a 1 year programme. This has been created in conjunction with our industry recognised training partner. The apprentices will be put through a broad agenda covering safety and more general business understanding, as well as their driving test and consequent ongoing assessment. We have recently extended this scheme and fifteen more apprentices will join Tarmac in our Aggregates & Asphalt business at the end of 2015.
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TRANSPORT SAFETY
SPOTLIGHT ON SAFETY Tarmac has the largest fleet in the industry and is committed to change. As a responsible fleet operator we believe action is required to secure the industries ongoing corporate license to operate – and most importantly, to keep everyone safe that uses our road network. We are:
FITTING OUR FLEET WITH CYCLE-SAFE TECHNOLOGY Since 2012 we have ensured that all new vehicles in our HGV fleet are fitted with cycle-safe technology by installing: • Side under run bars on all vehicles • Side sensors to help eliminate blind spot issues with audible warnings for cyclists • Warning signage on the rear of the vehicles and on the side under run bars By the end of 2015, all vehicles less than eight years old including tippers and mixers will have
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been retrofitted with cycle-safe technology.
CHANGING BEHAVIOURS THROUGH DRIVER TRAINING Progressive training is vitally important to changing driver behaviours. All of our drivers in London have completed a Vulnerable Road User (VRU) training course to help them understand the road from a cyclist’s perspective.
IMPROVING STANDARDS ACROSS OUR SUPPLY CHAIN Tarmac is the largest fleet operator in our industry and the first in the UK to be approved to undertake fleet audits as part of TfL’s Fleet Operator Recognition Scheme (FORS). By gaining approval to audit our fleet of HGVs - including those of our contractor haulier supply chain - we are proactively driving forward a nationwide commitment to improve safety and environmental standards. Our transport supervisors are specially trained to complete audits to the FORS standard.
FORS Accreditation Cement - Gold Accreditation expected by the end of 2015 Readymix Concrete Gold Accreditation for our own fleet Readymix Concrete Bronze Accreditation as a minimum for all Hauliers (Silver Accreditation within three years) Aggregates & Asphalt - Silver Accreditation in the Southern Region Aggregates & Asphalt - Bronze Accreditation as a minimum for all Hauliers in the London Area
Ian Wainwright, Head of Freight and Fleet at Transport for London said: “As the first company to secure nationwide accreditation, Tarmac has demonstrated a leading approach to embedding a consistent approach to safety and environmental standards across its fleet. It is also providing its independent contract hauliers with the necessary technical support and training to make both adaptations to vehicles and behavioural changes.�
HELPING CUSTOMERS TO MANAGE RISKS We are providing contractors and clients with an understanding of the steps that they need to take to ensure that their supply chain conforms with the cycle safety agenda. With greater early engagement on projects we can set out how construction logistics can help to improve fleet safety and ensure safer driver behaviour.
CHAMPIONING A NATIONAL FLEET STANDARD Working with TfL and industry partners we helped to develop the Construction Logistics and Cyclist Safety Standard (CLOCS), a new HGV fleet standard for London. With 11 different individual standards currently in existence across the UK, we need the need the construction industry to unite behind CLOCS. A failure to adopt a consistent national standard will not lead to the critical improvements in safety that construction logistics must deliver. We are proactively engaging with our customers, partners and supply chain to adopt this single standard.
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TRANSPORT INNOVATION
EPOD Currently in the final stages of process design, Tarmac are partnering with PODFather to trial an electronic version of a delivery ticket (ePod). The ePod delivers significant benefits to both our customers and us, primarily by driving out back office costs. The PODFather provides real-time scheduling and tracking information to fleets of construction vehicles allowing teams of large projects to dynamically manage the day-today running of sites. • Logistics teams receive real-time information on which vehicles are moving where. • QS’s receive real-time information on how much is moving, of what. • Environment teams can define the level of granularity of material tracking they require to meet Environmental reporting.
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• Accounts/Procurement teams receive quickly produced, reliable reports of movements to easily reconcile with Suppliers invoices. The PODFather platform for construction logistics has been used by some of the highest profile infrastructure projects of national importance to track material movements and vehicle safety checks; including M25 Road Widening, Olympic Park, Crossrail, Mersey Gateway and Heathrow T2B.
