ATTACHEMENT LETTER NO:

/ BAP-WASKITA-WIKA/JMD/IV/2011

METHOD STATEMENT
FOR
OUTLET FACILITIES WORK

CONSTRUCTION OF JATIBARANG MULTIPURPOSE DAM PROJECT

PACKAGE B-1 : DAM BODY AND RELATED STRUCUTRES

BRANTAS ABIPRAYA WASKITA WIKA JO.

JATIBARANG MULTIPURPOSE DAM PROJECT

I.

PREPARATORY WORKS

1.1.

GENERAL

1.1.1. Structural features (Dimension and Design)

Outlet Facilities is located at the right bank of dam with total length 397m, horse shoe type
section of the internal diameter 2,40m and longitudinal gradient of tunnel is 1/10.
1.1.2. Quantities
The Approximate quantity for Outlet Facilities works is refer to the contract document as
following table :

See Figure 1.1. Outline of Outlet Facilities

1.2.

Construction Method

1.2.1. Temporary Access Road to Tunnel Outlet

Alignment temporary access road is started from right side bailey bridge about elevation +
84,0m to control gate station area about elevation + 83,5m. Length temporary Access Road is
about 230m . Type of construction are compacted sand gravel combined with cement soil
t=0,20 m at straight section and Concrete type D at Curve Section. Please refer to figure 1.2.
Temporary Acces Road shall be generally have a driveway width about 6,00 m', where praticable
to do so and not less than 4,00 m. Radius of curvature is not less than 9,00 m. Longitudinal Slope
of the Acces Road not more than 15%. Please refer to figure 1.3.

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1.2.2. Temporary Acess Road to Tunnel Inlet
Alignment temporary access road is started from cofferdam about elevation + 113,0m to
inclined intake area about elevation + 123. Length temporary Access Road is about 240m . Type
of construction are compacted sand gravel combined with cement soil t=0,20 m at straight
section and Concrete type D at Curve Section. Please refer to figure 1.4.
Commence construct temporary access road after completion embankment cofferdam.
Embankment temporary access road obtained from result excavation inclined intake dropped
into river.
Temporary Acces Road shall be generally have a driveway width about 6,00 m', where praticable
to do so and not less than 4,00 m. Radius of curvature is not less than 9,00 m. Longitudinal Slope
of the Acces Road not more than 15%. Please refer to figure 1.3.
1.2.3. Temporary coffering at the Outlet
Temporary Coffering is necessary constructed to avoid river water overflow through the
working area to Inlet Tunnel. Concerning to the river wide at Inlet is narrow relatively, there is
difficult to maintain of river to be have width for 15 m', so it is necessary to lowering the river
bed to El.83.5,00 and provide the coffering up to El.89.00. Please refer to figure 1.5.

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1.3.

Procurement of Equipment and Materials

1.3.1. Equipment

1.3.2. Support

1.3.3. Concrete
No.
Description
1 Batching Plant Concrete
2 Reinforcement bars
3
4

Accelerator (6% cement weight)

Water Stop

OUTLET FACILITIES

Spesification
Class D, 215kgf/cm2
U30, SII 0136-1984
or JIS G3112
Technical Spec 9-7
Technical Spec 9-38
Technical Spec 9-40

Obtained From
Batching Plant 1
PT. Hanil Jaya Steel
- Surabaya
Sika Beton
CV. Beton Teknik
- Jakarta

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II. OPEN EXCAVATION AND SLOPE PROTECTION

2.1.

Excavation At Outlet
According to actual site ground face riverbank at the Outlet area is very steeply sloping /vertical
approximately . Clearing and open excavation at outlet use Hydraulic Excavator. There must
consider to prevent of rupture during excavation for Outlet face. Because of area design
temporary access road actual geology condition which is have slide potentially. Fore pooling
forward method or method by rock bolting shall be provided.

2.2.

Protection Works for Slope and Tunnel Mouth (Protection Of Cave In)
Protection for Tunnel Mouth to enforcing the steel portal use Gabion Sand Bag,
The sequent of Open excavation and Slope protection i.e.:
- Clearing/Stripping and excavation by Hydraulic Excavator of Outlet Tunnel mouth
- Rock Bolting dia.22 mm; L = 4,00 m follow of designated the pattern fore pooling.
- Installing H-100 Steel Ribs Support Outdoor of Tunnel Outlet, 100cm c.t.c = 5set
- Sand bag protection work, surrounding of steel rib support have installed wooden deck
- Wooden deck t =50 mm over outdoor Steel Ribs Support
- Excavating of outer face Portion by Giant Breaker.
- Installing H-100 Steel Rib Support Indoor of Tunnel Outlet, complete with tie bar, steel pipe
& jointing plates will be firmly installed.
- Wiremesh and shotcrete of tunnel t = 10 cm.

FRONT VIEW

LONGITUDINAL PROFILE

Fig. 2.1. Temporay Portal Protection Work for Slope and Tunnel Mouth

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Fore Pooling @ 0.5m

D22 L=4.0m (10nos)

Fig. 2.2. Pattern Fore Pooling Rock Bolt

2.3.

Excavation At Inlet
Excavation at Inlet tunnel will be commence at the same time river closure in near Inlet
Diversion Tunnel. Open excavation for Inclined Intake usually done by combination of
equipment, those are : Excavator and bulldozer . Material excavated at intake structure will be
movement direct to river by dozer. Material excavated using embankment temporary access
road to plan temporary inlet portal.

