Bridges Southeast Asia 3-4 August 2010 - Jambatan Kedua ...jambatankedua.com.my/.../papers/Bridges_Southeast_Asia-3-4.08.10… · Bridges Southeast Asia 3-4 August 2010 ... Method

Bridges Southeast Asia

3-4 August 2010

Sustainable Bridge Construction Practices

Case Study: Second Penang Bridge, Malaysia

Dato’ Prof. Ir. Dr. Ismail Mohamed Taib

Managing Director

Jambatan Kedua Ptd. Ltd.

JAMBATAN KEDUA PTD. LTD. (824573-U)

Wholly owned by Minister of Finance, Incorporated

GOVERNMENT OF MALAYSIA

MALAYSIAN HIGHWAY AUTHORITY

Bridges Southeast Asia – 3 to 4 August 2010

Sustainable Bridge Construction Practices – Case Study: Second Penang Bridge, Malaysia



PROJECT INTRODUCTION

UNDERSTANDING FAST-TRACK CONSTRUCTION

PROCESSES OF LONG BRIDGE

APPRECIATING INCREASING ENVIRONMENTAL

CONCERNS IN BRIDGE CONSTRUCTION

IDENTIFYING ALTERNATIVE MATERIALS AND

COMPOSITES FOR BRIDGES

IMPLEMENTING 4Rs OF SUSTAINABILITY IN BRIDGE

CONSTRUCTION

2

Sustainable Bridge Construction Practices

Case Study: Second Penang Bridge, Malaysia





3

Location of Second

Penang Bridge

Location Map

We are

Here





Project Alignment

9+

000.

10+000.

11+000.

12+000. 13+000. 14+000.

15+

000.

16+

000.

0.

1+000. 2+000.

3+000. 4+000. 5+000. 6+000.

7+

000.

8+

000.

17+

000.

18+

000.

19+

000.

20+

000.

21+000.

22+000.

23+000.

PULAU

JEREJAK

PULAU

AMAN

PENANG

ISLAND

(Batu Maung)

NAVIGATIONAL

SPAN

PENANG SECOND

CROSSING BRIDGE

TOLL PLAZA

PLUS TOLL

PLAZA

BATU MAUNG

DIRECTIONAL RAMPS

BATU KAWAN

CLOVERLEAF

INTERCHANGE

BATU KAWAN

TRUMPET

INTERCHANGE

MAIN LAND

(Batu Kawan)

4





General

Jambatan Kedua Ptd. Ltd. (“JKSB”), a wholly-owned

company of the Minister of Finance, Incorporated (“MoF

Inc.”) is the concessionaire for the Malaysian Second

Penang Bridge Project.

The 23.9km Second Penang Bridge project, when

completed will provide an alternative route between the

mainland in Batu Kawan and the island of Penang of

Malaysia in Batu Maung. The bridge will improve trade efficiency and enhance

logistics system by providing better connectivity and

accessibility to the Penang International Airport, boosting

economic growth in Penang.

5





Work Packages Diagram

6

Package 3B,3C,3D,3E, 3F & 3G :

Conventional Works

Package 3A:

Conventional

Works

Package 1 : Main Navigation Span &

Substructure & Foundation Works

for Approach Spans.

Package 2: Super Structure Works of

Approach Spans.

Integrated Toll System

Design & Build





Key Parameters

Length of Bridge 16.9km

Length of Expressway 7km

Lane Configuration Dual 2 traffic lanes and 1 motorcycle lane each direction.

Construction method:

Approach Spans

Main Span

Pre-cast Prestressed Segmental Box Girder

P0 to P24 = 24 span x 55m

= 1,320m.

P27 to P292 = 265 span x 55m

= 14,575m.

Cast in-situ Cable-Stayed Bridge

P24 to P27 = 117.5m + 240m + 117.5m

= 475m.

