This presentation was presented in Indian Railway's IPWE Seminar in January 2013 at Chennai. It depicts the innovations and new Technologies (in the context of Indian Railways) adopted on the project, and the various technical issues, and how they were dealt with.

1. INNOVATIVE CONSTRUCTION
SOLUTIONS IN RAILWAY DOUBLING
PROJECT
SHARING MALAYSIAN EXPERIENCE
-Hitesh Khanna

2. ME’s VISIT TO SGEDT / MLY.
HON’BLE ME DESIRED TO SHARE THE EXPERIENCE ON
A MUCH WIDER FORUM.
2

3. Gemas
Tampin
Rembau
Senawang
Sg. Gadut
Seremban
Batang Melaka
Legend :
Existing Alignment
New Major Realignment
Proposed station
CH : 461.234
CH : 469.275
CH : 483.750
CH : 509.675
CH : 535.150
CH : 562.270
CH : 465.300
3
STATION

4. PROJECT SUMMARY
4
COMMENCEMENT DATE 18th January 2008
ORIGINAL CONTRACT PERIOD
Seremban to Sg. Gadut 30 months i.e., 17th July 2010
Sg Gadut to Gemas 48 months i.e., 17th January 2012
REVISED CONTRACT COMPLETION
Seremban to Sg. Gadut 30th April 2011 (Completed & Handedover)
Sg Gadut to Gemas 31st July 2013
CONTRACT SUM RM 3,450 million
PROJECTED CONTRACT SUM RM 3,367 million
OVERALL PHYSICAL PROGRESS 94.00%
SCHEDULE PHYSICAL PROGRESS 93.89%
AHEAD (+) / DELAY (-) +0.11% ahead

5. PROJECT FEATURES
• Curve Radius min. 1268 mts. Design
Speed of 160 kmph (M.G.)
– MX Rail
– 29 Criss Crosses
• Hydrology Review through HACRAS
Modelling Software
• Total Grade Separation
– 13 ROBs, 8 VBCs, 8 MPOBs
• Integrated Pier / PSC Girders
– 15% Cost Savings
– Bearing Less, Maintenance Free
• Detention Pond up stream of
Bridges to Buffer Flash Floods
• Project FBW to weld 25 mts. Rail to
150 mts. Panel
• Old Hoppers Modifications For
Central Discharge.
5
• Maximum Design Speed:160
km/hr
• Maximum Operating Speed:140
km/hr
• Maximum Operating Speed for
freight train:90 km/hr
• Maximum Vertical Gradient:1%
• Minimum track spacing:4.2m
• Maximum Axel Load:20 tonnes
• Weldable CMS X-ings
• Through CWR
• Through FBW (AT @ T/Outs,
Destressing)
• Bidirectional Automatic Signalling,
ATP, SSI with Hot Stand by, CTC.

6. PHASE-2PHASE-1
COMMISSIONED
PROPOSED ALIGNMENT
Structure Total
Viaduct 03 number ( 2.2km)
ROB 14 nos
RUB 08 nos
BRV 35 nos
Culvert 124 nos
Linear Waterway 2000 m

7. SCHEMATIC LINE DIAGRAM OF TRACK WORK PROGRESS
DN LINE
UP LINE
Legend:
Completed (184 KM)
In progress (32 KM)
TDC: 30.12.12 TDC: 15.02.13
Length:8.04 Km Length:14.9 Km Length:24.8 Km
Length:21.9 Km Length:27.3 Km
Ch.461.234
Ch.564.000

8. TRADE WISE PROGRESS
MONITORING
8
TRADES OF WORKS
TOTAL WORK PROGRESS
AS ON 02.11.2012
CONSTRUCTION (INFRA WORKS) 98.54%
PACKAGE INF 1A (Sec. 1A : CH. 461.234 - CH. 472.500) 100.00%
PACKAGE INF 1B (Sec. 1B : CH. 472.500 - CH. 500.600) 99.90%
PACKAGE INF 2 (Sec. 2A : CH. 500.600 - CH. 506.558) 97.30%
PACKAGE INF 3 (Sec. 2B : CH. 502.400 - CH. 535.500) 99.88%
PACKAGE INF 4 (Sec. 3 : CH. 535.500 - CH. 563.496) 99.83%
PACKAGE INF 5 (Station Buildings & Platforms) 96.82%
PACKAGE INF 6 (TRACK WORK) 97.45%
PACKAGE INF 7 (MISC. WORKS-FENCING & GEMAS
FACILITIES)
78.11%
INSTALLATION OF SYSTEM WORKS 59.70%
PACKAGE SYS 1 (ELECTRICAL WORKS) 52.42%
PACKAGE SYS 2 (SIGNALLING) 61.81%
PACKAGE SYS 2 (COMMUNICATION) 78.97%
TESTING 57.18%
TOTAL 94.00%

