CONSULTING SUPERVISION

FOR CONSTRUCTION OF
KARIAN MULTIPURPOSE DAM
PROJECT
RIVER DIVERSION

October 2017

In Consortium with

KOREA ENGINEERING CONSULTANTS CORP. (KECC)

PT. INDRA KARYA(PERSERO)
PT. WIRATMAN
PT. METTANA
CONTENTS

Ⅰ
INTRODUCTION

Ⅱ
EXPLANATORY TECHNICAL FIELD

Ⅲ
RIVER DIVERSION CEREMONY
 Ⅰ
INTRODUCTION of River Diversion
 1. Introduction

Background
• EDCF Loan INA-19(22 December 2011)
• Commenced to service (11 January 2013)
• In the beginning Tunnel construction on Mar. 2016

Objectives • Separating the flood flow of the river.

• To securing safety during dam construction
• To efficient and safe construction

Outcome • Diversion Tunnels(D=4,500mm) 2 Lanes

• Coffer dam(Primery, up, down stream)
• 1 Temporary Bridge
• In, Outlet Portal

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General Plan of the River Diversion Works

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 2. Job Description
Diversion Tunnel
Division Description

Gate structure 2 x Box : 4.5m x 4.5m

Gate Clear span: 4.5 m, Clear height: 4.7 m
Inlet Gate leaf 6.3 t/set, Guide frame 3.6 t/set
Transition section Box : 4.5m x 4.5m→Dia 4.5m

Tunnel-1 Length: 512.6m Diameter. 4.5m

Lining concrete thk.: 50cm
Diversion tunnel
Tunnel-2 Length: 506.35m Diameter: 4.5m
Lining concrete thk.: 50cm
Outlet Valve chamber 7.9m x 11.m x 11.0m (B x L x H)

Penstock(Tunnel 1) Steel pipe Dia: 2.0m Thk.: 16mm

Discharge valve 1 set

Temporary bridge Length: 38m Width: 5.0m

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2. Job Description
Coffer Dam

Primary Coffer Dam Upstream Coffer Dam Downstream Coffer Dam

Design flood
2 Years 25 Years
frequency

Peak Flood 327 m3/sec 775 m3/sec

Peak Outflow 292 m3/sec 292 m3/sec

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 Ⅱ
EXPLANATORY TECHNICAL FIELD

1. GROUTING

2. GEOTECHNICAL

3. QUALITY CONTROL

4. TUNNEL

5. STRUCTURE
(DIVERSION TUNNEL)
1. GROUTING
Lugeon value distribution by segment(except plug in segment)

• Tunnel 1 Lugeon value range : 0.4 ~ 24.55

- Lugeon value ≥ 3 : 9 segments
• Tunnel 2 Lugeon value range : 0.68 ~ 117
-Lugeon value ≥ 3 : 13 segments
• The target Lu value after foundation treatment is ≤ 3
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1. GROUTING
Grouting work classification by segment

Segments for grouting work

Unit
Consolidation Curtain Backfill

9 1 14
Tunnel 1 Segment
(4,6,7,14,17,24,26,plug 1,plug2) (plug 2) (5,8,9,10,11,12,17,19,21,,22,24,25,26,27)

33
13 1 (2,3,4,5,6,7,8,9,10,11,12,14,15,16,17,18,19,20
Tunnel 2 Segment
(7,10,11,14,15,16,17,18,20,27,28,31,plug3) (plug 3) ,21,22,23,24,25,26,27,28,29,30,31,32,33,34,
plug3)

Grouting work data

Backfilling
Consolidation grouting(kg) Curtain grouting(kg)
grouting(cu.m)

52,716.90
Tunnel1 - Segment 4,6 > 7,000kg, 11,677.62 16.232
- Segment 7 is the least amount

56,361.04
Tunnel2 - Segment 31 > 7,000kg, 19,354.01 42.8517
- Segment 16 is the least amount

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1. GROUTING
Consultant suggestions

• Check hole test is basically performed in grouting work

- To confirm the grouting effect before and after construction
• It is considered necessary to thoroughly inspect and deal with the
Leakage in tunnel construction
- To maintain and prevent disaster in safety

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 2. GEOTECHNICAL
Gabion(Outlet)