• Expected Time of Arrival (ETA) can be sent by text message or email to individual Site gate staff or foreman to allow real-time site planning; • simplified Environment reporting by exact material delivered; • potential electronic feed of deliveries of materials to BIM model “as built”; • drivers can submit start-of-day FORS or CLOCS-compliant vehicle safety checks to TTT.
VERIFI
Using PODFather for Thames Tideway Tunnel will allow:
Integrated Concrete Consistence Control
• reduced paper administration cost for Tarmac and TTT in agreeing what was delivered, when, and with how much waiting time;
Tarmac have installed the latest Verifi technology on all truckmixers to provide Integrated Concrete Consistence Control. The system allows us to monitor and control, real time, concrete consistence throughout the whole life cycle of the load, from batching to delivery and placement. The system can auto add water to reach the target consistence whilst calculating and complying to the maximum water
• confirmed GPS location captured of what was delivered, when; • actual delivered volumes and dates/times can be fed towards the TTT Vehicle Booking Management System for reporting planned vs actuals;
cement ratio stipulated on the design criteria for each mix.
made, where, mix design data, batch data etc.
The Verifi system gives the following benefits:
For customers wanting information to support BIM (Building Information Modelling), the RFID tags allow traceability in materials that has never been seen before. For the client, the tags allow future maintenance of the asset; walking up to a structure with a hand-held device will allow access to the tag data, providing the client with asset information to enable real-time decisions without further interrogation of paper or electronic systems.
• Data collection of water additions (both time & quantity) • Automatic slump management during transit • Drum revolutions - time, number & speed • Data shared via a gateway upon truck return to our plant • Daily performance reports • No need for site operatives to add water • Improved consistency and quality
RFiD TAGGING Tarmac is pioneering technology in the UK to provide traceability of concrete, by incorporating RFID (Radio Frequency Identification) chips. The principle is to add the RFID tags during the manufacturing process, which contain information about the concrete such as when it was
The next steps for RFiD tagging could include embedded strain gauges so data can be captured of the concrete condition during its life in a structure. Interpretation of this type of data would allow a proactive approach to asset maintenance.
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CASE STUDY: CROSSRAIL FINSBURY PARK & BOND STREET As leaders in our field, we are playing a key part in projects for some of Europe’s largest railway and infrastructure projects including Crossrail:
MATERIALS • Supplied constituent products for over 100,000 segments • PCRM CEMI and EN450 S Grade fly ash supplied to the Precast facility • Supplied 10,000t of cement for annulus grout • Supplied cement for the track bed • Diaphragm Walls • Track Slabs • Piling
LOCATIONS PADDINGTON STATION BOND STREET STATION TOTTENHAM COURT ROAD
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WHITECHAPEL STATION LIMMO PENINSULA
The grout needs to be fluid enough to:
We are supplying Crossrail’s contractors BBMV (Balfour Beatty, Morgan Sindall, Vinci) and Bachy Solentanche, with a bespoke formulation of compensation grout.
• Be pumped from a surface mixing station to the substrate via a grouting gallery
The grout is being used in new underground tunnel construction works below built-up areas at Finsbury Park (Crossrail 510) and the Bond Street upgrade (London Underground).
WHAT DOES THIS UNIQUE FORMULA INVOLVE? The buildings are fitted with movement sensors that are hooked up to a highly advanced system that can immediately sense the smallest fraction of movement, narrowed down to a pinpoint location. In response, compensation grout is applied into the underground area at the injection points corresponding to the movement picked up at the surface.
• Remain live in the lines for 45 minutes • Withstand the effects of pressure filtration through the compensation grouting system • Gel and set when it reaches the substrate – providing that vital jacking action, leaving the buildings on the surface undisturbed and adequately supported.
PUTTING OUR EXPERTISE TO THE TEST Crossrail had experienced problems with the product it had previously been using, which gels in 15 minutes. This particular product had been undergoing pressure filtration – where water was being pumped out of the compound during use. This caused it to lose essential fluidity and, as a result, the lines used to apply it, began to block.
