CFRD Vs RCC Dams
CFRD Vs RCC Dams
Master of Science Thesis in the Masters Programme Geo and Water Engineering
TOM KARLSSON AND JONAS TALLBERG
Cover:
An Autocad figure of a CFRD design for Changuinola II, described in Chapter 4.
Jmfrelse mellan tv dammtyper, Concrete face rock-fill dam och Roller compacted
concrete dam
En fallstudie av dammbyggnader i Panama
Examensarbete inom Geo and Water engineering
TOM KARLSSON OCH JONAS TALLBERG
Institutionen fr Bygg- och miljteknik
Avdelningen fr Vatten Milj Teknik
Chalmers tekniska hgskola
SAMMANFATTNING
Det hr examensarbetet fokuserar p att jmfra tv olika dammtyper fr att
underltta Vattenfalls beslutsprocess d fretaget r involverat i ett
dammbyggnadsprojekt i Panama. De tv dammtyper som jmfrs r en skallad
Roller Compacted Concrete Dam (i examensarbetet kallat RCCD) och en Concrete
Face Rockfill Dam (i examensarbetet kallat CFRD).
Frst utfrdes en litteraturstudie fr att bygga p den basala kunskapen om de olika
dammtyperna. Den strsta delen av litteraturstudien gjordes med bcker, men ven
seminarier och samtal samt undervisning av kompetent personal p bde Chalmers
och Vattenfall Power Consultants frekom.
Examensarbetet fortstter sedan med en fallstudie av tidigare dammar som har byggts
i omrdet dr Vattenfall varit en del av projekteringen. De dammar som studerats r
Changuinola I, en damm vid floden Rio Esti samt ett frkastat projekt vid namn Chan75 som aldrig blev byggt. I fallstudien fann vi att Chan-75 var av strst intresse fr
oss d projektet hanterade samma frgestllningar som examensarbetet frsker
besvara.
Slutligen appliceras resultaten av fall- och litteraturstudien p Changuinola II
projektet. Rekommendationen r att Changuinola II byggs som en RCCD av
anledningar som redovisas i rapporten.
Nyckelord: CFRD, Concrete face rock-fill dam, RCCD, Roller Compacted Concrete
dam, dam, construction, Changuinola
II
Contents
ABSTRACT
SAMMANFATTNING
I
II
CONTENTS
III
PREFACE
INTRODUCTION
1.1
Background
1.2
Purpose
1.3
Problem
1.4
Method
1.5
Delimitation
DAM TYPES
2.1
Concrete Faced Rock-fill dam
2.1.1
History and expansion
2.1.2
Design
2.1.3
Material
2.1.4
Foundation
2.1.5
Construction
2.1.6
Risks and experiences
3
4
4
12
13
14
16
2.2
Roller-Compacted Concrete Dams
2.2.1
History and expansion
2.2.2
Design
2.2.3
Material
2.2.4
Foundation
2.2.5
Construction
2.2.6
Risks and experiences
18
18
18
22
24
24
26
CASE STUDIES
31
3.1
Rio Esti
3.1.1
Site description
3.1.2
Design
3.1.3
Construction
32
33
34
36
3.2
Changuinola I
3.2.1
Site description
3.2.2
Design
3.2.3
Construction
3.2.4
Challenges and experiences
36
38
39
40
40
3.3
Chan-75
3.3.1
Site description
3.3.2
Design
41
41
41
III
CHANGUINOLA II
44
4.1
Site description
4.1.1
Site C
45
46
4.2
RCCD alternative
4.2.1
Design
4.2.2
Construction
4.2.3
Material
46
47
49
49
4.3
CFRD alternative
4.3.1
Dam design
4.3.2
Dam body
4.3.3
Sealing design
4.3.4
Spillway design
4.3.5
Diversion
4.3.6
Final design
50
50
51
52
53
53
55
57
Conclusion
57
5.2
Discussion
5.2.1
Problems
5.2.2
Further work
57
57
58
IV
REFERENCES
59
Preface
We would like to thank everyone involved in the making of this report. Steffen
Hggstrm, our supervisor, who has provided us with invaluable input and writing
tips. We would also like to thank the staff at VPC (Vattenfall Power Consultants) who
were kind enough to let us take part of their work, as well as providing us with
extensive material and office space. A special mention also goes out to Anna
Gyllenswrd, who has helped us with picture editing and general layout design.
Lastly we send our gratitude to our examiner, Lars Bergdahl, for making this report
even possible. This would not have been done without him.
Abbreviations
CFRD
MD&A
RCCD
RMR
RQD
VPC
VI
Introduction
1.1
Background
In Sweden very few water power stations have been built during the last decades.
Thus there is very little experience of dams built with RCC and CFR technique.
Internationally, CFRDs and RCCDs are common and in many parts of the world there
is a large potential for new water power stations. The company Vattenfall is currently
involved in pre-studies, layout design and project management in several international
projects.
Three dams in Panama are some of the international projects that Vattenfall is
involved in. The dam types considered are RCCD (Roller Compacted Concrete dams)
and CFRD (Concrete Faced Rock-fill Dams).
1.2
Purpose
The main purposes of this project is to gather and provide information, knowledge
and experiences about RCCD and CFRD dam types, compare them to each other and
gain knowledge that can be used in planning of other projects in the future. The
increased understanding should include, but not be limited to, how the choice of dam
type is done in regard to different parameters such as geotechnical and geological
properties as well as accessible material and its difficulties during construction.
1.3
Problem
The main problem is to analyze which dam type that is preferable for the construction
of Changuinola II.
This report is mainly divided into three parts. Part one is a description of RCCD and
CFRD with respect to design and construction. Part two will try to answer the
following questions.
Part three represents the main conclusions and results based on part one and two. The
results are then applied to Changuiola II.
1.4
Method
Part one is a description of the two dam types, CFRD and RCCD. Knowledge about
e.g. design, foundation and construction are gathered is presented.
Part two is based on reports from already finished projects, mainly the Barrigon Dam
and Changuinola I in Panama. These projects are used as case studies along with
information from other projects worldwide. The original plans for Changuinola I was
to construct a CFRD at the same location, in the text referred to Chan-75. Because of
far-reaching plans and the amount of background material available, we have chosen
to also give a short description of this alternative. Part two also consist of a study of
the area for the planned dam Changuinola II.
Finally part three is a study of Changuinola II where part one and two are used as
base. Part three will describe and compare the different alternatives possible for
Changuinola II with focus on the features stated below. The main focus for the
evaluation of Changuinola II is on the two points below.
Time spent, e.g. total construction time, man-hours, need of vehicles etc.
In addition to the topics above, following points are also discussed and evaluated.
Time and costs used for trial tests, e.g. full scale trial test for RCCD.
These features are chosen from experiences from earlier constructions and in
discussion with supervisor.
1.5
Delimitation
The delimitations are done in order to obtain the purpose stated above. First the report
will concentrate only on the dam design and not take interest in powerhouse or any
other surrounding constructions.
Because of the limitation regarding time it has not been possible to consider all costs
tied to the construction. The emphasis has therefore been to the most distinguish costs,
based on experiences from earlier projects. The powerhouse part of the water power
plants is not treated.
The limitation will be as follow:
2 Dam Types
Chapter 2 in this thesis aims at finding an overall description of the two dam types,
Concrete Faced Rock-fill Dams (CFRD) and Roller-Compacted Concrete dams
(RCCD). The chapter is divided into two parts, one for each dam type, where each
part consists of chapters describing e.g. design, construction, material use and risks.
