SMART

Stormwater Management
and
Road Tunnel

Construction of the SMART

Project in MALAYSIA
Presentation for the
ITA-AITES WTC 2009 BUDAPEST
23d- 28th May 2009

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ITA2009 Budapest
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MMC-GAMUDA 11
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2009
 FLOODED AREAS IN
KUALA LUMPUR

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2009 BKV – DBR Metro
MMC-GAMUDA JV 22
BUDAPESTGus
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Gus
 TUN PERAK BRIDGE
Flow Capacity: 180 m³/s only

Flood Level on 26 April 2001

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24th October
WTC MMC-GAMUDA JV 33
2007, GSM by Gus
2009
 THE SMART IDEA
PROVIDE FLOOD RELIEF BY:
BORING A 13.26/11.83m
DIAMETRE 9KM LONG TUNNEL TO
PROVIDE FLOW OF 291m3/sec
MAKE IT CHEAPER TO THE PUBLIC
BY:
BUILDING A TWIN LEVEL 2 LANE
MOTORWAY IN THE CENTRAL 3KM
TO RELIVE TRAFFIC CONGESTION
AVAILABLE MOST OF THE TIME TO
THE PUBLIC
MAIN ELEMENTS:
PONDS
INTAKE & OUTLET STRUCTURE
GATE STRUCTURES
VENTILATION SHAFTS
TUNNEL
ROAD DECKS & ESCAPE PASSAGES

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2009
 THE FLOOD DIVERSION SYSTEM
TO
K
L
SG. BESI AIRFIELD
Floodgates divert storm-
water from Klang river to
K
L
-S

BY
E
R
E
M

PA
B
A
N

SS
H
IG
H

TU
W
A
Y

NN
EL
Holding Pond
OUTFALL
STRUCTURE RESTAURANT
DESA TO SEREMBAN
WATER PARK
ROW
NG
PA

RL=38m Flood Level

THEME PARK
. AM

DESA
RO

RL=30.7m Standing Water Level WATER PARK

SG

RO W

RO W

FLOATING
BOOM
S

TAMAN DESA POND

G

ROW

Water flows through

.K

ORIGINAL POND SIZE

L
A

RL 28m
N
G

AREA = 216594m2
OFFTAKE
STRUCTURE
 

Bypa
ss Tunn




el

NEW POND SIZE

R OW RL 20m
BELL MOUTH
DIVERSION WEIR STRUCTURE AREA = 119028m2

Intake Tower and tunnel

SG. KLAN

INTAKE GATED
STRUCTURE
G

OUTFALL
TWIN BOX CULVERT
STRUCTURE
(2 nos. 5.1m H x 5.5m W)

40

35

30
Sg
Klang
38.50 Flood Level

31.3
Holding
Pond

31.80 Standing W ater Level

38.00 Flood Level

28.70
33 .35
Bypass Tunnel
(Diameter 11.8m)
Offtake gated
structure Storage Reservoir
(TAMAN DESA POND)

28.00 Flood Level

Intake gated
structure Twin Box Culvert
(2 nos. 5.1m H x 5.5m W)
Outfall Sg
structure Kerayong
40

35

30
gravitationally to Storage
Reservoir at Taman Desa
24.50 25.70 Flood Level
25 25
21.55 20.00 Standing Water Level
20 19.50 18.55 Standing Water Level 20

15
18.05
15

10 8.20 10

5 5

0
-0.80 0

Max. flow: 280m³/sec

T
O
K
L
SG . B ESI AIRF IEL D

K
L
-
S

B YP
E

Water flows
R
E
M
B

AS
A
N
H

S TU
IG
H
W
A
Y

NN
O UTF AL L

EL
ST RUC T URE REST AUR ANT
D ESA TO SEREM BAN
W ATER PA RK

through Twin Box

NG

ROW
PA

RL=38m Flood Level

TH EM E PAR K
AM

W
RO

D ESA
WA TER PAR K
.

