The Challenge:
The project faced significant logistical challenges from the outset, with minimal laydown area and restricted working room due to the main on-site works being behind schedule. The construction of a substantial roundabout with drainage attenuation required careful coordination of activities and materials within a confined space, while maintaining access for other contractors working on the wider development. Complex drainage and duct crossings needed to be installed in high-traffic areas without disrupting site operations.
Scope of Works
Recognising the site constraints, we implemented a solution-focused strategy that prioritised flexibility and collaboration. Rather than requiring large material deliveries that would overwhelm the limited laydown area, we coordinated smaller, more frequent deliveries to maintain site progress without creating congestion. Our team worked closely with the client and other stakeholders to schedule activities that minimised disruption to all parties.
For particularly challenging elements such as drainage and duct crossings in high-traffic areas, we strategically scheduled these works during weekends when the wider site was closed. This approach maintained access for other trades during weekdays while ensuring our critical path activities progressed efficiently. Throughout the project, we maintained open communication with all stakeholders to coordinate activities and adjust work sequencing as site conditions evolved.
Location:
22 weeks (29th April 2024 - 2nd October 2024)
Project Value:
£806,000.00
Duration:
22 weeks (29th April 2024 - 2nd October 2024)
Client:
McLaren Construction Group PLC
Contract:
Client Bespoke
Horsley Cross Roundabout
Construction of 28-meter roundabout off B1035 Clacton Road, improving traffic flow and development access while enhancing highway safety.
Our Approach:
Our comprehensive delivery included:
Roundabout Construction:
Construction of a 28-metre diameter roundabout off the B1035 Clacton Road
Creation of flared approaches to the junction on all arms
Installation of a 4-metre diameter central island with 6-metre wide overrun area
Excavation of existing ground to formation level
Placement and compaction of sub-base materials
Installation of new kerbing throughout
Drainage Systems:
Installation of new road gullies, pipework and manholes
Construction of a new drainage attenuation basin south of the existing carriageway
Integration with existing drainage networks with controlled discharge rates
Highways Infrastructure:
Removal and replacement of street lighting to suit the new carriageway layout
Installation of new signage systems for the revised road configuration
Removal of redundant carriageway sections and reinstatement as verge areas
Final surfacing of both new and existing carriageway for smooth transitions
Overcoming Challenges:
When unexpectedly strong California Bearing Ratio (CBR) test results were obtained on the formation, we quickly adjusted our approach to reduce excavation depths and sub-base material requirements. This not only accelerated the construction programme but also reduced vehicle movements and material usage, creating both environmental and cost benefits.
A significant challenge emerged when the client’s appointed contractor for service installations was unable to obtain necessary permits in time, delaying access to certain areas and preventing timely handover to the local authority as some excavations remained open awaiting service connections. Our team responded by maintaining open communication with all stakeholders and adjusting work sequencing to minimise downtime.
The final road surfacing required careful coordination, as it needed to be executed during pre-agreed night-time road closures. These closures were planned and approved in collaboration with the local authority and National Highways three months in advance, ensuring all preparatory works were completed on schedule to take full advantage of these limited working windows.
Key Achievements:
Despite the initial site constraints and unexpected delays with service installations, we delivered the works with minimal disruption to the overall programme. The final surfacing was successfully completed during the pre-arranged night closures, demonstrating our ability to plan and execute time-critical activities effectively.
Our sustainable approach to material management saw surplus topsoil from the main on-site construction works repurposed for the Section 278 works, eliminating the need to import additional material. This innovative solution significantly reduced the project’s carbon footprint while providing cost benefits by avoiding off-site disposal.
The completed roundabout now provides safe, efficient access to the development while improving traffic flow on the B1035 Clacton Road. Through collaborative working and flexible solutions, we successfully navigated the challenges of working in a multi-trade environment to deliver high-quality infrastructure that meets both client and local authority requirements.