CIVIL & INFRASTRUCTURE

Contents

With an ever-evolving infrastructure industry

defined by dynamic challenges and exciting

opportunities, our dedication to being the best

at what we do is the only constant and is what

sets us apart. ”“

IntroductionRailRoadReclamationTunnel PowerEnvironmentRemote infrastructureMarine

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Since our first civil engineering project in Hong Kong in the 1970s, Leighton Asia has demonstrated a proven ability to undertake all aspects of the design, construction, refurbishment and maintenance of a wide range of infrastructure in often challenging environments. From reshaping shorelines for efficient land use to tunnelling in dense urban environments, we deliver flexible and innovative solutions that make us a trusted and valued partner to our clients. We have also upgraded national transportation networks with high-speed railway systems, roads, highways and bridges and built the infrastructure needed to benefit remote-site projects with operational productivity and efficiency. By collaborating closely with our clients at all stages, we ensure their projects benefit completely from our technical expertise and extensive experience in managing and developing complex systems.

Our civil and infrastructure services include:

• Site preparation and earthworks• Land reclamation• Rail• Bridges• Tunnels• Dams• Roads• Airports• Power stations• Marine and harbour works• Jetties• Breakwaters• Marine intakes and outfalls

Introduction

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RailRailway projects span many different civil engineering disciplines and often require specialised equipment and machinery. Our rail system design and construction expertise allows us to undertake all aspects of rail and associated works, including laying ballasted, high-speed, floating slab and special tracks, building bridges, viaducts, tunnels, stations and maintenance facilities, track rehabilitation, traction power design, constructing overhead systems, signalling and communications installation and more. We own, operate and maintain modern track-related installation equipment that can be mobilised to project locations across Asia together with experienced and registered operators.

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Downtown Line Stage 3 is a key component of Singapore’s 42-kilometre long Downtown Line and extends the existing Mass Rapid Transit railway network. In a joint venture with our sister company, John Holland, we are constructing Jalan Besar Station, a four-level station box with a platform, mezzanine, concourse and linkway, including related civil, structural, architectural, plumbing, drainage, landscaping and reinstatement works. Twin tunnels approximately 775 metres in length between Jalan Besar Station and Bencoolen Station are being built using two tunnel-boring machines. Jalan Besar Station, which is located where Jalan Besar and Weld Road intersect and is adjacent to Sim Lim Tower, serves many shops and businesses around the area.

Downtown Line Stage 3 – Contract C935 Singapore

To enable trains to travel at speeds of up to 160 kilometres per hour with enhanced operational safety and comfort for passenger travel and freight train services, the existing single-track rail infrastructure between Ipoh and Padang Besar is being upgraded to a modern electrified double-tracking network built to international standards. We are dismantling 417 kilometres of existing track and installing 759 kilometres of new track, 70 kilometres of which run on bridges and viaducts. We are also designing and constructing 5.5 kilometres of slab track in tunnels. The works feature 88,000 tonnes of rails and 1.22 million concrete sleepers and involve 70 kilometres of temporary track in enabling works, the relocation of 70 level crossings and the installation of 514 sets of turnouts. The plant mobilised for the project makes us the owner of the largest metre-gauge rail fleet in Malaysia.

Reinforcing Hong Kong’s status as a transport hub and international gateway to China, the cross-boundary Guangzhou-Shenzhen-Hong Kong Express Rail Link (XRL) provides high-speed rail service to Guangdong Province and major mainland cities through the national high-speed rail network. As one of Hong Kong’s most significant railway projects, the XRL extends underground for about 26 kilometres in the city and provides fast, convenient and reliable passenger service between the terminus in West Kowloon and the border. Our contracts include two key underground sections, the northern portion of the West Kowloon Terminus Station and a major mechanical and electrical (M&E) contract. For the 7.65-kilometre long section between Tse Uk Tsuen and Shek Yam, we are constructing tunnels and ventilation buildings, including 5.08 kilometres of twin-track tunnels, a pair of single-track tunnels, ventilation buildings at Shing Mun and Pat Heung as well as temporary magazines for storing explosives at Tai Shu Ha and So Kwun Wat.

The project introduced Hong Kong to many new techniques, especially for blasting. We monitored the level of construction noise and vibration, regularly tested the water and air quality around the area and actively engaged neighbouring communities to keep residents aware of the project’s progress. To reduce wastage, we processed excavated rock for use in a drainage layer under the invert of the tunnel. In joint venture contracts, we are also responsible for a 311-metre long approach tunnel, a 121-metre long track fan tunnel, a public transport interchange, two footbridges, a 300-metre long road underpass and other works as well as the construction of the West Kowloon Terminus Station North. The rail terminus building includes nine long-haul and six shuttle platforms, customs and immigration facilities, departure lounges, duty free and other retail outlets and features a dramatic steel and glass roof structure above the entrance. The M&E contract involves the design, manufacture, supply, installation and testing of fire services, plumbing and drainage at the West Kowloon Terminus Station.

