Section 13 Constr Methodology and Estimates of Cost

RVM Hydro Electric Project
Draft Construction Method Statement

7 May 2015
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RVM Hydro Electric Project ‐ Draft Construction Method Statement Revision No: 1.0
7 May 2015
Document information
Title RVM Hydro Electric Project
Draft Construction Method Statement
Client organisation RVM1 Hydro Electric Power (Pty) Ltd
Client contact Niel Theron
Document number
Project manager Nick West
Project reference E304773 ‐ P509337
Revision history
Revision 1.0
Revision description Draft for Information only
Prepared by Nicholas West
Reviewed by David Gerke
Approved by David Gerke
(name) (signature) (date)
Distributed to Niel Theron RVM1 Hydro Electric Power

(Pty) Ltd
(name) (organisation) (date)
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1. General
1.1 Background
The purpose of this method statement is to outline the steps to be taken before, during and after
construction of the RVM Hydro Electric Project to demonstrate compliance with:
 likely Environmental Authorisation conditions,
 likely Water Use Licence conditions,
 the likely Construction Environmental Management Plan (CEMP)
It is also intended that this report satisfy the Department of Water and Sanitation (DWS), local
authorities and surrounding property owners that on completion of the Project, there will be no
potential short or long term environmental or physical scarring to the immediately adjacent to
construction or operationally disturbed areas.
All the structures will be designed for a design life cycle of 40 years, however with appropriate
remedial and maintenance actions taken as required, structures can be expected to perform as
designed for over 100 years or more.
An overview of the arrangement is shown in Figures Figure 1.1 to Figure 1.4.
1.2 Site Establishment
The Contractor’s site office and construction camp locations are shown on in Figure 1.2. The
construction camp is the staging area for the contractors and will contain such items as:
 Concrete batch plant,
 Equipment stores,
 Fuel storage, and
 Maintenance facilities.
1.3 Borrow Pits and Spoil Sites
Potential borrow pits are not considered to be necessary for this project since material won from
headrace canal excavation and tunnel excavation is anticipated to be appropriate for use (once
crushed) for a variety of purposes across the project. Spoil will be stockpiled in an area identified and
assessed as part of the Environmental Impact Assessment (EIA) process (shown in Figure 1.4).
Drainage around the spoil site will be designed according to the conditions of both the
Environmental Authorisation and the Water Use Licence.
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Figure 1.1: General layout of project infrastructure from diversion weir to tailrace outfall (CES, 2015, p 57)
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Figure 1.2: Layout of weir and offtake structure (CES, 2015, p 58)
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Figure 1.3: Layout of headpond, underground power chamber, tailrace tunnel and outfall (CES, 2015, p 59)
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Figure 1.4: Position of the substation and proposed area for surplus spoil deposition (CES, 2015, p 60)
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1.4 Crusher
A mobile crusher will be established on the site. The location is yet to be determined but it is likely to
be near the spoil site.
The mobile crusher will be established to crush rock excavated from the headrace, penstock and
access shafts and powerhouse cavern and tailrace. This material will be used as coarse aggregate for
concrete, road construction and for erosion protection where required.
1.5 Pre‐Cast Yard
If required, a pre‐cast yard will be established in the vicinity of the construction camp.
1.6 Potable Water
The Contractor will ensure that potable water is supplied to and stored on site in adequate facilities.
1.7 Power
The temporary power to the site will be obtained from available local electricity infrastructure or, if
not available by generator with appropriate fuel bunding.
1.8 Sewerage
The Contractor will ensure that adequate facilities are available for the workforce in the form of
chemical toilets or via conservancy tank.
The disposal of waste will be undertaken with the approval of the local authority.
1.9 Batching Plant
A concrete batching plant will be established on site to produce all the concrete required for
construction of Project infrastructure. This will require local water and power.
Aggregate stockpiling as well as cement storage is required and will be located within the
construction camp.
1.10 Equipment
A comprehensive inventory of the construction equipment to be used on site will be prepared at a
later stage and prior to site establishment.
Refuelling and maintenance facilities will be located in the construction camp shown in Figure 1.2
and will have appropriate spill management systems in place.
