AANNGGKKAASSAA CCOONNSSUULLTTIINNGG SSEERRVVIICCEESS SSDDNN BBHHDD

NNeewwsslleetttteerrIssue No.1/2013 April –May 2013

Editor

Norzana binti MohdAnuar

Committee Member

Mohd Mirzan bin Mazlan

Mustapha Maarof binJunid

Norafizah binti AbdRahman

Chia Yean Ping

Pandima Devi

In this issue severalinteresting topics arefeatured:

1. Concrete Cut-off Wall forMengkuang Dam Projectby Steven Toh Chin Kok &Norafizah A. Rahman

2. Numerical Modeling for aConcrete Face RockfillDam (CFRD)by Steven Toh Chin Kok &Norafizah A. Rahman

3. Solar Hybrid Project forRPS Kemar, Gerik, Perak:ACS’s 1st fully operationalsolar hybrid Project, 2nd

biggest solar hybrid inMalaysiaby Lau Meng Yong

4. Joint Study of CoastalFlooding at GolokRivermouthby Norzana Mohd Anuar

5. Tailing Dam for Iron-OreMineby Mustapha Maarof binJunid

6. Catalogue Filing Systemby Tan Li Zhi

7. A Journey To The North-West of Indo-China –Myanmarby Ng Han Tiong

8. Continuous Improvementby Norafizah A. Rahman

BRAINSTORMING 2013was held on 5 Jan 2013 at Holiday InnGlenmarie, Shah Alam. All the engineerswere invited and we had almost 99%attendance. Our MD, Mr. Khor CH gave awelcoming speech follow-up with Mr.Steven Toh’s ‘Kaizen’s ContinuousImprovement’. Other interesting topicswere discussed, questioned, and opinionswere shared.The primary objective of the exercise was toprepare the engineers on what to expect inthe coming years and also the rewards thatis within reach with our continuousimprovement.

Hydro-thermally alteredgranite - Whitish Material

Discovered at Site

Structural and Geotechnical

Engineering

Steven Toh Chin Kok1,

Norafizah A. Rahman2

he Expansion of Mengkuang Dam Project,

Pulau Pinang is being implemented under

the 10th Malaysia Plan by the Federal

Government. The existing Mengkuang Dam was

built in 1983 with storage capacity of 22 million

cubic meters. It supplies raw water to Sg Dua

water treatment plant during drought season to

compensate the shortfall of raw water

from Sg. Muda.

The project involves raising of the existing dam by

11m and construction of a 45m high earthfill dam

at the adjacent valley. The

project are to increase the reservoir storage from

22 million cubic meters to 73.5 million cubic

meters and the

raw water

supply capacity

from 300 MLD

to 1000 MLD Sg

Dua water

treatment

plant.

Plastic concrete

cut-off wall is

incorporated in

the design of

the Mengkuang

Dam as a

seepage cutoff system. This would also prevent

internal erosion of the clay core

operation. A flexible and low strength plastic

concrete was selected as seepage barrier to

sustain deformations expected

and to resist erosion if a crack should

T

Concrete Cut-off Wall for

Mengkuang Dam Project

thermally alteredWhitish Material

Discovered at Site

he Expansion of Mengkuang Dam Project,

is being implemented under

the 10th Malaysia Plan by the Federal

The existing Mengkuang Dam was

built in 1983 with storage capacity of 22 million

cubic meters. It supplies raw water to Sg Dua

water treatment plant during drought season to

of raw water abstation

project involves raising of the existing dam by

11m and construction of a 45m high earthfill dam

objectives of the

project are to increase the reservoir storage from

22 million cubic meters to 73.5 million cubic

seepage cutoff system. This would also prevent

of the clay core or piping during

low strength plastic

concrete was selected as seepage barrier to

expected without cracking

and to resist erosion if a crack should happen.

Difficult construction problems were

including excavation through loose

hydrothermally altered granite, residual soils and

embedment of the toe of the wall into a Grade 3

granite rock.

