Technical Stage to Plug The Large Size Diversion Tunnel of

Jatigede Dam at West Java, Republic of Indonesia, 2017

Anwar 1
Makmur , Tulus H. 2
Basuki , Dony 3
Faturochman , Rosita H. 4
1 Sr.Engineering Geologist; 2 Sr. Dam Designer; 3 Head of Dam Planer at Jatigede dam; 4 Hydrologist
( weak zone ).

Plugging works is a water blocking process in diversion tunnel to block the flow
U
of water from reservoir through the diversion tunnel. Plugging work in Jatigede
dam is scheduled to be done at the construction stage. After the diversion Upper Halang Claystone
tunnel is closed, concrete material is filled in to the tunnel. After the initial gate
closed at August 31st, 2015 then continued with the plugging process on Conduit
September 1st, 2015.

Jatigede dam is located at the abutments of Cimanuk River, in Gambar Error! No text of specified style in document.-1 Geological Long section of Diversion
Jatigede village, Wado district, Sumedang regency, West Java Regional geological condition
Tunnel
in Jatigede dam consists of Pliosen breccia, claystone
province, Republic of Indonesia. The site can be accessed by two from upper Halang formation, breccia from lower Halang Formation and claystone
alternate routes, from Jakarta through Bandung to site about ±265 from Cinambo Formation. All the formations were covered by sand layer and clay.
km, or from Jakarta through Cirebon to site ±195 km (see Fig. 1). Diversion tunnel trace is located at the right abutment, with 546.221 m length layered
on claystone rock, volcanic breccia and tuff breccia (lapilli tuff).
Primary Plugging Main Plugging

Primary Plugging 10 m
7m 2,2 m
Block Block
2,4 m A B
2,4 m

• This primary works aimed to strengthen 17,74 m

61 m
18 m 23 m

diversion tunnel’s gate against reservoir water Divertion Divertion

pressure which gradually becomes higher as Conduit Tunnel

reservoir water level increased. This works

Main Plugging
also serve as a means to counter weight
Position and length of diversion tunnel is stated below: against uplift pressure and minimize leakage
• The function of main plugging is to clog
a. Length of diversion conduit : 61.454 m (sta.0+120,002 ~ sta.0+181,456) which might occur from gates
the water flow through diversion tunnel
b. Length of diversion tunnel : 546.221 m (sta. 0+181,456 ~ sta. 0+727,677) • The construction of primary plugging was not
during impounding of Jatigede reservoir,
completed with cooling pipe and grouting pipe
which have accomplished before full
Plugging stage of diversion tunnel is divided into 2 (two) stages: because it is considered temporary
reservoir operation
1. Primary plugging: sta.0+120,002 ~ sta.0+137,742 (17.74 m) construction
• Main plugging construction is completed
2. Main plugging : sta.0+361,757 ~ sta.0+402,757 (41 m) • The primary plugging applied in the back of
with cooling pipe to reduce concrete
diversion tunnel with trap pattern until 70% of
temperature and grouting pipe which filled
tunnel height
in cement into the shrinkage concrete.

Primary Plugging Main Plugging Pipa Concrete Pump Concrete Pump 1

Block Block
A B

Divertion Divertion
Conduit Tunnel

Pintu Diversion
Primary Plugging Pipa Concrete Pump Concrete Pump 1 Concrete Pump 2 • Different with primary plugging, one concrete pump machine was occupied for concreting of
Tunnel
main plugging due to shorter distance between concrete pump to concreting area.
• Before concreting work, additional equipment had been prepared, i.e. cooling pipe, grouting
pipe, and thermometer. The said equipment has to be installed and examined for it to
Divertion Divertion
Conduit Tunnel

• The first step before concreting the primary plugging is to prepare temporary access to diversion function perfectly, including water cooling or chiller is in normal condition.
tunnel by composing soil and rock embankment at the right abutment of plunge pool to the
adjacent of the diversion tunnel’s inlet. The preparation of temporary access aimed to make it Preparation before Plugging Concreting
easier to operate the concrete mixer car, and to move grouting equipment and staff to adjacent the CL
Concrete Type "G"
diversion tunnel’s inlet. a. Cooling pipe type 1, installation (2 unit)
Cooling pipe
Thermometer

