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José López1, Tim Griggs, Robert J. Montalvo, Richard Herweynen and Ernest Schrader

The Burnett Dam is a 50m high Roller Compacted Concrete (RCC) Dam with a total RCC volume of
400,000 m3. It is located on the Burnett River, approximately 50km inland from the town of Childers
in Queensland, Australia. The design of the dam commenced in 2003, construction started in
November 2003 and the dam will be completed by the end of 2005.

This paper discusses the construction processes, the extensive quality control program and the
innovations developed for the RCC dam construction.

Key features of the project discussed in this paper are:

The low cement RCC mix design and its optimisation during the construction stage.
Thermal issues and elimination of the need for cooling.
Performance of the ‘all-in-one’ aggregate stockpile.
Dual pugmills for RCC production.
RCC delivery in different areas of the dam undertaken by conveyor, Creter crane and trucks.
Extensive laboratory and field testing used to evaluate and improve production and quality
control procedures including an analysis of the Lift Joint Quality Index.

During construction, special emphasis was given to the inspection of the processes of production,
transportation, delivering, placement, compaction and curing of the RCC.

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2005 Papers

2005 – RCC Construction & Quality Control for Burnett Dam
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José López1, Tim Griggs, Robert J. Montalvo, Richard Herweynen and Ernest Schrader

The Burnett Dam is a 50m high Roller Compacted Concrete (RCC) Dam with a total RCC volume of
400,000 m3. It is located on the Burnett River, approximately 50km inland from the town of Childers
in Queensland, Australia. The design of the dam commenced in 2003, construction started in
November 2003 and the dam will be completed by the end of 2005.

This paper discusses the construction processes, the extensive quality control program and the
innovations developed for the RCC dam construction.

Key features of the project discussed in this paper are:
- The low cement RCC mix design and its optimisation during the construction stage.
- Thermal issues and elimination of the need for cooling.
- Performance of the ‘all-in-one’ aggregate stockpile.
- Dual pugmills for RCC production.
- RCC delivery in different areas of the dam undertaken by conveyor, Creter crane and trucks.
- Extensive laboratory and field testing used to evaluate and improve production and quality
  control procedures including an analysis of the Lift Joint Quality Index.
During construction, special emphasis was given to the inspection of the processes of production,
transportation, delivering, placement, compaction and curing of the RCC.
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2017 Papers

2017 – A Turkey’s Nest Dam on Top of a Waste Rock Dump – An Innovative Solution for the Kidston Pumped Storage Project
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Richard Herweynen, Jamie Campbell, Mohsen Moeini

Hydropower storage plays an expanding role in integrated power systems internationally and can enable increased use of intermittent renewable energy sources such as wind and solar.With an increased amount of renewable energy within the Australian grid, pumped storage has gained increased focus in the past 2years. Entura have been working with Genex Power Ltd. to investigate, evaluate, optimise and design the Kidston Pumped Storage Project, located at the old Kidston gold mine in Northern Queensland. Through this design process, the final arrangement developed included an upper reservoir turkey’s nest dam to be built on the existing waste rock dump on the northern side of the Eldridge Pit, using the existing waste rock dump material and lining it with an HDPE liner. The original waste rock dump was formed during the mining operation by progressively dumping the waste rock predominantly from the Eldridge Pit excavation, with the haul truck traffic being the only compaction that occurred. Since the closure of the mine about 20 years ago, some consolidation of the waste rock dump has occurred.As a result, the key risks identified for the construction of the turkey’s nest dam on top of the waste rock dump were: (1) the stability of the slopes of the waste rock dump, which were generally at the angle of repose for the rockfill material; (2) the absolute settlement of the waste rock dump as the final dam crest level requires a settlement allowance in excess of the flood freeboard requirements; and (3) the differential settlement as excess differential settlement could cause fatigue stress cracking within the liner.This paper presents the investigation and modelling undertaken to confirm the feasibility of constructing this turkey’s nest dam on top of the existing rock waste dump, utilising the historical data on dumped rockfill dams. The paper also presents the feasibility design developed for the upper storage.
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2017 Papers