RL=30.7m Standing Water Level

SG

ROW
ROW

FLOATING
BOOM
S

ROW

TA M AN DESA PO ND
G

Culvert to the
.
K

OR IG INA L PO ND SIZ E
L
A

RL 28m
N
G

AR EA = 2165 94m 2
OFFTAKE
STRUCTURE

 

Byp ass


 
 


Tunnel


NEW PON D SIZ E

ROW R L 2 0m
BELL MOUTH
DIVERSION WEIR STRUCTURE AR EA = 119 028m 2

Kerayong river
SG. KLAN

IN T AKE GA TED
ST RUC TU RE
G

O UT FAL L
T WIN BO X C UL VERT
STR UCT URE
(2 n o s. 5.1m H x 5.5m W)

Sg H old in g
Klang Po nd

Low section of
38.50 Flood Level Byp as s Tu n nel Offtak e ga ted In take g ated
31.80 Standing W ater Level structu re Sto ra ge R ese rvo ir Ou tfall Sg
(Diam eter 1 1.8 m) stru ctu re T w in Bo x Cu lv ert struc ture Ke ray on g
38.00 Flood Level (T AM A N DESA PON D)
(2 n o s. 5 .1 m H x 5.5 m W )
40 40

35 31.3 3 3.35 35

30 28.00 Flood Level 30

28.70 25.70 Flood Level
25 24.50 25
21.55 20.00 Standing Water Level
20 19.50 18.55 Standing Water Level 20

15
18.05
15

10 8.20 10

5 5
0 -0.80 0

tunnel pumped dry

ITA-AITES
ITA2009 Budapest
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 THREE MODES OF OPERATION

ITA-AITES
24th October
WTC MMC-GAMUDA JV 66
2007, GSM by Gus
2009
 THE SMART PROJECT ORGANISATION

After 2,2km the North Drive contract was terminated, the remaining
2.8km was completed by MMC-GAMUDA JV in 11 months.

ITA-AITES
24th October
WTC MMC-GAMUDA JV 77
2007, GSM by Gus
2009
GROUND CONDITIONS

SG. FROM SG. KLANG TO ALONG JALAN AL0NG JALAN KL - SEREMBAN SALAK SG.
Klang JALAN DESA PANDAN KPG. PANDAN ALONG JALAN TUN RAZAK CHAN SOW LIN HIGHWAY I/C KERAYONG
STORAGE
POND
40.00m

30.00m
1 : 650
20.00m
1 : 1000
10.00m

0.00m

-10.00m

LEGEND:-
OVER BURDEN
ROCK BED

SUBSURFACE CONDITIONS FOR SMART

OVERBURDEN KUALA LUMPUR LIMESTONE FORMATION

o SILTS & SANDS o DEEPLY FISSURED
o ALLUVIAL TIN DEPOSITS
o ERRATIC ROCKHEAD WITH RELIEF OF >30M
o SINK HOLES
o MINE TAILINGS o KARST SOLUTION CHANNELS, MOSTLY FILLED SOMETIMES
o SLUMP ZONES OVER THE KARSTIC ROCKHEAD OPEN

24th October MMC-GAMUDA JV 88

2007, GSM by Gus
 KARSTIC ROCKHEAD
EXPOSED DURING TIN MINING

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ITA2009 Budapest
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MMC-GAMUDA 99
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2009
 KARST MORPHOLOGY
kIV - KOMPLEX KARST

K IV is typical in tropical climate, rare in temperate

climate.
(from Waltham és Fookes)

ITA-AITES
24th October
WTC MMC-GAMUDA JV 1010
2007, GSM by Gus
2009
 KARST MORPHOLOGY
k V - EXTREME, COVERED KARST

k V is typical in Peninsular Malaysia. Climatic conditions

accelerate solution.
(from Waltham és Fookes )

ITA-AITES
24th October
WTC MMC-GAMUDA JV 1111
2007, GSM by Gus
2009
 KARST FEATURES
3D IMAGE OF THE NORTH VENTILATION & TBM’S
LAUNCH SHAFT
South

North
The widening at the ends are the two TBM launch areas.
‘L’ shaped walls used at ‘normal depth’ rockhead tied back
secant pile walls keyed into the rock at karstic features.
300m³ of grout was used to stem 4000l/min water inflow
at the south end (LHS).
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MMC-GAMUDA 1212
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2009
 KARST FEATURES
SUDDEN DROP OF ROCKHEAD
Tied back bored pile wall
temporary support next to the
generally used ‘L’ shaped walls

