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Presented by: Dato’ Prof. Ir. Dr. Ismail bin Mohamed Taib Managing Director, Jambatan Kedua Sdn Bhd
UNIVERSITI TEKNOLOGI MALAYSIA
SEMINAR KEJURUTERAAN AWAM (SEMKA) PROGRAM PERDANA SEMESTER II SESI 2010/2011
THE SECOND PENANG BRIDGE
PLANNING, DESIGN AND CONSTRUCTION
20 February 2011
JAMBATAN KEDUA
SDN BHD.
Introduction
The Second Penang Bridge (Project):
Planning
Design
Construction
Topics Covered
Began operations in 1920, making it the oldest ferry service in Malaysia. The iconic ferries ply between the Seberang Perai in mainland and
Penang Island.
Ferry Service
Then…
Today the ferry still continue its services which connects Sultan Abdul Halim ferry terminal in Butterworth to Raja Tun Uda ferry terminal at Weld Quay in George Town in Penang Island.
Now…
The idea to build a bridge linking the island and mainland was mooted by the late Tun Abdul Razak, the second Prime Minister of Malaysia in 1960’s. The construction was carried out during the premiership of YAB Tun Dr Mahathir bin Mohamad, the fourth Malaysian Prime Minister in 1982. The 13.5km (8.5km over water) bridge was officially opened to traffic on September 14, 1985.
The First Penang Bridge 1985
• The bridge widening initiatives were undertaken to accommodate the increase in traffic volume which has reached its maximum capacity of 120,000 vehicles per day.
• The project which started in December 2005 was completed in August 2009.
Additional 4.8m wide lane each carriageway
The First Penang Bridge – widening initiatives 2009
The Second Penang Bridge (24km total length and 16.9km over water) when completed will be the longest in Southeast Asia connecting Batu Kawan on the mainland and Batu Maung on the island.
The Second Penang Bridge 2013 – now under construction
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PULAU
JEREJAK
PULAU
AMAN
PENANG
ISLAND
(Batu Maung)
NAVIGATIONAL
SPAN
MAIN LAND
(Batu Kawan)
Existing Penang Bridge
Project Alignment
Legend: Existing Penang Bridge
North South Highway (PLUS)
Package 1&2
Package 3
Marine Bridge
Land Expressway
8.4 km
Objectives of Second Penang Bridge
Responding to National Objectives
Considering the importance of road network in the State, the following objectives of the Second Penang Bridge Project is identified as follows:
To strengthen the transportation system corresponding to national objectives
To support balanced economic development of the State
To provide smooth and safe traffic service
PLANNING STAGE
Traffic Demand
The traffic demand on the existing bridge has been increasing since its opening in 1985.
Traffic projection without Second Crossing:
2000 – 97,200 vehicle per day
2010 – 140,400 vehicle per day
2020 – 163,400 vehicle per day
Due to a tremendous increase of motorcycle traffic utilising the bridge, it has brought about declining in the bridge’s level of service enforcing the motorist into intolerable traffic condition.
Both the ferry service and existing widened Penang Bridge will imminently not be able to cater for the traffic demand hence, a Second Crossing is needed to continuously support the economic development of the Penang State in addition to providing a smooth and safe driving facility.
2000 2020 2010
Aft
er w
iden
ing
80,000
100,000
120,000
140,000
160,000
116,500
163,400
140,400
155,000 155,000
97,200
120,000
103,800
Legends
Maximum capacity at existing bridge
Actual / Projected capacity without Second Penang Bridge
Projected capacity with Second Penang Bridge
x
Traffic Study at Existing Penang Bridge
Veh/day
Year
Feasibility Study
The feasibility study was carried out with the objectives :
To investigate the technical and economic Feasibility of the alternative alignments
To prepare the necessary documents for loan facilities purposes
To prepare an Implementation Programme (IP) as well as a report on Preliminary Environmental Impact Assessment
To investigate the financial viability of tolling the proposed crossing
Southern Route C
Mid-Channel
Route
Northern Route
Alternative Alignments
Feasibility Study Alternative Alignments:
1. Northern Route
• Linking the Penang Outer Ring Road (PORR) at Bagan Jermal on the island with Butterworth Outer Ring Road (BORR) at Bagan Ajam on the mainland.
• The total length of crossing is 9.2km.
• Restricted by the Royal Malaysian Air Force (RMAF) aviation requirement.
• Hence, only immersed tube tunnel can be considered for the main crossing.
2. Mid-Channel Route
• Linking Georgetown with the Butterworth-Kulim Expressway (BKS).
• The total length is 8.3km long crossing which include the 2.4km long undersea tunnel.
