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LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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WSH INNOVATION AWARD 2016
Lian Soon Innovative Drain Project
“iDrain - The Durable-Reusable ECM Drain”
Presented by:
Lian Soon Construction Pte Ltd
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Lian Soon Construction iTeam
Steering Committee Executive Director KC Lee
Project Director Gary Tan
Facilitator HOD EHS Ariola Ruel Penaflor
Director Yuen Sik Weng*
Members Senior Project Manager Wong Chin Boom
WSH Officer T P Ramachandran
WSH Coordinator K. Balamurugan
Site Manager Tan Yong Keng
* Affiliated company (Greenleaf Industries Pte Ltd – in-charge in fabrication)
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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CONTENT
� Background of the Project
� Identification of the Root Causes of the Problem using Fish-Bone Analysis
� Introduction of iDrain
� Notable Comparisons – Environmental, Health, Safety & Financial Aspect
� Tangible & Intangible Results
� Continual Improvement thru PDCA Cycle
� Q&A
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Background of the Project
ECM Drainage system is a legal requirement by PUB before any earthworks can commence.
This is considered fixed-temporary structure.
Needed to be demolished at certain stage of the project or at the tail end of the project.
ECM Drainage installation is normally constructed using C7 concrete channel.
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Conventional C7 ECM Drain:
� Easy to break during raged handling
� Heavy to carry using manual labor
� Bulky to store, require more space
� Challenging to install due to it’s weight
� Require excavator to lift and install
� Require more manpower
� Require Lifting Plan & Lifting Team
� Require breaker to demolish
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Background of the Project
C7 Concrete Channel ECM Drain is prone to damaged due to raged handling.
Pure Expense – minimum recovery.
High recurring cost (install/demolish at certain stage)RECURRING
COST WITHOUT
RECOVERY
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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C7 Drain is costly &
Minimum RecoveryMATERIALS
Minimum recovery
Heavy Weight
Bulky to store
METHOD
High recurring Cost
(Install/Demolish)
MACHINERY
Raged handling
Prone to damage
MANPOWER
Poor handling
Need more man to carry
Bulky & heavy
Analysis of the ProblemUse of Conventional C7 Concrete Channel
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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C7 Drain is costly &
Minimum RecoveryMATERIALS
Minimum Recovery
Heavy Weight
Bulky to store
METHOD
High recurring cost
(Install/Demolish)
MACHINERY
Raged handling
Prone to damage
MANPOWER
Poor handling
Need more man to carry
Bulky & Heavy
Analysis of the Problem: Root CausesUse of Conventional C7 Concrete Channel
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Analysis of the Problem: Finding Solutions
Areas of Improvement Problem Identified
(C7 Drain)
Approach
Materials Minimum recovery Substitute an alternative material that is
durable, light weight and stackableHeavy weight
Bulky to store
Method Use of Excavator Elimination the use of heavy machinery by
employing manual laborExposed to heavy
machinery
Recovery Minimum recovery after
demolition
Substitute to reusable material
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Areas of Improvement Problem Identified Proposed Solution
Disposal Mixed waste Substitute to recyclable material – therefore
no need for disposal
Manpower Licensed Excavator Operator Elimination the requirement of heavy
machineryRigger man/Signalman
Tradesman Maintain manual labor for installation and
recoveryGeneral Worker
Work Sequence High recurring cost Substitute to reusable and recyclable
material to reduce cost
Analysis of the Problem: Finding Solutions
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Project Objective:
To innovate an alternative to conventional C7 Concrete Drain
Strategies:
1) To find an alternative durable/reusable material
2) To design an innovative and practical equivalent of C7
concrete channel
3) To reduce risk exposure of workers
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Parameters Option 1 Option 2 Option 3
Material Plastic* Aluminum** Mild Steel
Characteristics (20%) Very Light Light & Durable Moderately Light &
Very Durable
Reusable (20%) Yes Yes Yes
Recyclable (20%) Yes Yes Yes
Environmental Friendly (20%) No Yes Yes
Cost Effective (20%) No No Yes
Overall Score 60% 80% 100%
1) Finding a Durable-Reusable Material
Legend:
*Customized size & Plastics are non-biodegradable
**Aluminum sheet is very expensive. 40% more expensive that mild steel.
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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2) Designing an innovative & practical C7 equivalent
810mm
280mm
495mm
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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3) Reduce Risk Exposure to workers
C7 Drain Installation of ECM Drain iDrain
High Excavation using Excavator Reduced
High Installation using Excavator * Eliminated
High Exposure to Hot Weather Reduced
High Heavy Load Eliminated
Reduce to ALARP
2 High Risk
Eliminated
2 High Risk
Reduced
Legend:
*Excavator with Lifting Machine (LM) Certificate.
RL = Risk Level
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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3) Reduce Risk Exposure to workers
C7 Drain (RL) Demolition of ECM Drain iDrain (RL)
High Hacking Works Eliminated
High Hacking using Excavator Eliminated
High Exposure to Hot Weather Reduced
Legend:
RL = Risk Level
Reduce to ALARP
2 High Risk
Eliminated
1 High Risk
Reduced
Results of the 3 Strategies were collected.
