INNOVATIVE CONSTRUCTION

SOLUTIONS IN RAILWAY DOUBLING

PROJECT

SHARING MALAYSIAN EXPERIENCE

-Hitesh Khanna

ME’s VISIT TO SGEDT / MLY.

HON’BLE ME DESIRED TO SHARE THE EXPERIENCE ON A MUCH WIDER FORUM.

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Gemas

Tampin

Rembau

Senawang

Sg. Gadut

Seremban

Batang Melaka

Legend : Existing Alignment New Major Realignment Proposed station

CH : 461.234

CH : 469.275

CH : 483.750

CH : 509.675

CH : 535.150

CH : 562.270

CH : 465.300

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STATION

PROJECT SUMMARY

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COMMENCEMENT DATE 18th January 2008

ORIGINAL CONTRACT PERIOD

Seremban to Sg. Gadut 30 months i.e., 17th July 2010

Sg Gadut to Gemas 48 months i.e., 17th January 2012

REVISED CONTRACT COMPLETION

Seremban to Sg. Gadut 30th April 2011 (Completed & Handedover)

Sg Gadut to Gemas 31st July 2013

CONTRACT SUM RM 3,450 million

PROJECTED CONTRACT SUM RM 3,367 million

OVERALL PHYSICAL PROGRESS 94.00%

SCHEDULE PHYSICAL PROGRESS 93.89%

AHEAD (+) / DELAY (-) +0.11% ahead

PROJECT FEATURES

• Curve Radius min. 1268 mts. Design Speed of 160 kmph (M.G.)

– MX Rail

– 29 Criss Crosses

• Hydrology Review through HACRAS Modelling Software

• Total Grade Separation – 13 ROBs, 8 VBCs, 8 MPOBs

• Integrated Pier / PSC Girders – 15% Cost Savings

– Bearing Less, Maintenance Free

• Detention Pond up stream of Bridges to Buffer Flash Floods

• Project FBW to weld 25 mts. Rail to 150 mts. Panel

• Old Hoppers Modifications For Central Discharge.

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• Maximum Design Speed:160

km/hr

• Maximum Operating Speed:140

km/hr

• Maximum Operating Speed for

freight train:90 km/hr

• Maximum Vertical Gradient:1%

• Minimum track spacing:4.2m

• Maximum Axel Load:20 tonnes

• Weldable CMS X-ings

• Through CWR

• Through FBW (AT @ T/Outs,

Destressing)

• Bidirectional Automatic Signalling,

ATP, SSI with Hot Stand by, CTC.

PHASE-2 PHASE-1 COMMISSIONED

PROPOSED ALIGNMENT

Structure Total

Viaduct 03 number ( 2.2km)

ROB 14 nos

RUB 08 nos

BRV 35 nos

Culvert 124 nos

Linear Waterway 2000 m

SCHEMATIC LINE DIAGRAM OF TRACK WORK PROGRESS

DN LINE

UP LINE

Legend: Completed (184 KM) In progress (32 KM)

TDC: 30.12.12 TDC: 15.02.13

Length:8.04 Km Length:14.9 Km Length:24.8 Km

Length:21.9 Km Length:27.3 Km

Ch

. 46

1.2

34

Ch

. 56

4.0

00

TRADE WISE PROGRESS MONITORING

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TRADES OF WORKS TOTAL WORK PROGRESS

