Construction of the Bayan Baru Viaduct began around 2001. It was delayed a few times before it was eventually completed in July 2005, and was opened in stages. During the four-year span, there was massive congestion along Jalan Sultan Azlan Shah brought about by the construction.
The Bayan Baru Viaduct was originally planned to be 2.37 km in length, that is, it was supposed to start after the Kampung Jawa junction. However, midway through the construction, a decision was made to lengthen it to 3.5 km, allowing it to bypass the Kampung Jawa Junction, the Bayan Baru Roundabout and the Sungai Dua Junction.
The decision to lengthen the Bayan Baru Viaduct, without providing for additional ramps, is regarded today as insensible. Criticism centres on the failure of the highway to reduce congestion in Bayan Baru, chiefly along Jalan Sultan Azlan Shah, during rush hour. This is because the additional length added to the elevated highway has effectively cut it off from the bulk of traffic it is supposed to relieve. In other words, the Bayan Baru Viaduct becomes a white elephant that serves only a minor role in traffic dispersal, while the roads under it remains as congested as ever.