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PROJEK MENAIKTARAF LALUAN B9/FT015 DARI LAPANGAN TERBANG SUBANG KE HOSPITAL SUNGAI BULOH, SELANGOR DARUL EHSAN

UNIVERSITI TEKNOLOGI MALAYSIA

FACULTY OF CIVIL ENGINEERING

HIGHWAY ENGINEERING - SAB 2832

SEMESTER I - SESSION 2008/2009

NAME : MARDHIYAH SYAHIDA BT BERHANUDDIN

SECTION / GROUP : 2 SAW (SECTION 3) / GROUP 2

IC NO. : 870723035290

MATRIX CARD : BA 080032

LECTURER : HAJI CHE ROS BIN HAJI ISMAIL

DATE OF SUBMISSION : 29 /08 / 2008

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his assignment is designed to evaluate our generic skill on problem solving or ability to

think critically, identify, formulate, and solve the civil engineering related problems.TAs a potential highway engineer in my country, I am instructed by Works Ministry to give a report

on a highway construction problem in my country.

This report is provided based on a real problem on highway construction (Highway

Engineering). The problem was occurred in a real project in Selangor. This project is known as

PROJEK MENAIKTARAF LALUAN B9/FT015 DARI LAPANGAN TERBANG SUBANG KE

HOSPITAL SUNGAI BULOH, SELANGOR DARUL EHSAN. In this report, consist that a lot of

problem occured during the construction and possible suggestions which is can overcome the

whole problems.

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KERAJAAN MALAYSIA

JABATAN KERJA RAYA

PROJEK MENAIKTARAF LALUAN B9/FT015 DARI LAPANGAN

TERBANG SUBANG KE HOSPITAL SUNGAI BULOH,

SELANGOR DARUL EHSAN

No. Kontrak : KKR/JKR/UB/63/2003

HIGHWAY CONSTRUCTION

PROBLEMS REPORT

Provided by: MARDHIYAH SYAHIDA BT BERHANUDDINHIGHWAY ENGINEER

JABATAN KERJA RAYA MALAYSIA PERKIM (DAMANSARA UTAMA) RIRA BINA JV

CAWANGAN JALAN

Cawangan Jalan ( Tingkat 15 ), Letter Box No. 78

Ibu Pejabat JKR Malaysia, Level 18, UBN Tower

Jalan Sultan Salahuddin, No. 10, Jalan P. Ramlee

50582 Kuala Lumpur. 50250 Kuala Lumpur.

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Tel : 603 2691 9011 Fax : 603 2693 6662 Tel : 603 2023 2088 Fax : 603 - 2023 1688

TABLE OF CONTENTS

No Title Page

1.0 Description of The Project

2.0 Project Information

3.0 Location & Layout Plan

4.0 Related Photo

5.0 Description of The Problems & Possible Solutions

6.0 Recommendations

7.0 Appendixes

8.0 References

1) Description of The Project

The project is a part of the Government of Malaysia plan to upgrade the existing Federal route

FT015 and B9 from Terminal 3 of Subang Airport to Sungai Buloh Hospital.

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The original contract sum of the project for Phase 1 is RM 130,000,000.00 which will be

constructed over a period of twenty four (24) months. The site possession on 15th September

2003 and the original completion date shall be on 11th September 2005.

The Supplementary Agreementb No. 1 for Phase 2 has been approved by JKR dated

02/08/2006. The Phase 2 contract sum is RM 139,500,000.00 which will be constructed for a

period of 24 months. The date of possession of site for Phase 2 on 17 th July 2006 and the

original date of completion shall be on 16 th July 2008. The Extension of Time No. 3 has been

approved by JKR until 9th October 2008 due to delay on site possession caused by land

matters. The new completion date is 9 th October 2008.

Meanwhile, the remaining works under Phase 1 contract still pending due to water mains

relocation work along MCAO alignment by others and at this stage salvaging of the existing

main pipe in progress.

2) Project Information

2.1) Intoduction

The Government of Malaysia intends to upgrade the existing Federal Route FT015 and B9 from

Terminal 3 of Subang Airport to Sungai Buloh Hospital with approximately 12.0 km in length.

The previous access to the Sungai Buloh Hospital is via the state road B9, a 2-lane single

carriageway linked to the FT054 through a diamond interchange. It is also necessary to upgrade

the state road B9 from Subang Airport FT015 to linkup FT002 with FT054 in order to improve

traffic flow as heavy vehicles and other commercial vehicles heavily traverse the state road B9.

