D

DOHA
A INT
TERNA
ATIO
ONAL AIRP
PORTKEPPEL FMO
Annual Structu
S
ural Audit Report
R
for
The Midfiel
M
ld & FT
TZ Tunnels

Head
d Office (Q
Qatar)
KE
EO Intern
national C
Consultan
nts
C Ring Road
R
/ Al Mattar Street
S
Inte
ersection
P.O
O. Box 18
8108
Doha
Sta
ate of Qa
atar

(2
27th July 2015
2
Revision 01)
0

This Stru
uctural Auditt Report for the Midfield and
a FTZ Tun
nnels has bee
en prepared by KEO
International Consulttants. Contents of this Au
udit Report re
emain the prroperty of KE
EO Internatio
onal
Consulta
ants and may
y not be copied, used or distributed without
w
the exxpressed prior permissio
on of
KEO Inte
ernational Co
onsultants. Copyright.

R
Revision
0 15th June 20
015

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unnels

1. EXE
ECUTIVE SUMMAR
RY
KEO
O have been engaged by Keppel FMO to inspect and prrovide a rep
port for a thiird annual
aud
dit of the Mid
dfield and FTZ
F
tunnels that include
es,
of the curre
a) A general description
d
ent state off the buildin
ng structure
es including progress
of repair wo
ork.
b) Recommen
ndations forr short term and long te
erm mainten
nance and repair
r
requiirements
c) Recommen
ndations forr further inve
estigation iff required
d) Photograph
hs and a loccation diagrram of each
h photograph taken.
It should be noted
n
that the
t
Contracctors maintenance pe
eriod has expired
e
sincce 28th of
Feb
bruary 2015, after a durration of 365 days from
m the contra
actual comp
pletion date..
Bassed on our visual obse
ervations and
a
the As Built drawiings provided, the Mid
dfield and
Free
e Trade Zo
one (FTZ) tunnels ha
ave been constructed
c
d to a reas
sonable sta
andard in
acco
ordance wiith the As Built structtural drawin
ngs. Howev
ver, there are
a still defects that
requ
uire further repair workk now or ma
aintenance in
i future years.
In section
s
3.1 Visible
V
Defe
ects, in the Report the
ere is a list of
o eight (8) items that cover the
defe
ects found in the structtural audit. Based
B
on th
he observattions and re
esults of the
e previous
seco
ond audit report
r
of 15
5th Januaryy 2015 and combined with the present
p
one
e, we can
divid
de these ite
ems into fou
ur groups de
epending on
n the requirrements for repairs.
1. Items (i) an
nd (iii) need further sch
heduled mon
nitoring. These items relate
r
to gro
oundwater
leaking into
o the tunnels and affecct the operattion of the tunnels.
t
The
ese items w
were listed
on the DIA snag list.
2. Item (ii) ne
eed further scheduled monitoring
g. This item
m relate to groundwate
er leaking
into the tun
nnels throug
gh the consttruction join
nts and movvement jointts.
equires rep
pair before the next rrain season
n and frequ
uent monito
oring and
3. Item (v) re
maintenancce in a perm
manent and
d scheduled
d basis. Thiis item relates predom
minantly to
waterproofiing the Midffield and FT
TZ tunnel ellectrical sub
bstations roof slabs and
d keeping
water out of
o cable tren
nches. The Midfield tun
nnel roof sla
ab had been
n waterproo
ofed since
the first aud
dit inspectio
on. No further waterpro
oofing has been
b
observved.
4. Items (iv), (vi), (vii) an
nd (viii) requ
uire ordinarry maintena
ance works in a perma
anent and
scheduled basis.
The
e steel frame
ed doors for the electriical substations are russting and ne
eed repairs.
The
e Genset en
nclosures are
a still rustyy and need
d continuous repairs an
nd mainten
nance due
to th
he onset of rust. .
The
e concrete barriers witth observed
d cracks an
nd bubbling
g paint sho
ould be repa
aired and
kept in good co
ondition thro
ough contin
nuous and scheduled
s
m
maintenance
e activity.

