Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line

Stoked by their debut success with the timely completion of Kajang Line’s underground section, Gamuda Engineering found themselves pitted once more against the unique challenges of tunnelling in Kuala Lumpur’s notorious karstic limestone, abrasive granite regions, and complex geological interfaces.

Fresh from delivering Malaysia’s first metro with great success, tunnelling contractor MMC Gamuda KVMRT (T) (MGKT - a joint venture between MMC and Gamuda Berhad in which Gamuda Engineering is its subsidiary) has recently celebrated the completion of its tunnels on Putrajaya line; it is the second extension to the Klang Valley Mass Rapid Transit. The scope of work includes 13.5-km of twin bored tunnel (internal diameter of 5.8-m), 11 underground stations, and other ancillary structures. A total of 12 tunnel boring machines (TBMs) were deployed, out of which 8 were variable density TBMs, and 4 were Earth Pressure Balance TBMs.

At first glance, there are many striking facts about the project. The alignment falls within some of the capital city’s most prime locations, crossing high density neighbourhoods, high-rise buildings, and public infrastructures. What’s more, the geological profile of the region is heterogeneous, further complicating the mining and deep excavation works required for the shafts. The geology includes Kenny Hill formation and Kuala Lumpur limestone—similar to that of the previous job—plus a particularly abrasive granite region, new to the tunnellers this time around.

Considering that the varying geology itself poses a risk to tunnelling, a risk mitigation drive was established from the very beginning, where extensive ground treatment works, constant monitoring and use of innovative solutions (paired with the contractor’s intimate understanding of the ground gathered from their earlier experiences) were aligned to shape the success of the project.

Continued success of the Variable Density Tunnel Boring Machine
A common thread to the success of the KVMRT projects is the award-winning VD TBMs. Developed jointly with Herrenknecht to specifically address Kuala Lumpur’s Extreme V karstic limestone, the VD machine continued to prove its versatility and efficacy in the second line. In one instance where a particular 1.7 km-stretch crossed two distinct grounds, the tunnellers switched from Earth Pressure Balance mode to Slurry mode in a single VD machine with ease as they navigated from alluvium soil into mixed ground conditions of limestone and Kenny Hill alluvium. In contrast, a conventional method would have required more shafts to be built and more machines deployed to complete the job.

Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line

Says Ng Hau Wei, Head of Tunnels, Gamuda Engineering, “With the VD TBM, we could switch between multiple slurry and EPB modes with ease in a single drive. With the ATBM system, the possibilities are endless as we now have supervision over tunnelling parameters and operations for multiple machines simultaneously, at the speed and accuracy of a computer.”

World’s first Autonomous Tunnel Boring Machine
MGKT continued to push the envelope in pursuing tunnelling technologies, ultimately launching the world’s first autonomous tunnel boring machine. A shared vision of its leaders, the ATBM aspires to achieve a level of automation and digitalisation that will make tunnelling operations simpler and safer.

Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line

Typically, tunnelling operations tend to be labour intensive while, (at the same time) requiring attention to thousands of data points in real time. Seeing that there were plenty of avenues to modernise the sub systems of a TBM (steering, excavating, etc), MGKT developed a control algorithm that aggregates and analyses these data to deliver superior performance with faster response times, unbiased decision making and improved accuracies, resulting in overall safer operations.
Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line

Project: Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line
Location: Kuala Lumpur, Malaysia
Main contractor: MMC Gamuda KVMRT (T) SDN BHD
Scope of Work: 11 underground stations, complete with architectural and M&E services with escape shafts, all entrances, vent buildings at each station, tunnel portal structures, park & ride facilities, external works, roadworks, street lighting and landscaping, utility diversions, building protection works and temporary launch shafts for tunnelling. This is part of a larger scheme spanning 52.2km of MRT network connecting satellite towns of the Klang Valley to the city’s centralised business districts.

A large impetus behind the development was the shortage of mechanised tunnelling expertise in the local scene. With the ATBM, a world of possibilities has been opened up, reducing the menial and manual aspects of the job and elevating precious manpower into higher level tasks and oversight. By extension, a Tunnelling Command and Control Centre (TC4) was set up, where tunnellers can now monitor multiple TBMs remotely, thus enhancing communication and collaboration. The ATBM has been recognised by the New Civil Engineer society and International Tunnelling and Underground Space Association for its ground-breaking potential and has proven itself with over 9-km of tunnel successfully built in the Putrajaya line.

