Badenhorst - Design of Concrete-Faced Rockfill Dams PDF

The Design of Concrete-faced Rockfill
Dams
Danie Badenhorst
10/13/2005
SANCOLD/US 2005: The Design of

Concrete-faced Rockfill Dams
Constructed Concrete-faced Rockfill

Dams
Height (m)
Concrete-faced Rockfill Dams: Trends

220
Uncompacted
Compacted
200
180
160
140
120
100
80
60
40
20
0
1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010
Year
10/13/2005

The Lesotho Mohale Dam
10/13/2005

The Lesotho Mohale Dam
10/13/2005

Description of CFRD
Parape
t Wall
Concrete
Face
Plinth
10/13/2005
Rockfil
l

Description of CFRD
Zone designations:
1 for soil materials
2 for processed granular materials
3 for rockfill zones
10/13/2005

Section of CFRD
2B 3A
3A
3D
2B
2A
1B
3D
3B
1A
10/13/2005
3C
3E

Description of CFRD
Zone designations:
Zone 1A, a silt or fine sand act as face slab or perimeter

joint healer.
Zone 1B supports zone1 materials
Zone 2A is a processed fine filter < 20mm and will limit
leakage when a waterstop fails and can act to heal.
10/13/2005

Description of CFRD
Zone 2B, The face support zone, is crusher run < 75mm
Zone 3 is quarry run rockfill. The differences in A,B and C are

principally in layer thickness and size and type of rock.
Zone 3A, provides compatibility and limit void size adjacent to

Zone 2B.
Zone 3B provides mass, resist the water load and helps in limiting
face deflection.
Zone 3C receives little water loading, and settlement is essentially
during construction. The two-metre-thick layer in Zone 3C accepts
large size rocks, is more economical to place and its lower
density saves rock volume.
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Section of CFRD
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10
Materials Specification
MATERIALS & COMPACTION DETAIL
Zone
Classification
Lift Height
(m)*
Type of Roller
Passes (Number)
1A
Impervious earthfill
0,3
Compaction by rubber tyre

equipment
1B
Random earthfill
0,6
Compaction by rubber tyre

equipment
2A
Fine filter
0,2
50 kN vibrator
2B
Crushed rock
0,4
> = 10 tonne vibratory roller
10/13/2005

4***
4 + surface
compaction **
11
MATERIALS & COMPACTION DETAIL
Zone
Classification
Lift Height
(m)*
Type of Roller
Passes
(Number
3A
Selected small quarry run

rock
0,4
>= 10 tonne vibratory

roller
3B
Quarry run rockfill
1,0

roller
3C
Quarry run rockfill
2,0

roller
3D
Erosion protection, durable

rock
NA
3E
Drainage rock
10/13/2005
1,0/2,0
Placed by
backhoe
> = 10 tonne vibratory
roller

12
Maximum layer thickness after compaction.

**
Surface compaction by 130 kN vibratory plate on laser
controlled backhoe. Similar
compaction shall be achieved
as using: 2 passes with the 10 tonne vibratory roller without

and subsequently 4 passes downslope without and 4
passes upslope with vibration.
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13
Zone 2A material shall be thoroughly compacted with a

backhoe mounted plate vibrator with
at
least
50
kN
vibratory force to a density similar as achieved by 4 passes

using a 10 tonne
vibratory roller. Particular care shall be
taken to prevent damage to the concrete or to the

waterstops embedded in the plinth concrete. The
material shall be thoroughly wetted before
and
during
compaction.
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14
Site Requirements
CFRDs are best suited to sites where:

rock foundation is close to plinth
nearby source of rockfill is available
lack of suitable core material
there is location for economical spillway
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15
Features of a CFRD
Settlements of rockfill are small
Parapet wall can be placed on crest
Leakage is not a concern, face slab in biaxial compression,

rockfill stable without face slab
Water load transmitted into foundation upstream of dam axis
Uplift under rockfill is not involved. The pressure on the

foundation exceeds reservoir pressure over 3/4 of base width.
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16
Features of a CFRD
Sliding factor for reservoir water and rockfill exceeds 7
High shear rockfill, no pore pressures in rockfill, small settlement

of rockfill under seismic load make CFRD resistant to seismic
loading
Drainage galleries in abutments not required
Overtopping can cause failure
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17
Post Construction Crest Settlement

