Professional Documents
Culture Documents
MALAYSIA
MALAYSIAN HIGHWAY
AUTHORITY
JAMBATAN KEDUA
PTD. LTD.
Bridges Asia
22-25 February 2010
Sustainable Bridge Construction Practices
Case Study: Second Penang Bridge,
Malaysia
Location Map
We Are Here
Location of Second
Penang Bridge,
Malaysia
Project Alignment
Legend:
PENANG
ISLAND
(Batu Maung)
Package 1&2
Package 3
Marine Bridge
Land Expressway
PULAU
JEREJAK
0.
NAVIGATIONAL
SPAN
0.
4+
00
6+
23
+0
12
+0
000
00
.
00
+0
000
11
10+
9+000
8+000
0.
7+00
0.
00
00
.
000
21+
.
0.
20+00
0.
19+00
0.
18+00
0.
0.
17+00
0.
16+00
00
.
15+00
14
+0
.
00
0.
5+
00
22+
+0
13
00
0.
3+
0.
00
2+
0.
00
1+
PULAU
AMAN
MAIN LAND
(Batu Kawan)
Background
The traffic flow to the island has reached 65,000 vehicles per day. Despite
the existing Penang Bridge has been expanded, the number of vehicles
are expected to rise to 80,000 vehicles per day in two years time.
It is imminent that the existing Penang Bridge will not be able to cope
with the manifold increase of traffic volume.
Introduction
Package 3A:
Conventional
Contract
Design Features
Length of Bridge
16.9km
Length of Expressway
7.1km
Lane Configuration
Approach Span
Substructure
P0 to P24
Superstructure
= 24 span x 55m
= 1,320m.
P27 to P292 = 265 span x 55m
= 14,575m.
Height Clearance :
Low Piers: 6m
High Piers: 6m to 21.6m
ELEMENTS
DESIGN & BUILD CONTRACT vs Conventional
Contract
DESIGN CONCEPT
CONSTRUCTION METHODS
10
The
13
o
o
o
: 8 Nov 2008
: 8 Mar 2013
: 52 Months
: RM2.2 billion
: 8 Jun 2009
: 8 Sept 2013
: 51 Months
: RM1.55 billion
14
TIME
Oct 08
Technical Proposal
Nov 08
Sep 13
Nov 13
Design
Completed
Design
Procurement
Construction
Drawings
Completed
Construction
Completed
Construction Drawings
Construction
Commissioning
Overlap between
Design & Construction
15
16
Singular
Responsibility
Concept
JAMBATAN KEDUA
Ptd. Ltd.
Ptd.
INDEPENDENT CHECKING
INDEPENDENT
CHECK ENGINEER
ENGINEER
ERE CONSULTING
GROUP Ptd. Ltd.
ARUP Jururunding
Ptd. Ltd.
Package 1, 2 & 3
Package 1 & 2
Package 1, 2 & 3
CONTRACTORS
PACKAGE 1
PACKAGE 2
CHEC
Construction (M)
Ptd. Ltd.
CONSULTANT
(Designer)
HPDI Consultants
Co. Ltd
UEM Builders
Ltd.
CONSULTANT
(DESIGN REVIEW &
SUPERVISION)
EIA CONSULTANT
R-SYNC Tech.
Resources Ptd. Ltd.
EIA CONSULTANT
DR. Nik & Associates
Ptd. Ltd.
CONSULTANT
(DESIGNER)
RB Perunding Ptd. Ltd.
EIA CONSULTANT
YES Enviro Services
Ptd. Ltd.
16
Conventional Contract
Conventional Contract is adopted for Package 3 (Land Expressway
Portion) with the value of RM 750 mil or 17% of the Total Project Cost.
The objectives are:
Design Concept
Package 1 Main Navigation Span
Scope of D&B
Packages
m NGVD
117.5m
m NGVD
m NGVD
240m
m NGVD
m NGVD
NGVD
117.5m
m NGVD
m NGVD
m NGVD
P024
m NGVD
m NGVD
P025
P027
P026
19
Design Concept
3000
29800
Scope of D&B
Packages
PACKAGE 2
Superstructure
Horizontal Split
PACKAGE 1
Substructure
m NGVD
Approach Span
(Cross Section)
20
Design Concept
MAIN NAVIGATION SPAN
Foundation
Bored piles adopted for main and end piers at
thick layer of dense sand and silty
clayey below 45m of seabed level.
Total 66 pts. of 2.0m and 2.2m dia
Bored Piles with average length of
120m.
