UNIVERSITI TEKNOLOGI MARA

PERAK DARUL RIDZUAN

BQS 602

ROADWORK, HIGHWAY & VIADUCT CONSTRUCTION

CASE STUDY OF SUNGAI BESI - ULU KELANG ELEVATED

EXPRESSWAY (SUKE)

COURSE ODE : CONSTRUCTION

: DQS184
TECHNOLOGY Vi
PROGRAMME :
PROGRAMME CODE : AP224

GROUP : 5D

DATE OF SUBMISSION : WEEK 11

PREPARED FOR : CIK SITI NURHAYATI BINTI HUSSIN

PREPARED BY:

NAME MATRIX NO.

BADRUL AMIN BIN KHIF NOOR 2019461286

NUR AFIFAH ALIAA BINTI MUSA 2019607908

NURPREPARED
FARAH AFIFAHFOR :
BINTI ZAINUDDIN 2019607954
NUR SYAMIMI AMIRAH BINTI AZMAN 2019608016
MODE : INDIVIDUAL ASSIGNMENT
 PREFACE

The meaning of road in dictionary is a hard surface built for vehicles to travel on. It is

a pathway that been used to travel between places to other place, usually the surface of road

is asphalt or concrete. Modern roads for rural and urban are designed to accommodate vehicle

between both directions. Meanwhile from the other point view of road is it is a place for one

may ride or an open way for public passage for vehicles, a person, and animals. It is forming

a meaning of communication between one town, city, or place to another. The construction of

road is implemented by Federal government and State government but during the mid-1980s

the road has been construct by the private companies that been authorized by the

government. So, there will be a charge tolls to the road user. However, the road is an

alternative to the existing road network and be built with diversity facilities for the users.
 TABLE OF CONTENTS

Contents Page
Number

INTRODUCTION

CHAPTER 1.0 Introduction 1

CHAPTER 2.0 Literature Review 2

2.1 Type of Road 3

2.2 Design Consideration 3

2.3 Construction Sequence 4

2.4 Falsework 5

2.5 Material Used 6

2.6 Cost 7

CHAPTER 3.0 Case Study 8

3.1Brief Project/ Project Background 8

3.2 Parties involved 9

3.3Type of Construction Used 10

3.4 Major Components 11

3.5 Typical Construction Process 16

3.6 Materials Used 26

3.7 Issues and steps taken to resolve them 27

CHAPTER 4.0 Conclusion and Recommendation 28

5.0 References 29

6.0 Appendix 30
 CHAPTER 1

INTRODUCTION

1.1 Background of study

Generally, the road network system and road infrastructure in Malaysia already exists and was

built since or during the British Administration. The road network was built aimed to linking

mining area, agricultures and plantation to urban areas and the harbour. And after several

decades, and when Malaysia was born, the road network system is more developed and

become complexity around the country in line with the growing of our population. Besides, with

the expansion of our technology by producing cars or others vehicles and the increasing of

road user recently also make the demand toward road and infrastructure increase. Began from

two lane carriageway the road network and infrastructure had develop rapidly become a large

and width highway and expressway

Figure 1:Types of road in Malaysia

Source: Jabatan Kerja Raya Malaysia

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 CHAPTER 2

LITERATURE REVIEW

1.0 Types of road in Malaysia

Roads play a crucial role in our lives. They facilitate movement and permit the

realization of personal convenience, economic prosperity and social goals. There are two

types of road pavements that been used in road systems which is flexible pavement and rigid

pavement. The construction of road is implemented by Federal government and State

government but during the mid-1980s the road has been construct by the private companies

that been authorized by the government. So, there will be a charge tolls to the road user.

However, the road is an alternative to the existing road network and be built with diversity

facilities for the users.

Figure 2: Classification of road

Source: Road Engineering Association of Malaysia

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 2.1 TYPE OF ROAD

Mohamad
TYPE OF ROAD Sarvesh Zulhaidi
Mustafa Kareem, , M.,
NO Rajput , M., et Lenngren
(2018) al.,
, M. N.
A.
Kamarudi
(2014) TOTAL
CONSTRUCTION (2017) n et al.,
(2010)
(2010) (2013)

1 Flexible pavement 5
2 Rigid pavement 5
3 Semi-Rigid 3
pavement
4 Concrete 1
Pavement
5 Bituminous 1
Pavement
6 Composite 3
pavement