• Immersed tube tunnel is considered due to part of the straits is subjected to the movements of exceptionally high cargo vessels. Building a bridge structure will further constraint the waterway.
3. Southern Route C
• Linking Bayan Lepas Expressway at Batu Maung on the island with Batu Kawan on mainland and ended at North South Expressway at KM 154.
• This alternative involves a 24km long crossing in which 16.9km crosses the Straits of Penang and 7.1km long connecting road.
Feasibility Study Conclusion
The alignment of Southern Route was finally chosen by YAB Tun Dr Mahathir Bin Mohamad, the fourth Prime Minister of Malaysia. The decision was to promote socio-economics development in the south that would provide a balance across the Penang State.
Package 3B,3C,3D,3E, 3F & 3G :
Conventional Contract
Package 1 : Main Navigation Span & Substructure & Foundation Works for Approach Spans. Package 2: Superstructure Works of Approach Spans.
Package 3A:
Conventional
Contract
Integrated Toll System
Design & Build
Distribution of Contract Packages
8
Project Organization Chart
ARUP JURURUNDING S/B
Description Contract Period 2008 2009 2010 2011 2012 2013
Mths Start Finish
JKSB was Incorporated. - - 9-July-08
JKSB was appointed as the Concessionaire for the Second Penang Bridge
- - 5-Aug-08
Letter of Award for Package 1 Contract - - 20-Oct-08
Letter of Award for Package 2 Contract - - 4-Jun-09
Letter of Award for Package 3A Contract - - 5-May-10
Letter of Award for Package 3C Contract - - 5-May-10
Letter of Award for Package 3B Contract - - 14-Jun-10
Overall Construction Period: 60.0 8-Nov-08 8-Nov-13
Package 1 - Main Navigation Span & Substructure and Foundation Works for Approach Spans
52.0 8-Nov-08 8-Mar-13
Package 2 - Superstructure Works of Approach Spans
51.1 8-Jun-09 8-Sep-13
Package 3A - Batu Maung Interchange 24.0 19-May-10 18-May-12
Package 3B - Batu Kawan Expressways 31.0 28-Jun-10 27-Jan-13
Package 3C - Batu Kawan Trumpet Interchange 28.0 19-May-10 18-Sep-12
Package 3D - Toll Plaza and Related Works 14.0 1-Nov-11 31-Dec-12
Package 3E - Toll Collection System 12.0 9-Oct-12 8-Oct-13
Package 3F - Traffic Control and Surveillance System 12.0 9-Sep-12 8-Sep-13
Package 3G - M&E Works for Package 3A & 3C 24.0 9-Sep-11 8-Sep-13 18
Project Implementation Plan
DESIGN & BUILD CONCEPT
JKSB issue Letter of Offer (LOO) to Contractors including Employer’s Requirements (Need
Statement)
Contractors submit technical & financial proposal
JKSB issue Letter of Acceptance (LA)
Contractor submit design brief & work programme
Contractor submit the preliminary drawings
Contractor submit detailed drawing & method statements
Construction stage
Design & Build Contract Management
Employer‟s Requirements
A key feature of design and build contracts is the document commonly known as the employer‟s requirements or need statements which is drawn up by the employer and provides the outline design.
The Employer‟s Requirements set out the project needs in terms of specification, function and performance of the project required and if applicable will also define planning and any other restrictions.
Design & Build Contract Documentation Details
Design & Build Contract
Document
Employer’s Requirements
Letter Acceptance
Drawings Technical Proposal Condition of
Contract
Contract Sum Analysis (CSA)
Contractor’s proposal
Project Specifications
Contract Drawings
Form of Design Guarantee Form
Preliminary
Construction
As-Built
Due to time constraint to complete and to open the bridge for the traffic by end of 2013, a fast-track strategy was crucial.
Design and Build Contract
Conventional Contract
DESIGN & BUILD CONTRACT vs Conventional Contract
Design and Build contract is a combination of
all (running parallel), depending on the size, scope, and complexity.
In Second Penang Bridge, the contracts are divided into 2 types:
12
Due to stringent Project timeframe , most of the major Project Scopes will be implemented on a Fast Track Basis
DESIGN & BUILD CONTRACT vs Conventional Contract
Technical Proposal
Design
Procurement
Construction
Construction Drawings
TIME
Construction Drawings Completed
Commissioning Overlap between Design & Construction
Sep 13 Nov 13
Construction Completed
Design Completed
Nov 08
Oct 08
Package 1 & 2 – RM3.75 billion or 83% of the Total Project Cost
Package 1 – Main Navigation Span and Substructure and Foundation Works of Approach Span. o Contractor : China Harbour & Engineering Construction Ptd Ltd o Date of Site Possession : 8 Nov 2008 o Date of Completion : 8 March 2013 o Completion Period : 52 Months o Contract Amount : RM2.2 billion o Work Progress : 63.81%
Package 2 – Superstructure Works of Approach Span. o Contractor : UEM Builders Ltd o Date of Site Possession : 8 Jun 2009 o Date of Completion : 4 June 2013 o Completion Period : 48 Months o Contract Amount : RM1.55 billion o Work Progress : 29.69%
14
Design and Build Contract
DESIGN & BUILD CONTRACT vs Conventional Contract
The Design & Build contract implemented in the
Second Penang Bridge Project, provides the following advantages:
Singular Responsibility concept
Better Quality of product
Time Saving for the project
Improved Risk Management
16
DESIGN & BUILD CONTRACT vs Conventional Contract
27
JAMBATAN KEDUA Ptd. Ltd.