The next step was placing concrete pump machine at the outlet of diversion tunnel, one concrete
Copper Grouted stop
• 1.70
Lift 5 1.50

pump in the middle of diversion tunnel due to the distance between concreting area and the
Concrete Type "G"
1.90
A B 2.40 Lift 4 1.50 Concrete Type "G"
Copper Grouted stop Copper Grouted stop
in put-1
Lift 3

concrete pump is quite far,and shot to concreting area two times due to limitation on concrete
1.75 1.75 in put-2 2.00 1.50
10.00 2.40
0.50 0.50
1.50
Lift 2
3 2 3 2

4 3 4 5 2.00

pump’s capacity.
4 4
out put-2 2.40
10.00 3 5 10.00 out put-1 1.50
4 3 4 5
4 4

3 2 3 2
2.40 Lift 1 Temporary drain pipe

• Concrete type “F+ (plus)” (which using material of 20 mm maximum diameter) were taken into 1.75

18.00
41.00
23.00
1.75

consideration for concreting on plugging works. A B

0.80 1.20 1.20 1.20 1.20

10.00
1.20 1.20 1.20 0.80

No Lift Area (m2) Length (m) Vol (m3) b. Grout pipe installation
1 1 14.49 17.74 257,05 About 943.17 m³ volume of concrete CL

has been completed for executing the

2 2
Concrete Type "G"
Concrete Type "G"
Contact Grout Outlet AXIS OF MAINDAM Contact Grout Outlet Distribution Joint Grout
22.78 16.24 369.95 Copper Grouted stop Copper Grouted stop
Pipe Horizontal Grout Outlet

primary plugging work.

1.75
Distribution Joint Grout
3 3 21.45 14.74 316.17 5.25

Grout Supply/return
Pipe Vertical 1.70
Lift 5 1.50

Contact Grout Supply/return 1.90 Lift 4 1.50 Concrete Type "G"

Total 58.72 943.17 10.00

Contact Grout Supply/return

10.00
3.00

10.00
2.00 Lift 3 1.50

Grout Supply/return Check Hole Pipe 1.50

Contact Grout supply /
Lift 2
3.50 2.00 return headel

❑ Plugging work on a large diversion tunnel with 10 m diameter and 41 m length

1.50
1.75
2.40 Lift 1 Temporary drain pipe
18.00 23.00

in Jatigede Dam has been accomplished without any significant difficulties.

41.00

Contact Grout Outlet Contact Grout Outlet

0.80 1.20 1.20 1.20 1.20 1.20 1.20 1.20 0.80

PLUG BLOCK A (18.00 m) PLUG BLOCK B (23.00 m)

The primary plugging work begun on September 2nd, 2015 and finished by 10.00

September 13th, 2015 by using “F+(plus)” type (only for material with c. Thermometer installation
maximum size of 20 mm), by consuming 943.17 m3 volume of concrete. Concrete Type "G" Monitoring of temperature
during and after concreting
Copper Grouted stop Copper Grouted stop

❑ The following phase was preparing main plugging concrete work. Main
1.75

5.25

Thermometer No.2 Thermometer No.3

Thermometer No.1

plugging work with 41 m length begun on September 20th, 2015 and finished
10.00 10.00
3.00

Thermometer No.4 Thermometer No.5 Thermometer No.6

3.50

by October 26th, 2015, which spends grouting material about 30,907.50 kg of

1.75

18.00 23.00
41.00

Portland Cement. PLUG BLOCK A (18.00 m) PLUG BLOCK B (23.00 m)

❑ The obstacles of both primary and main plugging work was how to
manufacture groove for placing cooper plate water stop. Cooper
plate water stop should be installed precisely into the grip of uneven
groove. Similar precised work should be applied when connecting
cooper plate’s segment by using welding.
The work item that accomplished in this area During concrete process, temperature has
❑ Monitoring of temperature during and after concreting was one of
consist of : been examined and configured in the
the essential parts, this part is expected to gradually cools down into
1. Backfill Grouting/Mortar Grout graphics. The Figure shows graphic of
its normal condition about 77oF – 86oF, and to achieve that is by
2. Contact Grouting and Joint Grouting correlation between time and temperature
installing cooling pipe properly. High temperature concrete flow in
3. Check Hole of Joint Grouting Work during concreting process, the temperature is
concrete pipe should be well supervised, to avoid any unexpected
4. Backfill Grout for Access Gallery expected to go down gradually to its normal
clogging, curing was applied.
5. Backfill/Mortar Grouting of Access Gallery condition about 77°F – 86°F.