Ipoh to Padang Besar Double Tracking Malaysia

Guangzhou-Shenzhen-Hong KongExpress Rail Link Hong Kong

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Road

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Maju ExpresswayMalaysia

Manila North Tollways ProjectPhilippines

This design and construct project involved building a 26-kilometre long highway to connect Kuala Lumpur to Putrajaya, the new regional centre and administration complex of the Malaysian government. The highway consists of a two- and three-lane dual carriageway, 10 kilometres of which are elevated, as well as four major interchanges, six bridges and two toll plazas. The project incorporated modern design protocols for the toll system, lighting, variable message signs and noise barriers.

The North Luzon Expressway is an 84-kilometre long toll expressway running between Balintawak in Quezon City and Santa Ines in Pampanga. Upgraded, expanded and rehabilitated to US interstate highway standards, the expressway is a flagship infrastructure project of the Philippines government with daily traffic flow of over 160,000 cars. The world-class toll road connection is expected to boost the industrial development of central and northern Luzon, the largest and most economically significant island in the Philippines, and spur tourism in the north of the country.

Under a number of design and construct contracts since 1998 to redevelop the expressway, we were responsible for upgrading and widening 84 kilometres of expressway in North Luzon and constructing 110 additional lane kilometres. Other works included improvements to existing interchanges, demolishing more than 90 existing toll booths and constructing 145 new ones on the expressway and at interchanges, building two operation centres as well as bridge widening, traffic management and the relocation of utilities. The project is undertaken on a rehabilitate-operate-transfer basis with a 30-year concession period.

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Reclamation

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Central Reclamation Phase III and Central-Wan Chai Bypass Hong Kong

This massive and complex marine and civil infrastructure undertaking is an integral part of a high-profile waterfront reclamation project to create new land in Central district. Together with the construction of the underground Central-Wan Chai Bypass, the works provide much needed traffic congestion relief in Central, Wan Chai and Causeway Bay and allow for the future strategic development of the Central waterfront.

Reclaiming almost 18 hectares of land from Hong Kong’s harbour safely, responsibly and efficiently required

adherence to strict environmental standards and a number of technical innovations. Sedimentation pits lined both sides of the site to prevent polluted water from entering the harbour just 20 metres away while trucks drove through wheel washers before entering the city. A key innovation was the use of precast caissons, weighing as much as 9,500 tonnes, which greatly reduced noise, waste and water pollution. We also employed the much quieter diamond-wire saw for cutting instead of traditional hydraulic breakers.

The project involved the dredging of 900,000 cubic metres of material and the construction of over 1 kilometre of vertical wave-absorbing seawalls, ferry piers, a railway overrun tunnel, a dual three-lane road tunnel, a heliport, precast cooling water pumping stations and pipelines as well as drainage and other works. The precast components were made in China and delivered to Hong Kong by semi-submersible barge to be floated into position. For the dual three-lane road tunnel, we placed about 450 diaphragm wall panels on either side up to

55 metres below the sea level. This is one of the largest quantities of diaphragm wall used in a single project in Hong Kong.

We are also constructing the Central Interchange of the Central-Wan Chai Bypass and Island Eastern Corridor Link to connect the existing elevated highway in the west to the road tunnel. The works include two bridges totalling 305 metres, 224 metres of tunnels, a 116-metre long approach ramp and realigning and reconstructing existing roads.

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Tunnel

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Lai Chi Kok Drainage TunnelHong Kong

The Eagle’s Nest Tunnel is a critical link of Route 8, which connects Sha Tin in the New Territories to West Kowloon. With three lanes in each direction, the twin 2.1-kilometre long tunnels are designed to help ease traffic congestion on the main roads between the two districts. Six drill and blast jumbo rigs were employed to construct all the tunnels, including a 400-metre long adit used for tunnel ventilation. Tunnel blasting was required to adhere to strict vibration limits within a 60-metre protection zone around various key water supplies facilities.

The project also included the construction of various ventilation housings and an administration building, site formation and slope works, a toll plaza with a subway and footbridge as well as electrical and mechanical systems, such as tunnel ventilation, fire services, lighting, power supply, central monitoring and control, air quality and toll collection. Landscaping was extensive as a natural stream that originally crossed the site had to be recreated to flow along both sides of the southern approach to Butterfly Valley. Boulders from the original stream were placed along the recreated one.

