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Design Comparison of Wain River Bridge on New Capital City Toll Road Section
3A Karangjoang - KKT Kariangau

Conference Paper · September 2023

DOI: 10.58674/phpji.v16i1.299

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 Design Comparison of Wain River Bridge on New Capital City Toll Road
Section 3A: Karangjoang – KKT Kariangau
Andrew Nugraha Standyarto, ST, MSc1 , Dedi Prayitno, ST, MT2, Wira Wijaya, MT3
1FieldSupervision Coordinator of Section 3A, National Road Implementation Agency for East
Kalimantan Region, Directorate General of Highways, Ministry of Public Works and Housing,
Republic of Indonesia, andrew.standyarto@pu.go.id
2
Contract Signing Officer of Section 3A, National Road Implementation Agency for East
Kalimantan Region, Directorate General of Highways, Ministry of Public Works and Housing,
Republic of Indonesia, dedi.prayitno@pu.go.id
3
Head of Engineering Division, PT Wahana Perencana Persada (WPP), Indonesia,
wira.wijaya@gmail.com

ABSTRACT

To distribute country development and as a centralization of government, Indonesia will move its capital city
from the crowded Jakarta in Java Island to New Capital City (IKN) of Nusantara in East Kalimantan. To ensure the
connectivity and accessibility between existing city of Balikpapan to Nusantara, several sections of toll roads are built
from 2022 - 2024, including Toll Road of Section 3A that connects Karangjoang to Container Terminal of Kariangau.
There are many structures that will be built along the trace such as pile slab, box culvert, underpass, overpass and the
913 m long bridge that crosses 3 segments of Wain River on STA 18+664. From initial DED, the main span of bridge
only uses 50 m PCI Girder, but from more thorough survey and agreement with Ministry of Transportation, it’s agreed
that from the 5 m designed clearance is then changed to 10.5 m to accommodate local company’s passing tugboats
and pontons. Bridge design on the passed 3 main spans of river is then conducted on 2 alternatives, 66 m Steel Box
Girder (SBG) and 60.8 m Bulb Tee / Prestressed Concrete T (PCT) Girder. Both designs are compared based on
method, cost and duration. Both bridges will use launching gantry for erection with 250 billion IDR cost in 114 days
just for SBG main span while Bulb Tee with cost of 178.5 billion IDR in 102 days. From the analysis done, the SBG
design is more costly by 40.22% and time consuming by 11.76% to be implemented. Therefore, Bulb Tee Girder is
applied for Wain River Bridge main spans.
Keywords: New Capital City, Toll Road, Bulb Tee, Steel Box Girder, Launching Gantry

1. INTRODUCTION
Construction distribution, centralization of government and following Government Regulation, Indonesia will
move the capital city from the crowded Jakarta in Java Island to New Capital City (IKN) of Nusantara in East
Kalimantan. To ensure the connectivity, accessibility, goods mobility and travel time of 30 minutes between existing
city of Balikpapan to the new capital city of Nusantara, several sections of toll roads are built from 2022 - 2024,
Karangjoang – Kariangau – Tempadung – Balang Island - IKN. Toll Road of Section 3A specifically connects
Karangjoang to Container Terminal of Kariangau with 13.4 km length. IKN Toll Road section 3A is shown on Figure
1 as follow:

Figure 1. Section 3A of IKN Toll Road (Project Data, 2022)

 Beside 120 m width at grade road, there are many structures that will be built along the trace such as slab on
pile (SOP), box culvert, underpass, overpass and the 913 m long bridge that crosses 3 segments of Wain River on STA
18+664 with length of 71.5 m, 95.5 m and 60.6 m as bridge longest or main spans. The ortho photo and survey result
of Wain River is shown below on Figure 2:

Figure 2. Ortho Photo of Wain River (Project Data, 2022)