• Problem for Gabion

1. The extent of the excavation is larger than normally capacity of backfill, it is difficult to
manage the backfill construction, and it is highly the problem is likely to occur
2. It is not possible to exclude the possibility of potential deformation when the water level
of the outlet is increased or the amount of precipitation is high

• Suggest for Gabion

It is considered that continuous management is necessary for the follow-up
deformation should be observed constantly

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 2. GEOTECHNICAL
Coffer Dam

• Problem for Coffer Dam

1. Switching the flow of water into facility of river diversion
2. Construction condition of main dam keeps dry condition thus it will be improved
workability

• Suggest for Coffer Dam

It must maintain safety on only period of main dam construction, nevertheless
during the rainy season, care must be taken to ensure that the dam does not flood

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3. QUALITY CONTROL
Check the quality of the diversion

• Specification of the diversion tunnel

① Length : Tunnel No .1 → 512.6 m, Tunnel No .2 → 506.3 m
② Diameter : 4.5 m

• Major quantity to be tested

① Earths works
- Backfill : Random in inlet and outlet structure 1,980 cu.m
② Concrete works
- Concrete type A (fck=240kg/ ㎠ ) : 14,864 cu.m ← River diversion,
Outlet work
- Concrete type B (fck=210kg/ ㎠ ) : 1,964 cu.m ← River diversion
for plugging

• Construction period
- From February 2016 ~ To September 2017
(Works have been drived in 20 months)

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3. QUALITY CONTROL
Earths works (Result of field density test)

• Test result on construction quantity

① Earths works
- Check the result of field density test
Test location : Backfill Inlet Tunnel Portal

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3. QUALITY CONTROL
Concrte works (Result of field density test)

• Concrete type A (Fck = 240 kg/cm2, 28days), - Samples : 255 ea

- Standard Deviation : 29.74 kg/cm², - Average : 257.46 kg/cm²
- Percentage no less than design strength : 31ea(12.2%), than 80%
design strength : 1ea(0.4%)

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3. QUALITY CONTROL
Concrte works (Result of field density test)

• Concrete type B (Fck = 210 kg/cm2, 28days), - Samples : 60 ea

- Standard Deviation : 41.76 kg/cm², - Average : 256.76 kg/cm²
- Percentage no less than design strength : 5ea(8.3%), than 80%
design strength : 1ea(1.7%)

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3. QUALITY CONTROL
Details of under-compressive strength
Strength(kg/ ㎠ )
Pouring Testing Age
Location Remark
Date Date days Crushing standard

Upper lining concrete segment 19A (Tunnel 2) 13-May-17 15-Jun-17 32 173.1 240.0 〃

Conclusion
• As a result of verifying the degree of soil compaction, it was confirmed that the
construction condition was satisfactory because it exceeded the standard
compaction rate of 95% there was

• Concrete of each type of river diversion tunnels showed average of more than
80% of the standard strength after 28 days.
These results indicate that the series of processes from the manufacturing to the
construction of the concrete used in the river diversion tunnels are performed
well
• However, the upper lining segment 19A of tunnel 2, which is less than 80% of the
design strength, will be reinforced with plugging concrete as agreed with the
contractor during construction

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4. TUNNEL
Tunnel Excavation Method
• Ground condition
- Rock or Dense Soil (March 2016)
- weathered Rock (October 2016)
• Excavation Method : Small breakers

March 2016 October 2016

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4. TUNNEL
Analysed the cycle time of the tunnel excavation between
19th May and 5th June

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4. TUNNEL
Drainage During Excavation
• Time spent for the Dewatering Process

Side Ditch in Tunnels Drainpipe in Tunnel Bottom

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4. TUNNEL
Tunnel Support
• Constructed Tunnel Support

Construceted Tunnel Support Detail of the Tunnel Support

- Shotcrete : 300 mm 150 mm

- While it appears to have any particular for now, tunnel collapse
may happen with no prediction with such conditions

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4. TUNNEL
Ventilation System
• Drainage System in Tunnels, This Site

Intake Fan and Air Tube Air Leakage in Connection

This site After improvement

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5. STRUCTURE (DIVERSION TUNNEL)
Layout
No. Name of structure