1.11 Access Control Edge Protection of Animals and Humans
As the design develops, the access control measures for animals and humans will be developed in
conjunction with the EIA & WULA requirements.
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1.12 Initial Investigations
Detailed topographical survey has been performed, which will be used as the design develops.
Geotechnical investigations are planned to be undertaken that will allow the design to develop and
to provide more detailed information on the foundations and suitability of the in‐situ materials as
construction materials. These invasive investigations will include activities such as:
 Excavation of test pits,
 Drilling, and
 Seismic tests.
These investigations have the potential to cause disruption in the local area and any investigations
will be adopted in accordance with with the EIA & WULA requirements and in conjunction with the
relevant authorities.
1.13 Experience of Contractor, Staff and Senior Management
Construction of the RVM Hydro Electric Project is scheduled to begin in early to mid 2017. At this
stage it is envisaged that the majority of parties involved with the construction of the Neusberg
Hydro Electric Project, which is began operation in January 2015, will remain involved for the RVM
Hydro Electric Project. Experience at Neusberg will give all parties a comprehensive understanding of
the issues likely to be faced at RVM.
One major component of the works not present at the Neusberg Hydro Electric Project is tunnelling.
An experienced contractor will be engaged to undertake the Tunnelling Works. This contractor will
be a sub‐contractor to the Civil Works Contractor and will be made aware of the requirement of the
CEMP and the likely repercussions associated with a breach.
2. Weir
A coffer dam is required to create a “water‐free” environment in which to construct the weir. It is
envisaged that the cofferdam will be constructed in 2 stages (half of the river width each stage) to
ensure existing flows can pass unimpeded during construction of the weir. The cofferdam will not be
watertight, which will mean that continual pumping of seepage water will be required. Seepage
water could be contaminated with suspended fines and sediment from the foundations or coffer
dam and as such, will be treated to remove excess sediment and then discharged on the downstream
side of the coffer dam into the main river channel.
As the invert of the river will be sloping and uneven, it is envisioned that “heavy duty” sand bags
filled with a sand/cement mixture will be placed on the rock bed. The bags will be profiled to create a
top surface on which to build the coffer dam walls. The fill material will set when in contact with the
water to produce a solid and robust stable foundation.
The walls will be created by dry stacking a system of keyed pre‐cast blocks that can be tied together
with chains or cable to counter the infill surcharge. As blocks are laid and tied together, layers of infill
material, rock and finer material, will be placed with the block walls forming an almost impermeable
wall that will allow for dewatering on the offtake side.
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The weir will be constructed in two stages –the left and right stages. The cofferdam will need to be
removed from one site and replaced on the other side to allow construction of the weir in dry
conditions.
The coffer dam wall must be removed on completion of construction of the offtake structure. As
such, the proposed design will allow for the removal of the fill material followed by removal of the
blocks and lastly, the foundation bags, this process will minimise any contamination into the existing
watercourse.
The coffer dam will be constructed during the low flow summer season to ensure that this is
constructed when water levels are at their lowest.
This system is being proposed as it will be the least intrusive in terms of environmental impact. Mass
fill operations will result in silt and suspended materials impacting significantly on water quality in
the river downstream of the works.
3. Offtake Structure
The inlet structure will be a cast in‐situ reinforced concrete structure located on the right abutment
of the weir. The structure will house trashracks, stoplogs and gates. This structure will be the primary
mechanism for stopping flow in the headrace.
The river bed at the offtake structure will be excavated to a depth that allows efficient conveyance of
water into the headrace. The floor of the excavation will require blinding before the reinforced
concrete slab is cast. The walls will be cast hard onto the rock face with an internal shutter. The
superstructure will be cast with shutters on both faces.
The structure will have slots for stoplogs and gates cast in.
Inside, the structure will have a slab cast and frame constructed to accommodate a gantry and hoists
for stoplogs and gates. The structure will have a steel roof.
The hydromechanical equipment will be fitted once the concrete has reached the required strength.
4. Headrace
The headrace is a covered conduit that conveys water from the intake structure to the headpond, by
utilising a covered conduit it does not create a visual issue and allows animals to traverse safely
during operation. A trench will be excavated along the route and spoil will be stockpiled. Excavation
will be done by mechanical means as far as possible but it is considered that significant amounts of
controlled blasting may be required due to the presence of hard rock close to the surface.