In order to ensure all sections of toll road can be functional on 1st semester of 2024 to support capital city
movement, thorough research have to be done on all the structures in the project especially on Wain River Bridge
which has vertical clearance change from 5 m to 10.4 m due to local company passing of tugboat, coal ponton and
further development of nearby logistic harbor. Comparison then has to be done between bridge main span designs to
acquire the best design change caused by this active water way transportation.
2. LITERATURE REVIEW
To support the study, literature review of both Bulb Tee, SBG design and Launching Gantry erection method are
described as follow:
2.1 Bulb Tee / Precast Concrete T (PCT)
Bulb Tee or Precast Concrete T (PCT) Girder is an economical post-tension girder for span longer than 40 m
that is usually done with PCI Girder with “T” shape cross section. Bulb Tee is also advantageous because it eliminates
the need to install steel deck for concrete slab work due to its already casted half slab or full depth slab that’s installed
along with the girder itself. Bulb Tee uses less strand volume and distributes stresses more evenly than PCI Girder
(Leo et al., 2017) making it more efficient choice of a girder. Beside its built-in slab, it usually consists of mid span
blisters for more efficient tendon stressing. Schematic image of Bulb Tee Girder can be seen below on Figure 3:

Figure 3. Schematic of Bulb Tee Girder (Leo et al., 2017)

2.2 Steel Box Girder (SBG)

Steel Box Girder or SBG is a box shaped steel beam with lighter weight, fast fabrication & erection and optimum
single span of 60 m to 90 m and can also be made continuous for longer bridge of 200 m (Hazairin et al., 2022). SBG
design is favorable due to its better flexural strength and torsional stiffness than I Girder (Pohan & Abror, 2008 and
Sumaidi et al.). SBG design parameters are flexural strength, shear strength and also fatigue according to the agreed
standards of Load Resistance Factor Design (LRFD). SBG acts as a composite girder with bracings, shear connector
welded on the flange and later be casted together with concrete slab. Due to the fabrication, SBG can be produced
with smaller radius or skew, suitable for replacing existing road with overpass in a toll road project. As a steel material,
delicate attention to corrosion prevention has to be conducted on the SBG with galvanization or paint coating in the
fabrication workshop and need to be reapplied regularly over the years. There are also many methods for SBG erection
such as utilizing Launching Gantry with highest cost and time but suitable for river bridge, Crawler Crane with middle
cost and lowest work time or Mobile Crane with lowest cost and relatively high working time (Sangaji & Azhar,
2020).

2.3 Erection Method

For girder installation, there are several methods that can be done such as shoring, crane (mobile or crawler),
Launching Gantry (LG) or even multiaxle. Bulb Tee or segments of steel box girder can be erected using shoring if
the river depth is quite shallow and no water transportation present or also launching gantry if the river side cannot be
disturbed due to active water transportation and the river is deep. Crane can also be considered for greater mobility.
Crane should have the movement mechanism of lifting loads, trolleying, holding it airborne when necessary and
carrying the load to the specified place (slewing and traveling) (Ismerianto et al.). Crane should also consider the load
chart of weight lifted, boom angle, radius from the lifted load and ground support to ensure crane stability when
performing the erection.
LG has sets of steel truss rail of gantry crane machine and beam trolley. LG method is often used to erect
girder to the designated location on pillar or abutment because it has more benefits than crane in term of stability, need
of smaller working area along the bridge such as river, applicable for segment feeding from behind and constant load
chart capacity (Izza et al., 2019). This method sets the segmental girder between launcher using service crane, stress
it on stressing bed, position it on the trolly to be transported to the launcher, lift it with strand jack and trolley it to the
designated on base position (Liftindo, 2021). Capacity ratio of launcher’s elements and the loaded installed girder
have to be calculated on the condition of self-launching to new span and girder erection with Safety Factor (SF) ≥ 2.
Other things to be considered are its mobility and the area and time needed for assembling and dismantling of launcher
that is also critical and risky. Launcher detail and typical girder erection can be examined below on Figure 4:

