Concrete Roads:

Why

21st March 2012

1
1. Introduction
2. Concrete Roads in Malaysia
3. Why Concrete Roads/Advantages
4. Common Complaints/Disadvantages
5. Recent Breakthrough –10MP
6. Conclusions

2
2 Types of Roads Available in Malaysia
Asphalt/Flexible Roads - 99%
Concrete/Rigid Roads - 1%
Percentage of Concrete Roads Available in Other
Countries
Country % Conc Rd Country % Conc Rd
US 15% Philipines 40%
Germany 28% Indonesia 10%
Australia 40% (major hwys
hwys)) Thailand 10%

China 10% Myanmar 90%

S. Korea 40% Malaysia 1%

3

Road Ramps

Roundabouts

Heavy Traffic Areas

Heavy Vehicle Parking Areas

Toll Booths

Major Highways (e.g. NKVE)

…. heaviest traffic area.

…. road repair/disruption is not an option.

…. overloading

…. flooding

…. RURAL ROADS where it is difficult to repair

4
 Description Year Type Lgh Thkmm
km
1 Jalan Seratus Tahun
Tahun,, Olak Lempit
Lempit,, Sgor 1986 JRCP 1.8 150
2 Muda Irrigation Scheme, Kedah 1988 JRCP n/a n/a
3 N-S Expressway, Gurun
Gurun,, Kedah 1988 JRCP n/a n/a
4 N-S Expressway, Ayer Keroh
Keroh--Pagoh 1989 CRCP 19.0 230
5 North Klang Valley Expressway, Sgor 1990 CRCP n/a 260
.
6 North South, Rawang -Tanjong Malim 1990 CRCP n/a 230
7 Teluk Datai Road, P. Langkawi
Langkawi,, Kedah 1992 n/a n/a n/a
8 Federal Route 5, Sitiawan1998, Perak 1998 JRCP n/a n/a
9 Kulim Industrial Area, Kulim, Kedah 2003 PCP 3.2 220
10 Kaki Bukit – Wang Kelian
Kelian,, Kedah 2006 PCP 1.6 220
11 Ulu Pauh – Chuping
Chuping,, Perlis 2006 PCP 6.4 230
12 Ringlet
Ringlet-- Kg. Susu, Pahang 2009 JRCP 5.5 220
* NSE(Total= 846 km)
743km (88%) asphalt,
104km (12%) concrete
5

Year 1986

1 Lane Single
Carriageway

Total Length: 1.8km

Width: 3.66m

Type: JRCP

Thickness: 220mm

Joints @ 5m c/c

LMC: 150mm

Success-
Success-no repair
since construction!

(>25 years)
Olak Lempit Rural Concrete Road 1986 (JRCP)

6

Year 2001-2003 “..I’m very happy with the performance of the Kulim road”

2 Lane Single Ir. Dr. Azmi Hassan, Director of Highways MOW
Carriageway

Total Length: 3.2km

Width: 3.5m +3m

Type: PCP

Thickness: 220mm

Joints @ 5m c/c

Grade 40PQC

LMC: 150mm
Success-
Success-no repair
since construction!
(>8 years)

7

Year 2006

2 Lane Single
Carriageway

Total Length: 1.6km

Width: 3.5m +2m

Type: PCP

Thickness: 220mm

Joints @ 5m c/c

Grade 40PQC

LMC: 150mm

Success-
Success-no repair
since construction!

(>6 years)

8

Year 2006

2 Lane Single
Carriageway

Total Length: 6.4km

Width: 3.5m +3m

Type: PCP

Thickness: 230mm

Joints @ 4.5m c/c

Grade 40PQC

LMC: 150mm

Failure: Blacktopped

9

Year 2010

2 Lane Single
Carriageway

Total Length: 5.5km

Width: 3.5m +2m

Type: JRCP

Thickness: 220mm

Joints @ 10m c/c

Grade 30PQC

LMC: 160mm

Failure: Blacktopped

10

Year 1990

2 lane 3 carriage way

Total Length: 50km

Width: 3.5m +2m

Type: CRCP (0.7%
steel)

Thickness: 260mm

No Joints

Grade 40PQC

LMC: 150mm

Success-no repair
since construction!*
(>20 years)

* Some repair due to ground

settlement, not performance

11

Year 1988
“North South Expressway is Malaysia’s

2 lane 3 carriage way national asset” … Geoff Ayton, RTA,

Total Length: 186km Australia.

