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Concrete Roads: Why 1 21 st March 2012

Concrete Roads: Whyepsmg.jkr.gov.my/images/a/a3/1-_JKR_C_Road_-_Why.pdf · 2 Types of Roads Available in Malaysia Asphalt/Flexible Roads 99% Concrete/Rigid Roads 1% Percentage of

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Page 1: Concrete Roads: Whyepsmg.jkr.gov.my/images/a/a3/1-_JKR_C_Road_-_Why.pdf · 2 Types of Roads Available in Malaysia Asphalt/Flexible Roads 99% Concrete/Rigid Roads 1% Percentage of

Concrete Roads:Why

1

21st March 2012

Page 2: Concrete Roads: Whyepsmg.jkr.gov.my/images/a/a3/1-_JKR_C_Road_-_Why.pdf · 2 Types of Roads Available in Malaysia Asphalt/Flexible Roads 99% Concrete/Rigid Roads 1% Percentage of

1. Introduction

2. Concrete Roads in Malaysia

3. Why Concrete Roads/Advantages

4. Common Complaints/Disadvantages4. Common Complaints/Disadvantages

5. Recent Breakthrough –10MP

6. Conclusions

2

Page 3: Concrete Roads: Whyepsmg.jkr.gov.my/images/a/a3/1-_JKR_C_Road_-_Why.pdf · 2 Types of Roads Available in Malaysia Asphalt/Flexible Roads 99% Concrete/Rigid Roads 1% Percentage of

2 Types of Roads Available in MalaysiaAsphalt/Flexible Roads - 99%

Concrete/Rigid Roads - 1%

Percentage of Concrete Roads Available in Other Countries

CountryCountry % % ConcConc RdRd CountryCountry % % ConcConc RdRd

3

CountryCountry % % ConcConc RdRd CountryCountry % % ConcConc RdRd

USUS 15%15% PhilipinesPhilipines 40%40%

GermanyGermany 28%28% IndonesiaIndonesia 10%10%

AustraliaAustralia 40% (major 40% (major hwyshwys)) ThailandThailand 10%10%

ChinaChinaChinaChinaChinaChinaChinaChina 10%10% MyanmarMyanmar 90%90%

S. KoreaS. Korea 40%40% MalaysiaMalaysiaMalaysiaMalaysia 1%1%1%1%

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�Road Ramps�Roundabouts�Heavy Traffic Areas�Heavy Vehicle Parking Areas�Toll Booths

Major Highways (e.g. NKVE) �Major Highways (e.g. NKVE) �…. heaviest traffic area. �…. road repair/disruption is not an option.�…. overloading �…. flooding �…. RURAL ROADS where it is difficult to repair

4

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.

DescriptionDescriptionDescriptionDescriptionDescriptionDescriptionDescriptionDescription YearYearYearYearYearYearYearYear TypeTypeTypeTypeTypeTypeTypeType LghLghLghLghLghLghLghLghkmkmkmkmkmkmkmkm

ThkmmThkmmThkmmThkmmThkmmThkmmThkmmThkmm

11 JalanJalan SeratusSeratus TahunTahun, , OlakOlak LempitLempit, , SgorSgor 19861986 JRCPJRCP 1.81.8 150150

22 MudaMuda Irrigation Scheme, KedahIrrigation Scheme, Kedah 19881988 JRCPJRCP n/an/a n/an/a

33 NN--S Expressway, S Expressway, GurunGurun, Kedah, Kedah 19881988 JRCPJRCP n/an/a n/an/a

44 NN--S Expressway, Ayer S Expressway, Ayer KerohKeroh--PagohPagoh 19891989 CRCPCRCP 19.019.0 230230

55 North North KlangKlang Valley Expressway, Valley Expressway, SgorSgor 19901990 CRCPCRCP n/an/a 260260

66 North South, North South, RawangRawang --TanjongTanjong MalimMalim 19901990 CRCPCRCP n/an/a 23023066 North South, North South, RawangRawang --TanjongTanjong MalimMalim 19901990 CRCPCRCP n/an/a 230230