In order to ease the traffic flow, as well as to cater for the future development, the contract

Cadangan Projek Menaiktaraf Laluan B9/FT015 dari Lapangan Terbang Subang ke Hospital

Sungai Buloh has been awarded to Perkim (Damansara Utama)-Rira Bina Sdn. Bhd. JV by the

Government via Design and Build Contract comprise of Phase 1 and Phase 2.

2.2) Project Description

Phase 1

The combination of half-diamond interchange and the trumpet interchange implemented at the

existing Sungai Buloh Junction to provide a mainline link to the new Sungai Buloh Hospital.

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A new half-diamond interchange at the existing intersection between B9 and Route 54 will

accommodate for the right turning movement from Route 54 or Jalan Hospital to Subang and

from B9 to Route 54, Kepong direction. This allow for free flow movement at the existing Route

54.

The works also involve upgrading Jalan Hospital from two (2) lane single carriageway to two (2)

dual carriageway.

The work components of the Phase 1 project shall comprise the following :-

(a) Upgrading of existing Jalan Hospital from Hospital Sungai Buloh to the Sungai Buloh

interchange.

(b) Construction of new Sungai Buloh Interchange inclusive of new half diamond and

modified trumpet interchange.

(c) Vehicular underpass at KTM access road.

(d) Pedestrian bridges.

(e) Pedestrian box culvert.

(f) Sungai Gasi river bridge inclusive river protection work.

(g) Relocation of Water Mains.

(h) Works include relocation, replacement and construction of services including TNB,

SYABAS, Telekom and all other associated works.

Phase 2

The proposed works involve the upgrading of certain stretches of existing State road B9,

Federal Route 15 and construction of new alignment of Federal Route 15 between Terminal 3

Airport to existing T-Junction Batu Tiga Sg. Buloh. The total length of works involved covers a

distance of approximately 9 km. The geometric of the upgrading road shall be design to JKR U5

Standard. The road shall be 4-lane dual carriageway and paved shoulder on both side of

carriageway. It comprises of the following major component.

(a) Upgrading of five (5) at-grade signalized junction along State Road B9 as follows:-

i. Pinggiran Subang incorporation Batu Tiga Sungai Buloh Junction.

ii. Rubber Research Institute (RRI) Junction.

iii. Sg. Buloh Industrial Park Junction.

iv. Kota Damansara Junction.

v. Sri Sg. Buloh Junction.

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(b) Construction of two (2) new at-grade signalized junction along new alignment of Federal

Route 15 as follows:-

i. Kg. Muhibbah Junction.

ii. Airod Junction.

2.3) Scope Of Works

1. Roadwork

(a) Site Clearance and earthworks.

(b) Construction of approach and slip road as well as ramps including earthworks,

flexible pavement, shoulder and associated works.

(c) Provide and install street lightings, furniture, guardrails and necessary road markings

as well as landscaping works.(d) Traffic Management.

2. Drainage

(a) Construction of R. C. pipe culverts and R. C. box culverts including diversions,

excavation of unsuitable materials for foundation.

(b) Construction of ancillary drainage works including catchpits, diversions and scour

protection works.

(c) Construction of roadside drain, berm and toe interceptor drains.

3. Structures

Phase 1

(a) New Sg. Buloh Interchange inclusive of new half diamond and modified existing totrumpet interchange.

(b) Sg. Gasi River Bridge.

(c) Vehicular Underpass at KTM access road.

(d) Retaining walls of rubble type, reinforced concrete or reinforced earth wall.

(e) Pedestrian Bridges.

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(f) Pedestrian Box Culvert.

Phase 2

(a) Sg. Damansara (2 nos bridges).

(b) Pedestrian Bridge.

(c) Retaining wall.

(d) River diversion at Sg. Damansara.

4. Services

Works include recolation, replacement of services including TNB, Telekom, Maxis,

Celcom and all other associated works by others whereas SYABAS water pipe

recolation for Phase 2 will be carried out by the main contractor. Meanwhile, SYABAS

water pipe recolation on Phase 1 is in progress by others.

Project Summary

NAME OF PROJECT

CADANGAN PROJEK MENAIKTARAF LALUAN B9/FT015 DARI LAPANGAN TERBANG SUBANG KE

HOSPITAL SUNGAI BULOH, SELANGOR DARUL EHSAN.

