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 > Kuala Sawah Sewage Treatment Project

Project Background
The new Kuala Sawah Sewage Treatment Plant (KSSTP) involves the construction of a mechanised STP to provide additional treatment capacity at the existing Kuala Sawah STP site for 240,000 PE. It is proposed to divert the existing sewage flow to the new mechanised plant so that the existing ponds, having a design treatment capacity of 140,000 PE can be used to provide buffer capacity for any increase in flow until the 2nd stage upgrading of the mechanised STP, or as standby facility in case of breakdown of the new STP.

The proposed STP will receive sewage through a 1350 mm dia. MS force main from the existing Kuala Sawah Pump Station, which could be ultimately upgraded to handle 500,000 PE. The advanced oxidation ditch, which was preceded by automatic screen and Vortex Grit Chambers, will be provided with air diffusers and submersible mixers; followed by circular Clarifiers. Effluent from the Clarifiers will be UV-disinfected in order to meet "Standard A - Effluent Discharge Standards" set by DOE. Disinfected effluent will be measured by a fixed measuring weir and discharged via a 1650 mm dia. RC pipe connected to an existing outlet chamber before discharging to Sungai Linggi at 7km downstream from Sg. Linggi Raw water Intake/Treatment Plant site.

The overall project scope comprises of four (4) numbers of STPs; namely Damansara STP, Sunggala STP, Kuala Sawah STP and Sg. Udang CSTF. The implementation of this Sewage Treatment Project in Malaysia was funded by JBIC Loan No. MXVIII-2.

The above-mentioned overall project was awarded to Kajima-Ebara-Nishihara JV (in short, KEN Joint Venture). Asia Baru Construction Sdn. Bhd was involved in the construction of the civil portion of Kuala Sawah STP (P3C2) only and the scope of works as awarded by Kajima Corporation comprises of the following major components:

> Structural works: Construction of Grit Chamber (1 No.), Clarifiers (4 Nos.) and UV Disinfection (1 No.).
> Pipeworks: Supply and lay In-Plant Process Pipeworks (MS pipes ranging from 700mm dia. to 1400 mm dia.- overall about 2.0km) and Yard Works (1650mm dia. effluent RC pipe - about 1.05km).
Project Information
Client / Owner: KTAK/JPP
Consultant: Nippon Jogesuido Sekkei Co. Ltd and Minconsult Sdn. Bhd
Main Contractor: KEN Joint Venture
Sub-Contractor: Asia Baru Construction Sdn. Bhd.
Date of Commencement: 1st November 2007
Date of Completion: 7th July 2008
Project Methodology
The Letters of Acceptance (LoA) were received on 17th and 18th July 2007 for structural works and pipeworks respectively. After fulfilling all the conditions precedents like advance payment bonds, etc. the 1st kick-off meeting with KEN was convened immediately wherein discrepancies amongst drawings/lack of details were identified, clarified and resolved between KEN/Consultant/ABC.

As required, right from the outset of LoA receipt and 1st kick-off meeting, detailed pipe schedule shop drawings were prepared for all in-plant process pipeworks and submitted within a week to KEN/Consultant for approval before placement of order of the same from the pipe manufacturer. Similarly, proposed concrete paneling and detailed bar bending schedules were prepared for each structures i.e. Grit Chamber, Clarifier and UV Disinfection in early August 2006.

While waiting for the approval of the above schedules, physical mobilization of plant, machineries and labour was done on 1st November 2006, the same date of physical possession of site/commencement of work as directed by KEN. After the establishment of Contractor’s facilities like site office, carpentry and bar bending yard, incidental excavation and plate bearing test to determine the soil bearing capacity for each structures were carried out and completed in the month of November and December 2007. Besides that, preparation works on formworks and bar bending for Clarifiers and UV Disinfection had also started in November and on-going right through in December 2006. Welders qualifying tests were also conducted during this preparatory period until the arrival of pipes and fittings meant for pipeworks under the foundation of Clarifiers. The 1st batch was delivered in mid-December 2006. By end of December 2006, these built-in pipeworks under the foundation were butt welded, hydrostatically tested and subsequently laid in trenches and mass concreted under the Clarifier No.1. By end of January 2007, all these pipeworks under the Clarifiers were completed and base slab construction had started for Clarifiers No.1 and No.2. Owing to the tight time-frame of six (6) months to hand over the structure to M&E contractor for installation, two (2) separate gangs for structural works were utilized, one to handle the 4 Nos. of Clarifiers and the other gang to handle the UV disinfection and Grit Chamber.

As planned, Clarifier No.1 and No.2 were completed and handed over by end May 2007 and No.3 & No.4 in mid- October 2007. As for UV disinfection, it was hand-over in mid-August 2007 while Grit chamber it was expected to be handed-over in mid November 2007. Generally, each structure was ahead of schedule by about one (1) month.

For pipeworks other than those built-in under the foundation of Clarifiers, pipelaying of 1350mm dia. force main started by end January and completed by end September 2007, even though certain stretches were as deep as 6.0m from the original ground.

For Yard Works, the physical laying of the 1650mm dia. RC effluent pipes only started towards the end of June 2007 after the completion of haul road for access. Due to alignment changes, the type and total length of the RC pipes were affected whereby additional and changes to the pipe ordered earlier would have to be made. Owing to these changes, the overall in-plant process pipeworks and yard works was completed on 7th July 2008.

As part of the project requirements and Japanese works culture, permanent works would only allow to proceed after every aspect of the works had been approved. In almost all instances, design calculation complete with PE endorsement including detailed shop drawings, construction sequence and method statements were required before any physical construction work was allowed. This seemingly endless submission of design calculations and shop drawings (total to some 120 drawings) were extremely daunting initially to say the least. However, this proved to be quite effective and efficient once the submissions are done with and approval given, as minimal re-work or interruption were encountered during physical execution of the permanent works.

Despite the inevitable delay mentioned above due to changes on alignment route, the execution of the overall works were quite smooth and free from any major issue. The completion of this project by Asia Baru Construction Sdn. Bhd adds another milestone in its illustrious track record in that it demonstrated it capability and capacity to take-on sewage treatment plant project.