Details how a Motorway / Highway is constructed.

1. David H Moloney
Nov 2016
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.
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)

2. Contents
ⓒ David H Moloney

3. Earthworks
Earthworks
Includes
Excavations, filling, compaction, disposal and landscaping.
Cut through hills
Fill in low areas
Strip Vegetation &Topsoil

4. Mass Haul Diagram
Earthworks
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.

5. Outputs - Excavate & Load, Cart, Tip & Return
Brief Description
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
Earthworks
7 minutes
14 minutes
3 minutes
14 minutes 7 km
7 km

6. Outputs for Excavate & Load, Cart, Tip & ReturnEarthworks

7. 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

8. Outputs for Rock breakingEarthworks

9. Rock CutEarthworks

10. Trench - Safety Measures
Health,Safety&Environment

11. Existing Underground Utilities
ⓒ David H Moloney
Brief Description
Before digging establish the
location and route of
underground utilities.
Locator to find Utilities
Spray Paint to mark pavement
Health,Safety&Environment

12. Roads & Pavings
Roads&Pavings
Includes
Sub-base, base and surfacing, kerbs, footpaths, traffic signs and markings.
Signs & Markings
Asphalt pavement
Median Barrier
Basecourse

13. CABC ( Crushed aggregate base course )
Roads

14. CABC ( Crushed aggregate base course )
Earthworks
Mixing Plant
Testing Compaction
Site Trial

15. Crushed Aggregate Basecourse
ⓒ David H Moloney
Paving

16. Asphalt Paving
ⓒ David H Moloney
Paving

17. Asphalt Paving
ⓒ David H Moloney
Paving

18. Insitu Concrete Barrier
ⓒ David H Moloney
Paving
Slipform central median barrier, the
moving formwork allow for the
simultaneous extrusion and finishing
of the concrete. Powerful vibrators
compact the semi-dry concrete.

19. Steel Traffic Safety Barrier
ⓒ David H Moloney
Paving
The barriers are designed to keep vehicles
within their roadway and prevent vehicles from
colliding with dangerous obstacles such as
bridges, buildings, walls or large storm drains.

20. 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.

21. Road Signs
ⓒ David H Moloney
Paving
Road signs are signs erected at the side of or
above roads to give instructions or provide
information to road users.

22. Bridges
Bridges

23. Bridge Construction
ⓒ David H Moloney
Concrete

24. Bridge Construction
ⓒ David H Moloney
Concrete

25. Reinforced Wall Construction Sequence
ⓒ David H Moloney
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

26. Reinforced Wall Construction Sequence
ⓒ David H Moloney
Concrete

27. Concrete MixGeneralItems
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.

28. Vibrating Concrete
ⓒ David H Moloney
Concrete

29. Culvert Construction
ⓒ David H Moloney
Concrete

30. Piling Insitu Concrete

31. Piling Construction - Vertical PilesPiling

32. Piling Construction - Raking PilesPiling

33. Surveying&settingOut
Survey & Setting Out

34. Setting out & Surveying

35. Setting out & Surveying

36. Site Facilities & Temporary Works
SiteFacilities&temporaryWorks

37. Site Facilities
SiteFacilities&temporaryWorks

38. Welfare Facilities
ⓒ David H Moloney
GeneralItems
Toilets – Washing
Canteen, Drying Room, Toilet & Generator

39. Site Hoarding examples
ⓒ David H Moloney
GeneralItems

40. Wheel Wash Drive-through
ⓒ David H Moloney
GeneralItems

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

42. Dewatering
ⓒ David H Moloney
GeneralItems
Brief Description
Construction dewatering is the removal or drainage of
groundwater and or surface / rain water usually by
pumping to keep the works dry.

43. 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

44. Concrete Batching Plant YardGeneralItems

45. Quarry & Aggregate Production
3D image to show Sequence, Method & Plant.
ⓒ David H Moloney

46. Quarry Operations

47. Reinforcement Cutting & Bending Yard David H Moloney
ⓒ 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

48. 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.

49. Health, Safety & Environmental
Health,safety&environmental

50. Emergency Phone Numbers & Response

51. HSE Monitoring & Reporting - Dashboard Dashboard is a single page, graphical representation of
current HSE Issues and historical trends

52. Safety Training Matrix
Miscellaneous The purpose of safety training is to provide the knowledge necessary to
perform a job safely

53. 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

54. Safety Precautions

55. Site Safety Posters examples

56. Environmentally Friendly Site Air, Noise, Water & Soil Pollution

57. Hazardous Substances Symbols
Health,Safety&Environment
COSHH stands for the
Control of Substances
Hazardous to Health
Shown are the new
hazard symbols

58. Water Pollution PreventionGeneralItems

59. Segregation of WasteHealth,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

60. Putting Waste Concrete to use
ⓒ David H Moloney
Health,Safety&Environment Precast bases for signs and hoarding,
Precast blocks for walls.

61. Quality Assurance
QualityAssurance

62. Quality Assurance Dashboard Dashboard is a single page, graphical representation of
current statistics and historical trends

63. Laboratory
ⓒ David H Moloney
AsphaltPaving

64. Administration
Administration

65. Organogram
Brief Description
Shown are the line and
lateral relationships
between the various team
members and their relative
position in the site
organisation.

66. Staff Responsibility Matrix

67. Staff Directory
Brief Description
List of staff and their
contact details

68. Daily Work Record
Brief Description
Daily Work Records showing the
allocation of resources, materials and
work activities carried out daily.

69. Quotations Comparison Sheet

70. Filing System

71. Programme & Progress Monitoring
Programme&ProgressMonitoring

72. Progress Monitoring & Reporting - Dashboard
ⓒ David H Moloney
Dashboard is a single page, graphical representation of current progress and historical trends

73. 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

74. Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney

75. 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
Legend

76. End