The properties and construction features of the

cut off wall are as per following:

Maximum size of coarse aggregate

Slump between 180mm and 220mm

time of placement

Minimum 28 days unconfined compressive

strength to be 1.20 MPa

Maximum elastic modulus of 800 MPa

Coefficient of permeability equal or below 10

m/s

Construction Features

The thickness of the cut off wall is 600mm.

Bentonite is used as a drilling fluid during

excavation to stabilize trench wall.

The cut off wall is embedded with minimum 1m

key into bedrock.

Implementation issues

construction of the cut off wall

Quarry blasting adjacent the project site posing

risk of curing of the constructed cut off wall.

Risk of leakage from existing dam

construction of new dam and heightening of

existing dam. A comprehensive

measures

are

implemen

ted to

manage

the risks.

Collapse

of trench

during

construction due

to unstable material adjacent to the cut off wall

particularly the hydrothermally altered material.

off Wall for

Mengkuang Dam Project

2

Construction of PlasticConcrete Cut Off Wall

construction problems were encountered

including excavation through loose

ly altered granite, residual soils and

the toe of the wall into a Grade 3

The properties and construction features of the

cut off wall are as per following:

Maximum size of coarse aggregate – 20mm.

Slump between 180mm and 220mm at the

time of placement

Minimum 28 days unconfined compressive

strength to be 1.20 MPa

Maximum elastic modulus of 800 MPa

Coefficient of permeability equal or below 10-9

Construction Features

The thickness of the cut off wall is 600mm.

sed as a drilling fluid during

excavation to stabilize trench wall.

The cut off wall is embedded with minimum 1m

mplementation issues arise during

construction of the cut off wall

adjacent the project site posing

curing of the constructed cut off wall.

Risk of leakage from existing dam – during

construction of new dam and heightening of

A comprehensive mitigating

material adjacent to the cut off wall

particularly the hydrothermally altered material.

3

The unstable materials were removed during

construction of the trench.

Interfaced details and construction sequence of

consolidation grouting, jet grouting and curtain

grouting. A detailed methodology was

developed with input from the contractor for

proper execution of cut off wall.

Structural and Geotechnical

Engineering

Steven Toh Chin Kok1,

Norafizah A. Rahman2

t was in 1895, that the first concrete face rockfill

dam was built in California but the design and

construction have only improved considerably

since the 1970s. Concrete Face Rockfill Dam

(CFRD) is a kind of dam that conceives rockfill as

the supporting structure and concrete slabs on the

upstream slope as the impervious element. In the

early days of CFRD development the design were

empirical which mainly based on previous

experience and on engineers’ judgment. However

it is gradually change to an approach of being

constructed by theoretical analyses and laboratory

and field testing research.

Previous analyses of CFRD were performed mainly

using linear elastic models and most were 2D

analyses. In recent years, non-linear analysis has

become widely accepted and the main analytical

method is either the finite element method (FEM)

or the finite difference method (FDM).

Monitoring the behavior of the existing dam and

analysis of dam instrumentation data after

Phase 1 completion and transfer of water into

new reservoir. This is to ensure the new dam

constructed is safe for operation.

Current Project of Concrete Face Rockfill Dam

- Tawau Dam

Proposed dam site is located about 10 km north of

Tawau township. Land area (679 acre) from dam

construction and reservoir area has been

acquired.

Tawau dam will be designed as concrete face

rockfill dam, 65 m in height. The dam is required

to meet projected raw water requirement of 370

Mld to year 2050.

For CFRD, the stress and deformation properties

of the rockfill and the concrete face slab are the

most important issues regarding dam safety and

performance. In CFRD, settlement of the rockfill

during and after construction can cause

deformation and cracking of the concrete face. In

numerical analysis of CFRDs, the constitutive

model of the rockfill is the most important base of

an analysis. The stress and deformation analyses

of CFRD need comprehensive consideration of

different factors, which include the stress and

deformation relationship, strength properties and

deformation properties and et cetera.

