mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

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MESYUARAT PEGAWAI KANAN JKR MALAYSIA 2013 KUALA TERENGGANU PENANG SECOND BRIDGE ‘THE CHALLENGES, SUCCESS CRITERIA AND LESSONS LEARNT’ 28 MAY 2013 JAMBATAN KEDUA SDN BHD. LEMBAGA LEBUHRAYA MALAYSIA KERAJAAN MALAYSIA Presented by: Dato’ Ir. Dr. Ismail bin Mohamed Taib Managing Director, Jambatan Kedua Sdn Bhd

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Page 1: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

MESYUARAT PEGAWAI KANAN JKR MALAYSIA 2013

KUALA TERENGGANU

PENANG SECOND BRIDGE

‘THE CHALLENGES, SUCCESS CRITERIA AND

LESSONS LEARNT’

28 MAY 2013

JAMBATAN KEDUA SDN BHD.

LEMBAGA LEBUHRAYA MALAYSIA

KERAJAAN MALAYSIA

Presented by: Dato’ Ir. Dr. Ismail bin Mohamed TaibManaging Director, Jambatan Kedua Sdn Bhd

Page 2: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

content

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

INTRODUCTION

ISSUES AND CHALLENGES

SUCCESS CRITERIAS

LESSONS LEARNT

CONCLUSION

Page 3: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

Jambatan Kedua Sdn Bhd (JKSB), a wholly-owned company of the Ministry ofFinance, Incorporated (MoF Inc.), was appointed as the concessionaire for theSecond Penang Bridge Project in August 2008.

JKSB is responsible for the design, construction, management, operation andmaintenance of the bridge.

The Second Penang Bridge which connects Batu Kawan on the Mainland and BatuMaung on the Island when completed in September 2013 will be the longest inSouth-East Asia with the total length over water of 16.9km. The project overalllength is 24km with estimated construction cost of RM 4.5 billion.

introduction

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

Page 4: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

main navigation span

Fireworks show during final closure of mid span ceremony on 20th April 2013

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

Page 5: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

9+000.

10+000.

11+000.

12+000. 13+000. 14+000.

15+000.

16+000.

0.

1+000. 2+000.

3+000. 4+000. 5+000. 6+000.

7+000.

8+000.

17+000.

18+000.

19+000.

20+000.

21+000.

22+000.

23+000.

PULAU

JEREJAK

PULAU

AMAN

PENANG

ISLAND

(Batu Maung)

NAVIGATIONAL

SPAN

MAIN LAND

(Batu Kawan)

Existing Penang Bridge Legend:Existing Penang Bridge

North South Expressway (PLUS)

Package 1&2

Package 3

Marine Bridge

Land Expressway8.4 km

Second Penang Bridge

project alignment

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

Page 6: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

PLAZA TOL PB2X

PLAZA TOL PLUS

LEBUHRAYA UTARA

SELATAN

PERSIMPANGAN

BATU KAWAN

PERSIMPANGAN

CLOVERLEAF

BATU KAWAN

SECOND PENANG

BRIDGE

EXISTING

PENANG BRIDGE

project alignment (view from batu kawan)

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

Page 7: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

governance structure chart of jksb

SHAREHOLDER

( MINISTRY OF FINANCE)

BOARD TENDER

COMMITTEE

BOARD OF DIRECTORS

(CHAIRMAN: TAN SRI DR SULAIMAN MAHBOB)

BOARD AUDIT, RISK &

GOVERNANCE

COMMITTEE

NOMINATION &

REMUNERATION

COMMITTEE

BOARD FINANCE &

TECHNICAL COMMITTEE

MANAGING DIRECTORDATO’ IR. DR. ISMAIL

MOHAMED TAIB

TENDER MANAGEMENT

COMMITTEE

FINANCIAL TECHNICAL

COMMITTEE

OPERATING DIVISIONS

INTERNAL AUDIT

MANAGEMENT RISK

COMMITTEE

ENTERPRISE RISK

ASSESSMENT

CLAIM CONSULTANT

ISO ACCREDITION

CHIEF OPERATING OFFICERMEJAR (B) IR MOHD ASHARI ALIAS

CONSTRUCTION DIRECTORIR HAMIZOL NGAH

CHIEF FINANCIAL OFFICERDARWIS ABDUL RASAK

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Page 8: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

Project Organization Chart

TN Synergy S/BPa’ Wan Teh S/B

Page 9: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

Design &

Build

Package 3B,3C,3D & 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

Package 1, 2, 3E & 3F

Design & Build

Integrated Toll System

work packages diagram

Page 10: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

Summary of Progress –2 MAY 2013 (Rev. No. 04)

PAKE

JDESCRIPTION CONTRACTOR

COST

(RM

MIL.)

