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A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY

6.2

PRE CONSTRUCTION COST OF SENAI DESARU EXPRESSWAY

Table 6.1: Cost breakdown of pre - construction


DESCRIPTION

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

BRIDGE
(RM)

Traffic Study

2,539,200.00

610,677.00

480,924.00

376,817.00

1,070,782.00

Topographical and
Detail Survey

11,109,000.00

2,671,714.00

2,104,044.00

1,648,577.00

4,684,665.00

Soil Investigation

7,935,000.00

1,908,368.00

1,502,889.00

1,177,554.00

3,346,189.00

EIA Report

5,078,400.00

1,221,355.00

961,848.00

753,636.00

2,141,561.00

Safety Audit

2,856,600.00

687,012.00

541,040.00

423,920.00

1,204,628.00

Laboratory

2,221,800.00

534,342.00

420,808.00

329,717.00

936,933.00

TOTAL

31,740,000.00

7,633,468.00

6,011,553.00

4,710,221.00

13,384,758.00

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PRE - CONSTRUCTION COST (RM )

25
16
Traffic Study

Topograpical and Detail Survey

Soil Investigation

EIA Report
9

30

7
8

Chart 6.1

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Safety Audit

Laboratory

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Based on the chart 6.1, we can see the higher division of overall chart for preconstruction cost is the Topographical and Detail Survey that 30% from overall pre
construction cost or RM 11,109,000.00. Its main important element in pre-construction
cost because its to determine an accurate mapping of any terrain, in any environment.
Furthermore, it is used in the planning and design stage of the structure the highway.
Besides that, it is used in many works on pre-construction like to determine the
contours of the land, the terrain design as well as the high and lower water stage. In
summary, the extent to which data is already available is an important factor in
determining what field operations have to be performed
We also can see the second important role in the pre- construction stage on
this project is soil investigation. Based on the chart, soil investigation cost show RM
7,935,000.00 or 25% overall pre construction cost. Soil investigation also important
used for detected and identify bearing capacity of the soil and natured of the soil for
constructed the highway can be obtained. Soil Investigation cost more expensive in
Bridge construction because to determine changes in condition of the site such as the
piling works.
Other Than that, we also can see the cost for the element in the preconstruction cost like traffic study; safety audit and laboratory are around RM 2.2 Million
to RM 2.8 Million or 7% to 8% of the overall pre construction cost. Those elements are
not many contribute in pre-construction cost for the all package construction includes
the bridge construction.

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6.3 PROJECT MANAGEMENT COST

DESCRIPTION

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

BRIDGE
(RM)

16,769,300.00

4,033,016.00

3,176,105.00

2,488,564.00

7,071,615.00

Project
Management
Consultant

26,830,880.00

6,452,826.00

5,081,768.00

3,981,702.00

11,314,584.00

Construction
Supervision

13,415,440.00

3,226,413.00

2,540,885.00

1,990,852.00

5,657,290.00

Performance Bond

6,707,720.00

1,613,206.00

1,270,442.00

995,427.00

2,828,645.00

3,353,860.00

806,603.00

635,223.00

497,712.00

1,414,322.00

67,077,200.00

16,132,064.00

12,704,423.00

9,954,257.00

28,286,456.00

Design Consultancy

Levy To CIDB

TOTAL

Table 6.2: Cost Breakdown of project management cost in Senai Desaru Expressway

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Project Management Cost ( RM )

Design Consultancy

Construction
Supervision
10%
25%

40%

Project Mangement Consultant

Performance Bond and Insurance


20%
5%

Chart 6.2

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Levy to CIDB

A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY


Based on the chart 6.2, as we can see the higher cost used in project
management cost for this project is by the element project management consultants
which is RM 26,830,880.00 or 40% from all project management cost. Project
management consultancy important to advise training and project management
services for the project leader and team members. It is also important to ensure the
project run smoothly and effectively. For this project, the higher cost for project
management consultancy is RM 11,314,584.00 for bridge construction.
Next, the second important in project management is design consultancy,
which is was contribute RM 16,769,300.00 or 25% from overall cost in project
management for this project. Design consultancy also important role for project
management works include construction supervision which is RM 13,415,440.00, which
play an important role in construction management to monitor and determine the budget
time schedule and the quality of the construction project.
Lastly, Performance bond and insurance was contribute 10% and cost of levy
to CIDB was contribute 3% which is RM 6,707,720.00 and RM 3,353,860.00 for all
package and bridge construction.