Once the excavation has reached the design profile, the floor will be treated with a blinding layer of
concrete followed by a reinforced concrete floor for the headrace conduit. Inverted box culverts will
be cast on top of the floor to form two parallel culverts. Once the culverts are cost, the trench will be
backfilled with selected material and the surface will be rehabilitated.
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Where the headrace canal intersects existing drainage lines, additional compaction of backfill will be
required to ensure water flowing in the drainage lines can pass over the headrace without infiltrating
into the disturbed ground.
Construction will be staged so that the length of open trench is minimised for safety reasons,
although construction activities are likely to be continuous.
5. Headpond
The headpond is a small reservoir that regulates flow into the penstock. The headpond is formed by
an earth and rockfill embankment with a small spillway on the left abutment.
Topsoil within the headpond will be stripped and stockpiled for use elsewhere on the project. Once
stripping is complete the foundations of the headpond will be inspected and any locations of
potential excessive leakage areas will be grouted to prevent this leakage.
A cut‐off trench will be constructed along the alignment of the embankment. This trench helps to
seal the interface between the foundations and the embankment. A geosynthetic liner will be placed
over the foundation and the graded embankment fill be placed on top. Geofabric filters will prevent
seepage and loss of material through the embankment.
In the centre of the embankment, a concrete intake structure will be constructed that houses a
hilltop valve that closes to prevent flow into the powerhouse. This intake structure and valve are the
interface between the headpond and the penstock. The intake structure will be constructed out of
reinforced concrete, which will encase the hilltop valve.
The spillway on the left abutment of the headpond embankment will be a wide open channel that
follows the natural contours. Erosion protection downstream of the spillway will be in the form of
rip‐rap, depending on the erodability of the surface material.
Depending on the outcomes of sediment studies, a sediment settling basin may be required at the
headpond. This will be a reinforced concrete structure located within the headpond. Discharge of
slurry from the settling basin will be piped through the powerhouse and discharged into the tailrace.
6. Tunnelling (Penstock/Access Shafts, Powerhouse
Cavern and Tailrace)
The underground works are likely to be the first to start construction. It will be performed using the
drill and blast method.
The underground works include the:
 Access and penstock shafts,
 Powerhouse cavern, and
 Tailrace.
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Ground support requirements for the underground works will be determined based on the outcomes
of geotechnical investigations and will be refined once excavation has been carried out.
The powerhouse cavern and tailrace will be lined with cast in situ concrete with a floated floor.
The items listed below will be elaborated on as the design develops:
6.1 Excavation of topsoil and overburden
Loose material will be removed by excavator and trucks.
6.2 Tunnelling
The Tunnelling Contractor, once engaged, will provide a method statement on tunnelling prior to the
commencement of construction. This method statement will cover the following items.
 Temporary works
 Preliminary works
 Drilling
 Blasting
 Barring down
 Mucking out
 Ground support
 Tunnel lining
 Rehabilitation
6.3 Stabilisation of topsoil and overburden on exposed slopes
Suitably sized rip‐rap from the rock excavation will be used to stabilise exposed slopes.
6.4 Headrace tunnel lining
6.4.1 Overbreak/underbreak
Where gross overbreak is experienced, this will be filled with shotcrete filler.
Where there is underbreak, further blasting will be undertaken or hand or small mechanical rock
breaking equipment will be used to achieve the required design profile.
6.4.2 Floor
The headrace tunnel floor will receive a blinding layer to achieve level control.
The tunnel floor will then be cast. The floor will have thickened edges to support the wall lining.
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Based on modelling outcomes and expected sediment loads a rock trap may be required near the
downstream end of the tunnel.
6.4.3 Walls and crown
If required, lining of the walls and crown will be done with cast in‐situ concrete. The lining will be cast
hard against the excavated rock face with an internal shutter. The wall thickness will be confirmed
once rock conditions and design calculations have been confirmed.
6.4.4 Survey
Survey is a key aspect of tunnel construction. Prior to each blast, the excavated profile will be
surveyed against the required design profile.