Fig. 2.3. Plan Excavation at Inlet

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Fig. 2.3. Profile Inclined Intake Structures

Excavation at inlet will be execute about elevation + 157m until elevation +123.0m.

Fig 2.4. Excavation El.145.50

Fig 2.6. Excavation El.130.05

OUTLET FACILITIES

Fig. 2.5. Excavation El.138.00

Fig. 2.7. Excavation El.123.00

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III. TUNNEL EXCAVATION

3.1. Procedure of Full face excavation
Procedure of excavation will be divided into full face section and bottom section.
Excavation full face section, comply with optimum cutting height is 2.337m (overbreak = 5cm).
Excavation for full face will be commenced for every 1.5 m length, continue with supporting works
comply sequences as below :
-

Steel ribs support

Wiremesh

Shotcrete t=10cm

Rockbolt

Continue with excavation for next 1.5m forward.

Full Face
h = 2.287m

Bottom
h = 0.213m

Last excavation (bottom portion) will to commence while Installing steel pipe dia. 1400mm and
concreting is already for execution
Sequence excavation full face portion started first from downstream outlet tunnel to inlet tunnel
within productivity 1m/days. Excavation will be started at May 1 2011 and finished March 15
2012 for outlet to inlet tunnel. After river closure, excavation will be commence from 2 direction
(Inlet an Outlet).
Productivity

= 1m/days (May 2011 September 2011)

Prudctivity

= 2m/days (October 2011 March 2012)

Length

= 370m

Time for completion

= 320 days.

1. Productivity from Outlet to Inlet during period May 1 September 30 2011 = 115m
Remaining excavation after river closure = 255m
2. Productivity 2 direction from inlet and outlet 2m/days begin October 1 2011.
Time for completion

= 255/2 = 128days

Estimate finished breakthrough March 15 2012.

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3.2.

Applied Equipment for Excavation and Mucking

3.2.1. Tunnel Excavation

Pick Hammer shall be applied for tunnel excavation with 2 manpower continually each other in
one group workers, excavated material will be loaded to pick up by extend conveyor belt.

Fig. 3-1. Excavation with Pick Hammer by manpower

3.2.2. Mucking
Pick up 4 wheel drive capacity 0.8m3 shall be applied for tunnel mucking in Outlet and lorry
capacity 0,4m3 applied in inlet tunnel.
For effective mucking, the excavated material will be collect in the temporary disposal near of
inlet/outlet portal, and be handled to disposal area by other equipments.

Fig. 3-2. Mucking in Outlet Tunnel

Winches

OUTLET FACILITIES

Lorry

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Fig. 3-3. Mucking in Inlet Tunnel
3.3.

Tunnel Supporting (Shotcrete, Steel Rib Support and Rock bolt)

3.3.1. Shotcrete
- Type Shotcrete for tunnel is dry mix
- Gradation of aggregate shall conform to the specification, cement proportion > 400kg/m3
- Apply machine of pneumatic high velocity for the shotcrete work.
- Application thickness total 10 cm

Fig. 3-4. Sequence Shotcrete in Tunnel

3.3.2. Steel Rib Support
- The support is fabricated from steel H.100.100.6.8, will be installed 1,5m c.t.c.
- Steel Rib Support can be installed ,when steel mesh done install.
- Equipment use for entering and install Steel Ribs Support by 4 wheel drive pick up.
- TheUpper joint of the steel rib will be tightened firmly enough with bolt and nut.
- Steel Rib Support dimension and detail , see figure 3.8 Detail Steel Rib Support.
3.3.3. Setting Wiremesh
- Wiremesh (dia.5 mm, 150 mm x 150 mm) immediately to set after steel ribs have installed,laid
between streel ribs and face of excavation.
- Overlap not less than 15cm.
- Wiremesh will be fixed firmly to the steel ribs by wires and rod prevent to displacement due to
spraying pressure of shotcrete.
Rod
Wiremesh

OUTLET FACILITIES

Tie Road Steel

Support

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3.3.4. Rock Bolt

Fig.3-5. Sequence Installing Wiremesh and Steel Rib Support

- Drilling the hole use percussion drill (Legdrill or CRD) dia.38 mm.
- Drill holes must be exactly drilled at the desinated locations and intervals as shown in working
drawing.
- Rock bolt material deform bar, fabricated
mm,L=1,50m, see figure 3.9 Detail Rock Bolt.

threaded end with nut &washer dia.22

- Fixing bolt/nut by wrench

- Hand grouting to insert of cement plastic into the hole, after rock bolt installed.

3.4.

TEMPORARY FACILITIES FOR TUNNEL EXCAVATION (LIGHTING, VENTILATION, DRAIN)

3.4.1. Lighting
Apply halogen lamp 400W near cutting face, as illustrated in longitudinal profile .
3.4.2. Ventilation
Consider to air consumption related to working activity in the tunnel for the workers, equipment
and others with diameter tunnel 2,4m.
No

Job Item

1 Excavation Full face

Incl.mucking
2 Shotcrete Dust
3mg/m3
*)

Consumer matter
Name
Total
Pick Up 4WD
1
Person
8
Cement
Pick Up 4WD

Person
Note: *) : Not in the same time with excavation.

OUTLET FACILITIES

Air Consump(m3/Min.)