We quickly rose to the challenge and after conducting extensive lab and in-situ testing, we produced a solution that overcame all of the issues associated with the on-site process without compromising on performance.
Case Studies
UNDERGROUND TUNNEL CONSTRUCTION
OUR SOLUTION The bespoke formulation is very fluid for a longer period of time and very stable. What’s more, it still performs to the same original strength and setting time characteristics required of a compensation grout. All in all, the project featured a number of unique requirements, including: • The supply of 4,000 tonnes of low strength, high purity grout that prevents pressure filtration • Pumping over 100 metres in distance at pressures of 6-7 bar • Pumping through 1,800 individual injection points • A 20mm internal diameter line that reduces to 10mm at the sleeve
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CASE STUDY: CROSSRAIL WHITECHAPEL STATION
Product SPECIALIST TOPFLOW SELF-COMPACTING CONCRETE Client CROSSRAIL Engineer BALFOUR BEATTY, MORGAN SINDALL Main Contractor VINCI CONSTRUCTION Location WHITECHAPEL, LONDON Completion 2018
THE CHALLENGE East London’s vibrant and culturally diverse Whitechapel area, is undergoing a transformation as part of Crossrail’s £110 million project to give a facelift to Whitechapel station. The works which started in 2011 will see the new station act as an interchange between the Crossrail, Hammersmith and City, District and London Overground lines. Work is being conducted within a tightly constrained and highly populated area, with the aim of causing minimal disruption to daily commuters in and around Whitechapel.
OUR SOLUTION We supplied all the Readymix concrete for four large pours totalling 3,000m3 that went down throughout the night. Part of the specification had a limit on the core temperature of the placed concrete so we developed a new low-heat Topflow mix over a four week period that was used for
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lining the walls. Due to the highly congested environment and heavily reinforced nature of the structure at Whitechapel station, a product was required that would easily flow through steel structures. The client specified a bespoke blend of our specialist Topflow self-compacting concrete.
RESULTS AND BENEFITS Topflow’s rapid, flexible and easy placement means that large volumes could be poured quickly. Separate pours were scheduled in quick succession to enable the “leapfrogging” of pours and minimise the number of stop-ends required, which saved time and helped to create a better aesthetic finish. Each pour provided enough concrete for the full 5.55m height of each retaining wall, and had to be completed in one continuous pour. We reacted very quickly to the challenge of providing low heat concrete for the lining walls and we now have a new product in our Topflow range.
WHITECHAPEL STATION REFURBISHMENT
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SUSTAINABILITY
We embed sustainability at the heart of everything we do - it influences how we work, and drives our vision to become our customers preferred choice for sustainable construction solutions As a major provider of construction solutions, we recognise our responsibility to grow our business in a way that’s good for people and the environment. This means considering not only the goods we purchase, our operations and logistics, but also the performance of our products in use and how they are reused and recycled. By adopting this whole-life approach, we take action to minimise any negative aspects, while maximising the many positive sustainability benefits our business brings.
Using this whole-life thinking we engage with our stakeholders to develop our sustainability strategy. It sets out long-term, ambitious commitments to transform our business against four main themes, people, planet, performance and solutions. Achieving this transformation means thinking again about every aspect of our business, products and services, and pushing the boundaries to develop innovative solutions that help our customers create more sustainable buildings and infrastructure. We have set ambitious 2020 milestone targets for each of our key priorities, all of which are underpinned by a range of further performance targets.
PEOPLE
Safety and health Our people Community involvement
PERFORMANCE
Economic value Governance and ethics Communication
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PLANET
Sustainability
Climate change Environmental stewardship Resource efficiency
SOLUTIONS
Sustainable supply chain Innovation and quality Sustainable construction
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PEOPLE
Being a safe business, employing great people and having strong community relationships are key to our long-term success. ZERO HARM We are committed to building a zero harm culture that targets continuous improvement and an ever-safer working environment. In 2014 key initiatives included a new safety and health strategy, an industry-leading approach to road safety and mobile phone use, and the launch of an annual Safety Week.