Table 1.1 Summary of the type of road construction

2.2 DESIGN CONSIDERATION OF ROAD CONSTRUCTION

M Nurul
DESIGN Elma
Shamil Magdi Jayakumar Ei and
CONSIDERATION OF Kordi et
No Flamarz, Zumrawi, and Lee Khaing,
ROAD al.,
(2017) (2015) Chee Soon (2014)
CONSTRUCTION
(2015) (2012)

1. Design speed / / / /

2. Design traffic volume / /

3. Number of lanes / /

4. Quality of materials / / /

5. Construction practices / / /

Table 1.2 Summary of the type of road construction

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2.3 CONSTRUCTION SEQUENCE

(Concrete
(White, Pavement
(Manohar,
Hudson, (Stock, Specifiers
STEPS OF Reddy, &
Meyer, 1989) Guidelines M
NO CONSTRUCTION Dana, TOTAL
OF ROAD & Ii, Unicipal E
2018)
1984) Dition, 2009)

Prepared soil
1 subgrade / / / / / 4
foundation course

Granular sub-base
2 (GSB) or drainage / / / / 4
layer.
Curb, gutters,
3 manholes and catch / 1
basins

Base course/ (DLC

4 / / / 3
Dry lean concrete)

Asphalt concrete
5 / 1
pavement

CC pavement slab
4 using PQC (paving / / / 3
quality concrete

6 Joint / / 2

7 Reinforcement steel / / / 3

Table 1.3 Summary of the construction sequence of road

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2.4 FALSEWORK

sources

Mitchell, A., & Warrior,

Atherinis et al., (2018)

Jurkowski, D. (2014).
Fabian et al., (1986)

Carpenter, J. (2013)
Peng et al., (1998)

Duntemann et al.,
Hołowaty, J., &
D. (2018)

(1994)
no. Falsework in road construction

Falsework structure with steel frames for

1 the supports and steel rolled beams for /
the decks.

Temporary props as falsework use to

2 support the precast beams until the cast- /
in-situ concrete in the connections and the
top slabs have hardened.

3 Existing arch is used as falsework /

Falsework would include steel or timber

beams, girders, columns, piles and
foundations, and any proprietary
4 /
equipment including modular shoring
frames, post shores, and adjustable
horizontal shoring.

5 Speedy construction /

Temporary structure known as falsework

6 / / /

Falsework generally comprises a variety of

7 components to secure the structure / /

Falsework structures have the potential to

8 fail in many ways through a variety of / /
causes

Instability of falsework is the main reason

9 /
of falsework failure

Table 1.3 Summary of falsework in road construction

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2.5 Material Used in Road Construction

No Material in road Wu et Sihan et Tuncan Vegas et Engelsen

construction al., al., et al., al., et al.,
(2018) (2008) (2015) (2008) (2017)

1. Portland cement / /

2. Fly ash / /

3. Limestone / / /

4. Nickel slag /

5. Dunkirk marine dredged /

sand

6. Cement /

7. Construction Demolition /
Waste (CDW)

8. Waelz slag /

9. Municipal Silid Waste /

Incineration (MSWI)

10. Metal leaching from /

recycled concrete
aggregate

Table 1.4 Summary of Material in road construction

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2.6 COST

No Factor affecting cost Meeampol Pal et C (2016) Mahamid Alhomidan

in road construction and al., and (2013)
Ogunlana (2017) Bruland
(2006) (2011)

1. Management of / / / /
construction resources

2. Budget management / /

3. Construction method / /

4. Reduce emphasis on / / /
scheduling

5. Human resources / / /
management

6. Unforeseen ground / / /
conditions

7. Accident on site /

8. Land acquisition and /

increase in land cost

9. Delays in payment / / /

10. Material price / /

fluctuation

Table 1.5 Summary of factor affecting cost in road construction

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 CHAPTER 3

CASE STUDY

3.1 PROJECT BACKGROUND

SUKE or Sungai Besi-Ulu Kelang Elevated Expressway is a 24.4km long highway with three

lanes from Sri Petaling to Ulu Kelang. It was managed by Projek Lintasan Sungai Besi-Ulu

Klang Sdn Bhd which fully owned subsidiary of Projek Lintasan Kota Holdings Sdn Bhd

(PROLINTAS). It consists of 14 interchanges and has pass through over 60 residential areas

which also linked to major highways and roads in Kuala Lumpur. The purpose of SUKE

construction is to reduce traffic congestion in Cheras, Pandan Indah and Ampang as well as

become an alternative road for MRR2. Besides, SUKE highway will directly provide a

connection between new growth centers such as Kajang to Segambut or Kepong through

Klang Valley area highways. For instance,

a) Kuala Lumpur Middle Ring Road 2 (MRR2)

b) Duta-Ulu Klang Expressway (DUKE)

c) Shah Alam Expressway (KESAS)

d) KL-Seremban Highway (KL-SEREMBAN)

e) Cheras-Kajang Highway (CHERAS-KAJANG)

f) Sungai Besi Expressway (BESRAYA)

g) Ampang-Kuala Lumpur Elevated Highway (AKLEH)

SUKE highway will have three toll plazas, one rest stop and 14 entry and exit points. The

project cost was RM4.63 billion which expected to be completed by the end of 2019 and

opened in mid-2020. This project was estimated to minimize overall congestion by supporting

over 44,000 vehicles daily.

