KEMENA INDUSTRIES SDN BHD

RC OTHERS

BOX CULVERT, U-DRAIN, L-SHAPE (DRAIN / RETAINING WALL)

Product Specification

Certified to ISO 9001:2008 Cert No. AR3901

COMPANY PROFILE

KEMENA INDUSTRIES SDN BHD (KISB) was incorporated on

17 March 1987. It was jointly formed by IJM Corporation Bhd

(IJM) and Bintulu Development Authority (BDA). IJM is one of

the Malaysia’s leading conglomerates and is listed on the

main market of Bursa Malaysia Securities Berhad, whereas

BDA is the local government authority.

In 1997, KISB had started to manufacture various sizes of R.C.

Others products, which include box culvert, u-drain, L-shape

drain and retaining wall. Over the years, KISB has expanded

its business activities and improved its qualities of production

to meet customers’ expectation. The production operations

are carried out and supervised by experienced staff. KISB’s

quality control system was awarded the prestigious ISO

9001:2008 for the manufacturing of precast concrete

products and ready mixed concrete.

INTRODUCTION

R.C. Others products include box culvert, u-drain, L-shape

drain and retaining wall. Box culvert is used as drainage

channels, vehicular and pedestrian underpasses, highways,

bridges, river crossings, utility tunnels, subway lines, railway

crossings, canals, garages, motorcycle underpasses, etc. U-

drain and L-shape drain is used for the construction of

waterways and open flow channels. L-shape retaining wall is

used as earth retaining structure.

All R.C. Others products are specially designed by consultant.

The reinforcement requirements are predominantly catered

for handing during manufacture, storage, transport and on

site as appropriate.

SPECIFICATION AND DESIGN

Structural design of box culvert shall be in accordance to

MS1293: Part 1: 1992, BS5400: Part 4: 1990 and BS8110:

1985.

Structural design of U-drain, L-shape drain and retaining wall

shall be in accordance to BS8110: 1985.

APPLICATION

Drainage channels, vehicular and pedestrian underpasses,

highways, bridges, river crossings, utility tunnels, subway

lines, railway crossings, canals, garages and motorcycle

underpasses.

MANUFACTURE

Steel moulds are used to manufacture the RC Others unit

under a factory-controlled environment. The fabricated steel

cage is installed into the steel mould after the application of

mould oil. The mould shall be assembled properly to ensure

no gap between the edges of the mould walls. After the

concrete has been placed, vibrated by internal vibrators and

cured to sufficient strength, the products are demoulded and

the production cycle is repeated.

CONCRETE MATERIAL

AGGREGATE

Coarse aggregates and fine aggregates shall comply with MS

29.

CEMENT

Cement shall comply with MS 522.

CONCRETE

The concrete grade shall be 40 N/mm2.

REINFORCEMENT

Reinforcing steel shall comply with MS 146 for main

longitudinal bar.

HANDLING

The weep holes in the R.C. Others units act as lifting holes for

handling. It is recommended that a spreader beam is used

when slinging the units to avoid cracks in the legs.

STACKING

R.C. Others units are to be stacked on level and stable ground

to avoid cracking of base slab.

JOINTING

R.C. Others units are supplied with plain butt joints. Cement

mortar is normally used to fill the gaps between the R.C.

Others units.

QUALITY ASSURANCE

Quality Assurance in the manufacture of the products is

provided by established MS ISO 9001 Quality Management

System.

Box Culvert KISB box culvert is available in Standard Size (for nominal width between 600mm and 1800mm) in the length of 1 meter. Super Size

U-drain (for nominal width between 2100mm and 3650mm) is available upon request. KISB box culvert is usually available WITHOUT

Dry Weather Flow Channel. However, box culvert WITH Dry Weather Flow Channel is also available upon request. 50mm diameter

weep holes are provided to eliminate the effect of hydrostatic pressure.

Design Considerations

1. KISB box culvert is designed in accordance to MS1293: Part 1: 1992, BS5400: Part 4: 1990 and BS8110:1985.

2. Concrete shall be Grade 40.

3. All steel bar shall be Grade 460.

Standard Size Box Culvert – Dimensions (for nominal width between 600mm and 1800mm)

Nominal Size Length Dimension

b h tb tt ts

mm X mm mm mm mm mm mm mm

600 X 300 1000 600 300 70 62 135

X 450 1000 600 450 70 58 135

X 600 1000 600 600 70 54 135

750 X 450 1000 750 450 75 65 135

X 600 1000 750 600 75 61 135

X 750 1000 750 750 75 58 135

900 X 450 1000 900 450 80 69 140

X 600 1000 900 600 80 65 140

X 750 1000 900 750 80 62 140

X 900 1000 900 900 80 58 140

1200 X 600 1000 1200 600 95 77 150

X 750 1000 1200 750 95 73 150

X 900 1000 1200 900 95 69 150

X 1050 1000 1200 1050 95 64 150

X 1200 1000 1200 1200 95 60 150

1500 X 750 1000 1500 750 100 83 175

X 900 1000 1500 900 100 79 175

X 1050 1000 1500 1050 100 76 175

X 1200 1000 1500 1200 100 72 175

X 1350 1000 1500 1350 100 69 175

X 1500 1000 1500 1500 100 65 175

1800 X 900 1000 1800 900 115 93 200

X 1050 1000 1800 1050 115 89 200

X 1200 1000 1800 1200 115 85 200

X 1350 1000 1800 1350 115 81 200

X 1500 1000 1800 1500 115 78 200

X 1650 1000 1800 1650 115 74 200

X 1800 1000 1800 1800 115 70 200 (Subject to change without prior notice)