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unnels
Refe
er to Sectio
on 4 Recommendatio
ons, in this report. The
e recomme
endations fo
or Keppel
FMO
O are the fo
ollowing;
a) Major defects have be
een repaire
ed by the Contractor.
C
(The Contrractors Maintenance
th
Period has expired sin
nce 28 of February
F
20
015.)
e areas whe
ere stains of
o potential water ingre
esses have been inspe
ected and
b) Monitor the
the ongoing
g maintenan
nce work in the tunnel..
ast a copy of
o all the Wa
arranties forr work carrie
ed out on th
he project.
c) Have at lea
port as a re
ecord of defe
ects to hold
d any involved contracttor accounta
able..
d) Use this rep

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unnels

2. INT
TRODUCTION
O Internatio
onal Consultants have been comm
missioned by
b Keppel FMO
F
Pty Ltd to carry
KEO
out a third Sttructural au
udit of the Midfield an
nd Free Trrade Zone (FTZ) tunn
nels. The
prevvious Struc
ctural Audit Report forr The Midfield & FTZ Tunnels was
w
issued in March
2014, docume
ent numberr 13-5335-K
KEO-ST-RP
PT-0001, re
evision 1. In addition, a report
entitled Structu
ural Audit Report
R
for Th
he Midfield Tunnel Scrreens was issued
i
in Ju
une 2014,
doccument num
mber 13-533
35-KEO-ST
T-RPT-0002
2, revision 1. Likewise
e, an inspection and
aud
dit report wa
as conductted on Janu
uary 17th, 2015,
2
titled Second Audit
A
Reporrt. These
thre
ee previous reports sho
ould be refe
erred to.
The
e Main Contractor for the
t
tunnel projects is Sinohydro Gamuda
a - WCT JV
V, and the
Con
nsultant for design and site superv
vision is Sco
ott Wilson.
The
e latest aud
dit inspectio
on for the Midfield
M
Tun
nnel, two substations,
s
, and east and west
th
bou
und pump ro
oom began
n on 15 Ju
une 2015. At
A the time of the insp
pection therre was no
repa
air work in progress. Also,
A
there had been no
n rain for many
m
month
hs and therre was no
rain
nfall runoff on
o the road
d surface. Identificatio
I
n of ground
dwater leakking through the raft
slab
b was made
e easier.
The
e Midfield Tu
unnel scree
ens were ad
dded to the side of the tunnel and
d the soffit of
o the roof
slab
b for aesthe
etical and no
oise canceliing reasonss, and have not change
ed since the
e previous
aud
dit inspectio
on. The stee
el memberss and fixing
gs to the concrete
c
tun
nnel appear to be in
goo
od condition
n. Howeverr, the status of the re
ecommenda
ations included in the previous
repo
ort is not kn
nown at the time of writting this rep
port. Also, th
he fire ratin
ng of the scrreen such
as intumescen
nt paint, an
nd the effecct on the fire
f
protectiion systems is not kn
nown and
outsside the sccope of thiss report. Th
has been
he tunnel iss open to traffic
t
and inspection
i
conducted with
h increased caution an
nd difficulty. Carriagewa
ay inspectio
on was posssible only
duriing short tra
affic breaks.
The
e latest FTZ
Z tunnel aud
dit inspection began on
n 24rd June 2015.
2
Includ
ded in the inspection
werre two electrical substa
ations and tw
wo pump ro
ooms. The tunnel
t
was not open to
o traffic at
the time of th
he inspectio
on.
Therre had bee
en no rain for many months before the
insp
pection.
The
e tunnel stru
uctures are cast in-situ. There is a base raft slab,
s
retaining wall and
d roof slab
with
h Constructiion Joints through eacch element along the tunnel as sh
hown on the
e As Built
draw
wings in Ap
ppendix B, that also show
s
locatio
on of photo
ographs takken during the latest
aud
dit inspectio
on. At the east
e
and we
est portal of
o both tunn
nels there are
a movem
ment joints
betw
ween the tu
unnel road and the ap
pproach ram
mps. There are two pu
ump roomss for each
tunn
nel at road level that a
are cast in--situ structu
ures. These
e pump roo
oms are forr the road
draiinage. The Midfield tu
unnel has two
t
electriccal substations that arre supporte
ed by the
tunn
nel roof slab at the ea
ast and wesst portal. Th
he substatio
ons are casst in-situ fra
ames with
concrete colum
mns and roo
of slab. The
e external walls
w
are blo
ock in fill walls.
w
The FTZ tunnel
has two electrrical substa
ations that are separa
ate structurres to the south of th
he tunnel.
The
ese structurres are cast in-situ witth pad and strip footin
ngs, concrete columnss and roof
slab
b. The exterrnal walls arre block in fill
f walls.

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unnels
The
e purpose off these insp
pections and
d reports for the tunnell and substa
ation structu
ures is to
1.
2.
3.
4.
5.

Report on the
t progresss of repair work
w
and identify any new
n
structurral defects,
Photograph
h the defectts for record
d,
Identify the cause of th
he defect
Make recom
mmendation
ns for repair and mainttenance of minor
m
defec
cts
Confirm tha
at the structtural adequa
acy of the tu
unnels and substationss.