START

JKSB

TARGET

FINISH

PHYSICAL

PROGRESS %

SCH % ACT %

1

Main Navigation Span And

Substructure And Foundation

Works For Approach Spans

CHEC Construction

(M) Sdn Bhd2,200 8 Nov 08 24-Jul-13 99.21 99.17

2Superstructure Works of

Approach SpansUEM Builders Bhd 1,550 8 Jun 09 8-Sep-13 94.46 94.53

3A Batu Maung InterchangeCergas Murni Sdn

Bhd152.7 19 May 10 30-Jun-13 84.28 86.60

3B Batu Kawan ExpresswaysIJM Construction

Sdn Bhd349.9 28 Jun 10 8-Sep-13 76.87 82.10

3CBatu Kawan Trumpet

InterchangeHRA Teguh Sdn Bhd 67.3 19 May 10 30-Apr-13 76.69 68.94

3D Toll Plaza And Related Works Pa’ Wan Teh Sdn Bhd 79.8 15-Nov-11 15-Jul-13 52.82 28.95

3E Toll Collection SystemTERAS Teknologi

Sdn Bhd14.97 01-Jun-12

31-Aug-

1342.08 34.00

3FTraffic Control An

Surveillance System

Itramas Technology

Sdn Bhd19.8 26-Jun-12 25 Jul 13 55.74 55.26

3G M&E Installation WorksTN SYNERGY Sdn

Bhd13.4 26-Sept-12 30 Jul 13 64.20 70.68

Total4.5

billion8 Nov 08 8 Sept 13

94.06 94.29

Var 0.23

Page 11: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

In the feasibility study conducted in 2002, the following alternative alignments wereconsidered:

i. The Northern Route (highest IRR)

ii. The Mid-Channel Route

iii. The Southern Route

• The alignment of the Southern route was chosen as to promote socio-economics development in the south that would provide a balanceddevelopment across Penang state.

The Southern Route

background

Page 12: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

• The Government of Malaysia offered the privatisation of the Second Penang Bridgeto UEM Group Berhad in 2006. The ground breaking ceremony was performed on12 November 2006 by the fifth Prime Minister of Malaysia, Tun Abdullah AhmadBadawi.

• A joint venture between UEMC (a subsidiary of UEM Group) was formed with ChinaHarbour Engineering Company Ltd (CHEC) to execute the Project. MOA with ChinaExim Bank was later signed for the loan amount of USD800 Million.

• On 29 August 2008, the Government has revoked the offer to UEM Group Berhaddue to UEM and CHEC could not finalize the apportionment of jobs and cost.

• Subsequently, Jambatan Kedua Sdn Bhd (JKSB) a company of the Ministry ofFinance Incorporated (MoF Inc.), was appointed as the concessionaire for theSecond Penang Bridge Project.

BACKGROUND

Page 13: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

1. Design

o During initial stage of construction

• No design calculations.

• No detail & construction drawings available.

• CHEC has completed 10% of the piling works as of April 2009.

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 14: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• Perunding Zaaba Sdn.Bhd. was initially appointed as the IndependentChecking Engineer (ICE) on 20 April 2009.

• However, the service was eventually terminated and replaced by ArupJururunding Sdn. Bhd. on 27 January 2010 for Package 1 and 2.

• Minconsult was appointed as the Independent Checking Engineer forPackage 3.

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 15: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

o Ship Impact Requirement

• In the Employer’s Requirements (ER); the minimum collision force at anybridge pier is 6.24 MN based on fully loaded barge with SBG (in accordancewith AASHTO LRFD). However a minimum collision force of 1 MN withempty barge is adopted in CHEC’s Design Brief.

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Page 16: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o 2500 Years Earthquake Event.

• The Employer’s Requirement (ER) requires no damage criteria for a 500 yearsreturn period. In addition to this, a requirement of ‘no collapse’ criteria forthe most credible earthquake (2500 years return period) was also introduced.First Penang Bridge was design on a similar requirement.

• Based on ICE’s comments on the detail design, spun piles at the approachbridge of Package 1 could only cater for the 500 years return periodearthquake. No plastic hinge forms as required for ‘no collapse’ criteria of2500 years return period.