Navigational Channel

Other Spans

Width Clearance :150m

Height Clearance : 30m

Height Clearance : 6m

7





Overall works is divided into 3 packages as follows :

Package 1 – Main Navigation Span and Substructure and

Foundation Works of Approach Span.

Package 2 – Superstructure Works of Approach Span.

Package 3 :

Work Packages

Package 3A Batu Maung Interchange

Package 3B Batu Kawan Expressway

Package 3C Batu Kawan Trumpet Interchange

Package 3D Toll Plaza & Administration Building

Package 3E Toll Collection System

Package 3F Traffic Control & Surveillance System

Package 3G Mechanical & Electrical Works

8





UNDERSTANDING FAST-TRACK

CONSTRUCTION PROCESSES

OF LONG BRIDGE





Work Packages for Design & Build Contract

Package 1 – Main Navigation Span and

Substructure and Foundation Works of Approach

Span.

o Date of Site Possession : 8 Nov 2008

o Date of Completion : 8 Mar 2013

o Completion Period : 52 Months

Package 2 – Superstructure Works of Approach

Span.

o Date of Site Possession : 8 Jun 2009

o Date of Completion : 8 Sept 2013


10

Understanding Fast-Track Construction

Processes of Long Bridge







Design & Build Contract

Design & Build contract for the project delivery system

was adopted for Package 1 and 2 to reduce the delivery

schedule by overlapping the design phase and the

construction phase. For the Approach Spans, the works have been divided

into horizontal division between Package 1

(substructure) and Package 2 (superstructure).

The interfacing works between the two packages have

been identified in the Interfacing Agreement.







Design & Build Contract – (cont.)

Employer Requirement (ER) was introduced to

outline the scope of Design & Build (D&B) Contract. The D&B contract implemented in the Second Penang

Bridge Project, provides the following advantages:

i) Singular Responsibility concept

ii) Better Quality of product

iii) Time Saving for the project

iv) Improved Risk Management





13

P024

P025P026

P027

Main Navigation Span

(Front Elevation)

m NGVD m NGVD

m NGVD m NGVDm NGVDm NGVD NGVD

m NGVD

m NGVD m NGVD

m NGVD

240m 117.5m 117.5m







14

Employer’s Requirement (ER)/Need Statement

Need Statement in the form of Employer‟s Requirement (ER) is

introduced to the Design & Build contract as follows: The ER sets out the detail scope of works for General,

Contractual and Technical requirements

The contractor shall comply with all the requirements in

carrying out the detailed design, construction and

completion of the project within the stipulated time up to and

including the Defect Liability Period.







15

All design shall comply with the requirement of all relevant

authorities. Contractor/Consultant shall liaise with the

relevant authorities during the design and construction

period

All designs, drawings, technical specifications, method

statements, etc shall be checked by Independent Checking

Engineers (ICE)









16

The Second Penang Bridge Project - Overall Organization

Chart

i. Singular

Responsibility

Concept

CONSULTANT

(DESIGNER)

CONSESSIONAIRE

INDEPENDENT CHECK ENGINEER

GOVERNMENT OF

JAMBATAN KEDUA Ptd. Ltd.

ARUP JURURUNDING

Ptd. Ltd.

PACKAGE 1

CONTRACTORS

PROJECT OWNER

AUTHORITIES

CONSESSIONAIRE

INDEPENDENT CHECKING

ENGINEER

GOVERNMENT OF

MALAYSIA

MINISTRY OF

WORKS

MALAYSIA HIGHWAY

AUTHORITY

JAMBATAN KEDUA

UEM BUILDERS

Ltd.

PACKAGE 2

CHEC

Construction (M)

Ptd. Ltd.

ERE CONSULTING

GROUP Ptd. Ltd.

INDEPENDENT EIA CONSULTANT

FISHERIES IMPACT ASSESSMENT

CONSULTANT

FANLI MARINE AND

CONSULTING Ptd. Ltd.