Figure 4. Long Section and Plan View of Typical Girder Erection with Launcher (Izza et al., 2019)
3. MATERIALS AND METHODS
Materials and Methods to conduct the study of Wain River Bridge is shown on the flowchart as follow on Figure 5:

Figure 5. Flowchart of The Study (Author Data, 2023)

Based on the flowchart, the description of study steps are:

a. Initial Data Collection (Survey Data, Topograhy, Bathimetry, etc) from Project Team
b. Literature Review of PCT, SBG and Launching Gantry method
c. Design of Bulb Tee and Steel Box Girder
d. Method of Work Analysis of using Launching Gantry
e. Schedule Analysis of Erection Sequence
f. Cost Analysis according to the pay items
g. Comparison of Result Analysis between method, schedule and cost of each design
h. Conclusion and Report writing as paper

4. RESULTS
To ensure best design is selected in IKN Toll road, comparison is done on 3 significant aspects that are method of
erection, duration and cost. Due to vertical clearance change from 5 m to 10.4 m, DED structure such as embankments
are modified to Slab on Pile and also bridge to maintain the height and accommodate soft soil layers on swamp area
in Wain River. The bridges are separated as 18 spans on side A (north side of trace) and 19 spans on side B (south
side of toll trace). The design of Wain Bridge River uses various spans of standard bridges of 60ish m main spans
(PCT and SBG) highlighted in the red box and 40 – 40.5 m PCI Girder with all 19 spans of Wain River Bridge are
shown as follow on Figure 6:

IKN Balikpapan
Side A

Side B

Figure 6. Plan View of Wain River Standard Bridge (DED Review, 2022)
 Results of conducting 3 types of analysis to determine which design is better are below:
4.1 Design and Method of Work Analysis
To accommodate the passing boats under the bridge, the longest spans on the river will be compared between PCT and
SBG design. The 6 main spans are P5-P6, P10-P11, P14-P15 on Balikpapan direction and P5-P6, P11-P12, P15-P16
on IKN direction. Designs are modeled using Midas Civil software with appropriate loadings based on the standard.
PCT girder weight is 220 ton, SBG weight is 213 ton. PCI girder weight is 96 ton with 300 ton lifting capacity of
LG and 430 ton of weight. Both designs will use launching gantry for erection with slightly different steps for each.
Design comparisons are shown below:
a. Bulb Tee (PCT)
Bulb Tee girder with length of 60.8 m is chosen as the main span for crossing the Wain river with PCI girder ranging
from 40 m to 45 m are used for the approach span before connected to the Slab on Pile. Long section, cross section
and Bulb Tee girder detail are shown as follow on Figure 7:
IKN Balikpapan

SIDE A

SIDE B

Figure 7. (a) Long Section (Balikpapan and IKN Direction) and (b) Cross Section of Wain River Bridge with Bulb
Tee Main Span (Project Data, 2023)
The erection of all girders are done with a set of Launching Gantry for each direction to optimize time of girder
feeding and avoid disturbance to mangrove area on the ground.

b. Steel Box Girder (SBG)

Same with Bulb Tee design, the main spans are also on P5-P6, P10-P11, P14-P15 on Balikpapan direction and P5-
P6, P11-P12, P15-P16 on IKN direction highlighted by blue girder color. For every main span, 3 SBGs with span of
66 m are used making it 18 SBGs in total. The long section, plan view and cross section of SBG main span bridge
can be seen on Figure 8 below:
 Figure 8. (a) Plan View, (b) Long Section and (c) Cross Section of Steel Box Girder Spans of Wain River Bridge
(Project Data, 2023)

Same with Bulb Tee and other PIC girder spans, erection of all SBG and all precast concrete girders are done with a
set of Launching Gantry due to the crossing river of Wain.