Figure 2.1
One of the main characteristics with the CFRD is that the dam type enables usage of
local materials from the riverbed and the compulsory excavations in the rock-fill dam
body, as opposed to using expensive material from quarries which may have to be
transported a long way etc. However, there are some quality requirements on the
aggregates which have to be met in order to be able to use them in the dam body. The
quality is mainly determined by the local geology and highlights the importance of
good geological surroundings in order to exploit all advantages with the dam type.
When designing CFRDs there are certain properties that have to be assessed
thoroughly such as zoning of the dam body, filling materials, design of the dam body,
various analyses and seepage control to name a few. (Vncold, 2008)
2.1.2 Design
There are many ways to design a CFRD. Recently Vncold (Vietnamese national
committee of large dams) produced a paper containing some fundamental design
guidelines on behalf of ICOLD (International committee of large dams). In this
guideline there is detailed information of how the designing of the dam body should
be performed, the quality of materials used, foundation treatments as well as design
values for the face slab etc. The guideline summarizes experience from building
CFRDs and gives a valuable overview of the potential difficulties of building a dam
of this type. (Vncold, 2008)
We have decided to look in to these parameters and shortly describe them.
[Link] Dam body design
The dam body design includes several properties of the CFRD are:
Figure 2.2
When designing the dam slopes, consideration to the gravel material has to be taken.
If the material is of good enough quality, the up and downstream slopes can be
designed at a slope of 1:1.3 1:1.4. However, if the material consists of poorer quality
rock-fill the slopes should not be steeper than 1:1.5 1:1.6. (Vnocold, 2008) On the
crest of the dam there should be a parapet wall. Furthermore, Vncold (2008) suggests
that the crest width should be within the limits of five to eight meters wide. However,
the crest width is subject to the regulations of the local authorities as well as the
operation of the dam, perhaps there is a need for a road or other operations on the
crest.
The height of the dam is decided on an economical- as well as on a practical base. The
constructor and consultant have to calculate the reservoir volume and the height of the
dam in order to produce enough electrical power to ensure good economy within the
project. This means that also the variations of the river flow have to be considered.
(Vncold, 2008)
It is also important to make an analysis of the dam design to ensure that stresses and
deformation is within the set limits. Several models should be made on different parts
of the dam body. These include, but are not limited to, the concrete face slab,
perimeter joint of the dam body and rock-fill creep etc. When doing the analyses it is
important to include dynamic loading to see how the dam responds to seismic loads.
(Vncold, 2008)
If the dam is a high CFRD, above 100 meters (Vncold, 2008) it is also necessary to
make a stability analysis of the ground. It is also needed if the dam is constructed on
weak bedrock or a gravel foundation, if the seismic activity in the area is high, if the
dam is constructed with soft rock-fill materials or if there exists difficult terrain
conditions at the site.
Figure 2.3
The zones can have different relative volumes depending on how large the dam
should be, surrounding geology, bank slopes etc. Figure 2.3Error! Reference source
not found. (Zhang, Wang, & Shi, 2004) presents the different zones from the dam
Tianshengqiao 1 in China, where the following properties of the fillings are shown
Table 2.1.
Table 2.1
Material No.
Material description
II A
Processed Limestone
III A
Limestone
30
III B
Limestone
80
III C
80
III D
Limestone
160
[mm]
These values give us an idea of how the materials of the zonings in the CFRD body
can look like. The values can vary slightly depending on the rock types of the bedrock
and the aggregates available, since the values are determined by material properties.
[Link] Upstream sealing
The concrete face slab functions like an impermeable unit. However, there are both
vertical and horizontal joints to allow some deformation on the slab to prevent
cracking and thus leakage through the dam body. (Vncold, 2008)
When constructing the face slab thickness, Vncold (2008) suggest that it should be
calculated as:
T 0.30 0.0035 H
(2.1)
(VnCold, 2008)
Where T is the thickness in meters and H is the height of the dam, also in meters. This
suggests that the slab design gets thicker at the base since the variable, H, starts at
zero at the top of the dam. The minimum thickness of the slab should therefore be 0.3
m to allow for steel reinforcements and impermeable features.
T 0.40 0.0035 H
(2.2)
(Vncold, 2008)
Figure 2.4
In some cases, the minimum thickness of the slab can be increased to 40 cm for
certain high CFRDs in narrow valleys to account for the easy extruded failure zone of
central face slabs during these conditions. (Vncold, 2008)
[Link] Joint seals
Since the face slab is casted in a stage-by-stage construction and not a homogenous
slab, there are joints between the different slabs. These can be sealed and reinforced in
numerous ways. To prevent seepage through the joints in the face slab it is important
to seal them properly. The most important joint to seal, is however the perimeter joint
which is between the face slab and the concrete plinth. The plinth connects the slab
with the foundation. (Tan ev, 2005)
This is usually done by installing sheet plates. In some occasions asphalt is used in
between the sheet plates to seal the joints even better. However, the properties of the
asphalt need to be carefully chosen so that the asphalt does not become liquefied or to
stiff at extreme temperatures. (Reinus, 1968)
Some seals also include copper castings as well as PVC film. The most efficient way
to stop seepage through the perimeter joint is to use features of different materials and
shape at the same time. Tan ev (2005) proposes a design, which he states is the most
efficient one, shown in figure 2.5.
Figure 2.5
Perimeter joint
1.
2.
3.
4.
5.
Concrete plinth
Waterstop of copper sheet
Rubber waterstop
Concrete bedding
Face slab
(Tan ev, 2005)
Figure 2.6
The plinth is located on top of the bedrock underneath the dam. It should, according to
Vncold (2008), be joined with the bedrock trough grouted bolts, a so called grout
curtain. In figure 2.6 the loading condition for the concrete plinth is shown to give an
overview of how the loads are distributed upstream of the dam.
Table 2.2
Fresh weathering
>20
Moderate weathering
10 20
Intense weathering
5 10
Full weathering
35
The hydraulic gradient is sometimes called Darcys slope, which means it is the
difference between the head in two points divided with the distance along the flow.
The allowable hydraulic gradient shows the ability of the bedrock to withstand
leakage at an acceptable level, which is described in table 2.2. (Vncold, 2008)
[Link] Spillway and bottom outlet
There are several alternatives when designing the spillway and bottom outlet. For the
spillway there are two main types, spillway passing through the dam body and
spillway outside the dam body.
For embankment dam-types, such as the CFRD, the option of spillway outside the
dam body is most suitable. However, the spillway outside the dam body can also be
used in some concrete dams. Using crest spillways (spillways trough the dam body)
may increase the safety regarding flooding and overflow but that design is not
favorable for embankment dams. (Tan ev, 2005)
The spillway is also designed on behalf of the maximum flood occurrence which has
to be calculated so that the spillway can evacuate sufficient amounts of water. There
are three main spillway designs when considering the choice of a spillway outside the
dam body. These three options are:
The Ogee spillway (figure 2.7), is a spillway structure that is placed near the dam
body. It consists of a constructed pathway with banks that leads the water past the
dam to the riverbed downstream. In the case of soil foundation, the ogee must be
prepared with facing and lining to counteract erosion etc. (Tan ev, 2005)
The side-channel spillway and channel (figure 2.8) is very similar to the frontal
spillway. However, the water intake is located to the side of the dam.