CONSESSIONAIRE / PROJECT MANAGER
JAMBATAN KEDUA Ptd. Ltd.
INDEPENDENT CHECK ENGINEER
ARUP Jururunding Ptd. Ltd.
INDEPENDENT CHECKING ENGINEER
Package 1 & 2
ERE CONSULTING GROUP Ptd. Ltd.
INDEPENDENT EIA CONSULTANT
FISHERIES IMPACT ASSESSMENT CONSULTANT
FANLI MARINE AND CONSULTING Ptd. Ltd.
Package 1, 2 & 3
Package 1, 2 & 3
CONSULTANT (DESIGNER)
PACKAGE 1
CONTRACTORS
UEM Builders Ltd.
PACKAGE 2
CHEC Construction (M) Ptd. Ltd.
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.
Singular Responsibility Concept
DESIGN & BUILD CONTRACT vs Conventional Contract
• The primary advantage of design and build contracts is that this form of arrangement leaves the employer with a single point of responsibility for any problems, whether design or construction.
Employer „s Requirement (ER) ER was introduced by JKSB to outline the scope of Design & Build (D&B) Contract
for general, contractual & technical requirements and contractor shall comply with all the requirements within the stipulated time up to as well as defect liability period.
Independent Checking Engineer (ICE) ICE is appointed by JKSB for the following scope of works to ensure the specific
client’s requirements & high quality of work are delivered: Review design input parameters adopted to confirm on fundamental design
issue Review & comment design brief & final design report Prepare design check report & certification Verify & endorse progress payment Audit construction works
Design & Build Contractors Contractors hold most of the responsibility for the design, construction and
supervision of the project
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Client, Independent Checking Engineer and Contractor - Roles and Responsibilities
DESIGN & BUILD CONTRACT vs Conventional Contract
The objectives are: to give the opportunity to local/„Bumiputera‟ Contractor/Consultant
to participate in such prestigious project to expose local Contractor/Consultant in executing mega project to encourage transfer of technology to create job opportunities for local people to spur economic development for the benefit of local businesses and
trades
29
Conventional Contract is adopted for Package 3 (Land Expressway Portion) with the value of RM 750 million.
Conventional Contract
DESIGN & BUILD CONTRACT vs Conventional Contract
DESIGN STAGE
COMPARISON BETWEEN SECOND AND FIRST PENANG BRIDGE
First Penang Bridge
Year built: 1982
Overall length : 13.5 km
Length over water: 8.4 km
Type of bridge:
- Main bridge Cable-stayed concrete girder bridge
- Approach bridge Beam and slab deck bridge
Main Navigation Span 107.5m + 225m + 107.5m
Main Navigation Span Ship Protection
Man-made island
Other spans 40m
Speed limit 80 km/h
Second Penang Bridge
Year built: 2008
Overall length : 24 km
Length over water: 16.9 km
Type of bridge:
- Main bridge Cable-stayed bridge with beam and slab deck
- Approach bridge Box girder bridge
Main Navigation Span 117.5m + 240m + 117.5m
Main Navigation Span Ship Protection
Steel Box Buffer System
Other spans 55m
Speed limit 80 km/h
DESIGN COMPARISON BETWEEN SECOND AND FIRST PENANG BRIDGE
First Penang Bridge
No dedicated motorcycle lane
Traffic Loading to UK BS 153, 45 units HB guided along centreline of carriageway
Seismic design: 475 year event -Ground peak acceleration: 0.075 g 2500 year event - no collapse
Structural concrete design to CP110: 1972
No specific durability requirements
Normal concrete
Second Penang Bridge
2-lane dual carriageway with dedicated 3m motorcycle lane
Traffic Loading to UK BD 37/2001, 45 units HB unguided
Seismic design: 475 year event -Ground peak acceleration: 0.1773 g 2500 year event - no collapse -Ground peak acceleration: 0.3261 g
Structural concrete design to BS 5400: 2006
Durability requirements to latest Eurocodes
High performance concrete: RCPT less than 800 Coulombs for 56 days
DESIGN COMPARISON BETWEEN SECOND AND FIRST PENANG BRIDGE
First Penang Bridge
Estimated Concrete Strength: Spun pile : 50 N/mm2 Pile cap : 30 N/mm2 Pylon : 40 N/mm2 I-Beam : 40 N/mm2 Slab : 30 N/mm2
Expansion joint at every 5 spans (200 m)
Degree of compaction for earth embankment: 95 % : 0.75m below formation level 90 % : remainder
Settlement criteria for earth embankment: 367 mm in 5 years
Pavement IRR Index: Not specified
Second Penang Bridge
Estimated Concrete Strength: Spun pile : 80 N/mm2 Pile cap : 40 N/mm2 Pylon : 50 N/mm2 Box girder : 55 N/mm2
Expansion joint at every 5 or 6 spans (275m or 330m)
Degree of compaction for earth embankment: 100%
Settlement criteria for earth embankment: 100 mm in 5 years
Pavement IRR Index: 2m/km
34
Length of Bridge 16.9km
Length of Expressway 7.1km
Lane Configuration Dual 2 lanes traffic + emergency lane +
1 motorcycle lane each direction.
