Paul C. Rizzo, Ph.D., P.E.; Carl Rizzo; John Bowen
The Authors served in key roles for the design and rebuild of the Dam for the Taum Sauk Rebuild Project between 2007 and 2009. Taum Sauk is the largest RCC Dam in the United States and has a symmetrical cross-section with conventional concrete faces upstream and downstream. The curvilinear shape and the cross-section presented a number of placement issues. In addition, a large number of “Lessons” were learned because of the rapid construction schedule, highly variable temperatures, highly confined working space, numerous details related to waterstops, construction joints and crest-to-gallery drains, foundation preparation, lift maturity, bedding mixes, crack repairs and the conventional concrete upstream face. The authors discuss these issues from the perspective of the Designer, Contractor and Construction Manager.
Tony Harman, Richard Herweynen, Malay Ghosh
Following a number of years of investigation into the condition of the existing 1960’s post tensioned anchors at Catagunya Dam Hydro Tasmania embarked on an options study to determine the best method to restore the dam stability to acceptable limits for the long term. The required solution was intended to not only resolve the issue of anchor deterioration but also to increase the flood capacity of the dam.
Based on preliminary design work a concrete buttress solution was recommended and approved for detailed design. The preliminary design utilised a simplified, 2-dimensional, rigid body model, including crack analysis. As part of the detailed design a finite element model was developed to refine the preliminary design. However, this model did not support the simplified analysis and further non-linear finite element analysis demonstrated that the proposed passive buttress design solution was not technically feasible. The options were reconsidered and the adopted solution was to replace the original anchors with new modern anchors with a high level of corrosion protection.
The new anchors adopted are the largest post tensioned anchor loading currently used for a dam in the world. This along with the existing post-tensioned anchors and the tight geometry of the dam, which has a central spillway with a cantilevered ogee crest, provided significant challenges with the design of this dam upgrade. Some of the key design challenges included:
– Appropriate level of modeling and analysis to be able to make sound design decisions. (Hydraulic modeling and FEA).
– Congestion due to the tight geometry of the original design.
– Anchor head block detail to ensure the loads would be adequately secured and dispersed into the dam body
– Crest cantilever support to ensure that structural integrity was retained during construction and later in service. Innovative installation of carbon fibre reinforcement was used.
– Strain compatibility. It was important to ensure the structural contribution of new and old working together and that the consequences of application of new large stresses was manageable.
– Existing anchor degradation. The design needed to ensure that stability compliance was achieved for complete to zero effectiveness over time.
– Maintaining operability of dam and power station during construction.
– Achieving an effective long term maintainable solution.
This paper will present the risk associated with committing to a solution too early and the design challenges and the solutions finally developed, providing the dam industry with a valuable reference for future similar projects.
Analysis and Design Challenges Associated with the Catagunya Dam Restoration Project
Rick Friedel, Len Murray, Gerrad Suter, James Penman, James Watt, Hendra Jitno
The Hidden Valley tailings storage facility (TSF) has set a new precedent in environmental management of tailings in Papua New Guinea (PNG). Modern mining in PNG arguably began with the development of Bougainville Copper in the late 1960s, and continued through to Ok Tedi, Porgera, Lihir, Misima (and others). These mines have proceeded with deep sea or riverine tailings deposition, rather than construction of a tailings dam to retain the mine waste within an impoundment; as is the practice throughout the majority of the mining industry.
The Hidden Valley TSF is comprised of two large earth and rock fill dams, raised by the downstream method. Starter dam construction was completed in 2009. At final height the Main Dam will be one of the highest tailings dams in the world. The dams are constructed of pit waste and therefore have the dual function of storing tailings and waste rock.
Construction of the starter dams and subsequent raises is complicated by conditions at the site. Water management was, and remains, the dominant issue. High rainfall, weak erosive soils, material availability, dense vegetation and remoteness of the site provide constant challenges to construction. The Observational Approach to construction was recommended by the designers and adopted by the mine operator. This involves a knowledgeable pre-assessment of what is likely to change and having contingency plans to deal with possible major issues. This approach allows changes to the design during construction so the “as-built” product is suited for the site, fit for purpose, and remains consistent with the overall intent of the design.
The TSF has been in operation since August 2009 and monitoring data of the structures has been collected during construction and operation. This data is reviewed to confirm design assumptions and assess dam performance.
Personnel involved with this project combined their experiences working in the PNG environment and dam building from other locations. This process led to close interaction between the mine operators, designers and construction teams. Team work and diligent construction practices were and will continue to be necessary to construct and operate the pioneering TSF in PNG.