10
Figure 2.7
Ogee spillway
(Tan ev, 2005)
Figure 2.8
Side-channel spillway
(Tan ev, 2005)
11
Finally, the shaft spillway (figure 2.9) can be constructed in various ways. Normally it
consists of a vertical shaft or, in some cases, an inclined shaft. The shaft spillway is
very useful when evacuating large amount of water from high reservoirs. (Tan ev,
2005)
Figure 2.9
Shaft spillway
(Tan ev, 2005)
The bottom outlet should not be confused with spillways and is used for leading the
water to the powerhouse and generating power. The design is depending on the
surrounding topography and geological conditions. If the geological conditions are
satisfactory and the topography allows for it, then the most common and easy way to
construct a bottom outlet is through a tunnel on the side of the embankment dam.
(Tan ev, 2005)
There is also an option for constructing an outlet tunnel through the embankment dam
body; however this option is more difficult and is generally not done for CFRDs. The
tunnel option also allows large quantities of water which is necessary when building a
dam within a reasonably large river due to the high design flows. Somewhere along
the outlet the powerhouse is built, so the tunnel option also gives some freedom as to
where the powerhouse should be placed. (Tan ev, 2005)
The other option for an outlet is pipes or a gallery below the embankment dam, but
due to the very size and quantities of water within the Changuinola project this is
unfeasible. (Tan ev, 2005)
2.1.3 Material
According to Vncold (2008), the filling criterion varies for each subzone of the CFRD
body and is based upon engineering experience. The zones of the dam can be seen in
figure [Link] subzones consist of materials with different properties such as porosity,
permeability and dry density.
12
Table 2.3
Material / Zone
Porosity [%]
Cushion material
15 18
Transition zone
18 20
19 21
<22
Relative density
0.80 0.85
Also, the dry density can be derived from the porosity show in Table 2.3 if the rock
density is known. It is important that the mean dry density standard deviation of the
materials and zones are not bigger than 100 kg/m3 to ensure that the stability of the
dam is sufficient; the materials need to be homogenous. (Vncold, 2008)
2.1.4 Foundation
The main purpose of constructing a good foundation for the dam is to lessen the
deformation caused by the weight of the dam as well as increasing the compressive
strength of the bedrock, prevent seepage under the dam and erosion that may follow
seepage. According to Tan ev (2005), the requirements of any dam foundation
concern deformability, stability and water impermeability.
To prevent the seepage a grout curtain is used. The curtain grout should be well into
the bedrock depending on hydro geological conditions and lower the pressure lines
under the dam which originates from seeping water. (Renius 1968)
13
Figure 2.10
Grout curtain
(Reinius, 1968)
The curtain grout works as an impermeable shield and consist of cement, or other
compounds such as silica sol, which is pumped into the bedrock under large pressures
and thus sealing cracks and stabilizing the rock. (Renius, 1968)
Embankment dams, such as CFRDs, are normally built on rock. However,
foundations of gravel can also be feasible due to embankment dams transmitting
relatively low stresses to the foundation. If the dam is being constructed on gravel, the
curtain grout becomes even more important due to the fact that gravel is much more
permeable than bedrock, depending on the bedrocks RMR and RQD values. (Novak,
et al. 2001)
RMR and RQD are two methods of classifying the quality of a rock by comparing,
amongst other variables, discontinuities of the rock mass.
2.1.5 Construction
The construction process of a CFRD is fairly straight forward. However, an
equilibrium rise of both upstream and downstream zones is required. When building
the CFRD, the backfilling level should also be slightly higher due to different
settlement behavior compared to the materials used for the front filling. (Vncold,
2008)
The pre-settlement of the dam body also needs consideration. It is inevitable that
settlements will occur within the dam body and if the face slab is constructed too
early, the risk of cracking and failure of the slab is increased. Vncold (2008)
14
recommends the presetting period to be 5 to 7 months and the settlement should not
be higher than 5-6 millimeters per month depending on how large (heavy) the dam is.
The materials used for construction could be taken directly out of the riverbed or from
a nearby crushing plant. If conditions allow, the gathering of materials is preferably
done from the riverbed. (Vncold, 2008)
During construction a water diversion may be used by retaining water using a
temporary cross section or allowing a flood passing cross the dam during extreme
flows. If a temporary cross section is used, then the requirements of the temporary
cross section should be met regarding sliding stability, seepage and high water
conditions. (Vncold, 2008)
[Link] Diversion
During the construction on a dam site, it is vital to divert the river flow in order to
progress with the dam building. Especially during construction of CFRDs since the
gravel material can be easily flushed away or cause damage to an unfinished dam
body. Both Tan ev (2005) and Novak (et al. 2001) suggest some diversion options
which help to facilitate the erection of the dam, shown in figure 2.11. During normal
conditions, cofferdams are used to create a good working space for the erection but
also to shelter the construction site from potential flash floods etc.
Figure 2.11
15
There are two different types of cofferdam designs that preferably can be used when
building in a riverbed and there is a stream of water that needs to be controlled, which
is the same method used for the CFRD alternative. (Tan ev, 2005 and Novak, et al.
2001)
Overtopping
Seismic loads
In the following chapters we will try to explain what the risks mean and how to avoid
them.
[Link] Overtopping
The biggest risk for a CFRD is the case of overtopping. According to (Chinnarasri,
2001) overtopping has caused CFRDs to fail numerous times in the past. When water
starts overtopping the dam, an erosion process starts which will reduce the dams
general stability and could cause the dam to fail.
To counter this risk, an internal warning system could be installed to indicate too large
flows in the river or too high levels in the reservoir. If this warning system indicates
dangerously high levels of water (usually the CFRD is designed for the 10,000 year
flood), the outflow though the spillways can be increased and the risk of overtopping
is then reduced although a decrease in energy output is also likely. (Chinnarasri, 2001)
[Link] Frost and ice
When building dams in colder climates, the temperature change during the year can
have some unwanted effects. For CFRDs this affects the concrete face plate.
Temperature contractions and expansions can cause cracking leading to leakage and
erosion of the concrete. The main dam body of the CFRD is, however, fairly resistant
to frost problems due to the permeable nature of the rock-fill. (Reinius, 1968)
16
[Link] Seismic
There are some cases of CFRDs being subjected to seismic forces and earthquakes.
This can be potentially disastrous for the dam. It can fail or be heavily damaged due to
the dynamic forces of the earthquake. (Reinus, 1968)
Figure 2.12
In China this has been observed and studied by the Chinese committee of large dams
(Zeping, 2009) by firsthand experience. In 2008 an earthquake stroked the CFRD in
Zipingpu, measuring 8 on the Richter scale. This is the strongest earthquake a CFRD
has ever been subjected to. Even as this was a very intense earthquake the dam did not
fail, although the damages on the dam were substantial and the reservoir was filled
with water.
The main crest of the dam settled almost 800 mm, with more settlements higher up in
the dam body than in the lower parts, which should be expected. The face slab
suffered heavy cracking as well as the parapet wall on the dam crest. The cracking of
the face slab resulted in somewhat higher leakage. Also the seepage under the dam
increased after the quake. (Zeping, 2009)
The downstream slope was also affected by the earthquake. However, the deformation
of the downstream slope was not critical due to the two-part design of the slope where
the lower part of the slope had a lower inclination than the higher part. (Zeping,
2009)
After all, the water stopping effect of the dam was not fundamentally compromised
which concludes that CFRDs are very resilient to dynamic loads such as earthquakes.