Main Navigation Span
Approach Span
•Substructure
•Superstructure
Cast in-situ Cable-Stayed Bridge
P24 to P27 = 117.5m + 240m + 117.5m
= 475m.
Height Clearance: 30m
Navigation Channel: 150m
P0 to P24 = 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
Pre-cast Prestressed Segmental Box Girder
= 8,092 nos.
Design Features
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PULAU
JEREJAK
PULAU
AMAN
PENANG ISLAND
(BATU MAUNG)
MAIN NAVIGATIONAL SPAN
PENANG SECOND
CROSSING BRIDGE
TOLL PLAZA
PLUS TOLL
PLAZA
BATU MAUNG INTERCHANGE
BATU KAWAN EXPRESSWAYS
BATU KAWAN TRUMPET
INTERCHANGE
MAIN LAND
(BATU KAWAN)
PACKAGE 3A
PACKAGE 3C
P24-P27
P292
P0
Project Packages
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
36
Package 1 – Main Navigation Span
Design Concept
Scope of D&B Packages
29800
Approach Span
(Cross Section)
m NGVD
7300 3000
14400
37
PACKAGE 2 Superstructure
PACKAGE 1 Substructure
Horizontal Split
Scope of Works for the Design and Build Contractor
Package 1 & 2 – Approach Spans
Scope of D&B Packages
Design Concept
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.
38
MAIN NAVIGATION SPAN
Design Concept
Steel Fender Man-made Island
i) Easy to construct, hence shorter construction period
i) Difficult to construct & much longer construction period
ii) Compact thus does not restrict the navigation passageway
ii) Restrict navigation passageway
iii) Low impact on the environment and existing hydrological condition due to its relatively small size
iii) Occupy larger water area restricting flow tidal
Substructure Steel Fender vs Man-made Island (First Penang Bridge)
MAIN NAVIGATION SPANS
Design Concept
The steel fender system was adopted due to its environmental friendliness, cost saving and shorter construction period.
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
Steel Fender System
MAIN NAVIGATION SPANS
Design Concept
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.
MAIN NAVIGATION SPAN
Design Concept
SUPERSTRUCTURE FEATURES
• Type of Structure: prestressed concrete beam and slab deck
• Spans arrangement: 117.5m + 240m + 117.5m
• Pylon type: H shape concrete tower
• Pylon size: Upper – 3.0m x 4.0m Lower – Gradually increase from top to bottom (5.0m x 6.0m)
• The pylon concrete grade: 50 N/mm²
• Main beam: table shape section (2 side web and 1 top flange)
• Typical beam height : 2.8m
• Deck slab thickness : 28cm
• The main beam concrete grade: 55 N/mm²
Design Concept
Prestressed Precast – designed where the Concrete Spun Piles overlaid deposit is thick – 40m length for each pile total 5166 pts of 1.0m dia Spun Piles with average penetration length of 55m Tubular steel piles – adopted at deep water area – Total 368 pts of 1.6m dia Steel Piles with average length of 80m Bored piles – applied at the shallow water and thin deposit area – Total 80 pts of 1.5m dia Bored Piles
Foundation
APPROACH SPAN
Design Concept
a) Bored pile - easily adapted to the various load and soil requirements due to large variety in dia and construction techniques. - enable the immediate in-situ evaluation of drilled soil layers to revise foundation length due to changed soil conditions - Absence of vibration will not disturb adjacent piles b) Steel pile - have high load-carrying capacity for a given weight of pile, which can reduce driving costs - can be driven in very long lengths and cause little ground displacement - easy to splice 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
APPROACH SPAN
Advantages of different types of foundation
44
Design Concept
Prestressed precast concrete spun piles
Out of total of 292 piers, 248 piers or 85% adopted prestressed precast concrete spun piles.