Per unit
53.2
3

1
267
1
53.2
6
3
Total Cosumption =

Total
53.2
24

Remark
76 Hp/Unit

267 400 Kg/m3

53.2
76 Hp/Unit
18
415.4 m3/min.

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JATIBARANG MULTIPURPOSE DAM PROJECT

3.4.3. Drain
Draining water from the tunnel to outside by pumping. It necessary to prepare the collecting pit
for pumping location.

Fig.3-6. Cross Section Temporary Facilities

Fig. 3.7. Longitudinal Profile Temporary Facilities.

3.4.4. Spoil Bank and Disposal

Spoil Bank or disposal location result from tunnel activity is shown at figure 3.10 , for increase
speed of mucking activity, it necessary to provide the temporary spoilbank of excavated tunnel
material, laid near Outlet/Inlet Portal.

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JATIBARANG MULTIPURPOSE DAM PROJECT

IV. TUNNEL LINING AND GROUTING

4.1. Procedure
1. Sequence of concrete tunnel lining started from downstream to upstream direction.
2. Concrete lining can be start to commence after completion of steel conduit pipe setting ,
formwork setting and adequate support of steel conduit pipe, request and approval by the
Engineer during inspection.
3. Cleaning use water jet or pressure air compressor.
4. Concrete type D is produced from Batching Plant - wet mix type, and transported to the
location by Agitator Truck.
5. Pouring for concrete lining,conveying of concrete material use portable concrete
pump,without high velocity discharge and resultant segregation. Before completion placing
concrete at the crown, conveying of concrete material with high velocity discharge.
6. Compacting the concrete during laying use pneumatic concrete vibrator dia. 2" and vibrator
plate.

4.2. Setting Steel Conduit Pipe

1. Setting steel conduit pipe after underground excavation completion.
2. Steel conduit pipe transported from motor pool to the location by dump truck 16 ton.
3. Steel conduit can be carry with lorry to inside tunnel, lifting of steel conduit use chain block.
To get elevation which is comply with design, bottom steel conduit will be supported by Hbeam.

4.3. Lining Concrete Placing

1. Concrete type D obtained from batching plant, transported by concrete mixer truck.
2. Placing concrete use portable concrete pump.
3. Compacting concrete use pneumatic concrete vibrator.

OUTLET FACILITIES

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Chain Block
Stefner

H-100x100x6x8
100x100x8

Winches
Lorry

Steel Conduit Pipe

Temporary Steel support

Fig.4.1. Setting Steel Conduit Pipe

Concrete Type D
Steel Conduit Pipe
Stefner

H-100x100x6x8
100x100x8

Mixer Truck
Concrete Pump
Concrete Steel Pipe

Temporary Steel support

Fig.4.2. Placing Lining Concrete

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4.4. Consolidation Grouting and Curtain Grouting
-

Steel casing pipe dia. 50 mm shall be embed to the concrete lining where conformed with
the points position for drilling and grouting.

Commencing of Consolidation Grouting and Curtain Grouting after shotcrete lining have
minimum 28 days age.

Rotary Drilling will apply for drilling work.

Quantity of Curtain grouting L= 180m, Consolidation grouting L=240m.

Equipment and related drilling and grouting activities can illustrated in Figure 4.3.

Fig.4.3. Equipment Drilling And Grouting

Fig.4.4. Profile Arrangement Grouting Outlet Facilities

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Fig.4.5. Typical Arrangement Consolidation Grouting

Fig.4.6. Typical Arrangement Curtain Grouting

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V. CYCLE TIME ESTIMATION

5.1.

Time Schedule for Outlet Facilities Construction Works

5.1.1. Open Excavation

Open excavation for temporary portal and inclined intake sturcutres will be done by combination
of equipment, those are : Excavator, Buldozer for excavating/loading and Dumptruck for hauling.
The expected hourly production is about 40 m3 , with normal dayworks ( 8 hr /day) the
production will be 320 m3/day.
The cycle time is calculated based on the production of major equipment (excavator): 40 m3/hr ~
320 m3/day . Production for 1 month will be = 8,000 m3. Cycle time open excavation using for
excavation temporary access road and excavation in inlclined intake structures.

5.1.2. Underground Excavation

Excavation for outlet facilities using full face cut method with 2 shift working per days.
Underground excavation will be done by pick hammer.

5.1.3. Lining Concrete

Lining concrete for outlet facilities will be designed for 6 metre , except for curve section it will
apply 3 metre. Basically steel conduit pipe dia.1400mm will be installed earlier. Cycle time for
lining work is 6m / 3days.

5.1.4. Consolidation /curtain grouting

*) Please see detail time schedule.

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OUTLET FACILITIES

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OUTLET FACILITIES

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VI. QUALITY CONTROL

6.1.

Survey Works
Prior to commencement of excavation, temporary bench mark and reference point to be set up at
each portal area of tunnel. The points shall be places where no damage or movement are expect
and well protect. During tunnel excavation line and level marked by painted nail on the shotcrete
surface, will be setting up as near from the cutting face, that could be based of works.
During underground excavation must be checked to existence of displacement geology condition
using ekstensometer. Method of data sampling for displacement is executed once weeks.

6.2.

Laboratory and Testing

No
1
2

Work Activity
Drilling and Grouting
Shotcrete

Type of Test

Remark

Water Pressure Test

- 1 Stage = 5m, 5 pressure/5minutes

Washing andTesting

- Test Pressure

Material Test

- Water shall comply Clause 9.7.

