Choo-Choo, Let’s Talk Systems

13 May 2025 | Gamuda Berhad

How has Gamuda evolved from a construction company to a global rail systems integrator? Yeoh Hin Kok, Director (Special Project) at Gamuda Engineering, speaks to us about Gamuda’s transformative journey in delivering comprehensive rail solutions and the future of rail technology.

Rail rewired

Gamuda’s rail systems journey began with the Electrified Double Track Project (EDTP). Spanning 329km across northern Malaysia, this project involved retrofitting a century-old rail network with state-of-the-art electrification and signalling systems, setting a new benchmark for rail modernisation in the country.

Consisting of two tunnels, seven main stations and spanning 329km, the Electrified Double Track Project (EDTP) involved laying two parallel electrified tracks linking the states of Perak, Kedah, Penang, and Perlis.

“The EDTP was our foundation in rail systems integration,” explains Yeoh, who oversaw the entire construction of the EDTP as the Head of Construction. “We had to retrofit 100-year-old infrastructure, and it wasn’t simply about laying tracks; it required orchestrating multiple complex systems while maintaining existing services. It was like performing open heart surgery on a patient who needs to keep running.”

A veteran at Gamuda, Yeoh’s 30 years of experience began with the Stormwater Management and Road Tunnel (SMART) project before transitioning to large-scale rail systems for MRT Kajang and MRT Putrajaya Lines. He has also played a key role in securing rail projects across Taiwan and Singapore, earning a reputation for managing complex, multi-disciplinary initiatives.

Decoding systems works

Think of systems works as the brain and nervous system of a railway. It’s everything that makes the trains run smoothly and safely, from the signals that tell them when to go, to the power that keeps them moving.

What sets Gamuda apart is its ability to seamlessly coordinate and integrate critical components that makes modern railway function: civil works, track works, Integrated Communication Control System (ICCS) – which includes signalling and train control, power supply and electrification – communications, mechanical and electrical systems (M&E) and rolling stock.

Together, these sub-systems create a web of interdependencies that must align perfectly to ensure flawless execution. Managing systems works is like tackling a jigsaw puzzle with over a thousand pieces. There’s a myriad of things to consider and they all need to fit together in order to complete the puzzle.

This integration capability was showcased when Gamuda took the role of Project Delivery Partner for the MRT Kajang and Putrajaya Lines, where we coordinated over 200 civil contractors and seven sub-system contractors, each with their subcontractors,” Yeoh recalls.

“The level of coordination required was immense, ensuring every piece of the puzzle fits perfectly to deliver a seamless and reliable transit system.”

– Yeoh Hin Kok, Director (Special Project), Gamuda Engineering

Technical evolution: From manual to autonomous

Gamuda’s technical evolution in rail signalling illustrates our commitment to cutting-edge solutions. With EDTP, Gamuda deployed block-based signalling systems, the industry standard at the time. For the MRT Kajang and Putrajaya Lines, the focus shifted to Communication-Based Train Control (CBTC) systems, a leap forward in automation that allowed for dynamic train control, enabling trains to run at closer intervals without compromising safety.

Malaysia’s first metro system- the MRT Kajang Line, was handled from conceptualisation to completion by our joint venture, MMC Gamuda, in collaboration with globally renowned industry leaders. This included a partnership with Siemens Malaysia Sdn Bhd for knowledge transfer in train assembly and with Bombardier Malaysia Sdn Bhd to enhance expertise in Communication-Based Train Control (CBTC) technology.

For the MRT Putrajaya Line, Gamuda worked with Hyundai Rotem for the rolling stock. The Sungai Buloh Depot, serving both the MRT Kajang and Putrajaya Lines, houses the stabling yards and maintenance facilities where the trains undergo heavy servicing, repairs, inspections, and pre-operational testing, as well as being parked when not in service.

The MRT Lines now operate with Grade of Automation 4 (GoA4) systems—fully autonomous driverless operations with advanced integration between platform screen doors, where real-time communication between trains and control centres to ensure safety and efficiency. These advancements have significantly improved train frequency, reduced delays and enhanced overall passenger experience.

“Each project built upon our earlier experience, allowing us to push technological boundaries while maintaining highest safety standards,” Yeoh notes.

Inside the MRT Operations Control Centre room located at the Sungai Buloh Depot.

While some may have concerns about driverless trains, rest assured that each train is continuously monitored in real-time by the Operations Control Centre (OCC). “Staff at the OCC actively monitors operations, promptly detect and address any irregularities. As the central hub, the OCC ensures seamless coordination and safety across the entire rail network,” Yeoh added.

A key aspect of signalling works is the automatic platform door control. A set of automated instructions sent to the trains needs to be integrated with the trains to control the movements of trains from the OCC. Its application enables trains to align precisely with the designated stopping point according to their schedule, ensuring both the train and platform doors open in sync for safe and seamless passenger movement.

At every station, platform screen doors act as a barrier between passengers and the train tracks. These glass doors only open when a train is properly aligned at the station, ensuring that no one can accidentally fall onto the tracks.

A three-layered challenge

The journey from concept to operational railway unfolds in three distinct but interconnected stages.

Before any systems can be installed, the physical infrastructure must be precisely prepared. Civil works preparation involves civil contractors laying the foundation, constructing tunnels, viaducts and stations, as well as laying tracks with exact tolerances to accommodate complex system requirements.

The next layer is system installation, whereby system contractors do cable routing and equipment placement. “This stage often reveals challenges. Delays in civil works can create ripple effects, requiring intense coordination between contractors to maintain the timeline,” says Yeoh.

After installation, the focus shifts to rigorous testing, the final stage. Equipment undergoes functionality tests, followed by integration tests across sub-systems. Train operations are trialled extensively, with each train completing up to 6,000km of test runs to ensure readiness. These tests cover a wide range of real-world scenarios, including acceleration and braking performance, emergency stops, signal coordination and system integration under varying conditions.

The Sungai Buloh Depot is one of two train depots serving both the MRT Kajang and MRT Putrajaya Lines. The other depots are located at both ends of the respective line—Kajang for the MRT Kajang Line and Serdang for the MRT Putrajaya Line.

Serdang Depot, where light maintenance is carried out for the MRT Putrajaya Line.

Full speed ahead

The future of rail systems promises groundbreaking advancements. Predictive maintenance, powered by Artificial Intelligence (AI) and machine learning, will preemptively address potential issues to ensure high system availability. Fully autonomous rail networks, enhanced by smart technologies, are set to revolutionise urban transit. At the same time, system works will play a vital role in integrating rail networks into smart cities, enabling seamless, efficient, and sustainable mobility.

“Looking ahead, Gamuda is committed to driving innovation in rail systems for efficient transportation solutions,” Yeoh. concluded

As we continue expanding our expertise in digital and signalling infrastructure globally—such as our work on the DT Infrastructure’s METRONET High-Capacity Signalling Project in Australia—we are also eager to continuously contribute to the future of rail development in Malaysia, particularly in Penang, where transformative transit solutions are on the horizon.