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6.4 MAIN CIVIL WORK

Table 6.3: Cost Breakdown of Main Civil Work cost in Senai Desaru Expressway
DESCRIPTION

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

BRIDGE
(RM)

68,558,400.00

16,488,295.00

12,984,960.00

10,174,066.00

28,911,079.00

21,424,500.00

5,152,592.00

4,057,800.00

3,179,397.00

9,034,711.00

Earthworks and Soil


Stabilization Works

205,675,200.00

49,464,885.00

38,954,882.00

30,522,202.00

86,733,231.00

Rock Excavation

25,709,400.00

9,274,666.00

7,304,041.00

9,130,693.00

Drainage Works

42,849,000.00

10,305,184.00

8,115,600.00

6,358,793.00

18,069,423.00

Pavement Works

137,116,800.00

32,976,590.00

25,969,921.00

20,348,135.00

57,822,154.00

DESCRIPTION

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

BRIDGE
(RM)

General and
Preliminaries
Site Clearance

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Road Furniture

29,994,300.00

7,213,629.00

5,680,920.00

4,451,155.00

12,648,596.00

Utilities

34,279,200.00

8,244,147.00

6,492,480.00

5,087,035.00

14,455,538.00

RC Bridge

94,267,800.00

94,267,800.00

Cabling Works

51,418,800.00

12,366,221.00

9,738,720.00

7,630,552.00

21,683,307.00

Landscaping Works

42,849,000.00

14,427,258.00

16,231,201.00

12,190,541.00

Interchanges

102,837,600.00

41,220,738.00

32,462,402.00

29,154,460.00

856,980,000.00

207,134,205.00

167,992,927.00

138,227,029.00

343,625,839.00

Relocation of Public

Street Lighting and

TOTAL

Bar Chart 6.3

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Percentage From Total Cost Main Civil Works R


30

25

20
Total Main Civil Cost RM 856,980,000
15

10

The Bar Charts show the percentage from the total costs of main civil works for Senai
Desaru Expressway, which is the total RM 856,980,000.00. The bar charts clearly show
the highest rating is in item earthwork and soil stabilization which is 24% for RM
205,675,200.00 from the total main civil cost. The cost of earthwork and soil
stabilization was expensive because it is use for remove large volumes of
unsatisfactory soils and replaces them with suitable material, particularly if it is to be
imported. Furthermore, it is more expensive when much emphasis has been placed
upon finding methods of modifying the properties of soils available at the site. Besides

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that, the expensive costs included the works like site clearance, excavation works as
embankments.
The cost of pavement works also expensive, which is RM 137,116,800.00 or
16% of the total cost of main civil works. The total length of this highway is 77 km and
the material used for pavement construction will affect the expensive costs. Besides
that, cost of interchange construction also gives effect the main civil works. The
interchange cost is third highest in main civil costs which is RM 102,837,600.00
because this project involves 6 interchanges.
For the cost of main civil works, the lowest price of elements in main civil works
is site clearance and rock excavation. From the bar chart show that elements were
2.5% and 3% of the total main civil works which is the costs are RM 21,424,500.00 and
RM 25,709,400.00. We also can see the cost of RC bridges also highest in main civil
works which is RM 94,267,800.00 or 11% of total main civil cost. That costs was effect
by the works like piling works, construction of pile cap, crosshead, beam launching and
others.