AN EMPLOYER OF CHOICE We want to provide a great place to work, somewhere people can thrive and where everyone is treated fairly, with dignity and respect. To this end, we have introduced a number of progressive HR strategies designed to develop, motivate and empower our employees, ensure that their efforts are recognised and enhance the diversity of our workforce.
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NET POSITIVE CONTRIBUTION TO OUR COMMUNITIES We do all we can to avoid any nuisance our operations might cause local communities, while maximising the positive impacts we can have, such as creating jobs, supporting the local economy and championing community projects. This proactive relationship is also a key element in enabling us to maintain our licences to operate. We also became a business partner of Solutions for the Planet and launched our first Forest School.
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PLANET
We have set demanding commitments to help tackle climate change, enhance environmental stewardship and use resources efficiently.
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DESIGN CO2 OUT OF OUR PRODUCTS AND SERVICES
NET POSITIVE BIODIVERSITY CONTRIBUTION
ACCELERATE THE TRANSITION TO A CIRCULAR ECONOMY
By taking a whole life approach, we are working to reduce CO2 emissions from our supply chain, our operations and the transport of our goods and are helping our customers create sustainable, low carbon buildings and infrastructure.
With 100,000 acres of land under our stewardship, we recognise our duty to manage our assets responsibly and work hard to minimise the impacts of the activities at our sites, and to carefully manage biodiversity and archaeological heritage. In 2014, 100 percent of our mineral extraction sites had restoration management plans and many already have biodiversity management plans in place. We are developing a new approach to biodiversity, geodiversity and restoration management plans which will be launched across all our mineral extraction operations and will report on our progress in future years. We have also have begun to contribute to an important national register of natural capital.
We are using the concept of a circular economy to drive the efficient use of natural resources throughout their life-cycle. The circular economy, otherwise known as the closed loop economy, can help manage the strain on the world’s finite natural resources.
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It’s a way of thinking that means valuable resources remain in use, either being used for what they were originally designed for, or for something new. It replaces the old linear way of thinking, when resources are simply used and then disposed of, with one where waste is designed out from every stage of the supply chain and life-cycle. We are also supporting customers by considering what we can do to help them with resource-efficient design and reducing waste during the construction, use and end of life of buildings and infrastructure.
PERFORMANCE
Only by operating professionally and ethically can we build a business that creates long-term value and is capable of developing innovative sustainable construction solutions. CREATE SUSTAINABLE ECONOMIC VALUE It is only by creating economic value that we can continue to fulfil our responsibilities to our stakeholders, as well as develop initiatives such as low carbon technologies, energy efficient plants and new, innovative products. We create economic value in a number of ways: • by providing jobs and career opportunities; • through the taxes and levies to the Government; • by helping to create value for our communities, customers, suppliers and investors;
UPHOLD HIGHEST CORPORATE GOVERNANCE AND ETHICAL STANDARDS We have bolstered the ethical way in which we operate over the past 12 months with a new Anti Bribery and Corruption Policy and an updated Code of Conduct, which clearly defines the high standards we expect from both our employees, and those working on our behalf. During the year we maintained 100% compliance with our Code of Conduct, Anti Bribery and Corruption Policy. We have also re-launched our confidential “Speak Up” service that allows staff to report any issues across the business they feel compromises our ethical stance.
COMMUNICATIONS Clear and transparent communications are essential for keeping our stakeholders informed and connected with our business. We are constantly developing new ways to communicate with them. In 2014, we created a series of microsites designed to keep local communities informed about operations going on near them, while internally we launched Altogether, a new quarterly employee magazine. Alongside this we developed a new intranet site and a programme of communications aimed at further embedding sustainability in the business.
• through the new homes, offices and infrastructure created from our products.
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SOLUTIONS
We are playing an important role in helping to build a more sustainable society. RESPONSIBLY PROCURE ALL GOODS AND SERVICES We have introduced a new approach to procurement excellence which is focused on six priorities. As part of our responsible supply chain strategy, in 2014, we developed a new Responsible Procurement Policy, while aligning our procurement procedures and processes to BS 8903, the framework standard for sustainable procurement. Both of these will help to manage any potential risk within our supply chain and give our customers confidence.