Geological conditions will be mapped prior to lining of the tunnel.
7. Penstock
The penstock is likely to be steel pipes welded together to convey water from the headpond to the
powerhouse. A manifold in the powerhouse will distribute flow to each turbine.
The penstocks will be large diameter (up to 3.5m) so the pipe lengths will be very heavy. It is likely
that pipes will be shipped as two semicircular sections and welded together on site. This will be a
complex operation since one half of the pipe will have to be lowered into the shaft and attached to
the walls of the shaft. The second half of the pipe will then have to be lowered into position, welded
and fixed to the wall as well. This will require a crane to be located on site.
8. Powerhouse
The powerhouse is the structure that will house the turbines and generators, with a range of
mechanical and electrical equipment to service these main items. In this case, the powerhouse is
located in a cavern underground. It is expected that this cavern will be in the order of 45m long x
30m wide x 20m high. The depth of the powerhouse (approximately 120 m below the surface) is
determined by the water level required for flow to freely discharge from the tailrace. These
dimensions will be confirmed during the detailed design stage.
The transformer yard will have a transformer catch pit being a reinforced concrete slab as a floor
with upstand walls. Each transformer will be seated on a mass concrete plinth. The entire yard will
either near the surface or within the powerhouse, but will be set below ground level to reduce visual
intrusion.
8.1 Construction
The floor of the excavation will have a mass concrete blinding layer to create a surface as close as
possible to the underside of floor slab level. The floor slab will be a reinforced cast in‐situ slab.
Concrete will be lowered into the powerhouse cavern then pumped to cast slab and wall concrete.
The concrete will be manufactured at the site batching plant.
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The concrete mix design will be designed for strength, watertightness and have a longevity span of a
minimum of 40 years. This might require the introduction of additives into the concrete mix.
Concrete cube tests for this and all the other structures will be regularly tested to ensure they are
consistent with strength and quality requirements.
The turbines are fixed to the concrete floor slab as well as the downstream wall where the openings
to the draft tubes have been formed.
Access into the powerhouse will be via the access shaft lifts or steel staircases.
8.2 Installation
Many of the mechanical items required for placement in the powerhouse are very heavy. These
items will be lowered into the powerhouse by crane. Once inside the powerhouse, a gantry crane will
be used to move equipment about. The gantry crane must be installed first.
9. Access Roads
Access roads, both temporary and permanent will be required and will be designed for all weather
access during construction and operational phases.
9.1 Haul Roads
Temporary haul roads will be required for the full length of the construction process, between
various site locations. This road will be a basecourse finish and be reinstated once construction has
been finalised.
9.2 Permanent Roads
A permanent road will be required to the Power Station. This will also have a basecourse finish and
be designed to specific levels and falls required by the detailed design. The design life of the roads
will be consistent with the Project requirements and will need to be maintained during the
construction and operational phases.
Where haul roads and new roads cross existing roads, the existing roads will be overlaid with a
minimum of 150mm basecourse.
Culverts will be placed at necessary locations along all roads to prevent erosion of road materials.
10. Flood Protection
Structures will, in general be located outside the 1:100 AEP flood line. Where structures lie within the
1:100 AEP flood line they will be appropriately designed/protected to withstand flood events.
The offtake structure will have waterproof level above the 1:1000 AEP flood line.
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11. Conclusion
During the construction phase of this Project, the most important consideration for the Civil Works
Contractor is to adhere to the conditions of various authorisations. The significant issues to be
addressed are;
 The pre‐construction survey will document in detail the condition prior to construction of the
infrastructure.
 The safety of humans and animals is a priority and all necessary measures will be put in place
to ensure this.
 Blasting will be undertaken in accordance with accepted practices. This will mean that these
operations will pose no risk to the existing infrastructure.
 Site Management in all aspects will be carefully monitored to ensure that the site boundaries
are respected.
 Waste Management will be well controlled to ensure no contamination.
 Lastly, the environment will be returned to an acceptable condition which will allow for
rejuvenation of flora to natural pre‐existing state.
12. References
EOH Coastal & Environmental Services (CES), 2015, Environmental Impact Assessment Report, April
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