Smartr Brochure CBGM
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John G JoseSmartr Brochure CBGM
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John G JoseTM
Introduction
Client: EDF Energy Networks Contractor: Laing ORourke Infrastructure Producer: OKeefe Utilities Processing Facilities: Silvertown E16 and Atlas Road NW10 Product: Structural Material for Reinstatement Their requirement was for a viable, recycled product that could be used as the replacement of Type 1 sub-base as defined by the Specification for Highways Works. OKeefe Utilities had identified a need for a suitable ARM for the utilities industry and through extensive research; laboratory testing and field trials are able to produce a material that achieves the performance of a Structural Material for Reinstatement (SMR). PV1 is a SMR as defined under the New Roads and Street Works Act 1991 in the Second Edition of the Street Works Code of Practice: Specification for the Reinstatement of Openings in Highway. This document will provide an overview of the process, including the production and control methods of PV1 which has been designed specifically for the use as a replacement of virgin, quarried Type 1 for use as backfill and sub-base layer(s) for reinstatement in the highways.
The product name and its origins
The recycled material we produce is known by its trade name PAVIMENTUM and is abbreviated to PV1. The name originates from the material that was used by the Romans for the construction of their roads over 2,000 years ago. The roads were built with pieces of crushed stone, lime, flint, tile, and other materials which were set in a bed of ashes or cement and consolidated by beating down with a rammer. The earth bed/middle level of their road construction was known as Pavimentum.
Why use an Alternative Reinstatement Material?
The release of the Advice note 2009/1 in advance of the amended Appendix A9 of the HAUC New Roads and Street Works Act 1991, Specification for the Reinstatement of openings in Highways, encourages the use of Alternative Reinstatement Materials (ARM) to promote the use of recycled material under the EU Waste Directive. Supporting this Directive, EDF Energy Networks and Laing ORourke Infrastructure sought a process that would re-use as much of the circa 100,000 tonnes of material that is produced during excavation works, and had previously been sent to landfill every year.
Introduction
Arisings delivered to SMARTR Processing Facility
SMARTR Quality Protocol
driver issued a delivery ticket with individual reference number
inspection, does the material comply with defined acceptance Criteria?
Non-compliant materials rejected
Compliant material tipped in
Material sample is taken, data base updated & material removed to a land fill site
Visual inspection
Non-compliant material is rejected
Arisings screened, graded & stored
Graded material loaded into SMARTR plant & mixed with a primary binder producing a stabilised material
Stabilised material reintroduced to SMARTR plant and mixed with a secondary binder to produce PV1 to order
PV1 loaded onto individual lorries which are weighed and a ticket issued to each driver
Conformity Testing as per HAUC, SHW 800 series and WRAP using BSEN Test Methods
Data management system Corona when back fill is complete
The SMARTR Process
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The OKeefe SMARTR Processing Plant
OKeefe Utilities have designed, developed and commissioned the plant and process to receive utility arisings from the London Boroughs to recycle into a British Standard compliant product for use as sub-base and backfill for reinstatement. The process involves segregating, screening, re-grading, weighing, treating and stabilising the material ready for dispatching. We refer to this process as the OKeefe SMARTR process which is an acronym for: Stabilising Materials from Arisings - Re-grading & Treating for Re-use. 4. Accepted material is screened and any oversized particles are crushed to <40mm and stockpiled. 5. Graded material is loaded into the SMARTR plant and mixed with a primary binder producing a stabilised material. This is then stored ready for batching that will be carried out on demand as required for reinstatement. 6. The stabilised material is loaded into the SMARTR plant where a secondary binder is introduced and the material is treated producing the OKeefe SMR PVI. 7. This is a fully automated system, which ensures the correct quantity of binder is added to the material using computer controls and weighing belts. 8. The Pavimentum (PV1) is produced and used daily with a batch reference number issued to each grab lorry driver as they leave the Process Facility. 9. The batch reference number will be uploaded to Corona (the Laing ORourke Data Management System) against the relevant opening notice number, on completion of backfill. 10. The batch reference number will be entered into Mayrise (the EDF Energy ETON Street Works Management System), when the Section 70 registration notice is issued.
