Brunei Temburong Bridge

Feasibility Study Design and

Construction
Naeem Hussain
Arup Fellow | Director | Global Bridge Leader
 PROJECT ORGANIZATION CHART
EMPLOYER
MINISTRY OF DEVELOPMENT
GOVERNMENT OF NEGARA
BRUNEI DARUSSALAM

PUBLIC WORKS DEPARTMENT

TECH WORKING COMMITTEE PMC

PUBLIC WORKS DEPARTMENT UTAMACON S/B-

CORE GROUP TYLIN J/V

ENGINEER

OVE ARUP DAN RAKAN-RAKAN

CONTRACTOR

PACKAGE CC5B PACKAGE CC2 PACKAGE CC3 PACKAGE CC4

Power Supply System, Road Marine Viaducts Navigation Bridges Temburong Viaducts
Lighting & Traffic Signs
DAELIM-SWEE DAELIM-SWEE CSCEC-
J/V J/V Ocean Quarry
HSE Engineering J/V
 Brunei Temburong Bridge

• Project Background
• Feasibility Study
• Marine Viaducts
• Navigation Bridges
• Temburong Viaduct
• Conclusions

3
Project Background
 Project
Location

Regional map of south east Asia

5 Project Location
 BRUNEI- Brunei Bay
MUARA

MALAYSIA
TEMBURONG

BRUNEI

BRUNEI

MALAYSIA
MALAYSIA

6 Project Location
 Location

7
 Pulau Muara Beasar

Serasa

Brunei- Mentiri

Muara Brunei Bay

Kota
Batu

Malaysia

Temburong Piasau Piasau

Labu Estet

Malaysia
Nagalang Ering

0 2 4 6 8 1
0 Bangar
km

8 Location Map – Satellite View

 Bandar Seri Sea Route:
Begawan 1-2 hours

Land Route:
3-4 hours at peak
requiring cross-
border

Bangar
Kuala
Lurah Puni

Travel Routes between Brunei-

Muara and Temburong
Subject to:
• Boat and border operation schedule
• Passenger boat size and loads
• Traffic jams
• Weather

9 Existing Travel Routes

 Serasa
ExpandPulau Muara Besar
Infrastructure
and
Mentiri
Transport
Brunei-Muara
LinksBrunei Bay
Kota Batu

City Centre

Bridging
Brunei
Malaysia

Temburong Piasau Piasau

Labu Estate
Malaysia
Nagalang Ering

0 2 4 6 8 1
0 Bangar
km

10
Feasibility Study

Route Selection

Impact Assessments

Economic Analysis
Transport Network
Road Land Use
 Residential Area at Pekan Muara
Navigation Channels Pulau Muara Besar  Residential Area along Jalan Muara
Aviation  Residential Area along Jalan Kota Batu
 Pantai Mentiri Golf Course
 Military Base on Pulau Baru-Baru
 Agricultural Land
Pantai Mentiri
 Fisheries Areas in Brunei Bay
Golf Course

BRUNEI-MUARA Brunei Bay

Military Base on
Brunei Pulau Baru-Baru
Airport

Brunei’s
Capital

Shrimp Netting

TEMBURONG
Residential area

Gazetted
Agricultural Land
Potential Brackish
Water Shrimp
Cultivation

Residential area

12 Constraints
 BRUNEI-MUARA
Least impact  Finally
adopted alignment for
implementation
Brunei’s
Capital

TEMBURONG

13 Alignment Options Considered

 Mentiri Brunei Bay
Interchange Mentiri
Cable-stayed
Navigation
Bridges
Brunei
Airport

Brunei-Muara Sungai
Brunei
Jalan Kota Batu Pulau
Pepatan
Connection
Pulau
Baru-
Bandar Seri Baru

Begawan Pulau
Berbunut

Selirong
Recreational
Limbang Park
Pulau Total Length
Berambang = 30km approx.