Package 1 & 2 Package 1, 2 & 3

Package 1, 2 & 3

CONSULTANT

(Designer)

HPDI Consultants

Co. Ltd

CONSULTANT

(DESIGN REVIEW & SUPERVISION)

MMSB Consult Ptd. Ltd RB Perunding Ptd. Ltd.

EIA CONSULTANT EIA CONSULTANT

R-SYNC Tech.

Resources Ptd. Ltd. YES Enviro Services

Ptd. Ltd.

EIA CONSULTANT

DR. Nik & Associates

Ptd. Ltd.





ii) Quality

The Contractor‟s responsibility to deliver a product

according to Client‟s requirements and expectations as

documented in the Employer‟s Requirement (ER).

Independent Checking Engineer (ICE)

ICE is appointed for the following scope of works to ensure

the specific client‟s requirement and high quality of works are

delivered: Review design input parameters adopted to confirm on

fundamental design issue.



17





P226L Water Curing







Check for conformance with employer‟s and government

authorities requirements

Review and comment design brief and final design report

Prepare design check report and certification

Review and comment on specification

Verify and endorse progress payment

Audit construction works

Review and comment on work procedures, method

statements and quality records

Design and construction coordination between Package 1,

Package 2 and Package 3 contractors



19





20

iii)Time Saving

Materials, equipment procurement and construction

works can begin before construction documents are

fully completed.



Temporary Jetty

at P0

Load Out Jetty for the

Delivery of SBG





21

Pier 25 & Pier 26 Platform

Precast Segmental Box

Girder (SBG) Factory

Dredging Works







iv) Improved Risk Management

Method of construction can be suited to the contractor‟s

advantage.

Change orders due to errors and omissions are virtually

eliminated, Design & Build contractors have the

responsibility for drawings and specification

development as well as constructing a fully functioning

facility.

Risk Management identifies the Interfacing Agreement

under the Responsibility Matrix as a critical success

factor.





23



Interfacing Agreement

The interfacing Agreement has been included in the Contract

Document to define the scope of works at the interfacing

area such as:

Common Access at Main Dredged Channel

Access on the Deck via Pier 0 and Pier 292 from land sides.

Installation of Temporary Inserts for Launching Gantry at

Pier Head Top

Installation of Bearing Plinth

Synchronize Pier Handover and Launching Schedule

Installation of Temporary Fender at the Pier and Pilecap

during Launching





Launching Programme for SBG

Mob. – Start

Aug 2010 Mob. – Start

Aug 2010

LG 1

LG 2

LG 3

LG 4

Demob. – Jan 13

2 mth for shifting

Demob. – Apr 13

BATU

KAWAN

BATU

MAUNG

P

0

P

24

P

27

P

117

P

118

P

267

P

292

P

268

MA

IN

N

AV

IG

AT

IO

N S

PA

N

LG 3

LG 4

Demob. – Apr 13



Overall Launching Programme for SBG

24





Conventional Concept

Design Consultants were appointed for Package 3 and the

works have been tendered for the following purposes: To give the opportunity to local/„Bumiputera‟

Contractor/Consultant to participate in the Second Penang

Bridge Project

Exposure to local Contractor/Consultant in mega project

Transfer of technology

Create job opportunity for local people including

Engineers/Suppliers

Economic development for the benefit to the locals



25





Package 3 (Conventional Contract) is divided as follows:

Package 3A – Batu Maung Interchange

o Consultant : PJS Ptd. Ltd.

o Date of Site Possession : 19 May 2010

o Date of Completion : 18 May 2012


Package 3B – Batu Kawan Expressway

o Consultant : KKJP2 Ptd. Ltd.

o Date of Site Possession : 28 Jun 2010

o Date of Completion : 27 Jan 2013


Package 3C – Batu Kawan Trumpet Interchange

o Consultant : SSP Ptd. Ltd.

o Date of Site Possession : 19 May 2010

o Date of Completion : 18 Sept Jan 2012


Other Sub – Packages are to be tendered later

26







Appreciating Increasing Environmental

Concerns In Bridge Construction





Overview Fisheries Industry in Penang

There are 17 fishing villages on the island and 14 fishing

landing point on the main land.