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.
More competitive on cost compared to steel piles or bored piles.
Available locally from pile manufacturers and Installers.
Easy to install in marine environment.
Able to safely withstand ship impact forces via raking piles.
Does not involve usage of expensive steel casing.
Fast construction. One piling machine can complete 1 pier in 5 days compared to bored piles area which takes about 6 months to complete one pier with 2 RCD drilling machines based on the same number of quantity. 45
Foundation
APPROACH SPAN
Design Concept
46
Substructure •Pile caps, Columns and Crossheads are designed as reinforced concrete structures
•Total no of Piers – 289 nos at Approach Spans
•The sections and shapes of the pile caps, columns and crossheads are designed to enhance constructability, construction time and aesthetically pleasing.
APPROACH SPAN
Design Concept
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.
APPROACH SPAN
Superstructure
47
Design Concept
Construction Stage
Dredging Activities
PULAU JEREJAK
PULAU AMAN
TRUMPET INTERCHANGE AT Km 154 NSE
PULAU PINANG
NAVIGATIONAL SPAN
BATU MAUNG DIRECTIONAL RAMPS
RSA
PENANG SECOND CROSSING BRIDGE TOLL PLAZA
PLUS TOLL PLAZA (EXIT)
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BATU MAUNG TEMPORARY JETTY
PROPOSED
PROPOSED
PROPOSED
PROPOSED
PROPOSED
MAINLAND (BATU KAWAN)
LEGEND
Dredging works for 270m width Temporary Navigational Channel Total volume 11 million m³ of Dredged Materials
MATERIAL STORAGE YARD
BATU KAWAN TEMPORARY JTTY
BUKIT TAMBUN TEMPORARY
FABRICATION YARD
Construction Methods
50
Building Platform Casing Installation Mixing of Bentonite Slurry
Concrete of Bored Pile
Drilling with Bentonite slurry lining
Inspection of Drilled Hole Steel Cage Inspection
Construction Sequence of Bored Piling
Installation of Steel Cage
Construction Methods
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): 8.6×9.1m.
Installation Sequence For Steel Fenders - Main Pier P25 & P26
Installation Sequence For Steel Fenders - Transition Pier P24 & P27
MAIN NAVIGATION SPANS
Construction Methods
Slip Form System • Slip form is a self-climbing formwork that once set up as a desired-shaped
wall to be built, it ascends continually to the height of the structure. • Slip form system is used for the construction of pylon and piers which are
more than 8m height. • Each lift will be 4m ~ 5m height • Working platform will be provided at the top of the formwork system
• Slip form system provides high speed of erection (works’ execution speed
increases) and as a result, rapid completion of the project
• There is no need to dismantling or re-assembling.
MAIN NAVIGATION SPANS
Superstructure
54
Construction Methods
Reasons for the selection of cable stayed bridge
1. Allow for a slim section
2. Enable for long spans bridge
3. Better aspect in performance
4. Construction methodology
5. Project duration – faster
6. Cost optimization
55
MAIN NAVIGATION SPANS
Construction Methods
Superstructure
Deck Works Construction using Cantilever Method
Stage 1 – Construct piers and pylons
Stage 2 – Erect temporary falsework and cast first deck segment
Stage 3 – Remove temporary falsework, install cable, traveler form and cast the next deck segment.
Construction Methods
Stage 4 and onwards – The process is repeated until all the cables and decks are installed.
Deck Works Construction using Cantilever Method – Cont‟d
Construction Methods
Super Structure
Traveler form for deck
For deck works construction at
main navigation span, traveler
formworks system is used. This
method will start with stay cable
erection followed by the casting
and prestressing of segments in
stages until it reaches the
maximum free cantilever mode.
Then the same procedures will be
repeated for the next segments.
58
MAIN NAVIGATION SPANS
Construction Methods
Insitu construction is ruled out due to high cost and time requirements of cofferdam.
Precast Concrete Shells are adopted for:
• Minimisation of temporary works (no cofferdams).
• Minimisation of insitu works
• Speed of construction
• Better surface finishing works
Precast Concrete Shells are used as a formwork for second layer
casting and permanently incorporated into the pile cap
6 pieces of Precast Concrete Shell are required for each pilecap. Total of 3,468 nos of Precast Concrete Shell will be used
Casting and Curing are carried out in the Casting Yard
Transported to temporary jetty and delivered to worksite by barge.