- Aggregates shall comply Clause 9.5.

Rockbolt

Trial Test

- Field trials,horizontal&Vertical,comply

Sampling Test

to ASTM C 42.
- Compressive strength test comply to ASTM
C.42.
- Sample test 1 core per 3 span.

Pull Out

- 80 of cracking load.
- Sample test 1 per 25 Installed Rockbolt

Concrete

Material

- Cement, by factory
- Aggregate shal comply to Clause 9.5.3,
and Clause 9.5.4.

Concrete test

OUTLET FACILITIES

- Shall comply to Clause 9.14.

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JATIBARANG MULTIPURPOSE DAM PROJECT

6.3.

Mix Design Trial Mix Shotcrete

6.4.

Mix Design Trial Mix Concrete Type D

Site Mixing Adjustment

Rasio S/A

: 53

%
3

Unit Weight (kg/m )

Range of Slump

Range of
Air
Content

W/C
Ratio

S/A Ratio

Type. D

Maximum
size of
Coarse
Aggregates

Kg / Cm2

(mm)

(cm)

(%)

(%)

215

20

11 2

1.5

59

Basic

Add.-Sika

Water

Cement

Fine Agg.

Coarse
Agg.

(%)

(Kg)

(Kg)

(Kg)

(Kg)

(ltr)

53

189

320.00

1005.00

882.17

1.600

0.5 %x C

Site Mix

Water Content(%)
7.500

2.640

Absortion (%)
Vol = 1.000 m3
Mixing Adjustment
Site Mixing Volume =

1.000

m3

2.987

2.547

142.82

320.00

1050.36

882.99

1.600

142.82

320.00

1050.36

882.99

1.600

Vol

1.00

m3

8.530

Water

142.824

Kg

0.176

Cement

320.000

Kg

8.705

Fine Agg.

1050.356

Kg

Coarse Agg.

882.990

Kg

Add.-Sika

1.600

ltr

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6.5.

Pull Out Test

Testing pull out will be taken when the shotcrete age reach 1 (one) day, hollow jack equipment
shall be use.
DIRECTION OF
PULL OUT

PRESSURE GAUGE
HOLLOW.JACK

SUPPORT RING

SHOTCRETE
ESTIMATED
BREAKING LINE

SHOTCRETE

The Formula of pull out test can be shown as follow :

= P/A
A= (D/2

+ W / 2 ) H2 + ( D / 2 W / 2 )2

where :

= Pull out pressure

P = Maximum Pull Out Force ( N )
A = Surface area of cone shape of shotcrete pulled out
D = Upper diameter of Cone shape ( mm )
W = Lower diameter of Cone shape ( mm )
H = Hieght of Cone shape ( mm )
Conversion into compressive strength will be 4 times of pull out test
- Sampling for 3,7 and 28 obtained by coring from test panel box, and will be tested by
compression strength.

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Fig : Rock bolt Installation
1. anchor plate
2. hex nut
3. threadbar
4. Grouting by Cement milk + add sika Intraplas- Z

fIg : Rock bolt Pull out test

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FLOW CHART ROCK BOLT PULL OUT TEST

NB :
1. Drilling Hole deep 1.5m , equipment leg drill
2. Cleaning out hole by air compressor
3. Grout the hole by cement grout ( cement is inserted in a plastic medium and inserted in the
hole )
4. Then inserted after the cement rock bolts inserted into holes had been driven by
5. close the gap between the rock bolt holes so that no spills cement with cement paper.

OUTLET FACILITIES

6-5

Construction Method / Procedure

Concrete Work

The fig : The squence of work for leveling concrete and backfill concrete of Spillway and Outlet, Gallery work
Start
Rectify

Claening off of foundation

Request Joint Inspection to
Check Foundation

Satisfactory ?

No

Reinforcing bar Arrangement

Rectify

Form Work Final Cleaning

Request Joint Inspection

before Placing Concrete

No

Satisfactory ?

Palcing Concrete
Joint treatment
Removal of forms
Curing
End

Check Reinforcing bar Arrangement

Check instalation form work

Method Statement for Diversion Tunnel Works

1.Outline of the Work
(1) Structural Features (Dimension and Design)
Diversion Tunnel is located at the left bank of the damsite with total length of about 441m, horse shoe
type section of the internal diameter of 5,60 m and longitudinal gradient of the tunnel is 1/30.
(2) Quantities
Quantity for Diversion Tunnel works is refer to the Contract Document as Follow :
Payment
Item No.
Description
Clause
D.
Tunneling
D.1
Underground Excavation
D.1.1
TS.4.1.9.b
for Diversion Tunnel
Upper Half
Lower Half
D.2
Furnishing & Installing Steel Rib Support and Accesories
D.2.1
TS.7.7.7
for Diversion Tunnel
D.3
Production and Placing Shotcrete Lining
D.3.1
TS.7.2.15
for Diversion Tunnel
D.4
Furnishing & Installing Steel Mesh Reinforcement
D.4.1
TS7.5.4
for Diversion Tunnel
D.5
Furnishing & Installing Rock Bolts
D.5.1
TS.7.3.7
for Diversion Tunnel ( 25 mm dia. )
I.9
TS9.30.3 Concrete Type A for Diversion Tunnel Lining.
See Figure-1 : Outline of Diversion Tunnel