The
e visual insp
pection by KEO
K
docum
mented the concrete an
nd other de
efects in botth tunnels
and
d related building strucctures, referr to Append
dix A Photo
ographs. Fo
or the locattion of the
pho
otographs taken refer to Appen
ndix B. Th
he previouss audit rep
ports were used for
com
mparison wiith the latesst state of repair during the visu
ual inspectiion. This re
eport only
cove
ers items th
hat were vissible at the time of the
e inspection. It does no
ot include ite
ems such
as waterproofin
w
ng under th
he invert sla
ab of the tu
unnels and behind the
e retaining walls and
othe
er inaccessible items.
The
e purpose of
o this KEO report is to
o confirm maintenance
m
e requireme
ents for the Facilities
does not
Man
nager and is for the usse of Keppe
el FMO onlyy. KEO Inte
ernational Consultants
C
acce
ept any lia
ability for th
he design and constrruction sup
pervision off the existin
ng tunnel
stru
uctures outsside the sco
ope of this report. KEO
O will not be held liable for any use
u of this
repo
ort by third parties.

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unnels

3. MA
AIN REPOR
RT
3.1

Visible Defects
D
The First inspection of the Midffield tunnel was carried
d out on 26
6th October 2014 and
the FTZ tunnel on 23rd Decem
mber 2014 along with the electrical substations and
pump roo
oms.
efore the
The seco
ond one was
w
carried
d out on 1
17th January 2015, 10
1 days be
completio
on date of th
he Contracttors Mainte
enance perio
od.
Since the
e previous in
nspections carried out in Januaryy 2014, and January 20
015, there
have bee
en several repairs
r
carried out by T
The Contractor as parrt of the DIA
A snaglist.
Overall th
he condition
n of the tunn
nels, sump pump room
ms and electtrical substa
ations has
improved
d, the rema
aining work is mainly monitoring and mainte
enance wo
orks. Note
that there
e was rain around the time of the
t
initial audit
a
inspecctions carried out in
January 2014. For the
t
previou
us inspectio
ons carried out in Octtober and D
December
2014 there had bee
en no rain for many months
m
and
d hence no water runo
off on the
road. Like
ewise, durin
ng the curre
ent inspection there ha
ad been no rain for lon
ng and no
water run
noff on the road
r
was ob
bserved.
Refer to Appendix A for the photographs of defeccts observe
ed during the
t
visual
inspection
ns carried out,
o and Ap
ppendix B for the loca
ation of thes
se photogra
aphs. The
majority of defects mentioned in the seccond audit report can be summarised as
follows allong with prrogress mad
de to date;
Defects observations
o
s mentioned
d in the seccond and prresent third audit:
Water leaks thro
ough the co
oncrete base
e raft slabs
s, or invert slab
s
of the tunnels. Stainss of water ingress havve been ob
bserved in several loccations without water
prese
ence. Furthe
er scheduled monitoring is recomm
mended.
II. Water leaks thrrough the construction joints an
nd moveme
ent joints along
a
the
tunne
els and app
proach secttions. Add
ditional pipes installed
d to addresss leaking
waterr from movvement joints. No sign
ns of leaka
age thru mo
ovement jo
oints have
been observed during insp
pection in Midfield an
nd FTZ tun
nnels, exce
ept of the
move
ement joint at the entrance of West
W
Boun
nd of FTZ tunnel, wh
here it is
obserrved slight water
w
ingresss due to te
emporary divversion of water
w
spilled
d from fire
lines at
a east subsstation abov
ve.
III. Ingresss of water through the base of the retaining
g walls onto
o the road surface.
s

There
e was no evvidence, or leaking wa
ater, during the third inspection att the base
of the
e retaining walls.
w
Furthe
er schedule
ed monitorin
ng is recomm
mended.
IV. Excesssive shrinkkage crackss greater th
han 0.3mm in width in the slab around the
electrrical substa
ations in th
he Midfield tunnel. Ne
ew epoxy paint observed with
significant bubb
bling and damages
d
a
along
with several cracks
c
follo
owing the
shrink
kage crackss of the co
oncrete sla
ab. Deteriorrating epoxxy paint coa
ating and
shrink
kage crackss could lead
d to spalling
g of concrete. The electrical subsstations of
I.

