1. Presentation to Institution of Engineers, Malaysia Electrified Double Track Project Ipoh to Padang Besar PIPE ARCH TUNNEL by Mr. Don R. Hall Head of Tunneling Division, Gamuda Engineering Sdn Bhd May 2010

2. Outline of Presentation: General Project Information – Berapit Tunnel Pipe Arch Tunnel – Geological Profile & Concept Pipe Arch Tunnel – Chronology of Construction Construction of Triple Cell 3m Ф Drainage Culvert Demolition of Existing 3m x 3m Twin Box Drainage Culvert Pipe Arch Tunnel Construction Catastrophe Summary and Q&A

3. General Project Information – Berapit Tunnel

4. General Project Information – Berapit Tunnel

6. Twin Tunnels, Single track each

8. General Project Information – Berapit Tunnel Typical Berapit Tunnel Cross Section:

9. 8 General Project Information – Berapit Tunnel

10. General Project Information – Berapit Tunnel CROSS PASSAGES EVERY 350m

11. Pipe Arch Tunnel – Chronology of Construction

12. Pipe Arch Tunnel – Chronology of Construction 1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert Northbound Southbound railway tunnel Southbound Northbound railway tunnel 2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced 3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7 Plan Layout of Twin Pipe Arch Tunnel

13. 12 Pipe Arch Tunnel – Chronology of Construction 1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert Southbound Northbound 2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced 3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7 3-D View of Twin Pipe Arch Tunnel

14. Construction Of Triple Cell

15. Construction of Triple Cell 3m Ф Drainage Culvert Jacking Length = 45.5m LONGITUDINAL SECTION CROSS SECTION

16. Construction of Triple Cell 3m Ф Drainage Culvert First drive of jacking works of 3m Ф concrete pipes ongoing. Second & third drives awaiting for jacking with prepared entrance rings Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine

17. Construction of Triple Cell 3m Ф Drainage Culvert Jacking works ongoing Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine

18. Construction of Triple Cell 3m Ф Drainage Culvert Breaktrough of the first drive Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine

19. Construction of Triple Cell 3m Ф Drainage Culvert Lifting of microtunneling machine after breakthough of first drive Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine

20. Construction of Triple Cell 3m Ф Drainage Culvert Close up of RASA microtunneling machine Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine

21. Construction of Triple Cell 3m Ф Drainage Culvert Completed construction of triple cell drainage culverts Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine

22. Demolition of Existing 3m x 3m Twin Box Drainage Culvert

23. Demolition of Existing 3m x 3m Twin Box Drainage Culvert PLAN VIEW CROSS SECTION VIEW

24. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Existing twin box culvert at KM 232.7 PLUS North-South Expressway before demolition Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction

25. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction

26. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction

27. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Sealing of existing twin box culvert for pipe arch tunnel construction 2. Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction

28. Pipe Arch Tunnel Construction

29. Pipe Arch Tunnel – Concept

30. Pipe Arch Tunnel – Concept Mined excavation

31. Pipe Arch Tunnel – Concept Site picture of project by Metropolitan Atlanta Rapid Transit Authority in USA Construction Sequence 1. Execution of sheet piles 2. Execution of the pipe arch microtunneling 3. Mined excavation of tunnel with steel ribs with bullflex, reinforced shotcrete & fibre glass elements 4. Casting of permanent concrete lining

32. Pipe Arch Tunnel Construction LONGITUDINAL SECTION CROSS SECTION

33. Pipe Arch Tunnel Construction Limits of PLUS North-South Expressway (NSE) Receiving Pit Jacking Pit Top of Soil Support Pipes Southbound NSE Northbound NSE Fill Fill 0 Cut & Cover Section Cut &Cover Section Residual Soil Direction of Microtunneling 5 Weathered Rock 10 Bottom of Structure Rock 15 20 Scale in Meters 0 5 10 Jacking Length up to Toe of Highway Embankment= 90 m

34. Pipe Arch Tunnel Construction (Right Bore) Limits of PLUS North-South Expressway (NSE) Receiving Pit Jacking Pit Top of Soil Support Pipes Southbound NSE Northbound NSE Fill Fill 0 Cut & Cover Section Cut &Cover Section Direction of Microtunneling Residual Soil Weathered Rock 5 10 Rock Bottom of Structure 15 20 Scale in Meters 0 5 10 Jacking Length up to Toe of Highway Embankment= 92 m

35. Pipe Arch Tunnel Construction Cardox System – Non-explosive blasting

36. Pipe Arch Tunnel Construction Cardox Gas Filling Cardox Drilling & Connection Cardox Blasting Pipe Arch Tunnel Construction

37. Pipe Arch Tunnel Construction Mini Pipe Arch

38. Pipe Arch Tunnel Construction AVN500 Microtunneling machine with retraction mechanism in case of rock face encountered Pipe Arch Tunnel Construction

39. Pipe Arch Tunnel Construction 10mm Pipe Wall Thickness Jacking Direction 780mm OD Pre-welded Line-up Band Pipe joint detail Pipe Arch Tunnel Construction

40. Pipe Arch Tunnel Construction Construction & staged excavation of bored pile jacking pit Pipe Arch Tunnel Construction

41. Pipe Arch Tunnel Construction Coring of reinforcement of shotcreted bored pile wall to prepare soft eye for microtunneling machine advance Pipe Arch Tunnel Construction

42. Pipe Arch Tunnel Construction Construction of thrust wall for jacking of microtunneling machine Pipe Arch Tunnel Construction

43. Pipe Arch Tunnel Construction Microtunneling machine preparing to jack Pipe Arch Tunnel Construction

44. Pipe Arch Tunnel Construction Pipe Arch Tunnel Construction

45. Pipe Arch Tunnel Construction Jacking of microtunneling machine ongoing Pipe Arch Tunnel Construction

46. Pipe Arch Tunnel Construction Welding Of Pipe

47. Pipe Arch Tunnel Construction Pipe Arch Tunnel Construction

48. Pipe Arch Tunnel Construction Pipe Arch Tunnel Construction

49. Pipe Arch Tunnel Construction Pipe Arch Tunnel Construction

50. Catastrophe Catastrophe Pipe Arch Tunnel Construction

51. Catastrophe Pipe Arch Tunnel Construction

52. Catastrophe Pipe Arch Tunnel Construction

53. Catastrophe Pipe Arch Tunnel Construction

54. Catastrophe Set up to pull back pipe Pipe Arch Tunnel Construction

55. Catastrophe Locking device Pipe Arch Tunnel Construction

56. Catastrophe First pipe retreated Pipe Arch Tunnel Construction

57. Catastrophe Damaged section Pipe Arch Tunnel Construction

58. Catastrophe Damaged section exposed Pipe Arch Tunnel Construction

59. Catastrophe Pipe Arch Tunnel Construction

60. Catastrophe Existing drive pressurized Pipe Arch Tunnel Construction

61. Catastrophe Damaged pipe on surface Pipe Arch Tunnel Construction

62. Catastrophe Damaged pipe on surface Pipe Arch Tunnel Construction

63. Catastrophe Rebar excavated under Plus Highway Pipe Arch Tunnel Construction

64. THANK YOU

65. Q & A Session