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3.2 PARTIES INVOLVED

CLIENT  Projek Lintasan Kota Holdings Sdn Bhd (PROLINTAS)

ENGINEER  HSS Engineering

CONTRACTOR PACKAGE CA1

 Chengal Jati Sdn Bhd
 Contract: RM417.89 million

PACKAGE CA2
 HCM-Hatimuda JV
 Contract: RM315.8 million

PACKAGE CA3
 Syarikat Muhibah Perniagaan & Pembinaan Sdn Bhd
 Contract : RM1.05 billion

PACKAGE CA4
 MLM Sepakat Sdn Bhd
 China Harbour Engineering Co JV
 Contract: RM939.86 million

PACKAGE CB1
 Cergas Murni
 Contract: RM550.1 million

PACKAGE CB2
 Zelan Construction Sdn Bhd
 Hasrat Sedaya JV
 Contract: RM257.61 million

PACKAGE CB3
 JAKS Sdn Bhd
 Contract: RM508.5 million

PACKAGE CB4
 Cantilever Bumi Sdn Bhd
 Contract: RM352.67 million

PACKAGE CB5
 Bridgex – BBSB JV
 Contract: RM239.96 million

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 SUB-CONTRACTOR Foundation and substructure
 Econpile Holdings Bhd
 Contract: RM158.27 million

Construction of mainline and associated works

 China Communications Construction Co Ltd
 Kumpulan Jetson JV
 Contract: RM201.87 million

Street lighting and traffic light system

 Mudajaya Corp Bhd
 Contract: RM31.99 million

3.3 TYPE OF CONSTRUCTION

SUKE highway is a controlled-access highway that was designed for high-speed vehicular
traffic with all traffic flow ingress and egress regulated. It was also known as elevated highway
which built up above grade for its entire length. Elevated highway is commonly used when
there are several combinations on the desired route such as difficulty controlling access at
grade. For example, increase in cost to remove existing crossings. The construction of
elevation is typically built as viaduct which consist a long pier of bridge. SUKE highway
involved over 100 bored piles and 50 caisson piles with an approximate total length of 5.2km
(Package CA3). Down-the-hole (DTH) hammer was used to drill 200 points of large diameter
bore holes and in formation of rocks. The DTH technique give a better benefit compare to
conventional rotary drilling because it is more efficient in hard rock areas.

Hundreds of post-tensioned concrete portal beams were formed by EFCO Malaysia with a
range length from 20m to 50m including corbel at each side of the beam. The upper layer of
post tensioned concrete portal beams was installed by using E-Z DECK shoring towers and
SUPER STUD shoring towers. This shoring system provide an ability to pre-assemble shore
towers on the ground which then lifted the beam to its position by using crane. Moreover, it is
to magnify the efficiency of the erection as well as flexibility at the site especially in ensuring
a safe environment for workers. Besides, this technology help to save more time for cycling
equipment from pier to pier as it can easily modified, moved and assembled to assist any
height variance.

Rigid pavement generally acts as heavy-duty industrial floor slabs and heavy-duty vehicle
park. Rigid pavement is suitable for the highway because it is designed to be a long-lasting
structure to provide high speed traffic. The casting of concourse level slab for SUKE highway
was done by delivering the concrete using the concrete mixer truck from approved batching
plant and then placed in position by concrete pump truck. Normally, the pavement surfaces

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used for this highway construction is Portland cement concrete. It transferred the traffic
loadings between sections when bigger aggregates in the concrete linked together. Thus, this
provides a smooth and safe riding surface for the user to travel. Additionally, another
technology was used for this construction project such as variable-message sign (VMS) for
the upgrading of toll, vehicle detection system (VDS) and close-circuit television (CCTV). The
operation of this latest technology has led to a dynamic and superior performance.

3.4 MAJOR COMPONENTS

For our case study there are two major components of road, which are.