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6.5 TOLL PLAZA AND OPERATION OFFICES


DESCRIPTION

6.4:

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

Table
Cost

Toll Plaza Canopy


Including Concrete
Pavement

21,614,940.00

9,455,346.00

7,213,867.00

4,945,727.00

16,811,620.00

7,354,158.00

5,610,785.00

3,846,677.00

Officers

9,606,640.00

9,606,640.00

TOTAL

48,033,200.00

16,809,504.00

22,431,292.00

8,792,404.00

Toll Plaza
Supervision
Buildings
Administration

Breakdown of Toll Plaza and Operation Offices cost in Senai Desaru Expressway

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Costs Toll Plaza and Operation Offices (RM )

20%

Toll Plaza Canopy Including Concrete Pavement

Toll Plaza Supervsion building


45%

35%

Doughnut Chart 6.4

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Adminstartion Building / Offices

A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY


Based on the doughnut char 6.4, it is show the highest proportion is the toll
plaza canopy construction including pavements works which is contributes 45% or RM
21,614,940.00. This project have 4 toll plaza canopy which is 2 toll plaza in package 2
( Ulu Tiram to Pasir Gudang), and 1 Toll Plaza For package 1 ( Senai Ulu Tiram) and
package 3 ( Cahaya Baru- Desaru ).This project have one administration offices in
package 3 which is the cost is RM 9,606,640.00
For the second highest cost for contribution the toll plaza is supervision
building which is contribute 35% or RM 16,811,620.00 from the total construction on this
element.

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6.6 TOLL EQUIPMENT, TRAFFIC SURVEILLANCE AND CONTROL SYSTEM


DESCRIPTION

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

BRIDGE
(RM)

5,281,536.00

1,872,964.00

1,728,118.00

1,680,454.00

25,747,488.00

6,192,270.00

4,876,574.00

3,820,929.00

10,857,715.00

System

1,980,576.00

476,328.00

375,121.00

293,919.00

835,208.00

TOTAL

33,009,600.00

8,541,562.00

6,979,813.00

5,795,302.00

11,692,923.00

Toll Equipment
Traffic Surveillance
Emergency Phone

Table 6.5: Cost Breakdown of Toll Equipment, Traffic Surveillance and Control System cost in Senai Desaru
Expressway

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Toll Equipment, Traffic Survelliance And Control System

6%

16%

Toll Equipment
Traffic Surveilliance
Emergency Phone System
78%

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Pie Chart 6.5

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From the pie chart shows the result from the costs of toll equipment, traffic
surveillance and control system. The highest cots from that is 78% or RM
25,747,488.00 which is for the traffic surveillance. The highest cost effect by the works
like installation of traffic surveillance cameras and the loop detectors to control incident
detection, traffic management and travel time collection. That element costs also
included in all package construction and bridge construction
The second highest show in Toll equipment which is 6% or RM 5,281,536.00 for cover
the work in this element like cost of design and services of the toll equipment. Lastly for
emergency phone system only involve 6% of the overall total of this element cost which
is RM 1,980,576.00

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DESCRIPTION

OVERALL
COST (RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

West

10,580,000.0
0

East

10,580,000.0
0

TOTAL

PACKAGE 3
(RM)

21,160,000.00

6.7 REST AND SERVICES AREA (R&R)

Table 6.6: Cost Breakdown of Rest and Services area cost in Senai
Desaru Expressway

From the above table, we can see the total for the of the rest and services
area is RM 21,160,000.00. For this Senai Desaru Expressway was provide 2 R&R to
the consumers at the west and east on package 2 ( Ulu Tiram to Pasir Gudang). The
cost of construction for each R&R is RM 10,580,000. The total cost of construction
R&R which is 2% from the total of the development cost.
The costing was about the cost for the construction and also about the cost for
the services also the facilities was provided on the R&R. This R&R was new design
and have many different also more modern of R&R from others R&R was provided in
others highway.