77 TelukTeluk DataiDatai Road, P. Road, P. LangkawiLangkawi, Kedah, Kedah 19921992 n/an/a n/an/a n/an/a

88 Federal Route 5, Sitiawan1998, PerakFederal Route 5, Sitiawan1998, Perak 19981998 JRCPJRCP n/an/a n/an/a

99 Kulim Industrial Area, Kulim, KedahKulim Industrial Area, Kulim, Kedah 20032003 PCPPCP 3.23.2 220220

1010 Kaki Bukit Kaki Bukit –– Wang Wang KelianKelian, Kedah, Kedah 20062006 PCPPCP 1.61.6 220220

1111 UluUlu PauhPauh –– ChupingChuping, Perlis , Perlis 20062006 PCPPCP 6.46.4 230230

1212 RingletRinglet-- Kg. Susu, PahangKg. Susu, Pahang 20092009 JRCPJRCP 5.55.5 220220

** NSE(Total= 846 km)NSE(Total= 846 km)

743km (88%) asphalt,743km (88%) asphalt,

104km (12%) concrete104km (12%) concrete

5

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� Year 1986

� 1 Lane Single Carriageway

� Total Length: 1.8km

� Width: 3.66m

Type: JRCP� Type: JRCP

� Thickness: 220mm

� Joints @ 5m c/c

� LMC: 150mm

� SuccessSuccessSuccessSuccess----no repair no repair no repair no repair since construction!since construction!since construction!since construction!

� (>25 years)(>25 years)(>25 years)(>25 years)

6

Olak Lempit Rural Concrete Road 1986 (JRCP)

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� Year 2001-2003

� 2 Lane Single Carriageway

� Total Length: 3.2km

� Width: 3.5m +3m

� Type: PCP

“..I’m very happy with the performance of the Kulim road”Ir. Dr. Azmi Hassan, Director of Highways MOW

7

� Type: PCP

� Thickness: 220mm

� Joints @ 5m c/c

� Grade 40PQC

� LMC: 150mm

SuccessSuccessSuccessSuccess----no repair no repair no repair no repair since construction!since construction!since construction!since construction!

(>8 years)(>8 years)(>8 years)(>8 years)

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� Year 2006

� 2 Lane Single Carriageway

� Total Length: 1.6km

� Width: 3.5m +2m

� Type: PCP

8

� Type: PCP

� Thickness: 220mm

� Joints @ 5m c/c

� Grade 40PQC

� LMC: 150mm

� SuccessSuccessSuccessSuccess----no repair no repair no repair no repair since construction!since construction!since construction!since construction!

� (>6 years)(>6 years)(>6 years)(>6 years)

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� Year 2006

� 2 Lane Single Carriageway

� Total Length: 6.4km

� Width: 3.5m +3m

Type: PCP� Type: PCP

� Thickness: 230mm

� Joints @ 4.5m c/c

� Grade 40PQC

� LMC: 150mm

� Failure: Blacktopped

9

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� Year 2010

� 2 Lane Single Carriageway

� Total Length: 5.5km

Width: 3.5m +2m

10

� Width: 3.5m +2m

� Type: JRCP

� Thickness: 220mm

� Joints @ 10m c/c

� Grade 30PQC

� LMC: 160mm

� Failure: Blacktopped

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� Year 1990

� 2 lane 3 carriage way

� Total Length: 50km

� Width: 3.5m +2m

� Type: CRCP (0.7% steel)steel)

� Thickness: 260mm

� No Joints

� Grade 40PQC

� LMC: 150mm

� Success-no repair since construction!*(>20 years)

* Some repair due to ground settlement, not performance

11

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� Year 1988

� 2 lane 3 carriage way

� Total Length: 186km

� Width: 3.5m +2m

� Type: CRCP (0.7% steel)

� Thickness: 230mm

“North South Expressway is Malaysia’s “North South Expressway is Malaysia’s “North South Expressway is Malaysia’s “North South Expressway is Malaysia’s national asset” … Geoff Ayton, RTA, national asset” … Geoff Ayton, RTA, national asset” … Geoff Ayton, RTA, national asset” … Geoff Ayton, RTA, Australia.Australia.Australia.Australia.