1. Piling

 A type of deep foundation

 Higher in cost
 A suitable type of pile needed that can contain with the load.
 A suitable diameter of pile required according to engineers
 Transfer load to ground

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2. Pile cap

 Reinforced concrete pile cap.

 Have the erection of reinforcement in the pile cap.
 Erection of formwork is required in order to make a shape for the pile cap.
 Transfer the load from superstructure to the pile.
3. Pier

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  Compression member.
 Construct on site.
 Have the erection of reinforcement in it.
 The size or diameter of the pier is very important in order to receive the load form the
upper structure.
 Transfer the load to the pile cap.
 Height of the pier is depending on the location of the site.

4. Transom

 A horizontal superstructure.
 Transfer the load to the pier.
 For our case study they use in-situ pier and pre-cast pier.
 In-situ transom is used if the location is free from the public.
 Pre-cast transom will be use if the site is near public area.

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5. Girder

 The most components use.

 The most expensive components.
 Transfer the load to the transom.
 Length of the girder is depending on the site and the distance between the transom.

6. Slab

 Reinforced slab.
 Include the erection of reinforcement in the slab.
 Use the Portland cement to ensure the quality of cement.

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7. Road pavement

 Surface of the road.

 Located on top of the slab.
 Surface that will avoid the water from concrete slab.
 Hot mix asphalt is used as road pavement.

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3.5 TYPICAL CONSTRUCTION PROCESS

For the construction process for Sungai Besi – Ulu Kelang SUKE elevated expressway, there
are difference compare to a typical road construction. An elevated expressway which means
the road is above the ground and that the main reason that makes the process is different.

1) Installation of piling.

Piling is used as for the SUKE elevated expressway because of the load that will be
received make the piling is the best foundation to be used. The suitable diameter and
type of piling will be installed as the foundation for this project.

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2) Installation of sheet pile.

Installation of sheet pile is required to continue the work for preparing the pile cap. It is
the best way to avoid the movement of ground at the surrounding area.

3) Preparing the pile cap

The excavation will be done in preparation of preparing the pile cap. The preparation
of pile cap including all the necessary works which is include all the erection of
reinforcement and concrete works. The specs from the engineer need to be followed
and might be different with typical pile cap since it is an infrastructure works.

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4) Construction of pier

Once the pile cap is completed, the pier will be construct on top of the pile cap. The
construction of pier will be done with climbing system formwork. The climbing formwork
will climb to the upper part of pier once the bottom part has been completed.

This is the picture of the construction process of pier by using climbing formwork.

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 5) Backfilling

Once the pier has been completed, backfill process will be undergoing in order to
cover the pile cap and to prevent the pile cap from damages.

6) Extraction of sheet pile

Once all the piers have been completed, the sheet pile will be extract from the ground.

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 The process will be repeated until all the piers have been completed construct on site
while waiting for the pre-cast component to be prepared.

7) Installation of transom

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The installation of precast transom is done once the pier is completely constructed.
The installation of transom will require a crane in order to lift the pre-cast component
to the required position. The installation will be done at night where the traffic is not
heavy. It is because a trailer will be needed to deliver the pre-cast component to the
site.

This is the pictures of the pier and the transom that have been completely construct.

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8) Installation of girder.

The pre-cast girder will be placed on top of the transom. The girder is required to
transfer the load to the pier. The pre-cast girder will be prepared at the factory by
following all the engineer’s requirement and spec for girder. It is very important to
ensure that the girder able transfer the load.

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9) Construction of slab.

The slab will be construct on top of the girder which have been installed before. The
erection of formwork is necessary to receive the concrete. Portland concrete will be
used for the slab. The slab includes the erection of reinforcement in order to receive
heavy load from the vehicles.

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10) Installation of parapet wall

The installation of pre-cast parapet wall will be taking place as soon as the slab is
completely constructed. The parapet wall is used to prevent any object fall from the
road.

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 11) Surfacing of the road.

The final or top of the slab will have wearing course where a layer which will have
direct contact with traffic. Hot mix asphalt is used as a wearing course.

12) Road furniture

The final process which is the furniture of the road. It including road marking, signboard and
traffic sign which is required.

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3.6 MATERIAL USED

The PCC pavement is to be laid on a granular subbase

material. Portland cement concrete or PCC
pavements consist of a PCC slab that is usually
supported by a granular or stabilized base, and a
subbase. For this case study, the PCC slab
overlaid with a layer of asphalt concrete.

Portland cement concrete

Hot mix asphalt is used as a wearing course. It is used

for this elevated highway due to its flexibility,
weather resistance and ability to repel water. Hot
mix asphalt is used when the outside air
temperature is above 40 degrees, due to its
propensity for rapid cooling.