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unnels
FTZ tunnel
t
are constructed
d beyond the
t
tunnels
s footprint and no surrounding
concrrete slab exists.
V. Poor drainage and deteriora
ating waterp
proof coatin
ng for electrrical substa
ation roofs
for bo
oth tunnels.. Minor re
epairing wo
orks on the coating ob
bserved. Ap
ppropriate
repairr of the coating
c
is absolutelyy necessarry.
Additional sadd
dle type
waterrproofing me
embrane is proposed around
a
the upstand.
VI. Rusty
y door fram
mes for su
ubstations, rusting Ge
enerator se
et covers and
a
other
misce
ellaneous de
efects. Po
oor and inco
omplete wo
orkmanship.
Defects not
n mentioned in the se
econd auditt:
VII. Shrin
nkage crackks in external concrete barriers an
nd sidewalk concrete slabs have
been
n observed.. Repairing works have
e been obs
served, while the crackks are still
visible.
VIII. Bub
bbling and peeling
p
pain
nt of barrierrs is observed, externa
ally in the to
op surface
and in
nternally in the base of
o barrier ad
djacent to asphalt,
a
due
e to previou
us ingress
of water.
Items (i), (ii) have be
een repaired
d
Item (V) is item th
hat require repair beffore the next rain se
eason and frequent
monitorin
ng and main
ntenance wo
orks in a pe
ermanent an
nd schedule
ed basis.
Item (VI) covers item
ms such ass rusting do
oor frames and Gense
et enclosure
es. These
defects would
w
need to be addressed in frequent basis mainten
nance to avvoid deep
rust pene
etration with
h appropriatte anti-rust materials and
a final co
oating the p
painting of
door frames aroun
nd the ele
ectrical sub
bstations, especially the Gene
erator set
enclosure
es, is of poo
or quality. The
T rust nee
eds to be sa
andblasted to grade 2..5, primed
and then an approprriate paint system applied.
Items (IV
V), (VII) and
d (VIII) nee
ed repairing
g works in a frequent maintenan
nce basis,
proposed
d as describ
bed below (clause 4c)) in a six months
m
grid, every Octtober and
April.
3.2

y of Defectts
Summary
A brief description of the outstanding
o
defects fo
or the tun
nnel area, electrical
substations and pum
mp rooms ca
an be summ
marised as follows;
f
Midfield Tunnel:
T

Bubbling paint off barriers.

Shrinkage crackss in concrette barrier.

In unccovered are
ea of tunne
el, deteriora
ation in pain
nt of the co
oncrete barrrier at the
joint with
w asphaltt due to surfface water or
o existence
e of sand in
n utilities tun
nnel.

Dama
aged by trafffic accidentt side scree
en

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unnels
There wa
as no moistture on the road surfacce adjacentt to the trafffic barrier to
o suggest
that there
e was groun
ndwater lea
aking throug
gh the consstruction joint at the ba
ase of the
retaining walls, unde
er the pede
estrian acce
ess way and through the
t construcction joint
at the bas
se of the tra
affic barrier..
Midfield Tunnel
T
Elecctrical Substtations:

Bubbling and damaged epo

oxy paint.

Shrinkage crackss in wall at the

t interface of the con
ncrete elem
ments and bllockwork.

Shrinkage crackss in roof sla

ab of electriccal substatio
ons.

Shrinkage crackss on the sla

ab surrounding electrica
al room.

Bad finishing dettail for wate

er proofing.

Rustin
ng surfacess, doors and
d louvers.

No waterr was observed at the

e time of th
he most rec
cent inspecttion, howevver, cable
trenches should be inspected straight afterr the next siignificant ra
ainfall.

Midfield Tunnel
T
Pum
mp Rooms:

Appea
arance of resin mate
erial on su
urface of wall
w
where injection h
had been
applie
ed.

Sign of
o moisture in ceiling of
o room due the existen
nce of shrinkkage crackss.

FTZ Tunn
nel:

Water leakage was

w
observved in the movement joint at th
he entrance
e of West
Bound
d of FTZ tunnel due to
o temporaryy diversion of
o water spiilled from firre lines at
east substation above, Shrinkage cracks
c
in concrete
c
barrier and sidewalk
concrrete slabs.

Bubbling paint off barriers.

There wa
as no moistture on the road surfacce adjacentt to the trafffic barrier to
o suggest
that there
e was groun
ndwater lea
aking throug
gh the consstruction joint at the ba
ase of the
retaining walls, unde
er the pede
estrian acce
ess way and through the
t construcction joint
at the bas
se of the tra
affic barrier..

FTZ Tunn
nel Electrica
al Substatio
ons:

Shrin
nkage crackks in electriccal substation roof.

Rustting surface
es, doors an
nd louvers.

Still some
s
peelin
ng paint on external wa
all.

Shrin
nkage crackks on Genset plinths.

