KVMRT SSP Line Conlay Station

Excavation in Limestone Formation
of KVMRT Conlay Underground

Station, Malaysia
By : Fong-Wah, Chee
1
G&P Professionals Sdn Bhd (www.gnpgroup.com.my)
Please Read Carefully !!!!
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2
G&P Professionals Sdn Bhd (www.gnpgroup.com.my)
INTRODUCTION
3
© G&P Professionals Sdn Bhd Quality Services - Our Commitment
Overview of Project
4
Overview of Project
• Klang Valley Mass Rapid
Transit (KVMRT) Sungai Buloh-
Serdang- Putrajaya (SSP)
• Total 37 stations
(11 underground stations)
• Total alignment length of
52.2km
(13.5km underground tunnel)
5
Site Location
Conlay Station
TRX Station
Chan Sow Lin Station
6
Overview of Project
7
SUBSURFACE INVESTIGATION
8
General Geology
• Limestone Formation
• Alluvium: very loose sand/
very soft to soft silt.
9
Subsurface Investigation
Legend:
Existing boreholes (11 nos)

Additional boreholes (16 nos)
10
Subsurface Investigation
• SPT-N generally less than 10.

• Bedrock level varies.
• Cavities
11
Bedrock Contour
Localised deep bedrock (37.2m)
Localised deep bedrock
12
Subsoil information
Overburden Bedrock
Material Alluvium Limestone
Depth Varies; deepest recorded at Varies

37.2m
Unit weight 19 kN/m3 24 kN/m3
RQD - 0 – 100%
SPT-N <10 ; average = 6 -
Average UCS - 50 MPa
Effective shear strength c’ = 1kPa ; c’ = 400kPa ;

φ’ = 29˚ φ’ = 32˚
Elastic modulus, E’ 18,000 kPa 1,000,000 kPa
Hydraulic conductivity, k 1x10-6 m/s 0 – 10 x 10-7 m/s

13
EARTH RETAINING STRUCTURE
SYSTEM (ERSS)
14
ERSS
Design Consideration:
Configuration of SBP adopted:
- To check the overlapping of
• 1480mm/1180mm (SP/PP) @ 1.92m spacing c/c SBP after considered pile
• 1180mm/880mm (SP/PP) @ 1.66m spacing c/c deviation and verticality such
that the SBP still overlapped
at the bedrock level. (to
prevent water seepage if the
SBP is deviated)
15
Typical Elevation for Rock Socket
16
ERSS
Ground Anchor
Strut
17
Modelling Input Parameters and
Criteria
Descriptions Modelling Input
Model Type Plain Strain analysis
Soil Model Hardening Soil model
Soil Shear Strength Effective Stress parameters
Soil Material Type Drained
Soil Loading Stiffness 18,000kPa
Soil Unloading Stiffness 54,000kPa
Soil/wall interface factor 0.8
Wall Element Plate element
Wall Bending Stiffness 0.7x EI
Wall Compression Stiffness 0.7x EA
Construction Surcharge 20kPa
Groundwater condition Phreatic
18
Finite Elements (FE) Model
Bottom-up construction
Temporary ground
anchors (45°) due to
limitation of ROW
Easier for excavation
works due to open space
within excavation pit
19
Finite Element (FE) Model
Bottom-up construction
Temporary struts due to
site constraint
Contractor not prefer as
the excavation works are
limited by the headroom
available below struts
20
Finite Element (FE) Model
Wall Estimated Supporting Support Deflection
arrangement Bedrock System Layers
Level
1180mm/880 10m-30m Ground 3-13 0.18% - 0.45%
mm Anchor
1180mm/880 14m-30m Strutting 3-5 0.14% - 0.44%
mm
1480mm/1180 12.5m – 38m Strutting 5-10 0.1% - 0.35%
mm
Ok. < 0.5%
21
Temporary Support
Ground Anchor
Anchor
Head Bearing
Plates
Gusset
Plates
Anchor Walers
Strands Waler
Bracket
22
Temporary Ground Anchor
Ground Anchor
Designed to BS8081:1989
Structural Geotechnical Other Steel