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The services and facilities were providing in this R&R as:

A food court within a reasonable walking distance from the car park

Clear unobstructed access from the food court to the toilets and surau

Surau strategically sited at a quiet end in a park-like landscaped setting

A simple two-way car parking system for smooth traffic flow and drivers
convenience

Police Station is located at the centre of a group of three buildings for better
supervision and visibility

ATMs are placed immediately outside the police beat for similar safety reasons

Wakafs, playground and fruit stalls are provided at strategic locations to further
enhance travellers' convenience

Extensive covered walkway system to assist visitors getting to the public


convenience with minimal exposure to the weather

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6.8 TOTAL DEVELOPMENT COST


DESCRIPTION

OVERALL COST
(RM)

PACKAGE 1
(RM)

PACKAGE 2
(RM)

PACKAGE 3
(RM)

BRIDGE
(RM)

Pre - Construction
Cost

31,740,000.00

7,633,468.00

6,011,553.00

4,710,221.00

13,384,758.00

Project
Management Cost

67,077,200.00

16,132,064.00

12,704,423.00

9,954,257.00

28,286,456.00

Main Civil Works

856,980,000.00

207,134,205.00

167,992,927.00

138,227,029.00

343,625,839.00

Toll Plaza and


operation Offices

48,033,200.00

16,809,504.00

22,431,292.00

8,792,404.00

Toll Equipment,
Traffic Surveillance
and Control System

33,009,600.00

8,541,562.00

6,979,813.00

5,795,302.00

11,692,923.00

Rest and Services

21,160,000.00

21,160,000.00

TOTAL

1,058,000,000.00

237,280,008.00

167,479,213.00

256,250,803.00

Table 6.7: Cost Breakdown of total development cost in Senai Desaru Expressway

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396,989,976.00

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Bar Chat 6.6: Development cost of Senai Desaru Expressway

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Development Cost ( RM )
900,000,000.00
800,000,000.00
700,000,000.00
600,000,000.00
500,000,000.00
400,000,000.00
300,000,000.00
200,000,000.00
100,000,000.00
-

Series 1

Based on that Bar Chart 6.6, it is can be con conclude the highest proportion show of
the Senai - Desaru Expressway for development cost is clearly cost of main civil works.
Which is the cost of main civil works is RM 856,980,000.00 or 81% from the total
development cost. The main civil works consists pavement works, site clearance
drainage works, interchange, bridge and others. As we can see, bride construction
definitely show the highest cost of development cost other than that all package in this
highway construction which is RM 396,989,976.00. The bridge construction will be one
of the longest single plane cable stayed bridges in the world. Furthermore bridge
construction used 740m long span composite steel and concrete box girder is used for
the main span and side spans of the cable-stayed portion of the structure.

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A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY


remaining 968m of approach deck (484 m on each side) are structured using an all
concrete multi-cell box girder section. The highest of bridge construction also effect by
the foundation for the two main pylons utilize 2,000 mm diameter bored piles encased
in 19mm thick steel casing with 5.5 m thick cast in-situ reinforced concrete pile caps.
The abutments and the 10 piers on either side of the river for the approach spans are
founded on 600 mm and 1000mm diameter spun piles with 2.5 m thick cast in-situ
reinforced concrete piles.

The height of the cast-in situ reinforced concrete piers

ranges from 3 m to 17 m. The piers are spaced at 48 m centers.


For the others works in development cost, overall others cost was not more
than RM 100,000,000.00 for development costs.

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6.9 ANALYSIS COST ON SENAI DESARU EXPRESSWAY


The Senai Desaru Expressway was totally finished on 31th Dicember 2009
The total length of the highway is 77km which is this construction have 3
package and 1 bridge stay bridge construction. Package 1 (Senai to Ulu Tiiram ) and
Package 2 ( Ulu Tiram to Cahaya Baru ) are four lane dual carriageway with lane width
of 3.65m and paved shoulder witdh of 3.0m. But package 3 ( Cahaya Baru Desaru )
including cable stay bridge was constructed with a two lane single carriageway. On
Package 3 is the only one in Malaysias highway have two lane single carriageway on
cable stay bridge.

