Presentation about Ircon's SGEDT project in Malaysia.

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This presentation was presented in Indian Railway's IPWE Seminar in January 2013 at Chennai. It depicts the innovations and new Technologies (in the context of Indian Railways) adopted on the project, and the various technical issues, and how they were dealt with.

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Presentation about Ircon's SGEDT project in Malaysia.

  1. 1. INNOVATIVE CONSTRUCTION SOLUTIONS IN RAILWAY DOUBLING PROJECT SHARING MALAYSIAN EXPERIENCE -Hitesh Khanna
  2. 2. ME’s VISIT TO SGEDT / MLY. HON’BLE ME DESIRED TO SHARE THE EXPERIENCE ON A MUCH WIDER FORUM. 2
  3. 3. Gemas Tampin Rembau Senawang Sg. Gadut Seremban Batang Melaka Legend : Existing Alignment New Major Realignment Proposed station CH : 461.234 CH : 469.275 CH : 483.750 CH : 509.675 CH : 535.150 CH : 562.270 CH : 465.300 3 STATION
  4. 4. PROJECT SUMMARY 4 COMMENCEMENT DATE 18th January 2008 ORIGINAL CONTRACT PERIOD Seremban to Sg. Gadut 30 months i.e., 17th July 2010 Sg Gadut to Gemas 48 months i.e., 17th January 2012 REVISED CONTRACT COMPLETION Seremban to Sg. Gadut 30th April 2011 (Completed & Handedover) Sg Gadut to Gemas 31st July 2013 CONTRACT SUM RM 3,450 million PROJECTED CONTRACT SUM RM 3,367 million OVERALL PHYSICAL PROGRESS 94.00% SCHEDULE PHYSICAL PROGRESS 93.89% AHEAD (+) / DELAY (-) +0.11% ahead
  5. 5. PROJECT FEATURES • Curve Radius min. 1268 mts. Design Speed of 160 kmph (M.G.) – MX Rail – 29 Criss Crosses • Hydrology Review through HACRAS Modelling Software • Total Grade Separation – 13 ROBs, 8 VBCs, 8 MPOBs • Integrated Pier / PSC Girders – 15% Cost Savings – Bearing Less, Maintenance Free • Detention Pond up stream of Bridges to Buffer Flash Floods • Project FBW to weld 25 mts. Rail to 150 mts. Panel • Old Hoppers Modifications For Central Discharge. 5 • Maximum Design Speed:160 km/hr • Maximum Operating Speed:140 km/hr • Maximum Operating Speed for freight train:90 km/hr • Maximum Vertical Gradient:1% • Minimum track spacing:4.2m • Maximum Axel Load:20 tonnes • Weldable CMS X-ings • Through CWR • Through FBW (AT @ T/Outs, Destressing) • Bidirectional Automatic Signalling, ATP, SSI with Hot Stand by, CTC.
  6. 6. PHASE-2PHASE-1 COMMISSIONED PROPOSED ALIGNMENT Structure Total Viaduct 03 number ( 2.2km) ROB 14 nos RUB 08 nos BRV 35 nos Culvert 124 nos Linear Waterway 2000 m
  7. 7. SCHEMATIC LINE DIAGRAM OF TRACK WORK PROGRESS DN LINE UP LINE Legend: Completed (184 KM) In progress (32 KM) TDC: 30.12.12 TDC: 15.02.13 Length:8.04 Km Length:14.9 Km Length:24.8 Km Length:21.9 Km Length:27.3 Km Ch.461.234 Ch.564.000