AS ON 02.11.2012

CONSTRUCTION (INFRA WORKS) 98.54%

PACKAGE INF 1A (Sec. 1A : CH. 461.234 - CH. 472.500) 100.00%

PACKAGE INF 1B (Sec. 1B : CH. 472.500 - CH. 500.600) 99.90%

PACKAGE INF 2 (Sec. 2A : CH. 500.600 - CH. 506.558) 97.30%

PACKAGE INF 3 (Sec. 2B : CH. 502.400 - CH. 535.500) 99.88%

PACKAGE INF 4 (Sec. 3 : CH. 535.500 - CH. 563.496) 99.83%

PACKAGE INF 5 (Station Buildings & Platforms) 96.82%

PACKAGE INF 6 (TRACK WORK) 97.45%

PACKAGE INF 7 (MISC. WORKS-FENCING & GEMAS

FACILITIES) 78.11%

INSTALLATION OF SYSTEM WORKS 59.70%

PACKAGE SYS 1 (ELECTRICAL WORKS) 52.42%

PACKAGE SYS 2 (SIGNALLING) 61.81%

PACKAGE SYS 2 (COMMUNICATION) 78.97%

TESTING 57.18%

TOTAL 94.00%

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GEO-TECH CONDITIONS AND SOLUTIONS

• Malaysia: – Very Poor Soil Conditions.

• Peat, Marine Clay, Organic Soils or Lime Stone Cavities • Geo-tech solutions aim at ZERO Formation settlement despite poor

Soil Conditions • Ground Improvement Cost May be as much as 20% of the Infra

Project Cost

– Stone Columns – RE walls used in Rly. Bridge Approaches! – Soli Nails and Crib Walls are very common in Cutting – Geotextile sandwitched between sand layers is a standard,

even for Existing Track Rehabilitation • PVD • Geo-wrapping on Temporary Railway Banks • Geo Cells

Typical Track Structure

Sub-Ballast

Sub-Grade

Ballast Psc Sleeper

Fittings (Pandrol fastclip) Rails (UIC 54)

Sand and Geotextile

300 mm

300 mm

100 mm

600 mm

TYPICAL CROSS SECTION

DN LINE UP LINE

DN LINE UP LINE

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HIGH FORMATION / CUTTINGS

• HIGH EMBANKMENT IN COUNTRY SIDE

• HIGH CUTTING • 3mt BERM EVERY 6mt HEIGHT

• BERM DRAIN, CASCADING DRAIN, TOE SIDE DRAIN

• RAIL HANDLING CRANE EQUPIED DMT

• STEEL CHEQURED PLATE TROLLEY PATH WAY

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NEW SOLUTIONS

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MPOB (MOTOR CYCLE/ PEDESTRAIN BRIDGE)

BALLAST BOX FOR BOTTOM BALLST SPREADING

• EVEN 150mm BOTTOM BALLASTING

• LESS MANUAL LABOUR

• BETTER INITIAL TRACK GEOMETRY ON LAYING SLEEPERS WITH SLEEPER LAYING BEAM

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STONE COLUMNS FOR WEAK SOILS

• FASTER CONSOLIDATION AND STRENGTH MOBILIZATION: – PROVIDES A DRAINAGE PATH THROUGH ORGANIC PEAT /

MARINE CLAY

– PROVIDES A SUPPORT COLUMN 17

Existing track

23.1 m

ROB 09 ABUTMENT B MATIER’S ARCH

Longitudinal profile of proposed road

• LENGTH OF MATIER’S ARCH CONSTRUCTED IS 62.5m AT A TOAT COST

OF RM 1.24 MILLION. RATE PER METER OF MATIER’S ARCH IS RM19,840.

• MATIER’S ARCH AT ROB 09 WAS COMPLETED WITHIN THREE MONTHS.

MATIER’S ARCH AT ROB 09

MATIER’S ARCH AT ROB 09

MATIER’S ARCH AT ROB 09

SOIL NAIL SUPPORTED CUTTING

• WHEN FLAT SLOPES ARE NOT POSSIBLE – CONTINUOUS HILL SLOPES AT 1 FOS, MINIMAL

MUCK GENERATION

– BUILT UP AREA AT TOP, MACHINE ACCESS AT TOP MAY NOT BE POSSIBLE

– TOP DOWN EXCAVATION AS YOU PROTECT 21

Pedestrian Bridge

ML

Main Building Secondary

Building

SENAWANG HALT

Viaduct

Main Building

DN UP

SUNGAI GADUT STATION

Pedestrian Bridge

DN Loop UP Loop ML

Main Building Secondary

Building

REMBAU STATION

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FIRST TRIAL TRAIN ACROSS PIR PANJAL