(Zeping, 2009)
17
2.2
Figure 2.13
2.2.2 Design
There is no set way to design an RCCD since RCC simply stand for the construction
method and material. The most common design is however the theoretical triangular
cross-section which functions as a gravity dam. Figure 2.14 shows a typical crosssection for a RCCD.
18
Figure 2.14
The cross-section can as well consist of a shaped crest, sloped upstream face, drainage
gallery and toothed foundation. (Tan ev, 2005)
[Link] Dam body design
The dam body can be built after various designs where arch dams and buttress dams
are most common together with the gravity dam. The choice of design is normally
done after considering the general environment and topography as well as geological
conditions for the foundation. The dam body of Changuinola I is designed as an arch
dam.
Arch dams are a type of construction method that is built to transfer the water loading
from the dam itself, to the banks. Conventional gravity dams, on the other hand,
transfer the loading from the upstream face to the foundation.
There are two basic construction designs for arch dams, shown in figure 2.15, one
with constant external radius along the height of the dam and the other with constant
central angle. (Tan ev, 2005)
19
Design 1
Figure 2.15
Design 2
Geo-membrane
Asphalt layer
Higher content of binder in the cement in the vicinity of the upstream face
Both the geo-membrane and the asphalt layer are applied behind prefabricated
concrete panels that are placed as the upstream face of the dam.
20
Figure 2.16
The method of using a concrete with higher binder close to the upstream face will
decrease the permeability by creating a water tight barrier of concrete with higher
quality. However, according to some theories in RCCD building the most permeable
part of the dam is the joints between the RCC layers and if these joints can be sealed
properly then the upstream face treatment might be unnecessary. (Tan ev, 2005)
[Link] Spillway and bottom outlet
Commonly, crest spillways are used for concrete dams. This means that excessive
flood water will be evacuated through the dam, using an overflow section. The
overflow section might be placed in the middle of the dam, or more to the sides,
shown in figure 2.17. (Tan ev, 2005)
21
Figure 2.17
2.2.3
Material
There are several options when it comes to the choice of material used for the RCC.
Novak (et al. 2001) mentions that research, mainly done in Japan and America, has
resulted in two distinct approaches in RCCD construction which demands different
materials.
The two approaches will result in different dam profiles as shown in figure 2.18.
22
slipformed
concrete
facing if
required
horizontally
slipformed
facings
mass RDLC
fill in 0.3m
layers
RCC hearting
in 0.3m
layers
gallery
grout
curtain
grout
curtain
base layer
uplift relief drains
Figure 2.18
(Moffat p.133)
The main difference between the two is the upstream sealing and the possibility of
constructing an optimized profile.
Since the RCCD constructed with a dry concrete that is more permeable than the
option of a high-paste compacted concrete, it needs a high-quality concrete membrane
for water stopping upstream. When using the dry concrete, it also becomes easier to
develop an optimum profile during construction.
Table 2.4
Characteristics
100-125
> 150
0-30
70-80
1.0-1.1
0.5-06
90-day compressive
strength (MN/m2)
8-12
20-40
23
23
25
0.3
0.3
Contraction Joints
Sawn
Sawn or formed
One important parameter is that the high-paste concrete, while having a higher
compressive strength, is demanding a lot more PFA or cement which can be difficult
to attain in desolate places. Specifications of the composites of the different concrete
mixes mentioned by Novak (et al. 2001) are shown in table 2.4.
2.2.4 Foundation
Foundation of the RCCD is very similar to the foundation described for CFRD. The
main difference is that the RCCD is much heavier and thus demand better bedrock
allowing the stresses produced by the dam weight and the water pressure. If the
bedrock is heavily foliated, the foundation may suffer from shearing failure according
to Tan ev (2005). Before and during construction of RCCD, the geological conditions
at the site must be investigated much more thoroughly than for example during a
CFRD project.
The foundation treatment of the Changuinola I dam has been covered in Design
Criteria Memorandum. Several tests of rock masses and geotechnical conditions have
been performed.
Due to the weight of the dam and the bedrocks general condition, an excavation
foundation treatment has been carried out. The decision was made due to rather poor
RMR-values and the joint conditions.
In addition to the excavation, a grout curtain should also be constructed so the
foundation meets the set value of seepage of 2-3 Lugeon. (Changuinola Civil Works
Joint Venture, 2009)
2.2.5 Construction
The big advantage with RCCDs is the rapid and simple construction. According to
CA the construction method gained their popularity because it proved to be less
expensive than conventional methods of dam construction, including rock-fill and
earth-fill construction. The main reason to the smaller expense is assigned the shorter
construction time (Portland Cement Association, 2011). Also in Hydraulic structures
(Novak, et al. 2001) the shortened construction time is mentioned as one of the
advantages.
24
Figure 2.19
It is also important to have a full-scale testing of the RCC to ensure the quality of the
construction and that the concrete is impermeable enough, but also that the
construction equipment is functional as well as the education of the workers on how
an RCCD project is performed. Another reason to have a full-scale test is that the test
will yield important data on:
Aggregate mix
Concrete mix
Fresh concrete behavior
Hardened concrete behavior
In-situ behavior, such as compaction of the concrete and foundation
25
[Link] Diversion
The sensitivity of the cofferdam structure is not as high for an RCCD as for a CFRD.
This means that less time and money can be spent on building smaller provisory
cofferdams since RCCDs can be erected much faster than a CFRD. Thus the
cofferdams only have to be designed for seasonal high flows and not more than
annual high flows. Furthermore, the RCCD structure is not as sensitive to erosion as
the CFRD, so overtopping of the cofferdams is not necessarily catastrophic. (US
Army Corps of Engineers, 1995)
Internal uplift
Sliding stability
Seismic loads
Other considerations when building RCCDs also have to be made, such as bedrock
and foundation stability. However, those aspects are already described earlier in the
report.
[Link] Internal uplift
The internal uplift is caused by seepage through the concrete in the dam body. This
pressure is due to water penetrating along the upstream face as well as water seeping
through the foundation. This uplift pressure has caused several dam failures. The
seepage through the dam causes not only uplift pressures, but also chemical erosion
problems like hydratisation etc. (Renius, 1968)
To solve the problem of internal uplift in the dam body a drainage system can be built
in the dam. Normally this is done by constructing a drainage gallery inside the dam
which reduces the pressure downstream in the dam body. A drainage gallery in the
foundation reduces the water pressure and stabilizes the dam (figure 2.20). This
measure can also be used to improve the water permeability of the dam. (Renius,
1968)
26
Figure 2.20
27
Figure 2.21
Another way to eliminate this risk is to lower the uplift pressure under the dam. This
can be done by having a grout curtain under the dam front which will decrease the
pressure; if the grout curtain also is complemented with a drainage gallery the uplift
pressure will be greatly reduced. (Hggstrm, 2011 and Tan ev, 2005)
[Link] Internal stress and loads
The internal loads within the dam can be minimized by designing the profile of the
RCCD, especially for large dams. It is important that the stress levels give no tension
under any loading condition (full reservoir, empty reservoir etc.)
However, since multi-stage profiles are somewhat more expensive to build singlestage design is often used today. Single-stage means that the downstream slope is
uniform while the multi-stage design consists of multiple angles of the slope, shown
in figure 2.22. (Novak, et al. 2001)
28
Figure 2.22
[Link] Seismic
Earthquakes and dynamic loads affect the RCCD type quite differently than the
CFRD type. Since concrete dams are considered as compact elastic structures it is
important that the dynamic loads does not give tension stresses that can induce
cracking in the dam body. However, this risk is reduced in the design phase where
such loadings are considered.