We foresee a great challenge and experience

ahead to precisely predict and simulate the

surface contact and joints between the concrete

slabs, construction steps and reservoir

impounding sequence.

I

Numerical Modeling for a

Concrete Face Rockfill Dam (CFRD)

4

Map to RPS Kemar from Pulau Banding

Midas GTS as the Geotechnical Software Used For

the Concrete Face Rockfill Dam

Midas GTS is all-in-one Finite Element (FE) analysis

software for the use of geotechnical engineering.

It is a total, state of the art solution which has

been developed through integrating all the

functionality necessary for structural analysis for

geotechnical and tunnel engineering.

The software is used for the analysis of

Tawau Dam Project which include stress

analysis reflecting construction stages,

seepage analysis, consolidation, etc.

The model of dam-foundation-reservoir

system can be used for a wide range of

analysis for the Tawau Dam Project such as :-

Civil Infrastructure Project Engineer

Lau Meng Yong

“ACS’s First Fully Operational

Solar Hybrid Project, Second Biggest

Solar Hybrid In Malaysia”

PS Kemar is a remote orang asli settlement

consisting of 15 villages located in the

southern tip of Tasik Temenggor, Gerik,

Perak. It has a total population of 5,000. The main

mode of transport to RPS Kemar is by a 1.5 hours

boat ride from Pulau Banding, Tasik Temenggor

followed by 20 min 4WD from the jetty to RPS

Kemar. An alternative access is by way of a logging

track from Lasah, Sg Siput (travelling time, 8 to 12

hours in wet condition and unusable during very

wet condition).

Prediction of the structural stability and

simulation of any possible failure mechanisms

under a range of loading scenarios (typically

normal operation, flood, earthquake)

Optimization of dam components

Prediction of the behavior of dam under

operation and assessment of their safety.

In an effort to provide a more reliable power

supply to selected remote orang asli villagers, the

Kementerian Kemajuan Luar Bandar dan Wilayah

(KKLW) has implemented the ‘PROJEK BEKALAN

ELEKTRIK LUAR BANDAR (BELB) KE

PERKAMPUNGAN ORANG ASLI 2010-2011’.

R

RPS Kemar

GerikTasik

Temenggor

Pulau Banding

Solar Hybrid Project For RPS

Kemar, Gerik, Perak

5

Arrays of Polycrystalline Solar Panels

Power House

Inverter Control Room

RPS Kemar Solar Hybrid Diagram

KKLW has appointed TNB Energy Services Sdn Bhd

(TNBES), a subsidiary of TNB, as the project

implementer, who in turn has appointed ACS to

undertake the full scope of engineering

consultancy services from detailed design and

tender documentation to contract administration

and construction supervision.

The whole project took 12 months to complete.

One of the major obstacles faced is the logistic

problem. All construction machineries and

materials were transported by barges across the

vast expanse of Tasik Temenggor. This is especially

challenging when the water level of lake was at its

lowest.

The project consists of a solar hybrid station -

combination of solar PV, diesel generators and

battery, with power generating capacity of

850kW. At peak load, the hybrid station is capable

of producing 1.5MW of which 850kW is generated

by the solar PV and 650kW by diesel generators. It

is currently the second largest solar hybrid power

station in Malaysia.

The whole project used a total of 3,696 numbers

of 230W Polycrystalline solar panels and stores

the generated electricity in 960 numbers of

4500kWh batteries. Power generation reverts to

diesel generators during cloudy periods of the day

or when the battery is not able to fully support the

consumer loading. Transformers then step-up the

power from 415V to 11kV and is distributed via 3

main distribution lines. It is then stepped down to

415V before reaching the consumers.

Solar Hybrid system based on photovoltaic is

considered an effective option to electrify remote

and isolated areas far from the national grid such

as RPS Kemar which receives an average of 4.43

kWh/m²/day solar radiation annually.

