From Johor’s shores to the streets: Building a new bitumen hub in Malaysia

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In memory of Mr. Krishnan Chelvanathan – a valued colleague and key part of this achievement

Whether you’re driving along a city motorway, taking a rural back road or cycling to your favourite neighbourhood coffee shop, roads form part of almost every journey we take. They are so seamlessly woven into our daily routines that we often forget about the layers of engineering, planning and materials beneath our wheels that make smooth travel possible.

In Malaysia, those roads face heavy rain, intense heat and constant traffic – conditions that demand especially resilient materials. Bitumen, a key ingredient in road construction, is used to create durable, weather-resistant surfaces of roads.

This is where the Bitumen Terminal in Tanjung Bin, Johor, comes in. The newly built plant is a prime example of modern infrastructure, offering storage, blending – and fuelling to support the region’s future mobility needs. Strategically located by the sea and equipped with deep-water jetties, the terminal is set to become a cornerstone for the supply of road-building materials across Southeast Asia.

For the construction phase, Rotary Engineering served as EPCC contractor and awarded the scaffolding and insulation scope to KAEFER Malaysia, with the contract issued through its local entity, Singlobal. With more than three decades of proven project management and delivery capabilities in Malaysia, KAEFER took smooth control from the outset, working collaboratively with the client, end-user, and other contractors in a fast-paced environment that required precision, agility, and effective communication at every turn.

KAEFER’s scope on the project? Significant in every sense of the word:

  • 80,000 m³ of scaffolding – hanging and tower scaffolds – erected
  • Over 13,000 m² of insulation work completed on piping, equipment and storage facilities
  • ~ 115 skilled workers deployed at peak manpower

Suspended scaffolds, tight timelines & one-way roads

While every industrial project presents its own unique challenges, this one involved solving a particularly complex puzzle: jetty-based scaffolding. Constructing 60,000 m³ of medium duty suspended scaffolding along the jetty meant working over water with limited material storage space and just a single one-way access road where vehicles could stop for no longer than 20 minutes. Logistics became a challenge.

The project was steered by two discipline managers: Krishnan Chelvanathan, who managed the scaffolding scope, and Iqbal Zaid, who led the insulation works. They were supported by KAEFER Malaysia’s general manager, Jeevanantham Karuppiah, providing technical and operational oversight, and Nitin Trivedi, offering commercial and contracts support.

“It was a big task,” recalls Krishnan. “But we had successfully completed similar scaffold work on jetty piping and tanks in Malaysia before, so we relied on that experience, as well as strong planning and seamless coordination with the customer.”

This careful planning included:

  • a detailed material and manpower action plan
  • regular daily updates and meetings with the client
  • Strict mobilisation and de-mobilisation sequencing to align with construction phases

When it came to safety, KAEFER brought their A-game. By implementing the ProtAct QR system, the team could quickly report and track safety observations, near misses, and hazards – creating a proactive culture of continuous improvement and zero-incident execution.

Teamwork made the terminal

With over 36,000 direct man-hours and a dynamic site that shifted week by week, it was the strength of the team that saw the project through to completion. Regular internal coordination meetings, both weekly and monthly, ensured that everyone stayed informed, supported, and motivated – regardless of the obstacles.

“Teamwork was everything on this project,” explains Krishnan. “From the scaffolders to the safety supervisors to the project engineers, everyone played their part and rose to the challenge.”

The same spirit was echoed by Iqbal, who highlighted how close cooperation across disciplines made it possible to deliver both scaffolding and insulation works safely and on time.

Several team members stood out for their exceptional contributions during the project among whom some deserve a special mention

  • Krishnan Chelvanathan from the Scaffolding Team
  • Iqbal Zaid from the Insulation Team
  • Muhammad Rafi, Project Engineer, and
  • Akmal Mazlan, Safety Supervisor

From Tanjung Bin to every road, we travel

The successful delivery of this project also strengthened KAEFER Malaysia’s position as a trusted partner in high-performance, high-pressure environments. In fact, since the project wrapped, the team has already seen an increase in local market enquiries.

Every smooth ride has a story behind it – one of innovation, teamwork, and the people who make it all possible. At the Bitumen Terminal, this story features KAEFER Malaysia’s hands-on dedication. They worked high above the jetty and inside vast storage tanks, always prioritising safety, precision and reliability. After all, the road ahead – both literally and figuratively – starts with the right foundation. And that foundation is now firmly in place.

Note: Crafted by people – with a little help from gen AI. This article combines human insight, storytelling, and smart digital tools to bring KAEFER stories to life.

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