ttts tt

tbtb b

h

12m

m R

ebate

Super Size Box Culvert – Dimensions (for nominal width between 2100mm and 3650mm)

Nominal Size Length Dimension

b h tb tt ts

mm X mm mm mm mm mm mm mm

2100 X 1200 1000 2100 1200 180 151 200

X 1500 1000 2100 1500 180 141 200

X 1800 1000 2100 1800 180 130 200

X 2100 1000 2100 2100 180 120 200

2400 X 1200 1000 2400 1200 180 150 200

X 1500 1000 2400 1500 180 143 200

X 1800 1000 2400 1800 180 135 200

X 2100 1000 2400 2100 180 128 200

X 2400 1000 2400 2400 180 120 200

2700 X 1500 1000 2700 1500 180 141 200

X 1800 1000 2700 1800 180 133 200

X 2100 1000 2700 2100 180 126 200

X 2400 1000 2700 2400 180 118 200

X 2700 1000 2700 2700 180 110 200

3000 X 1500 1000 3000 1500 180 140 200

X 1800 1000 3000 1800 180 132 200

X 2100 1000 3000 2100 180 124 200

X 2400 1000 3000 2400 180 116 200

X 2700 1000 3000 2700 180 108 200

X 3000 1000 3000 3000 180 100 200

3300 X 1800 1000 3300 1800 200 132 225

X 2100 1000 3300 2100 200 124 225

X 2400 1000 3300 2400 200 116 225

X 2700 1000 3300 2700 200 108 225

X 3000 1000 3300 3000 200 100 225

3650 X 1800 1000 3650 1800 200 132 255

X 2100 1000 3650 2100 200 124 255

X 2400 1000 3650 2400 200 116 255

X 2700 1000 3650 2700 200 108 255

X 3000 1000 3650 3000 200 100 255

X 3300 1000 3650 3300 200 92 255

X 3600 1000 3650 3600 200 84 255 (Subject to change without prior notice)

ttts tt

tbtb b

h

12m

m R

ebate

U-Drain KISB U-drain is available in Small Size (for nominal width between 300mm and 450mm) and Standard Size (for nominal width

between 600mm and 2100mm) in the length of 1 meter. Super Size U-drain (for nominal width between 2400mm and 3600mm) is

available upon request. KISB U-drain is usually available WITH Dry Weather Flow Channel. However, U-drain WITHOUT Dry Weather

Flow Channel is also available upon request. 50mm diameter weep holes are provided for drainage of the retained soil so that when

combined with the butt jointed units, the buildup of hydrostatic pressures can be prevented.

Design Considerations

1. KISB U-drain is designed in accordance to BS 8110:1985.

2. Concrete shall be Grade 40.

3. All steel bar shall be Grade 460.

Small Size U-drain – Dimensions (for nominal width between 300mm and 450mm)

Nominal Size Length Dimension

b h tb tt

mm X mm mm mm mm mm mm

300 X 300 1000 300 300 50 50

X 450 1000 300 450 50 45

X 600 1000 300 600 50 40

450 X 300 1000 450 300 55 55

X 450 1000 450 450 55 51

X 600 1000 450 600 55 48

X 750 1000 450 750 55 44

X 900 1000 450 900 55 40 (Subject to change without prior notice)

Standard Size U-drain – Dimensions (for nominal width between 600mm and 2100mm)

Nominal Size Length Dimension

b h tb tt

mm X mm mm mm mm mm mm

600 X 300 1000 600 300 70 62

X 450 1000 600 450 70 58

X 600 1000 600 600 70 54

X 750 1000 600 750 70 49

X 900 1000 600 900 70 45

750 X 300 1000 750 300 75 69

X 450 1000 750 450 75 65

X 600 1000 750 600 75 61

X 750 1000 750 750 75 58

X 900 1000 750 900 75 54

X 1200 1000 750 1200 75 50

900 X 300 1000 900 300 80 73

X 450 1000 900 450 80 69

X 600 1000 900 600 80 65

X 750 1000 900 750 80 62

X 900 1000 900 900 80 58

X 1050 1000 900 1050 80 54

X 1200 1000 900 1200 80 50 (Subject to change without prior notice)

tt tt

h

t

t b t

R=b/2

tt tt

tbbtb

b/2

tb

tb

h

Standard Size U-drain – Dimensions (for nominal width between 600mm and 2100mm)

