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This Structural Audit Report for the Midfield and FTZ Tunnels has been prepared by KEO International
Consultants. Contents of this Audit Report remain the property of KEO International Consultants and
may not be copied, used or distributed without the expressed prior permission of KEO International
Consultants. Copyright. Revision 0 15th June 2015
Contents
1.
EXECUTIVE SUMMARY.....................................................................................2
2.
INTRODUCTION..................................................................................................4
3.
MAIN REPORT....................................................................................................6
3.1 Visible Defects..............................................................................................6
3.2 Summary of Defects.....................................................................................7
3.3 Discussion of Defects...................................................................................9
4.
RECOMMENDATIONS......................................................................................12
APPENDIX A................................................................................................................15
PHOTOGRAPHS OF DEFECTS..................................................................................15
APPENDIX B................................................................................................................16
LOCATION OF PHOTOGRAPHS OF DEFECTS.........................................................16
Revision
Date
Description
Author
Checked
17/07/15
Mohamed Afify/
Emmanouil Fiorakis
C. Davey
27/07/15
Mohamed Afify/
Emmanouil Fiorakis
C. Davey
Reviewed: .
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1. EXECUTIVE SUMMARY
KEO have been engaged by Keppel FMO to inspect and provide a report for a third annual
audit of the Midfield and FTZ tunnels that includes,
a) A general description of the current state of the building structures including progress
of repair work.
b) Recommendations for short term and long term maintenance and repair requirements
c) Recommendations for further investigation if required
d) Photographs and a location diagram of each photograph taken.
It should be noted that the Contractors maintenance period has expired since 28th of
February 2015, after a duration of 365 days from the contractual completion date.
Based on our visual observations and the As Built drawings provided, the Midfield and
Free Trade Zone (FTZ) tunnels have been constructed to a reasonable standard in
accordance with the As Built structural drawings. However, there are still defects that
require further repair work now or maintenance in future years.
In section 3.1 Visible Defects, in the Report there is a list of eight (8) items that cover the
defects found in the structural audit. Based on the observations and results of the previous
second audit report of 15th January 2015 and combined with the present one, we can
divide these items into four groups depending on the requirements for repairs.
1. Items (i) and (iii) need further scheduled monitoring. These items relate to groundwater
leaking into the tunnels and affect the operation of the tunnels. These items were listed
on the DIA snag list.
2. Item (ii) need further scheduled monitoring. This item relate to groundwater leaking
into the tunnels through the construction joints and movement joints.
3. Item (v) requires repair before the next rain season and frequent monitoring and
maintenance in a permanent and scheduled basis. This item relates predominantly to
waterproofing the Midfield and FTZ tunnel electrical substations roof slabs and keeping
water out of cable trenches. The Midfield tunnel roof slab had been waterproofed since
the first audit inspection. No further waterproofing has been observed.
4. Items (iv), (vi), (vii) and (viii) require ordinary maintenance works in a permanent and
scheduled basis.
The steel framed doors for the electrical substations are rusting and need repairs.
The Genset enclosures are still rusty and need continuous repairs and maintenance due
to the onset of rust. .
The concrete barriers with observed cracks and bubbling paint should be repaired and
kept in good condition through continuous and scheduled maintenance activity.
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2. INTRODUCTION
KEO International Consultants have been commissioned by Keppel FMO Pty Ltd to carry
out a third Structural audit of the Midfield and Free Trade Zone (FTZ) tunnels. The
previous Structural Audit Report for The Midfield & FTZ Tunnels was issued in March
2014, document number 13-5335-KEO-ST-RPT-0001, revision 1. In addition, a report
entitled Structural Audit Report for The Midfield Tunnel Screens was issued in June 2014,
document number 13-5335-KEO-ST-RPT-0002, revision 1. Likewise, an inspection and
audit report was conducted on January 17th, 2015, titled Second Audit Report. These
three previous reports should be referred to.
The Main Contractor for the tunnel projects is Sinohydro Gamuda - WCT JV, and the
Consultant for design and site supervision is Scott Wilson.
The latest audit inspection for the Midfield Tunnel, two substations, and east and west
bound pump room began on 15th June 2015. At the time of the inspection there was no
repair work in progress. Also, there had been no rain for many months and there was no
rainfall runoff on the road surface. Identification of groundwater leaking through the raft
slab was made easier.
The Midfield Tunnel screens were added to the side of the tunnel and the soffit of the roof
slab for aesthetical and noise canceling reasons, and have not changed since the previous
audit inspection. The steel members and fixings to the concrete tunnel appear to be in
good condition. However, the status of the recommendations included in the previous
report is not known at the time of writing this report. Also, the fire rating of the screen such
as intumescent paint, and the effect on the fire protection systems is not known and
outside the scope of this report. The tunnel is open to traffic and inspection has been
conducted with increased caution and difficulty. Carriageway inspection was possible only
during short traffic breaks.