� Thickness: 230mm

� No Joints

� Grade 40PQC

� LMC: 150mm

� Success-no repair since construction!*

(>23 years)* 75km blacktopped for 3* 75km blacktopped for 3* 75km blacktopped for 3* 75km blacktopped for 3rdrdrdrd lane wideninglane wideninglane wideninglane widening

12

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1. Low maintenance2. Ability to Handle

Increased Traffic and Loading

3. New Niche Industry

7. Safety8. Greater Visibility

at Night/Less Energy Usage

9. Fuel SavingsLess CO2

New Niche Industry4. Save on Foreign

Exchange5. Avoid Dependence on

Fluctuating and Rising Oil Prices

6. Use of Local Products/Assurance of Cement Supply

13

10. Less CO2 Emission

11. Savings on Raw Material Usage

12. Green Technology

13. No Disruption

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� Little or no maintenance on Kulim Access Road since � construction in 2003. � We expect it to perform well for 40 years.

14

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15

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�Concrete Roads as an Alternative toAsphalt. Keep both industriescompetitive, healthy, alive and not havea monopoly.

�Export concrete road constructionexpertise overseas. IJM and Gamudahas already constructed concrete roadsoverseas.

�To be the Leader for Concrete RoadConstruction in ASEAN.

16

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� Cement is 95% local (5% foreign content)

� Bitumen is 0% local (100% foreign content)

17

We are losing out on foreign exchange!

Better Balance of Trade by using local

products

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� Oil is a non-renewable energy.

� Bitumen prices fluctuates. Cost of Bitumen will only

Year Bitumen Price, RM/ton

Jan 1990Jan 1990 387.50387.50

Jan 1995Jan 1995 418.00418.00

Jan 2000Jan 2000 735.00735.00

18

Bitumen will only

go up in future.

� Contractors refused to start work when bitumen price shot up in 2008.

Jan 2005Jan 2005 610.00610.00

Jan 2006Jan 2006 990.00990.00

Jan 2007Jan 2007 1,100.001,100.00

Jan 2008Jan 2008 1,459.001,459.00

Jan 2009Jan 2009 980.00980.00

Jan 2010Jan 2010 1,900.001,900.00

Jan 2011Jan 2011 1,600.001,600.00

Apr. 2011Apr. 2011 1,826.001,826.00

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Bitumen Price

100.00

120.00

140.00

160.00

1,500.00

2,000.00

2,500.00

COMPARISON OF BITUMEN/CRUDE OIL/CEMENT PRICES

Bitumen Price RM/tonne

Cement Price RM/tonne

Crude Oil Price US$/Barrel

Expon. (Cement Price RM/tonne)

Expon. (Crude Oil Price US$/Barrel)

19

Cement Price

336.00

-

20.00

40.00

60.00

80.00

-

500.00

1,000.00

Jan-9

8M

ac-9

8M

ei-98

Jul-98

Sept-98

Nov-

98

Jan-9

9M

ac-9

9M

ei-99

Jul-99

Sept-99

Nov-

99

Jan-0

0M

ac-0

0M

ei-00

Jul-00

Sept-00

Nov-

00

Jan-0

1M

ac-0

1M

ei-01

Jul-01

Sept-01

Nov-

01

Jan-0

2M

ac-0

2M

ei-02

Jul-02

Sept-02

Nov-

02

Jan-0

3M

ac-0

3M

ei-03

Jul-03

Sept-03

Nov-

03

Jan-0

4M

ac-0

4M

ei-04

Jul-04

Sept-04

Nov-

04

Jan-0

5M

ac-0

5M

ei-05

Jul-05

Sept-05

Nov-

05

Jan-0

6M

ac-0

6M

ei-06

Jul-06

Sept-06

Nov-

06

Jan-0

7M

ac-0

7M

ei-07

Jul-07

Sept-07

Nov-

07

Jan-0

8M

ac-0

8M

ei-08

Jul-08

Sept-08

Nov-

08

Jan-0

9M

ac-0

9M

ei-09

Jul-09

Sept-09

Nov-

09

Jan-1

0M

ac-1

0M

ei-10

Jul-10

Sept-10

Nov-

10

Jan-1

1M

ac-1

1M

ei-11

Jul-11

Sept-11

Nov-

11

US

$/B

arr

el

RM

per

ton

ne

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�Government Circular 7/2002

“ Bahan/barangan/perkhidmatan tempatan

hendaklah digunakan sepenuhnya oleh

agensi dalam perolehan masing masing”agensi dalam perolehan masing masing”