  8. 8. TRADE WISE PROGRESS MONITORING 8 TRADES OF WORKS TOTAL WORK PROGRESS AS ON 02.11.2012 CONSTRUCTION (INFRA WORKS) 98.54% PACKAGE INF 1A (Sec. 1A : CH. 461.234 - CH. 472.500) 100.00% PACKAGE INF 1B (Sec. 1B : CH. 472.500 - CH. 500.600) 99.90% PACKAGE INF 2 (Sec. 2A : CH. 500.600 - CH. 506.558) 97.30% PACKAGE INF 3 (Sec. 2B : CH. 502.400 - CH. 535.500) 99.88% PACKAGE INF 4 (Sec. 3 : CH. 535.500 - CH. 563.496) 99.83% PACKAGE INF 5 (Station Buildings & Platforms) 96.82% PACKAGE INF 6 (TRACK WORK) 97.45% PACKAGE INF 7 (MISC. WORKS-FENCING & GEMAS FACILITIES) 78.11% INSTALLATION OF SYSTEM WORKS 59.70% PACKAGE SYS 1 (ELECTRICAL WORKS) 52.42% PACKAGE SYS 2 (SIGNALLING) 61.81% PACKAGE SYS 2 (COMMUNICATION) 78.97% TESTING 57.18% TOTAL 94.00%
  9. 9. 9
  10. 10. GEO-TECH CONDITIONS AND SOLUTIONS • Malaysia: – Very Poor Soil Conditions. • Peat, Marine Clay, Organic Soils or Lime Stone Cavities • Geo-tech solutions aim at ZERO Formation settlement despite poor Soil Conditions • Ground Improvement Cost May be as much as 20% of the Infra Project Cost – Stone Columns – RE walls used in Rly. Bridge Approaches! – Soli Nails and Crib Walls are very common in Cutting – Geotextile sandwitched between sand layers is a standard, even for Existing Track Rehabilitation • PVD • Geo-wrapping on Temporary Railway Banks • Geo Cells
  11. 11. Typical Track Structure Sub-Ballast Sub-Grade Ballast Psc Sleeper Fittings (Pandrol fastclip) Rails (UIC 54) SandandGeotextile 300 mm 300 mm 100 mm 600 mm
  12. 12. TYPICAL CROSS SECTION DN LINE UP LINE DN LINE UP LINE
  13. 13. 13 HIGH FORMATION / CUTTINGS • HIGH EMBANKMENT IN COUNTRY SIDE • HIGH CUTTING • 3mt BERM EVERY 6mt HEIGHT • BERM DRAIN, CASCADING DRAIN, TOE SIDE DRAIN
  14. 14. • RAIL HANDLING CRANE EQUPIED DMT • STEEL CHEQURED PLATE TROLLEY PATH WAY 14 NEW SOLUTIONS
  15. 15. 15 MPOB (MOTOR CYCLE/ PEDESTRAIN BRIDGE)
  16. 16. BALLAST BOX FOR BOTTOM BALLST SPREADING • EVEN 150mm BOTTOM BALLASTING • LESS MANUAL LABOUR • BETTER INITIAL TRACK GEOMETRY ON LAYING SLEEPERS WITH SLEEPER LAYING BEAM 16
  17. 17. STONE COLUMNS FOR WEAK SOILS • FASTER CONSOLIDATION AND STRENGTH MOBILIZATION: – PROVIDES A DRAINAGE PATH THROUGH ORGANIC PEAT / MARINE CLAY – PROVIDES A SUPPORT COLUMN 17
  18. 18. Existing track 23.1 m ROB 09 ABUTMENT B MATIER’S ARCH Longitudinal profile of proposed road • LENGTH OF MATIER’S ARCH CONSTRUCTED IS 62.5m AT A TOAT COST OF RM 1.24 MILLION. RATE PER METER OF MATIER’S ARCH IS RM19,840. • MATIER’S ARCH AT ROB 09 WAS COMPLETED WITHIN THREE MONTHS. MATIER’S ARCH AT ROB 09
  19. 19. MATIER’S ARCH AT ROB 09
  20. 20. MATIER’S ARCH AT ROB 09
  21. 21. SOIL NAIL SUPPORTED CUTTING • WHEN FLAT SLOPES ARE NOT POSSIBLE – CONTINUOUS HILL SLOPES AT 1 FOS, MINIMAL MUCK GENERATION – BUILT UP AREA AT TOP, MACHINE ACCESS AT TOP MAY NOT BE POSSIBLE – TOP DOWN EXCAVATION AS YOU PROTECT 21
  22. 22. Pedestrian Bridge ML Main Building Secondary Building SENAWANG HALT
  23. 23. Viaduct Main Building DN UP SUNGAI GADUT STATION
  24. 24. Pedestrian Bridge DN Loop UP LoopML Main BuildingSecondary Building REMBAU STATION
  25. 25. 30 FIRST TRIAL TRAIN ACROSS PIR PANJAL

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