Border line Brunei

Malaysia Pulau
Siarau
Temburong

Sungai Labu

Labu
Estet

Labu
Interchange

14 Selected Route
 Minimal
land use
impacts

Hydraulic Constructed
regime not with
adversely existing
affected technology

Technical
Feasibility

Minimal Environmental
Impacts can be
impact on managed and
shipping mitigated

Traffic
dispersal
will be
acceptable

15 Conclusions of Feasibility Study

Detailed Design
& Procurement
 CC1 - Mentiri Tunnel &
Viaducts PROJECT LAYOUT
CC3 - Brunei Channel Bridge

CC3 - Eastern Channel Bridge

CC2 - Marine Viaducts CC4 - Temburong Viaducts

17 Four Civil Construction Contracts

 PERSPECTIVE VIEW

18 Perspective views
CC2 – Marine Viaducts
• PROJECT : Cadangan Projek Jambatan Temburong, PKG CC2 – Marine Viaducts
• LOCATION : Brunei Bay (Link between Brunei-Muara Temburong
• WORK SCOPE : 13.35km
- Viaduct from Brunei Channel to Eastern Channel (CC2-1 : 8.25 km)
- Marine Viaduct from Eastern Channel to Tanjung Kerasek (CC2-2 : 5.10 km)
• BRIDGE TYPE : PSC Box Girder (L=13.5km, W=11m)
 2
1

Thank You
21
22 Marine Viaduct
 Marine Viaducts – Key Design Considerations
• Shallow water
• Soft ground
• Speed of construction
• Economy of scale

CC2 CC2

Very soft to soft clay

100m

Firm to very stiff clay

Hard
Mudstone clay

sand

23
 General Arrangement
Typical module - 50m x 6 spans = 300m
MJ MJ

Precast segmental or
full span post-
tensioned concrete
box girders High Damping
Rubber Bearings

Concrete columns
and pile caps above
M.H.H.W.

Driven precast
concrete spun piles or
steel tubular piles

24
 DREDGING WIDTH

DISPOSAL AREA

Dredging works at bridge alignment are completed. However, maintenance

dredging are done as necessary. DISCHARGE PIPE
BOOSTER
PUMP

25 Dredging and Disposal Plan

 Temporary Jetty

Bund Installation

Disposal
Area
B

26 Dredging Work
 Excavator Mounted Cutter Suction Booster Pump

Water Master Silt Curtain Bund in Pulau Pepatan

27 Dredging Works
PILING WORKS
Pile Works (4,780 nos) Pile Arrangement

• D1.0 Spun Piles : 2 30,000 m ( 3 ,931 n os )

P1 P166 P167 P269
• D1.0 Steel piles : 2 2,000 m ( 6 34 n os)
• D1.6 Steel piles : 1 4,000 m ( 2 15 n os)
• Pile Driving Equipment :
- V i bro H ammer & H ydraul ic H a mmer
• Working Groups : 3 - teams @ 3 - shif ts
( 2 6 m anpower p e r t e am)

Pile Driving Equipment Construction Procedure

Plan

Guide
Pile Plug
Frame
installation
Installation

Leading
Pile Head
Pile
Treatment
Driving

Pile joint Pile Joint

Welding Welding
2nd /3rd
TUG BOAT SETTING BRGE CRANE BARGE MATERIAL TUG Pile
BARGE BOAT
Driving

28 Piling Works
 Piling

29 Spun Piles
 Preliminary Pile Test (PPT10)

Pile Delivery Pile Driving Welding Inspection

30 Piling Works
 Temporary Platform Bracket Installation

Lowering Soffit Formwork Pile Plug

31 Fixing Soffit Formwork for Pilecap

 Pile Caps and Pier Columns

32
 COLUMN

PIER COLUMN DETAILS

Quantity: 596 nos.

33 Substructure | Pier Column

CC2 – Marine Viaduct Superstructure
Serasa Casting Yard – Casting bed for Superstructure

Rebar fabrication
and
Inner mould Stock
yard area

Girder casting Area

Concrete
Bridge Type Total
Grade
Main Girder 516 nos

GIRDER TYPE : Pre-Stressed Concrete Box Girder Ramp Girder 62 nos C45/55

SPAN LENGTH : 50m Total 578 nos

35 Girder Casting Facility

 Girder Production, 578 nos.
Bottom & Web Girder Mould Bottom, Web Rebar & Strand Works 3 Rebar & Strand Transfer to Girder Mould
1 2

Top Slab/Deck Rebar Works Strand Tensioning

4 5

36 Girder Casting Facility

 Full Span Precast Segments

37
38 Girder Stock Yard
39 Girder Loading onto Barge
 Cycle Time – One erection ( 2 girders) every two days
1 2 3 4