EMPLOYER

JABATAN KERJA RAYA MALAYSIA, CAWANGAN

JALAN, JLN SULTAN SALAHUDDIN, 50582 KUALA

LUMPUR.

CONTACT PERSON:

1) Ir. Abd. Rahman Abd. Aziz

2) Ir. Sheikh Ismail Sheikh Salleh

3) En. Shukri Ishak

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DESIGN & BUILT

CONTRACTOR

PERKIM (DAMANSARA UTAMA) RIRA BINA JV

LETTER BOX NO. 78,

LEVEL 18, UBN TOWER,

NO. 10, JALAN P. RAMLEE,

50250 KUALA LUMPUR.

SITE OFFICE:

NO. 3-1, 1st FLOOR, JLN DINAR E,

U3/E, SEKSYEN 3, TMN SUBANG PERDANA, 40150

SHAH ALAM, SELANGOR DARUL EHSAN.

CONTACT PERSON:

1) En. Md. Ismail Abd. Kader

2) Ir. Rofie Sarbini

3) En. Ahmad Ismail Nik Aman

CONSULTING

ENGINEERINGS

PERUNDING SSE

2-2, JLN IMPIAN PERDANA 1

SAUJANA IMPIAN

43000 KAJANG

SELNGOR.

SEPAKAT SETIA PERUNDING SDN BHD

WISMA SSP LEVEL 8-18

NO. 1 JLN SR 8/3

SERDANG RAYA SEKSYEN 8

43300 SERI KEMBANGAN

SELANGOR.

CONTACT PERSON:

1) Ir. Shahbudin Anuar

2) Ir. Ilyas Ibrahim

3) En. Zaini Ibrahim

1) Ir. Teh Ming Hu

2) Ir. Izam Razali

3) Ir. Shuhaimi Mohd

INDEPENDENT CHECKER

(STRUCTURE)

T-CROP ENGINEERING SDN. BHD.

NO. 80-B, JALAN SS21/39,

DAMANSARA UTAMA,

47400 PETALING JAYA,

SELANGOR.

TEL : 03-7710 1382

FAX : 03-7710 1398

CONTACT PERSON:

1) Ir. Tham Kum Weng

GEOTECHNICAL PERUNDING ZMS SDN. BHD.

NO. 50/3, LORONG 6C/91,

TAMAN SHAMELIN PERKASA,

CONTACT PERSON:

1) Ir. Saidin Abu Bakar

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BATU 3 , JALAN CHERAS,

56100 KUALA LUMPUR.

TEL : 03-9200 3734

ROAD SAFETY AUDITOR PB-TRSS CONSULTING,

NO. 9, JALAN SS 15/4C,

SUBANG JAYA,

47000 PETALING JAYA,

SELANGOR.

TEL : 03-5633 6899

CONTACT PERSON:

1) Ir. Che Ali b. Che Hitam

ORIGINAL CONTRACT DETAILS

Phase Phase 1 Phase 2

Contract Sum RM 130,000,000.00 RM 139,500,000.00

Commencement Date (Original) 15 th September 2003 17 th July 2006

Completion Date (Original)

Completion Date (Revised)

11 th September 2005 16 th July 2008

9 th October 2008

Construction Period (Original)

Construction Period (Revised)

104 Weeks (24 Months) 24 Months

27 Months

Defect Liability Period 24 Months 24 Months

Road Length (km) 4.5 km 9.0 km

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JABATAN KERJA RAYA

PROJECT DIRECTORS ORGANISATION CHART

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Line of Communication

Reporting to

Reporting to

Awarded

Supervising

Government of Malaysia

Jabatan Kerja RayaGovernment

Structure Auditor

T-CorpGeotechnic Auditor

Perunding ZMS

Safety Auditor

Perunding TRSS

Auditing

Consultants

Traffic Management

T&D Consult S/B

Contractors

Utilities Relocation

Subcontractors

To Be Awarded

Design and Build Contractor

Perkim(Damansara Utama)-Rira Bina JVUtilities Companies

TNB, Telekom,Maxis,Time, PUAS

Design

ConsultantsDesign Co nsultant

Sepakat Setia Perunding

Supervision

Consultants

Contractor

Sub-Contractor

Landscape Contractor

TBA

Landscaping

ANZ Landscape S/B

Appointed

Specification & Construction Drawings

Specification & Construction Drawings

Appointed

Awarded

Awarded

Appointed

Supervising Consultant

Sepakat Setia Perunding

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3) Location & Layout Plan

UPGRADING OF ROAD

ALIGNMENTS

4) Related Photo

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Signboard Of The Project

Road Location

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5) Description of The Problems & Possible Solutions