850kWp Solar PV

1600kVa

Genset

4500kWh Battery

Step-Up Transformers Consumers

Controller

Battery Room

The villagers in RPS Kemar now enjoy 2

electricity supply like the rest of Malaysians

average electricity bill per household ranging from

as low as RM20 to less than RM 100/month.

This is a considerable saving

which use to incur an average of RM400/month to

operate the diesel genset for only about 5 h

day.

Senior Coastal Engineer

Norzana binti Mohd Anuar

“The catastrophic results of

extreme global flood events continue to

have major damaging effects in both the

developed and the developing world”

e have to live by the consequences of

development for better or for worse. Since

20 to 30 years ago. Malaysia has been

straddled by fast pace development

yearly precipitation between 2000mm and

3000mm, the degree of excess runoff

from developed areas apart from silts coming

from bare land areas are merely too taxful to deal

with.

W

Joint Study of Coastal Flooding at

Golok Rivermouth

Perak’s MB Visit to RPS Kemar

he villagers in RPS Kemar now enjoy 24 hours

electricity supply like the rest of Malaysians. The

average electricity bill per household ranging from

as low as RM20 to less than RM 100/month.

This is a considerable saving to the household

incur an average of RM400/month to

set for only about 5 hours a

“The catastrophic results of

events continue to

have major damaging effects in both the

developed and the developing world”

e have to live by the consequences of

development for better or for worse. Since

20 to 30 years ago. Malaysia has been

straddled by fast pace development projects. With

yearly precipitation between 2000mm and

3000mm, the degree of excess runoff generated

from developed areas apart from silts coming

areas are merely too taxful to deal

This project adds another feather to ACS’s cap

with experience in the first fully operational Solar

Hybrid power project!

Without notice, flash flood occurs in a few

minutes leaving most of the urban dwellers in

awry. These floods occurred mostly

Northeast Monsoon.

In the east coast of Peninsular Malaysia, three

states affected are Pahang, Terengganu and

Kelantan. Sg. Golok, situated in Narathiwat

Province, border between Malaysia and Thailand

flood seasonally in the monsoon. The worst flood

event was recorded on the 21

where Sg. Golok overflows, top up with the

clogging at rivermouth have caused severe

inundation in low lying area especially in Rantau

Panjang.

Joint Study of Coastal Flooding at

Golok Rivermouth

6

Perak’s MB Visit to RPS Kemar

This project adds another feather to ACS’s cap

experience in the first fully operational Solar

Hybrid power project!

Without notice, flash flood occurs in a few

minutes leaving most of the urban dwellers in

awry. These floods occurred mostly during

of Peninsular Malaysia, three

states affected are Pahang, Terengganu and

Kelantan. Sg. Golok, situated in Narathiwat

Province, border between Malaysia and Thailand

flood seasonally in the monsoon. The worst flood

event was recorded on the 21st December 2009

where Sg. Golok overflows, top up with the

clogging at rivermouth have caused severe

inundation in low lying area especially in Rantau

- NEXT STEP -

The repeated events have

instigated

Irrigation and drainage (DID) to come up with a

“Joint Study of Coastal Flooding at Golok

Rivermouth” in collaboration with Thailand

counterpart to mitigate the recurrence events

As an established local Consultant, ACSSB has

been honored to represent the Malaysia team to

carry out an in depth hydrology

on the flood issue, in land and near river mouth

area.

Thailand on the other hand is taking up coastal

erosion study along Narathiwat Province shoreline

until Sg. Kelantan.

The repeated events have

instigated Department of

Irrigation and drainage (DID) to come up with a

“Joint Study of Coastal Flooding at Golok

Rivermouth” in collaboration with Thailand

counterpart to mitigate the recurrence events.

local Consultant, ACSSB has

represent the Malaysia team to

carry out an in depth hydrology / hydraulic study

on the flood issue, in land and near river mouth

Thailand on the other hand is taking up coastal

erosion study along Narathiwat Province shoreline

The study commenced in October 2012 and until

to date several joint meetings with Thailand

counterpart regarding data sharing has been

initiated. Desk study and analysis,

hydrology/hydraulic model setup, calibration

analyses and simulations are all in progress.