Tindakan sewajarnya akan diambil keatas

agensi yang gagal mematuhi peraturan

diatas. Perunding akan disenaraihitam…

20

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Cement Supply and Demand in Malaysia, Year 2010

Unit: Million tonnes

Actual

2010

21

2010

Cement Capacity 28.89

Cement Consumption 16.62

Excess Capacity 12.27

Cement Utilisation Ratio 58%

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Safer Stopping on Concrete

• Stopping

distances for

concrete concrete

surfaces are

much shorter

than for asphalt

surfaces

Especially when

asphalt is wet and

rutted

22

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Safer Driving on Concrete

• Increased visibility:4 X Surface Reflectivity

Concrete

23

4 X Surface Reflectivity

Safety for both

Pedestrians and

Vehicles

Asphalt

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Asphalt Road Lighting Concrete Road Lighting

24

Safer for pedestrians, carpark and road user

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�1111----7% 7% 7% 7% Fuel Savings (heavy vehicles)Fuel Savings (heavy vehicles)Fuel Savings (heavy vehicles)Fuel Savings (heavy vehicles)less “rolling resistanceless “rolling resistanceless “rolling resistanceless “rolling resistance”

“If 60% of the US National Highway System were converted to concrete pavements, the annual converted to concrete pavements, the annual savings in diesel is about US$8.2 billion/year” (G. Voigt, ACPA’s testimony in US Congress).

�Less consumption of fossil fuel (nonLess consumption of fossil fuel (nonLess consumption of fossil fuel (nonLess consumption of fossil fuel (non----renewable energy)renewable energy)renewable energy)renewable energy)

�Less emission of COLess emission of COLess emission of COLess emission of CO2222

�Consumes 5X less diesel to construct Consumes 5X less diesel to construct Consumes 5X less diesel to construct Consumes 5X less diesel to construct (thinner) (thinner) (thinner) (thinner) see next slide

25

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�Consumes 5X less diesel to construct.Consumes 5X less diesel to construct.Consumes 5X less diesel to construct.Consumes 5X less diesel to construct.

50mm Asphaltic Concrete Wearing Course

60mm Asphaltic Concrete Binder Course

75mm Dense Bituminous Macadam roadbase

300mm Crushed Aggregate roadbase

26

300mm Crushed Aggregate roadbase

225mm Crushed Agregate subbase

Cross-Section Detail - Asphaltic Concrete Pavement

200mm Plain Jointed Concrete

150mm Lean Concrete sub-base

Subgrade

Cross-Section Detail - Plain Concrete Pavement

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�Reuse Waste Material Reuse Waste Material Reuse Waste Material Reuse Waste Material : Pulverised Fly Ash (PFA), Ground Granulated Blastfurnace Slag (GGBS).

�PFA and GGBS are cement PFA and GGBS are cement PFA and GGBS are cement PFA and GGBS are cement replacement materials replacement materials replacement materials replacement materials ---- reduce cement reduce cement reduce cement reduce cement usageusageusageusage

�PFA used in concrete roads PFA used in concrete roads PFA used in concrete roads PFA used in concrete roads

�Note: 1ton cement ≈1 ton CONote: 1ton cement ≈1 ton CONote: 1ton cement ≈1 ton CONote: 1ton cement ≈1 ton CO2222 emissionemissionemissionemission

27

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� Once project completed, road builders want to Once project completed, road builders want to Once project completed, road builders want to Once project completed, road builders want to move on to new roads. move on to new roads. move on to new roads. move on to new roads.

