Professional Documents
Culture Documents
Concrete Dams
William G. Reinhardt
Westfield, New Jersey
McGraw-Hill, Inc.
New York St. Louis San Francisco Auckland Bogoti
Caracas Hamburg Liabon London Madrid
Mexico Milan Montreal New Delhi Paris
San Juan S&o Paul0 Singapore
Sydney Tokyo Toronto
Library of Congress Cataloging-in-Publication Data
Hansen, Kenneth D.
Roller-compacted concrete dams / Kenneth D. Hansen, William G.
Reinhardt.
p. cm.
ISBN o-07-026072-9
1. Concrete dams. 2. Roller compacted concrete. I. Reinhardt,
William G. II. Title.
TC547.H26 1 9 9 1
624.2-dc20 go-41276
CIP
1 2 3 4 5 6 7 8 9 0 DOC/DOC 9 5 4 3 2 1 0
I S B N 0-07-026072-9
The sponsoring editor for this book was Joel Stein, the editing
supervisor was Dennis Gleason, the designer was Naomi Auerbach,
and the production supervisor was Suzanne W. Babeuf. This book was
set in Century Schoolbook. It was composed by McGraw-Hills
Professional Publishing composition unit.
I I
Preface ix
1 .l Background 1
1.2 Definition and Scope 1
1.3 Development of the RCC Dam 2
1.4 Three Paths Taken in RCC Dam Design 0
Bibliography 14
Bibliography 137
Bibliography 154
Bibliography 197
Bibliography 227
index 293
Preface
iX
X Preface
presented in Chaps. 4,5, and 6. The lean RCC dam and the high-paste-
content RCC dam are significantly different in their approach to mix-
ture and dam design. Our thanks go to Ernest K. Schrader and Malcolm
R. H. Dunstan for presenting their concepts for the lean and high-paste
RCC dams. As the development of the RCC dam moves forward, we
are seeing many designs moving in between these two approaches.
These may be termed medium-paste designs and include the Japa-
nese RCD method.
Acknowledgments
When you start to write an all-inclusive book on a specific subject,
you find there are certain chapters that you can proceed with directly
and others that require extensive research and outside assistance. This
means that you must rely on technical assistance and review from
many of your colleagues and friends.
In addition to thanking Ernest Schrader and Malcolm Dunstan for
contributing their specific chapters, special thanks goes to Francis A.
McLean for his input and editing of Chap. 2 and to Glenn S. Tarbox
for Chap. 10. Others who have made significant contributions from the
United States are Howard L. Boggs, Milton A. Kramer, Stephen B.
Tatro, Eric J. Ditchey, Louis H. Roehm, Garry Tucker, Cliff Schex-
nayder, Jeff Allen, Alvin Vissers, Charles C. Hutton, Alan T. Rich-
ardson, Dennis R. Hopman and J. Fred Burns. From Japan, assistance
came from Takeshi Yamauchi, Kentaro Takahi, and Shuhie Kazusa.
Others providing much needed aid were Frank Hollingworth of South
Africa, Brian A. Forbes of Australia, and Shen Chongang of China.
Others who have been involved with the development, technology, and
application of RCC dams are listed in the bibliography at the end of
each chapter. Our sincere appreciation is extended to all who have
participated in the production of this book. It is possible that some
worthy contributor has not been mentioned and, if this is the case, we
apologize.
Kenneth D. Hansen
William G. Reinhardt
Chapter
1
Development of a
New Type of Dam
1 .l Background
Roller-compacted concrete (RCC) dams emerged as a viable new type
of dam during the 1980s. They have gained acceptance worldwide in a
relatively short time due to their low cost, which is derived in part
from their rapid method of construction.
The RCC method evolved not only from the efforts of some influen-
tial concrete dam designers but also from the work of geotechnical en-
gineers who have traditionally designed earth and rockfill embank-
ments. Their combined efforts have produced a concrete dam built by
methods usually associated with earth dam construction. The product
is a less costly dam with the same inherent safety as a conventionally
placed concrete dam.
1
2 Chapter One
cement in dams. Some of the knowledge derived from the use of RCC
in pavements and soil-cement in dams does provide information for
the text, however.