To alleviate flooding in Cheung Sha Wan, Lai Chi Kok and Sham Shui Po, situated in the downstream area of West Kowloon, the Lai Chi Kok Drainage Tunnel was commissioned under the Drainage Services Department to capture and discharge rainwater into Victoria Harbour using a drainage tunnel spanning 3.7 kilometres in urban areas. The project uses a tunnel-boring machine to construct main and branch storm water tunnels. At 4.9 metres in diametre, the tunnels are designed to direct rainwater from streams and open channels to a stilling basin via six intake shafts. The tunnel-boring machine operates at depths of 40 metres below the groundwater

table, necessitating additional safety measures, including requiring the maintenance team to be pressurised when entering the excavation chamber and then decompress safely when exiting to prevent workers from getting the bends. As the project is located in urban areas, we have introduced a number of enhancements during construction to improve the surroundings for neighbouring communities, including erecting temporary noise barriers, spraying water to reduce dust emissions and controlling the diversion of streams within the site area. Our efforts were recognised at the 2010 Considerate Contractors Site Award Scheme.

Eagle’s Nest TunnelHong Kong

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Power

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Manjung Power StationMalaysia

Designed to help address rising electricity demand in Malaysia, the Manjung Power Station was developed by TNB Janamanjung as one of the largest coal-fired projects in Southeast Asia and the first to meet World Bank standards on emissions in Malaysia.

The 2,100-megawatt capacity coal-fired power station was constructed on a man-made island of about 325 hectares, approximately 288 kilometres north of Kuala Lumpur. We were subcontracted by the engineering, procurement and construction contractor, a consortium formed by Alstom and Peremba Construction,

to prepare the site as well as the power block, combustible, coal effluent and flue-gas desulfurisation areas, main cooling system, electrical substation, utilities and networks.

For the cooling water intake, we manufactured and placed 10-metre long three cell precast concrete box culverts weighing 490 tonnes in a pre-dredged trench. We also constructed a 200-metre high and 20-metre diametre chimney with a reinforced wind shield as well as the infrastructure needed to receive and transfer coal, including transfer towers and conveyors.

Phu My 3 Power Station – Main Civil WorksVietnam

Coordinating with the Siemens design team in Germany on the detailed civil works design of the 716-megawatt combined cycle gas turbine Phu My 3 Power Station, we were responsible for all aspects of the project, including compliance with the health and safety regulations of Siemens and the power station owner.

The design and construct contract required us to construct a main turbine building, including gas and steam turbine foundations, pits, structural steel and acoustic cladding and roofing systems, fuel farm foundations, control room and other utility buildings, permanent road works, storm water systems and waste water systems, including oily water disposal.

Our civil works also included installing 2,000 precast driven piles, an inlet water canal, a 2.6-metre diametre cooling water pipeline, and all temporary and permanent works associated with the circulating water pump structure 15 metres underground. We procured all major supply items, including the glass-reinforced plastic cooling water pipeline, 1,500 tonnes of structural steel and 700 tonnes of permanent sheet piling.

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Environment

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Harbour Area Treatment Scheme Stage 2AHong Kong

Sludge Treatment FacilityHong Kong

In one of the most important environmental protection initiatives undertaken in Hong Kong, the government introduced the Harbour Area Treatment Scheme (HATS) to collect and treat sewage on both sides of Victoria Harbour.

The HATS Stage 2A Project further improves the city’s water quality by treating the remaining 25% of sewage generated on the northern and southwestern sides of Hong Kong Island. With Stage 2A, the capacity of sewage collected a day increases from 1.7 million cubic metres to 2.44 million cubic metres for centralised treatment on Stonecutters Island under the HATS project.

Every day, about 800 tonnes of sludge are produced by Hong Kong’s 11 sewage treatment plants and much of it is simply dumped in landfills, which have a limited life. With the amount of sludge forecast to rise to some 2,000 tonnes a day in the coming years, the government is turning to incineration as a sustainable treatment that is more in line with international practice.

We are part of an engineering, procurement and construction joint venture that is designing,

constructing, testing and commissioning a state-of-the-art self-sufficient sewage sludge incineration facility that can treat 2,000 tonnes a day, making it the biggest of its kind ever built.

Inside, the facility is equipped with incinerator boiler furnaces that produce steam, which drives turbines capable of generating 14 megawatts of electricity, more than enough to cover the plant’s energy needs. Surplus electricity can be exported to the power grid for external use. There are also flue gas treatment

lines that comply with emission standards. A seawater desalination plant supplies the facility with up to 600 cubic metres of desalinated water per day while wastewater is recycled at the site to help protect the environment.