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ITA2009 Budapest
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MMC-GAMUDA 1313
2009
Gus Klados
 KARST FEATURES
POTHOLE or BURIED SINKHOLE

AS SHOWN BY WALTHAM & AS FOUND ON SITE

FOOKES

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ITA2009 Budapest
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MMC-GAMUDA 1414
Gus Klados
2009
KARST FEATURES
POTHOLE AT THE NORTH JUNCTION BOX

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ITA2009 Budapest
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MMC-GAMUDA 1515
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2009
 RESISTIVITY TOMOGRAPHY

Successfully used in the South Drive to detect anomalies in the karst well ahead
of the TBM. The suspect areas were investigated by drilling from the surface
and treteated if necessary. Probing from the machine was abandoned.

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 KARST FEATURES
AS MAPPED AT AN EGRESS RAMP

From SSP’s Lee & Tan Oct 2008

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 RCC LINING
External diametre: 12,83m
Internal diametre: 11,83m
Ring length: 1,70m
Ring split: 8+1
Ring weight: 82t
Normal segment weight: 10t
Reinforcement ratio: 82kg/m3
Concrete: Grade 50

24th October MMC-GAMUDA JV 1818

2007, GSM by Gus
 GATES AT THE NORTH JUNCTION
BOX
AY
HW
H IG
EMERGENCY GATE N
SOUTH JUNCTION BA
SERVICE GATE EM
ER
GRID GATE MOTORWAY K L -S
UPPER DECK TUNNEL GATE TO
SERVICE GATE
G IL
AT A
E M
SH IS
AF N GA
T A TE
T SH
L AF
U T
S TO
N WA ST
JL VENTILATION AND VENTILATION AND TE OR
O EMERGENCY ESCAPE SHAFT EM ERGENCY ESCAPE SHAFT R AG
T UPPER DECK FL
OW E
SERVICE GATE PO
ND
MOTORWAY TUNNEL
SERVICE GATE
GATE
EMERGENCY GATE
NORTH JUNCTION
KEY PLAN

SERVICE & EMERGENCY GATE SHAFT UPPER DECK SERVICE GATE SHAFT

AIR RELEASE SHAFTS

GROUND LEVEL

UPPER DECK SERVICE GATE

EMERGENCY GATE
LOWER DECK SERVICE GATE

DIRECTION OF WATER FLOW

LONGITUDINAL SECTION

Upstream Stormwater Tunnel Flood Gates

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 ROAD CLOSURE/FLOOD GATES
Prevents vehicle acces during flood EMERGENCY GATE
SERVICE GATE
GRID GATE
SOUTH JUNCTION
MOTORWAY
KL
-S
ER
E MB
A N
HIG
HW
AY

diversion
UPPER DECK TUNNEL GATE TO
SERVICE GATE
GA IL
T E A
SH M
AF IS GA
T N TE
A SH
T AFT
L
U
S TO
N WA ST
JL VENTILATION AND VENTILATION AND TE OR
O EMERGENCY ESCAPE SHAFT EMERGENCY ESCAPE SHAFT R F AG
T UPPER DECK L OW E

Prevents flooding of ramps and reduces

PO
SERVICE GATE ND
MOTORWAY TUNNEL
GATE SERVICE GATE
EMERGENCY GATE
NORTH JUNCTION
KEY PLAN

cleaning time

GROUND LEVEL

FLOODGATE
HYDRAULIC RAM

HYDRAULIC RAM

GATE MOTOR ROOM

PLAN SHOWING ROAD GATE ASSEMBLY

Traffic MOTOR ROOM ACCESS

UPSTREAM MOTORWAY TUNNEL GATE SHAFT

See Detail 1 Traffic

TYPICAL MOTORWAY TUNNEL SHAFT DETAIL 1 - OPERATION OF TYPICAL ROAD GATE

ITA-AITES
24th October
WTC MMC-GAMUDA JV 2020
2007, GSM by Gus
2009
 ESCAPE ARRANGEMENTS

