Case Study: Material Logistics Planning Tubney Barn, Oxfordshire: … final.pdf · 2019-05-09 · While steps have been taken to ... Beard’s customers are involved in arts and culture,

Case Study: Material Logistics Planning

Tubney Barn, Oxfordshire: Beard Construction

Demonstrating the benefits of implementing a Material Logistics Plan on a grade ll listed barn conversion to improve material recovery and reuse.

Project code: WAS610 Research date: December 2008 - June 2009 Date: March 2010

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Written by: Greger Lundesjo, The Logistics Business

Front cover photography: Tubney Barn conversion to student accommodation, Oxfordshire WRAP and (The Logistics Business believe the content of this report to be correct as at the date of writing. However, factors such as prices, levels of recycled content and regulatory requirements are subject to change and users of the report should check with their suppliers to confirm the current situation. In addition, care should be taken in using any of the cost information provided as it is based upon numerous project-specific assumptions (such as scale, location, tender context, etc.). The report does not claim to be exhaustive, nor does it claim to cover all relevant products and specifications available on the market. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. It is the responsibility of the potential user of a material or product to consult with the supplier or manufacturer and ascertain whether a particular product will satisfy their specific requirements. The listing or featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual products or materials. This material is copyrighted. It may be reproduced free of charge subject to the material being accurate and not used in a misleading context. The source of the material must be identified and the copyright status acknowledged. This material must not be used to endorse or used to suggest WRAP’s endorsement of a commercial product or service. For more detail, please refer to WRAP’s Terms & Conditions on its web site: www.wrap.org.uk

Executive summary Beard Construction, based in Swindon and Oxford, is used to working in historical surroundings and has developed considerable expertise in refurbishment of historical and listed buildings. Beard expressed an interest in taking part in WRAP’s (Waste & Resources Action Programme) programme to identify and promote tangible benefits in terms of waste and CO2 reduction by implementing a Material Logistics Plan (MLP). Tubney Barn was selected as a pilot project. It is a relatively small project, £600,000 in value and with a six-month project plan. As such, it could be monitored from beginning to end and would allow Beard to learn from the experience of using an MLP in a fairly short time frame. Recovery and reuse of materials are essential aspects of working with listed buildings. They also serve to minimise waste, and were the main strategies of this project. Reused bricks, stonework and tiles were never classified as waste and therefore do not appear as “reuse on site” in the statistics. Only materials that could not be used on site were recorded as waste. At Tubney Barn, a barn conversion to provide student accommodation, 98% of waste was diverted from landfill. Key elements in logistics strategy

Adapt and use the MLP template. Beard’s project manager adapted the WRAP MLP template to the company’s spreadsheet-based planning system and used it for planning materials and resources. The MLP was a useful tool when working with contractors; it helped the project manager co-ordinate contractors and plan for appropriate handling equipment to deal with deliveries.

Engage major sub-contractors in waste minimisation efforts. Logistics and waste minimisation were put on the agenda at sub-contractor meetings. Sub-contractors were asked to plan major deliveries with a view to minimising waste.

Small call-off volumes, just-in-time. For some materials orders were placed for the total expected usage, but only 25% was delivered to site at any one time. It was a small site but limiting the quantities delivered at any one time meant loads could be dropped conveniently for the trade contractors. This avoided both damage in storage and surplus materials being left on site at the end of the project.

Focus on materials reuse. Stone, brick and tiles were reused as far as possible – a requirement when working with grade II listed buildings. Where necessary quantities were made up from materials recovered from other sites.

Introduce carbon neutral processes. Internal walls and insulation were based on Hempcrete mixed on site. This is a carbon neutral process/material. Only the required volume is mixed and there is no waste other than some packaging from the process.

Pool surplus materials between sites. Beard works on many old buildings where material recovery is a key feature. Rather than sending surplus materials to external reuse/recovery Beard often pools such materials for reuse in other local projects.

Use local recycling specialists. By careful segregation of wood on site and by using a local wood recycling company, the wood is reused in manufactured products rather than converted to MDF.

