In July 2023, Concrete Canvas Ltd’s revolutionary product, CCX-MAT® GCCM (CCX-M®), was employed to address a critical need in a hydroelectric project in Semarang, Java, Indonesia. The product was used to line and provide erosion control for a water diversion channel, demonstrating the potential for innovative materials in enhancing the sustainability and efficiency of hydroelectric projects.
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The Challenge
The water diversion channel was designed as a temporary structure with the goal of blocking and diverting water run-off from the hydroelectric project site. The channel was intended to be fully submerged within two years, making it essential to line the channel to prevent erosion and water seepage into the surrounding area.
Traditional Solutions Fall Short
Initially, traditional poured concrete was suggested for lining the channel. However, the remote location and scale of the project made this approach financially unfeasible due to high costs associated with logistics, materials, specialist equipment, and labour. Similarly, shotcrete was considered and initially used, but it failed to adhere to the existing soil, further complicating the project.
The CCX-M® Solution
CCX-M® emerged as the optimal solution for this hydroelectric project. This Type II GCCM, as defined in ASTM D8364 – Standard Specification for GCCMs, is ideal for lining hydraulic structures with both soil and solid subgrades. The choice of CCX-M® was driven by its ease and speed of transportation and installation, which required minimal equipment and a small team, significantly reducing overall costs.
Preparation and Installation
Before the installation of CCX-M®, the 360-meter-long channel was excavated and prepared to precise specifications. Anchor trenches were excavated at the shoulders, upstream, and downstream of the channel. Bulk Rolls of CCX-M® were transported to the site and lifted into place using a crane with a spreader beam attachment. The material was laid transversely across the channel’s width and cut to length with basic hand tools. The installation process involved overlapping each layer of CCX-M®, secured with stainless steel screws along the overlap marker line. The material was hydrated after each shift using a hose and water pumped from a nearby stream.
Project Success
Thanks to the speed and ease of application, the CCX-M® was installed at an impressive rate of 700m² per day (during 7-hour shifts) by a team of nine installers. The project was completed ahead of schedule, earning praise from both the clients, The Ministry of Public Works & Housing Indonesia, and the sub-contractors, PT Prima Minechem Indonesia.
Conclusion
The successful use of CCX-MAT® GCCM in this hydroelectric project highlights the importance of innovative materials in the construction and maintenance of hydraulic structures. The project in Semarang serves as a model for future hydroelectric projects, demonstrating how advanced materials can provide effective solutions for erosion control, cost efficiency, and project sustainability.
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