UPPER UPPER
ROAD DECK ROAD DECK

LOWER LOWER
ROAD DECK ROAD DECK

LOWER LOWER
CHANNEL CHANNEL

ESCAPE SHAFTS AT 1 km INTERVALS CROSS PASSAGE AT 250m INTERVALS

ITA-AITES
24th October
WTC MMC-GAMUDA JV 2121
2007, GSM by Gus
2009
 VENTILATION
LOWER ROAD DECK

EXHAUST SUPPLY ESCAPE STAIR

AIR DEFLECTORS
IN VENT DUCT
UPPER
ROAD DECK

LOWER
ROAD DECK

INVERT
EXHAUST SUPPLY

PLAN
SECTION

24th October MMC-GAMUDA JV 2222

2007, GSM by Gus
 REVISION OF PLANNED EXCAVATION
METHODS
Planned Drill & Blast with shotcrete temp. support tunnelling
method and Cut & Cover method in South Drive revised, changed
to closed TBM drive for:
Drill & Blast Cut & Cover
o Difficult to prevent groundwater o Major disruption in an urban

drawdown, triggering sinkholes environment

away from the alignment o Difficult to prevent groundwater

o Risk of inundation if major open drawdown, triggering sinkholes

karstic system is encountered away from the alignment
o Major noise and vibration problems o Major noise and vibration problems

while blasting while blasting over 1million m3 rock

o Erratic rockhead forces frequent in the city
excavation method changes o Difficult temporary sidewall support

o Many sections require partial face o Risk in passing under sensitive

excavations railway structures (ERL, KTM, LRT)

o Difficult to support soft overburden o Costly utilities diversions

in mixed faces while blasting rock

THIS RISK MANAGEMENT DECISION INTRODUCED A NEW RISK; SLURRY SHIELD
TUNNELLING WAS TO BE PERFORMED BY FIRMS WITH NO EXPERIENCE IN TUNNELLING.
THE NEW RISK WAS PROVED TO BE EMINENTLY MANAGEABLE BY EMPLOYING A
PROFESSIONAL TEAM.
ITA-AITES
24th October
WTC MMC-GAMUDA JV 2323
2007, GSM by Gus
2009
METHOD SELECTION DEVELOPMENT
SOUTH SECTION

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 METHOD SELECTION DEVELOPMENT
NORTH SECTION

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 SHAFT EXCAVATION
Ventilation and TBM
launch shaft

‘Y’ shaped junction box

ITA-AITES
24th October
WTC MMC-GAMUDA JV 2626
2007, GSM by Gus
2009
 TBM SELECTION CRITERIA
GENERAL
o Short, one year delivery time to satisfy tight concession
contract program
o Design and build to high standards to survive long drive
and difficult geology
o Large, 13,25m excavation diametre
o Able to negotiate tight R=200m curves; tunnel design
R=250m curves
o Low overburden
o Minimum 0.9D
o Maximum 1.5D
o Urban tunnelling environment
o Restricted access to alignment at 2/3d of the cases for
ground treatment

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 TBM SELECTION CRITERIA
GEOTECHNICAL
o ~70% of tunnel in the KL Limestone Formation (marble)
o ~25% of tunnel in full face mine tailings at the North end
o ~5% of the tunnel in Kenny Hill formation (stiff soils of
granitic origin)
o Karstic rock with solution features such as channels and
interconnected cavities
o Highly variable, pinnacled rockhead causing frequent mixed
face conditions
o Alluvial or mine tailing overburden with low SPT ‘N’ values
o High groundwater table close to surface
o Slump zones in the overburden above rockhead
o Solution channels, cavities mostly filled with slumped soil
o Extremely high permeability at open karsic solution channels
o Naturally occurring sinkholes caused by cyclical water table
changes or during earthquakes

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2009
 TBM SELECTION BASED ON SOIL
PARTICLE SIZE DISTRIBUTION

Herrenknecht brochure

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 TBM SELECTION BASED ON GROUND
PERMEABILITY
The answer depends
on placing the
following foreseen
situations in this
table.
Fractured rock
1.

