Holdfast Training Services Trial Blog

My main focus over the last two weeks has been the planning and execution of the trials of the water proof membrane layer of the Sprayed Concrete Lining tunnels. Following the application of the initial layer of spray concrete (min 75mm), which stabilises and regulates the substrate, the primary layer (between 250mm and 350mm) , which is comprised of the same concrete mix, with steel fibre reinforcement to provide the main structural element of the tunnel the waterproof membrane is applied. This will subsequently be ‘sandwiched’ by secondary layer and finally a surface layer which I will not discuss here. See drawings  Typical Lining and Thicknesses

The ‘Eye of Sauron’ is now on this section of the works, and I have lost count of the amount of times the client side have reminded me that we dont want to be standing on the platform in a few years time next to a bucket catching the drips from the lining. The chemical is polyurethane based, and is delivered as a white powder in 20kg bags. Designed to be used in hand or spray application, the powder is mixed with water and applied to the lining as a paste, which then cures to a material of the texture of a hard rubber. The lining is applied to a thickness of 4mm, which leaves a smooth and shiny finish.

Logica spraying MasterSeal (Top)
Inspection of MasterSeal layer for compliance, alongside MottMac Designers (bottom)

Concurrently, a spray application machine known as the Logica has been procured from BASF, one of the suppliers of waterproof membrane. This machine not only doubles the rate of production, but minimises wastage by its ability to automatically spray to a pre programmed profile. The trial of this machiine was observed by a number of nozzlemen who obviously felt consigned to the stoneage! However, the procurement of material and machine have thrown up a number of interesting contractual notes.

ISSUES

1.     Logica.

        A flat bed lorry carrying a hose arragement designed to attach to a spray concrete delivery system, applying upto 20m3/hr of concrete to the walls. Much the same as a system that already exists on site, uniquely it is has an on board automated survey system allowing it to scan a the profile of the tunnel, then apply material to a consistent thickness. Manufactured by MeyCo in Switzerland there are only 5 operational units in the world. BASF purchased one, and are seeking to procure a second. (This is important later.)

The BFK JV deemed it appropriate to rent this machine to apply the waterproof membrane across all SCL sites. A smart move given that 373tonnes are required, not including tolerances or wastage. BASF now lease the vehicleto us at a flat rate of £12500/month. The delivery to site and subsequent testing and approval then became my issue.

For someone who has now embraced Whole Fleet Management, and a few headaches aside, been impressed, I was astionished at how little we got for our money. The vehicle turned up at site having been ‘refurbished’ Despite having been given a thorough wash and wax, it immediately became clear that this had not happened , as I quickly found myself replacing water pipes and watching the replacement of a hydraulic ram on the boom. Clearly the machine had not been run up at all before delivery.

Secondly, and mainly due to the unique nature of the machine the corporate knowledge for operation is almost nil, even with BASF. It is all contained witin the head of an Austrian fellow called Kristian, who lives, conveniently, in the Faroe Islands! He nursed the machine back to life over the course of a day and night and we were back in business and now the best of friends (although I strongly suspect he may be an android!)

So….the program for waterproofing and secondary lining is now solely reliant on 1 machine, and 1 man. More to follow

2.   MasterSeal.

The BASF branded waterproof membrane product. By far the most expensive element of the tunnel lining, and the the 373 tonnes will cost us just shy of £1.3million. Not only that, it is manufactured in the States and comes with a 6 week lead time. Additionally it will arrive in 20ft shipping containers, and since space on site is at a premium it certainly wont be stored here. But surely, considering the size of this order, all this will have been thought about? See below…

WHAT HAVE I DONE?

Considering the issues surrounding the vehicle, I sought out the contract to establish a what we could expect from BASF. There wasn’t one. The best I came up with was a Plant Hire Order detailing the quote and generic T&Cs. A bit more investigation found the initial invoice with an attached, generic contract from BASF which amongst other things told us that it was our perks to repair and maintain this machine AT OUR COST!
Given the lack of knowledge I organised the nozzlemen and fitters (M&E) to udergo familiarisation training at the beginning of each shift to try to mitigate the reliance on one Faroe Islander. Having directed this on the Friday, I expected 3 of the 4 shifts to have been trained by the Monday morning. Most were pulled away elsewhere !!!

Neatly slipped into the T&Cs was a clause that dictated the Logica was only to be used with BASF products…ie MasterSeal. This clearly makes it difficult to conduct a fair and objective commercial assessment of suppliers as it seems the horse has already bolted.
So based on this newly found knowledge, and a serious indicator in the fact that BASF are the only supplier seemingly in the race, I began to look into how the order was progressing. Again, there wasn’t one.

Next, I collated all the site programs, and established that the Fisher Street site intend to begin spraying waterproof membrane on 3 Jun 14, meaning that with the lead time for deliver plus a weeks contingency, the last safe moment to order this stuff is 14 Apr 14…11 days from now.

Thus, and in a mild panic by this stage, I returned to the commercial team to discuss lead times on the procurement process on an order so large. I was told and average of 2-3 months. Red Card moment.

REFLECTIONS

It seems that a limited Commercial Assessment was done in July of last year which compared 4 suppliers. BASF were preferred almost immediately despite being 2nd most expensive, as they could provide a better level of technical support, with the added sweetner of the Logica. However, since that point, nobody has been repsonsible for this section of work. This speaks to wider issueS at BFK which is thematic across the project.

Communication. Despite everybody being cognascent of the importance of this section of works, a robust plan has not been considered, resourced and properly tasked. This lack of proper tasking is exacerbated by the retincence of people to take responsibility for execution. Below senior management there is very little accountability. In this example, the commercial team have done a bit, and the construction team have done a bit and the whole process has been bounced around before being completely dropped. There is now NCO equivalent who seeks an intent, follows an endorsed scheme of manouevre, and is accountable for achieving an endstate.

So after a series of polite prompts, I presented all this to my line manager and said, we need to get this order completed, supported by a robust contractual agreement which details ongoing maintenance and technical support, and includes a training program for the guys, and guaranteed delivery times and storage for the product…and we need it yesterday. I was told ‘Ok…we best do that then…’

http://www.dailyecho.co.uk/news/11124187.BREAKING__Explosion_and_fire_in_student_block/?ref=var_0

No punchline, my building really is burning.

I’ve received a bit of a random cry for help that I could use the advice of the collective group for….

I have a mate who is now working out in Africa for the Halo Trust doing de-mining in Angola. The camp that he is running is basically built on sand. No problem for the buildings but the vehicles they use to get to the de-mining areas are struggling. He’s asked me what he can do to improve it (his first mistake could be asking for my help!).

I’ve attached the some photos he sent me below. He has a limited budget to improve the area (it being a charity that he works for) and is looking for the best “sticks and string” answer. The camp needs to last at least 5 years and the rainy season is November to end of March.

The town he is in is called Cuito Cuanavale in Kuando Kubango province Angola. You can google it and you’ll find a small airport, his compound is about 2.5Km NW of the airport. He’s up at 1250m above sea level and where he’s seen some exposed strata by the river it is all sandy soil with no rocks.

To find out a bit about the soil I got him to drop some of the material into a glass of water and see what happened – the photo below is after 3 mins. There is a sketch above that he sent me of the layout. The key areas are the vehicle park and the areas that the tractor towing the water tank on needs to get to – so a bit of a one way circuit around the edge would cover that. He should be able to get his hands on a roller from another de-mining camp without too much bother and maybe a local JCB for a short period.

Any and all (sensible) suggestions welcome!