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

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Page 17: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Durability Requirement

• JKSB requires the durability requirements based on the latest EurocodesBS EN 1992-1-1:2004 and for high performance concrete: RCPT shall beless than 800 Coulombs for 56 days. CHEC claimed that the requirementsare deemed as additional requirements as design are based on BS 5400.

o 6 Span and 5 Span Module

• JKSB adopted the 6-span module / 5 span module based on CHEC’s designfor the Approach Span Bridges instead of 15-span module proposed byUEMB.

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 18: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Notional Lanes

• CHEC has designed the Main Navigation Span (cable stay bridge)where the loading is based on 3 notional lanes with New JerseyBarrier (NJB) a divider for motorcycle lane is consideredpermanent.

• JKSB maintains that the practice in Malaysia is to design the full deck for 4 notional lanes with the NJB as a removal structure.

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

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Page 19: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Pilecap/Pier• Hairline cracks appeared in all Package 1 piers due to Package 2 SBG

launching works and eccentricity of launching gantry legs. Package 1 pierdesign consider no eccentricity.

o Dry Joints or Glued Joints for SBG prestressing tendon• UEMB had adopted external tendon in their original proposal with dry joint.

However, JKSB highlighted that for marine condition the standard practice isto adopt the glued joint.

o Change of Mechanical Pot Bearings to High Damping Rubber Bearings.• In order to cater for the 2500 years period earthquake with ‘no collapse’

criteria for Package 1 piles, JKSB decided to adopt High Damping RubberBearings in lieu of Mechanical Pot Bearings for Package 2.

Gluing works in progress

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 20: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

2. Contract

o Advanced Payment

• RM330 million advance payment requested by CHEC exceeds the TreasuryGuidelines of either RM10 million or 25% of the contract sum (whichever islower). National Audit Department upon auditing in January 2009 statedthat special approval needed from MOF for the payment.

o Lump Sum Item

• Cable stay works was issued as a lump sum item with only 6 preliminarydrawings available.

o Variation of Prices (VOP) Basic Price

• JKSB have fixed the Variation of Prices (VOP) for the three materials only i.ecement, steel and diesel. CHEC proposed to include other steel basedmaterials for VOP.

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 21: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o CHEC’s Contract Document

• CHEC has submitted the Contract Document Proposal based on FIDICConditions of Contract for EPC/Turnkey Projects. However, JKSB requiresthe contract based on PWD Form DB. (Rev. 2007).

o Late Site Possesion

• Handing over of site at Batu Kawan to CHEC was late by 5.5 months dueto delay in settlement of payment issues to local fishermen and cocklesbreeders.

Compensation amounting RM6.6 million

to fishermen and cockle breeders was

made on 24 Oct 2011

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 22: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

3. Construction

o Interfacing works with Package 2

• Blockage and barge collision incidents occurred during the disposal ofmud by Package 2 subcontractor due to commercial dispute withPackage 1 subcontractors.

• The use of main dredged channel was required by Department ofEnvironmental (DoE).

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Article from Guangming

Daily dated 22nd Sept 2009

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 23: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Erection of SBG at interface Pier 292, Pier 0, Pier 27, Pier 24.

• There was a constraint and timing factor where the erection of SBG has to becompleted prior to launching of beams and side spans of cable stayed bridgeconstruction by Package 3B & 3A and Package 1 contractors.

• If the launching of beams or side spans construction is carried out earlier thanSBG launching, prestressing works of the SBG has to be carried out at 3m abovethe deck level. This will pose a very high risk in terms of safety.

• Similarly, for Pier 24 and 27 where the pier height is 28m above sea level and atslope position, the launching of SBG will be extremely dangerous.

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 24: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Land Access from Batu Kawan to the Approach Span (Marine bridge)

UEMB has requested to have an early land access from Batu Kawan to ApproachSpan as to expedite the finishing works. However, there were several issues to beresolved by Package 1 as follows:

• Waste Disposal RouteThere was an existing waste disposal route which passed through Pier 272 to279. The State Government requested that the route is to be maintained untilMay 2011 when the Pulau Burung disposal ramp completed.

• Bored Pile ConstructionFrom Pier 283 to Pier 292, the water is shallow and muddy thus bargemovement is not possible for driving spun piles. The bored pile design adoptedwould require longer period for construction.