� Complaints by road users during road repairs Complaints by road users during road repairs Complaints by road users during road repairs Complaints by road users during road repairs ––––TRAFFIC JAMSTRAFFIC JAMSTRAFFIC JAMSTRAFFIC JAMS

� More Road Accidents during repairsMore Road Accidents during repairsMore Road Accidents during repairsMore Road Accidents during repairs

� Antwerp’s major roundabout repair scenario: Antwerp’s major roundabout repair scenario: Antwerp’s major roundabout repair scenario: Antwerp’s major roundabout repair scenario: 1 time inconvenience = 40 years of convenience1 time inconvenience = 40 years of convenience1 time inconvenience = 40 years of convenience1 time inconvenience = 40 years of convenience

� CONCRETE ROADS = LESS/NO MAINTENANCECONCRETE ROADS = LESS/NO MAINTENANCECONCRETE ROADS = LESS/NO MAINTENANCECONCRETE ROADS = LESS/NO MAINTENANCE

� end

28

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A. Higher Initial CostB. Difficult and more expensive to repairC. Noise

Wear out TyresD. Wear out TyresE. Slipform Machines not availableF. No Trained Crew

29

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� Initial Cost (Construction Cost)� Acquisition

� Concept Planning

� Preliminary Design

� Detail Design

� Construction Cost

� Life Cycle Cost (LCC)� Initial Cost +Use & Maintain Cost + Disposal/Residual

�Whole of Life Costing (WHOLC)� WHOLC = LCC + Road User Cost

30

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Pavement TypeInitial Cost

Vs. Asph.

Vs. Asph.

RM/m2 RM/m2 %

1PCP -Truss Screed - No

Dowels 95.85 8.5 9

2 PCP -Truss Screed – Dowelled 111.23 23.88 27

3

PCP -Slipform Paver - No Dowels 96.81 9.46 10

4PCP - Slipform Paver -

Dowelled 112.20 24.85 28

5CRCP - Slipform pavers(PCP +RM48) 144.81 57.46 65

6 Asphalt Road (Typical) 87.35

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Whole-of-Life Costing

(WHOLC=1+2+3+4)

1. Construction Cost

(Initial Cost=1)

2. Maintenance

Cost

4.Road User Cost

3. Residual

32

(Initial Cost=1) Cost(LCC=1+2+3)

User Cost

Vehicle Operating Cost

•Fuel Consumption•Tyre Wear•Maint. and Repair•Depreciation

Travel Time Cost

•Normal Travel Time•Maintenance Delay•Construction Delay

Accident Cost

•Insurance Cost •Loss to nation

Residual Cost

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Item Pavement Type Initial Cost

A$/m2

WHOLC

A$/m2

A

Granular Granular Granular Granular Overlay + ACOverlay + ACOverlay + ACOverlay + AC

57.1357.1357.1357.13 117.87117.87117.87117.87

� Source: Queensland Dept. of Main Roads

A Overlay + ACOverlay + ACOverlay + ACOverlay + AC

B AC + CTBAC + CTBAC + CTBAC + CTB 66.3166.3166.3166.31 120.52120.52120.52120.52

C Full Depth ACFull Depth ACFull Depth ACFull Depth AC 95.8195.8195.8195.81 148.02148.02148.02148.02

D PCPPCPPCPPCP 65.4665.4665.4665.46 77.1577.1577.1577.15

E CRCPCRCPCRCPCRCP 77.5177.5177.5177.51 82.5982.5982.5982.59

33

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Australian Experience (Queensland Australian Experience (Queensland Australian Experience (Queensland Australian Experience (Queensland report)report)report)report)

�PCP < 2/3 cost of cheapest AsphaltPCP < 2/3 cost of cheapest AsphaltPCP < 2/3 cost of cheapest AsphaltPCP < 2/3 cost of cheapest Asphalt

�PCP becomes the MOST POPULAR PCP becomes the MOST POPULAR PCP becomes the MOST POPULAR PCP becomes the MOST POPULAR CHOICE of pavement for NEW ROADS CHOICE of pavement for NEW ROADS CHOICE of pavement for NEW ROADS CHOICE of pavement for NEW ROADS IN AUSTRALIAIN AUSTRALIAIN AUSTRALIAIN AUSTRALIA

34

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� Concrete roads if constructed well, no Concrete roads if constructed well, no Concrete roads if constructed well, no Concrete roads if constructed well, no major repair is needed for 40 years.major repair is needed for 40 years.major repair is needed for 40 years.major repair is needed for 40 years.