Capacity Capacity Elements
To determine
working load a) Waler
To determine the fixed
of GA length of GA b) Gusset Plates
(in our case is rock socket c) Bearing Plates
To determine length) d) Waler Bracket
how many U-
loops of GA
Designed to BS5950:2000
23
Ground Anchor Properties
Descriptions Properties
Working loads (kN) 212; 424; 636; 848; 1060
No. of strand 2; 4; 6; 8; 10
Strand diameter (mm) 15.24
Breaking load (kN) 260.7
Factor of safety 1.6
Strand U-loop radius (mm) 47.5
Reduction factor 0.65

Drillhole diameter (mm) 175
Allowable bond stress (kPa) 400
Free length Varies

Bond length (m) 3; 3; 4.5; 6; 7.5
24
Temporary Support
Ground Anchor
GA Installation Procedures
Coring of SBP Wall
Drilling in Soil
Coring in Rock
Installation of GA
strands
Grouting
25
Temporary Support
Ground Anchor
Coring of SBP Wall
Drilling in Soil
Coring in Rock
Installation of GA
strands
Grouting
26
Temporary Support
Ground Anchor
Coring of SBP Wall
Drilling in Soil
Coring in Rock
Installation of GA
strands
Grouting
27
Temporary Support
Ground Anchor
Coring of SBP Wall
Drilling in Soil
Coring in Rock
Installation of GA
strands
Grouting
28
Temporary Support
Ground Anchor
GA Stressing Procedures
Initial Stressing of Strands
(from longest strands to shortest strands)
On-site Acceptance Test

(for all GA)
Lock-off GA
(normally extra 10% of designed prestressed load )
Lift-off Test
(to check the lock-off load)
Lock-off GA again
29
Temporary Support
Ground Anchor
Type of Test Test Maximum Creep Monitoring Remarks
Frequency Test Load
Proving Test Each GA 160% WL 10 days -
type (80% of fpu) (or longer subjected to loss
of load/displacement)
On-site 1% of total 125% WL 10 days -

Suitability Test working (Temp GA) (or longer subjected to loss
of load/displacement)
GA
On-site ALL 125% WL 50 mins Creep

(or longer subjected to loss monitoring on
Acceptance working (Temp GA) of load/displacement) 10% of total
Test GA working GA only.
Lift-off test after
lock-off of GA.
30
Temporary Support
Ground Anchor
31
Temporary Support
Ground Anchor
32
Temporary Support
Strut
• Designed to BS5950:2000- Structural Use of Steelwork in Building.
• Check strut force from Finite Elements (FE) and determine working
load.
• Design elements:
a) Strut (lacing, tie-panel) f) Tie-Beam
b) Waler (stiffener) g) Splice Joints
c) Kingpost h) Shear Connector
d) Bracing i) Concrete waler
e) Runner Beam
33
Temporary Support
Strut
Tie-beam
Kingpost
Splice joint
Tie-panel
Runner Beam Diagonal Strut
Lacing
34
Temporary Support
Strut
One-Strut Failure shall be considered in the design to ensure the
robustness of the ERSS.
For first layer strut

-designed to FOS=1.05
-waler bending length
increased
Strut fell off
Waler bending
length increased
35
Temporary Support
Strut
Different waler size
specified for 1st layer
36
Temporary Support
Strut
One-Strut Failure shall be considered in the design to ensure the
robustness of the ERSS.
For subsequent layer strut

-designed to FOS=1.05
-whole layer of strut is
removed in each excavation
stage to simulate OSF.
-SBP to transfer load to top
and bottom layers struts.
37
Temporary Support
Strut
38
Temporary Support
Strut
39
Grouting
40
Grout Termination Criteria
a. Surface ground heave >25mm
b. Refusal at pre-determined pressure
Depth, (m) Recommended Holding
Pressure (Bar)
5 – 10 17
10 – 15 18
15 – 20 19
20 – 25 20
25 - 30 21
30 – 35 22
35 - 40 23
c. Volume of grout exceeded 5m3 41