Through the same mission of assessing the Coastal

Flood Conditions and to provide concept design

for Coastal Flood Mitigation Measures for Sg

Golok (river) for both sides of the Malaysia

Thailand.

It is in the hope of both countries, Malaysia and

Thailand, that this study could benefit both

regions in the needs and aspirations for current

and future generations.

Su-Ngai Kolok

Rantau Panjang

7

The study commenced in October 2012 and until

to date several joint meetings with Thailand

counterpart regarding data sharing has been

initiated. Desk study and analysis,

hydrology/hydraulic model setup, calibration

analyses and simulations are all in progress.

Through the same mission of assessing the Coastal

Flood Conditions and to provide concept design

for Coastal Flood Mitigation Measures for Sg

Golok (river) for both sides of the Malaysia-

the hope of both countries, Malaysia and

Thailand, that this study could benefit both

regions in the needs and aspirations for current

and future generations.

Rantau Panjang

8

Inlet

Outlet

Access Bridge Pier 1 & Pier 2

Senior Project Engineer

Mustafa Maarof bin Junid

he owner of Sri Jaya iron-ore mining in

Pahang, Phoenix Lake Sdn Bhd engaged ACS

to design a surface storage dam to store

unwanted solid waste from mineral extraction as

well as managing free water. The waste in the

form of slurry will be pumped into the dam from

iron – ore processing plant which is located about

2.5km from the dam site.

The job was successfully completed in August

2012.

Design Consideration of

this dam include:

The embankments

must store solids

deposited as slurry

and also able to

manage free water.

Both the solids and

water stored in dams

may contain

contaminants which

have the potential to

cause harm to

environment if not

contained properly

both now and in the

future.

Dam operating life is

relatively short but it

is required to safely

store the tailings for

extremely long

periods of time,

possibly “in

perpetuity’.

Water management is crucial, particularly if

harmful materials are contained

Daily operations such as placement of tailings

and recovery of water are critical to the safety

of the storage.

The filling rate, the ultimate height and even

the overall storage configuration will change

to meet the demand for storage during

operation; and

The storage must be designed with mine

closure in mind, so as to create a permanent,

maintenance free deposit that does not pose

any unacceptable long-term environmental

impact or risk.

The design of dam involves:

The safe and stable containment of tailings

and contaminants.

The safe management of decant and rainfall

runoff.

The management of seepage.

The ability to achieve long-term effective

closure, leaving no unacceptable

environmental legacy; and

The meeting of these objectives in a cost

effective manner

Regular monitoring of the dam behavior and

safety inspection is necessary to avoid

consequential harm due to failures of dam which

may involve:

Loss of lifeCatastrophic environmental damage

Public outrage

Restrictive regulatory interventionFinancial losses

The dam which also acts as sediment pond. Since

its operation, the effluent from iron ore is

channeled into the pond to minimize pollution

due to operation of the iron-ore mining.

T

Tailing Dam For Iron-Ore Mine

A spreadsheet is created to record all new and existing

Senior Project Engineer (Mechanical)

Tan Li Zhi

undreds of product catalogues are being

delivered to the M&E Department every

year.

As the library of catalogue grows, they are often

misplaced, lost and unable to locate.

In 2012, a new catalogue filing system

used to manage all the new and existing

catalogues.

Each catalogues will be assigned a category, code

number, file location, company, sub company and

product. This will ensure the ease of

new catalogues are received.