Transport of Girder to Bridge Placement of Girder on Pier

Girder Positioning and Lifting Completed Girder Erection
Alignment Column

TEMBURONG
BRUNEI-MUARA

40 Girder Erection
 CC2 – First Few Spans Erected

41
42 Girder Erection
43 Girder Erection
 Girder Erection

44
45 A view of erected girders
CC3 - Navigation Bridges
 CC3 Navigation Bridges

47
 Work Scope : 1.1 km
• Navigation bridges across the Brunei Channel and Eastern Channel (BCB: 290m, ECB: 520m)
• Viaduct to Brunei Channel navigation bridge (Connecting Bridge: 312m)
• Connecting ramps to Jalan Kota Batu (Northern: 413m, Southern: 348m)

48 Navigation Bridges
49 Navigation Bridges
 Legend:
• BCB
• ECB

107.0m

110.5m
37.2 m
30.2m

50 Superstructure for Cable Stayed Bridges

 Brunei Channel Bridge
145m span

+22.6

130m minimum clearance

(85m marked navigation channel)

51
 Eastern Channel Bridge
260m span

+32.6

235m minimum clearance

(175m marked navigation channel)

52
Tower Design
54
 Islamic Architectural Gateways

•Islamic Arches as Gateways

55
 Islamic Architectural Screens

•Use of Islamic arches as decorative form

56
57
 5
8

58
 Brunei Channel Bridge

Eastern Channel Bridge

Brunei Channel Bridge Eastern Channel Bridge
59 Parametric Definition of the Tower Geometry
 Brunei Channel Bridge Deck

Edge Beam

Stay
Crossbeam
tendons

Edge Crossbeam tendons Stay Anchorages

Longitudinal
girder Anchorages space space allowance
tendons
allowance

60
 Construction Planning
• Out of balance loads during cantilevering
• Use of buffeting cables to compensate out of balance loads

61
 Installation of Pin Piles Installation of Jig Jacket and Guide Frame Installation of Permanent Steel Casing

RCD and Hammer Grab Drilling Installation of Rebar Cage Pouring Concrete

62 Construction of Marine Bored Piles

1 PC SHELL INSTALLATION 2 PC SHELL GROUTING 3 PC SHELL AFTER DEWATERING
WORKS

4 PILE CAP REBAR WORKS 5 PILE CAP CONCRETING 6 COMPLETED PILE CAP
WORKS

63 Construction of Pilecap Works for Cable Stayed Bridge

 Casting a Tower Pile Cap

64 Construction Photos
 © Daelim-Swee Joint Venture © Daelim-Swee Joint Venture

© Daelim-Swee Joint Venture © Daelim-Swee Joint Venture

65 Construction Planning of Towers and Deck (Daelim-Swee Joint Venture)

66 Construction of Pilecap for Connecting Bridge
67
 TOWER 1

68 Brunei Channel Bridge – Tower Works

 TOWER 3

TOWER 2

69 Eastern Channel Bridge – Tower Works

CC4 – Temburong Viaduct
 CC4 – Temburong Viaduct – Scope of Works

• 12km viaduct over swampland

- Piled Slab (Swamp Crossing)
- Approx. 1950 x 12m spans
- Top down Construction
- Precast RC Deck Beams,
pile cap and spun piles

• Sungai Labu Bridge

- Twin deck 100m main spans
- 6 x 60m adjacent spans Sg Labu Bridge
- Post-tensioned cast in-situ
- Balanced cantilever construction

71
 Package CC4 Temburong Viaduct

TEMBURONG
VIADUCT (11.8 KM)
BRIDGE OVER LABU RIVER

LABU RIVER

LABU ROUNDABOUT

Land Viaduct consist of:

• Total Length: 11.8km
• Span: 12.0m from pier to pier
• Width: 10.0m
• Total Pier: 965 nos. + 4 nos (Sg Labu Bridge)
• Foundation: Spun pile and bored pile.
• Girder:
• Temburong viaduct: double T-beam reinforced deck
structure
• Bridge at Sungai Labu: Prestressed, cast-in-situ,
balanced cantilever box girder deck
• Construction Technique: Top down construction

72 Package CC4 Temburong Viaduct

 Temburong – Typical Mangrove Forest

73
 Temburong – Swamp Forest

74
 Temburong – Key Design Considerations
• Soft ground
• High water level
• Sensitive environment
• Top down construction
• Limited working fronts
• Speed of construction
• Economy of scale

75
 Temburong – Constructability
Brunei Bay
• Maximise use of CC2
precast concrete
CC4
• Minimum amount of Workfronts
in-situ concrete from 2 ends