The OKeefe SMARTR Process
1. A visual and olfactory inspection will be made of the excavated material on arrival to the processing facilities. Each load will be weighed and a ticket issued to the grab driver. 2. Material is stockpiled in designated storage areas where a secondary inspection is carried out of the entire load. 3. Non-compliant material will be stored in a separate storage area until removed to an external landfill site. The database will record load rejected, reason and the origin of material. LOR will be advised and contamination tests carried out.
The Smartr Process
How the Process Meets British and European Standards
WRAP have provided guidelines in their Quality Protocol of Aggregates from Inert Waste, revised edition: ISBN 1-84405-217-6, which have been applied to our process. All of the factory controls and quality management systems are compliant with British and European Standards. In addition to our Factory Production Control manual and Method Statement of Production the SMARTR Quality Protocol incorporates the following: 1. Organisation: Management and staff responsibilities Resource Management Audit and Records 5. Recovery from inert waste: Incoming waste materials Receipt of waste materials Records of received material Accepted loads Rejected loads Weighing and categorising Re-inspecting and stockpiling
2. Control Procedures:
Production management Inspection, calibration and control of equipment Handling and storage Production process control
6. Quality Control:
Testing procedure and frequency Stockpiling/dispatch Placement training/inspection
3. Inspecting and Testing of constituents and mixture during production:
Composition of the mixture Sampling from stockpiles
7. Information by producer:
Test results Test procedures Details of factory production control manual Conforming to the protocol provided by WRAP
4. Non-conformity:
Constituent non conformity Product non conformity
8. Quality Statement:
Quality Control for Dispatch and Batch Records of PV1
PVI will be used on the day of production, batch volumes will be determined by planned reinstatement requirements. Production will commence at approximately 6.30am and PV1 is loaded directly onto the grab wagons for deployment to site for placement. The material will be used within 8 hours of production. PVI will be covered with sheeting during transit and whilst storing on site prior to placement, as per best practice methods.
PV1 is an Alternative Reinstatement Material (ARM) and will be laid as per the reinstatement methods in accordance of Appendix A8, of the HAUC Specification for the Reinstatement of Openings in Highways, New Roads and Street Works Act 1991.
Recording batch details Web portal Corona
All grab drivers will be issued with a batch reference number once PV1 has been loaded and they are exiting the Processing Facility. This number will be recorded against the specific opening notice number on Corona (Laing ORourke Data Management System) from site, on completion of the backfill process. Photographs of each stage of the compaction process will be captured on Corona and are available live for Local Authorities to view on line. A clegg hammer test is also carried out as per best practice. Batch reference details will be uploaded onto Mayrise (the EDF Energy Management System for Street Works) against each opening notice number when submitting the Section 70 registration notice.