21
Design Concept
MAIN NAVIGATION SPANS
Substructure
Man-made Island
Design Concept
MAIN NAVIGATION SPANS
Substructure
Total pilecap
: 4 nos
Pilecap size (P25 & P26): 48.1m x 17.5m x 6m
Pilecap size (P24 & P27): 42.7m x 10.6m x 4m
Design Concept
MAIN NAVIGATION SPAN
Superstructure
Cable Stayed Bridge
The cable stayed bridge design is adopted for its advantages in the
aspects of performance, construction methodology, project duration
and cost competitiveness.
The main navigation is a 3-span twin tower fan-type cable stayed
bridge of continuous rigid beam and slab deck with span arrangement
of 117.5m + 240m + 117.5m and to be erected by the balanced
cantilever method.
Design Concept
SUPERSTRUCTURE FEATURES
Main beam: table shape section (2 side web and 1 top flange)
Design Concept
APPROACH SPAN
Foundation
Prestressed Precast
Concrete Spun Piles
Bored piles
Design Concept
APPROACH SPAN
c) Spun pile
- Faster, prefabricated allows longer length with less joint
- Efficient mass to strength ratio
- Piles can be withstand higher tension forces which make them suitable for cater
wind load & earthquake problem
27
Design Concept
APPROACH SPAN
Foundation
Advantages:
Suitable for the Project by dredging at the thick overlaid deposit area. Dredging is also
carried out to allow for the transportation of materials and movement of marine traffic.
28
Design Concept
APPROACH SPAN
Substructure
Pile caps, Columns and Crossheads are
29
Design Concept
APPROACH SPAN
Superstructure
Segmental Box Girders
The precast segmental box girder is designed as a continuous single twin box of 14.08m width,
4.0m length and 3.20m depth structure with match cast joints, multiple shear keys and
prestressing tendons.
This type of box-girder was selected because of its size that does not require extensive casting
facilities, special heavy lifting equipment and storage as compared to a precast full-length box
girder.
The design of the segments is repetitive which allows the same formwork to be used
The depth is maintained constant to present aesthetically consistent soffit line.
Total 7 types of Segmental Box Girder are designed for each span.
30
Construction Methods
Main Navigation Span
1. Foundation & Substructures
a) Method of Reverse Circulation Drilling (RCD) drilling bored piles
b) Construction sequence of pile cap and installation of steel fender
2. Superstructures
a) Slip form system for pier column and pylon
b) Cable stayed system
c) Traveler form for deck
Approach Span
1. Foundation & Substructures
a) Precast RC Shell
b) 2 stage construction of pile cap (low tide or high tide)
2. Superstructure
a) 1 system steel formwork for the column and crosshead
b) Precast segmental box girder
c) Launching of SBG using span by span method
31
Construction Methods
MAIN NAVIGATION SPANS
Substructure
The first stage of the borehole is bored by rotary drill and lined with
a temporary steel casing.
Slurry waste and debris are then conveyed into mud container and
transported to centralized treatment.
32
Construction Methods
Construction Sequence of Bored Piling
Building Platform
Casing Installation
33
Construction Methods
MAIN NAVIGATION SPANS
Substructure
Steel Fender
Fabrication : Factory Dongguan Yin Ji Heavy Industry Con. Ltd
Maximum dimension of Steel Fender (Main Pier P25 & P26) : 8.6m 9.1m.
Maximum dimension of Steel Fender (Transition pier P24 & P27): 8.69.1m.
Installation
Sequence For Steel
Fenders - Main Pier
P25 & P26
Installation
Sequence For Steel
Fenders - Transition
Pier P24 & P27
Construction Methods
Construction Sequence of Pile Cap
Construction Methods
Construction Sequence of Pile Cap Contd
Construction Methods
MAIN NAVIGATION SPANS
Superstructure
Slip form system is used for the construction of pylon and piers which are
more than 8m height.
Slip form system provides high speed of erection (works execution speed
increases) and as a result, rapid completion of the project
Construction Methods
MAIN NAVIGATION SPANS
Superstructure
38
Construction Methods
Deck Works
Construction using
Cantilever Method
Stage 1 Construct
piers and pylons
Construction Methods
Deck Works
Construction using
Cantilever Method
Contd
Construction Methods
Traveler form for deck
41
Construction Methods
APPROACH SPAN
Pilecap Construction
Construction Methods
APPROACH SPAN
Substructure
Two stage construction of pilecap
The pilecap is designed in accordance to method
43
Construction Methods
APPROACH SPAN
Substructure
Steel formwork
The bridge consists of 578 nos. of Piers i.e. P0(L/R) to P292 (L/R)
Piers are classified as Low (max height 6m) and High Piers (> 6m to
21.6m) from top of pile cap to top of crosshead - using self climbing
formwork.
modules installed, cast, removed and installed for the next layer.