The technology of mass concrete construction simply has not kept pace
with the art and science of earthmoving. It is time for a study into ways
of reducing the cost of concrete dams.. . .Dams must be conservatively de-
signed and carefully built. But it does seem that in all the years since
Hoover Dam, there should have been more change in the bucket-by-
bucket method of moving mass concrete into place. Whats needed is a lot
more systems analysis and a bit less grandpa-ism.
Several projects in the 1960s were designed with the idea of combin-
ing the advantages of concrete and embankment dams. These hybrid
dams were the brainchildren of both structural and geotechnical en-
gineers. Unfortunately, because of a high degree of specialization in
these fields, there was limited communication between the early the-
orists. Hence, there was little incremental understanding gained from
these early efforts.
The most notable and earliest example was the 564-ft-high (172-m)
Alpe Gera Dam in Italy, designed by structural engineer Giulio Gen-
tile and completed in 1964. The concept behind Alpe Gera was to
maintain the traditional cross section of the concrete gravity dam
while reducing the unit cost of placing the mass concrete. Some of the
cost reduction was accomplished by reducing the cement content in
the concrete mix used for the interior of the dam, where stresses are
low and durability requirements are minimal.
Placing this lean concrete using earthfill construction methods was
the greatest step forward, however. Instead of building the concrete
dam in vertical lifts to form cantilever blocks, horizontal placement
was introduced. Dump trucks delivered the interior concrete to the
_ dam rather than buckets moved by crane or cableway. Side forms for
blocks were eliminated, as were cooling coils. The consolidation of the
lean concrete by internal immersion vibration rather than external
roller compaction was about all that kept Alpe Gera from being the
first RCC dam (Fig. 1.1).
4 Chapter One
Figure 1.1 (CL) Ape Gera Dam; (b) Close-up from downstream.
Development of a New Type of Dam 5
Embankmemt
Figure 1.3 Tarbela Dam, Pakistan. From 1974 to 1986, 3.5 million yd3 of RCC were
placed.
at the site of Lost Creek Dam in Oregon in 1973. The field tests con-
firmed the basic construction method and provided information on
material properties and the strength of the bond between successive
layers of RCC. In fact, the name roller-compacted concrete may have
been first used by Corps investigators Hall and Houghton in reporting
on the Lost Creek test section.
Based on the data developed in these tests, the Corps Walla Walla
District in 1974 designed an RCC alternative for Zintel Canyon Dam
near Kennewick, Washington. Following up on Raphaels Optimum
Gravity Dam paper, the first dam section investigated in the design
was an embankment with a 45 face (1 H : 1 V) on the upstream and
downstream slopes. It was to be constructed almost entirely of a lean
RCC mixture, enriched only in the exposed exterior zones.
As initially proposed, however, the cross section contained too great
a volume of RCC to economically compete with the Corps original
rockfill embankment design. It was not until the designers reduced
the section to one more typical of a conventional concrete gravity dam
with a vertical upstream face that the RCC option was estimated to be
the most cost-effective solution for the flood control project (Fig. 1.41.
The Corps designers called their final RCC product the optimum
gravity dam.
Zintel Canyon Dam was not funded at the time, but many of its con-
cepts were carried over to Willow Creek Dam, another Corps flood
control project, at Heppner, Oregon. That 16sft-high (52-m) dam was
built in less than five months in 1982 and became the worlds first ma-
jor dam to be built entirely of RCC.
6.0 m 6.0 m
20ftOinT P I P20ftOin
*;fl
Thus, the lean RCC dam evolved from a concept in which a cement-
stabilized, controlled-gradation aggregate is placed and compacted
rapidly from abutment to abutment without forms or joints. In order
to make the idea work economically the slopes had to be steepened,
creating a need for some method of forming the vertical upstream
face. The initial plan at Zintel Canyon was to build an earth berm up-
stream to buttress and form the RCC mass. At Willow Creek, that
method was first specified as precast reinforced earth concrete pan-
els tied back into the RCC. Later, the contractor proposed to use ex-
ternally supported precast panels, combined with two coil rods per
panel set into the RCC, and that was the method adopted for the ac-
tual costruction.
The design and construction of the lean RCC dam alternative are
described by the principal designer of Willow Creek, Ernest K.
Schrader, in Chap. 4.
Figure 1.5Upper Stillwater Dam. (Courtesy of U.S. Department of the Interior, Bureau
of Reclamation, Upper Colorado Region.)