2017 – Nagmati Dam – A Project of Environmental and Cultural Significance
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Richard Herweynen, Suraj Neupane, Paul Southcott and Ashish B. Khanal

Kathmandu, the capital city of Nepal, is home to more than five million people. Three major rivers including the Bagmati run through the city of Kathmandu, providing the environmental and cultural lifelines for the civilisation and local people. High population growth in Kathmandu over the past 30years has put a serious environmental strain on the Bagmati River. Water is drawn from the Bagmati River for drinking, farming, industries and construction. Due to the lack of capacity in the current sewerage systems, untreated sewage is entering the river system, along with high quantities of rubbish. Although a holy river, the Bagmati River is highly degraded, with reduced flows, high pollution, and a fresh water ecosystem that is now destroyed.To revive the Bagmati River, the Government of Nepal with funding from the Asian Development Bank (ADB), is undertaking the Bagmati River Basin Improvement Project (BRBIP). One of the sub-projects is the construction of a dam on the Nagmati River to store water during the monsoon period for environmental release during dry season.Since November 2015, Entura have been involved in the investigation and detailed design of the Nagmati Dam. Through a simple storage model, it was determined that 8.2Mm 3 of live storage was required to meet the environmental flow objectives. To achieve this storage a 95m high dam was required at the Nagmati site, with a concrete faced rockfill dam (CFRD) determined to be the best option.This paper will present the development of this unique project, highlighting how a number of the challenges were addressed, leading to a sustainable project.
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2012 Papers

2012 – Diversion Design for Dam Construction
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Tim Griggs and Richard Herweynen

The river diversion is an important aspect to be considered in the design of a dam. It generally consists of an upstream cofferdam, river diversion conduit and downstream cofferdam and allows the dam to be constructed in a dry section of river.
This paper reviews the diversion design adopted at three recent Australian roller compacted concrete (RCC) dams and comments on the effectiveness of the design in providing risk mitigation during the construction of each of these dams. The dams considered are Paradise Dam (2005), Meander Dam (2007) and Wyaralong Dam (2011).
Rather than selecting an arbitrary design flood for the diversion, a risk-based assessment was used that generally resulted in a relatively low design capacity. Even though there were cases where the diversion capacity was exceeded, it is considered that the risk based design process provided an economical diversion design for these recent Australian dams.
Keywords: Diversion, roller compacted concrete dam, RCC.
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2010 Papers

2010 – Using a clay cemented sandstone as RCC aggregate – a major breakthrough at Wyaralong Dam
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Richard Herweynen, Robert Montalvo, John Ager

The choice of materials used in the construction of a dam is one of the most critical decisions in the design process. Our natural behaviour as engineers is to adopt materials which have proven performance, and which conform to Australian or international standards, which sometimes causes us to overlook the specific conditions and demands of the project at hand. In an environment where the majority of concrete produced is for structural purposes, the properties of these concretes is often vastly different to those desired for mass concrete structures such as dams and spillways.

The big question at Wyaralong Dam was could onsite aggregate be used in the Roller Compacted Concrete (RCC)? The Wyaralong Dam is located in the Gatton Sandstone (early Jurassic), predominantly feldspathic to lithic‐feldspathic sandstones with a clay matrix. Early analyses and tests suggested that the Gatton Sandstone was not suitable for RCC aggregate due to a 68% wet/dry strength reduction, high water absorption (5.2 – 7.5%) and petrographic interpretation that clay content was mainly swelling clay, leading to durability concerns.

Due to significant community, safety and cost issues with importing aggregate, Wyaralong Dam Alliance (WDA), during the development of the RCC mix design for Wyaralong Dam, chose to pursue the use of onsite quarried sandstone aggregate instead of importing aggregate. Additional petrographic and XRD analyses and extensive durability tests were undertaken on cores of sandstone and RCC samples, including wet‐dry cycles, soak tests in ethylene glycol, soaks in sodium hydroxide, and heating and cooling cycles. These tests indicated that, if swelling clays are present, they do not impact the durability behavior of the RCC aggregate.