PACKAGE

WHOLE
LENGTH
(KM)

WIDTH (M)

TOTAL AREA

Package 1

22

20

440

Package 2

27

20

540

Package 3

26

10.5

27.3

Bridge

1.7

22

37.4

TOTAL

77

48

1,045

Table 6.8 Cost breakdown for cost/km of Senai Desaru Expressway

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Package 1
(RM)

Package 2
(RM)

Package 3
(RM)

Bridge
(RM)

Total
Construction Cost

256,250,803

237,280,008.

167,479,213

396,989,976

Total Length of
Highway (KM)

22

27

26

1.7

COST PER KM OF
THE HIGHWAY

11,647,763

8,788,148

6,441,508

233,523.515

From the above table, we can see and conclude the cost or per km of each
package include a cable stay bridge. For the highest cost of per km is on bridge
construction which is RM 233,523.515/km and follows up by package 1 and package 2
RM 11,647,763/km and RM 8,788,148/km. For the lowest cost is on package 3 RM
233,523.515/km.

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6.10 ANALYSIS ON COST OF SENAI DESARU EXPRESSWAY AGAINST LEKAS HIGHWAY AND
LEBUHRAYA PANTAI TIMUR PHASE 2 PACKAGE 12

For more finding about the cost of highway construction, this chapter also carries out the comparisons of cost with LEKAS Highway
and Lebuhraya Panatai Timur Phase 2 Package 12.
Table 6.9 shows the comparisons of cost/km with LEKAS Highway and Lebuhraya Pantai Timur Phase 2 Package 12.
LEKAS HIGHWAY

LEBURHRAYA
PANTAI
TIMUR PHASE
12

SENAI DESARU EXPRESSWAY

Package

Total
Construction Cost
(RM)
Total Length Of
Highway in KM
Cost per km of
the highway (RM )

165,254,
789

174,106,17
2

169,656,52
5

18.2

14.5

11.575

9,709,9
34

12,007,32
2

14,657,15
1

158

12

256,250,80
3

237,280,00
8

167,479,21
3

22

27

26

12,222,500

11,647,76
3

8,788,148

6,441,508

97,780,000

A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY

Construction Cost ( RM )
Series 1

Package 3(SDE )

167,479,213

Package 2 (SDE )

237,280,008

Package 1 (SDE )

256,250,803

Package 12 (LPT Phase 2)

97,780,000

Package 3( LEKAS )

169,656,525

Package 2 ( LEKAS )

174,106,172

Package 1 ( LEKAS )

165,254,789

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Chart 6.7 The comparisons of construction cost between Lekas Highway and Lebuhraya Pantai Timur Phase 2 with Senai
Desaru Expressway.

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Based on Bar Chart 6.7., it is really proved and explained that the construction
cost of Senai - Desaru Expressway is more expensive other than types of highway
construction.
But, for the comparisons depending on cost per km of the highway cannot can assumed
as a factor give effect to expensive for the construction cost because the construction
cost also depending of the site projects and the location of the project itself.

6.12 CONCLUSION
From the discussed and analyzed about the all elements involved for this
construction and about the length of km Senai - Desaru Expressway also the
comparative study about the comparisons with other type of highway construction, as
the conclusion Senai Desaru Expressway more expensive and required the really big
budget from government

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CHAPTER 7
CONCLUSION AND RECOMMENDATION

7.1

CONCLUSION
Highway construction plays a vital role in the development of a country. The

economic success of country depends not only on the availability and proper utilization
of its natural resources but also rely heavily on its efficient form of transportation
system, of which systematic, well-planned and good road networks provide the principal
venue for the rapid conveyance of the commodities produced. The growth in road
transport in recent years has focused attention on the importance of well-planned
highway system to the economy of any nation.
For this study overall finding about the information expressway system in
included constructability concept of expressway Malaysia especially Senai Desaru
Expressway (SDE).From the study of Senai Desaru expressway, we can know and
learned about why the needed of this construction, how it is construct, overall cost
involved in this project and others.