In 2007, marine fisheries catch in Penang amounted to

37,774 tonnes (or about 3.7% over total marine catch in

Peninsular Malaysia) worth RM 218.9 million.

The industry provides livelihood to nearly 3,193 fulltime

fishermen.



28





Location of Fisheries Landing

Points

Location of Cage Culture

Farms

Location of Cockle Farms

29







Environmental Monitoring and Auditing (EMA)

Base line data have been established by the respective Package 1

and 2 contractors as referenced data for EMA for dredging and

offshore disposal of spoils, piling, construction machineries and

equipment during the Construction Phase of the Penang Second

Bridge.

Sampling Points for

the Monitoring

Study

Location of Ambient

Environmental

Monitoring Station

Location of Water

Quality Sampling

Works

30







Scope of dredging activities

The dredging activities have to be carried out due to shallow

water conditions at certain portions of the bridge alignment

which affect the barges movement for piling, pier and launching

activities.

The estimated amount of spoil to be dredged is 11,000,000 m3.

Dredging Works Location of dredge channel

31







-3.5m ACD

Sea Bed Level

Sea Water

Level

-3.0m ACD

1:5 1:5

1:5

Viaducts

60m 170m 40m

270m

Note:

National Geodetic Vertical Datum (NGVD)

Admiralty Chart Datum (ACD)

(+0.00 NGVD = +1.72m ACD)

C L

Main Dredged Channel

(MDC)

Barges Navigation

Channel (BNC)

CROSS SECTION OF MAIN DREDGED CHANNEL

32







Package 1: EMA Consultant

R- Sync Technical Resources Ptd. Ltd is appointed as the EMA

Consultant for the monitoring of dredging and offshore disposal

Of spoils during construction phase. The Scope of works cover:

o TSS mapping via satellite imagery

o Marine water quality monitoring at disposal site

o Marine water quality monitoring along transportation on route

o Composition of dredged materials

o Bathymetric survey at disposal site

o Final Environmental Audit

Equipment used:

o Garmin GPS Receiver ( Model GPSMAP 76 CSx) 33







Disposal Area

Water Quality sampling

location at disposal route

Package 1 : Location of Water Quality Sampling by R-Sync

Ptd Ltd

34







Package 1: Environmental Monitoring (EM)

Consultant

Dr Nik & Associates Ptd Ltd is appointed to carry out the

environmental monitoring which cover the following scope of

work:

• Environmental Impact Assessment (EIA)

• Environmental Management Plan (EMP)

35







Water Quality : Comparison data between baseline and

actual for total suspended solids (TSS)

36







Water Quality Sampling

stations

Activities Location : Batu Kawan

Activities Location : Batu Maung

Package 1 : Location of Water

Quality Sampling by Dr Nik &

Associates Ptd Ltd

37







Package 2: EIA Consultant

YES Enviro Services Ptd Ltd is appointed to carry out the

EIA monitoring and preparing the reports which cover the

following scope of work: Marine Water Quality during construction of load out jetty

River Water Quality

Air Quality

Noise Level

Discharge from Sedimentation Ponds

Discharge from Septic Tank

38







At the load out jetty

Sampling location for dredging activity

At the casting yard

Location of sampling

39







Independent EIA Auditor / Consultant

To ensure the compliance to Department of Environmental

(DOE) requirements, ERE Consulting Group Ptd. Ltd. is

appointed by JKSB as the Independent EIA

Auditor/Consultant for the overall project.

The scopes and objectives of the EIA Auditor are to:

o Check the implementation of environmental mitigation

measures

o Review environmental monthly report

o Review methodology, sampling and testing

o Identify potential environmental issues and recommend

the mitigation measures

40







Independent Consultant of FIA

Fanli Marine & Consultancy Ptd. Ltd. (Fanli) is appointed by

JKSB as the Independent Consultant to monitor the

Fisheries Impact Assessment (FIA) for this project. Fanli had

earlier completed the base line study in 2007 for the

Fisheries Department.