The strategies and results highlighted in this report are influenced by logistics principles. Focus on materials, analysis and planning of materials movements, and collaboration with sub-contractors are all parts of the logistics approach and will have even more of an impact in larger projects where a greater variety of materials are brought to site.

Tubney Barn, Oxfordshire: Beard Construction 1


Contents 1.0 Beard Construction ..................................................................................................................... 3

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10

2.0 Tubney Barn................................................................................................................................ 3.0 Material Logistics........................................................................................................................

3.1 Implementing the WRAP Material Logistics Plan (MLP) ................................................................ 3.1.1 Adapting the MLP ...................................................................................................... 3.1.2 Project management advantages of using MLP............................................................

3.2 Material supply and usage ......................................................................................................... 3.3 Waste handling......................................................................................................................... 3.4 Wood recycling .........................................................................................................................

4.0 Waste Data ................................................................................................................................. 5.0 Conclusions ...............................................................................................................................

1.0 Beard Construction Beard is a medium sized construction company based in Swindon and Oxford, undertaking construction projects typically ranging in value from £1 million to £3 million, and occasionally up to £10 million. The company employs over 150 people and has a turnover of £55 million. Beard’s customers are involved in arts and culture, commerce and industry, education, healthcare, elderly care, emergency services and sports and leisure. Critical to one aspect of Beard’s success has been its experience both in the use of traditional materials and methods, and in the recovery and reuse of materials. Beard’s considerable expertise in refurbishment of historical and listed buildings is demonstrated by awards won in recognition of the contribution made to the preservation and enhancement of Oxford’s heritage. Beard has won awards for work on well-known buildings such as the Sheldonian Theatre, the Pitt Rivers Museum and the Radcliffe Science Library. 2.0 Tubney Barn Tubney Barn is the conversion of a grade II listed building for student accommodation.

Conversion of farm buildings of stone construction into student accommodation. Project value £ 600,000. Project programme: November 2008 – May 2009.

Figure 1 One of the two buildings being converted.

Figure 2 The same building complete with original tiles and solar panels for hot water supply.


3.0 Material Logistics 3.1 Implementing the WRAP Material Logistics Plan (MLP) Prior to this project, developing a logistics plan was not a formalised activity within Beard – logistics planning was just an implicit part of the project manager’s role. After discussions with WRAP, Beard’s project manager took the decision to implement and use WRAP’s MLP template, using the Tubney Barn project as a pilot study. Beard uses an Excel spreadsheet system as a planning tool, so to make the logistics plan compatible they copied the tables of the MLP onto a spreadsheet format. See below.

Figure 3 The spreadsheet-based MLP made by Beard’s project manager - red indicates critical items

Item

Project Stage

Expected Construction

Period

Material/Resource

Pre‐estim

ate of Quantity

Actual Quantity (KPI)

Delivery Method

Delivery Timings

Design W

aste (e.g. off

cuts) %

Construction process

wastage %

1

Justification of design &

process wastage

Supply route

Receiving Location

Storage Location

Guidelines for reception

and storage of materials

Procedures for handling

(incl equipmen

t)

Commen

ts

1 Strip roof coverings Jan‐09 Tiles Un‐quantified

Un‐

quantified

Already on site. No material to

be removed from site. Re‐

usable tiles set aside for

reuse. Broken tiles set aside

for use on site as hardcore. N/A 0% 0%

On some projects all roof coverings

would e stripped and sent to landfill i.e.