Process is repeated until crosshead level is reached.
44
Construction Methods
APPROACH SPAN
Superstructure
Casting of Segmental Box Girder (SBG)
Due to requirements of the project and
launching speed, short line match-casting
method is used for precasting of segmental box
girder.
WORK
BATCHING SHOP
PLANT
OPERATION
CENTRE
LAB
OFFICE
OPEN CASTING
YARD 1
(7 BAYS)
OPEN CASTING
YARD 2
(9 BAYS)
567m
REBAR
CUT
SHOP
COVER CASTING
YARD
(7 BAYS)
298m
Construction Methods
APPROACH SPAN
Superstructure
SBG Casting Requirements
Method of casting
Concrete volume
Steel Reinforcement
8,092 numbers
Total moulds
21 moulds
Daily output
Casting Cycle
3 days/bay
28 months
46
Construction Methods
Methods of Segmental Box Girder Casting
Shortline Casting (Match Cast)
Perfect Match
Construction Methods
SBG Casting Sequence
Placement of reinforcement
cage in the SBG mould using
overhead crane.
Concreting of
SBG
Construction Methods
APPROACH SPAN
Launching of SBG using Span by Span Method
Features and Advantages
Construction Methods
APPROACH SPAN
Launching Requirements
Total Marine Bridge Span
578 spans
4 nos.
84 nos/wk
750 nos
12~14 nos/day
Overall Planning
A dedicated jetty is also built near the
precast factory to facilitate the delivery of
SBG to the bridge via sea barges.
There will be 4 barges carrying 5 numbers
Construction Methods
Segment Transportation Procedure
Approaching, berthing and mooring at Jetty
51
Construction Methods
Mooring Barges At The Erection Fronts
Anchor Handling Tug Boat disengage from working barge
52
Construction Methods
Launching Sequence
Offloading of segment from Barge
53
Construction Methods
Launching Sequence contd
- Segments have been installed to form a full span
- First stage Post Tensioning & Incremental Load Transfer
to form simply supported span
- Release hanger bars and remove lifting beams after the span
supported on the temporary support on pier
- Launch Main Girder to next pier
APPRECIATING INCREASING IN
ENVIRONMENTAL CONCERNS IN
BRIDGE CONSTRUCTION
55
Introduction
Environmental concerns in bridge construction take into
account the health and marine ecosystem as well as to
reduce demands and complaints from fishermen and fish
farmers who ostensibly incurred losses as a result of the
bridge construction.
56
Environmental Management
Organization Chart
Fisheries
Overview Fisheries Industry in Penang
58
Fisheries
Location of Fisheries Landing Points
59
60
Temperature (C)
levels at Study
Area
Dissolved Oxygen
(mg/L) levels at
Study Area
pH level at Study
Area
1st Sampling
2nd Sampling
61
o
o
o
o
Equipment used:
o
Dredging Works
65
Viaducts
Sea Water
Level
Sea Bed Level
-3.0m ACD
-3.5m ACD
1:5
60m
170m
270m
40m
Note:
National Geodetic Vertical Datum (NGVD)
Admiralty Chart Datum (ACD)
(+0.00 NGVD = +1.72m ACD)
66
Disposal Area
67
71
72
Location of Ambient
Environmental Monitoring
Station
76
PACKAGE 1
PACKAGE 2
Piling Barge Pier 200
Good housekeeping on
the barge
77
77
Embodied energy is the total amount of energy required for the processes of
extraction, processing, construction, and disposal of a material
High performance concrete with silica fume and pfa cement is used to give the
durability required
Silica Fume
78
IDENTIFYING ALTERNATIVE
MATERIALS AND COMPOSITES
FOR BRIDGES
79
HDRB Layout
HDRB Section
81
82
83
83
Conclusion Remarks
Despite its implementation in a fast track manner, the
Penang Bridge Second Crossing is being constructed to the highest
quality, considering health, safety, cost, 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.
84
Thank You
For Your Kind Attention
* JKSB acknowledges the assistance of CHEC & UEMB for the preparation of this
presentation.