• As for Package 3B Land BridgePart of the land access to the marine bridge was theconstruction of 160m land bridge and also the 200mapproach access. Since Package 3B had not beenawarded, the early land access can be onlymaterialise in January 2011.

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 25: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Spun Piles - Short length• JKSB was concerned that there were groups of piles at Pier P170, P180, P181 and

P183 where the piles driven length were shorter by more than 10m from thedesigned length.

o Bored Piles• Sonic Logging & Class II and III defects

Based on the result, the Class III defects were detected at 30m to 60m depthat various piles needs to be repaired & retested.

• Failed test pile failed at less than half design capacity. At Main Span, 2.0mdiameter and 100m length bored piles needs to be socketed 5m in rock.

o Spun Piles Cracked• Total of 12 piles cracked for the month of July 2010 and stop work order was given

after the 11th pile cracked. Concrete spalling appeared at top of the pile due toheavy driving.

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

P24 P25 P26 P27

Installed 11/12 21/21 21/21 12/12

CSL carried out 6/12 21/22 21(22) 12/12

Class 1 4 15 15 10 10 8

Class 2 2 2 3 10 11 3

Class 3 0 1 0 0 0 1

Class 4 0 3 3 1 0 0

Def

ect

ive

*red color represent after remedial work

Page 26: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Sequence of Pier Works and SBG Launching

• Under the Employer’s Requirement, the sequence of pier construction is asbelow:

CHEC’s Sequence of Pier Works

GROUP PIER

Group 1 Pier 178 to 282

Group 2 Pier 46 to 28

Group 3 Pier 47 to 144

Group 4 Pier 283 to 292

Group 5 Pier 0 to 23

Group 6 Pier 145 to 177

Group 7 Pier 24 to 27

SBG Launching SequenceP0

P27

P292

P24

P46

P144P177

P282

CHEC’s Sequence of Pier Works

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 27: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

UEMB’s SBG Launching Proposal

GANTRY PIER

LG1 & LG2 Pier 267 to Pier 117

Pier 267 to Pier 292

LG3 & LG4 Pier 117 to Pier 27

Pier 0 to Pier 24

o Sequence of Pier Works and SBG Launching (continue)

• However UEMB had submitted the new SBG launching sequence tofacilitate early land access and to expedite the finishing works.

SBG Launching Sequence

P1

53

P2

67

P0

P2

7

P2

92

P2

4

P1

17

LG1 & LG 2

SBG Launching Sequence

P15

3

P26

7

P0

P27

P29

2

P24

P11

7

LG3 & LG 4

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ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

Page 28: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

o Dredging of Main Channel and Maintenance Dredging Works by Package 1 Contractor

• The dredged channel was purely to facilitate CHEC’s foundation and pier works.However, it did not consider the Package 2 SBG erection works.

ISSUES AND CHALLENGES FACED IN THE PACKAGE 1 & 2

JAMBATAN KEDUA SDN BHD.Wholly own by Ministry of Finance

• The maintenance dredging works by Package 1 Contractor would be ceased afterthe last pier is completed in October 2012 while the SBG erection would continueuntil May 2013.

• The SBG delivery by barge maybe disrupted if siltation rate is high as the draftclearance for the barge need to be maintained at -3.5m ACD.

Page 29: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

During early construction of the project, JKSB has :

o Minimal manpower

Chief Executive Officer - 1 Chief Operating Officer - 1 Senior Manager - 2 Chief Financial Officer - 1

o Limited office equipment.

o Proposal for the Consultant Project Management Team was rejected by Board ofDirectors. JKSB was directed to set up own Project Team.

o RM80 million budget approved but only RM50 million was given to JKSB by MOFfor operation during 5 years construction period.

ISSUES AND CHALLENGES FACED BY JKSB

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Page 30: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• Appointment of consultant for Package 3 Land Expressway not formalized.

• Discrepancies on the land acquisition cost between Valuation and Property ServicesDepartment and Penang State Government.

• Comparative assessment made by the Valuation and Property Services Departmentof MOF (JPPH) and State Government is tabulated as follows:

ISSUES AND CHALLENGES FACED BY JKSB

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Page 31: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• RM500 million Bridging Facility from Bank Pembangunan needs to be taken forPackage 1. Further payment only can be made after execution of the formalContract Agreement with China Exim Bank and the Concessionaire Agreementwith LLM. Package 1 claimed delay due to the late finalization of the ContractDocument.

• Delay finalizations of financing requirements of PB2X.