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unnels

Crum
mbling conccrete around
d top of eartthling pit lid.

Note tha
at the botttom of the
e cable tre
enches inside the FT
TZ tunnel electrical
substations is below
w ground levvel. Water ingress could be from the roof sla
ab or from
the side wall
w of the cable
c
trench
h.
FTZ Tunn
nel Pump Rooms:
R

3.3

Shrinkage crackss in the walls. To be monitored.

Discussiion of Defe
ects
3.3.1

Water
W
leaks through th
he invert sllab of tunnels
Att the time of the third structural
s
au
udit inspectiions in June
e 2015, therre was no
ra
ainwater run
noff and lea
aks from the
e movemen
nt joints at the entrancces to the
tu
unnels had at
a least bee
en containe
ed. This ma
ade any watter leaks through the
invert slab easier to ide
entify. There
e are not any
a leaks th
hrough the base raft
slabs in both tunnels.
Ass stated in
n the first audit inspe
ection repo
ort dated March
M
2014, in our
exxperience, crack
c
injecttion stops water
w
leakin
ng through that individ
dual crack
on
nly. New water
w
leaks then becom
me apparen
nt in adjace
ent areas. The
T
crack
injjection repair work sh
hould be an
a iterative process until finally the
t
water
leaks stop alltogether. Once
O
there have been no more water
w
leakss for more
th
han three months, then that whole area of con
ncrete is wa
ater tight.
of the roa
Th
he recent inspections
i
ad surface on the invvert slab of the two
tu
unnels do no
ot show any
y new leakss adjacent to
o the previo
ous repairs..

3.3.2

Water
W
leaks through co
onstruction
n joints and moveme
ent joints
Repair work has been completed
d since the
e previous inspections. Where
movement
m
jo
oints at the entrance to
t both tunn
nels are still leaking, additional
PV
VC pipes have been added
a
below
w the road surface
s
to funnel waterr from the
movement
m
jo
oint to the nearest gra
ated inlet pit
p and into the tunnel drainage
syystem. Whillst this is no
ot the perfect solution, repair of a flexible wa
aterstop in
th
he raft slab
b is extrem
mely difficultt if not imp
possible. Demolition
D
w
work
may
crreate more leaks and problems
p
than before.
Exxamples of Constructio
on Joints and Moveme
ent Joint de
etails for the
e Midfield
tu
unnel can be
e found on As Built drawing E13
320-10-DO--S-017 deta
ails 1 to 3,
6 and 7 for base raft slabs and reta
aining walls..
Fo
or the FTZ tunnel simiilar details can
c be foun
nd on As Built
B
drawin
ng E150010
0-DO-S-119
9.
Th
he Construcction Joints
s rely on a re-injectable
r
e waterproo
of system to
o seal the
joint after construction
c
n. Rascote
ec re-injecta
able waterrproofing system or
ap
pproved equ
uivalent at construction
c
n joints. Re
efer to detail 1.

13-5335--KEO-ST-RPT
T-0003
Revision 1

P
Page
9 of 16

DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels
Th
he Moveme
ent Joints re
ely on flexib
ble watersto
ops to make
e the joint waterproof.
Ty
ypical areass where this system fa
ails is wherre the waterrstops are spliced
s
or
bu
utted togeth
her.
3.3.3

In
ngress of water
w
through base off retaining walls
w
onto road surfa
ace
During the inspection off The Midfie
eld tunnel an
nd the FTZ tunnel, there was no
moisture
m
on the road su
urface to suggest thatt the joints through the
e base of
th
he retaining
g wall were actually le
eaking. Acccessibility under
u
the pedestrian
p
walkway for inspection purposes iss impossiblle. No furth
her action iss required
fo
or now. Thiss item can be
b monitore
ed again during the nexxt audit insp
pection.
Th
he Constru
uction Jointt at the ba
ase of the retaining wall
w
relies on a reinjjectable wa
aterproofing
g system in the same way
w as othe
er constructtion joints
in the base raft slab and
d vertical joints in the retaining
r
wa
all. Refer to
o As Built
drrawing E1320-10-DO-S
S-510 for tyypical sectio
ons through
h the Midfie
eld tunnel.
Th
he FTZ tunn
nel Constru
uction Joint at the base of the retaining wall iss similar.
Acccess to th
he construc
ction joint at
a the base
e of the re
etaining wa
all can be
acchieved only by remo
oving the pedestrian
p
a
access
grating and so
oil below.
Th
here are se
ervices run
nning below
w the pedesstrian access path wh
hich adds
more
m
comple
exity of inspection.

