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Stay Cable Curved BridgeG. Machinchang,

Langkawi, Malaysia

BBR CONSTRUCTION SYSTEMS (M) SDN BHD, MALAYSIATel: +603 5636 3270 Fax: +603 5636 3285 www.bbr.com.my

ACEM Seminar on Brid e Desi n and Construction 21-22 June 2005 Kuala Lum ur

21-22 June 2005

LIM Chin-Beng


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IT STARTED WITHADREAM.....IT STARTED WITHADREAM.....

Swiss Architect & Planner, DrPeter Wyss visualised a uniquebridge on the mountain top......

Gunung Machinchang.........


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Where is Langkawi....?Where is Langkawi....?

G. Machinchang


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Consultants,Designers,Contractors..Consultants,Designers,Contractors..


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Visualisation...Visualisation...


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Visualisation...Visualisation...


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From concept to reality.....From concept to reality.....


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The Present as Seen from aboveThe Present as Seen from above


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SummarySummary

Built on top of the Cable Car Station, the curved steelbridge will be a good lookout point, looking towards the

Andaman Sea, north of Langkawi.

125m curved length, jointing 2 lookout platforms at a

distance of 110m apart

It will be the main focal attraction for the Langkawi Cable

Car , one of the longest span between towers (900m) in

South East Asia.

8 front stay cables BBR Cona Stay 706

2 back stay cables BBR Cona Stay 1206

Structural Steel 85,000 kg

Precast Deck panels 285 sq. m

Ground anchors to stabilise base of foundations


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Technical Information ...........

Structural Deck:

Total size 125m Curved Leng

Steel Tonnage 45 tons

Structural Steel Pipes

Bot Chord ROR 219/12.7mm

Top Chord 150x150x6mm

Vert Members 293 -150x100x4.5mmDiag Members 150x150x 6&9mm

Podest Deck:

Total size 8m Eq Triangle



Bot Chord ROR 219/12.7mm

Top Chord 150x150x6mm

Vert Members 293 -150x100x4.5mm

Diag Members 150x150x 6&9mm

Pylon :

Total length 83.409m

Final Inclination 12o/ 2.3o



Main Pipe 219mm/12.7mm

Horiz Bracing 101.6mm/3.2mm

Diag Bracing 76mm/2.9mm


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Technical Information ...........

Stay Cables:

Front Stay (706) 8 nos

Back Stay (1206) 2 nos

F1

F2

F3

F4

F5

F6

F7

F8

BS1BS2

Cable Size Length Ult orce Weight

(m) (kN) (kg)

1 7 6 43 745 182 7 336 7875

2 7 6 45 612 182 7 351 1613

3 7 6 28 93 182 7 222 72864 7 6 3 283 182 7 233 1452

5 7 6 28 848 182 7 222 973

6 7 6 3 2 3 182 7 232 5293

7 7 6 43 564 182 7 335 394

8 7 6 45 434 182 7 349 79 9

BS1 12 6 77 94 3121 2 1 17 493

BS2 12 6 81 989 3121 2 1 82 97

W 4383 224


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In the beginning....In the beginning....


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Briefing former PMTun DrBriefing former PMTun Dr

Mahathir....Mahathir....


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Briefing former PMTun DrMahathirBriefing former PMTun DrMahathir

& Thai PMThaksin....& Thai PMThaksin....


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Construction begins....Construction begins....

The Deck Erection...


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Construction sequenceConstruction sequence

1. Footing : Podest, Pylon, Back Stay Cable

2. Podest Erection & Pylon Erection in vertical

3. Install 1st deck segment; Incline pylon to initial inclination

4. Continue to install deck segments until 5th segment; incline pylon

5. Erect deck segments until 8th segment; incline pylon

6. Connect all deck segments to podest

7. Final inclination of pylon together with deck level adjustment

8. Final fine tuning of stay cable forces and deck levelling


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Foundation Footing

The foundation for the pylon andthe podest legs are dug into theMachinchang formation, make up

of rocks as old as 4,000,000years.

The Pylon foundation ends upbeing a hand dug caisson of 6m indepth.


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Foundation.....Foundation.....


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Back Stay CableFoundation

The pylon isbalanced with 2 backstays (2 x 1206) BBRCona Stay cables tiedinto a back stayfoundation.


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Back Stay Box.....Back Stay Box.....


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Construction begins....Construction begins....Erection of Pylon

The terrain does not permit any other kindof transportation.

Helicopter of carrying capacity 4.5 tonswas employed for vertical lifting anderection.


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Helicopter Ops.....Helicopter Ops.....


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Podest Platform Erection

The podest platform segmentare lifted from the staging areaand erected in similar manner.

The site team will then use

chain blocks and other lightequipment to align properly thestructure.


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The completed Podest Platform


Erected segments beforealignment


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Podest Erection...Podest Erection...


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Pylon Erection

The pylon is split into 7 segments within the 4.5 tons lifting capacity of thehelicopter.

Each subsequent segments are lifted from the base and inserted intoposition.


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Pylon Erection.....Pylon Erection.....


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Staging Area at Base level

Structural steel deck & pylonsegments unloaded andprepared for helicopter lifting


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Pylon Erection

Topping it off withthe pylon head!!


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Construction begins....Construction begins....The Deck Erection...

Initial deck segment was lifted andlowered by helicopter.

Subsequently helicopter erectionwas aborted due to safety concerns.


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Construction begins....Construction begins....The Deck Erection...