Unit

Total

m3

18.300

m3
m3

10.500
7.800

tonne

200

m2

1.800

kg

11.400

m
m3

17.400
6.800

2. Construction Method
2.1. Preparatory Work
2.1.1 Acces Road to Tunnel Outlet
(1) Alignment of Acces Road to Tunnel Outlet
Acces Road to Outlet Div. Tunnel is started from Point A about elevation +180,00 m' , and finally to Point
B about elevation +85,00 m'; length of Acces Road is about 815.80 m'. Type of construction are
Compacted Sand Gravel combined with Cement Soil t=0.20 m at straight section and Concrete Type D at
curve section. Please refer to figure-2a
(2) Design of Acces Road (Slope, Section and Curvature)
Temporary Acces Road shall be generally have a driveway width about 6,00 m', where praticable to do
so and not less than 4,00 m. Radius of curvature is not less than 9,00 m.
Longitudinal Slope of the Acces Road not more than 15%. Please refer to Figure-2b.
(3) River Crossing Facilities
The River around the Outlet Tunnel is about 15-20 m' wide. It is necessary to build bridge construction
crossing the river from right to left side . Bailey Bridge is reasonable to install crossing the river through
to the Outlet Tunnel location. It is designed having length about 24 metre at elevation +83.00 .
At the beginning, the abutment of bridge will be built with Concrete Type D both at right and left section.
The temporary bamboo bridge will be installed to deliver labours and also concrete material crossing the
river. Next the bailey bridge component will be assembled at land side and will be Installed using
cantilever method. Please refer to Figure-3 .

(4) Temporary Coffering at the Outlet

Temporary Coffering is necessary constructed to avoid river water overflow through the working area
of Outlet Tunnel. The river condition at outlet should be maintained to keep the width of river not less
than 15 metre . Coffering elevation at outlet is designed up to El.86.00 , Please refer to Figure 3a.
2.1.2 Acces Road to Tunnel Inlet
(1) Alignment of Acces Road to Tunnel Inlet
Acces Road to Inlet Div. Tunnel is started from Point C about elevation +132,00 m' , and finally to Point D
about elevation +101,77 m'; length of Acces Road is about 1,379 m'. Type of construction are Compacted
Sand Gravel combined with Cement Soil t=0.2 cm at straight section and Concrete Type D at curve
section. Please refer to figure-2a
(2) Design of Acces Road (Slope, Section and Curvature)
Temporary Acces Road shall be generally have a driveway width about 6,00 m', where praticable to do
so and not less than 4,00 m. Radius of curvature is not less than 9,00 m.
Longitudinal Slope of the Acces Road not more than 15%. Please refer to Figure-2b.
(3) Coffering
Temporary Coffering is necessary constructed to avoid river water overflow through the
working area to Inlet Tunnel. Concerning to the river wide at Inlet is narrow relatively, there
is difficult to maintain of river to be have width for 15 m', so it is necessary to lowering the river
bed to El.98,00 and provide the coffering up to El.105.00
Inlet Structure will be commenced at the 1st dry season as the priority before excavation of inlet tunnel
begin. The construction of Inlet structure doesn't have enough space for equipment operation, so it is
difficult to construct both structure and tunnel in the same time.
For Detail see Figure 3b.

2.1.3 Procurement of Equipment and Materials

(1) Equipment (Common use Equipment, Load Header, Centre, etc.)
Specification
No
Description
Total Unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Excavating :
Road Header
Pick Hammer
Excavator+Breaker
Hauling :
Wheel Loader
Dump Truck
Supporting works :
Welding Trafo
Bar Bender
Bar Cutter
Shotcrete Machine
Crawler Drill Rig (CRD)
Legdrill
Grout mixer
Grouting pump
Concrete Lining
Agitator Truck
Concrete Pump
Concrete Vibrator
Centre/Sliding Form
Crane Truck
Other's Equipment :
Air compressor
Blower / Ventilator
Submersible Pump 2"
Generator Set
Hand Grouting

1
2
1
1
3

90 kW
8 PS
0.8 m3

Note
Rental
Owned
Rental

2.2 m3, Side Dump Rental

4 m3
Owned

2
1
1
2
2
2
2
2

300 A
3 PS , D32"
3 PS , D32"
10 m3/hr
62 mm
38 mm
200 x 2 liter
97/200 ltr .min

Owned
Owned
Owned
Owned
Owned
Owned
Owned
Owned

3
1
4
2
1

5 m3
40 m3/Hour
Dia. 2"
R = 2.800;L=6.000
5 Ton

Owned
Owned
Owned
Owned
Rental

2
2
2
1
1

17 M3/Min
37 KVA
H > 15 m'
250 KVA
-

Owned
Owned
Owned
Owned
Owned

(2) Support (Rock Bolt and Stell Rib, etc.)

No
Description
Total Unit
1
Rock Bolt L = 4,00 m'
15.400 m'
2
Rock Bolt L = 3,00 m'
2.000 m'
3
Steel Mesh
11.400 Kg
4
Steel Rib Support
200 Ton

Type/Specification Note
D25, Deform Bar SD-35;JIS G 3112
"
"
5-150x150 Wire St.Fab. ASTM A 185
H-125x125x6.5x8
JIS G 3103, SS 400

(3) Concrete ( Cement, Aggregate, Water, Reinforcement Bars, Form etc.)