There is also the risk of structural resonance when the dam is being subjected to
dynamic loads. Structural resonance is more likely to occur in high (large) dams
rather in smaller dams. This is because the natural frequency of the dam is normally
estimated as:
600
T
2
H
(2.4)
(Novak, et al. 2001)
Where H is the height of the dam and T is the length of the dam base. This basically
means that dams 20 meters high have a natural frequency of 15-25 Hz, depending on
base thickness. Dams 50 meters high have a corresponding frequency of 6-9 Hz.
Normally, major seismic shocks are in the range of 1-10 Hz. (Tan ev, 2005)
Resonance in the entire structure is very unlikely but due to inertia forces created by
the dynamic loading, local high-stress areas in the dam can produce cracking. These
effects can be reduced by designing the cross-section of the dam in such ways that the
vulnerable areas are satisfactory. (Novak, et al. 2001)
CHALMERS, Civil and Environmental Engineering, Masters Thesis 2011:120
29
30
Case Studies
When planning a dam project there is an infinite amount of choices to make. The most
urgent choices may be where to place the dam and what kind of dam construction
should be used. In this report the two different dam constructions CFRD and RCCD
are compared and evaluated. This is done on the basis of four case studies:
The Rio Esti Hydropower Project (Rio Esti) in the Chiriqu province is the
oldest project of the case studies and was finished already in 2003. The entire
hydropower project consists of two dams where the Barrigon dam, evaluated
in this report, is constructed as a CFRD.
Changuinola I in the Bocas del Toro province is the first part of the
Changuinola hydropower project. The dam is under construction when this
report is written (2010). Changuinola I was first planned as a CFRD (see the
study of Chan-75 below.) but plans were changed in an early stage and the
dam is now built with RCC-technique instead.
Chan-75 is used as a case study though it was never built. The dam was
planned as a CFRD, slightly lower than Changuinola I but higher than Rio
Esti. Chan-75 was replaced with the Changuinola I project.
The four cases appear in text in the same order as listed above. The description is
based on the same aspects as the dam type description in Chapter 2. The aim of the
project is not to do any economical study of which alternative is preferable. It is
impossible to ignore that money is the main driving force when the choices are made.
This comparison between the case studies is used for evaluation of the Changuinola II
project since the case study for this dam is slightly different due to the fact that
Changuinola II is yet to be built.
Panama City
Chiriqui Province
31
Figure 3.1
Overview of Panama
The two case studies have the same layout in order to simplify the comparison. Below
follows a short description of the properties described for each case.
Site
This part describes the conditions for the different sites, which includes for
example geology, topography, flows and climate.
Design
This part aims to give a summary of the chosen dam design, CFRD or RCCD
and how the spillway is designed.
Construction
This part will describe the construction procedure.
3.1
Rio Esti
The Rio Esti hydroelectric power project was completed during 2003. It is located 400
km west of Panama City in the province of Chiriqu. The plant partially regulates the
daily flow during dry season and it is projected to have a total installed capacity of
120 MW. Besides canals, tunnels and powerhouses Rio Esti consists of two dams,
Chiriqu Dam and Barrigon Dam. (Swedpower, 2001)
32
Figure 3.2
The Chiriqu Dam is a 213 meters long concrete dam located in the Chiriqu River. It
is 35.5 meters high and has an ungated spillway with a discharge capacity of 3,390
m3/s. The Barrigon dam, which is the one of interest for this project, is a 60 meters
high CFRD which has a chute spillway with a discharge capacity of 1077 m3/s.
(Swedpower, 2001)
The main part of the inflow to the Barrigon reservoir is water conveyed from Chiriqu
through a canal. The canal is a 6.1 km long concrete channel with intake in the
Chiriqu reservoir and outlet in the Barrigon reservoir. The position of the cannel is
shown in figure 3.2 and figure 3.3. (Swedpower, 2001)
The Barrigon Dam is a storage reservoir and has a total volume of about 47 million
m3. The operation elevation is between +218.0 and +222.0 m.a.s.l and gives an active
volume of 10 million m3. (Swedpower, 2001)
3.1.1
Site description
The dam site is mainly formed of volcanic sedimentary rocks and some more recent
fluvial deposits. The deposits, which can be found on the right side of the valley, can
be up to 35 meters deep according to the performed geological survey. The survey
also concludes that the bedrock can be considered to be of good quality. (AES
Panama, 2001:1)
33
3.1.2
Design
The design for Barrigon Dam is distinct described in Esti Hydroelectric Project:
Owner's technical requirements, part B - Design requirements and criteria (AES
Panama, 2001:1) and this part will contain the most important features and
assumptions. First it is a description of the criteria determining what properties are
used for design. Followed by summary of the design details used for Barrigon Dam.
Figure 3.3
The canal
Spillway chute
Bottom outlet
Dam body
Headrace tunnel
34
Downstream slope
1:1.6
192
Figure 3.4
60
[m]
During construction the river will be diverted through the bottom outlet culvert, later
used for emergency drawdown. The culvert is dimensioned to control the 1 in 50 year
flood flow (464 m3/s). (AES Panama, 2001:1)
35
3.1.3
Construction
3.2
Changuinola I
Changuinola River lies in the far north-west of Panama in Bocas del Toro province. In
2003 the first water rights concession was issued to Hydroteribe S.A. Though, the
company had not enough financial resources and in 2004 the water rights were sold to
AES Changuinola S.A. AES is one of the largest power companies in the world and
has a capacity to serve 100 million people worldwide. In Panama AES is the largest
energy producer with a capacity of more than 480MW. (AES Changuinola, 2008)
The project head is between the elevation +320 and +55 m.a.s.l and the original plan
was to split the range into three power stations, according to figure 3.5. Problems with
the projects economical feasibility made it desirable to raise the reservoir level for
Chan-75 to +165 m.a.s.l, which inundated the power station for Chan-140.
36
Figure 3.5
Figure 3.6
The layout was now changed and the three projects were reduced to two large
projects, Changuinola I and II (figure 3.6). Changuinola I has the same position as the
former Chan-75 and Changuinola II is placed about two kilometers upstream the
37
Figure 3.7
3.2.1
Site description
The area at Changuinola River is characterized by very steep slopes and a deep river
valley. The geology and geotechnical properties of the area are, however, poorly
studied which means that the case study will lack certain valuable information
regarding said properties. (Monaghan, 2007)
38
3.2.2
Design
200
Figure 3.8
400 m
Left abutment
Right abutment
Dam body with uncontrolled ogee spillway
Downstream cofferdam
Upstream cofferdam
Diversion inlet and outlet
Diversion channel
(Changuinola Civil Works Joint Venture, 2009)
39
3.2.3
Construction
[Link] Material
The total volume of concrete needed for Changuinola I is approximately 900,000 m3
(Changuinola Civil Works Joint Venture, 2009). Therefore, the access to cement, fly
ash and aggregate is essential during construction. The concrete is produced in a
batching and mixing plant located just downstream the construction site. From there
the concrete is delivered to the dam wall by a conveyor belt.
Besides the importance of efficient production and transportation of the RCC, the
access of raw material is essential to an effective construction. Following chapter will
describe the producing of RCCD at Changuinola I.