Grouting
42
Typical Section for GA
43
Typical Section for Struts
44
Instrumentations
• For excavation of depth 4.0m or deeper:-
a. One type of C1, C2, C3 or C4 array for
every 25m of perimeter wall
b. Average of one type C2 or C3 array for
every 100m of perimeter wall
c. Average of one type C3 or C4 for every
100m of perimeter wall
d. Average of one type C4 array for every
200m of perimeter wall
45
Typical Array
46
Instrumentations

Instrumentations
• For buildings within monitoring zone:-
a. Min. 4 nos. building settlement markers
for low and medium rise building
b. Min. 8 nos. for high rise building
48
Instrumentations

Monitoring Frequency
50
Review Level for Movements
51
Alert Level
52
Action Level
53
Alarm Level
54
CONSTRUCTION WORKS
55
GA loosening
Observed the strand is

not in tension mode.
56
GA loosening
Probable cause of loosen strands:
1) Irregular hole diameter of anchor block.
2) Seating of wedges not balance.
3) Rusting of wedges due to weather.
57
GA loosening
Remedial works:
1) Inspect all previously installed GA.
2) Replace all wedges.
3) Make sure all 3 pieces of wedges seating evenly and equally
inside the anchor block hole.
4) Apply grease after locked the wedges to prevent rusting.
5) Install additional inclinometers, settlement markers and optical
prisms to monitor.
58
GA loosening
Recommendation to use the following tool to lock-off the ground
anchor and ensure all wedges are gripping the strands uniformly.
59
Rock Mapping
Rock mapping carried out by G&P geologists in every 3m rock excavation.
Kinematic analysis (Stereonet) to check stability of rock slope.
Rock bolts installation if necessary.
60
Progress Photos
61
62
63
64
65
66
67
Achievements
• Commencement of work  2017
• Excavation to Final Excavation Level (FEL)

 April 2019
• Max recorded deflection ratio  0.18%
• Vertical rock excavation >> save cost +

time 68
CONCLUSIONS
69
Conclusions
1) Secant bored pile (SBP) supported with temporary support i.e.
temporary strutting / ground anchor and rock strengthening were
successfully implemented for underground station excavation
works.
2) SBP  prevent excessive groundwater drawdown and settlement
70
Conclusions
3) Credit to team members G&P Geotechnics Sdn Bhd &
project team of MMC Gamuda
List of team members from G&P

Ir. Dr. Tan Y.C. Ryan Low Y.L.
Ir. Koo K.S. Bonnie Lau
Ir. Lee Y.C. Ang J.S.
Tan P.Y. Desmond Teh Kok Loong
71
THANK YOU
72

KVMRT SSP Line Conlay Station

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Excavation in Limestone Formation

of KVMRT Conlay Underground

Chan Sow Lin Station

Existing boreholes (11 nos)

• SPT-N generally less than 10.

Localised deep bedrock (37.2m)

Localised deep bedrock

Material Alluvium Limestone

Depth Varies; deepest recorded at Varies

Unit weight 19 kN/m3 24 kN/m3

SPT-N <10 ; average = 6 -

Average UCS - 50 MPa

Effective shear strength c’ = 1kPa ; c’ = 400kPa ;

Elastic modulus, E’ 18,000 kPa 1,000,000 kPa

Hydraulic conductivity, k 1x10-6 m/s 0 – 10 x 10-7 m/s

Structural Geotechnical Other Steel

Working loads (kN) 212; 424; 636; 848; 1060

Strand U-loop radius (mm) 47.5

Reduction factor 0.65

Allowable bond stress (kPa) 400

Free length Varies

Coring of SBP Wall

Coring of SBP Wall

Coring of SBP Wall

Coring of SBP Wall

On-site Acceptance Test

On-site 1% of total 125% WL 10 days -

On-site ALL 125% WL 50 mins Creep

Runner Beam Diagonal Strut

For first layer strut

Strut fell off

For subsequent layer strut

c. Volume of grout exceeded 5m3 41

© G&P Professionals Sdn Bhd Quality Services - Our Commitment

© G&P Professionals Sdn Bhd Quality Services - Our Commitment

Observed the strand is

• Excavation to Final Excavation Level (FEL)

• Max recorded deflection ratio  0.18%

• Vertical rock excavation >> save cost +

2) SBP  prevent excessive groundwater drawdown and settlement

List of team members from G&P

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