Project-wide Digital Transformation
In fact, a distinct feature of the project is the strategic roll-out of digitalisation initiatives unlike any before in Malaysian construction. In view of the overwhelmingly large volume of information transaction and construction activities happening daily across 17 construction sites, involving hundreds of staff, consultants, subcontractors and players, it only makes sense to wield the benefits of technology to streamline all workflows. Some examples of MGKT’s in-house solutions are:

Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line

The Project GIS (Geographic Information System) Portal: A web-based platform that grants a bird’s eye view of project site survey models. These surveys were developed using drone-captured photographs pinned with GIS applications. The Portal strengthens and informs decision-making processes by providing visualisation of these sites in their localities, granting context and a sense of proportionality. Even staff based overseas are now able to review site activities virtually and identify potential construction or temporary work-related issues in a timely manner, via the Portal.

Viewpoint Field View™ : A common data environment database that has taken field documentations for quality, safe, project delivery, closeouts and commissioning unto a Cloud, while simply using offline based mobile applications for input. Field View enables easy tracking, access and sharing of large quantities of project documents, ultimately offering the benefits of data analytics and security to boost project synergy

BIMAR (Augmented Reality in Building Information Modelling): An AR application for site inspection that allows real-world visualisation of 3D building designs through a mobile device. A first such in the industry, the app was developed in-house using Unity and Apple software development kits. A crucial key to the success of BIMAR is the accurate Building Information Modelling (BIM) renderings established early in the project and hosted on a reliable Cloud system. These were, in fact, BIM Level 2 certified from the British Research Establishment, a rare achievement from a contractor’s standpoint. BIMAR has radically enhanced the quality and safety aspects of overall operations with interactive and tangible means of visualisation, thus enhancing cross-collaboration and yielding efficient and meaningful outcomes to the business.

Klang Valley Mass Rapid Transit (KVMRT) Putrajaya Line

Success Despite Unforeseen Circumstances
It is noteworthy that these grassroot initiatives were successfully rolled out despite a chain of national affairs that had impacted the mega infrastructure project to a great extent. In late 2018, at almost halfway through the construction progress, an austerity drive by a newly elected government led to a change in the overall KVMRT project cost and contract. The project budget was slashed by 8.82 billion Malaysian Ringgit and converted into a turnkey model, resulting in major shifts in the organisational structure and work scope. Some of the major modifications affecting the underground section include the deferred opening of two stations (which were converted into shell and core stations), and rationalisation of architectural, electrical, and mechanical system works.

Another unforeseen incident was the onset of the Coronavirus-19 pandemic. When the country went into lockdown, 8 TBMs were already mining underground. To safeguard staff and workers well-being, numerous control measures and reconfiguration (both at worker’s residential and working spaces) were swiftly devised and implemented to allow essential construction works to proceed. Considering the far-reaching impact of these incidents (to name a few), on the project and its people, it is no mean feat for MGKT to deliver the tunnel completion with no compromise in safety, quality or schedule.

The entire Putrajaya Line is on track for full opening by January 2023, and Gamuda Engineering is ready to move on to other complex tunnelling projects, be it in Malaysia or elsewhere. Says Gusztáv Klados, a leading tunnel specialist with up to 50 years of industry experience, describes the phenomenal growth of GE with whom he has been with for almost 20 years. “Once we were awarded the construction of Line One (Kajang line) tunnels, we had to build on the capabilities of the people who were with the company and nurture local knowledge and talent. In fact, it is with such capabilities and commitment to the task, that the VD TBM, was developed to tackle the challenging geology of the Kajang line. Our technical knowledge is convertible … there will be other places where we have an opportunity, and we will have a good chance of getting jobs.”

Contributed by Joyce Shamini Rajendran, Specialist Writer at MGKT
Project Pricing
A P MOLLER Group's acquisition of MARTIN BENCHER set to trigger pricing challenges for many project forwarders globally The process of forward integration by Major Shipping lines is slowly affecting many small and medium Forwarders. Many

Read more ...

Gati Shakti National Master Plan - Fast Tracking Infra Development
Gati Shakti is a digital backbone on which infrastructure projects planned by the government under the ₹110 trillion National Infrastructure Plan (NIP) will be implemented by 2025. It provides an institutional framework

Read more ...