� If repair is needed, it is similar to normal If repair is needed, it is similar to normal If repair is needed, it is similar to normal If repair is needed, it is similar to normal concrete repair concrete repair concrete repair concrete repair

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� Whisper (Exposed) Whisper (Exposed) Whisper (Exposed) Whisper (Exposed) Concrete Concrete Concrete Concrete ––––e.g.Belgiume.g.Belgiume.g.Belgiume.g.Belgium and and and and HollandHollandHollandHollandHollandHollandHollandHolland

� US research on US research on US research on US research on Grinding and Grinding and Grinding and Grinding and Grooving Grooving Grooving Grooving technology. technology. technology. technology.

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� Safety or Cost of Safety or Cost of Safety or Cost of Safety or Cost of TyresTyresTyresTyres????

� Concrete road is rougher Concrete road is rougher Concrete road is rougher Concrete road is rougher –––– more friction and more friction and more friction and more friction and stops vehicle better (shorter stopping stops vehicle better (shorter stopping stops vehicle better (shorter stopping stops vehicle better (shorter stopping distance) distance) distance) distance) distance) distance) distance) distance)

� Better skid resistanceBetter skid resistanceBetter skid resistanceBetter skid resistance

� Think Safety!Think Safety!Think Safety!Think Safety!

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SlipformSlipformSlipformSlipform Machines in AsiaMachines in AsiaMachines in AsiaMachines in AsiaCountry Country Country Country SlipformSlipformSlipformSlipform MachinesMachinesMachinesMachines

� ChinaChinaChinaChina 80808080� IndiaIndiaIndiaIndia 40404040� KoreaKoreaKoreaKorea 85858585� JapanJapanJapanJapan 15151515

PhilipinesPhilipinesPhilipinesPhilipines 40404040

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� PhilipinesPhilipinesPhilipinesPhilipines 40404040� IndonesiaIndonesiaIndonesiaIndonesia 20202020� ThailandThailandThailandThailand 15151515� Vietnam Vietnam Vietnam Vietnam 12121212� MyanmarMyanmarMyanmarMyanmar 15151515� Malaysia (1990)Malaysia (1990)Malaysia (1990)Malaysia (1990) 9999� Malaysia (2011)Malaysia (2011)Malaysia (2011)Malaysia (2011) 0000

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� No new ProjectsNo new ProjectsNo new ProjectsNo new Projects

� No ContinuityNo ContinuityNo ContinuityNo Continuity

� NSE (1988), NKVE (1990) , KLIA (1990) NSE (1988), NKVE (1990) , KLIA (1990) NSE (1988), NKVE (1990) , KLIA (1990) NSE (1988), NKVE (1990) , KLIA (1990) crew GONEcrew GONEcrew GONEcrew GONE

� CIDB to train and certify pavement CIDB to train and certify pavement CIDB to train and certify pavement CIDB to train and certify pavement workers workers workers workers

� Engage Airport Concrete Pavement Engage Airport Concrete Pavement Engage Airport Concrete Pavement Engage Airport Concrete Pavement (KLIA2?) or (KLIA2?) or (KLIA2?) or (KLIA2?) or flatfloorflatfloorflatfloorflatfloor specialist contractors specialist contractors specialist contractors specialist contractors as Temporary Measure as Temporary Measure as Temporary Measure as Temporary Measure

� end

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� Item 39 of keynote address delivered by

Dato’ Shaziman during the 8th Malaysia Road

Conference, Oct. 2010

� “The Government has also approved 5% of

new roads in the 10th Malaysian Plan to be

constructed using cement concrete”.

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New Roads length, km 5% Conc, km

Sarawak 2,819 141

Sabah 2,540 127

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Sabah 2,540 127

Peninsular 6,312 316

Total 11,671 584

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�Think Low Maintenance and WHOLC�Think New Niche Industry : Alternative Competitor to Asphalt

�Think Safety

Advantages of Concrete Road are numerous�Advantages of Concrete Road are numerous

�Common complaints/disadvantages of concrete road can be dispelled.

�Policy for 5% of roads in 10MP to be concrete roads

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