Brendan Sheehan, Chris Topham, Alan White, Rowenna Lagden
Darwin Dam is a 21m high embankment dam constructed on a geologically complex foundation that includes karst limestone features. The dam retains the top 15m of Lake Burbury on Tasmania’s west coast, and borders the Tasmanian Wilderness World Heritage Area. Defensive design of the dam addressed the key failure modes of piping through the complex foundations of limestone, sandstone, gravels and silts, and guarding against sinkholes forming in the limestone foundations. During construction, a comprehensive range of instruments were installed in the dam and foundation, as a long term means of monitoring this structure. A range of surveillance data has been collected since lake filling and this data, along with historic geological investigation information, was used to develop a three dimensional (3D) geological model of the dam and
foundation with phreatic profiles. The software used was a commercially available geographical information system. This tool has assisted Hydro Tasmania to better understand and manage the dam. The paper outlines the need for a 3D model, the methodology for development of the model, resources required, limitations and lessons learned. The benefits of the model, such as aiding understanding of foundation behaviour, assisting with interpretation of surveillance data, supporting decision making, and potential use during incident response are also discussed.
Keywords: Three dimensional, computer model, karst foundation, geology, hydrogeology ,dam surveillance
Richard Herweynen, Colleen Stratford
Assessing the potential for erosion of foundation rock downstream of a spillway is a problem faced on many dams, whether new or existing. The problem is made particularly difficult not only due to the uncertainty in determining the erosion potential of the rock, but also due to the variable hydrologic characteristics of flood events.
The selected spillway option for Wyaralong Dam comprises a centrally located primary spillway with a secondary spillway located on the left abutment. A stilling basin energy dissipater is provided at the toe of the primary spillway. Downstream of the secondary spillway, an apron channel will direct flows back to the stilling basin. However, for flood events larger than the 1 in 2000 AEP event, the capacity of the secondary spillway apron is exceeded and flows spill out across the left abutment of the dam towards the river channel. Erosion of this left abutment was viewed to be a potential dam safety issue, and as such, careful consideration was required during the design stage to determine the acceptability of this spillway arrangement.
In order to provide structure to a problem which often relies solely on engineering judgment, a decision process was developed, taking into consideration some of the more definable aspects of the problem. These aspects included the geological characteristics, the initial hydraulic characteristics, the flood duration, the nature of erosion should it occur and the stability of the dam. This paper describes the decision process and methodology used at Wyaralong Dam to
determine the acceptability of erosion. This paper will present the process in a way that it can be used by others in future dam projects, both new and upgrades.
A Unique and Holistic Approach to the Erodibility Assessment of Dam Foundations
Ben Greentree, David Bamforth, Matthew O’Rourke and James Willey
A series of relatively small floods occurring between end of construction in 1978 and late 1980s caused extensive and dramatic rock erosion to the very steep unlined section of the Googong Dam spillway. Following a review of hydraulic performance at larger floods, the spillway’s future erosion potential was evaluated and it became clear that extensive remedial work was required. A detailed design was developed comprising the retro-fitting of a full concrete-lined chute, the raising and extension of the spillway chute walls, strengthening of the upstream training walls and excavation of a large plunge pool. The Googong Dam has an ANCOLD hazard rating of ‘extreme’ because of its location upstream of Queanbeyan and Canberra.
In early 2008, the Bulk Water Alliance (BWA), comprising ACTEW Corporation Ltd, (in cooperation with ActewAGL) (the Owner), GHD Pty Ltd (the Designer) and Abigroup Contractors Pty Ltd in joint venture with John Holland Pty Ltd (the Constructors) was formed to deliver a package of water security projects for the ACT, one of which is the Googong Dam Spillway Upgrade.
After preparation of a construction methodology and target outturn cost (TOC), the project was approved by the Actew Board and construction commenced in February 2009. Completion is due in late 2010. A number of significant geotechnical, structural and logistical challenges were encountered during construction, resulting in major changes to the construction methodology necessitating design changes. The changes were incorporated within the original TOC, without instigating scope change contractual claims and while still maintaining spillway functionality in line with Owner operational requirements.
This paper presents delivery phase challenges that necessitated construction methodology and design changes to achieve best for project outcomes; how these challenges were overcome through genuine innovation reliant on a collaborative effort by all the Alliance partners; and how the contractual framework of the Alliance was essential for the change management process to be successful.