[Link] RCCD
The production of an RCCD can roughly be divided into four parts.
1.
2.
3.
4.
Raw material supply. Such us cement, aggregate, fly ash and water.
Batching and mixing
Transportation to construction site.
Construction, spreading and vibrating.
To achieve efficiency during the construction period it is essential to take all these
parts in consideration and make them work smoothly.
It is preferable to have a nearby access to raw material as it is of such a great
importance for the construction. It can be assumed that water supply wont be any
problem at this site and will therefore not be treated here.
Cement and fly ash have to fulfill certain criteria and also have a steadiness in their
quality. This is necessary in order to warrant an even and high quality of the concrete
in an RCCD. At the Changuinola I project it was not possible to meet these demands
in Panama and therefore both cement and fly ash were shipped from Florida, United
States. (Frostberg, 2010)
According to Frostberg (2010) the choice of shipping material from Florida lead to
significant problems with logistics. The cement and the fly ash were shipped to the
harbor in Amirante. Those continuous transportations were made on a ship specially
modified for this purpose. Cement and fly ash were pumped into two silos and from
there loaded on trucks for transportation to the batching plant at Changuinola.
3.2.4
The challenges for the Changuinola I project are similar to the standard dam
construction problematics; materials and location.
The construction of a RCCD at Changuinola I have not been totally fuss-free.
According to Gunnar Frostberg problems have occur as an affect of underestimations
of the complexity of the problems and too optimistic approach concerning the time
aspect. Frostberg (2010) is pointing at:
40
Access to cement and fly ash of sufficient quality. In the case for Changuinola
I this has been bought from Florida, US, leading to extended logistic problems
compared to a local solution in Panama.
Numerous tests are required in order to get a proper aggregate mix. Plants for
aggregate crushing has to be built if they don not already exist.
Numerous tests have been done in order to find a proper formula for the RCC.
It has also been an extensive work finding rock that satisfies the necessary
criteria.
It is not possible to cast RCC when it rains more than 0.2 0.5 mm per hour,
which can occur in this region.
Capacity for batching plant and conveyor belts also limits the construction
speed.
According to Frostberg (2010) it takes about 12 months to cast RCC for a dam with
similar size as Changuinola I. But it is important to be well prepared for those
parameters mentioned above.
3.3
Chan-75
The Changuinola Hydropower Project has been re-projected several times and there
have been a lot of different design alternatives. Because of the access to material
about earlier plans and the near relation to Changuinola II, it will follow a summary of
the plans for Changuinola I as a CFRD. These plans are most often referred to as
Chan-75.
Chan-75 is the original plans for the Changuinola River. The dam was designed as a
CFRD and the preliminary design was evaluated in 2005 and it is located at the same
place as Changuinola I. This chapter is based on the background material from these
plans and it is noteworthy that this dam has not been built. For further information
about the project see chapter 3.2.
3.3.1
Site description
3.3.2
Design
41
Figure 3.9
42
Figure 3.10
Figure 3.11
43
Changuinola II
Changuinola II will be located a few km upstream the site for Changuinola I in the
Changuinola River. Further location details are described in chapter 3.2 and in figure
4.1. The head elevation for Changuinola I is +165 m.a.s.l and it is reached somewhere
around two kilometers upstream the confluence of Changuinola and Culubre rivers.
In November 2007 a preliminary conceptual design was developed for how the
remaining head between +320 and +165 m.a.s.l shall be used. The preliminary
conceptual design (Frostberg, 2007) is developed by VPC with assistance of
MD&A. This report is used as a base in this part, which will describe the alternatives
developed and evaluated by VPC and MD&A. There will also be a description of a
possible location and construction of a CFRD.
The The preliminary conceptual design (Frostberg, 2007) considers three different
dam sites, A, B and C, and for all sites a RCCD is suggested.
In the report from 2007 (Frostberg, 2007) the biggest focus is on site C which
according to VPC would be the optimal site for a RCCD. A further development of
this assumption is done below in chapter 4.1.1.
As mentioned above this chapter will both describe a RCCD and CFRD alternative for
the constructing of Changuinola II. The RCCD alternative, developed by VPC and
MD&A, is described in chapter 4.2. The CFRD alternative, developed based on
descriptions in this report, is developed in chapter 4.3.
Figure 4.1
The preliminary conceptual design does only consider the alternative to constructing a
RCCD but according to Gunnar Frostberg (2010) it would be possible to build a
CFRD at for example site B. In order to compare the CFRD with RCCD it is
necessary to create a CFRD option. This chapter both gives a summary of the RCCD
alternatives in the Preliminary Conceptual Design and compares those with possible
CFRD alternatives.
44
4.1
Site description
Beneath three different site alternatives are described, A, B and C. The alternatives
are developed by VPC in assistance with MD&A and they are described in The
preliminary conceptual design (Frostberg, 2007) and the following text is based on
this report. All three sites are located upstream of the confluence between
Changuinola and Culubre rivers, within a span of 1 km, and figure 4.1 shows the sites
intermutual location.
Figure 4.2
As mentioned above the emphasis for the conceptual design (Frostberg, 2007) is in
site C, which is considered to be the most favorable site for a RCCD. In the report this
choice is based on the amount of concrete needed for the construction, shown in table
4.1. Assumptions and calculations for this decision are done on basis of satellite maps.
The obvious focus on site C in the The preliminary conceptual design (Frostberg,
2007) will also reflect on this chapter.
45
Table 2.4
GEVR
[Mm ]
[m ]
Convetional
concrete, [m3]
Site A
1.46
67,760
22,810
Site B
1.84
79,220
22,810
Site C
1.15
47,620
22,810
Dam site
The considerable smaller amount of concrete needed and the narrow floodway for site
C makes it more favorable for an RCCD. But according to Gunnar Frostberg (2007) it
would be possible to build a CFRD at site A which is not as narrow and have not as
steep embankments as site C. Therefore there is more room for diversion tunnels and
spillway.
Site A, the most upstream site, located about 2 km upstream of the confluence
with Culubre River. (figure 4.2)
Site B, located around 1600 meters from the confluence between Changuinola
River and Culubre River. As shown on the map (figure 4.2) the site is located
just upstream of a bend on the river.
4.1.1
Site C
According to Frostberg (2007), the valley slopes on both sides are very steep,
typically 65 degrees over 200 meters, which indicates very good rock mass quality.
RMR was estimated to around 73 while RQD was thought to be 24. Site C is also
thought to be particularly in favor for an arch dam type.
At the time for this report, no thorough geotechnical survey has been done which
leaves an uncertainty regarding some of the dam features such as the spillway
construction etc. This will have to be resolved before initiating the final design stage.
4.2
RCCD alternative
The plans in The preliminary conceptual design (Frostberg, 2007) are to construct
an RCCD at site C. This construction will be described in the following text
46
4.2.1
Design
The dam body design is proposed as an arch dam due to the site conditions with steep
slopes and relatively narrow valley.
Downstream face
Figure 4.3
Upstream face
Figure 4.4
47
[Link] Sealing
GEVR (Grout Enriched Vibratable RCC) will be used for sealing the interface
between the rock abutments and the dam body. It will also be cast against the
formwork. All this together will ensure a good bonding with the rock and an excellent
surface finish for the dam face. (Frostberg, 2007)
[Link] Spillway design
The preliminary report presents the 10,000 year flood at 6,554 m3/s and the proposed
highest water level as 323 meters above sea level. To handle these design criteria a
type of splitter spillway is recommended by the preliminary report, which is shown in
figure 4.5.
