SG. Rasau Water Treatment Plant | Selangor, Malaysia

EFCO Standard Systems Deliver Complex Water Treatment Solutions in Malaysia

Selangor, Malaysia

Project Brings Essential Infrastructure to Growing Community

The SG. Rasau Water Treatment Plant in Selangor, Malaysia, represents a critical infrastructure investment for a rapidly developing region. This massive facility features eight treatment tanks containing 25 individual hopper structures for sediment and sludge separation during water purification.

The project’s scale and complexity presented significant challenges, including 16,000m² (172,250 ft²) of slab area, 6,400m² (70,000 ft²) of wall structures, complex trapezium-shaped and slanted hopper walls, and aggressive construction timelines.

China Railway Shanghai Group Relies on EFCO’s Proven Performance

China Railway Shanghai Group, the project contractor, selected EFCO after other formwork providers could only offer costly custom fabrication for the complex hopper geometries. EFCO’s innovative approach used entirely standard components to form the structures while enabling large concrete pours essential to the construction schedule.

The project deployed two key EFCO systems: EFCO DECK® with E-Z DECK® Posts for the slab work and the E-BEAM & SUPER STUD® System for the wall and hopper structures.

E-BEAM & SUPER STUD Conquers Complex Geometries

The project’s most challenging aspect involved forming the slanted and trapezium-shaped walls of the hopper structures, where conventional formwork systems would have required expensive custom fabrication. EFCO’s E-BEAM & SUPER STUD® system demonstrated remarkable adaptability, using various E-BEAM sizes to accommodate the complex geometries without special components. The system’s rigid structure allowed for larger spacing between supports and fewer tie holes, which reduced patching work and enhanced concrete finish Quality. Over the eight-month wall construction period, the 1000m²(10,750ft²) of SUPER STUD® formwork supplied by EFCO formed all hopper walls while maintaining structural Integrity and dimensional accuracy.

EFCO DECK System Accelerates Slab Construction

The project’s 550mm(22′)-thick flat slabs required a shoring solution to handle substantial loads while maintaining installation efficiency. EFCO’s single-post E-Z DECK® system proved ideal, enabling crews to complete 1,200m²(4,333 ft²) of slab work in three days. The system’s drop head feature delivered measurable productivity gains, allowing early striking primary beams, secondary beams, and plywood ahead of the full concrete curing. This Innovation reduced plywood consumption—one of the major cost components in slab formwork—while accelerating the reuse cycle to just 14 days per cycle across the four-month slab construction phase. The lightweight, modular design eliminated crane dependency in areas with limited access, reducing equipment costs and scheduling constraints.

Field Service Excellence Ensures Project Success

EFCO’s experienced field service team provided on-site support throughout the project, developing innovative solutions to overcome unique challenges. When height clearance limitations prevented the use of standard EFCO DECK® posts, the team quickly substituted E-Z DECK® posts to maintain structural performance while accommodating the restricted workspace. The field service engineer guided the contractor in creating templates using square hollow sections to determine the precise slanted angles of the hopper walls, ensuring accurate geometry without costly rework. This hands-on technical guidance and responsive problem-solving exemplified the comprehensive support that keeps projects moving forward efficiently.

Why China Railway Shanghai Group Chose EFCO

By utilizing EFCO’s proven standard systems, China Railway Shanghai Group achieved its Lowest in-Place Concrete Cost through reduced labor hours, faster cycle times, lower material consumption, and elimination of custom fabrication expenses.

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EFCO’s formwork system delivered exactly what we needed for the SG Rasau project. The ability to form complex structures like the trapezium-shaped hopper using only standard equipment saved us both time and cost. Their team provided excellent technical support and responsive service throughout the project.

-Mr. Dai ShenMiao, Site Engineer