Damname
Rock type
Height (m)
Aguamilpa
Gravel
187
Tianshengqiao
Limestone and mudstone
178
Foz do Areia
Basalt
160
Segeredo
Basalt
145
Alto Anchicaya
Hornfels-Diorite
140
Xingo
Granite
140
Golillas
Gravel
130
Khao Laem
Limestone and mudstone
130
Ita
Basalt
125
Turimiquire
Limestone
115
R.D. Bailey
Sandstone and shale
96
Sugarloaf
Sandstone
85
Chengbing
Lava tuff
75
Minase
Liparite
76
Cabib Creek
Gneiss
64
Kangaroo Creek
Weak schist
60
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Settlement (mm)
340
1060
210
160
170
49
50
150
450
270
420
40
100
400
110
180

Settlement (% of height)
0.18
0.6
0.13
0.11
0.12
0.33
0.04
0.16
0.36
0.23
0.44
0.04
0.13
0.6
0.22
0.3
18
Height (m), Settlement (mm)
Post Construction Crest Settlement

1200
1000
800
Height (m)
600
Settlement (mm)
400
200
0
1
10
11
12
13
14
15
16
Dam or rock type
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19
Disadvantages of CFRDs
z Plinth to be designed well where rock is poor.
z Care to be taken in fabrication and construction of waterstops.
Design movement on perimetric joint is 200 to 300mm.
z Further research required for joints and seals on joints for dams
higher than 200m
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20
Advantages of CFRDs
Ancillary works shorter than for earthfill dams
Diversion capacity can be reduced by allowing overtopping of

rockfill
Rockfill is suitable for wet weather placement
Foundation clean-up required no hand-work except at plinth
Grouting can be done parallel to placement of rockfill
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21
Advantages of CFRDs
Multistage construction of the rockfill embankment is possible
Slipforming provides rapid and economical method of face slab

construction
10/13/2005

22
Plinth Foundation Preparation
The foundation is subdivided into three main parts:

The plinth foundation
The embankment foundation
The transition foundation between the two
10/13/2005
Last mentioned is a non-differential deformable base

23
Foundation Preparation
10/13/2005

24
Plinth Foundation Preparation
10/13/2005

25
Plinth layout
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26
Plinth functions
Connects the face slab to the rigid rock
Act as a grout cap during grouting
provides a starting position for concrete face slab slipforming

equipment
10/13/2005

27
Plinth section
10/13/2005

28
Dimensioning plinth
Standardization of the slope and dimensions will reduce cost and

limit construction time
minimum plinth widths of 2m and 3m for <25m high and >25m

high dams respectively
Thickness for plinth on sound rock = face slab thickness.

Minimum 300mm and 500mm for lower and higher dams
respectively
10/13/2005

29
Hydraulic gradient guide for plinth
Ratio of reservoir head to plinth width = hydraulic gradient
Foundation erodibility in terms of rock erosion/acceptable

hydraulic gradient
Fresh : 20
Slightly to moderately weathered : 10
Moderatelty to highly weathered : 5
Highly weathered : 2
10/13/2005

30
Plinth Backfill Concrete
10/13/2005

31
Orientation of the plinth apron
Apron contours normal to plinth line
Apron contours normal to dam axis
Apron contours to suit as-excavated contours
The alignment should always allow the concrete face to pull away
from the plinth and move downstream under water load.
10/13/2005

32
Plinthline
10/13/2005

33
Layout geometry in three dimensions
B
V
Plinth Control Point

10/13/2005

34
Plinth concrete and reinforcement
High durable, low permeability concrete
0,3% steel
anchored with grouted dowels
10/13/2005

