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SEMINAR ON EARTHQUAKE PROTECTIONAWARENESS AND PROMOTION OF HIGH DAMPING RUBBER BEARING

Presented by : Dato’ Ir. Dr. Ismail Mohamed Taib,Managing Director, Jambatan Kedua Sdn Bhd

12th November 2015Hotel Promenade

Kota Kinabalu, Sabah, Malaysia

PERFORMANCE OF HIGH DAMPING NATURAL RUBBER BEARING (HDNRB) AT JAMBATAN SULTAN ABDUL HALIM MU’ADZAM SHAH

JAMBATAN KEDUA SDN. BHD. (824573-U)

Wholly owned by Minister of Finance, Incorporated

CONTENT

Project Introduction

Design Consideration

Structural Health and Monitoring System

Awards

Conclusion



PROJECT INTRODUCTION

The construction of PB2X commenced in November, 2008 was open totraffic on 1st March 2014.

The Project faces various challenges in applying sustainability to bothdesign, construction, operation and maintenance.

Jambatan Sultan Abdul Halim Mu’adzam Shah is the longest bridge in theworld to have High Damping Natural Rubber Bearing (HDNRB).

Jambatan Kedua Sdn Bhd (JKSB), awholly-owned company of theMalaysia Minister of Finance (MoFInc.) is the concessionaire for theSecond Penang Bridge Project (PB2X).

The RM4.5 billion bridge project is thelongest in South-East Asia with a totallength of 16.9 km over water.



JKSB was appointed as concessionaire for PB2X in August 2008 forperiod of 45 years. It is responsible for the project management, design,construction, operation and maintenance.

Overall View of Jambatan Sultan Abdul Halim Mu’adzam Shah, Malaysia (Second Penang Bridge)



Overall Project Organization



Distribution of Contract Packages

• PB2X is divided into the following packages :-

Package 1, 2, 3A & 3B Involves HDNRB



• Second Penang Bridge area is located within the stable Sunda tectonic platewith low seismic activity level. However, this low seismic region is situatedabout 300-600 km from Sumatran faults which have produced earthquakeswith ground motions that are felt in buildings in Kuala Lumpur andSingapore.

Seismic Design Consideration

• The seismic design was based on the Design Response Spectrum obtainedfrom a Seismic Hazard Assessment Study carried out for the Project.

DESIGN CONSIDERATION



The Employer’s Requirement (ER)requires no damage criteria for a 500years return period. In addition to this, arequirement of ‘no collapse’ criteria forthe most credible earthquake (2500 yearsreturn period) was also introduced.

During the design review process, theIndependent Checking Engineer (ICE)had highlighted that the spun piles at theapproach marine bridge by Package 1Contractor could only safely cater for the475 year earthquake and found to beoverstressed under the 2500 yearsearthquake event and the piles wouldexperience section failure due tobrittleness.



In line with the current design requirement, the Second Penang Bridge ispioneering in Malaysia to be fully designed for seismic load for a 475 yearreturn period earthquake and a 2500 year return period earthquake with ‘nocollapse’ criteria.

Minimal Damage

• Essentially elastic performance• Minor inelastic response may

occur and post earthquake damage is limited to cracking of concrete and minor yielding of steel components

• Permanent offsets associated with plastic hinging or with non-linear foundation behavior are not apparent

• Full access to normal traffic is available almost immediately following the earthquake

Repairable Damage

• Damage that can be repaired without compromising the requirement service level

• Inelastic response is acceptable including concrete cracking reinforcement yielding, local minor spalling of cover concrete

• The extent of damage is to be sufficiently limited such the structure can be restored essentially to its pre-earthquake condition without replacement of reinforcement bars of primary structure members.

• Repairs will not require structure closure to traffic

No Collapse

• Damage that does not cause collapse of any span or part of the structure, non lead to the loss of ability of primary support members to sustain gravity loads

• Permanent offsets may occur and damage consisting of cracking, reinforcement yielding and major spalling of concrete may require bridge closure

• Reinstatement of the structure may require extensive repairs and potentially the reconstruction of the bridge.

