To build a 10.6-km section of the toll road from the city of Bandung, Indonesia, to Kertajati International Airport, the project team had to overcome logistical challenges, COVID-19 and weather, but it delivered ahead of schedule.

Unable to divert traffic from existing roadways, the team found that the narrow, congested roads leading to the site proved unsuitable for transporting the large beams needed for the project’s largest structure. The solution was to prefabricate the 40.8-meter beam body in sections and assemble onsite. To ensure accuracy when connecting the sections, the team used pre-buried positioning pins and adopted a new binding process to fix the sections together.

The project area is densely populated, so team members also paid close attention to the effects of construction. Work was performed off-peak when possible, and sites were regularly watered. The team hired professional monitoring agencies to ensure the project met the area’s strict environmental protection requirements.

With COVID-19 affecting availability of local construction materials, the project procurement team went global, sourcing stock from Malaysia, the Philippines and China, among other countries. The construction sequence was also optimized to minimize earthwork and pavement operations during Indonesia’s long rainy season.