Figure 4.5
48
4.2.2
Construction
[Link] Diversion
As diversion solution the preliminary conceptual design describes two solutions.
For the RCCD alternative the preferred option is used and therefore the only option
described in this chapter. The second option is assumed to be used for a CFRD and
therefore described in chapter 4.2.1.
The preferred option entails two reinforced concrete culverts, 9 times 9 meters, and
two cofferdams, one 20 meters high upstream and one 6 meters high downstream.
This corresponds to at least a four year recurrence interval flood and has clear
similarities with the diversion solution for Changuinola I. It is also noted in the
Preliminary conceptual design that it would be possible to enhance the diversion
capacity with higher cofferdams. (Frostberg, 2007)
4.2.3
Material
49
Figure 4.6
1.
2.
3.
4.
Dam site
Concrete production area (option 1)
Concrete production area (option 2)
Aggregates production area
5. Alluvium deposit
6-10. Access roads
(Changuinola Civil Works Joint Venture, 2007)
4.3
CFRD alternative
4.3.1
Dam design
It is likely to assume that the dam design will have a lot of similarities with the design
for Rio Esti and the planned CFRD alternative for Changuinola I (Chan-75), see the
CFRD section in figure XX. Therefore these two projects can be used as model for the
design in of a CFRD alternative for Changuinola II. It is important that the design fits
the certain properties at the Changuinola II dam site.
.
50
Figure 4.7
The most important difference when designing a CFRD for Changuinola II is the
height. The RCCD planned are distinctly higher than the CFRDs described in
previous chapter and this will obviously influence the design. Improvements are done
in accordance to chapter 1.
4.3.2
Dam body
The geometry of the dam body can be split into five parts, whereof four are shown in
section (figure 4.7).
1. Height
2. Upstream slope
3. Downstream slope
4. Crest width
And the fifth geometrical property is the crest length. If these properties can be
determined it will be possible to calculate the amount of rock-fill needed. Below
follows a description of how the determination is done.
The height is depending on head elevation chosen for the project. For Changuinola II
the head elevation is investigated in The preliminary conceptual design (Frostberg,
2007) and set to +320 m.a.s.l. In combination with head elevation for Changuinola I,
+165 m.a.s.l, a dam height of at least 155 meters are needed.
Upstream and downstream slopes are chosen in accordance to chapter 2. Natural
gravel fill results in less steep slopes instead of what could be applied if rock-fill were
used. However, the access of alluvial material is hopefully very good and therefore it
will not be a problem.
51
According to chapter 2 the crest should has width between 6 and 8 meters. Due to size
of the dam an 8 meter wide crest is used.
4.3.3
Sealing design
As described in chapter 2.1.2 and also in the case studies, sealing is done by using a
concrete face slab. Sealing to the foundation is done in combination with a concrete
plinth. In chapter 2.1.2, thickness of the concrete slab is calculated as:
Ti Tmin X H i
(4.1)
(Vncold, 2008)
Where Tmin is 0.3 meters in the regular case and increased to 0.4 meters for high dams.
Hi is the distance from the top and Ti is the thickness at certain height. As described in
chapter 2.1.2 the increased thickness is used to avoid ruptures in the upper part of the
slab, due to compaction in the dam body. Using the given dam height of 155 meters a
horizontal joint should be placed approximately 50 meters from top for the central
slabs. Equation 4.2 gives the thickness at the top of the lower stage slab.
(4.2)
(Vncold, 2008)
Next step is to correlate the thickness at the top of the lower stage with bottom of the
upper stage.
T50 0.40 X 50
(4.3)
(Vncold, 2008)
T50 0.40
0.0015
50
(4.4)
(Vncold, 2008)
Ti 0.40 0.0015 H i
52
(4.5)
(Vncold, 2008)
And for the lower stage:
Ti 0.30 0.0035 H i
(4.6)
(Vncold, 2008)
The increased thickness are only used for the central slabs were the stresses are
highest. For lower slabs closer to the abutments, equation 4.1 is used for the whole
height.
4.3.4
Spillway design
What spillway design to use depends on the design flood. The RCCD alternative for
Changuinola II are dimensioned to control the 10,000 year flood, which corresponds
to 6,554 m3/s. Comparing to Rio Esti and Chan-75, it is likely to assume that the
10,000-year flood is enough also for the design of a CFRD alternative.
Spillway for Chan-75 was preliminary designed for a capacity of 10,000 m3/s, which
will clearly be enough. Figure 3.11 shows the spillway design for Chan-75. As shown
it is four gated spillways, each 16 meters wide and 18.5 meters high.
4.3.5
Diversion
For diversion design it is assumed that the second option in chapter [Link], diversion
tunnels in the left abutment, can be used. This alternative is originally designed for the
RCCD alternative and described in the The preliminary conceptual design
(Frostberg, 2007). However, it is in this report assumed that it is a suitable solution for
diversion design when constructing a CFRD. Assumptions are done in comparison
with diversion design for Rio Esti and Chan-75.
The diversion for the CFRD is designed with two circular tunnels in the left abutment,
each with a diameter of 9.9 meters. The lengths of the tunnels are 413 and 366 meters.
53
Table 4.2
Lining options
(Frostberg, 2007)
Type of lining
Lining
thickness [mm]
Cross-sectional
area [m2]
Velocity1
[m/s]
Velocity2
[m/s]
Shotcrete
150
72.4
12.4
16.2
Concrete
500
62.2
14.5
18.9
1)
2)
There are two alternatives of lining for the tunnels (table 4.2), 150 mm shotcrete or
500 mm concrete. Diversion should be designed for a four year recurrence interval
flood (1798 m3/s), which corresponds to a velocity of about 12 m/s for the shotcrete
lining and about 14.5 m/s for the concrete lining. The shotcrete velocity is on the limit
for the shotcrete lining and at the same time the concrete velocity is well below limit.
This makes it likely to assume that concrete lining should be used. As bonus the
diversion solution would even manage the ten year recurrence interval flood of 2350
m3/s, which corresponds to a velocity of about 18.9 m/s.
54
4.3.6
Final design
This part is a brief description of what a CFRD alternative could look like for
Changuinola II. The figures made in AutoCAD are simplified models of a possible
dam construction. Figure 4.8 show perspective view of the CFRD with attached
spillway construction. The total volume of the dam body is more than 11 million m3.
Spillway
Upstream face
Downstream face
Concrete facing
Water direction
Figure 4.8
Figure 4.9 shows the spillway solution. It is the same spillway design used for Chan75 and it has a capacity of 10,000 m3/s. This is more than enough considering the
design flow for Changuinola II is 6,554m3/s.
Figure 4.9
55
74
155
[m]
Figure 4.10
56
Upstream face
In this chapter we will firstly present our conclusions from the project. We will then
continue by a discussion regarding the conclusion and then finish the report by a brief
discussion about problems encountered during the process of writing this report and
some recommendations for further work.
5.1
5.2
Conclusion
Changuinola II dam should be constructed as a RCCD due to reasons
discussed in the discussion chapter.
The choice of dam type is a very complex issue which is influenced by
multiple variables such as topography, access of material, geological
surroundings and economy.
Dam features, such as spillways, outlets and power houses all depend on the
dam type, economy and surrounding topography which means no general
conclusion can be made regarding this.
Both RCCD and CFRD are viable options when choosing a dam type.