475 Years Return Period Earthquake

2500 Years Return Period Earthquake



• A resolution between JKSB, ICE and Package1 and 2 designer was reached by changingthe bridge articulation via introducingseismic bearing as construction was alreadyat an advanced stage.

• High Damping Natural Rubber Bearing(HDNRB) has the ability to withstand largedisplacement in bilateral and rotationaldirection, durable with minimal maintenanceas well as utilizing natural rubber availablelocally

• Packages 3A and 3B was also instructed toadopt HDNRB to replace the conventionalmechanical pot bearings.



Principal Plastic Hinge

Secondary Plastic Hinge

Package 1

Package 2

It is observed that the seismic design criteriaand design response spectra for both 475years and 2500 years return periodearthquake have been derived by the designand build contractor responsible for Package1 but that the criteria are also being used inthe design of Package 2.

Coordination is required between Package 1and Package 2 in order that the performancelevel can be achieved for the wholestructure.

Interface Between Package 1 and Package 2



Comparison between CHEC and ICE Design Response Spectrum



HDNRB provides a simple and economical isolation system. It possesses thelow horizontal stiffness needed and is capable of safely withstanding thelarge horizontal displacements imposed during an earthquake. The bearingwas designed to meet two sets of action as per below:

o SLS non-seismic actions – conformance with BS5400

o SLS non-seismic actions simultaneous with a 2500-year returnperiod seismic event – conformance with EN15129



On 11 April 2012, 3.30 pm, anearthquake measuring 8.6 on the Ritcherscale shook Northern Sumatra just 419km away from Second Penang Bridgeproject site. It was a moment ofreckoning for JKSB. The bridge was notyet complete, but its earthquakeprotection system had been installed, sothis was a real test of its efficacy. Thebridge passed the test with flyingcolours.

Although cracks appeared on one of landpier, Package 3B, this was due to the factthat the pier has been cast only threehours before the earthquake, hence theconcrete had yet to set. The pier was ofcourse, duly repaired.



Two (2) bearings will be required ofeach intermediate pier and 4 bearingswill be required of each expansion jointpiers. For this project there are 88 nos.6 spans modules in total. Also, have 10nos. 5 span modules in total.

HDNRB will be required for theinstallation at each pier heads of thebridge for the purpose to transmit theloads from the superstructures to thesubstructures and to accommodatetranslation movement due to expansionand contraction and restrain the bridgewithin its alignment.

HDNRB Installation



There are two types of pier for the bearing installation. One is forintermediate joint where the bearing will be installed underneath the1.4m width the cast in-situ stitch segment and another one will beinstalled underneath the P1 segment (for movement joint pier). The topmasonry plate will be cast into the down-stand plinth of the P1 segmentat the casting yard.

Bridge articulation for a 6 span module

Bridge articulation for a 5 span module



Typical Types E1 & E4 Typical Types E2 & E3

Four types of High Damping Natural Rubber Bearing (HDNRB) used inthe project and they are as follows:

1) HDNRB Type E12) HDNRB Type E2 with preset displacement3) HDNRB Type E3 with preset displacement4) HDNRB Type E4

Only two type HDNRB have preset displacement, Type E2 and Type E3.For this HDNRB, the preset plate will be used for the bearing installation.Once the bearing has been grouted and all loads have been transferred tothe bearing, the preset plate will be removed from the bearing



The bearing with preset plates in place were installed when the deck is atit’s lowest temperature, i.e. between nightfall and daybreak. This is toreduce the possibility of excessive loads on the uncured installation groutand so that the expansion of the deck assembly during subsequentthermal cycles causes the unidirectional preset plates to becomedisengaged from each other. The preset plates were removed when in thedisengaged condition in the early morning hours.

HDNRB with preset plate (background),HDNRB with preset plate removed (foreground)



Sequence Installation of HDNRB

Installation of HDNBR at Package 2 ( Marine )



Installation of HDNBR at Package 3B ( Land )



• In order to meet 2500 years return period earthquake criteria, Package1’s contractor also re-designed the cable stayed bridge.

• Bridge dampers are also installed at the critical cables.