Quality control for dispatch and batch records of PV1
Pavimentum (PV1)
Compacting Pavimentum (PV1)
Product Criteria
The material is to be produced in accordance with the BS EN 14227-1 Hydraulically Bound Mixtures Specification Part 1: Cement Bound Granular Mixtures. PVI is classified a CBGM A In addition, the material meets the specifications for production, storage and testing in accordance with Series 800 of the Manual of Contract Documents for Highway Works Volume 1 Specification for Highway Works Amendment May 2009, and the quality guidelines set out by the Waste and Resources Action Plan (WRAP). The testing schedule of PVI as required by HAUC, SHW: 800 series and WRAP is listed below:
Test Description
Test Method Full waste suite of solids and 2-part leachate suite MCERTS Lab Clause 710
Source of requirement
Frequency
WAC Contamination analysis Sulphate/organic analysis Particle size distribution (grading) Moisture content Optimum water content by compaction test Compressive strength Immediate bearing index (tested 60-90 minutes after compaction) Strength after immersion Fines quality (tested before addition of cement binder) Workability period Frost susceptibility test
WRAP
1 per 2 weeks on rejected and accepted material 1 per 2 weeks on accepted material 2 per week 2 per week in lab 1 per day at plant 1 per week
SHW: 820.1
BS EN 933-1 BS EN 1097-5
SHW: 821.2 SHW: 821.3
BS EN 13286-4
SHW: 821.3
BS EN 13286-41
SHW: 821.4
2 per week
BS EN 13286-47
O'Keefe Quality Control Process
2 per week
SHW:880
SHW: 821.2
1 per week
BS1377-2
SHW: 821.1 O'Keefe Quality Control Process HAUC A9.2
1 per month
BS EN 13286-45
1 per month
BS1924-2
1 per month
Product criteria
Performance Properties
Cumulative percentage passing
100 90 80 70 60 50 40 30 20 10 0 0.01
Particle size distribution
Figure 1 Indicates the Particle Size Distribution Grading Envelope for CBGM A. Four separate samples of PVI taken over a one-month period show consistent grading characteristics within this envelope.
Figure 1 Particle Size Distribution for PVI within the Grading Envelope for CBGM A
0.1 1 10 Nominal aperture of test sieve (mm)
100
Figure 2 Assessments of Performance Properties of PVI
Moisture Condition Curing Condition 14 days soaked & 14 days sealed 28 days sealed 14 days soaked & 14 days sealed 28 days sealed 14 days soaked & 14 days sealed 28 days soaked 14 days soaked & 14 days sealed 28 days soaked 14 days soaked & 14 days sealed 28 days soaked Bulk Density (Mg/m3) 2.259 2.221 2.208 2.230 2.223 2.234 2.114 2.158 2.184 2.168 2.193 2.184 2.200 2.197 2.202 2.198 2.215 2.221 2.211 2.195 2.156 2.175 2.144 2.149 Compressive Strength (N/mm2) 5.7 4.9 5.1 6.2 5.5 5.2 2.8 1.6 2.4 2.8 2.9 2.8 4.5 3.9 5.0 4.7 3.0 2.9 3.0 3.0 2.9 3.6 3.6 3.8 4.2 4.0 3.6 90% 3.0 100% 4.8 4.2 86% 2.3 84% 2.8 Mean Compressive Strength (N/mm2) Volume Stability
5.2 92% 5.6
At vibrating hammer optimum moisture content
At 2.5kg rammer optimum moisture content
At vibrating hammer optimum moisture content
At 2.5kg rammer optimum moisture content
At vibrating hammer optimum moisture content*
* with additional 4 hours between mixing of cement and compaction
The results show that the compressive strength of the material meets the HAUC requirement and the measured volume stability exceeds the 80% value required by the Specification for Highway Works Series 800.
HAUC & Local Authorities Memorandum of Understanding
WRAP Materials Resource Efficiency in Street Works HAUC/RAUC released the following Memorandum of Understanding Update on the 10th March 2009:
The Commitment This memorandum of understanding sets out the Local Authority and Regional & National HAUC/RAUC commitment to: approving and encouraging the use of recycled and stabilised materials in street works where they meet specified performance and quality requirements; supporting the Street Works community (Utility Companies, Contractors, Local Authorities and Material Suppliers) in increasing the use of recycled and stabilised materials and reducing the waste arisings sent to landfill; using trial data and case study information to inform the approval of recycled and stabilised materials in street works; and pro-actively sharing knowledge on the use of recycled and stabilised materials.
EDF Energy Networks, Laing ORourke Infrastructure and OKeefe Utilities are committed to providing a quality, recycled product for use in reinstatement in the highways.
OKeefe Utilities Limited
St. Andrew's House 1 Dreadnought Street, off Boord Street, Greenwich, London SE10 0PU Tel: 020 8858 9124 Fax: 020 8858 0806 [email protected]