35
Face curb placing procedure
10/13/2005

36
Face starter slab
10/13/2005

37
Face thickness
H = 0,3 + 0,003H m
10/13/2005

38
Slipform
10/13/2005

39
Copper waterstop joint
10/13/2005

40
Typical PVC Waterstop
10/13/2005

41
Typical Stainless Steel waterstop joint
10/13/2005

42
Copper waterstop joint
10/13/2005

43
Plinth rubber and copper waterstop
10/13/2005

44
Plinth rubber waterstop
10/13/2005

45
Perimetric joint
10/13/2005

46
Three dimensional perimeter joint

meter
10/13/2005

47
Perimeter Joint Movement

Damname Rock type
Height ( Opening normal to joinSettlement normal to concrete fShear parallel to joint
Aguamilpa
Gravel
187
19
16
5
16
23
7
Tianshengqestone and mudst 178
Foz do Arei
Basalt
160
23
55
25
Salvajina
Gravel
148
9
19
15
Alto AnchicaHornfels-Diorite
140
125
106
15
Xingo
Granite
140
30
34
0
Golillas
Gravel
130
100
36
0
5
8
0
Khao Laemestone and mudst 130
Shiroro
Granite
125
30
60
21
Dolerite
122
7
70
0
Lower Piem
Reece
Dolerite
122
7
70
0
Cethana
Quartzite
110
11
0
7
Kotmale
Charnokite
97
2
20
5
Xibeikou
Dolomite
95
14
25
5
Murchison
Rhiolite
89
12
10
7
Sugarloaf
Sandstone
85
9
19
24
MacIntosh
Graywacke
75
5
20
3
Bastyan
Graywacke
75
5
21
0
Chengbing
Lava tuff
75
13
28
20
Gravel
40
2
12
1
Pichi-Picun-
10/13/2005

48
Perimeter Joint Movement

200
H e ig h t (m )
175
150
O p e n in g
n o rm a l t o jo in t
(m m )
125
100
S e t t le m e n t
n o rm a l t o
c o n c re t e fa c e
(m m )
S h e a r p a ra lle l
t o jo in t (m m )
75
50
25
0
P e r d a m m e n t io n e d in t a b le
10/13/2005

49
Joint meter
10/13/2005

50
Face slab: temperature??
10/13/2005

51
Plinth and face slab joints
10/13/2005

52
Waterstops
10/13/2005

53
Placement of rockfill
Rockfill is end dumped on the edge of a placed layer and spread

by dozer. There is inherent segregation in the dumping and
intentional segregation in the spreading. The smooth surface on
top of the layer is desirable for compaction and for reduced tyre
and dozer track costs. The top half consists of smaller size rock
and is well graded in comparison to the larger rocks in the bottom
half. The upper half is of higher density. Energy is transmitted
through the larger rocks providing strength and density by
wedging and crushing of edges. Water is added during
compaction to smooth the edges and to increase the density.
The maximum size rock in a layer may be equal to the layer

thickness. Immediately adjacent rockfill will not be fully
compacted and does not need to be. The larger rock particles will
attract load in the area.
10/13/2005

54
Rockfill and Cohesionless fines
2A
3A
CF
2B
3B
10/13/2005

55
Zone 2A compaction
10/13/2005

56
Requirements of Zone 2A material
Non plastic mixture of rock fragments with hard durable particles
Designed as a filter - must retail silt and fine sand, (D15/d85<4)
Filter material must be more permeable than the clogged filter

interface, (D15/d15>4)
To achieve the above 2A material will
not segregate during placement, uniform -not change in gradation during processing
not have cohesion or will cement
be eternally stable
have the ability to control and seal a concentrated leak
10/13/2005

57
Functions of Zone 2B material
10/13/2005

58
Requirements of Zone 2B material
It forms a cushion to uniformly support the face slab
It must provide a smooth dense surface on which to place the

face slab to reduce concrete quantities
It restricts leakage flows that might result from damage to the

concrete face
Under draw down conditions is free draining through the

downstream rockfill
10/13/2005

59
Requirements of Zone 2B material
In case of weak rockfills, measures as flattening the upstream

slope or providing drainage downstream of the transition zones
may be a requirement
Must be designed as self healing in case of a crack in the face

slab
Permeability>10-4 cm/s
Must be protected against erosion during construction
10/13/2005

60
Requirements of Zone 3A material
The transition between 2B and 3B consists of 3 to 4m wide zone

3A material
it provides filter stability between the zones and
ensure limiting differential movement of the face slab
10/13/2005