Karstic rock with

2.

partly filled solution

channels
Karstic rock with
3.

completely filled
solution channels
Mixed face of soil
4.

and rock with all the

above as possible
Herrenknecht combination
brochure

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2009
 STM SCHEMATICS

Herrenknecht brochure

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2009
TBM SELECTION
TECHNICAL COMPARISON POINTS

Description Herrenknecht Hitachi Kawasaki Mitsubishi NFM

General 25 14 13 6 24

Cutterhead 85 53 57 33 72

Cutterhead Drive 65 63 50 43 62

Shield 44 30 27 21 29

Segment Handling 35 22 24 20 35

Probe drilling 10 7 7 6 12

Manlocks 17 16 8 8 24

Trailer 26 18 18 12 26

Guidance & Monitoring 44 28 31 27 42

Services 75 53 40 41 78

Slurry System 49 41 43 37 55

Total 475 345 318 254 459

ITA-AITES
24th October
WTC MMC-GAMUDA JV 3232
2007, GSM by Gus
2009
 TBM SELECTION
COMMERCIAL COMPARISON

Herrenknecht Hitachi Kawasaki Mitsubishi NFM

Price
1.00 1.41 1.28 1.21 1.01
ratio

The prices were adjusted by:

o Cost of items not included in the offer but considered
necessary and included by others
o Delivery time impact on schedule
o Finance costs

ITA-AITES
24th October
WTC MMC-GAMUDA JV 3333
2007, GSM by Gus
2009
 SELECTED TBMS
TWO HERRENKNECHT MIXSHIEDS S 252 & S 253

Cutterhead dia.: 13.260mm Length of shield : 10.245mm

Drive: 4.000kW hydraulic Weight of shield : ~1.500t
Torque: 24.400kNm Thrust cylinders: 3x16=48Nos
Rotation: 0-3 rpm Max. thrust: 94.500kN
Displacement thrust force: Grout lines: 8Nos
28.900kN Guidance: VMT SLS T-APD
Length of machine: 71m Tailseal: 3 rows, wire brushes
Two trailer cars on haunch rails Disc cutters: 17”; 76 Nos
Weight of machine: 2.500t
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 SPECIAL FEATURES
o Spherical main bearing to negotiate tight, min. R200m
curves (tunnel min. radius R250m)
o Cutterhead retraction of 400mm by axial displacement
through main bearing without shield movement for easier
cutter replacement
o Articulated tailskin to negotiate the tight curves (at the
time of manufacturing the largest in the world)
o Cutterhead tilt moment indicator to detect karstic
features and mixed face conditions
o Two probe drilling rigs in fixed downward looking
position, mounted on the erector the rig could drill through
any port in the skin
o Inflatable “pig” (obdurator) for slurry pipe extensions
o SSP Sonic device mounted on the cutterhead to detect
cavities and rock/soil interfaces (did not survive the mixed
face environment)

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THE TWO SEPARATION PLANTS
Refurbished plant used
to build the Elbe tunnel
in Hamburg

Capacity:
3x800=2400m³/óra

New plant of at the

factory yard in
Műhlheim

Capacity:
4x600=2400m³/óra
ITA-AITES
24th October
WTC MMC-GAMUDA JV 3636
2007, GSM by Gus
2009
THE TBMs IN SCHWANAU AT THE
HERRENKNECHT FACTORY

S
252
S 253

S 253
in winter

ITA-AITES
24th October
WTC MMC-GAMUDA JV 3737
2007, GSM by Gus
2009
 LIFTING OF THE 160t
ARTICULATED TAIL SKIN

ITA-AITES
24th October
WTC MMC-GAMUDA JV 3838
2007, GSM by Gus
2009
 LIFTING THE S 252 CUTTERHEAD
The head segments were weldeded
together by 8t of electrodes

Lifted load 295t

ITA-AITES
24th October
WTC MMC-GAMUDA JV 3939
2007, GSM by Gus
2009
 BREAKTHROUGH, NORTH DRIVE

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Gus
 MOVING THROUGH THE NORTH
JUNCTION BOX

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Gus
 ASSEMBLY OF THE SOUTH TBM

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 THE SOUTH TUNNEL
1xΦ2000mm ventduct
2Φ500mm slurry pipes
2xΦ200mm cooling water
2xΦ200mm compressed air

The end of the trailer with

the escape container

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2009
 PASSING THROUGH A VENT SHAFT

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 BREAKTHROUGHS
IN ROCK IN SOFT GROUND

TAMAN DESA

NORTH TEMP SHAFT

ITA-AITES
24th October
WTC MMC-GAMUDA JV 4545
2007, GSM by Gus
2009
 PREPARATIONS TO RELAUNCH

Fixing of the starting seal

ring in the eye.