1964 Alpc Gera Dam, a 564-ft-high (172-m) concrete gravity dam in the
Itallan Alps was constructed like an earth embankment, using
dump trucks, dozers. and tractor-mounted immersion vibrators to
place lean concrete in horizontal lifts.
1970 Jerome Raphael presents a paper, The Optimum Gravity Dam, in
\rhlch hc proposes the concept of an embankment made of cement-
enriched, g-ranular pit-run material placed and compacted with
high-speed earth-moving equipment.
1970-1973 Research in the United States by the Tennessee Valley Authority at
Tims Ford Dam and by the Corps of Engineers at Jackson, Missis-
sippi. and at Lost Creek Dam helped to prove the economic feasi-
bility of RCC and to develop the construction methods for its mass
placement.
1975 The emergency repair of a collapsed outlet tunnel at Tarbela Dam
in Pakistan using RCC demonstrated the rapid placement rates
possible: 460,000 yd3 (350,000 m3) of RCC were placed in 42 work-
ing days.
1978 Research started four years earlier by Japans Committee on Ratio-
nalized Construction of Concrete Dams led to the start of RCC
placement for the body of Shimajigawa Dam, a 292-ft-high (89-m)
gravity dam.
1978 A full-scale trial of the use of high-fly-ash-content RCC together
with laser-controlled slip-formed facing elements was successfully
completed at Wimblehall Dam in England. This work on high-
paste RCC contributed significantly to the design in the early
1980s of the U.S. Bureau of Reclamations Upper Stillwater Dam
in Utah.
1982 The placement of 433,000 yd3 (331,000 m) of RCC in less than live
months for the U.S. Army Corps of Engineers Willow Creek Dam
in Heppner, Oregon, confirmed the rapid construction rates and
economic viability of dams built entirely of RCC.
1984 RCC came to the southern hemisphere with the design and con-
struction of Australias 131-ft-high (40-m) Copperfield Dam in only
10 months.
1984 The construction of 70-ft-high (21-m) Winchester Dam in Kentucky
using precast concrete panels and an attached polyvinylchloride
membrane to both form the RCC and provide an impervious up-
stream face initiated a concept that may be called a concrete-faced
RCC dam.
1985 The erosion resistance of exposed RCC was proven in the field when
Kerrville Ponding Dam in Texas, a 20-ft-high (6.1-m) RCC dam,
was overtopped during a flood by 14.4 ft (4.4 ml 30 days after con-
struction was completed. It was overtopped by 16.2 ft (4.9 m) due
to an even greater flood two years later, with no appreciable wear
of the RCC crest and downstream slope.
Bibliography
American Society of Civil Engineers (ASCE), Rapid Construction of Concrete Dams,
New York, 1970.
Avera, J. K., Jr., and K. D. Hansen: Dams That Never End, Wafer Power and Dam
Construction, March 1978.
Cannon, R. N.: Concrete Dam Construction Using Earth Compaction Methods, Eco-
nomical Construction of Concrete Dams, ASCE, New York, 1972, pp. 143-152.
Chao, P. C.: Tarbela Dam-Problems Solved by Novel Concretes, Civil Engineering,
ASCE, December 1980.
Chao, P. C., and H. A. Johnson: Rollcrete Usage at Tarbela Dam, Concrete
International: Design and Construction, vol. 1, no. 11, November 1979.
Dunstan, M. R. H.: Trial of Lean Rolled Concrete at the Tamar Treatment Works,
Report to the Southwest Water Authority, June 1977.
Dunstan, M. R. H.: Rolled Concrete-With Particular Reference to Its Use as a
Hearting Material in Concrete Dams, The Concrete Society, London, March 1978.
Dunstan, M. R. H.: Rolled Concrete for Dams-Construction Trials Using High-
Flyash-Content Concrete, CIRL4, Technical Note 106, London, May 1981.
Dunstan, M. R. H.: Rolled Concrete for Dams-A Laboratory Study of the Properties of
High-Flyash-Content Concrete, Construction Industry Research and Information
Association (CIRL41, Technical Note 105, London, May 1981.
Engineering News-Record Concrete Gravity Dam Built Like Earthtill, Dec. 24, 1964.
Esteves, V. P., J. Folque, and M. Rocha: The Application of Cement-Stabilised Soil in
the Construction of Earth Dams, Proceedings of the Fifth International Conference
on Soil Mechanics and Foundation Engineering, vol. 2, 1961, pp. 701-707.