Chardham Tunnel Project
Equipment with cutting edge technologies is making tunneling smoother at RVNL’s mega railway project and helping contractors overcome geological complexities. Sandvik’s DT 821 C and DT 922i advanced automatic

Read more ...

India’s Metro-Rail Industry Expanding Fast
The Metro-Rail segment in India is growing at a frantic pace with positive long-term prospects, supported by the impetus provided by the government by way of business-friendly policies and financial support. Use of advanced

Read more ...

Lucknow Metro - The Fastest Built Metro Rail Project
Lucknow Metro has achieved the distinction of becoming the fastest built metro rail project in the country - both in terms of completion of construction work and execution. On 25th November 2013, LMRCL

Read more ...

Ropeways - Alternative Mobility Solution in Urban India
India received its first mode of modern transportation in 1853 when the first railway line was laid from Bombay to Thane to boost industrial activities and ensure easy accessibility to heavy raw materials. In the following

Read more ...

India’s Tunnelling Industry Opportunities & Challenges
The growth of the tunnel construction in the country has been driven by a robust pipeline of projects and investments in setting up hydropower projects, developing urban mass rapid transit systems, improving road

Read more ...

Sandvik DT 821C Tunneling Jumbo Setting a New Standard in Speed & Precision
A tunnelling project is a race against time and costs. Getting it right from the very beginning requires knowledge, skill and experience, as well as a proper range of equipment that fulfils the customer’s tunnelling

Read more ...

German manufacturer GHH brings special Shotcreting Machine to help complete Mumbai Nagpur Expressway
The Mumbai-Nagpur Expressway is delayed until 2022. In the meantime, a machine ‘GHH IS26’ with remarkable reliability has been specially flown in from the supplier and is in operation to help complete the project

Read more ...

CRCHI’s EPB TBM ‘Victory’ Achieves New Records in Construction of Moscow Metro
The project, located at the riverside of the Moscow River, passes under heavy traffic and crowded buildings. It includes two sections of a total length of 2947m. One is from Maple Avenue Station to No.2 Working Shaft

Read more ...

Pull Force
Pull Force is the force that a truck or prime mover can exert onto a transporter or any type of trailer. It has been a subject of much controversy and misunderstandings as truck manufacturers and end-users often do not talk

Read more ...

Fully Automated Jumbo Revolutionizing Tunneling in India
The first Sandvik DT922i, a computer controlled fully automatic tunneling jumbo, has been introduced by Sandvik Mining and Rock Technology in India with a vision to achieve high levels of safety, productivity and

Read more ...

HDD Machines Best Suited for Gas, Cable, and Sewerage  Pipeline Projects
Horizontal Directional Drilling is a technology in pipe and utility installation that allows greater accuracy and flexibility in placement and ends the need for costly digging, large crews, road closures and other

Read more ...

Progress Maschinen & Automation: Reinforcing cages for tunnel construction and wind-energy solutions
Special knowledge is required for building tunnels and wind energy plants in order to implement demanding projects. The facilities and manufacturing processes required for such projects can be adjusted well in advance for

Read more ...

Tunnelling for Science - Special formworks from Doka for tunnel system at CERN
The Large Hadron Collider (LHC) at CERN is the biggest particle accelerator in the world – and growing. To equip the LHC for new, more ambitious experiments in the next decade, the accelerator is currently

Read more ...

Proven Technology in Use
The river has its source at over 3000 meters high in the snow-covered Andes. It reaches the Pacific Ocean after 250 km. On its way, it overcomes a considerable gradient and is, therefore, ideally suited to generate electricity

Read more ...

CREG: Distinctive Amongst Peers
Tan Shunhui, Chairman, CREG, discusses the competitive advantages of the company’s tunneling equipment and solutions, emerging opportunities in developing countries, factors driving its growth and success across

Read more ...

CRCHI TBM at work in Hangzhou Genshan East Road Crossing River Tunnel
15-meter mega Slurry TBM rolled off the assembly line at CRCHI. The excavation diameter of the equipment is 15.01 m, its total length is about 130 m, total weight is about 4300 t, installed power is about 9755 kW, rated

Read more ...

Open-type TBM produced by CRCHI creates a new record in China
Being the longest water delivery line in the history of Jilin province, transferring water from Songhua River into Central Jilin Province will transfer the largest capacity of water and cover the largest areas. The water diversion

Read more ...