The latest FTZ tunnel audit inspection began on 24rd June 2015. Included in the inspection
were two electrical substations and two pump rooms. The tunnel was not open to traffic at
the time of the inspection.
There had been no rain for many months before the
inspection.
The tunnel structures are cast in-situ. There is a base raft slab, retaining wall and roof slab
with Construction Joints through each element along the tunnel as shown on the As Built
drawings in Appendix B, that also show location of photographs taken during the latest
audit inspection. At the east and west portal of both tunnels there are movement joints
between the tunnel road and the approach ramps. There are two pump rooms for each
tunnel at road level that are cast in-situ structures. These pump rooms are for the road
drainage. The Midfield tunnel has two electrical substations that are supported by the
tunnel roof slab at the east and west portal. The substations are cast in-situ frames with
concrete columns and roof slab. The external walls are block in fill walls. The FTZ tunnel
has two electrical substations that are separate structures to the south of the tunnel.
These structures are cast in-situ with pad and strip footings, concrete columns and roof
slab. The external walls are block in fill walls.
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Report on the progress of repair work and identify any new structural defects,
Photograph the defects for record,
Identify the cause of the defect
Make recommendations for repair and maintenance of minor defects
Confirm that the structural adequacy of the tunnels and substations.
The visual inspection by KEO documented the concrete and other defects in both tunnels
and related building structures, refer to Appendix A Photographs. For the location of the
photographs taken refer to Appendix B. The previous audit reports were used for
comparison with the latest state of repair during the visual inspection. This report only
covers items that were visible at the time of the inspection. It does not include items such
as waterproofing under the invert slab of the tunnels and behind the retaining walls and
other inaccessible items.
The purpose of this KEO report is to confirm maintenance requirements for the Facilities
Manager and is for the use of Keppel FMO only. KEO International Consultants does not
accept any liability for the design and construction supervision of the existing tunnel
structures outside the scope of this report. KEO will not be held liable for any use of this
report by third parties.
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3. MAIN REPORT
3.1
Visible Defects
The First inspection of the Midfield tunnel was carried out on 26 th October 2014 and
the FTZ tunnel on 23rd December 2014 along with the electrical substations and
pump rooms.
The second one was carried out on 17th January 2015, 10 days before the
completion date of the Contractors Maintenance period.
Since the previous inspections carried out in January 2014, and January 2015, there
have been several repairs carried out by The Contractor as part of the DIA snaglist.
Overall the condition of the tunnels, sump pump rooms and electrical substations
has improved, the remaining work is mainly monitoring and maintenance works.
Note that there was rain around the time of the initial audit inspections carried out in
January 2014. For the previous inspections carried out in October and December
2014 there had been no rain for many months and hence no water runoff on the
road. Likewise, during the current inspection there had been no rain for long and no
water runoff on the road was observed.
Refer to Appendix A for the photographs of defects observed during the visual
inspections carried out, and Appendix B for the location of these photographs. The
majority of defects mentioned in the second audit report can be summarised as
follows along with progress made to date;
Defects observations mentioned in the second and present third audit:
I.
Water leaks through the concrete base raft slabs, or invert slab of the tunnels. Stains of water ingress have been observed in several locations without water
presence. Further scheduled monitoring is recommended.
II. Water leaks through the construction joints and movement joints along the
tunnels and approach sections. Additional pipes installed to address leaking
water from movement joints. No signs of leakage thru movement joints have
been observed during inspection in Midfield and FTZ tunnels, except of the
movement joint at the entrance of West Bound of FTZ tunnel, where it is
observed slight water ingress due to temporary diversion of water spilled from fire
lines at east substation above.
III. Ingress of water through the base of the retaining walls onto the road surface.
There was no evidence, or leaking water, during the third inspection at the base
of the retaining walls. Further scheduled monitoring is recommended.
IV. Excessive shrinkage cracks greater than 0.3mm in width in the slab around the
electrical substations in the Midfield tunnel. New epoxy paint observed with
significant bubbling and damages along with several cracks following the
shrinkage cracks of the concrete slab. Deteriorating epoxy paint coating and
shrinkage cracks could lead to spalling of concrete. The electrical substations of
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Summary of Defects
A brief description of the outstanding defects for the tunnel area, electrical
substations and pump rooms can be summarised as follows;
Midfield Tunnel:
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Shrinkage cracks in wall at the interface of the concrete elements and blockwork.
No water was observed at the time of the most recent inspection, however, cable
trenches should be inspected straight after the next significant rainfall.