1 Approach channel

2 Side channel

3 Gated ogee

4 Chute

No. Name of structure

5 Plunge pool

6 Intake tower

7 Access bridge

8 Connection tunnel

General (include purpose and explanatory contents)

Item Purpose
Check for load carrying Check of the stability on the inlet portal(temporary road over the upper part of the inlet
capacity of inlet portal portal)
Review the construction of In order to shorten the construction period after river diversion, it is reviewed to construct the
valve chamber plunge pool before river diversion.
Hardening problem of lining It aims to find the causes of unhardened lining concrete and to propose an effective repair
concrete in tunnel-2 method.
Stilling basin wall As a result of excavation, the ground on the back of stilling basin wall was not same as detailed
reinforcement design. So it is required to checking again in accordance with the actual ground condition.

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5. STRUCTURE (DIVERSION TUNNEL)
Load Carrying Capacity of Inlet Portal(Temporary road)

• Checked the safety of Inlet portal for construction of temporary road

- Consider live load, dead load, earth pressure and hydrostatic pressure
- Available embankment is up to 13m over the inlet portal

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5. STRUCTURE (DIVERSION TUNNEL)
Review the Construction Method of Valve Chamber
• Construct the plunge pool before river diversion
- In order to shorten the construction period after river diversion
- Original Design

Construct open channel before river diversion

Construct valve chamber and plunge pool after river diversion

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5. STRUCTURE (DIVERSION TUNNEL)
Review the Construction sequence of Valve Chamber
- Design change (Construct valve chamber first)

Construct valve chamber, plunge pool, facing slab(Before river diversion)

Before river diversion Construction narrow channel with

connecting bars(After river diversion)
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5. STRUCTURE (DIVERSION TUNNEL)
Checked work progress (3rd August 2017)
• Outlet Wall behind the schedule (Ceremony: 30th Aug. 2017)

Inlet Potal Oulet Wall

Bridge
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5. STRUCTURE (DIVERSION TUNNEL)
Re-change the construction sequence to meet the schedule.
• Construct Outlet Wall after river diversion as following drawing.

Outlet Portal Plan

Outlet portal facilities during river diversion Plan view of temporary bridge
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5. STRUCTURE (DIVERSION TUNNEL)
Hardening problem of lining concrete in Tunnel-2 (Seg.-19)
• Concrete of black color and not hardened is observed(2017.5.18)
Cause
- Rupturing of pipeline
Concrete was not continuously casted, and
after the addition of water to prevent the
blockage of the pipeline, the mortar
without aggregate was pushed first in
order to reduce the pumping pressure,
which caused defects in the concrete.
The lining concrete is not hardened
• Remedial method

During River Diversion After River Diversion

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5. STRUCTURE (DIVERSION TUNNEL)
Stilling Basin Wall Reinforcement
• Ground condition of Stilling Basin Wall
- Originally Design : Rock
- After excavation : Soil
• Analyzing of the stilling basin wall as actual ground condition and present the
reinforcement method

Reinforcement method based on the results of calculation

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 Ⅲ
RIVERDIVERSION CEREMONY
 Diversion Ceremony

• The River Diversion works have been begun excavating tunnel March
2016, and finished all works of river diversion in 20 months.
• 30th August 2017, We celebrated the river diversion ceremony with VIPs.
• For this ceremony, Minister Dr.Ir.M.Basoeki
Hadimoeljono(Kementerian Pekerjaan Umum dan Perumahan
Rakyat), Ir. Nursiwan (Anggota, DPR R1), Ir.Imam Santoso (KPUPR,
Direkur Jenderal Sumber Daya Air), Tris Raditian St (KPUPR,
Kepala Balai Besar Wilayah Sungai C3), Embassy of the Republic of
Korea, EDCF and many other distinguished guests attended.

• These facilities will be operated during under construction of main dam

for the remaining important processes.
And, the completion of this first process will ensure the perfect success
of Karian Multi Purpose Dam PROJECT.

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Diversion Ceremony

Minister Dr.Ir.M.Basoeki Hadimoeljono

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Diversion Ceremony

Participation Expert Group

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Diversion Ceremony

Before and after opening(Inlet)

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Diversion Ceremony

Outlet Portal

Temporary Bridge

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Thanks