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 > Penggantian Paip Air Lama Di Wilayah Kuala Lumpur

Project Background
The works under this project form part of the overall works under the programme of replacement of existing asbestos cement pipes in Wilayah Kuala Lumpur for reduction of non-revenue water (NRW).

SYABAS had identified that the existing asbestos cement pipes in the following areas were in poor structural condition and frequently burst causing serious leakage and lost of treated water. Therefore, these pipelines require to be urgently replaced to reduce the NRW:

1) Brickfield - approximately 8.0km of pipelines with diameter 100mm - 300mm.
2) Bukit Tunku - approximately 1.2km of pipelines with diameter 100mm.
3) Jalan Sg. Besi/Chan Sow Lin - approximately 7.6km of pipelines with diameter 100mm - 250mm.
4) Jalan Maarof & Bukit Pantai - approximately 3.8km of pipelines with diameter 150mm - 200mm.
5) Jalan Sentul - approximately 4.2km of pipelines with diameter 150mm - 200mm.
6) Taman Bamboo, Off Jalan Ipoh - approximately 3.9km of pipelines with diameter 100mm - 200mm.
7) Jalan Segambut - approximately 4.5km of pipelines with diameter 300mm.

To implement the above project, SYABAS invited open tender from qualified Class 'A' Contractor registered with both PKK and CIDB. The Contract was awarded to Casavest (M) Sdn Bhd, i.e. the lowest qualified tenderer after evaluation. The physical pipelaying and associated works was in turn sub-contracted to Asia Baru Construction Sdn. Bhd.

Briefly, the scope of works for this Contract Package comprises the following major components:

> Carry out topographical survey and underground utility detection along the proposed pipe routes.
> Supply and lay ductile iron and mild steel pipes, fittings and specials of diameter 100mm - 300mm to replace the existing asbestos cement pipelines.
> Carry out pressure and leakage tests for the proposed pipelines.
> Supply and install ductile iron tapping saddle with brass ferrule and new stainless steel communication pipeworks up to the consumers' meters.
> Sterilisation and flushing of all pipelines including communication pipeworks.
> Inter-connection of proposed pipelines to the existing pipelines.
> Consumer meter change-over and commissioning of the new system.
> Road reinstatement using "mill and pave" technique.
Project Information
Client / Owner: Syarikat Bekalan Air Selangor Sdn Bhd
Consultant: Ranhill Consulting S/B
Main Contractor: Casavest (M) Sdn Bhd
Sub-Contractor: Asia Baru Construction S/B
Date of Commencement: 17th April 2006
Date of Completion: 30th August 2007
Project Methodology
Upon receipt of Letter of Award from the Main Contractor, Asia Baru immediately initiated meeting/discussion with the Main Contractor, Consultant and Client to confirm the proposed pipe routes. Upon lodgement of all the necessary insurances and performance bond, thus fulfilling all the conditions precedent, topographical survey commenced on the third week after receipt of LoA. Preliminary survey plans were made available within 2-3 weeks to enable commencement of under-ground utility detection. By the end of second month, sufficient survey plans and utility detection plans were made available for selection of best possible pipeline alignment. These alignment were jointly inspected and agreed by the Consultant and Client (SYABAS) representatives. By mid June 2006, working drawings incorporating the proposed alignment and pipeline details including pipeline profile were available and submitted to the Consultant for approval.

However, the commencement of physical pipelaying work was delayed until August 2006. This was due to late issuance of working permit by the Local Authority, Dewan Bandaraya Kuala Lumpur (DBKL). As all the proposed pipelines are to be laid along the metalled road in built-up area, especially for main/trunk road like Jalan Sg. Besi/Chan Sow Lin, Jalan Sentul, Jalan Segambut, Jalan Ipoh and Jalan Maarof, DBKL imposed very stringent working conditions including short working hours at night (from 10:00 PM - 5:00 AM next morning).

The sequence of typical pipelaying works was as follows:

1) Set up traffic signage for partial road closure and traffic control including traffic diversion.
2) Cutting of metalled road along the proposed alignment using diamond cutter.
3) Trench excavation and disposal of excavated materials.
4) Laying of ductile iron pipes, fittings and specials covered with polyethylene sleeve.
5) Backfilling of trench with compacted sand layers.
6) Spread and compact crusher run as sub-base.
7) Temporary reinstatement with 60mm thick binder course and 40mm wearing course.

It must be emphasized here that open excavation and laying of pipeline along major road in built-up commercial area in capital city Kuala Lumpur is a difficult task which require additional resources with skill and experience compared to the normal pipelaying work in rural or sub-urban areas. Among the difficulties encountered during implementation include:

1) Excavation on thick road pavement (up to 600mm thick)
- A breaker attached to backhoe was used to break the thick road pavement after the edge of trench was cut using diamond cutter.
2) Existence of abundance existing services along and across the proposed alignment
- Excavation was carried out carefully with backhoe including manual digging with hand-held tools in order to preserve the existing services.
3) Laying of pipes "through" the existing pipes
- Pipes were laid carefully underneath or across the existing services without disturbing these services.
4) Immediate reinstatement
- The excavated trench was backfilled, compacted and reinstated up to wearing course level everyday before removal of temporary barricade so as to open the road to traffic. This has to be completed before 5:00 AM daily.

Upon completion of sufficient length of pipeline, pressure test (15 bars) and leakage test (12 bars) were carried out. Again, it must be mentioned here that ductile iron pipeline with flexible spigot and socket ended joint are very vulnerable to leak under high pressure. Only trained skilled pipelaying with sufficient experience shall be deployed for the laying of this pipeline. Despite this, leaks still occurred but were painstakingly repaired/rectified finally.

After successful completion of pressure and leakage test, tapping saddle with ferrule and stainless steel communication pipework were installed up to the consumer's meter point. This was carried out by licensed plumber registered with SYABAS. Upon completion, the whole pipeline including communication pipeworks were sterilised and flushed to the satisfaction of SYABAS's representative. The completed pipelines were inter-connected to the existing pipeline and commissioned. Subsequently, the consumer's meter was changed-over to the new communication pipework, thus abandoning the old existing system.

After completion of all the pipeworks, no further digging/excavation will be required, the excavated trench (which had been temporarily reinstatement) was then "milled and paved" to meet the DBKL requirements.

All the works under the Contract were successfully tested and completed within the extended/approved Contract Period i.e. on 30/8/2007. The management and supervisory team involved in the Contract had gained invaluable experience in the implementation of pipe replacement (NRW) project especially in dealing with open excavation in built-up commercial area in the city.