Two casting yards have been establish for overall production
Total 27 sets of precast mould are used which consist of 18 sets
of 9m dia. and 9 sets of 10m dia.
APPROACH SPAN
Pilecap Construction
Construction Methods
Two stage construction of pilecap
APPROACH SPAN
Substructure
60
• The pilecap is designed in accordance to method construction sequence where 2 stages casting are allowed.
• The 1st layer is cast to act as a base for the installation of precast concrete shell which is designed to act as permanent formwork for the 2nd layer pile cap construction. Both casting to be carried out during low tide condition
Construction Methods
Steel formwork
APPROACH SPAN
Substructure
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.
60 nos. of high piers constructed using layer of prefabricated steel Pier modules – installed, cast, removed and installed for the next layer. Process is repeated until crosshead level is reached.
518 nos. of low piers to be constructed using one continuous set installation of pre fabricated steel formwork from pier to crosshead.
The crosshead forms are erected, fixed, cast and removed
61
Construction Methods
Superstructure
APPROACH SPAN
• Due to requirements of the project and launching speed, short line match-casting method is used for precasting of segmental box girder.
• Segments are being cast similar to cast of any structure via moulds to specific shapes and dimensions
• Main components of the segments are reinforcement bars and concrete.
• Segment cast is allowed to cure prior to opening of moulds section
• Similar process is being adopted for casting of next segment in the exception that frontal side of the next segment shall be cast against the previous cast segment. This term is match casting. The shear keys act as the interlocking shapes between the two segments.
Casting of Segmental Box Girder (SBG)
OPEN CASTING
YARD 1
(7 BAYS)
OPEN CASTING
YARD 2
(9 BAYS)
COVER CASTING
YARD
(7 BAYS)
REBAR
CUT
SHOP
WORK
SHOP
OFFICE
BATCHING
PLANT
OPERATION
CENTRE
LAB
SEGMENT STORAGE AREA 1 & 2
SEGMENT STORAGE AREA 3 & 4
567m
29
8m
Total area= 50 Acres
Construction Methods
SBG Casting Requirements
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 – 8,092 numbers
Total moulds – 21 moulds
Daily output – 14 nos/day (at peak)
Casting Cycle – 3 days/bay
Total casting duration – 28 months
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APPROACH SPAN
Superstructure
Construction Methods
SBG match casting concept applicable for every span.
Segmental Box Girders Match Casting
Shortline Casting (Match Cast)
Perfect Match
Methods of Segmental Box Girder Casting
Construction Methods
Tying rebar to in the dedicated reinforcement jig.
Concreting of SBG
Completed SBG transported to yard by Straddle Carrier
Final inspection prior to concreting of SBG
SBG storage yard
Construction Methods
SBG Casting Sequence
Placement of reinforcement cage in the SBG mould using overhead crane.
Launching of SBG using Span by Span Method
Features and Advantages
Flexibility to use overhead or under-slung gantries Fast rate of erection – due to use of external post tensioning Segment delivery is possible along completed deck to rear of gantry or
at sea level Smaller crew size is required compared to balanced cantilever construction Good access provided within the gantry to all work fronts
APPROACH SPAN
Construction Methods
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 of SBG on each barges for delivery to the 4 launching gantries.
Each 55m span consists of 14 SBG which are 1 type P1, 1 Type P2, 2 Type S1, 2 Type S2, 2 Type D1, 5 Type S3 and 1 Type S3A.
APPROACH SPAN
Launching Requirements
Total Marine Bridge Span – 578 spans
Total launching gantry – 4 nos.
Total launching output/gantry – 1.5 span/wk
Total segments required – 84 nos/wk
Plant storage capacity – 750 nos
Plant daily output – 12~14 nos/day
Construction Methods
Tug barge loaded with segment to the erection front
Approaching, berthing and mooring at Jetty
Segment Transportation Procedure
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Construction Methods
Anchor Handling Tug Boat disengage from working barge
Mooring Barges At The Erection Fronts
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Construction Methods
Launching Sequence
70
Construction Methods
Offloading of segment from Barge
Gluing and temporary stressing
Launching Sequence – cont‟d
Construction Methods
- Segments have been installed to form a full span
- Launch Main Girder to next pier
- 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
APPRECIATING INCREASING IN ENVIRONMENTAL CONCERNS IN
BRIDGE CONSTRUCTION
72
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Introduction
Sustainable development is an enduring balanced approach to economic activity, environmental responsibility and social progress.
Environmental Management Organization Chart
Design & Build Conventional
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 worth RM 218.9 million.
The industry provides livelihood to nearly 3,193 fulltime fishermen.
