Client : Leighton Contractors (Malaysia)
Location : Lekir, Malaysia
Year : 1999-2001

Madsen Giersing designed the marine structures for a coal unloading facility at Lekir on the west coast of Malaysia, 3 hours drive north of Kuala Lumpur, as part of a design and construct contract with Leighton Contractors (Malaysia) Sdn Bhd. The majority of imported coal will be used for a new 2100MW power station (stage 1) on a reclaimed island

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The marine structures consist of the following :

• 540m long unloading wharf, capable of berthing and unloading fully laden Capemax vessels of 160,000 DWT, with 20m minimum water depth alongside at all tides.
• 2,028m long approach trestle supporting 3 import conveyors and 1 future export conveyor, with single lane roadway and discrete passing bays. A future export berth with access from the trestle is proposed.
• Single mooring dolphin with access from the wharf.
• Small boat berth suitable for tugs and line boats, with access from the trestle.

Innovations used in the design that led to cost savings include:

• Open trough precast prestressed concrete T-girders spanning 33.5m with in situ concrete topping for the trestle (refer photograph above left). Extensive use of precast elements (refer photograph above middle).
• 11.75m x 11.75m precast prestressed slab supported on 4 sides, avoiding the need for slab falsework.
• Precast concrete fender boxes with circular hollow struts transferring the fender reaction back to the middle of the wharf where raker piles are located. This avoided the need for berthing dolphins under the wharf structure.