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A spectacular view of the pylon andthe cable car top station.


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Due to safety concerns and the pilotaborted erection of deck elements, asimple winch and working wire ropeway was devised and implementedto erect the remaining deck

segments.


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Working Cable.....Working Cable.....


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Lowering the pylon for subsequenterection and final position


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The Deck Erection...And Pylon

adjustment inclination...


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C i b iC i b i


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C t ti b iC t ti b i


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Various views of the deck erection...

C t ti b iC t ti b i


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D k E tiD k E ti


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Deck Erection.....Deck Erection.....

D k E tiD k E ti


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D k E tiD k E ti


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D k E tiD k E ti


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D k E tiD k E ti


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D k E tiD k E ti


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Stay AnchorageStay Anchorage


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Stay Anchorage.....Stay Anchorage.....

Completed Bridge ViewCompleted Bridge View


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Completed Bridge View.....Completed Bridge View.....

Stay Cable Fine TuningStay Cable Fine Tuning


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Stay Cable Fine Tuning....Stay Cable Fine Tuning....

Stay Cable Fine Tuning andDeck Levelling...

Using mono-jack stressing toequalise the forces and at the sametime to level the deck.


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As Built Geometry ...........

RL 604.5

RL 659.884 RL 659.850

RL 686.4

81.90m

110.0m

88o


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110.0m

7106

15366

3016


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RL 604.5

RL 659.884

RL 659.850

RL 686.4

81.90m

110.0m

92

3016


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15366

79.37o

7106


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As Built Drawing ...........


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Spectacular ViewsSpectacular Views


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SpectacularViews...SpectacularViews...

Working in the clouds.....



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Working in the clouds..... andhigh above the ground.....



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Other snap shots ......

Bridge CompletionBridge Completion


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Completed Bridge ViewCompleted Bridge View


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Completed Bridge View.....Completed Bridge View.....

...G.Machincang...G.Machincang


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This Project has received 3 awards:-

One Local Award

The Malaysian Construction Industry Excellence Awards2005 (MCIEA 2005)

Two International Awards

Swiss Steel Design Award named Prix Acier

in November 2005

International Footbridge Award 2005

Project Awards 2005: Engineering


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Project Awards 2005: Engineering

The award is presented to the Contractor who have demonstrated excellent performance in

implementing construction projects in Engineering Works.Project Award Engineering Category

ALAM LANGKAWI SDNBHD

The Project

BRIDGE AT THE PEAK OF GUNUNG MATCINCANG,PADANG MAT SIRAT, LANGKAWI

The 125 metre long Cable Stayed Curved Steel Bridge is an eco-tourism project located

at the peak of Gunung Matcincang. Access to the site is via the Cable Car located at theOriental Village in Langkawi.

The Bridge connects the two protruding hilltops separated by a deep chasm to providetourists a spectacular view of the island. Built on a very sensitive geological andecological environment, careful measures were practiced to prevent any harm anddamage to the environment.

Building of the bridge proved to be a major engineering challenge. Extreme slopes andcontours make laying the foundation an uneasy task. To achieve this, foundations forpylons and podest were hand dug to a depth of 6 metres in solid rock. Installing of

the 7 pylon segments were done by helicopter and erected in a vertical position.

Restrictions and weather conditions forbade the further use of helicopter in later stages ofinstallation. Considering all safety aspects, installation works resumed using a workingcable system to further transport and install the pylons and podest platforms.

The Cable Stayed Curved Steel Bridge of Langkawi, a truly construction engineeringmarvel at the rooftops of Langkawi!

Swiss Steel Design AwardSwiss Steel Design Award


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Swiss Steel Design AwardSwiss Steel Design Award

November 2005

Prix Acier

Awarded by the Swiss

Institute of Steel

Construction

International Footbridge Award 2005International Footbridge Award 2005


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International Footbridge Award 2005International Footbridge Award 2005

There were 30 entries from 11 differentcountries, competing for the honours.

The Panorama Bridge in Langkawi,

with a free span of 126 m, was selected

as Winner in the category

T

echnology-Longspan

Acknowledgements & Thanks .....Acknowledgements & Thanks .....


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Langkawi Development Authority (LADA)

Owner/Developer

Angkasa Jurutera Perunding Sdn Bhd

Principal Consulting Engineer

Wyss Planning Consultant

Planning Consultant

Alam Langkawi Sdn Bhd

Main Contractor

BBR Construction Systems (M) Sdn Bhd

Specialist Bridge Contractor

Acknowledgements & Thanks .....Acknowledgements & Thanks .....

The People that made itThe People that made it


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ppPossible.......Possible.......

Dr Peter Wyss* Engr Schurter*Ir Shin Yoke Keong*IrEddy Ng*Ir Soon Eng Kiong*Mat Isa*Tung*

Lim Chin Beng* Chang Chee Cheong*Charles S. Barker*Sui Woei Aun*Helen Wong*Saiful Wong*Low Ah

King* Meor* Apy*Ah Pong*Norizan*Selva and many others...........

....and the Organisations.......and the Organisations...


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gg

SpecialistB

ridgeSub Contractor

CivilW

orks SubContractor

Consultant Team

Client/Owner

Main Contractor

B & OB & O

BBRCONSTRUCTION SYSTEMS

LADA



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Thank You and

Have A Nice Day

BBR CONSTRUCTION SYSTEMS (M) SDN BHD, MALAYSIA

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