4.2 Schedule Analysis

Schedules for main span girder erection using standard bridges design are show as follow on Table 1:
Table 1. Schedule of Wain River SBG Bridge (Author Data, 2022)
Duration (Day)
No Work Sequence
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Bulb Tee (PCT) Main Span
P5 - P6 Side A (7 Girders)
1 Launcher Setting from P4-P5
2 PCT Segment Mobilization & Setting 2 2 2 1
3 Strand Installation, Setting & Grouting
4 PCT Erection 2 2 3
P5 - P6 Side B (7 Girders)
5 Launcher Slide to Side B
6 PCT Segment Mobilization & Setting 2 2 2 1
7 Strand Installation, Setting & Grouting
8 PCT Erection 2 2 3
Steel Box Girder (SBG) Main Span
P5 - P6 Side A (3 Girders)
1 Launcher Setting from P4-P5
2 SBG Segment Mobilization & Setting 1 1 1
3 Internal Bracing Installation & Bolt Jointing
4 SBG Erection 1 1 1
P5 - P6 Side B (3 Girders)
5 Launcher Slide to Side B
6 SBG Segment Mobilization & Setting 1 1 1
7 Internal Bracing Installation & Bolt Jointing
8 SBG Erection 1 1 1
 According to the schedule analysis, the duration to finish PCT main span is faster by 4 days than SBG. With 3
main spans of each design, duration for PCT erection is 3 x 34 = 102 days while SBG erection is 3 x 38 = 114 days,
making SBG erection is slower by 11.76% due to its more complicated sequence of SBG segment & accessories
mobilization to site and also installation including the internal bracing inside the SBG and many bolt and plate
connections along the girder need extra attention.

4.3 Cost Analysis

Based on Directorate General of Highways’ General Specification 2018 Rev 2, there are 3 pay items affected by these
2 respective designs that are girder provision, girder installation and foundation. Each pay item are structured from 3
components which are man, material and machine. The 30 MPa reinforced concrete volume (m3) of pile cap, pier and
pierhead elements are considered similar and can be neglected. The cost of each method is explained in Table 1 below:

Table 2 Cost Comparison of Bulb Tee and Steel Box Girder (Author Data, 2023)

Pay Item Work Item Unit Unit Price (IDR) Volume Price (IDR)
Bulb Tee (PCT) 178,496,681,080
7.2.(11a) Provision of 60 m Bulb Tee (PCT) Girder Pcs 2,341,490,500 42 98,342,601,000
7.2.(11b) Installation of 60 m Bulb Tee (PCT) Girder Pcs 511,735,240 42 21,492,880,080
7.6.(19b) 1000 mm Diameter Boredpile m 5,800,000 10,114 58,661,200,000
Steel Box Girder (SBG) 250,282,920,000
7.4.(1b) Provision of Structural Steel Grade 345 MPa Kg 41,830 3,834,000 160,376,220,000
7.4.(2) Installation of Structural Steel Kg 11,750 3,834,000 45,049,500,000
7.6.(19b) 1000 mm Diameter Boredpile m 5,800,000 7,734 44,857,200,000
71,786,238,920
Deviation
40.22%

From the cost analysis, it can be clearly seen that provision and installation costs are higher by 63% and 109,6%
respectively in SBG than in Bulb Tee design while boredpile foundation cost is lower by 23,53% in SBG due to its
lighter girder weight withstood by substructure. In total, the cost to construct SBG bridge along with its accessories
(bolt connection, internal and external bracing) are more costly by 40,22% than Bulb Tee designed bridge.

