Civil Engineering

StoneMaster
Sustainable In-Situ Filter Drain Refurbishment.

StoneMaster is a unique in-situ method for removing the sediment within roadside filter drains. The process returns the filter drain media to its optimum condition, improving road safety and pavement integrity by reducing flooding events and occasions of standing water on the carriageway.

6X STONEMASTERS

Multiple units can work in tandem in single closure.

250M PER SHIFT

Linear metres covered by each unit.

VARIABLE EXCAVATION DIMENSIONS

Any filter drain can be recycled to required depth.

DOUBLE SIDED LOADING

Recycles drains in verge or central reserve.

SMARTSCAN SURVEYS

Advanced GPR surveys identify filter drain condition

STABLEDRAIN REINFORCEMENT

Stabilisation applied to drain during the recycling process.

StoneMaster is a unique in-situ method for removing the sediment within roadside filter drains. The process returns the filter drain media to its optimum condition, improving road safety and pavement integrity by reducing flooding events and occasions of standing water on the carriageway.

The StoneMaster units are custom built, self-contained vehicles that enables us to meet all site safety requirements. They can be operated during the day or night in virtually all weather conditions and in most carriageway locations without the need for road closures.

The process is sustainable in that it recycles existing material and minimises the volume of additional material that has to be quarried and transported to site, thus significantly reducing the number of vehicle movements to and from site. Multiple units can work in the same TM closure for even greater savings and efficiencies.

Carnell’s 6 StoneMaster machines have operated in all the National Highways Areas and Scottish Operating Units, Welsh TRAs and most DBFO contracts. A number of Local Authorities have also utilised the innovative process.

265,477m3

of roadside filter drain recycled by StoneMaster, in the last 5 years, on the strategic road network. That’s the same volume as 106 Olympic sized swimming pools.

£25.1m savings

generated in the last 5 years by StoneMaster. The recycling process reduces the volume of new filter stone required and reduces haulage costs. (When compared to a traditional excavate and replace solution)

53,095

lorry movements removed from site, in the last 5 years. Reducing the number of roadworkers killed and seriously injured from the people-plant risk.

1.4 million

miles of HGV movements removed from our roads in the last 5 years. That’s the same as travelling 56 times around the World... saving over 300,000 litres of diesel!

79% Reduction

in lorry journeys to and from site. Minimising congestion for customers by recycling filter media in-situ.

7.1 tonnes

of CO2 saved for every kilometre of filter drain recycled By reducing aggregate production and transportation to site.

Benefits

The advantages of StoneMaster align with the three National Highways imperatives:

Safety
  • People-plant interfaces on site reduced by a factor of 4.75 due to fewer lorry movements.
  • Reduced vehicle movements Improves air quality, contributing to improved health.
  • Stabilised verges minimises the risks of stone scatter and vehicle embedment.
  • Smarter surveying reduces need for trial excavations.
Customer Service
  • Less congestion through reducing lorry journeys by 79%
  • Fewer movements in and out of TM means road users feel safer.
  • Reduced flood risk helps customers feel safe on the network.
  • The faster process reduces network occupancy and provides customers with stress free journeys.
Delivery
  • StoneMaster generates £1million cost savings per 10,500m3 recycled.
  • Efficient process reduces volume of new filter stone and haulage costs.
  • CO2 emissions reduced by 7.1 tonnes for every km recycled.
  • Multiple units operating in tandem increases productivity.
  • Maintaining drainage prolongs pavement life demonstrating effective asset management.

TRADITIONAL METHOD

Wasted Resources

> Higher use of virgin aggregate
> Higher disposal/transport costs
> Higher landfill costs
> 4x the volume of HGV movement

SAFETY RISKS

> More HGVs exiting closure
> Increased stone scatter hazard

OTHER ISSUES

> Invasive trial hole excavations

100 METRES PER SHIFT

Innovations that show the way

SafetyCam

Mobile road worker protection system

SmartScan

Cost-effective risk-based tool which assesses filter drain performance to improve network knowledge

EcoSite

Carbon & Customer Considerate Compounds