100% waste N/A N/A

Stored on

scaffold ready

to be reused N/A Manual handling

2 Roof coverings

March‐

April 09

Additional salvaged

tiles to be brought

to site from

elsewhere, plus felt

and batten Un‐quantified

Un‐

quantified

Flat bed lorry from Bicester

Roofing TBA 5% 5%

Small off cuts of felt and tile batten

cannot be reused. Unusable cuts of tiles

will be used as hardcore on site

From roofing

contractors

yard in

Bicester Oxon

to site

Site

office

To be loaded

directly onto

scaffold or roof N/A Manual handling

3

Breaking out concrete

floors

Nov‐Dec

08 Waste concrete Un‐quantified

Un‐

quantified

To be set aside on site as for

reuse as hardcore N/A 0% 0%

On some projects 100% demolition

material would be taken off site although

some would be recycled N/A

On site storage

area N/A

Move to storage area

with dumper

4 Metal from demolition

Nov‐Dec

08 Waste metal Un‐quantified

Un‐

quantified

All waste metal set aside for

recycling. Removed from site

in scrap metal bin

On completion of

demolition once

all metal

removed and

separated 3% 3%

On some projects it would not be

possible to separate the materials so

100% would be taken off site as mixed

waste although some could be separated

at waste transfer station

To local

salvage yard

To local

salvage

yard Scrap metal bin Manual handling

Wear appropriate PPE

gloves etc

5 Roof structure Feb‐09 Crane 1 visit 1 visit Moblie Crane

12th February

2009

From storage

yard to site,

via local roads.

Site

office At point of use N/A

Contract lift with lifting

certificates, Risk

Assesments and Method

statements.

Ensure lifting plan is

arranged in advance.

Ensure crane base is

prepared

6 All stages

Nov 08‐

May 09 Skip 5 nr 5 nr skip lorry

Phone call off

when required.

Wood

57%,Plast

ic

13%,Bric

ks 13.2%,

From yard via

local roads

Site

office

As shown on

site plan

Material to be loaded

into skip manually.

Segregate timber to be

collected separately and

recycled

7 Masonry

Nov 08 ‐

March 09 Lime mortar Un‐quantified

Un‐

quantified Subcontractors van 2% 2%

Builders

Merchant via

local roads

Site

office

Store outside in

bags sheeted

over close to

point of use

(mixer) Keep dry

Hiab offload, manual

handle thereafter

Lime can be reused by

mixing up with new

batch

3.1.1 Adapting the MLP Apart from copying the MLP format onto a spreadsheet, Beard’s project manager also adapted the MLP to suit the project in question and his way of controlling the project. The MLP template and guidance document can be downloaded from: http://www.wrap.org.uk/construction/how_do_i_reduce_waste/logistics.html

Some of the main tables in the plan are:

section 3 Material Requirements, which identifies materials, quantities, delivery methods and timings, expected wastage and supply routes;

section 4 Material Receipt, Storage and Management, which defines receiving and storage locations for materials and resources, and also specifies guidelines and procedures for storage and handling; and

section 6 Site Mobilisation and Construction, which identifies staff, equipment and plant required for managing the different materials.

These three parts of the plan were combined in one large spreadsheet. For a small project like Tubney Barn this provided a convenient overview of materials, resources, timings and expected wastage in one place.


http://www.wrap.org.uk/construction/how_do_i_reduce_waste/logistics.html

3.1.2 Project management advantages of using an MLP On implementing an MLP the project manager directly experienced several advantages.

Working through the planning structure makes materials and logistics an integral part of the project and not something that comes as an afterthought once the construction plan has been drawn up.

It helped in co-ordination between the main contractor and sub-contractors. Where for instance a sub-contractor was responsible for material delivery but the main contractor for providing necessary handling equipment, the plan ensured that equipment was available at the right time and storage areas provided.

The project manager engaged the main sub-contractors in waste minimisation efforts. The plan was useful in communicating the concept of materials logistics planning with the sub-contractors – identifying major material deliveries, storage and handling requirements.

3.2 Material supply and usage As far as is possible Beard reuses materials from the site and from other similar sites. When new materials have to be supplied, natural materials are used wherever possible. Listed building status makes this an imperative.

An overall quantity of wood was estimated and ordered for all joists and rafters, but only 25% of the order was called off at any one time so smaller quantities were delivered to prevent surplus wood being on site at the end of installation.

Stonework was recovered, cleaned and reused wherever possible.

Roofing tiles had to be reused but where unsalvageable, tiles had to be replaced. Beard used tiles from another site where the roof was being replaced by new materials.

Beard generally attempts to pool materials that are surplus to any one site for possible reuse on other sites before considering wasting the material.