4.4 Comparison Result

According to the conducted analysis, the result of comparison for each aspect is as follow on Table 3:

Table 3 Aspect Comparison of Bulb Tee and Steel Box Girder (Author Data, 2023)

Option
Aspect
1 2
Design Bulb Tee (PCT) Steel Box Girder (SBG)
Method Launching Gantry Launching Gantry
Duration (Day) 102 114
Cost (IDR) 178,496,681,080 250,282,920,000
Maintenance Minimum Routine

From the table above, Bulb Tee excels in 3 aspects that are fewer main span duration by 12 days or 11.76%, lower
cost by 71.79 billion IDR and minimum maintenance for concrete structure rather than SBG. SBG option has
disadvantages due to more complicated erection method, more expensive structural steel and routine maintenance of
coating for steel structure preservation.
 5. CONCLUSIONS
To conclude, from the analysis done, Bulb Tee and SBG designs are compared based on method, cost and duration
aspects. Using launching gantry for erection of both designs, Steel Box Girder (SBG) main spans cost 250 billion IDR
in 114 days with further extra cost for coating, while Bulb Tee cost 178.5 billion IDR in 102 days. From the result,
the special bridge design is more costly by 40.22% and time consuming by 11.67% to be implemented. Therefore,
Bulb Tee Girder is used to ensure Wain River Bridge can be functional by July 2024.

6. ACKNOWLEDGEMENTS
In writing this paper, the writers would give the utmost gratitude to Ministry of Public Works and Housing of
Indonesia, IKN Toll Road Segment Karangjoang – KKT Kariangau Project Team that consists of HK-Adhi-Abipraya
JV and PT Wahana Perencana Persada (WPP) for the opportunity, sharing of data and continuous discussion.

7. REFERENCES
[1] Detail Engineering Design (DED) of IKN Toll Road: Segment Karangjoang – KKT Kariangau.
[2] Hazairin, Widyaningsih, E. & Sakinah, N. N. 2022. Analisis Perbandingan Biaya Penggunaan Steel Box Girder
Berdasarkan Variasi Jumlah dan Dimensi (Studi Kasus: Jembatan Cimanuk Maktal). RekaRacana: Jurnal Teknik
Sipil, Maret 2022.
[1] Ismerianto, Nuh, S. M. & Syahrudin. METODE PELAKSANAAN STRUKTUR ATAS JEMBATAN TAYAN.
Program Studi Teknik Sipil Universitas Tanjungpura Pontianak. Pontianak.
[2] Izza, F. K., Praditama, M. A., Kirana, C. N., Setiyono, K. J., Sudarmono. (2019). KAJIAN WAKTU
PENYELESAIAN METODE CRANE DAN METODE LAUNCHER DALAM PELAKSANAAN ERECTION
GIRDER JEMBATAN (Studi Kasus : Pembangunan Jalan Tol Semarang – Solo Ruas Salatiga – Boyolali Sta
40+409 – Sta 71+785). Wahana TEKNIK SIPIL Vol. 24 No. 1 Juni 2019 47 – 59.
[3] Leo, E., A. M. H., Nur. (2017). KAJIAN EFISIENSI BULB-TEE SHAPE AND HALF SLAB GIRDER
DENGAN BLISTER TUNGGAL TERHADAP PC-I GIRDER. Jurnal Muara Sains, Teknologi, Kedokteran, dan
Ilmu Kesehatan Vol. 1, No. 1, April 2017: hlm 309-317.
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JEMBATAN PEREULAK, ACEH.
[5] Pohan and Abror N. 2008. Perencanaan Jembatan Steel Box Girder Berdasarkan AASHTO LRFD 1998 dan
Aplikasi Program Utrap 2.0. Repositori Institusi Universitas Sumatera Utara (RI-USU)
[6] New Capital City Toll Road Section 3A: Karangjoang – KKT Kariangau Project Data
[7] Sangaji, A., Azhar, M. (2020). PENGARUH BIAYA DAN WAKTU ERECTION STEEL BOX GIRDER (SBG)
JALAN TOL JAKARTA CIKAMPEK ELEVATED II RUAS SIMPANG SUSUN CIKUNIR KARAWANG
BARAT. Jurnal Sain dan Teknologi TEKNIK UTAMA, Edisi khusus, No 3, Oktober 2020
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