Channelling Works
2020
CIBINONG - WEST JAVA - Indonesia
PT Indocement Tunggal Prakarsa Tbk in cooperation with Heidelberg Technology Center
INDOCEMENT FACTORY RIVERBANK PROTECTION
Factory outlflow structure before the intervention
Riverbank lining using a Gabion Wall
Gabion and Reno Mattress as riverbank protection
Erosion control with BioMac
Reno Mattresses combined with BioMac, after vegetation establishment
Problem
Indocement factory is located in the South of Jakarta and it is the second-largest cement producer in Indonesia. PT Indocement Tunggal Prakarsa Tb in cooperation with Heidelberg Technology Center aimed to provide protection against the erosion affecting the banks of the river flowing adjacent to their cement production plant. During the rainy season, the riverbanks were severely damaged by erosion processes which were threatening the plant structures nearby (conveyor belts and storage tanks). The ongoing erosion had to be minimized through an engineered river lining.
Solution
The solution proposed by Maccaferri involved mainly Gabion structures coupled with Reno Mattresses used as toe scouring protection. The solution, if compared to traditional stone masonry walls, is more flexible, permeable and durable. In addition, all the areas interested by occasional floods were protected using a 100% natural biomat (Maccaferri BioMac) along with the manual application of mulching in order to rapidly establish the vegetation. The solution proposed is designed in order to withstand a maximum water velocity equal to 3,0 m/s. The riverbank protection designed and build is approximately 1,0 km long and divided in the following stretches: Chainage 0+400 – 0+650: BioMac + Mulching as riverbank erosion control. Chainage 0+650 – 1+250: Gabion wall + Reno Mattresses as scour protection Chainage 1+250 – 1+320: Reno Mattresses All the factory outflow structures are protected using Reno Mattresses supported by Gabions. All the double twisted products involved are Galfan (Zn+Al) and PVC coated in order to guarantee high durability when used in river training works. All the stability checks of the Gabions and Reno Mattresses structures were performed using the internally developed Maccaferri software (MacStars W 4.0). Furthermore, Maccafferri provided the Client with job site supervision and the Contractor with installation assistance in order to ensure that the highest construction and installation standards were followed.