Subang Kelana Link Malaysia

Reuse of a modular launching gantry for the free-cantilever erection of the segments of a major viaduct

VSL adapted its modular launching gantry to carry out the segment erection.

Subang Kelana Jaya Link is an elevated highway in Subang Jaya, Selangor, Malaysia. At the time of construction it was the tallest elevated highway in the region. The project saw a return to action for an overhead launching gantry previously used on the MalaysiaSingapore Second Crossing Bridge, the Pakse Bridge in Laos and the Bayan Baru Viaduct in Penang. The gantry had first been used in 1995, before being sent to Laos in 1998 and returning to Malaysia for the Bayan Baru Viaduct in 2002. On the Subang Kelana Link, it was used to build the 34 spans of an elevated viaduct consisting of precast segmental twin-cell box girders. It was assembled at the Subang site in September 2006, after some Scope of works performed
Design and supply of the launching gantry Segment casting and erection Supply and installation of posttensioning

components had been modified, strengthened and upgraded to suit the latest project. VSL Malaysia in joint venture with precaster Projalma was awarded a contract for the casting and erection of 747 precast segments, weighing between 80t and 120t, and the supply and installation of 1,100t of posttensioning. The segments were cast in Ipoh approximately 200km from the Subang site - and delivered to a point directly beneath the gantry. The viaduct was built by the free-cantilever method and segments were lifted up in pairs using VSLs strand lifting units. VSL JVs scope of work included provision of the casting yard at Jalan Gopeng, Ipoh, including steel moulds, the straddle carrier system, reinforcement jigs and the bar bending yard for the 747 segments. The scope also covered provision of the storage yard to store and cure the segments, the supply of rebar, concrete and prestressing components, and the trailer to deliver the segments to site.

The greatest challenge faced was that the segments were 20.34m wide with rather thin concrete sections. Vibrations during transportation could cause cracking and so most required fitting with temporary props before setting out on the journey. Travel was at low speed to minimise vibration. The segments adjacent to the pier had to be strengthened by temporary strutting and increases to the bottom slab thickness to allow nailing of deck to pier during cantilever construction.

Falsework was used in erecting the end spans.

ID 2557

This ensured that the gantry loads could be transferred to the crosshead. For the post-tensioning, VSL supplied and installed approximately 1,100t of internal and external tendons, as well as providing specific cast-in components for incorporation into the segments. Segment erection works covered the design and supply of the launching girder, the falsework to support out of balance part of side

OWNER Malaysias public works department ENGINEER Maunsell, Sharma & Zakaria (MSZ) MAIN CONTRACTOR Ahmed Zaki Sdn. Bhd (ASZSB) VSL ENTITY VSL Malaysia in JV with Projalma DATE 2006

The segments had to be carefully prepared for transport.

spans and provision of all labour and supervision for the launching girder operation and the falsework installation and dismantling. VSL was also responsible for all aspects of the construction engineering, including the design of temporary stressing for segment erection, pre-camber and alignment calculations, preparation of the erection kinematics and calculation of the stressing elongation for the post-tensioning tendons.

Casting of segments in Projalma's casting yard approximately 200km from the site.

Remember to comment the picture

Edited 2012

Deck access at pier locations

www.vsl.com

ID 2557