The substantial effort put into testing the sandstone aggregate has paid off for WDA. Not only have the results indicated that the RCC mix performs remarkably well in terms of durability, but the very low modulus of elasticity of the mix has provided exceptional performance in terms of thermal loading; with all the related benefits in reduced restrictions to placement schedule and cooling requirements. Onsite sandstone was not only proven to be a feasible option, it has been demonstrated that it is the best option for the project. Details of the study are provided in this paper.

Keywords: Roller Compacted Concrete (RCC), Sandstone, Aggregate, Clay, Mix, Durability
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2010 Papers

2010 – Challenges Associated with Identifying and Analysing Potential Failure Mechanisms in Dam Foundations – Taum Sauk Upper Reservoir Dam & Wyaralong Dam Case Studies
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Jared Deible, Richard Herweynen, Gary Dow

The foundation is an important element in the stability of any dam. Understanding the foundation and the potential failure mechanisms associated with the dam foundation is critical to developing the final dam design. This paper will discuss the challenges encountered with the foundation at the Taum Sauk Upper Reservoir Dam and the Wyaralong Dam.
The Upper Reservoir of the Taum Sauk project is a 2.3 million cubic metre roller compacted concrete (RCC) dam located near Ironton, Missouri, USA. The RCC dam was constructed in accordance with United States Federal Energy Regulatory Commission (FERC) guidelines to replace a rockfill dike that failed abruptly on December 14, 2005. Wyaralong Dam is a new RCC dam, for water supply, located on the Teviot Brook near the township of Beaudesert in south-east Queensland.
Wyaralong and Taum Sauk each had challenges associated with identifying potential failure mechanisms in the foundation and with analysing the stability of the dam for these potential failure mechanisms. The geology at the projects was very different, but challenges for each project were quantifying the amount of reliance that was placed on the rock mass at the toe of the dam, developing the shear strength parameters, and developing the associated failure mechanisms that would be analysed.
The design of Wyaralong and the rebuilt Taum Sauk Upper Reservoir, including the geometry of the dam sections, were developed based on the foundation features at each project. Foundation treatments and excavation designs were developed based on the stability analyses conducted during the design phase. These foundation treatments included removal of weak layers or defects where necessary, but features were left in place in the foundation at selected locations at each project. Where features were left in place, stability analyses concluded the dam was stable. The stability analyses at each project considered three dimensional effects along features in the foundation where appropriate.
As the foundation was uncovered during the construction phase of each project, the parameters used in the stability analysis conducted during the design phase were confirmed or adjusted. The excavation and foundation preparation activities were adjusted as necessary based on actual conditions during the construction phase.

Challenges Associated with Identifying and Analysing Potential Failure Mechanisms in Dam Foundations – Taum Sauk Upper Reservoir Dam & Wyaralong Dam Case Studies
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2010 Papers

2010 – Analysis and Design Challenges Associated with the Catagunya Dam Restoration Project
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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
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2010 Papers

2010 – A Unique and Holistic Approach to the Erodibility Assessment of Dam Foundations
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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
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2010 Papers

2010 – A Bi-Directional Fishlift – An Innovative Solution for Fish Passage
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Graeme Maher, Richard Herweynen, Martin Mallen-Cooper and Stuart Marshall

Increasing awareness of the environmental impact of dams means that fish passage is emerging as a critical issue for both existing and new dams in Australia.

The fish passage and outlet works for Wyaralong Dam, a new dam currently under construction, required accommodation of large ranges of head and tailwater levels. The solution that has been adopted, a bi‐directional fishlift using a single hopper with trapping for downstream fish movement occurring within the intake tower, is a world first. The solution required the innovative integration of a number of existing technologies to create a system which is necessarily complex, yet reliable and effective.

The paper incorporates discussion of the critical design constraints, the biology of fish passage, the process adopted to reach the concept solution and a description of the final design including its integration with the outlet works. A number of design issues and their solution are discussed in detail, particularly those associated with dealing with the complexity of the design constraints and how the components of the solution were integrated into a seamless design.

The paper will be of use to those involved in the process of providing fish passage on both existing and new structures that obstruct river flow.

A Bi-Directional Fishlift – An Innovative Solution for Fish Passage

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