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We collaborate with our customers and our suppliers to develop new ways of working that make operations more efficient and help them to meet their own sustainability targets. Through our membership of the Supply Chain Sustainability School we have continued to help suppliers within the construction industry embed sustainability into their operations.
DEVELOP NEXT GENERATION SUSTAINABLE SOLUTIONS We are committed to exploring how different construction methods and materials can enhance the sustainable properties of major infrastructure, from residential buildings to offices or schools. The aim is to gain a better understanding of how construction materials could perform in the built environment of the future, and how these properties could be
manipulated or developed for the best sustainable outcomes. In 2014 we have established a number of key programmes with universities and research institutions to develop new sustainable construction solutions.
ENABLE CUSTOMERS TO USE INNOVATIVE SOLUTIONS TO CREATE A SUSTAINABLE BUILT ENVIRONMENT To help our customers understand our solutions and their attributes throughout the whole life-cycle of their use within the built environment, we classify our solutions within four categories: In built, In construction, In use and In support.
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HEALTH & SAFETY
Through proactive health and safety management, Tarmac aims to achieve and maintain the highest standards of health and safety for all employees, contractors and members of the public and is committed to continual improvement in its health and safety performance. Protecting the health, safety and well-being of our employees, contractors and those around us is the core value of our business. We work in potentially hazardous environments so it’s important that everyone understands how to go about their jobs safely. Our role is zero harm to anyone working for, or with, Tarmac.
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Creating a consistent, proactive safety culture through engagement, training and behaviour change, will support us in achieving our goal. We are passionate that all tasks are done safely and through measurement and learning we can continuously improve our performance. Everyone working at Tarmac is expected to work in a safe, responsible manner and to challenge unsafe behaviour. We are committed to building a zero harm culture that targets continuous improvement and an ever-safer working environment. Over the past 12 months, we have continued to prioritise the safety, health and well-being of our employees and everyone who comes into contact with the business. In 2014, key initiatives have included a new health and safety strategy, an industry-leading
approach to road safety and mobile phone use, and the launch of an annual Safety Week. We have also begun introducing a new OHSAS 18001 safety management system at all our sites, which will be completed by the end of 2015. Our efforts to improve health and safety have been recognised through a number of industry awards.
MPA AWARDS FOR SAFETY Our work to continuously improve health and safety across our business was recognised at the UK Health and Safety Awards, run by the Mineral Products Association (MPA).
We won four awards covering all areas of the business. The winning projects were: • Our work on road safety, which won the Reducing Occupational Road Risk category • Our Switch Programme for employees and hauliers, which prevents the use of mobile phones while driving, including hands-free. It won in the Behavioural Safety, Safety Culture, Leadership category • Our Traffic Safety Wand, which helps ensure workers are easily visible to delivery trucks and reversing plant when working at night. It won the Bitumen, Asphalt, Contract Surfacing category. Health & Safety
• A new way of changing rollers on conveyor belts developed by engineers at our Mountsorrel Quarry to reduce the risk to fitters, which won the Engineering Initiatives category.
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INNOVATION
QUALITY We are developing nextgeneration sustainable solutions and meeting our customers’ quality performance needs. We are committed to exploring how different construction methods and materials can enhance the sustainable properties of major infrastructure, from high speed rail to nuclear power stations. The aim is to gain a better understanding of how construction materials could perform in the built environment of the future, and how these properties could be manipulated or developed for the best sustainable outcomes. In 2014, we established a number of key programmes with universities and research institutions to develop new sustainable construction solutions. As product quality is a cornerstone of good sustainability performance, we operate robust quality management systems certified to ISO 9001 across our business so customers can be confident that they are made with the utmost consideration for quality.
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ACADEMIC EXCELLENCE AND INDUSTRY COLLABORATION
BUILDING INFORMATION MODELLING
By collaborating with universities and research bodies, we are also developing a network of Centres of Research Excellence to help ensure that innovative and cutting-edge thinking remains a key asset within the business.