Fanli scope of works cover:

o To assess on the impact of construction activities on

fishing, cockle farming

o To advise for such measures as necessary

o To propose the mitigation measures

41







Result of Water Quality in the fisheries landing point

42







Location of Ambient

Environmental

Monitoring Station

Location of Water

Quality Sampling Works

Implementation of Environmental Monitoring Control

43







IDENTIFYING ALTERNATIVE

MATERIALS AND COMPOSITES FOR

BRIDGES





Identifying Alternative Materials

And Composites For Bridges

High Damping Rubber Bearing (HDRB)

i. The Employer‟s Requirement (ER) requires no damage

criteria for a 500 years return period. In addition to this, a

requirement of „no collapse‟ criteria for the most credible

earthquake (2500 years return period) was also introduced.

First Penang Bridge was design on a similar requirement. ii.Based on ICE‟s comments on the detail design, spun piles

at the approach bridge of Package 1 could only cater for the

500 years return period earthquake. No plastic hinge forms

as required for „no collapse‟ criteria of 2500 years return

period.

45







HDRB – Cont’d

iii. Considering the current progress of works, it was

decided that a change of bridge bearing system shall be

the best solution. The original Pot Bearing system has to

be replaced with High Damping Rubber Bearing to

provide an effective seismic isolation system.

iv. Environment Friendly Natural Rubber

The Malaysian Rubber Board (MRB) is positioning the

Malaysian rubber industry to be the leader in technology

and environmental conservation.

46







High Damping Rubber Bearing (HDRB)

HDRB provide a simple and economical isolation system. It

possesses the low horizontal stiffness needed and are

capable of safely withstanding the large horizontal

displacements imposed during an earthquake. The bearing

was design to meet two set of action as per below:

o SLS non-seismic actions – conformance with BS5400

o SLS non-seismic actions simultaneous with a 2500-

year return period seismic event – conformance with

EN15129

47







High Damping Rubber Bearing

(HDRB)

The design of the HDRB is by Tun

Abdul Razak Research Centre (TARRC),

a laboratory of the Malaysian Rubber

Board (MRB). MRB works with the

Andre Rubber Company and W S

Atkins Consulting Engineers to

implement the concept of laminated

rubber bridge bearings in earthquake

engineering in the 70‟s.

48

HDRB –Section

HDRB – Layout





IMPLEMENTATION OF 4Rs

(RESPECT, REDUCE, REUSE

AND

RE-ENVIROMENT)





i) Respect

The project is critically monitored on the environmental and

marine ecosystem aspect due to sensitive marine

Environment in the Penang Straits as presented earlier.

Implementation of 4Rs - Respect,

Reduce, Reuse and Re-Environment

50





Respect (Cont’d)

Minimal Maintenance Design

The structure is design for high durability in marine

environment with concrete cover conforming Eurocode.

High strength concrete with silica fume and PFA cement is

used to give the durability required. The Rapid Chloride

Permeability Test (RCPT) values less than 800 coloumbs at

56 days.

The Embankment is design with 100% primary

consolidation settlement criteria to ensure that the rate of

settlement is not more than 100mm in five years.



51





ii) Reduce

a) The design construction of precast SBG has been highly

optimized and constructed efficiently to reduce raw

material, energy and cost.

b)The first Penang Bridge used protection island for ship

impact protection. The use of steel fender at the Second

Penang Bridge instead have reduced the impact to the

marine ecosystem.

c)The function of steel fender also act as a formwork for the

pilecap which help to reduce pollution to the marine area.



