CASE STUDY CMA544 CIVIL WORKS CONSTRUCTION (TUNNEL)

Bsc. (HONS) CONSTRUCTION MANAGEMENT (AP246)
FACULTY ARCHITECTURAL, PLANNING AND SURVEYING (FSPU)

SHAH ALAM CAMPUS

Project details Segmental Lining
System
Case Study : Smart Tunnel
Location : Kuala Lumpur, Malaysia Segmental concrete tunnel liners
Contractor : MMC Corp Berhad - Gamuda Berhad JV are prefabricated structural support
Consulting Engineer : Sepakat Setia Perunding Sdn Bhd and Mott MacDonald of UK pieces that are combined to form a
Dimension : 11.5km length x 13.2m diameter complete tube along tunnel
passageways. The segments are
STORMWATER MANAGEMENT created in manufacturing plants for
AND ROAD TUNNEL (SMART) specific tunnel projects. These
materials are commonly used in
Flood and Traffic Congestion Solutions For KL City Centre very large trenchless construction
operations around the world.
Figure 1: SMART Tunnel logo
Figure 2: Precast segmented lining was used in SMART Tunnel
Background : What is SMART Tunnel?
Precast segmental lining
SMART is an acronym for Stormwater Management and Road Tunnel, a project under the federal
government initiated to alleviate the flooding problem in the city centre of Kuala Lumpur. The Each tunnel ring is completed by joining together a
project is implemented through a joint venture pact between MMC Corp Berhad and Gamuda
Berhad with the Department of Irrigation And Drainage Malaysia and the Malaysian Highway number of the precast segments (varies from 4 to
Authority as the executing government agencies.
10, depending on the tunnel geometry and other
Studies had indicated that the critical stretch of Sungai Klang between Sg Klang /Sg Ampang
confluence and Sg Gombak/ Sg Klang confluence to be flood prone areas and the fact that the river factors) and locking the arrangement in position
is further constrained by the Jalan Tun Perak Bridge (near Masjid Jamek) which is low, has resulted
in the surrounding areas to experience floods. The SMART Tunnel system will be able to divert using a trapezoidal key segment. When installed in
large volumes of flood water from entering this critical stretch via a holding pond, bypass tunnel and
storage reservoir. This will reduce the flood water level at the Jalan Tun Perak Bridge, preventing the tunnel the set of segments fit together naturally
spillover.
due to their shape and moulding pattern and are
Other benefits of SMART
joined together using specialized connecting
The Stormwater Management and Road Tunnel (SMART) project was incepted by the project
proponent, namely MMC Corp Berhad-Gamuda Berhad Joint Venture, primarily to mitigate the devices at the circumferential and radial joints as
recurring floods in the city of Kuala Lumpur; The financial, business and commercial hub of
Malaysia. However, at the design stage of SMART, the dual purpose concept was born from the per the design provided. These devices not only fix
ingenuity of the project proponents and the motorway tunnel was integrated into the system to
relieve traffic congestion at the main Southern Gateway to the city centre. the segmental arrangement but also play a key role

Civil Works Construction : SMART Tunnel, Kuala Lumpur. in the seismic performance of the tunnel. Figure 3: Typical precast segmental lining

Characteristics

The underground tunnel liners given a design life of usually 120 years are expected to demonstrate
the following:

Structural capacity – including static, seismic and fire
Water-tightness
Manoeuvrability
Ease of installation
Settlement control and seismic stability

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The construction methods of SMART Tunnel project consists of 95% using the Tunnel Boring Advantages of Using TBM
Machine (TBM) and 5% using cut and cover method. Cut and cover method was widely used
around the world before TBM was invented. The first modern TBM machine was invented by Higher advance rates
James S. Robbins for the Oahe Dam project in the United States of America in 1950s. His design One of the significant advantages of TBM includes high advance rates or the excavation rate which
and experiments bought to light the two basic concepts of TBMs that are carried through to today’s is calculated on the basis of shift time and the total distance mined.
machinery. Based on these two concepts, all modern-day TBMs were invented. Continuous operations
TBM is a giant that can work continuously without any significant delay thereby, increasing the
What is TBM? advance rate.
Less rock damage
A tunnel boring machine (TBM) is a piece of equipment designed to bore circular tunnels TBM causes less rock damage as compared to the other drilling machines that decrease the over
through dense, hard rock, relatively soft sand or any substrate of any hardness between the two. break value.
They come in various sizes capable of creating bores with diameters as small as 1 meter and as
large as 13 meter. SMART Tunnel used slurry shield type TBM. This type is used when the Main Components of TBM
ground conditions are granular with very high water pressure. Hydrostatic pressure is applied on
the excavation by filling the cutter head with pressurized slurry, which is also used as a Cutter head
transporting medium when mixed with the excavated material before it is pumped to the cutter Breaks and grinds rock by rotating disc cutter.
head back and then to a separation plant outside the tunnel. Refer 'How Does a TBM Work?' in Conveyor belt
the next chapter. Moves excavated rock from the cutter head back
past for the working platform for removal.
The SMART Tunnel uses the slurry shield TBM for the boring of the tunnel. The tunnel length is Working platform
approximately 9.7km in length and diameter is around 11.83m (inner diameter). There are two (2) Allows workers to guide the TBM
TBMs used in this project, named as Tuah and Gemilang.
Figure 5 : Tunnel Boring Machine (TBM)
Tuah was the first TBM for this project, delivered to Malaysia on 4th of June 2004 from
manufacturer in Germany named Herrenknecht AG. Tuah was assigned for the tunneling works at How Does a TBM Work?
the northbound. The 2nd TBM, Gemilang was delivered at later stage and was used at
southbound. These 2 machines completed 95% of the tunneling works while remaining 5% were Now that we know what a TBM is and it’s types. Let’s talk about how a Tunnel Boring Machine
using cut and cover method. works. The cutter head on the TBM rotates and thrusts into the rock surface that lies ahead of it.
This thrust causes the cutting disc tools to break the rocks. The grippers / braces develop the
Cut and cover method reaction to applied thrust and torque forces with the help of anchoring.