3.3.4

Sh
hrinkage cracks
c
and
d deteriora
ating epox
xy paint co
oating for Midfield
tu
unnel roof around
a
Ele
ectrical Roo
oms
Prrior to the initial audit inspection of two elecctrical substtations supported by
th
he Midfield tunnel rooff slab at th
he east and
d west porttal, there have been
su
ubstantial re
epairs to shrinkage cra
acks in the tunnel roof slabs.
s
Ad
dditional re
epairing beffore the ne
ext rain sea
ason and frequently
f
s
scheduled
monitoring
m
an
nd maintena
ance work is
i required.

3.3.5

Po
oor draina
age and deteriorating waterrproof coa
ating of e
electrical
su
ubstation roofs
r
Th
he roof slab
bs for each of the fourr electrical substations
s
s for the Mid
dfield and
FT
TZ tunnel, and Foam room build
dings for th
he FTZ tun
nnel adjace
ent to the
electrical roo
oms, are all similar in constructio
on. Drainag
ge relies on
n the roof
slab sloping to
t the side walls and th
hen draining through a spigot at the
t corner
off the building. There arre no downp
pipes.
Th
here has be
een no repair work ca
arried out on
n these roo
of slabs. Th
he defects
re
emain unchanged. As stated in the previouss audit repo
ort, these roof
r
slabs
along with large shrinka
age cracks and
a poor waterproofing
w
g, could be
e the point
off water ing
gress into the electriccal substattions below
w. Shrinkag
ge cracks
re
equire crackk injection and the wate
erproofing membrane
m
n
needs
to be
e redone.
Ad
dditional wa
aterproofing
g repairing of the mem
mbrane in th
he sides an
nd the top
su
urfaces of the upstand is requirred, in all Electrical
E
Rooms,
R
As Soon As
Po
ossible.

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 10 of 16

DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels
3.3.6

Rusting doo
or frames and
a
other miscellaneo
m
ous defects
s
Since the previous
S
p
au
udit inspecttion, some new doorr frames ha
ave been
in
nstalled in the
t electrical substatio
ons. Repain
nting has ta
aken place, including
the Genset enclosures, while in many
m
places
s the rust iss coming through the
n
new
paintwo
ork. The rust needs to
o be sandbllasted off, a primer ap
pplied and
then a good quality paint system th
hat can with
hstand the harsh
h
enviro
onment.
These items will need
T
d maintena
ance preferrably now and in a frequently
f
s
scheduled
maintenance activityy, avoiding deep rust penetra
ation and
d
deterioration
n of the stee
el structure.. This task needs
n
to be
e completed
d.
The Gensett enclosure
T
es are a modified
m
shipping container with door and
lo
ouvers insta
alled to suitt. The door frames, me
etal sheeting and louve
ers are all
s
showing
sig
gns of rust and
a
clearlyy do not havve an apprropriate pain
nt system
fo
or the harsh
h external environment
e
t.
There are many
T
m
otherr minor deffects such as repaire
ed shrinkage cracks,
s
shrinkage
c
cracks
in th
he concrete
e traffic barrriers, bubb
bling paint, damaged
s
side
screen,, crumbling concrete around the pit
p lid for the
e earthing pits and so
o These types
on.
t
of de
efects need
d scheduled
d maintena
ance freque
ently, and
m
monitoring.
(Note: type and lo
ocation of each defect is spe
ecified in
A, B)
a
appendices
Iff there is in
ncreasing discoloration
n of concrette noticed in future insspections,
then a cove
er meter tesst is non-de
estructive, quick
q
and in
nexpensive. This will
d
determine
iff spalling ha
as commencced.