There are several problems that caused the extended period in project constructions:

Structure Component:

DAMAGED OF L-SHAPE DRAIN AT SG. DAMANSARA RIVER TRAINING WORK

The construction of L-shape structure for river training works were begin on February 2007

between Ch. 0m to Ch. 250m (LHS). The affected location by the major flood is on the down

stream (LHS) of the river alignment.

The affected portion is between Ch. 80m to Ch. 125m (WB017 to WB026) which completed with

the capping beam structure on March 2007. However, during heavy down pour dated

14/04/2007, sudden increase of water levels was happen due to accumulate volume from the up

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stream section. The up stream section was widened by JPSs project. The accumulate volume

were flowing through the L-shape section at that time is under construction.

At the same time, it was created overflow condition on top of L-shape section. The problem

arises when the existing river at down stream side yet to be widened by JPSs project during

incident. Hence, this situation was created the bottleneck and scouring action and damaged the

portion of completed L-shape at down stream side especially at the bend with drain outlet

discharge points.

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General View RE Wall (MCDO) towards Sungai Buloh

CAST IN-SITU DECK RIB BEAMS AND SLAB CRACKINGS (PROPOSED SG. BULOH

EXPRESSWAY UPGRADING WORKS MCAO )

Issue Date : July 2005

The content of this problem deals with the cracking of cast in-situ rib beams and deck slab top

cracking incidence observed on the Span 1 Left Hand Side deck slab from Abutment A to Pier 1.

On the morning of 18 July 2005, the side formworks of the outer faces of the decks rib beams

and cantilever flanges were stripped.

Several vertical crack lines were seen on both of the exposed surfaces. The finishing on the

concrete surfaces were considered very good without obvious blemishes. Concreting of the said

sections was done on the evening of 27th

of June from approximately 6pm until 2am thefollowing day. The total concrete volume in this single pour was 314m 3. The method of placing of

concrete was by means of concrete pump. Thus, the average speed of concreting is almost 40

m3 per hour. The weather report during the whole concreting operation was reported as fine. The

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concrete supply to site was considered consistent and supply trucks were delivering and

discharging the loads in an orderly manner. The proposed concrete mix was of Grade 50

nominal strength with cement content of 460Kg/m3 and the water cement ratio is 0.37. The cube

samples taken for this batch of concrete pour were sent for testing and the results for 7-days

strength and 28-day strength were considered within the expected range. The average cube

test results show that the 7-days strength was of average 44MPa while the 28-days strengths is

not available as of this date.

The top surface of deck slab was sprayed with proprietary curing compound before the

anticipated 2-hour setting time. However, some isolated crack lines were observed on the

following day. The cracking patterns were in random and appeared to be fan-out shape. The

surface cracks observed on the vertical faces of the exposed rib beams after formwork stripping

is presented in Appendix A of this report. There were about 8-10 crack lines on each of the

vertical surface. The crack lines are almost vertical, and the maximum crack width when

measured on site is approximately 0.35mm measured by inspection with a transparent plastic

marked with varying line thicknesses and superimposed over the crack locations. Most of the

crack line extend from soffit to the underside of the cantilever flange, but some are

discontinuous and less than 750mm long either near the soffit of the rib or near to the underside

of the flanges. It is also observed that the first crack line started approximately at 5-7m from the

either end of the stop ends.

Slope Component:

SLOPE FAILURE.

Issue Date : May 2008

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Traffic and Safety Management:

Issue Date : DURING CONSTRUCTION

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6) Recommendations

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Structure Component:

Rapid drying of the concrete will significantly increases the possibility of cracking. The chemical

reaction which causes concrete to go from the viscous or plastic state to a solid state requires

water and heat is generated in the process.

Shrinkage is a primary cause of cracking in freshly set concrete. As concrete hardens and dries,

it shrinks. This is due to the loss of water through evaporation before the complete hydration

has taken place.