Other initiatives worthy of note though not related to logistics:

o the characteristics of the lime mortar used mean that any surplus can be remixed with a new batch, instead of disposing of the unused mix at the end of day;

o Hempcrete, a hemp-based material, was used for wall insulation. It is mixed on site and the whole process is carbon neutral. It leads to no waste as only the volume required is mixed; and

o sheep wool was used for roof insulation.

Figure 4 Recovering stone and brick on site and (right) cleaned stone ready for reuse.


Figure 5 Tiles collected and cleaned.

Figure 6 Hempcrete wall finished off using only water-based materials.


3.3 Waste handling

For waste recording Beard uses the BRE Smart Waste tool.

Waste materials were sorted approximately 10 miles away at Aasvogel’s transfer station in Wantage.

Plasterboard was segregated from general waste and collected by Aasvogel Skips.

Timber was segregated on site and recycled by Oxford Wood Recycling, see Figure 9.

Excavated material and surplus stone were collected with the intention of bringing a crusher to site and using the material for the (very necessary) improvement of the access roads. Unfortunately the client decided to buy new material rather than bring in a crusher as the cost was slightly lower. The material was sent to off-site reuse – resulting in 21 lorry loads.

Figure 7 Only one skip was kept on site with waste segregated at the transfer station.

Figure 8 Excavated materials and surplus stone removed rather than reused on site.


3.4 Wood recycling Oxford Wood Recycling Ltd (OWR) aims to reuse and recycle wood and timber, helping to reduce the amount of waste wood sent to landfill. By careful sorting and processing of the waste wood collected, OWR is able to supply a wide range of reclaimed timber and other wood materials for garden or household projects. Oxford Wood Recycling Ltd is a social enterprise creating jobs and training opportunities for people in Oxfordshire, particularly people who face barriers to working.

Figure 9 Timber was segregated on site.

Figure 10 Oxford Wood Recycling collecting from site.


4.0 Waste Data Reuse is the main feature of this project and it should be noted in the table below that bricks, stonework and tiles that have been reused were never classified as waste and therefore do not appear as “reuse on site” in the statistics. Only materials that could not be used on site were recorded as waste. This is normal in a listed building conversion where in fact the major part of the materials are reused.

Table 1 Data extracted from the SmartWaste Plan for the complete project – m3 Type of waste Reuse off

site Reuse on

siteRecycle offsite

Sent to landfill

Total

Bricks/Stone 174.32 0 3.85 6.96 185.13Wood 31.29 15.01 0 4.2 50.5Green Waste 0 0 0.21 0.14 0.35Soil 0 0 7.39 2.43 9.82Plastic 0 0 6.13 0.3 6.43Plasterboard 0 0 7.34 0.07 7.41Plastic Wrap 0 0 3.45 1 4.45Metal 0 0 20.19 1.04 21.23Tiles 50 0 9.31 0 59.31Concrete Floor 550 0 0 0 550Total 805.61 15.01 57.87 16.14 894.63

Graph 1 %breakdown of waste categories



Table 2 Waste breakdown and divert from landfill %.

Graph 2 % waste breakdown.

Waste breakdown

90%

8%2%

ReuseRecycleLandfill

5.0 Conclusions It was the focus on material recovery and reuse that had the main impact on waste minimisation in this project. By working with recycling specialists, Beard was able to divert from landfill 98% of the waste generated. The only negative experience in the project was that a substantial volume of excavated materials could have been reused on site for access road improvements. For cost reasons the client chose not to do this. As a result 21 additional lorry loads were needed to transport the material to off-site recovery. Beard used this barn conversion as a pilot project for trying out and evaluating Material Logistics Planning. While a small project like this doesn’t present the same logistics challenges as a large project, as a pilot it had advantages. The small size meant that with a reasonably minimal effort the project manager could adapt the MLP format to the project and to Beard’s working practices. The short time plan meant that within less than a year of first engaging with WRAP, Beard was able to review the experience and decide on how to extend Material Logistics Planning within the organisation.

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Case Study: Material Logistics Planning Tubney Barn, Oxfordshire: … final.pdf · 2019-05-09 · While steps have been taken to ... Beard’s customers are involved in arts and culture,