Aerial view of a highway interchange, rail station, parking area and adjacent construction site where Secugrid® is installed.

Keeping Malaysia’s busiest corridor moving with strength that lasts

The Light Rail Transit Line 3 improves Klang Valley connectivity. At Johan Setia, access roads were widened and linked to the station on Federal Route 5, a key Port Klang route for heavy container traffic. Soft silty clays required durable pavements with settlement control.

Secugrid® installed across a road construction area with workers, machinery and traffic barriers. — Secugrid^® as base course reinforcement

Building resilience on Malaysia’s busiest coastal corridor

The Light Rail Transit Line 3 (LRT3) enhances connectivity across the Klang Valley, Malaysia. At Johan Setia – the line’s southern terminus – works included widening and tying in access roads to the station. The site lies on Federal Route 5, a Class T2 trunk road linking directly to Port Klang. This coastal corridor carries heavy container traffic and high-capacity commercial vehicles, demanding resilient pavements with settlement control on soft alluvial silty clays of very low bearing capacity.

Construction site showing damaged ground before reinforcement and Secugrid® placement beneath a sand layer. — Road in need of repair (left) and reconstruction with Naue Secugrid^® geogrid (right)

Problem – Too deep, too slow, too disruptive

The original Removal and Replacement (RnR) design called for excavating 1.5m of weak soil and backfilling. Though feasible, excavation would have severely disrupted traffic and clashed with viaduct works. Uninterrupted access – critical for Port Klang freight and passengers – had to be maintained, so a solution was needed to ensure performance while keeping works efficient and traffic moving.

Solution – Smart ground improvement with Naue Secugrid^®

In partnership with Naue, Alpha Pinnacle proposed a Reinforced Soil Foundation (RSF) using Secugrid^® 40/40 Q1 geogrids. Instead of cuts, shallow subgrade preparation limited disruption and earthworks. A two-layer system was used: a Secugrid^® layer on the levelled subgrade, 150mm of compacted engineered fill, then a second geogrid beneath the roadbase prior to paving. Lane-by-lane sequencing kept traffic flowing. Secugrid^® 40/40 Q1 uses monolithic polypropylene flat bars with welded junctions to deliver 40kN/m biaxial strength and high stiffness at low elongation, providing efficient lateral restraint to control deformation under heavy loads. Immediate mobilisation of tensile stiffness spreads wheel loads, reduces shear and limits rutting/reflective cracking. The result is a stiffer composite layer with reduced strain under repeated traffic, enhanced bearing capacity and limited settlement over soft ground.

Faster, less fill, built to last

Avoiding deep excavation and large imported fill accelerated construction and cut material use. Single-lane workfronts minimised disruption. The geogrid’s rigidity enabled easy placement with minimal wrinkling, and its robustness resisted installation damage under heavy compaction. Using Secugrid^® within the base course transformed weak subgrade into a load-bearing composite, replacing deep soil replacement with an engineered, durable solution. This approach aligns with JKR ATJ 5/85 for cost-effective road improvement on compressible ground and has proven durable in tropical conditions. Post-construction observations confirmed stable pavement with no cracking or distress.

Conclusion

Transitioning from deep RnR to a mechanically stabilised foundation with Secugrid^® 40/40 Q1 delivered comparable bearing performance with > 50% less fill, faster construction with minimal disruption, and long-term stability. Naue Secugrid^® 40/40 Q1 combines durability and efficiency - an optimal solution for challenging ground and demanding traffic.

All images courtesy of Alpha Pinnacle Sdn Bhd.

Project benefits

More than 50% less fill required
Secugrid^® replaced deep soil removal and replacement, reducing imported material volumes and associated transport.
Easy and robust installation
The rigid geogrid can be placed with minimal wrinkling and withstands installation loads during heavy compaction.
Faster construction with minimal disruption
Shallow ground preparation and lane-by-lane installation helped maintain access along the heavily trafficked corridor.