Cable Stayed Design



• The total weight of the form travelleris 1,655kN.

• Package 1 analysis indicate that therisk during construction is withinacceptable limit based on a 100 yearsreturn period. ICE also agreed to theanalysis.

• ICE also noted that the travellerformwork design did not take intoaccount of any seismic effect.

Balanced Cantilever Construction



With the introduction of HDRB, the Modular Typeexpansion joint system with 3D movement capabilitywas adopted for the interface between the approachspans and the Cable-Stayed Bridge and between theapproach spans and interface piers at the landexpressways to cater for the difference in structuralbehavior.

Expansion Joint



The segmental box girders (SBGs) for theapproach spans were redesigned withInterlocking Finger-type expansion jointsassisted with twin dowels at the expansionjoint piers segments to control the seismictransverse movement.

Expansion Joint



Liquefaction

A report of “Study of Likelihood of Tsunamiand Resulting Liquefaction Phenomena inthe Second Penang Bridge Site” had beencarried out in August 2009 concluded thatthe probability of liquefaction wasgenerally less than 50% for earthquakemagnitude of less than 7, with a maximumacceleration of 0.1g based on a returnperiod of 500 years.

For earthquake of magnitude greater than7 and a horizontal acceleration 0.1g, theprobability of liquefaction is 50% to 95%for the layers with SPT-N values less than10 which mean likely to be liquefied. Withlikely epicenters of earthquake being300km to 500km away from the bridge theground acceleration are much lower thanthe values adopted in the study and so thepotential risk of liquefaction at the site issmall.



• Original Package 2 contract amount for bridge bearing wasRM 32,024,454.40.

• HDNRB was installed at Package 2 to replace the Mechanical Potbearings at NO ADDITIONAL COST.

Cost



© 2014 Jambatan Kedua Sdn Bhd

View of Bandar Cassia Toll Plaza at Night



Integrated Module Overview

Structural Health & Monitoring System (SHMS)



To monitor the HDNRB’s performance, accelerometers and FBG displacementsensors for bearings and expansion joints are used. Data loggers and relatedcomponents are configured to transmit the acquired monitoring data to theDAQ server

The data from FBG displacement sensors for bearings and expansion joints areto be acquired by the FBG data loggers.

The data from FBG displacement sensors for bearings and expansion jointsinstalled at the interface between the cable-stayed bridge and the approachbridges are to be acquired by the FBG data logger located at the cable-stayedbridge.



The data from FBG displacement sensors for bearing and expansion jointsinstalled at the interface between the approach bridges and expressway, andthe ramp in Batu Maung area are to be acquired by the FBG data logger locatedbetween the approach bridges and the expressway.

Acceleration data is acquired by the dedicated dynamic acceleration dataloggers.

Data loggers are deployed on the same sections as where the rubber bearingdisplacement sensors are located for easy maintenance.



FBG Displacement Sensor

By monitoring the horizontal and vertical displacement of the bearings installed atthe ramp in Batu Maung area as well as the bearings at approach bridges, compareand analyse the tolerance of the bearings to evaluate their operational status.

Analyse with the same behavioral analysis method as for the bearing in Cable-stayed section.

Monitor the operational status of bearings to evaluate the structural health of thebridge and use the data for reinforcement and maintenance.

FBG displacement sensors for therubber bearings are placed at theexpansion joints between theapproach bridge and cable-stayedbridge, the approach bridge andexpressway, and the ramp in BatuMaung area so that strain gaugesare placed evenly in the ApproachBridge section.



Accelerometer

• In order to evaluate the damping performance of bearings, monitor thevibration which transfers from the upper structure to the lower structure.

• Compare and analyse the acceleration data with the displacement data toevaluate the bearings’ status.

• By evaluating the operationalstatus of bearings, compare withthe displacement data to use forreinforcement and maintenance.

• Accelerometers for the rubberbearings are placed on theinterfacing piers between theapproach bridges and cable-stayed bridge, the approachbridge and expressway, and theramp in Batu Maung area.