Width: 3.5m +2m

Type: CRCP (0.7%
steel)

Thickness: 230mm

No Joints

Grade 40PQC

LMC: 150mm

Success-no repair since
construction!*
(>23 years)
* 75km blacktopped for 3rd lane widening

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1. Low maintenance 7. Safety
2. Ability to Handle 8. Greater Visibility
Increased Traffic and at Night/Less
Loading Energy Usage
3. New Niche Industry 9. Fuel Savings
4. Save on Foreign 10. Less CO2
Exchange Emission
5. Avoid Dependence on 11. Savings on Raw
Fluctuating and Rising Material Usage
Oil Prices 12. Green
6. Use of Local Technology
Products/Assurance of 13. No Disruption
Cement Supply

13

Little or no maintenance on Kulim Access Road since

construction in 2003.

We expect it to perform well for 40 years.

14
15

Concrete Roads as an Alternative to
Asphalt. Keep both industries
competitive, healthy, alive and not have
a monopoly.

Export concrete road construction
expertise overseas. IJM and Gamuda
has already constructed concrete roads
overseas.

Tobe the Leader for Concrete Road
Construction in ASEAN.

16
 Cement is 95% local (5% foreign content)
 Bitumen is 0% local (100% foreign content)

We are losing out on foreign exchange!

Better Balance of Trade by using local
products

17

Oil is a non- Year Bitumen Price,
RM/ton
renewable energy.
Jan 1990 387.50

Bitumen prices
Jan 1995 418.00
fluctuates. Cost of
Jan 2000 735.00
Bitumen will only
Jan 2005 610.00
go up in future. Jan 2006 990.00

Contractors Jan 2007 1,100.00
refused to start Jan 2008 1,459.00
work when bitumen Jan 2009 980.00
price shot up in Jan 2010 1,900.00
2008. Jan 2011 1,600.00
Apr. 2011 1,826.00

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 RM per tonne

-
1,000.00
1,500.00
2,000.00
2,500.00

500.00
Jan-98
Mac-98
Mei-98
Jul-98
Sept-98
Nov-98
Jan-99
Mac-99
Mei-99
Jul-99
Sept-99
Nov-99
RM/tonne
RM/tonne
Jan-00

US$/Barrel
Mac-00
Mei-00
Cement Price
Bitumen Price

Jul-00
Crude Oil Price

Price RM/tonne)
Expon. (Cement
Sept-00

Price US$/Barrel)
Expon. (Crude Oil
Nov-00
Jan-01
Mac-01
Mei-01
Jul-01
Sept-01
Nov-01
Jan-02
Mac-02
Mei-02
Jul-02
Sept-02
Nov-02
Jan-03
Mac-03
Mei-03
Jul-03
Sept-03
Nov-03
Jan-04
Mac-04
Mei-04
Jul-04
Sept-04
Nov-04
Jan-05
Mac-05
Mei-05
Jul-05
Sept-05
Nov-05
Jan-06
Mac-06
Mei-06
Jul-06
Sept-06
Nov-06
Jan-07
Mac-07
Mei-07
Jul-07
Sept-07
Nov-07
Jan-08
Mac-08
Mei-08
Jul-08
Sept-08
Nov-08
Jan-09
Mac-09
Mei-09
Jul-09
Sept-09
Nov-09
Bitumen Price

Jan-10
Mac-10
Mei-10
Jul-10
Sept-10
Nov-10
Jan-11
Mac-11
19

Mei-11
Jul-11
Sept-11
Nov-11
336.00
Cement Price

-
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
COMPARISON OF BITUMEN/CRUDE OIL/CEMENT PRICES

US$/Barrel

Government Circular 7/2002
“ Bahan/barangan/perkhidmatan tempatan
hendaklah digunakan sepenuhnya oleh
agensi dalam perolehan masing masing”

Tindakan sewajarnya akan diambil keatas

agensi yang gagal mematuhi peraturan
diatas. Perunding akan disenaraihitam…

20
Cement Supply and Demand in Malaysia, Year 2010
Unit: Million tonnes

Actual
2010
Cement Capacity 28.89
Cement Consumption 16.62
Excess Capacity 12.27
Cement Utilisation Ratio 58%

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 Safer Stopping on Concrete
• Stopping
distances for
concrete
surfaces are
much shorter
than for asphalt
surfaces
Especially when
asphalt is wet and
rutted

22
 Safer Driving on Concrete
Concrete

• Increased visibility:
4 X Surface Reflectivity

Safety for both

Pedestrians and
Vehicles

Asphalt

23
Asphalt Road Lighting Concrete Road Lighting

Safer for pedestrians,

carpark and road user
24

1-7% Fuel Savings (heavy vehicles)
less “rolling resistance”
resistance

“If 60% of the US National Highway System were

converted to concrete pavements, the annual
savings in diesel is about US$8.2 billion/year”
(G. Voigt, ACPA’s testimony in US Congress).

Less (non--
consumption of fossil fuel (non
renewable energy)

Less emission of CO2

Consumes 5X less diesel to construct
(thinner) see next slide
25

Consumes 5X less diesel to construct.