No
Description
Type/Specification
Obtained From
1
2

Batched Plan Concrete

(Readymix)
Reinforcement Bars

3
4

Accelerator (6% cement weight)

Water Stop

Class A, 270 kgf/cm2 PT. Armada Hada

Graha - Semarang
PT. Hanil Jaya Steel
U30, SII 0136-1984
- Surabaya
or JIS G3112
Sika Beton
Technical Spec 9-7
Technical Spec 9-38 CV. Beton Teknik
Technical Spec 9-40 - Jakarta

2.2 Open Excavation and Slope Protection

(1) Excavation at Outlet
According to actual site ground face riverbank at the Outlet area is very steeply sloping /vertical
approximately . Clearing and open excavation at outlet use Hydrauic Excavator
There must consider to prevent of rupture during excavation for Outlet face.
Fore pooling method forward or method by rock bolting shall be provided.
(2) Protection Works for Slope and Tunnel Mouth (Protection of Cave In)
Protection for Tunnel Mouth to enforcing the steel portal use Gabion Sand Bag,and necessary
to shotcrete the rock face arround of outlet.
See Figure 4a : Conceptual Protection Work for Slope and Tunnel Mouth.
The sequent of Open excavation and Slope protection i.e.:
- Clearing/Stripping and excavation by Hydraulic Excavator of Outlet Tunnel mouth
- Rock Bolting dia.25 mm; L = 4,00 m follow of designated the pattern
- Installing Anchor D 16 L=1,2 m ;45 nos
- Excavating of Portal Foundation by Excavator
- Setting position of Portal, 3m length from outer rockwall toward tunnel axis
- Backfill concrete for Portal Foundation
- Setting Re-Bar and formwork for 1st stage
- Placing Concrete 1st stage h=2,4 m
- Setting Re-Bar and formwork for 2nd stage
- Placing Concrete 2nd stage h=2,4 m
- Setting Re-Bar and formwork for 3rd stage
- Placing Concrete 3rd stage h=2,297 m
- Setting Re-Bar and formwork for 4th stage
- Placing Concrete 4th stage h=2,253 m
See Figure 4b : Placing Concrete for outlet portal

2.3 Tunnel Excavation

(1) Procedure of Short Bench Cut
Procedure of excavation will be divided into upperhalf section and lowerhalf section.
- Upper half section, comply with optimum cutting height of Road Header is about 4,00 m measured from track shoe to upper roof of tunnel excavation.
- Excavation for upper half section will be commenced for every 1.5 m' length, continue with
supporting works with the sequences as below :
- Primary Shotcrete t = 5 cm, an waiting for 2 hours
- Wiremesh
Upper Half = 4,,00 m
- Steel Rib Support upper portion
- Rockbolt
- Secondary Shotcrete t = 10 cm.
Lower half = 2,235 m
- Continue with the excavation for next 1.5 m' forward
0,645 m

- After completion of upper half for 30 m', then the lowerhalf section excavation can be executed.
- Height of bench is 2,235 m to the bottom of lowerhalf excavation.
- The excavation of lowerhalf section will be executed for 3.00 m' forward continue with
the supporting work, with the sequence as below :
- Primary Shotcrete t = 5 cm
- Wiremesh
- Steel Support lower portion
- Rockbolt
Note :Last Excavation(Bottom Portion) will to commence while invert
portion of concreting is already for execution
- Secondary Shotcrete t = 10 cm.
- Continue with the excavation for next 3.00 m' forward
(2) Applied Equipment for Excavation and Mucking
i. Tunnel excavation.
Road Header shall be applied for tunnel excavation, electromotor power belt conveyor extension
is necessary involved for extend to convey the excavated rock and directly fill to the dump truck.
Lower half portion excavation can be carry on alternative by Giant Braker Excavator, excavated
material will be load to Dump Truck by Wheel Loader.
ii. Mucking
- Dump Truck Cap.4m3 shall be applied for tunnel mucking.
- Procedure for applied equipment for excavation and mucking is illustrated in Figure 5.
- For effective mucking, the excavated material will be collect in the temporary disposal near of
Inlet/Outlet Portal, and will be handled to disposal area by other equipments.
(3) Tunnel Supporting (rock Bolt, Shotctrete and Steel Rib Support)
i. Rock Bolt
- Drilling the hole use percussion drill (Legdrill or CRD) dia.40 mm.
- Drill holes must be exactly drilled at the desinated locations and intervals.
- Rock bolt material deform bar,fabricated threaded end with nut &washer dia.25 mm,L=3,00m.
and L = 4,00 m for type "a" support.
- Chemical anchor - epoxy resin shall be applied.
- Fixing bolt/nut by wrench
- Hand grouting to insert of cement plastic into the hole, after rock bolt installed.
See Figure 6.

ii.Shotcrete
- Type Shotcrete for the tunnel is wet mix.
- Gradation of aggregate shall conform to the spacification, cement proportion >400 Kg/m3
- Apply machine of pneumatic high velocity for the shotcrete work.
- Application thickness total 15 cm
For illustration see Figure 7