61
Segragated 3B Material
10/13/2005

62
Requirements of Zone 3B and 3C

material
Capable of carrying the imposed reservoir load
10-2 to 10-1 cm/s for 3B and 3C respectively
3B - 1m layers, water added during compaction
3C - 2 m layers, water not added during compaction
Shear strength varies from about 450 for low density poorly
graded weak particles to 600 for high density, well graded strong
particles
10/13/2005

63
Seggregated 3B material
10/13/2005

64
Series of filters/seals of perimeter joint
Zone 1A and Zone 2A material
Cohesionless fines
top stainless steel waterstop
Central PVC waterstop
Bottom copper waterstop
10/13/2005

65
Series of filters/seals of perimeter joint
Zone 2A fine filter material
Zone 2B transition filter material
Zone 3A small quarry run material
Zone 3B rockfill
10/13/2005

66
Plinth-cohesionless fines
10/13/2005

67
Placement of impervious 1B blanket on

face slab and fly ash on perimeter joint
10/13/2005

68
Upstream Coffer Dam, Plinth
10/13/2005

69
Downstream cofferdam
10/13/2005

70
Parapet wall connected to face slab
10/13/2005

71
Parapet Wall Functions
Provide freeboard
act as wave wall
provide access during construction of face slab
to provide safety barrier on crest
10/13/2005

72
Parapet Wall
Heights up to 8.5m have been successfully constructed
Stability regarding shear and overturning important
Seismic loads must be considered - the crest of an embankment

dam is moving maximum during the occurrence of earthquakes
CFRDs can easily be raised by adding a parapet wall
Finish of parapet wall is important - the wall is visible after

completion and impoundment
10/13/2005

73
Snowy conditions
10/13/2005

74
CFRD
Simple
Safe
10/13/2005

75

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The Design of Concrete-faced Rockfill

SANCOLD/US 2005: The Design of

Constructed Concrete-faced Rockfill

Concrete-faced Rockfill Dams: Trends

SANCOLD/US 2005: The Design of

The Lesotho Mohale Dam

SANCOLD/US 2005: The Design of

The Lesotho Mohale Dam

SANCOLD/US 2005: The Design of

SANCOLD/US 2005: The Design of

1 for soil materials

2 for processed granular materials

3 for rockfill zones

SANCOLD/US 2005: The Design of

SANCOLD/US 2005: The Design of

Zone 1A, a silt or fine sand act as face slab or perimeter

SANCOLD/US 2005: The Design of

Zone 3 is quarry run rockfill. The differences in A,B and C are

Zone 3A, provides compatibility and limit void size adjacent to

SANCOLD/US 2005: The Design of

SANCOLD/US 2005: The Design of

Compaction by rubber tyre

Compaction by rubber tyre

> = 10 tonne vibratory roller

SANCOLD/US 2005: The Design of

Selected small quarry run

>= 10 tonne vibratory

Quarry run rockfill

>= 10 tonne vibratory

Quarry run rockfill

>= 10 tonne vibratory

Erosion protection, durable

SANCOLD/US 2005: The Design of

Maximum layer thickness after compaction.

Surface compaction by 130 kN vibratory plate on laser

controlled backhoe. Similar

compaction shall be achieved

as using: 2 passes with the 10 tonne vibratory roller without

SANCOLD/US 2005: The Design of

Zone 2A material shall be thoroughly compacted with a

vibratory force to a density similar as achieved by 4 passes

vibratory roller. Particular care shall be

taken to prevent damage to the concrete or to the

SANCOLD/US 2005: The Design of

CFRDs are best suited to sites where:

SANCOLD/US 2005: The Design of

Settlements of rockfill are small

Parapet wall can be placed on crest

Leakage is not a concern, face slab in biaxial compression,

Water load transmitted into foundation upstream of dam axis

Uplift under rockfill is not involved. The pressure on the

SANCOLD/US 2005: The Design of

Sliding factor for reservoir water and rockfill exceeds 7

High shear rockfill, no pore pressures in rockfill, small settlement

Drainage galleries in abutments not required

Overtopping can cause failure

SANCOLD/US 2005: The Design of

Post Construction Crest Settlement

SANCOLD/US 2005: The Design of

Height (m), Settlement (mm)

Post Construction Crest Settlement

Dam or rock type