Experiences on Construction of Concrete

Pavements

PAKEJ 3 : GUA MUSANG - KG. RELONG (68KM)

PAKEJ 1 : KUALA KRAI - JAMBATAN SG. LAKIT (51KM)

PAKEJ 2 : JAMBATAN SG. LAKIT - GUA MUSANG (63KM)

PAKEJ 4 : KG. RELONG - RAUB (56KM)

PAKEJ 5 : RAUB - BENTONG (60KM)

PAKEJ 6 : BENTONG - SIMPANG PELANGAI (53KM)

KOTA BHARU

GUA MUSANG

KUALA LIPIS

RAUB

BENTONG

SIMPANG PELANGAI

KOTA BHARU - KUALA KRAI (71KM)

KUALA KRAI

KUALA KRAI – SIMPANG PELANGAI (368 km)

KOTA BHARU - KUALA KRAI

(71 km)

KE

LA

NTA

N

20

2 k

m

PA

HA

NG

23

7 k

m

MENTARA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

TYPES OF

CONCRETE

PAVEMENT

Jointed Plain

Concrete

Pavement

(JPCP)

Jointed

Reinforced

Concrete

Pavement

(JRCP)

Continuously

Reinforced

Concrete

Pavement

(CRCP)

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

DATA COLLECTION

Concrete Pavement History in Malaysia

PLUS HIGHWAY

NKVE

Concrete Pavement

Visit

SAKATA, JAPAN

SEMERANG, INDONESIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

PLUS HIGHWAY

(TAPAH)

PLUS HIGHWAY

(BIDOR)

JABATAN KERJA RAYA

MALAYSIA

SMOOTHNESS

SKID RESISTANE

CO

NC

RE

TE

PA

VE

ME

NT

E

NG

INE

ER

ING

DESIGN

MATERIAL

CONSTRUCTION

ENSURE

SATISFACTORY

PERFORMANCE

OVER THE

PROJECTED

LIFE OF

PAVEMENT

PAVEMENT

OBJECTIVE

AVOID

PAVEMENT

DISTRESS

CRACKING

JOINT DEFICIENCIES

SURFACE DEFECT

MISCELLANEOUS DISTRESS

JABATAN KERJA RAYA

MALAYSIA

REAM GL 7/2004 : Design of Plain Concrete Pavement

Road Note 29

Method

Empirical approach based on ESAL

AASHTO

Method

Empirical

approach based

on ESAL

Portland Cement

Association (PCA)

Method

Mechanistic Approach

based on axle load

distribution

JABATAN KERJA RAYA

MALAYSIA

CRCP

ADVANTAGES

DIS-ADVANTAGES

• LONG DESIGN LIFE UP TO 40 YEARS

• HEAVY DUTY PAVEMENT

• POSSIBLE TO PRODUCE SMOOTH RIDING SURFACE

• HIGH FRICTION CHARACTERISTIC

• LOWEST MAINTENANCE

• HIGHER CAPACITY TO ABSORB SETTLEMENT

• LOWEST LIFE DISTRUPTION DURINGSERVICE

• LOWEST MAINTENANCE WORKER EXPOSURE DURING

SERVICE

• ABILITY TO ADD FUTURE AC SURFACING

• NO SAW CUTTING REQUIRED TO FORM TRANVERSE JOINTS

• GOOD HYDRO-PLANING CONTROL PROPERTIES

• DIFFICULT TO REPAIR

• REQUIRES HIGHEST LEVEL OF QUALITY CONTROL

• RELATIVELY HIGHER INITIAL COST

JABATAN KERJA RAYA

MALAYSIA

CRCP DIFFICULT

TO CONSTRUCT

AT

Road Gradient

more than 6%

Tight Horizontal

Curve

Junction and

Interchange

▪ Constraint of Paving Machine

▪ Super-elevation▪ Irregular Shapes

JABATAN KERJA RAYA

MALAYSIA

SELECTION OF 1ST CONCRETE ROAD PROJECT▪ SECTION 3H – 7.5 KM OF CRCP FROM 12.0 KM OF ROAD

▪ RELATIVELY FLAT AREA IN FELDATELANG

▪ BIG HORIZONTAL CURVE

▪ NO INVOLVEMENT OF JUNCTION/INTERCHANGE

JABATAN KERJA RAYA

MALAYSIA

3HST

2.89

km

CRCP

Bridge No

1

VBC No 1

JABATAN KERJA RAYA

MALAYSIA

CONSTRUCTION

CONSTRUCTION

COMPLETED–APR 18

COMPLETED–JAN 14

COMPLETED–JAN 14

COMPLETED–JUL 15

COMPLETED–JUL 15

COMPLETED–DIS 16

RMK 11

RMK 11

RMK 11

EXISTING ROAD

107KM

TOTAL CRCP = 10.39KM

PEMBINAAN KERY SDN.

BHD.