Expansion Joint Displacement

In addition to LVDT and accelerometers, tri-axial and uni-axial load cells and strain gaugesare suggested in the pre-bid document in order to monitor the function of rubber bearing.As the load cell shall be installed between superstructure and bearing, bridge deck shall belifted up for the installation, which is impracticable due to potential structural damage.

Moreover in case strain gauges are installed at rubber bearing, actual displacement ofbearing exceeds the measurable range of strain gauges. So load cells and strain gauges areexcluded and it is preferable to measure the displacements instead of strain to evaluate thefunction of bearings.

Expansion joint displacement measurement is required to analyse the relationship betweenbearing and superstructure, which is to evaluate the rubber bearing function by comparingthe expansion of Approach Bridge with displacement measurement of the bearings.Monitoring the expansion joint displacement of approach bridge box gives a basis foroperation status evaluation and planning of repair and rehabilitation.

The movements of bearing and superstructure are analysed and the result will be used toevaluate the function of expansion joint. Analysis of expansion joint displacementmeasurement will be done in the same way as that in the cable-stayed bridge.

Expansion joint displacement transducers in Approach Bridge are deployed at the samelocation as rubber bearing sensors.



Deployment Plan for Expansion Joint Transducers



Data logger deployment



The International Green Apple Awards; forthe BuiltEnvironment & Architectural Heritage 2013– 24 June 2013

The award is giving by The Green Organizationwhich recognize and reward those who are making apositive contribution to their built environment andarchitectural heritage. JKSB also became the GreenWorld Ambassador for year 2014.

Platinum Building Award (DesignAssessment) – Green Building Index (GBI)– 27 February 2014

The benefits of GBI are; Save energy and resources,minimize the emission of toxic substancesthroughout its life cycle, harmony with the localclimate, traditions, culture and the surroundingenvironment and increase workplace activities.

AWARDS



Geneva International Star Award for Quality (ISAQ) 2014 -International Star Quality Convention in Geneva, 2014– 21 September 2014

The objective of the International Star Award for Quality (ISAQ) is to recognize thecommitment to quality in the top areas of business, services and industry fromdiverse sectors all around the world.

Jambatan Kedua Sdn Bhd (JKSB), the concessionaire for the Sultan Abdul HalimMu’adzam Shah Bridge or Penang Second Bridge, won a gold award at theInternational Star Award for Quality (ISAQ) during the International QualityConvention in Geneva.



Road Engineering Excellence Award 2014 -Road Engineering Association Of Malaysia(REAM)– 10 November 2014

This award was introduced to confer recognition tothe most outstanding road engineering project builtwithin Malaysia.

Special Project Award (Silver Awardee) -Prime Minister’s Hibiscus Award 2014/2015

Prime Minister’s Award 2014/2015 presents anopportunity for public recognition of business,industry’s environmental accomplishment, leadershipand serves to create environmental awarenessamongst enterprises that have yet to demonstrateenvironmental stewardship. JKSB was the firstconstruction company/concessionaire to participateand achieve the Special Project Award.



The Brunel Medal Awards 2015 - ICE (Institution of Civil Engineers), UK– 9 October 2015

ICE's Annual Awards are designed to recognize both outstanding civil engineeringachievements and contribution to the profession and the institution. The Brunel Medalis awarded to a project or individual that represents excellence within civil engineering.

Jambatan Kedua Sdn Bhd (JKSB), has carved Malaysia name on the 'Civil EngineeringWall of Fame' after being the first Southeast Asian country and the third countryoutside the United Kingdom to be honoured with the prestigious Brunel Medalaward.

The ICE Awards Ceremony was held at ICE Headquarters, One Great George Street,Westminster, London.



CONCLUSION

After almost two years since Jambatan Sultan Abdul Halim Mu’adzam Shahopen to traffic, the performance of HDNRB are within the expectation andJKSB is proud on the implementation of HDNRB in the project.

Despite its implementation in a fast track manner, the Jambatan Sultan AbdulHalim Mu’adzam Shah project was constructed to the highest quality,considering health, safety, cost, sustainability and environmentalconservation.



Thank You For Your Kind Attention

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