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 11 of 16

DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels

4. REC
COMMENDATIONS
At the
t
time of the inspections for the latest third audit rep
port, no rep
pair work was
w taking
placce in the Midfield
M
or FTZ
F
tunnel. At the time of writing
g this reporrt, it is clea
ar that the
Maintenance Period
P
for Th
he Contracttor has finisshed.
The
e key recom
mmendations for the structural ma
aintenance of
o the two tunnels
t
hass changed
sincce the initia
al audit insp
pections due to the co
ompletion of
o the Contrractors Maintenance
periiod on 28th of
o Februaryy 2015. We recommend
d Keppel FM
MO carry ou
ut the follow
wing:
a) Major defec
cts have be
een repaired
d by the Contractor durring mainten
nance perio
od.
b) Monitor the
e areas whe
ere stains off potential water
w
ingres
sses have been
b
inspeccted.
c) Follow maintenance and
a repair schedule
s
for the defeccts of catego
ory (iv), (v), (vi), (vii)
and (viii). In
nspection and
a appropriate repairiing works are
a propose
ed in a time
e frame of
six months, followed by
b corresponding repairing works, if required.. Given thatt the main
reason of the cracks is the extrreme tempe
erature diffferences be
etween sum
mmer and
winter, pro
oposed periods for insspection an
nd repairing
g works are
e October and April
every year..
d) Ensure that Keppel FM
MO have att least a cop
py of all the Warranties
s for work carried
c
out
on the pro
oject. This is specified
d in the co
ontract doccuments forr the Airport Works.
Relevant to
o the structu
ural audit, Warranties
W
w
would includ
de the wate
erproofing system
s
for
the Midfield
d tunnel roo
of slab at th
he east and
d west porta
al, the wate
erproofing system
s
for
all the roofs
s of the elecctrical subsstations and Foam room
ms. There should
s
be Warranties
W
for the waterproofing system
s
for the tunnelss for the base raft slab
b, retaining walls and
roof slab, plus
p
the app
proach ramps to the tu
unnels. The
ere should be
b Warranties for the
paint work for structural elementts such as the electric
cal substatiion walls and doors,
generator enclosures
e
and so on. Ask for Warranties
W
o the repa
on
air work takking place
during prevvious audit report,
r
such
h as the crack injection work.
e) Use this re
eport as a record of defects
d
to hold the Main
M
Contractor accoun
ntable for
warranties.
An updated su
ummary of recommend
dations for each of the items req
quiring repa
air are as
follo
ows;
(i)

Water lea
aks through the invert slab
s
of tunn
nels:
Crack inje
ection has been carrie
ed out on th
he shrinkag
ge cracks in
n the base raft
r slabs.
No waterr ingress has been obs
served, but a few stains
s of water presence
p
off unknown
origin. Wa
ater leaks th
hrough the invert slab of tunnels are
a conside
ered stopped
d.

(ii)

Water lea
aks through constructio
on joints and
d movemen
nt joints:
The latesst audit inspection carrried out on
n both tunn
nels did nott show anyy water or
moisture on the road
d surface du
ue to groundwater leakks through movement
m
j
joints
and

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 12 of 16

DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels
constructtion joints except
e
of th
he moveme
ent joint at the
t
entrancce of West Bound of
FTZ tunn
nel, where itt is observe
ed water ingress due to
t temporary diversion
n of water
spilled fro
om fire lines at east substation above.
a
The leaking mo
ovement joints at the
tunnel en
ntrances have now been
b
conta
ained. Additional PVC
C pipes ha
ave been
installed in trenchess from the movement
m
joints to a grated
g
inlet pit in the tu
unnel that
funnels th
he groundw
water into the
e tunnel dra
ainage syste
em.
Keppel FMO should monitor the
e movemen
nt joints and
d constructiion joints fo
or signs of
any furthe
er failure. Otherwise,
O
no
n further acction is needed.
(iii)

Ingress of
o water thro
ough base of
o retaining walls onto road
r
surface:
The latesst audit insp
pections did not reveal any water or moisture
e on the roa
ad surface
that could
d be attribu
utable to leaks through
h the consttruction join
nt at the ba
ase of the
retaining wall. Accesss to the joint for inspe
ection is und
der the ped
destrian walkway and
behind tu
unnel servicce pipes wh
hich makes inspectionss extremely difficult. Fo
or now no
further work is recom
mmended. Should leaks be found
d, crack injection will be
b similar
to items (i)
( and (ii).

(iv)

Shrinkage
e cracks an
nd deteriora
ating epoxyy paint coa
ating for Miidfield tunnel around
Electrical Rooms:
Repair be
efore the ne
ext rain sea
ason and fre
equent mon
nitoring and
d maintenan
nce works
in a perm
manent and scheduled basis
b
is req
quired

(v)

Poor drainage and deteriorating

d
g waterproo
of coating off electrical substation
s
r
roofs:
The latesst audit insspections showed
s
tha
at nothing has
h
change
ed for the electrical
substation roofs sincce last audit, January 2015. Rep
pairing and appropriate
e finishing
of the wa
aterproofing
g system on
n the roofs perimeter of these su
ubstations is the first
step, follo
owed by a correct clea
aning and patching
p
of the shrinka
age cracks by silicon
or butylic elastic puttty with anti-UV charactteristics and
d final epoxyy paint in tw
wo layers.
Even tho
ough rain is scarce here in Qatar,
Q
wate
er entering
g into the electrical
substations could ca
ause a majo
or problem for obviouss reasons. If the water tests on
the roof slabs
s
pass but
b there is still water ingress into the cable trenches
t
aftter rainfall
then check the exte
ernal walls for points of water in
ngress. Forr the Midfie
eld tunnel
check the
e flashing frrom the tunn
nel roof slab
b up the base of the wall
w (there m
may not be
any flash
hing). For th
he FTZ tun
nnel, the ele
ectrical sub
bstation cab
ble trench levels
l
are
below the
e ground le
evel outside
e. Check th
he waterpro
oofing system for the concrete
trench wa
all externallly and belo
ow ground level and th
he masonryy wall above
e ground.
This item is still pend
ding.