Nominal Size Length Dimension

b h tb tt

mm X mm mm mm mm mm mm

1200 X 300 1000 1200 300 95 86

X 450 1000 1200 450 95 82

X 600 1000 1200 600 95 77

X 750 1000 1200 750 95 73

X 900 1000 1200 900 95 69

X 1050 1000 1200 1050 95 64

X 1200 1000 1200 1200 95 60

(Subject to change without prior notice)

Nominal Size Length Dimension

b h tb tt

mm X mm mm mm mm mm mm

1500 X 600 1000 1500 600 100 86

X 750 1000 1500 750 100 83

X 900 1000 1500 900 100 79

X 1050 1000 1500 1050 100 76

X 1200 1000 1500 1200 100 72

X 1350 1000 1500 1350 100 69

X 1500 1000 1500 1500 100 65

1800 X 600 1000 1800 600 115 100

X 750 1000 1800 750 115 96

X 900 1000 1800 900 115 93

X 1050 1000 1800 1050 115 89

X 1200 1000 1800 1200 115 85

X 1350 1000 1800 1350 115 81

X 1500 1000 1800 1500 115 78

X 1650 1000 1800 1650 115 74

X 1800 1000 1800 1800 115 70

2100 X 1050 1000 1800 1050 180 156

X 1200 1000 1800 1200 180 151

X 1350 1000 1800 1350 180 146

X 1500 1000 1800 1500 180 141

X 1650 1000 1800 1650 180 135

X 1800 1000 1800 1800 180 130

X 1950 1000 1800 1950 180 125

X 2100 1000 1800 2100 180 120 (Subject to change without prior notice)

150

tb

btb tb

h

tt tt

b/2

1000

btb tb

h

tt tt

200

tb

L-Shape Unit KISB L-shape units are divided into two categories, namely ‘L6’ and ‘L9’ Series. Both series are available in drain type and retaining wall type. The standard size of the L-shape units available are shown in the table below. However, other sizes can be customized as per request, subject to the structural stability of the L-shape units.

Design Considerations

1. KISB U-drain is designed in accordance to BS 8110:1985.

2. Concrete shall be Grade 40.

3. All steel bar shall be Grade 460.

Standard Size L-shape Unit L6 Series – Dimensions

Nominal Size Length Dimension

B H tt tb

mm X mm mm mm mm mm mm

600 X 900 1000 600 900 143 145

750 X 1200 1000 750 1200 138 143

900 X 1200 1000 900 1200 138 140

900 X 1500 1000 900 1500 134 140

1050 X 1500 1000 1050 1500 134 137

1200 X 1500 1000 1200 1500 134 135

1350 X 1500 1000 1350 1500 134 132

1350 X 1800 1000 1350 1800 130 132

1500 X 1800 1000 1500 1800 130 130

1500 X 2100 1000 1500 2100 126 130

1650 X 2100 1000 1650 2100 126 127

1800 X 2100 1000 1800 2100 126 124

1800 X 2400 1000 1800 2400 122 124

1950 X 2400 1000 1950 2400 122 122

2100 X 2400 1000 2100 2400 122 119

2100 X 2700 1000 2100 2700 118 119

2400 X 2700 1000 2400 2700 118 114

2400 X 3000 1000 2400 3000 114 114 (Subject to change without prior notice)

H

tt

tb

B

R203

50mm Dia. Weep Hole

450 152

152

Standard Size L-shape Unit L9 Series – Dimensions

Nominal Size Length Dimension

B H tt tb

mm X mm mm mm mm mm mm

2700 X 3300 1000 2700 3300 194 193

2700 X 3600 1000 2700 3600 190 193

3000 X 3600 1000 3000 3600 190 189

3000 X 3900 1000 3000 3900 187 189

3300 X 3900 1000 3300 3900 187 184

3300 X 4200 1000 3300 4200 183 184

3600 X 4200 1000 3600 4200 183 180

3600 X 4500 1000 3600 4500 180 180 (Subject to change without prior notice)

H

tb

tt

B

230

R203 R203

230600

230

50mm Weep Hole

MANUFACTURING PROCESS

1. Reo Cage Preparation

3. Reo Cage Installation

5. Pipe Demoulding

2. Mould Preparation

4. Casting

6. Stacking

CERTIFICATES

KEMENA INDUSTRIES SDN BHD (CO. NO. 143829-U)

OFFICE Sublot No. 56, First Floor, Tanjung Batu Commercial Centre, Jalan Tanjung Batu,

P.O.Box 280, 97007 Bintulu, Sarawak. Office Tel: 086-333524, 332866 Fax: 086-331506

FACTORY Lot 1176, Kemena Industrial Estate, Block 32, Jalan Bintulu-Sibu,

97007 Bintulu, Sarawak. Factory Tel: 086-325004 Fax: 086-339927

A subsidiary of

IJM CORPORATION BERHAD (104131-A)