Construction and Completion of Zone I, J AND K at Container Terminal 4 in WESTPORT, Malaysia Report on Alternative Design for Pavements and

Drainage by

- Infratek Projects Sdn. Bhd -

BACKGROUND The original design of the container terminal pavement (consisting of both extra heavy duty and heavy duty pavements) was to be constructed on reclaimed area with sand placed as hydraulic fill on the seabed, consisting of soft clays of varying depth. The container stacking area was to be an aggregate bed of an average of 1m and the internal access road, a normal JKR type asphalt premix road. The RTG track beam was designed as a beam on elastic foundation. The design of the pavements assumed a CBR of 6% for the reclamation sand, with an expectation of a further 1 to 1.5m settlement over the next 15 to 20 years, as seen on the earlier constructed container terminals. CONCLUSION The alternative pavement design provided by Infratek Projects Sdn Bhd achieved the following:Improvement of the reclamation sand engineering properties by High Impact Energy Dynamic Compaction (HIEDYC). A CBR of 20% to 30% was expected in the improved sub-grade, however for design purpose a CBR value of 15% was assumed conservatively for all the alternative pavement designs. The HIEDYC compaction created a solid sand raft of least 2m depth providing superior foundation and bearing capacity to the container stacking yard, RTG beam foundations, concrete block pavements and the internal road pavements. This enabled the design of pavement with less chances of differential settlement and much better performance. The improvement affected due to HIEDYC compaction was accessed by Macintosh Probe Penetration tests as well as Perth Sand Penetrometer tests. Based on the improved bearing capacity of the sand fill, the thickness of the container stacking yard pavement was reduced from an average of 1m to 350mm. The improved allowable bearing capacity in the container staking yard was expected to be between 800-1000 KN/m3. This was proved by plate bearing tests. Alternative designs were also provided for the concrete block pavements as well as for the internal premix roads using cement stabilised crushed rock base where the pavement layer thickness were reduced due to the higher stiffness of the sub-grade and base . The improved condition also allowed a more economical design of the sub-soil drainage.

The improved economical design brought about by the usage of the High Impact Energy Dynamic Compaction (HIEDYC) lead to substantial savings in the construction cost of the Container Terminal 4 in West Port, Pulau Indah, Malaysia.

Various HIEDYC models owned and operated by Infra Tech Group

WORK IN PROGRESS AT WESTPORT, MALAYSIA

COMPLETED WORK AT WESTPORT, MALAYSIA