Alongside sustainable construction products, we are constantly investigating new services and ways of delivering information which can help customers to meet their own sustainability targets. Building Information Modelling (BIM) enables the more effective management of information linked to a built asset, be it a building or an element of infrastructure. The UK Government has mandated from 2016 that all of their new construction projects must be BIM compliant.
We also work on innovative new ideas with some of the UK’s leading universities, including University of Nottingham, University of Hertfordshire, University of Birmingham, Loughborough University, Cardiff University and Herriot Watt University, matching our business acumen and industry knowledge with their academic excellence to develop some ground-breaking ideas and also new thinking around sustainability and the built environment.
Over the next few years, BIM is likely to become the single industry approach to construction. Many are already recognising the significant cost and efficiency savings it offers. These benefits derive from improved access to information and increased supply chain collaboration, including early stage design efficiency, modelling of whole life sustainability performance, traceability of components, product maintenance data and end of life scenarios and opportunities.
We are leading the way by being the first company in our sector to launch specific BIM objects for readymix concrete, and we are working with the UK BIM Task Group to define data requirements for construction products.
With the majority of emissions from the built environment coming from the “in use” phase, it can also help us to calculate the carbon footprint of a whole project and help our customers to manage carbon in their supply chain.
CARBON FOOTPRINT CALCULATOR
Following on from the success of the calculator, in 2015, we aim to launch our environmental product declaration (EPD) tool, providing customers with life-cycle analysis (LCA) information for our product range in a clear and standardised format. It will consider a number of different indicators including embodied carbon, raw material use and toxicity. The EPDs will be compliant with EN 15804 and will support our customers in making an informed decision about the products they buy.
Innovation
With an increasing number of customers asking for carbon footprint information, we have developed a comprehensive carbon footprint calculator for our products and, in 2014, we launched an upgraded system. It enables us to measure carbon in everything from the raw materials we use, to the energy used in manufacturing and transport in accordance with PAS 2050, a specification for assessing the life-cycle of greenhouse gas emissions of goods and services.
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COMMITMENT TO RESEARCH & DEVELOPMENT Research & Development is a core activity of Tarmac’s business strategy enabling us to be a supplier of solutions, valueadded products and services. The business has a powerful central R&D structure including technical centres and development laboratories operating as close as possible to the markets. Our vision is to be the market leader in the construction sector through our value-added products, sustainable solutions, performance and innovation. We view innovation and research as major levers for inventing materials and construction solutions able to respond to the population increase to an estimated 9 billion people by 2050.
FUTURE TRENDS & INNOVATION A cross functional future trends and innovations committee meets quarterly to keep abreast of market developments, propose ways in which Tarmac should innovate its customer offer and set up and govern projects to deliver innovative solutions and products for our customers. This high level committee generates ideas through market intelligence, insight into customer needs and business performance. Over the years the business has successfully delivered through the innovation programme a wide portfolio of value-added products, new processes, performance optimization, resource efficiency and cost management and control. Our laboratories also provide design support to the business and quality testing of products. Tarmac will put at your disposal all of our testing facilities and laboratories.
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OUR BUSINESS AT A GLANCE
6,900 EMPLOYEES
5
CUSTOMERS
TURNOVER
20
123
1,700
25
110
72
VEHICLES
TRAINS
AGGREGATE DREDGERS
MARINE WHARVES
QUARRIES
READYMIX PLANTS
ASPHALT PLANTS
40
44
22
3
2
TARMAC BUILDING SITES
RECYCLING OPERATIONS
CONTRACTING DEPOTS
50 MILLION
8 MILLION
3.8 MILLION
TONNES AGGREGATE PRODUCTION
50
15,000 £2BILLION
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TONNES ASPHALT PRODUCTION
TONNES CEMENT
CEMENT PLANTS
LIME PLANTS
3 MILLION
66 THOUSAND
METRES3 READYMIX PRODUCTION
ACRES OF LAND
OUR PARTNERSHIPS
Portland House, Bickenhill Lane, Solihull, Birmingham B37 7BQ +44 (0)800 1 218 218
Š2015 Tarmac Trading Limited.