JW CRUICKSHANK

PWD PROJECT

TEAM

PRINCIPAL

CONSULTANT

CRCP

TECHNICAL

ADVISOR

MACHINE

SUPLIER

MAIN

CONTRACTOR

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

1. Project Name: Seksyen 3H : Felda Telang ke Kg. Kechur, Pahang

Skop Tambahan : Kg. Kechur ke Kg. Seberang Jelai,

Pahang

2. Superinteing Officer (S.O)

Pengurus Besar Kanan Pembinaan

Pasukan Projek Pembangunan Wilayah Ekonomi Pantai

Timur (ECER)

Cawangan Jalan

Ibu Pejabat JKR Malaysia

3. Consultant Iktisas Ingenieurs Sdn Bhd

4. Contractor Pembinaan Kery Sdn Bhd

5. Scope of Works Seksyen 3H : Felda Telang

ke Kg. Kechur, Pahang

Skop Tambahan : Kg.

Kechur ke Kg. Seberang

Jelai, Pahang

11.9 km of 4-lane dual

carriageway road

3.85 km of 4-lane dual carriageway road

7.5 km of CRCP 2.89 km of CRCP

6. Contract Duration 36 months 24 months

7. Start Date 15 June 2011 8 October 2014

8. Completion Date 7 October 2016

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

SEARCHING FORSPECIALIST

IDENTIFIED NIPPON ROADSDN BHD & NNF SDN BHD

NIPPON ROAD SHORTLISTED

NIPPON ROAD PULLED OUT AT LAST MOMENT

MAIN-CONTRACTOR HADNO CHOICE TO DO IT ALONE

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

➢ CRCP construction is unique

➢ Roadworks under CRCP layer shall be thoroughly supervised as well. The

works include:

❑ Road Formation

▪ prepared as normally done for flexible pavement

▪ proof rolling is carried out

❑ Base Course

▪ base courses which consist of 250mm Crushed aggregate and 40mm

ACWC

▪ inspection and testing of these works are the same with other road works.

❑ End Terminal Anchor Block

▪ Anchor blocks as per drawing

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Placement of Reinforcement

▪ reinforcement as per drawing

▪ laps shall be placed at staggered position

▪ Reinforcement shall be watered

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Concrete Production at Batching Plant

▪ Control of Concrete Temperature

- Aggregate

- Chilled Water

- Fly Ash

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Cube & Flexural Tests

▪ Cube and flexural tests - 7 days, 28 days and 56 days

▪ establish project correlation chart

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Fresh Concrete

▪ Transport with tipper trucks were used instead

▪ Planning transportation time

▪ Emergency joint in CRCP

▪ Container with moving capability

▪ Slump test

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Paving Operation

▪ Paving operations using Wirtgen SP 500 machine

▪ Overall speed of paving operation is approximately 1 m/minute

▪ Control speed and vibrators

▪ Maintain path and level

▪ String line & censor control CRCP Level▪ Vibrators ensure full concrete compaction

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Texture and Curing Machine (TCM)

▪ Create surface texture roughness

▪ Curing compound

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Movable Shaded Cover

▪ protect freshly cured concrete surface

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ End of The Day Construction Joint

▪ The joint shall be constructed at the end of the day’s operation.

End of the Day Construction Joint shall be done manually.

JABATAN KERJA RAYA

MALAYSIA

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Inspection and Testing of CRCP

▪ Inspection of CRCP thickness regularly checked.

Checking of CRCP thickness

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Texture Depth

▪ The finished pavement surface shall be tested using Sand Path method.

Sand Path Method performed by IKRAM

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Coring Test.

▪ Samples at random locations were cored to check the density of the CRCP

panel. Visual inspection of samples was done to check on aggregate

distribution and voids.

Cores appear reasonable uniform in aggregate distribution

and colours

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Crack Spacing and Crack Width

▪ spacing and depth must be controlled

Crack Spacing and crack width appear to be normal

JABATAN KERJA RAYA

MALAYSIA

Surface of CRCP during crack spacing and crack width checking

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ International Roughness Index (IRI)

▪ international roughness index as a quantitative measure of smoothness

IRI result shown 98% of lane IRI complied with JKR

JABATAN KERJA RAYA

MALAYSIA

QUALITY CONTROL

❑ Skid resistance

▪ Important pavement evaluation

JABATAN KERJA RAYA

MALAYSIA

PROVIDE TRAINING FOR WORKERS

It is anticipated that more CRCP shall be built in the near future. The main

contractor take the opportunity to train more workers to familiarise with the CRCP

construction.

JABATAN KERJA RAYA

MALAYSIA

CRCP Thickness❑ Thickness of CRCP much

lower than 230mm

JABATAN KERJA RAYA

MALAYSIA

Uniformity of Subgrade Support.

❑ CRCP Settlement

Location of CRCP settlement (Red Circle)

JABATAN KERJA RAYA

MALAYSIA

Installation of Raised Pavement Marker (RPM)

Some of the RPM heads that have been installed were detached from their

body due to impact with vehicle tires.