WATER PUMP
SHOTCRETE
MACHINE

AIR COMPRESSOR
TRUCK MIXER

WATER
TANK

Figure 7
iii.Steel Rib Support
- The supprort is fabricated from Steel H.125.125.6,5.9, will be installed 1,00m c.t.c.
- Steel Rib Support at upperhalf section portion can be installed ,when primary shotcrete finish
and setting time about 2 hours later.
- Equipment use for entering and install Steel Rib Support, Hydraulic Excavator and Dump Truck.
- TheUpper joint of the steel rib will be tightened firmly enough with bolt and nut.
- The base plate of the upper Steel Rib Support will be laid on the correct position.
- Steel Rib Support of Lower Position will be installed after the lower half excavation and the
primary shotcrete finish, and connect by firmly bolting with the upperhalf Steel Rib Support.
Steel Rib Support dimension and detail, see Figure 8
iv.Setting Wiremesh
- Wiremesh (dia.5 mm, 150 mm x 150 mm) immediately to set after steel ribs have installed,laid
between steel ribs and face of primary shotcrete t = 5 cm.
- Overlap not less than 15 cm.
- Wiremesh will be fixed firmly to the steel ribs by wires prevent to displacement due to spraying
pressure of shotcrete.
(4) Temporary Facilities for Tunnel Excavaion (Lighting, Ventilation, Drain)
i.Lighting
Apply Flourescent lamp and Haloge lamp and movable Halogen lamp near the cutting face , as
illustrated in Figure 9.
FLOURESCENT
LAMP 25W

FLOURESCENT LAMP 25W @ 8m'

LAMP 400W @ 15 M'

CUTTING
FACE

LONG VIEW, LAY OUT OF LIGHTING

FRONT VIEW

Figure 9 : Lighting in Tunnel

ii.Ventilation
Consider to air consumption related to working activity inthe tunnel for the workers,equipments and others can be estimated as follow :
Consumer matter
Air Consump(m3/Min.)
No
Job Item
Remark
Name
Total
Per unit
Total
1
Excavation Upperhalf Road Hd
1
0
0
Incl.mucking
D.Truck 4T
2
54
108
90 Hp/Unit
Person
6
3
18
2
Excavation Lowerhalf Excav.
1
110
110
110 Hp/Unit
Incl.mucking
D.Truck 4T
2
54
108
90 Hp/Unit
W.Loader
1
110
110
110 Hp/Unit
Person
6
3
18
3
Shotcrete Dust
Cement
0
267
0
400 Kg/m3
3mg/m3 *)
D.Truck 4T
0
66
0
110 Hp/Unit
Person
0
3
0
Note: *) : Not in the same time with excavation.
Total Cosumption =
472 m3/min.
Fan use =1 x 37 KVA
iii. Drain
Draining water water from the tunnel to outside by pumping with electric water pump or
submersible pump. It necessary to prepare the collecting pit for pumping location.

Submersible
Pump 2"
Hose/Steel Pipe
Sump Pit &
Temporary
Ditch in Tunnel
Pumping and Dispose to River

(5) Spoil Bank and Disposal

Spoil Bank or Disposal location result from Tunneling activity is shown at Figure 2, for increase
speed of mucking activity, it necessary to provide the temporary spoilbank of excavated tunnel
material, laid near Outlet/Inlet Portal.
(6) Safety and Health Management for Underground Works
Will be submitted later at separate proposal.

2.4 Tunnel Lining and grouting

(1) Procedure
- Sequence of concrete tunnel lining started from the downstream to upstream direction.
- Concrete lining can be start to commence after completion of rebar setting , formwork setting and
adequate support of formwork , request and approval by the Engineer during inspection.
- Cleaning use water jet or pressure air compressor.
- Concrete type A is produced from Batching Plant - wet mix type, and transported to the location
by Agitator Truck.
- Pouring for concrete lining,conveying of concrete material use portable concrete pump,without
high velocity discharge and resultant segregation.
- Concrete shall be forced into the top of placement to fill completely the crown at the tunnel, the
discharge pipe shall be burried at least 2 m.
- Compacting the concrete during laying use pneumatic concrete vibrator dia. 2".
- Remove the Crown Form minimum of 3 days age.
(2) Form Works/Reinforcement Arrangement
- Use Fabricated Sliding form, 12m long setting@6m length per segment, see Figure 10
- Reinforcement arrangement will be submitted later on.
(3) Lining Concrete Placing
- Concrete Type A obtained from Bathing Plant, transported by Mobile Concrete Mixer.
- Placing of concrete use Portable Concrete Pump.
- Compacting concret use pneumatic concrete vibrator
Concrete placing for Lining is illustrade at Figure 11.
12,00

CONCRETE
MIXER MOBILE

CONCRETE
PUMP
CONCRETE
STEEL PIPE

STEEL SLIDING FORM

Concrete Lining Upper/Crown Portion

CONCRETE
MIXER MOBILE

CONCRETE
PUMP
CONCRETE
STEEL PIPE

Concrete Lining Invert

Figure 11

12,000

(4) Back Fill Grouting

Before Lining Concrete work begin, Steel pipe dia 1.5" thread end will be installed into the determined
points at the wall of sliding form. This pipe will be use for backfill grouting work. The execution of backfill
grouting can be started after the concrete lining reach 28 days.
Backfill grouting execution :
- Equipment to be used :
2 units grouting pump & 2 units grouting mixer stayed on truck for grouting operation
- Two stage of grouting :
> Stage 1 : grouting with proportion of 2 water : 1 cement mix for bonding
> Stage 2 : grouting with proportion of 1 cement : 2 sand mortar for concrete filling ;
cement content = 600 kg / m3
- Mortar material is supplied from batching plant and transported by Mixer Truck