Discussion
The logistics for transport of concrete and fly ash with ship from Florida,
through the port in Almirante, to Changuinola River are in a large extent
already built.
Trial tests for the concrete may not have to be done in the same extent.
5.2.1
Problems
Material for the case studies have been rather difficult to assess, mostly
regarding economic information but also time consumption for the
construction and project planning stage as well as the amount of material used.
The scope proved to be very extensive which resulted in cutting down certain
features that were meant to be included.
57
5.2.2
Further work
We propose that further studies regarding a cost study should be done, where key
numbers for the different dam types are evaluated. Such key numbers could include,
but are not limited to, man hour per m3, hours needed for project planning, cost per
kWh.
Furthermore a study could be done evaluating concrete choices for the RCCD, since
the material is a significant cost to the project as well as the possibility to place the
concrete in desired pace and in a correct profile.
Also, a study concentrating on dam features and general recommendations for dam
features could be done in order to help the project planning process and choices.
58
References
Literature
Chinnarasri, T. T. (2001). Numerical modelling of dam failure due to flow
overtopping. Hydrological Sciences-Journaldes Sciences Hydrologiques, 46(1)
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Novak, P., Moffat, A., Nalluri, C., & Narayanan, R. (2001). Hydarulic Structures 3rd
Edition.
Reinius, E. (1968). Vattenbyggnad, del 3. Dambyggnader. Stockholm .
Tan ev, L. (2005). Dams and appurtenant hydraulic structures.
Vncold. (2008). Guidelines for Design High Concrete Face Rockfill Dam.
Zeping, X. (2009). Performance of Zipingpu CFRD during the strong earthquake.
Retrieved 05 07, 2010, from Chinese national committee of large dams:
[Link]
Zhang, B., Wang, J., & Shi, R. (2004). Time-dependent deformation in high concretefaced rockfill dam.
Consult reports
AES Panama. (2001:1). Esti Hydroelectric Project: Owner's technical requirements,
part B - Design requirements and criteria.
AES Panama. (2001:2). Esti Hydroelectric Project: Owner's technical requirements,
part C - Construction requirements.
Changuinola Civil Works Joint Venture. (2009). Changuinola I dam, foundation
approval report.
Changuinola Civil Works Joint Venture. (2007). Changuinola II dam - Memorandum
on preliminary site evaluation for alignment IIc.
Frostberg, G. (2007). Preliminary Conceptual Design - Changuinola II HPP.
Gavilan group. (2005). Evaluation of the design and target price for the hydropower
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Monaghan, B. (2007). RCC dam site investigation factual report - Report: EHP 003.
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AES Changuinola. (2008). Retrieved June 26, 2011, from:
[Link]
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Frostberg, G. (2010). Electronic correspondences with Gunnar Frostberg.
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River diversion methods are crucial in dam construction to ensure that construction can proceed efficiently and safely. For embankment dams like CFRDs, temporary cross sections such as cofferdams are commonly used to create stable working conditions and protect the site from flash floods. These methods need careful design to handle sliding stability, seepage, and high water levels. For RCCD projects, reinforced concrete culverts along abutments are preferred due to their efficiency and ease of construction. Effective diversion strategies prevent damage to unstable materials and ensure that the dam's construction progresses without interruptions from natural water flows .
Grout curtains play a vital role in enhancing dam stability by preventing seepage under the structure. They act as impermeable shields by sealing cracks and stabilizing the rock mass through high-pressure injection of materials like cement or silica sol. This action reduces uplift pressures, which can destabilize the dam. In permeable foundations like gravel, grout curtains are especially critical as they prevent water from infiltrating through the foundation, which can lead to erosion and structural instability .
The primary geotechnical considerations for constructing a dam foundation include deformability, stability, and water impermeability. When constructing a dam on gravel, the curtain grout is crucial due to gravel's higher permeability compared to bedrock. The rock mass rating (RMR) and rock quality designation (RQD) methods help classify the rock quality and guide the design to minimize deformation and seepage. If the rock mass is good enough, techniques like adding "teeth" to the foundation can stabilize it. Moreover, a grout curtain is recommended to lower uplift pressures and prevent seepage, especially if complemented with drainage galleries .
The spillway design in CFRD and RCCD projects reflects the differing requirements for flood management. In CFRD projects, such as Chan-75, spillways like gated chutes allow for controlled discharge capacities, crucial for managing high-volume floods. For RCCD projects, especially with designs like the splitter spillway recommended for Changuinola, the focus is on accommodating extreme flood events with large natural discharge capacities. These design choices are essential for preventing overflow and ensuring the dam's structural safety during floods .
The construction process of Roller-Compacted Concrete Dams (RCCDs) significantly influences their integrity and longevity. Key factors include consistent supply and careful processing of materials, like cement, aggregates, and fly ash, to maintain workmanship quality. Efficient material transportation and site spread are crucial for structural homogeneity. Settlement considerations also impact integrity; preemptive measures against material displacement and risk of cracking from settlement are vital, with recommended presetting periods helping mitigate early-age cracking risks. These factors, collectively, ensure that each component functions as intended under variable load and environmental conditions .
Key challenges in accessing and transporting raw materials for the Changuinola I project involved ensuring a steady supply of essential materials like cement, aggregate, and fly ash. The production relies on batching and mixing at a plant near the construction site, but material access is complicated by the need to transport them from distant locations like Florida, due to a lack of local resources. Transportation logistics from the receiving ports to the construction site are vital, impacting overall construction efficiency and project timelines .
Key factors influencing the decision to change the Changuinola I dam design from a Concrete-Faced Rockfill Dam (CFRD) to a Roller-Compacted Concrete Dam (RCCD) included economic considerations, construction time, spatial constraints, and the cost of necessary diversion tunnels. The RCCD design was found to be more economically viable and allowed for a more manageable construction schedule. Additionally, the spatial constraints related to spillway and diversion channel design favored the RCCD due to its simpler and more cost-effective execution .
Material selection is critical for the structural stability and functionality of different zones within a Concrete-Faced Rockfill Dam (CFRD). Each subzone of a CFRD body requires materials with specific porosity and density attributes to fulfill its structural role. The main rock-fill zone and downstream rock-fill zone must have controlled porosity to ensure the dam can support its weight and withstand water pressure. Cushion materials and transition zones are selected for their ability to absorb deformation and reduce seepage. These selections are based on engineering experience and are evaluated through criteria such as porosity and relative density to avoid excessive settlement and deformation .
The choice between Concrete-Faced Rockfill Dams (CFRD) and Roller-Compacted Concrete Dams (RCCD) significantly impacts project costs and timelines due to several factors. For the Changuinola I project, the decision to switch from CFRD to RCCD was influenced by economic considerations, reduced construction time, spatial constraints for spillways and diversions, and the high cost of diversion tunnels needed for CFRD. Building a CFRD would have been more expensive due to the need for additional infrastructure to manage water flow during construction .
Seismic activity is a crucial consideration in dam engineering as it can induce dynamic loads leading to structural resonance and cracking. This is particularly relevant for Roller-Compacted Concrete Dams (RCCDs), which, being compact elastic structures, must be designed to handle seismic stress without tension cracks. The design phase includes considerations to minimize these risks by adjusting the dam's cross-section to mitigate local high-stress areas that could lead to structural failure. Larger dams, with their naturally lower frequencies, are more susceptible to major seismic events, necessitating careful engineering to avoid resonance and ensure safety .