(vi)

Rusting door
d
framess and other miscellaneo
ous defectss:
The main
n defect for this item is the rusting door frame
es and Gen
nset enclosu
ure. Since
the initial audit inspe
ection, man
ny rusting door framess in the elecctrical buildiings have
been replaced. How
wever, the re
epainting off the door frrames, espe
ecially for th
he genset
enclosure
es, is of po
oor quality. In many ca
ases, rust is reappearring through
h the last
coat of pa
aint. Steel members such
s
as doo
or frames and louvers need to be
e replaced
or sandblasted and repainted in
i accordan
nce with the
e project sp
pecificationss and the

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 13 of 16

DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels
Qatar Co
onstruction Specificatio
ons. Keppe
el FMO sho
ould follow up on this item with
The Conttractor.
As has alreadyy referred, there are many
m
other minor defe
ects such ass repaired shrinkage
s
craccks, shrinka
age cracks in the con
ncrete traffiic barriers, bubbling paint,
p
dama
aged side
scre
een, crumblling concrette around the pit lid fo
or the earthiing pits and
d so on. The
ese types
of d
defects need
d scheduled
d maintenan
nce frequen
ntly, and mo
onitoring.

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 14 of 16

DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels

APPE
ENDIX A
PHOT
TOGRAP
PHS OF DEFECTS
D
S
Midfield
d Tunnel:
Midfield
d Tunnel Ea
ast Bound Photographs
P
s 1 to 29 & 48
4 to 56
Midfield
d Tunnel We
est Bound Photograph
P
s 30 to 47 & 57 to 67
Midfield
d East Porta
al Electrical Building Photograph
hs 1 to 42
Midfield
d West Portal Electriccal Room Photographs
P
s 1 to 33
Midfield
d East Boun
nd Sump Pump
P
Cham
mber Photographs 1 to
o 10
Midfield
d Tunnel We
est Bound Pump
P
Room
m. Photogra
aphs 1 to 7

FTZ Tunnel:
FTZ Tunnel East Bound.
B
Phottographs 1 to 27 & 37, 38
FTZ Tunnel West Bound.
B
Pho
otographs 28
2 to 36 & 39 to 50
FTZ Ea
ast Portal Electrical Building.
B
Pho
otographs 1 to 20
FTZ We
est Portal Electrical Room.
R
Phottographs 1 tto 19
FTZ Ea
ast Bound Sump Pum
mp Chambe
er. Photogra
aphs 1 to 7
FTZ We
est Bound Sump Pum
mp Chambe
er. Photogra
aphs 1 to 4

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 15 of 16

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DOHAIN
NTERNATION
NALAIRPORTTKEPPELFM
MO
AnnualSStructuralAu
uditReportfforTheMidfiield&FTZTu
unnels

APPE
ENDIX B
LOCA
ATION OF
F PHOTO
OGRAPH
HS OF DE
EFECTS
Midfield
d Tunnel:
Midfield
d Tunnel Ea
ast & West Bound.
B
Pho
otographs 1 to 67
Midfield
d East Porta
al Electrical Building. Photographs 1 to 42
Midfield
d West Portal Electriccal Room. Photographs
P
s 1 to 33
Midfield
d East Boun
nd Sump Pump
P
Cham
mber. Photo
ographs 1 to
o 10
Midfield
d Tunnel We
est Bound Pump
P
Room
m. Photogra
aphs 1 to 7

FTZ Tunnel:
FTZ Tunnel East & West Bound. Photographs 1 to 50
5
FTZ Ea
ast Portal Electrical Building.
B
Pho
otographs 1 to 20
FTZ We
est Portal Electrical Room.
R
Phottographs 1 tto 19
FTZ Ea
ast Bound Sump Pum
mp Chambe
er. Photogra
aphs 1 to 7
FTZ We
est Bound Sump Pum
mp Chambe
er. Photogra
aphs 1 to 4

13-5335--KEO-ST-RPT
T-0003
Revision 1

Pa
age 16 of 16

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