• Top down construction

i.e. piling from deck level
• Possible with the use of Workfronts
from middle
crawler cranes
Temburong
Sungai Labu

CC4

76
 Piled Slab – Typical Section & Elevation
Precast Double-T Deck Beam

~2 - 4m
Precast Pile Cap

Precast Concrete
Spun Pile
Span length = 12m

Precast Double-T Deck Beam In-Situ Diaphragm

Precast Pile Cap

Pile Cap at Movement Joint Pile Cap at Typical Pier

(every 10th pier)

77
 Package CC4 | Design Features
Land Viaduct consist of:
• Total Length: 11.8km
• Span: 12.0m from pier to pier
• Width: 10.0m
• Total Pier: 958 nos.
78
• Foundation: Spun pile and bored pile.
• Girder:
• Swamp viaduct: double T-beam reinforced deck
structure
• Bridge at Sungai Labu: Prestressed, cast-in-situ,
balanced cantilever box girder deck
• Construction Technique: Top down construction
 Piled Slab – Constructability Checks

79
 Piled Slab – Envisaged Piling Operation

1. Drive pile, weld at connections 2. Cut pile beneath gate and remove excess

3. - Remove piling gate 4. - Attach piling gate and extend steel girder
- Jack up crane platform - Lower crane platform
- Retract steel girder and install temporary steel pile cap - Add addition piece of crane platform
- Move crane forward

80
 Piled Slab – Overall Construction Sequence

• 3 day working cycle

• Launching platform
• Crawling cranes
• Temporary deck
• Independent piling and
deck working fronts

81
 1. Maximise usage of precast concrete (economy of scale)
2. Minimum amount of cast insitu concrete (speed of construction)
3. Top down construction – i.e. piling from deck level using
crawler cranes and movable platform (minimize environmental impact)

82 Temburong Solution
 Four Work Fronts

 P269 → P509 .
 (Access from Brunei Bay)
Works area at
 509 ← P739 → P969 P269
 (Access from Sungai Duwau)
P509

 969 ← P1209 → P1237 Works area at

 (Access from Sungai Labu) P739
P989
CC4
 Sungai Labu Bridge
Works area at
and Jalan Labu Roundabout P1209

83 Work Fronts
 Work Fronts

P739

Brunei Bay at P269

Sungai Duwau Besar & Haul Road to P739

84 Work Fronts
 Site Clearing – 40m wide clearance

SITE CLEARING

40m

Proposed Sungai
Labu Bridge and
Jalan Labu
Roundabout

B14+600 to B17+000

40m

B20+000 to B17+000

40m Labu River

B20+000 to 24+000

85
 ACCESS TO WORK FRONTS
Pier 269
B 14+600
Pier 269

B 17+000
Pier 739
Pier 739

Pier 739
B 20+000

Pier 1209
B 24+000

Pier 1209
Proposed Sungai
Labu Bridge, Jalan
Labu Roundabout B 26+000
& Labu Secondary
Support Complex

86
 P1209

87 Package CC4 | P1209 Work Front

 P510

Access from
Sg. Duwau

P739

P970

88 Package CC4 | P739 Work Front

 P269 to P509

P269

BRUNEI BAY

89 Package CC4 | P269 Work Front

 (3.5-day cycle per span)

DRIVING OF SPUN PILE

SHIFTING OF MOVABLE PLATFORM

90 Typical Construction Activities 3.5-day cycle per span)

 INSTALLATION OF PILECAPS CONCRETING OF PILE PLUGS

BEAM STITCHING

BEAM LAUNCHING

91 Typical Construction Activities (3.5-day cycle per span)

92 Construction Front
93 Construction Front
94 Deck Erection
95 Deck Erection
 P269 P274
P509

NORTH

SOUTH

96
 P510 P739 P969

NORTH

SOUTH

97
 P1209
P970

98
 P269

99
 P739 – P509

100
Conclusions
 Conclusions
• Difficult foundation conditions and varied environmental
conditions, meant using precast spun piles, special concrete and
stainless steel reinforcement for durability.
• To achieve short construction period, adopted innovative gantry
that could lift two precast full span girders at the same time. This
effectively means one deck being erected in one day.
• For environmental reasons of minimizing destruction to the
swamp forest, only linear access from the two ends and the
middle of the viaduct were allowed along with top down
construction.
• Maximum use of precast construction for marine viaduct and
swamp forest viaduct.

102
 Thank You
103