50mm Asphaltic Concrete Wearing Course

60mm Asphaltic Concrete Binder Course
75mm Dense Bituminous Macadam roadbase

300mm Crushed Aggregate roadbase

225mm Crushed Agregate subbase

Cross-Section Detail - Asphaltic Concrete Pavement

200mm Plain Jointed Concrete

150mm Lean Concrete sub-base
Subgrade
Cross-Section Detail - Plain Concrete Pavement

26

Reuse Waste Material : Pulverised Fly
Ash (PFA), Ground Granulated
Blastfurnace Slag (GGBS).

PFAand GGBS are cement

replacement materials - reduce cement
usage

PFA used in concrete roads

Note: 1ton cement ≈1 ton CO2 emission

27

Once project completed, road builders want to
move on to new roads.

Complaints by road users during road repairs –

TRAFFIC JAMS

More Road Accidents during repairs

Antwerp’s major roundabout repair scenario:

1 time inconvenience = 40 years of convenience

CONCRETE ROADS = LESS/NO MAINTENANCE

end

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A. Higher Initial Cost
B. Difficult and more expensive to repair
C. Noise
D. Wear out Tyres
E. Slipform Machines not available
F. No Trained Crew

29

Initial Cost (Construction Cost)

Acquisition

Concept Planning

Preliminary Design

Detail Design

Construction Cost

Life Cycle Cost (LCC)

Initial Cost +Use & Maintain Cost + Disposal/Residual

Whole of Life Costing (WHOLC)

WHOLC = LCC + Road User Cost

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 Initial Vs. Vs.
Pavement Type Cost Asph. Asph.
RM/m2 RM/m2 %
PCP -Truss Screed - No
1 Dowels 95.85 8.5 9

2 PCP -Truss Screed – Dowelled 111.23 23.88 27

PCP -Slipform Paver - No

3 Dowels 96.81 9.46 10
PCP - Slipform Paver -
4 Dowelled 112.20 24.85 28

CRCP - Slipform pavers

5 (PCP +RM48) 144.81 57.46 65

6 Asphalt Road (Typical) 87.35

 Whole-of-Life
Costing
(WHOLC=1+2+3+4)

1. Construction 2.
3.
Cost Maintenance 4.Road
Residual
(Initial Cost=1) Cost User Cost
Cost
(LCC=1+2+3)

Vehicle Operating Cost Travel Time Cost

•Fuel Consumption Accident Cost
•Normal Travel Time
•Tyre Wear •Insurance Cost
•Maintenance Delay
•Maint. and Repair •Loss to nation
•Construction Delay
•Depreciation

32

Source: Queensland Dept. of Main Roads
Item Pavement Type Initial Cost WHOLC
A$/m2 A$/m2
Granular 57.13 117.87
A Overlay + AC
B AC + CTB 66.31 120.52
C Full Depth AC 95.81 148.02
D PCP 65.46 77.15
E CRCP 77.51 82.59

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Australian Experience (Queensland
report)

 PCP < 2/3 cost of cheapest Asphalt

 PCPbecomes the MOST POPULAR

CHOICE of pavement for NEW ROADS
IN AUSTRALIA

34
 Concrete roads if constructed well, no
major repair is needed for 40 years.

 Ifrepair is needed, it is similar to normal

concrete repair

35

Whisper (Exposed)
Concrete –
e.g.Belgium and
Holland

US research on
Grinding and
Grooving
technology.

36

Safety or Cost of Tyres?
Tyres?

Concrete road is rougher – more friction and
stops vehicle better (shorter stopping
distance)

Better skid resistance

Think Safety!

37
 Slipform Machines in Asia
Country Slipform Machines

China 80

India 40

Korea 85

Japan 15

Philipines 40

Indonesia 20

Thailand 15

Vietnam 12

Myanmar 15

Malaysia (1990) 9

Malaysia (2011) 0

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39

No new Projects

No Continuity

NSE (1988), NKVE (1990) , KLIA (1990)
crew GONE

CIDB to train and certify pavement
workers

Engage Airport Concrete Pavement
(KLIA2?) or flatfloor specialist contractors
as Temporary Measure

end

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41

Item39 of keynote address delivered by
Dato’ Shaziman during the 8th Malaysia Road
Conference, Oct. 2010

“TheGovernment has also approved 5% of

new roads in the 10th Malaysian Plan to be
constructed using cement concrete”.

42


New Roads length, km 5% Conc,
km
Sarawak 2,819 141
Sabah 2,540 127
Peninsular 6,312 316
Total 11,671 584

43
Think Low Maintenance and WHOLC
Think New Niche Industry : Alternative
Competitor to Asphalt
Think Safety

Advantages of Concrete Road are numerous

Common complaints/disadvantages of
concrete road can be dispelled.

Policy for 5% of roads in 10MP to be concrete

roads

44
45