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Fisheries
Location of Fisheries Landing Points Location of Cage Culture Farms
Location of Cockle Farms
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Fisheries
Independent Consultant of Fisheries Impact Assessment (FIA) Fanli Marine & Consultancy Ptd. Ltd. (Fanli) is appointed by JKSB as
an 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
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Appreciating Increasing Environmental Concerns In Bridge Construction
Appreciating Increasing Environmental Concerns In Bridge Construction
78
Result of Water Quality in the fisheries landing point
Temperature (°C) levels at Study Area
Salinity (ppt) level at Study Area
Dissolved Oxygen (mg/L) levels at Study Area
• Generally, most parameters were recorded within suitable range for marine environment and fisheries purposes
Previous Study Current Study
Research by Lund University in Sweden has discovered that the Oresund Bridge connecting Denmark and Sweden have improved the Marine Environment in 10 years since it was built.
In the Second Penang Bridge, aquatic life such
as algae and fishes are found around the driven piles.
They become food for fish like the Longfin Bannerfish (Heniochus acumiratus), Rock Grouper (Epinephelus fasciatomaculosus) and White Cheeked Monocle Bream (Scolopsis vosmeri) and the local “udang lipan” (Stomatopod Crustacean).
Appreciating Increasing Environmental Concerns In Bridge Construction
Dredging activities at Package 1
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
Appreciating Increasing Environmental Concerns In Bridge Construction
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CROSS SECTION OF MAIN DREDGED CHANNEL
-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)
Appreciating Increasing Environmental Concerns In Bridge Construction
82
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)
Appreciating Increasing Environmental Concerns In Bridge Construction
83
Disposal Area Water Quality sampling location at disposal route
Package 1 : Location of Water Quality Sampling by R-Sync Ptd Ltd
Appreciating Increasing Environmental Concerns In Bridge Construction
84
Result of Water Quality Sampling by R-Sync Ptd Ltd
Appreciating Increasing Environmental Concerns In Bridge Construction
All sampling locations generally recorded a significant decrease in TSS level compared to the baseline level. This shows that the spoils disposal activities are being carried out in a proper manner.
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)
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Appreciating Increasing Environmental Concerns In Bridge Construction
Total Suspended Solids (TSS) - Marine
Water Quality Sampling stations
Appreciating Increasing Environmental Concerns In Bridge Construction
Package 1 : Location of Water Quality Sampling by Dr Nik & Associates Ptd Ltd
Activities Location : Batu Kawan
Activities Location : Batu Maung
Water Quality : Comparison data between baseline and actual for total suspended solids (TSS)
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Appreciating Increasing Environmental Concerns In Bridge Construction
Above baseline TSS level at station W18 may be caused by surface run-off originated from northern coastline.
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
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Appreciating Increasing Environmental Concerns In Bridge Construction
At the load out jetty
Sampling location for dredging activity At the casting yard
Location of sampling YES Enviro Services Ptd Ltd
Appreciating Increasing Environmental Concerns In Bridge Construction
Results of sampling YES Enviro Services Ptd Ltd
Appreciating Increasing Environmental Concerns In Bridge Construction
Generally, suspended solids and turbidity values were below the baseline conditions although the values showed fluctuations
Independent EIA Auditor / Consultant To ensure the compliance to Department of Environmental (DOE) requirements, ERE Consulting Group Ptd. Ltd. is
appointed by JKSB as an 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
Appreciating Increasing Environmental Concerns In Bridge Construction
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Best Management Practices At Site
Appreciating Increasing Environmental Concerns In Bridge Construction
Dredging Work Silt curtain was erected and maintained properly
PACKAGE 1 PACKAGE 2
PACKAGE 3A
Generator set was placed in containment area
PACKAGE 3B
Skid tanks and diesel drums was placed in containment area
Piling Barge Good housekeeping on the barge
Embodied energy is the total amount of energy required for the
processes of extraction, processing, construction, and disposal of a material
The design of Segmental Box Girder is optimized by adopting higher reinforcement ratios and less concrete with a higher strength concrete
High performance concrete with silica fume and pfa cement is used to give the durability required
Effective use of embodied energy; designs to be efficient and reduce waste
Embodied Energy
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Appreciating Increasing Environmental Concerns In Bridge Construction
IDENTIFYING ALTERNATIVE MATERIALS AND COMPOSITES
FOR BRIDGES
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High Damping Rubber Bearing (HDRB)
• 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.
• Detail design checking by ICE indicated that 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.
Identifying alternative Materials And Composites For Bridges
HDRB –Section
HDRB – Layout
HDRB – Cont‟d • 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.
• Elastomeric bearing have a low embodied energy per m² of the bridge deck.
