Asia Baru Construction
We are in civil and building construction with particular specialisation in Water Works and Sewerage project ranging from sewerage treatment plant, river intakes, water treatment plants, storage tanks, reservoirs, pipe laying and major diversion...etc
PROJECTS > New Sg. Dua Treatment Plant (Package 3)

Project Background
The Works under this Contract forms part of Muda River Water Scheme Phase 4A which was implemented in the State of Pulau Pinang to augment water supply in the State. The New Sg. Dua Treatment Plant was planned for an ultimate capacity of 450Mld but the current Contract only involved the first module of 112.5Mld. Perbadanan Bekalan Air Pulau Pinang Sdn. Bhd. (PBAPP) awarded the project to Road Builders-Asia Baru-ADP Teknologi Consortium based on the open competitive bid. The Consortium was to complete the construction of the project within 18 months with a Defects Liability Period of 12 months.

Asia Baru Construction Sdn. Bhd. was one of the Consortium partners responsible to undertake the civil and structural works of the Process Unit. The 112.5Mld capacity Process Unit encompasses a raw water inlet Mixing Chamber and Distribution Channel, Flocculation Tanks, Dissolved Air Flotation (DAF) Tanks and Filter Tanks; all to be constructed contiguously but with provision of future extension to 450 Mld.

Generally, the scope of works under Asia Baru Construction Sdn. Bhd. consisted of the following major components:-

> Construction of water retaining R.C. structures comprising of inlet mixing chamber & distribution channel, 6 Nos. each of flocculation tanks, DAF tanks, filter tanks including filter gallery and filter control rooms.

> Design and erection of structural steel dome roof complete with metal cladding, skylight and turbine ventilators for DAF tanks.
> Building in pipes, supply and installation of valves and actuators for sludge scouring system for flocculator and DAF tanks.

> Complete supply and installation of metal works for Process Unit, such as stainless steel hand railings, cat ladders, insect screen, manhole access panels, aluminium gratings, etc.

> Civil finishing works which includes common and facing brickworks, painting, floor tiling, aluminium doors and windows and waterproofing works.
Project Information
Client / Owner: Perbadanan Bekalan Air Pulau Pinang Sdn. Bhd. (PBAPP)
Consultant: Angkasa Consulting Services Sdn. Bhd.
Main Contractor: Road Builders-Asia Baru-ADP Teknologi Consortium
Sub-Contractor: Asia Baru Construction Sdn. Bhd.
Date of Commencement: 2nd January 2002
Date of Completion: 1st July 2003
Project Methodology
Asia Baru Construction Sdn. Bhd. took possession of the site and began the construction of the Process Unit in April 2002 after the lead Consortium member, Road Builders, had completed the piling works. Asia Baru Construction Sdn. Bhd. completed the construction of the Process Unit in March 2003.

Due to the configuration of the New Sg. Dua Treatment Plant layout, the compactness of the Process Unit and the congested nature of the site, maneuverability and interfacing works were the major challenges experienced at site. For reach, a 45 ton crane had to be used for concreting purposes and handling of construction materials and installation of the Steel Dome Roof with the highest level about 12.7m above finished ground level and spanning some 45.6m. Some of the major construction constraints encountered at site were as follows:-

> Initial delayed in the supply and installation of 2500mm dia. raw water inlet pipe and 1500mm dia. filtered water outlet pipes by one of our Consortium partners effectively limit the Process Unit available for construction initially to half the size. That is, 3 contiguous tanks only can be opened up instead of the overall 6 units. The constraint severely limits the choice of panel construction in chequer pattern and it also necessitated the fabrication of different formworks for different tanks at the outset. This constraint at the initial stage had also affected the water tightness testing later, as concurrent 3 tanks (alternate tanks) for filter tanks streams and DAF/Flocculator tanks streams etc. could not be done. This resulted in odd tanks testing which resulted invariably in time over run from the original planning of such activity.

> Owing to the design and complexity of the Process Unit, as many as 5 to 6 vertical lifts in construction joints were required before reaching the walkway level of the tanks, especially the filter and DAF tanks. This is in contrast to other smaller plants of similar design and process system where 3 to 4 vertical lifts would normally be sufficient.

Despite the above, Asia Baru Construction Sdn. Bhd. as one of the partners of the Consortium still manage to complete the Process Unit within 12 months and handed over to our M&E counterpart, ADP Teknologi Sdn. Bhd. for M&E installation. This thus added another water treatment plant project, albeit only the construction of Process Unit, to its already impressive list of completed water treatment plant undertaken by Asia Baru Construction Sdn. Bhd.