Backfill grouting

Concrete Lining
A

DETAIL A

DETAIL B

kertas sak
semen

100
1.5
1.5
100

120

80 50
30

120

120

DETAIL OF PIPE INSTALLATION

posisi lubang

1.00
0.6 0.6
1.00
0.50
1.00

PIPE POINT PATTERN

0.6 0.6

(5) Contact Grouting and Curtain grouting

- Steel casing pipe dia. 50 mm shall be embed to the concrete lining where conformed with the
poins position for drilling and grouting.
- Commencing of Contact Grouting and Curtain Grouting after concrete lining have minimum
14 days age.
- Rotary Drilling will apply for drilling work
- Equipment and related drilling and grouting activities can illustrated in Figure 12.
- Arrangement of Drilling and Grouting is shown in Figure 13
GROUTING
DRILLING
WT. PUMP
WATER TANK
RUBBER HOSE

GROUTING
DRILLING
MACHINE

CEMENT
SAND

GROUTING
PUMP

PLATFORM
PLATFORM

DRILLING AND GROUTING

Figure 12

RUBBER
HOSE

2.5 Inlet and Outlet Structure

(1) General Construction Method
- Inlet and Outlet Structure concrete type C, can be starting immediatelly when concrete lining
of tunnel for inlet or Outlet portion is completed.
- Due to limit of space at inlet foundation location, coffering use by Stone masonry.
- It necessary to provide dewatering system for inlet location,use Submersible Pump dia.2"
- To excavate the inlet foundation to elevation +92,60, use Excavator or Giant Breaker.
- After rock foundation have inspacted, immediately pouring the lean concrete.
- Installation rebar and Formwork
- All dimession and shape following the approved drawing.
- Concreting stages for walls or Piers per 2m high is applicable.
- Maximum drop of direct concrete placing is 2 m, and then use Concrete Pump.
- Outlet structure: rather enough for work space.
See Figure 14 Coffering at Inlet during excavation and construction
(2) Timing of Construction
- Timing of Construction expected in the dry season then discharge of river flow is minimum.
- Programe for execution of inlet,is very tight, design must be proper and fixed, then the resour
ces(man power, material and equipment) must be in adequate requirement.

3. Time Schedule for Diversion Tunnel Construction Works

3.1 Cycle Time Estimation
(1) Open Excavation
Open excavation for inlet or outlet diversion tunnel usually done by combination of equipment, those are
: Excavator, Buldozer for excavating/loading and Dumptruck for hauling. The expected hourly production
is about 40 m3 , with normal dayworks ( 8 hr /day) the production will be 320 m3/day.
The cycle time is calculated based on the production of major equipment (excavator): 40 m3/hr ~ 320
m3/day . Production for 1 month will be = 8,000 m3
(2) Underground Excavation
Excavation for diversion tunnel using short bench cut method . The area of excavation is divided into 2
section upperhalf section and lowerhalf section .
Please see table 3.1.2 and 3.1.3
(3) Lining Concrete
Lining concrete for diversion tunnel will be designed for 12 metre , except for curve section it will apply 6
metre. Basically two (2) centre/ sliding form will be installed for lining work. Cycle time for lining work is
divided for upper section and invert.
*)Please see Detail time schedule
(4) Back Fill Grouting
*)Please see Detail time schedule
(5) Consolidation/Curtain grouting
*)Please see Detail time schedule
(6) Concrete Works
*)Please see Detail time schedule

3.2 Detail Time Schedule

(1) Timing of commencement of each works and Critical Path
Please see attachment Detail time schedule
(2) Detail Time Schedule
Please see attachment Detail time schedule
3.3 Schedule for Equipment, Materials and Labors
(1) Equipment(Type, Number)
Please see annex 3.3.1
(2) Material (Item, Quality, Quantity)
Please see annex 3.3.2
(3) Labors (Schedule for Number of Employee)
Please see annex 3.3.3

35

4. Quality Control and Progress Control of the Works

(1) Survey Works
Prior to commencement of excavation, temporary bench mark and refernce point to be set up at
each portal area of tunnel. The points shall be places where no damage or movement are expect
and well protect.
During tunnel excavation line and level marked by painted nail on the shotcrete surface, will be
setting up as near from the cutting face, that could be based of works.
The important marking reference shown as :
TUNNEL
IF REQUIRED
TEMPORARY

DESIGN 2,80 m'

DESIGN 2,80 m'

TEMPORARY
LEVELLING POINT

TEMPORARY

(2) Laboratory and Testing

No
Work Activity
1 Drilling and Grouting
2 Shotcrete

Type of Test
Water Pressure Test
Washing and Testing
Material Test
Trial Test
Sampling

3 Rockbolt

Pull out

4 Concrete

Material

Concrete Test

Remark
-1 Stage = 5 m', 5 pressures/5minutes.
- Test pressure
- Water shall comply Clause 9.7.
- Aggregates shall comply Clause 9.5.
- Field trials,horizontal&Vertical,comply
to ASTM C 42.
- Compresive strength test comply to
ASTM 109.
- 80% of Cracking load.
- Cement, by factory
- Aggregate shal comply to Clause 9.5.3,
and Clause 9.5.4.
- Shall comply to Clause 9.14.