FTZ Tunnel:
Water leakage was observed in the movement joint at the entrance of West
Bound of FTZ tunnel due to temporary diversion of water spilled from fire lines at
east substation above, Shrinkage cracks in concrete barrier and sidewalk
concrete slabs.
There was no moisture on the road surface adjacent to the traffic barrier to suggest
that there was groundwater leaking through the construction joint at the base of the
retaining walls, under the pedestrian access way and through the construction joint
at the base of the traffic barrier.
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Note that the bottom of the cable trenches inside the FTZ tunnel electrical
substations is below ground level. Water ingress could be from the roof slab or from
the side wall of the cable trench.
FTZ Tunnel Pump Rooms:
3.3
Discussion of Defects
3.3.1
3.3.2
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3.3.4
3.3.5
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4. RECOMMENDATIONS
At the time of the inspections for the latest third audit report, no repair work was taking
place in the Midfield or FTZ tunnel. At the time of writing this report, it is clear that the
Maintenance Period for The Contractor has finished.
The key recommendations for the structural maintenance of the two tunnels has changed
since the initial audit inspections due to the completion of the Contractors Maintenance
period on 28th of February 2015. We recommend Keppel FMO carry out the following:
a) Major defects have been repaired by the Contractor during maintenance period.
b) Monitor the areas where stains of potential water ingresses have been inspected.
c) Follow maintenance and repair schedule for the defects of category (iv), (v), (vi), (vii)
and (viii). Inspection and appropriate repairing works are proposed in a time frame of
six months, followed by corresponding repairing works, if required. Given that the main
reason of the cracks is the extreme temperature differences between summer and
winter, proposed periods for inspection and repairing works are October and April
every year.
d) Ensure that Keppel FMO have at least a copy of all the Warranties for work carried out
on the project. This is specified in the contract documents for the Airport Works.
Relevant to the structural audit, Warranties would include the waterproofing system for
the Midfield tunnel roof slab at the east and west portal, the waterproofing system for
all the roofs of the electrical substations and Foam rooms. There should be Warranties
for the waterproofing system for the tunnels for the base raft slab, retaining walls and
roof slab, plus the approach ramps to the tunnels. There should be Warranties for the
paint work for structural elements such as the electrical substation walls and doors,
generator enclosures and so on. Ask for Warranties on the repair work taking place
during previous audit report, such as the crack injection work.
e) Use this report as a record of defects to hold the Main Contractor accountable for
warranties.
An updated summary of recommendations for each of the items requiring repair are as
follows;
(i)
(ii)
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(iv)
Shrinkage cracks and deteriorating epoxy paint coating for Midfield tunnel around
Electrical Rooms:
Repair before the next rain season and frequent monitoring and maintenance works
in a permanent and scheduled basis is required
(v)
(vi)
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APPENDIX A
PHOTOGRAPHS OF DEFECTS
Midfield Tunnel:
Midfield Tunnel East Bound Photographs 1 to 29 & 48 to 56
Midfield Tunnel West Bound Photographs 30 to 47 & 57 to 67
Midfield East Portal Electrical Building Photographs 1 to 42
Midfield West Portal Electrical Room Photographs 1 to 33
Midfield East Bound Sump Pump Chamber Photographs 1 to 10
Midfield Tunnel West Bound Pump Room. Photographs 1 to 7
FTZ Tunnel:
FTZ Tunnel East Bound. Photographs 1 to 27 & 37, 38
FTZ Tunnel West Bound. Photographs 28 to 36 & 39 to 50
FTZ East Portal Electrical Building. Photographs 1 to 20
FTZ West Portal Electrical Room. Photographs 1 to 19
FTZ East Bound Sump Pump Chamber. Photographs 1 to 7
FTZ West Bound Sump Pump Chamber. Photographs 1 to 4
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APPENDIX B
LOCATION OF PHOTOGRAPHS OF DEFECTS
Midfield Tunnel:
Midfield Tunnel East & West Bound. Photographs 1 to 67
Midfield East Portal Electrical Building. Photographs 1 to 42
Midfield West Portal Electrical Room. Photographs 1 to 33
Midfield East Bound Sump Pump Chamber. Photographs 1 to 10
Midfield Tunnel West Bound Pump Room. Photographs 1 to 7
FTZ Tunnel:
FTZ Tunnel East & West Bound. Photographs 1 to 50
FTZ East Portal Electrical Building. Photographs 1 to 20
FTZ West Portal Electrical Room. Photographs 1 to 19
FTZ East Bound Sump Pump Chamber. Photographs 1 to 7
FTZ West Bound Sump Pump Chamber. Photographs 1 to 4
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