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HDRB Prototype testing - Shear Test for 240 mm
displacement
Identifying alternative Materials And Composites For Bridges
HDRB – Cont‟d
The design of the HDRB is by Tun Abdul Razak Research Centre (TARRC) at Brickendonbury, United Kingdom, a laboratory of the Malaysian Rubber Board (MRB).
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Identifying alternative Materials And Composites For Bridges
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HDRB Prototype testing -
Compression test
HDRB – Cont‟d
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
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Identifying alternative Materials And Composites For Bridges
ISSUES
Seismic Design Detailed Study Detailed study was carried out on the seismic design to ensure the
structure could cater for earthquakes loading. Based on the outcome of the study, High Damping Rubber Bearing (HDRB) designed by Malaysian Rubber Board in conjunction with Tun Abdul Razak Research Centre (TARRC) in UK is adopted in lieu of the original pot bearing design.
Ship Impact Load Assessment Further assessment was also carried out on the ship impact load
criteria to ascertain that the bridge could withstand any accidental ship impact.
Additional Soil Investigations Soil investigations for design does not reflect the actual soil
condition causing several incidents of broken pile heads, piles driven shorter than the design length and drilling bit broken inside the bored holes. Additional soil investigations was conducted to ascertain the profile and conditions of soil below seabed level.
Issues Affecting Marine Bridge Works
Dredging works The area along the alignment of the bridge is shallow and need to be deepen
to facilitate for the movement of working barges. It takes approximately 2 years to dredge the 10 million cubic meter of sludge. However, due to fast rate of siltation, maintenance dredging is being carried out to ensure the depth is sufficient for the movement of segmental box girder barges.
Interfacing works Interfacing works between Package 1, 2 and 3 contractors require longer
time to resolve due to matters related to design and technical issues at the interfacing packages. For example, Package 3 deck has to be redesigned (strengthened) to sustain the launching gantry load imposed by Package 2 works.
Additional load tests on the driven piles Additional load tests were imposed to verify the quality of piles driven is to
the highest standard and provide solid foundation to the bridge. Note: The above issues have initially affected the completion of the marine bridge portion. However, it has now been resolved and the construction is moving forward for the completion in September 2013 with the commitment to achieve highest standard quality of works.
Issues Affecting Marine Bridge Works
Additional Materials Testing for Geotextiles Compliance tests carried out in PSB Lab in Singapore, indicate that
the geotextile materials did not comply with the specifications and thus rejected.
Further confirmatory test was carried out at TRI lab in Austin, Texas, USA which also demonstrates failure. Approval of other alternative suppliers shall be subjected to compliance of similar tests.
Additional Test of Prefabricated Vertical Drains (PVD) To ensure ‘no settlement’ criteria is complied, buckling test for PVD
was carried out at PSB Lab in Singapore and subsequently to National University of Singapore to show that the results complement the compliance test.
Load Test for Stone Column Compliance test that was carried out failed to comply with the
specification criteria. Consultant was directed to review their design and ensure that no sliding failure during construction and no settlement after completion occurs.
Issues Affecting Land Expressway Works
Additional Soil Investigations (SI) The number of boreholes done for the previous SI works is inadequate to determine the soil profile. Thus, the contractors are required to conduct additional soil investigation works to confirm the existing SI. Other Non Compliance Issues
Several materials were tested to the Project specification and were found to be non compliant. (e.g pipe culvert, sand and spun piles). JKSB have rejected the materials which do not meet the Project requirements as we are committed to produce the highest quality of works.
Note: Since the activities at land expressway works are not critical, JKSB is confident and committed to ensure the Project is delivered with the highest standard of quality and meets the target completion of September 2013.
Issues Affecting Land Expressway Works
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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.
Conclusion
SITE PROGRESS PHOTOGRAPHS
Main Span at P26
Main Span at P25
Site Progress Photograph
P25/9 - World largest statnamic load test
Site Progress Photograph
Transferring fenders for P26 at southern channel
Site Progress Photograph
View of the Construction of Pilecaps at P218
Site Progress Photograph
View of the Completed Piers from P237
Site Progress Photograph
View of the Launching Girder at Pier 117
Site Progress Photograph
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Launching Gantry Load Test
Site Progress Photograph
View of the Segmental Box Girder (SBG) Storage at Casting Yard with Production Line in Background
Site Progress Photograph
PVD installation at
Ramp 4
Jack in spun pile works at Pier 2 of
Ramp 3
Site Progress Photograph
PVD installation at CH18100
Stone Column installation at Ramp 3
of Cloverleaf Interchange Stone Column load test
Site Progress Photograph
Stone Column installation at CH23325
PVD installation at MSL 2
Site Progress Photograph
Thank You
For Your Kind Attention
* JKSB acknowledges the assistance of CHEC & UEMB for the preparation of this presentation.