Rapid cooling of external surfaces and fast building up of hydration heat within the inner core

creates a drastic thermal gradient across the concrete section. These two extreme phenomenon

poses the greatest threat to undermine the weak tensile strength within the concrete.

The effects of prestressing forces will tend to substantially close, if not complete, the cracks

present on the rib surfaces.

The recommendations are suggested as following below:

1. For the isolated cracks observed on the top of deck slab, it is required that liquid curing

compound will still be applied after completion of concreting work but not more than 2

hours after pouring on any part of the surface. In addition, covering with plastic sheets or

wet Hessian are proposed to lower the possibility of top surface cracking. It is

recommended that these additional measures be carry out for at least 5 days

continuously after concreting works.

2. It is proposed to control the speed of concrete placement carefully in order to minimizethe amount of heat trapped inside of the rib core by allowing heat to escape freely over a

reasonable larger open area. Timing of subsequent layer pour must not exceed the

anticipated setting time of the previous poured and vibrated load in order to avoid the

forming of cold joint across separately laid layers.

3. To limit the length of each pour operation to a smaller distance to reduce the possibility

or quantum of cracking, if any, but on the other hand, also achieve reasonable work

progress.

4. To carry out through inspection on the line and levels of formwork and falsework in order

to reduce the external factors to it minimum.

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5. After prestressing, majority of the crack lines will be closed due to the compression

introduced to the rib. If cracks were not fully closed, it is proposed that high strength

epoxy grout be injected into the cracks to seal it off completely.

Slope Component:

Failure of slope stability such as landslides cause property damage, injury, and death and

adversely affect a variety of resources. For example, water supplies, fisheries, sewage disposal

systems, forests, dams, and roadways can be affected for years after a slide event. The

negative economic effects of landslides include the cost to repair structures, loss of property

value, disruption of transportation routes, medical costs in the event of injury, and indirect costs,

such as lost timber and fish stocks. Water availability, quantity, and quality can be affected by

landslides. Geotechnical studies and engineering projects to assess and stabilize potentially

dangerous sites can be costly.

RC Retaining Wall:

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Traffic and Safety Management:

The control of vehicular traffic movement at the worksite and at public areas requires an

organized traffic management system, as some of the work will be performed at public roads.

i) At Worksite

Proper traffic signages shall be erected at the worksite to guide worker and drivers of

vehicles on speed limit and other traffic requirement.

An orderly traffic flow system shall be established for the smooth flow of vehicular

traffic in the worksite

When access roads are partially obstructed, proper traffic management signages

shall be posted (i.e detour signs shall be properly posted)

During nights hours proper flashing amber lamps and reflectorized signages (if

required flagmen) shall be posted to guide vehicular traffic.

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Prior to commencement of work, flagmen shall be deployed and traffic signages shall

be placed at the work area to direct and caution motorist of the impending works. (ie

traffic signages safety cones, reflectorized traffic signs, flashing ambler lamps)

Flagmen shall be deployed at areas where vehicular traffic need to be guided and at

locations where trucks and heavy equipment enter and exit. Wash troughs shall be

installed at the entrance to public roads.

During the night, work areas shall be properly posted with reflectorized traffic

signages and flashing amber lamps.

All workers engaged in traffic management shall wear safety reflective vest.

Note : Traffic management method statement shall be developed.

No unauthorized usage of transport shall be tolerated. All drivers must comply with

the following basic rules.

Valid driving licences

Follow traffic rules especially load and speed limit

Never drive when tired

Make sure the vehicle is in good condition and properly maintained.

iii) Emergency Response Team (ERT)

The ERT works round the clock

Each team consists of 1 foreman cum driver and 2-traffic controller equipped with 1

no of vehicle and equipment for arranging emergency road closure.

ERT is to assist the public in case of any accident occur along the work area.

ERT is to ensure there are no potholes left unattended

ERT to control traffic flow in case of traffic light black out or malfunction until policetraffic arrived to take over or the light rectified and repaired.

ERT is also trained to intercept any incomings or emergencies at any time, place or

situation and condition.

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7) Appendixes

Appendix A

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Appendix B (SCENERY)

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8) References

a) Project Report - PROJEK MENAIKTARAF LALUAN B9/FT015 DARI LAPANGAN

TERBANG SUBANG KE HOSPITAL SUNGAI BULOH, SELANGOR DARUL EHSAN

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b)

PERUNDING SSE

c)

d)

e)

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