9. 9

10. GEO-TECH CONDITIONS AND SOLUTIONS
• Malaysia:
– Very Poor Soil Conditions.
• Peat, Marine Clay, Organic Soils or Lime Stone Cavities
• Geo-tech solutions aim at ZERO Formation settlement despite poor
Soil Conditions
• Ground Improvement Cost May be as much as 20% of the Infra
Project Cost
– Stone Columns
– RE walls used in Rly. Bridge Approaches!
– Soli Nails and Crib Walls are very common in Cutting
– Geotextile sandwitched between sand layers is a standard,
even for Existing Track Rehabilitation
• PVD
• Geo-wrapping on Temporary Railway Banks
• Geo Cells

11. Typical Track Structure
Sub-Ballast
Sub-Grade
Ballast
Psc Sleeper
Fittings (Pandrol fastclip)
Rails (UIC 54)
SandandGeotextile
300 mm
300 mm
100 mm
600 mm

12. TYPICAL CROSS SECTION
DN LINE UP LINE
DN LINE UP LINE

13. 13
HIGH FORMATION / CUTTINGS
• HIGH EMBANKMENT IN
COUNTRY SIDE
• HIGH CUTTING
• 3mt BERM EVERY 6mt HEIGHT
• BERM DRAIN, CASCADING DRAIN,
TOE SIDE DRAIN

14. • RAIL HANDLING CRANE
EQUPIED DMT
• STEEL CHEQURED PLATE
TROLLEY PATH WAY
14
NEW SOLUTIONS

15. 15
MPOB (MOTOR CYCLE/
PEDESTRAIN BRIDGE)

16. BALLAST BOX FOR BOTTOM BALLST
SPREADING
• EVEN 150mm BOTTOM
BALLASTING
• LESS MANUAL LABOUR
• BETTER INITIAL TRACK
GEOMETRY ON LAYING
SLEEPERS WITH
SLEEPER LAYING BEAM
16

17. STONE COLUMNS FOR WEAK SOILS
• FASTER CONSOLIDATION AND STRENGTH
MOBILIZATION:
– PROVIDES A DRAINAGE PATH THROUGH ORGANIC PEAT /
MARINE CLAY
– PROVIDES A SUPPORT COLUMN
17

18. Existing track
23.1 m
ROB 09 ABUTMENT B
MATIER’S ARCH
Longitudinal profile
of proposed road
• LENGTH OF MATIER’S ARCH CONSTRUCTED IS 62.5m AT A TOAT COST
OF RM 1.24 MILLION. RATE PER METER OF MATIER’S ARCH IS RM19,840.
• MATIER’S ARCH AT ROB 09 WAS COMPLETED WITHIN THREE MONTHS.
MATIER’S ARCH AT ROB 09

19. MATIER’S ARCH AT ROB 09

20. MATIER’S ARCH AT ROB 09

21. SOIL NAIL SUPPORTED CUTTING
• WHEN FLAT SLOPES ARE NOT POSSIBLE
– CONTINUOUS HILL SLOPES AT 1 FOS, MINIMAL
MUCK GENERATION
– BUILT UP AREA AT TOP, MACHINE ACCESS AT TOP
MAY NOT BE POSSIBLE
– TOP DOWN EXCAVATION AS YOU PROTECT 21

22. Pedestrian Bridge
ML
Main Building
Secondary
Building
SENAWANG HALT

24. Viaduct
Main Building
DN UP
SUNGAI GADUT STATION

26. Pedestrian Bridge
DN Loop UP LoopML
Main BuildingSecondary
Building
REMBAU STATION

30. 30
FIRST TRIAL TRAIN ACROSS PIR PANJAL