Business Development Manager

Ng Han Tiong

yanmar, also known as Burma, is

bordered by China, Thailand, India,

Laos and Bangladesh. It is the world’s

24th highest populated country with over 60

million population and its also 2nd

H

M

Catalogue File System

A Journey To The North

Indo-China - Myanmar

A spreadsheet is created to record all new and existing catalogues

(Mechanical)

undreds of product catalogues are being

delivered to the M&E Department every

As the library of catalogue grows, they are often

misplaced, lost and unable to locate.

catalogue filing system has been

new and existing

Each catalogues will be assigned a category, code

number, file location, company, sub company and

product. This will ensure the ease of filing when

yanmar, also known as Burma, is

bordered by China, Thailand, India,

Laos and Bangladesh. It is the world’s

highest populated country with over 60nd largest country

By categorize the said

information, users will be

able to search not only the

category, but the

company, sub products

etc. They can also trace

the latest products in

chronological order by

looking at the code

number.

The implementation

system has garnered good response as the

catalogues are more organized, easy to search and

easy to update. Such filing system can be

expanded in the future to include filing of books,

drawings, specification, costing etc.

in Southeast Asia.

Myanmar is a country rich

in natural resources such

as precious stones, oil,

natural gas, etc. The

country has been under

military control since

1962 but was recently

release in 2011. It is rated as one of the most

promising development

Asia in this decade.

Catalogue File System

A Journey To The North-West Of

Myanmar

9

catalogues

Files Arrangementwith Labeled Code

Number

By categorize the said

information, users will be

able to search not only the

category, but the

company, sub products

etc. They can also trace

the latest products in

chronological order by

looking at the code

The implementation of the new catalogue filing

system has garnered good response as the

catalogues are more organized, easy to search and

easy to update. Such filing system can be

expanded in the future to include filing of books,

drawings, specification, costing etc.

Myanmar is a country rich

in natural resources such

as precious stones, oil,

natural gas, etc. The

country has been under

military control since

1962 but was recently

release in 2011. It is rated as one of the most

promising development country among Southeast

10

On 7th September

2012, Angkasa

Consulting Services

Sdn Bhd (ACS) jointly

organized a technical

seminar together

with PPI Industries

Sdn Bhd, Sika Kimia

Sdn Bhd, Spirolite

(M) Sdn Bhd and

Jotun (M) Sdn Bhd

for Myanmar Engineering

Society which located at

Hlaing Universities’

Campus, Yangon,

Myanmar.

It was a great opportunity

for ACS to venture into

this new emerging

market. There were over

100 participants’ from

almost all engineering

related industries

attending this technical

seminar. ACS presented a

paper entitled “Risk

Management for Water

Resources Development

Project”. It raises the

importance and risk of

water resources development in a developing

country such as Myanmar.

The risk involve at various stages of project

development from planning, feasibility study,

design, tendering, construction and

commissioning were outlined. The route map and

past cases for risk management in dam project

were also outlined in ACS presentation.

The president of Myanmar Engineering Society, U

Win Khaing gave a warm welcome to us. This

technical seminar is an important event for the

Myanmar Engineering

Society. ACS has

recorded an interest

in this emerging

country, Myanmar

and continue to

explore new

opportunity for business

expansion in Indo-China.

11

Geotechnical Engineer

Norafizah binti Andul Rahman

Learning AUTOCAD CIVIL 3D

CS engineer’s Encik Fairul and Cik

Norafizah, Chief Draftswoman, Puan

Romah attended the AutoCAD Civil 3D

2010 on 3, 7 and 24

April 2013. This

program will enable

them to implement

a more quality

drawing specifically

for dam projects.

MIDAS GTS Training

ustomized MIDAS GTS Internal Training was

conducted by the Structural and

Geotechnical Division on

12th until 14th April 2013. Dr

Song Ki Il from the Inha

University, Korea was invited

as the trainer, as he specializes

in tunnel and also actively

involved in the CFRD design in

Korea. Overall there were

eight participants that involve

all division for the training.

Midas GTS is a fully integrated 2D/3D Finite

Element Analysis Software dedicated to

geotechnical engineering application including

tunneling, excavation foundation, soil-structure

interaction, settlement analysis, seepage

(groundwater flow) analysis, consolidation

analysis and much more.

The participant confirm that by implementing this

program, their design works can be made easier

with better quality.

A

C

Continuous Improvement

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