• As of December 2009, the actual physical progress of works is 8.65%compared to schedule physical progress of 39.7%. This was due tocontractual, design and construction issues.

ISSUES AND CHALLENGES FACED BY JKSB

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Page 32: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

Business &

Organization

Management

Share-

holders

Board

SUCCESS CRITERIA

1. BOARD PLAY A CENTRAL ROLE TO DRIVE GOVERNANCE AND PERFORMANCE.

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Page 33: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

Structure

STRUCTURE

Culture

Policies & Procedures

Leadership &Talent

OrganisationalConfiguration

2. THE LEVEL FOR ACHIEVING WORLD - CLASS RESULTS…

Business Results

Process

SUCCESS CRITERIA

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Page 34: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

vi. Persuade, inspire and motivate others to follow you

ii. Foster innovation

i. Set and achieve business goals

iv. Set priorities and focus on key tasks

iii. Solve problem and make decisions

vii. Perform and get result

v. Set high standards and lead byexample

Leadership:Seven responsibilities of leadership (extract from

“ How the Best Leaders Lead” by Brian Tracy)

SUCCESS CRITERIA

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Page 35: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• 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

Lessons learnt

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Page 36: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• Independent Checking Engineer (ICE) site audit:

Conducted once every 2 months to ensure the quality of the construction meets the international standard specifications.

LESSONS LEARNT

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Page 37: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• Penalty system

A well balanced training/ penalty/ award system is utilized to keep allmanagement staff and contractors up to date with the Quality and HSEstandards to ensure their compliance.

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• INTERNATIONAL GREEN APPLE AWARDSFOR THE BUILT ENVIRONMENT & ARCHITECTURAL HERITAGE 2013

Page 38: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• Innovative High Dumping Rubber Bearing (HDRB)

The design of the HDRB is by Tun Abdul Razak Research Centre (TARRC), a laboratory of the Malaysian Rubber Board (MRB) and manufactured locally.

Second Penang Bridge is the longest bridge in the world using HDRB.

HDRB at Package 2

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Page 39: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• Settlement criteria 50mm in 20years

• 100% primary consolidation (according to Asoka Plot)

For minimal maintenance requirements JKSB hasreviewed the settlement criteria of the surcharge from100mm in 5 years to 50mm in 20 years with minimaltime and cost penalty.

Prefabricated Vertical Drain (PVD)To ensure ‘no settlement’ criteria is complied,buckling test for PVD was carried out at PSB Lab inSingapore and subsequently to National University ofSingapore to show that the results complement thecompliance test.

Stone columnLoad test that was carried out all failed to complywith the specification criteria. Consultant wasdirected to back analyze their design and ensure thatno sliding failure during construction and nosettlement after completion occurs.

Overall view of the Trumpet

Interchange

Plate Bearing of Group 4 Column at

CH 23300, M001PVD installation Sonic logger

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Page 40: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• Design & Built for relocation of services

Under Package 3C contract, the scope of relocation of TNB Pylon wasspecified as Design and Built item. However, in Package 3A contract, therelocation of services is specified as provisional items.

Package 3C contractor is responsible for design, obtaining approval fromauthorities and construction within time and cost. The works is successfullycompleted on time. Package 3A contractor has claimed on the additionalworks and delays occurred due to authorities approval.

TNB Pylon relocation

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Page 41: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• Design for ease of construction compared with minimum material cost.

DESIGN CRITERIA PACKAGE 1 PACKAGE 3A

Piling Design The pile was designed in a circularposition which make it easier forpiling operation. Requires lessmovement of piling barge.

The pile was designed in arectangular position whichrequires piling barge movement.

Pilecap Design Twin Circular Pilecap. Proximity ofpilecap make it easier to construct.The first layer of pilecap was used asa permanent base of formwork.Precast shell act as a permanentside formwork.

Single Pilecap make it longertime to construct and extraformworks used.

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Page 42: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• UEMB SBG’s quality problem due to minimum weight design.

Excessive blow holes at surface

Rebar exposed at the haunch area

Honeycombing at surface

LESSONS LEARNT

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Page 43: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• All products must be tested for compliance

Additional Materials Testing for Geotextiles

Compliance tests carried out in PSB Lab in Singapore, indicate that thegeotextile materials did not comply with the specifications and thusrejected.

Further confirmatory test was carried out at TRI lab in Austin, Texas,USA which also demonstrates failure. Approval of other alternativesuppliers shall be subjected to compliance of similar tests.