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7.2

ANALYSIS ON CONSTRUCTION OF SENAI DESARU

EXPRESSWAY (SDE)
Overall the analysis the construction of Senai Desaru Expressway was be
described on the chapter 4. For the summary of the construction of the Senai Desaru
expressway, generally the method of construction of highway is commonly based on
principle and the standard specification of highway construction issued by the Jabatan
kerja Raya (JKR) and Lembaga Lebuhraya Malaysia (LLM) To avoid waste and to
ensure the project complete within the construction period, all the construction method
must be determined and prepared early by the contractor. For the construction flexible
pavement especially on the layer must be smooth and followed the Specification and
followed Specification. Other than that, the bridge construction also important and the
construction consist of foundation of main pylons, pile cap or abutment, column or piers,
crosshead, beam launching, diaphragm and deck, parapet and railing as well as the
miscellaneous.

7.2.1 Problems Encountered During Construction Highway


From the study there are several of problems that need to be bare by
the contractor and the client in construction of this highway.
From the interview with Ir Mohd Iqbal, Executive Of Engineers Department
from Ranhill Engineers and Construction Sdn Bhd the problems for this
construction especially on the bridge construction like:

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Foundation and substructure related problems like weakness signal of


GPS, machineries break down, miss-installation of piles see (Figure

7.1) and hammer drilling cracked piles.


Superstructure related problems such as improper slab fabrication,
The problem used to reinforce the weak pier columns see (Figure
7.2), incremental launching caused the column tends to cracking and
spalling, limited space of storage of precast segments and concrete
quality problems.

Pylon

related problems.

For

example,

the inconvenience of

hammerhead crane during pylon construction

see (Figure 7.3) if

compare to luffing crane, costly probes used to prevent collapse of the


pylon structure, lifting problems of the steel anchorages box,
installation of hydraulic cylinder to avoid sliding or overturning see
(Figure 7.4).

Other activities related problems like difficulties of transportation of


materials, corrosion of materials, poor climate and inconveniences of
accessibility

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A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY

Figure 7.1

Figure 7.2

Figure 7.3

Figure 7.4

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A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY

7.3 ANALYSIS ON THE COST CONSTRUCTION OF SENAI


DESARU EXPRESSWAY (SDE)
As for the cost and analysis in chapter 5, the elements was involved in this
construction cost of this highway which is likes pre-construction cost, development
cost, cost of main civil works, toll plaza and operation Offices, toll equipment, Traffic
surveillance and control system and rest and services. The highest of percentage of
breakdown cost in civil main works. It is become important element to determine of the
successful for this project. The total of this construction is RM 1,058,000,000.00 which
is higher than others highway like LEKAS Highway and Lebuhraya Pantai Timur Phase
2.

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A STUDY ON CONSTRUCTION AND COST OF SENAI-DESARU EXPRESSWAY

7.4 RECOMMENDATION
Based from the case study and overall the topic include in this case study, some
recommendation about this project is made as below:

During construction all participants must involve must take a responsible to do


research and also find the most effectiveness and economical ways to construct a
highway. By the way, a developer must have a huge sum of money for the bear of

the all cost and standby for the contingencies works.


Furthermore, as a quantity surveying, we must know the process of highway from
the planning stage until the finishes of the construction include maintenance of
highway. It is important to make the estimate and give advice to client about the

cost of highway.
We also must take note and make important to the decrease of the failure in
highway construction. Because of that, the engineer should still undergo some
improvement like using high quality of the materials and also choose the right

material with approved by JKR and LLM.


If any problems occur during the construction period, all the participant site together
to find out the solution. It is important to make sure that progress of project not

delay.
Recommendation for this highway is further study should made to find the most
effective and economical ways to construct this highway and also study the detail
about the strategic location of the project. Besides that, more research should be
carried out for all highways project to gather more and more cost yard stick so that
cost yardstick will be more reliable.

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