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Introduction of iDrain (The Durable-Resuable ECM Drain)
� Durable
� Light-weight
� Easy to install
� Eliminates use of heavy machinery
� Reduce manpower requirement
� Eliminate lifting requirement
� Stackable – save space for storage
� Easy to recover and re-usable
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Introduction of iDrain – The Durable-Reusable ECM Drain
� 3mm thick (S275 Mild steel)
� 9mm flat bar stiffener along its perimeter
and center section
� Weep hole provisions
� Galvanized coated to prevent rapid corrosion
iDrain specifications:
Length: 1220mm
Width: 580mm
Weight: 38 kg
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Designing an innovative & practical C7 equivalent
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Designing an innovative & practical C7 equivalent
� Corrosion protection (Galvanized Coated)
� Eliminate connection joint sealing (Overlapping joints)
� Improved flow* (MS plate is more fluid in terms of water flow)
� Reusable to >5 cycle years (100% ROI after 2nd use)
* Manning’s coefficient of roughness in average velocity flow in open channel
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Notable Comparisons (C7 Drains vs iDrain)
C7 Drain Physical Comparison iDrain
70kg Weight 38 kg (72% Wt. Reduction)
600mm Length 1220 mm
810mm Section 580mm
495mm Depth 470mm
Notes:
iDrain is 2x length of the C7 Drain.
iDrain is easier to maintain & clean.
iDrain cross section A=0.2m2 (thinner)
C7 Drain cross section A=0.2m2
Manning’s coefficient of roughness:
C7 Drain = 0.025 iDRAIN = 0.012
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Notable Comparisons (C7 Drains vs iDrain)
C7 Drain Cost Comparison iDrain
$10.60 Market Price Unit Price Fabrication Cost $106.00
167 100m run (qty) 84
$1,910.20 Material Cost $ 9,754.00
$720.00 Manpower Cost $120.00
$840.00 Machinery Rental $280.00
$800.00 Hacking Cost $120.00
$350.00 Disposal Cost $0.00
$46.20 Unit Rate per 100m run $102.74
0 Cycle to break even 2.2
Notes:
100m = C7 Drain = 3 days to complete = 2 Workers + 1 Rigger/Signalman + 1 Excavator Operator
100m = iDrain = 1 day to complete = 2 Workers
Please refer to the detailed costing comparison for details.
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Notable Comparisons (C7 Drains vs iDrain)
C7 Drain Safety iDrain
High Exposure to heavy machinery* Eliminated
Moderate Exposure to heavy manual lifting Eliminated
Notes:
The change in material equate to safer methodology.
Total elimination of hazards associated to heavy machinery.
Eliminate manual lifting of heavy material.
* Excavator with Lifting Machine Certificate (LM)
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Notable Comparisons (C7 Drains vs iDrain)
C7 Drain Health iDrain
Moderate Exposure to Noise (Hacking) None (Elimination)
Long Exposure to hot weather
(during Installation)
Reduced (Substitution)
High Exposure to Dust (Hacking) Low (Substitution)
Moderate Productivity* Very HighNotes*:
C7 installation rate at 100m = 2-3 days.
iDrain installation rate at 100m = 1 day (Reduction of 67%)
Resulting to shorter exposure to hot weather = faster to complete.
No need to seal the connection joints. Overlapping method.
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Notable Comparisons (C7 Drains vs iDrain)
C7 Drain Environmental iDrain
Minimum recovery Sustainability Reusable
Mixed Waste Disposal Recyclable
Notes:
iDrain is made of superior material (mild steel) – equating to longer life cycle to reuse.
Use of iDrain will result in the reduction of the amount of waste to be dispose.
Environmental friendly – recycle after the reusable life of 5 years.
Disposed as scrap metal – cost recovery.
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Tangible Results:
� Cost savings on material cost (iDrain is reusable for >5 years)
� Cost savings of manpower (Reduction of manpower requirement)
� Cost savings on disposal cost (iDrain is recyclable)
� Cost savings on recovery cost (Disposed as scrap metal)
� Reduced storage space (Stackable)
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Intangible Results:
� Safer, Faster & Efficient as compared to C7 concrete drain
� Higher Productivity (+67%) as it requires lesser manpower & zero
heavy machinery
� Sustainable as iDrain is Reusable for 5 years
� Green Product as iDrain is Recyclable
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Continual Improvement using PDCA Cycle
• Check effectiveness
• Adopt/adjust new design/new material
• Fabricate new sections
• Introduce shorter/new sections
Plan Develop
CheckAct
Future Improvements:
Introduction of smaller size and corner
sections for challenging
terrain/curvatures profiles
� iDrain 600mm length
� iDrain 300mm lenght
� iTraps (Silt Traps)
� 90/45 Degree Sections
This PDCA cycle will be use to continuously
improve this product and review it’s
effectiveness
� Earthing provision as enhanced
safety measure
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Use 2 manpower to install - overlapping. Complete installation.
Two-man carry – moderately light weight. Stacking of iDrain for storage.
Application of iDrain at Project 1: ST. JOSEPH INSTITUTION A&A PROJECT
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Regular cleaning of iDrain.
Two-man carry – moderately light weight.
Stacking of iDrain for storage.
Application of iDrain at Project 2: NUS RVA Project
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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Impact of iDrain to Construction Industry
iDrain is offered as an alternative option
for C7 Concrete Channel Drain
Make a smart switch -
Use iDrain in your next project
LIAN SOON CONSTRUCTION PTE LTDWSH INNOVATION AWARD 2016: LIAN SOON iDRAIN (THE DURABLE-REUSABLE ECM DRAIN)
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WSH INNOVATION AWARD 2016
Lian Soon Innovative Drain Project
“iDrain - The Durable-Reusable ECM Drain”
Presented by:
Lian Soon Construction Pte Ltd
End of Presentation. Safe Regards.