Hot mix asphalt

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3.7 ISSUES AND STEPS TAKEN TO RESOLVE

Problem/issue Solution

The limited workspace for the cutting or the All precast item was used for this
filling operations at construction site. The construction to minimise the time and suited
construction site at congested traffic area the workspace.
which is mainly in Kuala Lumpur Middle Ring
Road 2. Sungai Besi-Ulu Kelang SUKE
elevated expressway mostly constructed
above the main road before. The project
team must construct piling and precast pier
besides the main traffic road used.

Second problem could be public There already have one accident happen
acceptance. The residential neighbourhood, while the construction occurs but all the
which faces the Sungai Besi-Ulu Kelang parties involves already get their insurance.
Expressway (SUKE) highway, has borne the Moreover, they had limited their working time
brunt of the construction works with heavy especially during peak hours.
vehicles plying Persiaran Alam Damai as
well as constant noise pollution and some
near misses

The availability of workforce, availability of They already hired expertise contractor that
materials, availability of equipment could be can handle all the project flow smoothly from
another problem. As we know, Malaysian the start.
already have the problem with the shortage
of workforce. Overall total of this highway is
31.8km required a bulk of material at the
same time and special equipment.

Weather in Malaysia hot and rainy all the The technology of precast material really
year could be one of disturbance for the helps to finish this project. All the material in
construction process. from factory and just install in site. Less time
constrain in the construction site occur.

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 CHAPTER 4

CONCLUSION AND RECOMMENDATION

In overall this case study, give more knowledge towards us about the Elevated Expressway
(SUKE) in term of design, development process and stages, parties involved and the
highlighted issues and problems that probably occurs in any type of Elevated Expressway
projects especially in Malaysia. Besides we also gain knowledge about the hierarchy of
highway organization in Malaysia and also construction process during the construction.
Besides that, this case study has highlighted more on the implementation of Elevated
Expressway project especially in Malaysia in term of design stage, construction stage and
post completion stage with the issues and problems that always arise. For recommendation,
the road user as well as public people should more concern and alert with the project and give
cooperation to the project team to finish the project successfully.

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 5.0 REFERENCES
Chandra, S. (2017). Flexible pavement versus rigid pavement. NBM&CW, 23(3), 38-48.

Mohod, M. V., & Kadam, K. N. (2016). A comparative study on rigid and flexible pavement:
a review. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), 13(3), 84-88.

Alhomidan, A. (2013). Affecting Cost Overrun in Road Construction Projects in Saudi Arabia.
International Journal of Civil & Environmental Engineering, 13(3), 1-4.

Azhar, K. (2016, September 1). Private entities to the fore in SUKE and DASH projects. Retrieved
from EdgeProp: https://www.edgeprop.my/content/867968/private-entities-fore-suke-and-
dash-projects

C, R. A. (2016). Analysis of Cost Overrun in Road Construction Activities – A Critical Review.

International Research Journal of Engineering and Technology (IRJET), 3(4), 1433-1439.

Engelsen, C. J., Sloot, H. A., & Petkovic, G. (2017). Long-term leaching from recycled concrete
aggregates applied as sub-base material in road construction. Science of the Total
Environment , 1-8.

Mahamid , I., & Bruland , A. (2011). Cost Overrun Causes in Road Construction Projects:
‘’Consultants’ Perspective. International Conference on Construction and Project
Management, 15, 6-10.

Meeampol, S., & Ogunlana , S. O. (2006). Factors affecting cost and time performance on highway
construction projects: evidence from Thailand. Journal of Financial Management of Property
and Construction, 11(1), 3-20.

Pal, P., Pandey, D. M., & Bhadaoriya, O. P. (2017). Factor Affecting Construction Cost and Time in
road project. International Research Journal of Engineering and Technology (IRJET), 4(8),
1561-1563.

Siham, K., Fabrice, B., Edine, A. N., & Patrick, D. (2008). Marine dredged sediments as new
materials resource for road construction. Waste Management, 919-928.

Tuncan, A., Tuncan, M., & Koyuncu, H. (2015). Use of petroleum-contaminated drilling wastes as
sub-base material for road construction. Waste Management and Research, 489-505.

Vegas, I., Ibanez, J. A., San Jose, J. T., & Urzelai, A. (2008). Construction demolition wastes, Waelz
slag and MSWI bottom ash: A comparative technical analysis as material for road
construction. Waste Management, 565-574.

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 6.0 APPENDIX

Figure show SUKE Expressway schedule maps

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