M40/M42 Interchange Central Barrier Replacement 

Innovation and high productivity on the M40/M42 interchange. We delivered a high-quality scheme, 3 months ahead of schedule, with substantial efficiencies, carbon reduction and minimal customer disruption. 

Project overview

Our M40/M42 Interchange team developed an outstanding, innovative solution for the first precast foundation and above-ground barrier installation of 10.5km of Central Reserve Rigid Concrete Barrier (RCB).  

Our challenge was to find a solution that would avoid costly drain relocations and minimise impact on existing infrastructure. Our solution is surface mounted, enabling quicker installation and eliminating time consuming post installation operations normally required for traditional barrier options. 

We rehearsed delivery and installation of the 8m long, 4t precast foundation units, using exclusion zones and handling plans. We developed a safety methodology where units could be delivered and installed without requiring further traffic management, eliminating months of additional traffic management night-time lane closures, significantly improving safety and production outputs. 

We also undertook a full installation rehearsal of foundations and barriers and proved that we could safely install 12 barrier units (96m in total) in 1 hour, with our automated, precision-drilling rig simultaneously drilling two holes for connection of foundation and barrier unit per minute. The rehearsal confirmed that all required specification tolerances could be successfully achieved.  

Our solution provided journey time reliability and reduced traffic disruption duration with our 3-month early reopening, whilst causing zero harm and delivering maximum carbon reduction.