Laying of Geotextile Separator

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Page 44: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

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• All products must be tested for compliance (continue)

Perkins Generator Set

The FAT for the generator set type Perkins has failed twice due tofailure on alternator (Stanford). However the third FAT has passedusing alternator by Merrilly.

Anchorage Leakage Test

The test was done and only pass at the 3rd time.

Page 45: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LESSONS LEARNT

• Used of sonic logging (CSL) for Quality Control of bored piles

Cross-hole sonic logging (CSL) is a non-destructive method which involvedultrasonic signal transmission through the shaft between two parallel waterfilled access tubes. CSL is used by JKSB to evaluate the concrete and shaftconstruction quality of bored piles.

The defect identified by CSL include but are not limited to lower qualityconcreted due to mixing with drilling slurry, honeycombing, necking and soilintrusions, and soft toe conditions.

Defects are classified based on Class I, II, III, IV.

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Page 46: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• Site clearing & earth work proceeded before land acquisition finalized.

JKSB has proceeded with land rental agreement with private land owners prior to land acquisition. This will enable the contractor to commence their works without awaiting for the land acquisition.

LESSONS LEARNT

Government land – 195.50 acres

Private Lots – 60.67 acres

Total land acquisition at Batu Kawan is = 256.17

acres

Land Acquisition – Batu Kawan

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Page 47: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

• Package 3A – Marine piling

Package 3A contractor was unable to proceed with work

The scope of works for marine piling work at Package 3A was novated to Package 1 contractor.

The work was successfully completed and Package 3A is back on track.

LESSONS LEARNT

Page 48: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

LATEST PROGRESS

PHOTOS

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Page 49: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

Package 1

P25P26

P24 P27

Final Mid Span Closure cast completed MS19

on 21 April 2013

Overall View of Main Navigation Span

Balance of Works Start Date

1. Mid Span Deck of P25 & P27:

MS 19 Final stitchingCuring In

progress

2. Crown Structure Installation (1st

Set)08 May 2013

3. HT Cable Installation 07 June 2013

4. Transformer T24 & T27

Installation06 May 2013

5. Parapet Installation 15 May 2013

6. Premix Works 07 June 2013

7. Expansion Joint Installation 17 June 2013

LATEST PROGRESS PHOTO

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LATEST PROGRESS PHOTO

Completed

Parapet

NJB Installation (as of 21/04/2013)

Total Completed : 5,140 / 9,750 (52.71%)

Balance : 4,610 nos

Prod : Current 56 nos/day, Target 66 nos/day

Target to complete by June 2013

Parapet Installation (as of 21/04/2013)

Total Comp : 23,650 / 29,796 (79.33%)

Balance : 6,146 nos

Prod : Current 193 nos/day, Target 154 nos/day

Target to complete by en of May 2013

Package 2

Completed

NJB

Installation of Parapet and NJB in progress.

Street Lighting Poles Installation (as of

22/04/2013)

Total Comp : 200 / 578 (34.6%)

Balance : 378 nos

Target to complete by July 2013

Completed Street

Lighting Pole

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Completed Deck Slab

Ramp 1 : R1/P7-M2/P1

Ramp 2 : R2/P11-M1/P1 & R2/A-R2/P3

Ramp 3 : Completed

Ramp 4 : Completed

Ramp 4Ramp 2 Ramp 1

Ramp 3

Completion date on 30 June 2013

TNB

Substation

Construction of deck slab, box girder & RE wall is in progress

Package 3A

LATEST PROGRESS PHOTO

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LATEST PROGRESS PHOTO

M1/P2

M1/P3

M1/P4

M1/P5

M1/P6

Land access ready on 30 March 2013

Deck Slab Work is in progress

M1/P7

M1/P8

Completion Deck Slab

M1/P1 – P0 : 30 Nov 12 – 15 May 13

M2/P2 – P0 : 21 Nov 12 – 30 Mar 13

Launching completed on 16

March 2013 (P0)

M1/P10

M1/P9

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Package 3B – Earthwork

CH 18500

CH 17900

CH 18400

DBM

Roadbase

Overall view from CH 17900 – CH 18500

DBM

LATEST PROGRESS PHOTO

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Page 54: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

54

CONCLUSION

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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 September 2013.

Page 55: mesyuarat pegawai kanan jkr malaysia 2013 kuala terengganu

Thank You

For Your Kind Attention

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