Cut and cover is the oldest method Stage of TBM Construction
of tunneling. The basic concept
involves the digging of a trench, the Stage 1 - Excavate the launching shaft and the retrieve shaft.
construction of a tunnel, and then Satge 2 - Assemble the TBM at the launching shaft.
returning the surface to its original Stage 3 - Cut and excavate the tunnel using TBM.
state. This technique usually Stage 4 - The TBM finally arrive at the retrieve shaft dan ready to be dismantled.
reserved for relatively shallow
tunnels. Retrieve shaft Launching shaft

Figure 4 : Cut and cover method TBM

Civil Works Construction : SMART Tunnel, Kuala Lumpur. Figure 6 : Tunneling process using TBM

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4 4
The main features of SMART Tunnel
Soil condition : Karstic limestone and alluvium
1 Automated flood 4 First responder 7 Radio re-broadcasting
Part of the challenge was dealing with the soil condition of Kuala Lumpur which mostly consists of control gates vehicle (FRV) services
karstic limestone and alluvium. Limestone, also known as chalk or calcium carbonate, is a soft rock
that dissolves in water. As rainwater seeps into the rock, it slowly erodes. Karstic limestone has a 2 Cross Passage 5 Air quality monitoring 8 Medical response
highly variable profile caused by weathering which creates pinnacles, troughs, overhangs, floaters equipment (AQME) vehicle (MRV)
and caverns. In Kuala Lumpur these are filled with water and very weak soil. If tunnelling disturbs
the equilibrium of water pressure in channel and caverns it can create large sinkholes in the 3 Ventilation / 6 SCADA monitoring 9 Alam Flora road
ground surface. Few sinkhole incidents happend during the construction process. escape shafts & surveillance sweeper

Sinkhole Dual-function tunnel reduces traffic jams

Sinkhole at Jalan Bukit Bintang (refer figure 7), Kuala SMART Tunnel is the world-first dual-purpose tunnel diverts flood waters away from the confluence
Lumpur caused by the pressurised bentonite slurry leaking of the two rivers running through Kuala Lumpur while its middle 3km section doubles up as a two-
to the surface. Soil type of this underground area is mostly deck motorway to relieve traffic congestion at the main southern gateway into the city centre.
karstic limestone. The main contractor for this project, MMC- Detailed studies led to the concept of a tunnel for stormwater storage, and then at design stage
Gamuda Berhad later upgrade the TBM from slurry shield came the novel idea of using it to tackle traffic congestion.
type to variable density type to avoid sinkhole incident from
recur. Diverted flood water

Figure7 : Sinkhole incident at Jalan Bukit Bintang, Kuala Lumpur. SMART works on a three-mode system. Mode one operates under normal conditions or when
rainfall is low such that no water needs to be diverted into the tunnel. Moderate storms activate
Lesson from SMART Tunnel mode two. This diverts flood water into a bypass tunnel in the lower section of the motorway
tunnel which remains open to traffic. During the once or twice yearly heavy storms, a switch is
Dewatering can cause sinkholes far away from the excavation site made to mode three when the tunnel is closed and the full tunnel section with a combined
EPB (earth pressure balance) machines are inappropriate because it cannot anticipate capacity of 3 million m3 becomes available to divert the dramatically increased flows. Extensive
sinkholes incident monitoring stations ensure sufficient time is allocated to allow the last vehicle to exit before the
Slurry shield type TBMs are inadequate automated water-tight gates open.

A revolutionary new design of TBM based on SMART experience Air Quality Monitoring Equipment (AQME)

Upgrade slurry shield type TBM to variable density TBM There are 38 sets of AQME monitoring carbon monoxide (CO), nitrogen monoxide (NO) and
Able to excavate in limestone areas particulate. They are cited in the upper and lower decks. The ventilation system will be operated
Easily convertible from slurry to EPB mode automatically based on the air quality monitoring system outputs. The ventilation will provide for
Greater efficiency in dealing with karstic limestone the supply and extract of air for both the upper and lower road decks and consists of 4 nos. of
Reduction in settlement / sinkholes ventilation shafts each containing 8 set of fans. This system will ensure sufficient fresh air intake.

4Reduction in surface grouting 4
1.Stormwater Management and Road Tunnel (SMART) (n.d). SMART. What is smart.
The construction of SMART Tunnel gives a lot of benefits to our country especially during flood https://smarttunnel.com.my/operational-modes/
disaster in 2022. This project set a very high standard for engineering works, recognized by the
world as one of the engineering marvels. SMART Tunnel demonstrates how an effective 2. Road Traffic Technology (n.d). SMART (Stormwater Management And Road Tunnel), Kuala Lumpur, Malaysia.
engineering works can creates a better atmosphere not only to the end users but also to the https://www.roadtraffic-technology.com/projects/smart/
environment.
3. M. Kannapiran, Ram Kumar (2005). A Study and Evaluation on SMART Project.
Civil Works Construction : SMART Tunnel, Kuala Lumpur. Malaysiahttps://eprints.usq.edu.au/617/1/RamKumarM.KANNAPIRAN-2005.pdf

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