52





Precast Segmental Box

Girder (SBG) for the

Superstructure Section

53

View of a completed

segment

Typical Section



Reduce (Cont’d)





Reduce (Cont’d)

Production Planning for Segmental

Box Girder

Method of casting – Short Line Match-Casting

Concrete volume – 260,000 cu.m Gd 55/20

Steel Reinforcement – 60,000 metric tonne

Weight of each SBG – 65 tonne to100 tonne

Total SBG required – 8,176 numbers

Total moulds – 21 moulds

Daily output – 14 nos/day

Casting Cycle – 3 days/bay

Total casting duration– 28 months



54

Starter Frame





The view of

Protection Island at

First Penang Bridge

Reduce (cont’d)

Steel Fender - Plan

Steel Fender - Section



55





iii) Reuse

IBS System

i. Production of 8,176 of precast SBG

ii. Production of 3,336 of Precast Shell

iii.Use of Climbing Form & Travelling

Formwork for Main Navigation piers

and pylon

iv.Production of 63,580 lin.m precast

Parapet

v. Production of 31,790 lin.m precast NJB

56







iv) Re-Environment

Piles driven become heaven for fish and marine life.

Research by Lund University in Sweden have discovered

that the Oresund Bridge connecting Denmark and

Sweden have improved the Marine Environment in 10

years since it was built.

They found increased of fish activity around the bridge‟s

pillars as well as plenty of other marine life, such as

mussels.

In the Second Penang Bridge, it has attracted the local

prawn “Udang Lipan (Stomatopod Crustacean)” and

other marine life.

57







Fisheries activities near the work site



“Udang Lipan (Stomatopod Crustacean)” have become popular food

among the visitors at Aman Island, near the Second Penang Bridge

58





iv) Re-Environment (cont’d)

The Second Penang Bridge project was also designed to

have minimal blocking effect in the Penang Straits in

order to reduce the risk for potentially damaging

changes in the Penang straits composition.

Cut energy use – The Second Penang Bridge will have

negligible impacts on the sensitive environment and will

also reduce air pollution compared to traffic jams at the

First Penang Bridge and usage old ferry transport across

the straits.



59





Current Piling Activities at Second Penang Bridge

Oresund Bridge - Sweden

Marine life around

the bridge pillars –

Research by Lund

University, Sweden



60





CONCLUSION REMARKS

61

Despite its implementation in a fast track manner, the

Penang Bridge Second Crossing is being constructed to the

highest quality, considering health, safety, sustainability

and environmental conservation.

The Second Penang Bridge when completed will be the

longest bridge in Malaysia and South East Asia when it

opens for traffic in 2013.





Thank You

For Your Kind Attention

* JKSB acknowledges the assistance of CHEC & UEMB for the preparation of this presentation.





SITE PROGRESS PHOTOGRAPH Main Span at P25

Main Span at P26




Wholly owned by Minister of Finance, Incorporated SITE PROGRESS PHOTOGRAPH

RCD Drilling at P26-12 for Bored Pile





Chisel Hammer for P26-06 Bored Pile





Section 2 Pile Cap Construction





P185 Statnamic Test





P267 Pier & Crosshead Concreting





Assembly of Launching Girder at Load Out Jetty area





Pre-assembly of Launching Girders in progress

SITE PROGRESS PHOTOGRAPH





Movable Cover at Open Casting Yard






Concreting of segment is in progress






73



SBG Launching Method - Span By Span

Stage 1

Stage 2

Stage 3





SBG - Overall Planning

Total Marine Bridge Span - 584 spans

Total launching gantry - 4 nos.

Total launching output - 1.5 span/week

Total segments required - 84 nos/week

Plant storage capacity - 750 nos

Plant weekly output - 102 nos/week



74

Assembly of Trusses

for the Launching

Gantry

Assembly of Box section

for the Launching Gantry





Overall Project Implementation Programme



75

Documents

Bridges Southeast Asia 3-4 August 2010 - Jambatan Kedua ...jambatankedua.com.my/.../papers/Bridges_Southeast_Asia-3-4.08.10… · Bridges Southeast Asia 3-4 August 2010 ... Method