Excvation of the road ramp

during the relaunch of the
TBM

ITA-AITES
24th October
WTC MMC-GAMUDA JV 4646
2007, GSM by Gus
2009
 RELAUNCH AT THE SOUTH DRIVE

24th October MMC-GAMUDA JV 4747

2007, GSM by Gus
 SOUTH DRIVE PRODUCTION SUMMARY

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2009
MOTORWAY TUNNEL CROSS SECTION

RAHSIA

UPPER DECK

2550
LOWER DECK

2550
LOWER CHANNEL

150
2000 3350 3350
Emergency
Lane Traffic Lane Traffic Lane

NOTE: INTERNAL TUNNEL DIAMETER IS 11.8 M OR EQUIVALENT SECTION

Figure 3.11 : Cross Section For The Motorway

Stormwater Management And Road Tunnel Concession Agreement
SMART Page 30 of 56 Appendix 3

RAHSIA

ITA-AITES
24th October
WTC MMC-GAMUDA JV 4949
2007, GSM by Gus
2009
 ANALYSIS OF ROAD DECK
RESULTANT
FORCE UP

LOAD TRANSFER
TO SEGMENTS
(TENSION AND
SHEAR)

WATER UPLIFT

ITA-AITES
24th October
WTC MMC-GAMUDA JV 5050
2007, GSM by Gus
2009
 TESTING THE THIN SLABS OF THE
ROAD DECK 125 125
8600(T25)

125
250

125
125
125
125
125
1625
1625

125
125
125
125
125
125
6550

PLAN
SCALE1:12.5

2T16Links
A B 2T16Links
T12Links

175 350 350 350 350 350 350 350 350 350 350 350 350 350 350 350 350 350 350 350 175

G40N(Slump150+/-25mm)

40
25mmCoupler (Lower MainBarsOnly) 25mmCoupler (Lower MainBarsOnly)

100
1025 125 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 125 1025

A B 8600

6550

LONGITUDINALSECTION
SCALE1:12.5

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2009
Ø32

Ø32
Ø25

625
Ø32

Ø32
Ø25

625
TOPSURFACETOHAVE
 ROAD DECK CONSTRUCTION

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WTC BKV-DBR MetroJV
MMC-GAMUDA 5252
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2009
 ROAD DECK CONSTRUCTION

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WTC2009
2009 BKV – DBR Metro
MMC-GAMUDA JV 5353
BUDAPESTGus
Budapest by Klados
Gus
CROSS or ESCAPE PASSAGES AT
25OM INTERVALS
Provide escape to
smoke free
environment between
road decks

ITA-AITES WTC
WTC2009
2009 BKV – DBR Metro
MMC-GAMUDA JV 5454
BUDAPESTGus
Budapest by Klados
Gus
 CROSS PASSAGE CONSTRUCTION

ITA-AITES WTC
WTC2009
2009 BKV – DBR Metro
MMC-GAMUDA JV 5555
BUDAPESTGus
Budapest by Klados
Gus
HOLDING POND & FOUNDATION OF
THE WATER INTAKE TOWER

ITA-AITES
ITA2009 Budapest
WTC BKV-DBR MetroJV
MMC-GAMUDA 5656
Gus Klados
2009
 TWIN BOX CULVERT AT TAMAN
DESA

ITA-AITES
ITA2009 Budapest
WTC BKV-DBR MetroJV
MMC-GAMUDA 5757
Gus Klados
2009
 TIME-CHAINAGE DIAGRAM
SOUTH TUNNEL

ITA-AITES
24th October
WTC MMC-GAMUDA JV 5858
2007, GSM by Gus
2009
 TIME CHAINAGE DIAGRAM
NORTH TUNNEL

ITA-AITES
ITA2009 Budapest
WTC BKV-DBR MetroJV
MMC-GAMUDA 5959
Gus Klados
2009
 THE UPPER ROAD DECK BEFORE
OPENING

ITA-AITES
24th October
WTC MMC-GAMUDA JV 6060
2007, GSM by Gus
2009
 THANK YOU

FOR YOUR PATIENCE

ITA-AITES
ITA2009 Budapest
WTC ex. MMC-GAMUDA
BKV-DBR Metro JV. 6161
Gus Klados
2009 BKV-DBR Metro