Outside, the facility adopts an aesthetically pleasing wave form architectural design inspired by the sea and hills surrounding the waterfront site in the

western part of the New Territories. Visitors are transported by electric bus to the facility’s environmental education centre. There is also a landscaped garden with a habitat for water birds.

In a joint venture contract to construct a sewage conveyance system from Aberdeen to Sai Ying Pun, we constructed 7.5 kilometres of deep sewage tunnels. The use of advanced drill and blast techniques, which were new to Hong Kong, resulted in more precise detonations that significantly reduced blast vibrations and noise and required less explosives and concrete backfill. Grouting was used to prevent water inflow during the tunnel construction. We also erected noise enclosures that are twice as effective as common ones in Hong Kong. The project was recognised at the 2010 Hong Kong Awards for Environmental Excellence and the 2010 Considerate Contractors Site Award Scheme.

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Remote infrastructure

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Donggi-Senoro LNG Site PreparationIndonesia

Tangguh LNG Camp FacilitiesIndonesia

To allow the development of an LNG facility capable of producing 2 million tonnes of liquefied natural gas annually, we cleared and prepared the site for the LNG plant and supporting infrastructure, set up drains and roads and provided paving and slope protection. Dump trucks, excavators and other necessary heavy equipment had to be transported to the site by landing craft due to the project’s remote location in Central Sulawesi.

Occupying approximately 37,000 square metres, the permanent camp facilities provide accommodation at the Tangguh LNG Project in the Bintuni Bay area of Papua. In a joint-venture project, we were required to engineer, supply and install camp facilities for over 7,000 people. As the site is very remote with no existing infrastructure and had to be accessed via a beach landing, the camps were constructed in modules that were delivered to the site, where they were assembled. All the buildings and pre-fabricated components were manufactured at our Bekasi Workshop on the outskirsts of Jakarta.

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Marine

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Aviation Fuel Supply Facility – Offshore WorksHong Kong

SPM, PLEM System and Offshore Pipeline for Brunei Methanol PlantBrunei

With the construction of a methanol production plant on a 16-hectare site at the Sungai Liang Industrial Park in the Brunei district of Belait, a pipeline system capable of handling up to 1,600 tonnes of methanol per hour was developed as an export terminal for the plant. The project involved the installation engineering, procurement, installation and commissioning of a 60-centimetre diametre 13.4-kilometre long offshore pipeline and a single point mooring system. The installation works included four subsea pipeline crossings and a shore pull, six anchor chains and marine anchors, the pipeline end manifold tie-in to the pipeline, under-buoy hoses for the tie-in to buoy, floating hose connections, about 3 kilometres of post-trenching to bury the near shore pipeline and the pre-commissioning and commissioning of the pipeline, pipeline end manifold and single point mooring system. The single point mooring system is a catenary anchor leg mooring buoy capable of handling 46,000-deadweight tonne tankers. The pipeline was installed using the Leighton Faulkner, a pipe-lay barge owned by the Leighton Group.

With more than 900 daily flights, the Hong Kong International Airport at Chek Lap Kok needed an aviation fuel facility to supply fuel. To facilitate the offloading and transfer of the fuel by pipeline, we were required to dredge 700,000 cubic metres of marine mud from the seabed to create a 1.75-kilometre long approach channel and a turning area large enough for tankers with a capacity of 6,000 deadweight tonnes to reach the offloading jetty. Tankers berth at twin platforms at the jetty, which spans 280 metres and is capable of transferring 40,000 cubic metres of fuel a day.

In addition to the berths, the facility has a fuel transfer platform, two separate service platforms and associated pipe racks and walkways. Another 700,000 cubic metres were excavated to allow two 6-kilometre long 50-centimetre diametre welded submarine pipelines to be buried below the seabed.

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Lekir Bulk Terminal JettyMalaysia

Built to service Malaysia’s 2,100-megawatt capacity coal-fired Manjung Power Station, the coal terminal is capable of supplying 8 million tonnes of coal annually. The jetty, situated off a 325-hectare man-made island, approximately 288 kilometres north of Kuala Lumpur, is able to handle different size dry bulk carriers and features a 2-kilometre long trestle between the jetty head and the shore, a small boat berth along the trestle for tugboats and similar craft, two coal unloaders and associated conveyor systems. The jetty head can accommodate Capemax, Panamax and Handymax vessels and barges.

In Asia, where economic growth is underpinned

by marine infrastructure, we believe our expertise

in creating great offshore assets will produce

long-term value and outstanding results for clients,

communities and stakeholders. ”“

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www.leightonasia.com