Hall, D. J., and D. L. Houghton: Roller-Compacted Concrete Studies at Lost Creek
Dam, United States Army Engineer District, Portland, Ore., June 1974.
Hansen, K. D.: Roller-Compacted Concrete Dams Worldwide, Water Power and Dam
Construction Handbook, 1987.
Hirose, T., and S. Takebayashi: Present State and Problems of Rationalized Construc-
tion of Concrete Dams, Concrete Library of Japan Society of Civil Engineers, no. 2,
December 1983.
Humphreys, T. D., F. M. Jardine, and J. K. T. L. Nash: The Economic and Physical
Feasibility of Soil-Cement Dams, Proceedings of the Sixth International Conference
on Soil Mechanics and Foundation Engineering, vol. 2, 1965, pp. 517-521.
International Commission on Large Dams (ICOLD), World Register of Dams, 1984.
Jansen, Robert B.: Dams and Public Safety, United States Dept. of Interior, Bureau of
Reclamation, revised reprint, Denver, 1983.
Kokubu, M.: Development in Japan of Concrete Dam Construction by the RCD
Method, Technical Lecture at 52nd ICOLD Executive Meeting, Tokyo, 1984.
Portland Cement Association, Fact Sheet on Sly Creek Dam, Denver, 1973.
Raphael, J. M.: The Optimum Gravity Dam, Rapid Construction of Concrete Dams,
ASCE, New York, 1970, pp. 221-244.
Raphael, J. M.: Construction Methods for the Soil-Cement Dam, Economical Con-
struction of Concrete Dams, ASCE, New York, 1972, p. 217.
Sivley, W. E.: Zintel Canyon Optimum Gravity Dam, XII ICOLD Congress, vol. 5,
Mexico City, 1976, pp. 141-145.
Tynes, W. 0.: Feasibility Study of No-Slump Concrete for Mass Concrete Construc-
tion, Miscellaneous Paper C-73-10, United States Army Corps of Engineers Water-
ways Experiment Station, Vicksburg, Miss., October 1973.
Wallingford, V. M.: Proposed New Technique for Construction of Concrete Gravity
Dams, Xth ICOLD Congress, vol. 4, Montreal, 1970.
Chapter
2
Roller-Compacted
Concrete as a Material
15
16 Chapter Two
Characteristics of All voids not filled- Voids filled with paste & ex-
voids particle-to-particle con- cess
tact
Percent theoretical Usually less than 98% Greater than 98%
air-free density
145.
I I I
Material: Crushed limestone, 1.5 in MSA
Cement content: 5.5 96
by dry weight ofsolids
Fly ash content: 2.2 %)
140 -
Compactive effort
=32.5 ft+Ib/in3
(modified proctor-ASTM D15571
Compactive effort
= 13.3 **lb/in3
125 -
120. I I I
0 5 10 15 20
Moisture content, % dry wt. of solids
2.2 Laboratory moisture-density curves for RCC subjected to various
Figure
compactive energies. [From Reeves & Yates (1985)/
PUJ
Pd = -
1tw
18 Chapter Two
142
t I
P
\/
Compressive
strength curve
1600
P
Y
1 8 0 0 NC
5
i?!
1400 f
al
a
-rl=
1200 g
E
8
1000 6
1; Density curve \T i3
:,r?:4 5 6
Moisture
Moximum oggregolx size: 2.5 in
7 8
content, %
9
800
10 6oo
Mold size : 6 in X 12 in
Cement content: 4.0 %* Hommer: 10 lb
Fly-osh content: 3.0 %* Drop: 18in
Loyers: 6
*By dry weight oggreguk Blows: 123/layer
, .
Water/cement rotio
E
\
P. 100,
(1422)
E
:
I
t
tion and a delay in compaction, both of which can affect the results. Ag-
gregate gradings that are not uniform or that are deficient of sand may
be fully compacted yet still have coarse aggregate to coarse aggregate
contact, creating rock gaps or voids. Any delay in compaction from when
the water is added to the cement also causes reduced density. A one-hour
delay in compaction has been shown to cause as much as a 20 percent
reduction in seven-day compressive strength in laboratory specimens.
With all other factors being constant, the wetter consistency of the
mixes designed by the concrete approach usually results in somewhat
lower compressive strengths and less abrasion resistance than the drier
soils approach mixes. However, high-paste and RCD mixes usually pro-
duce improved bonding at the horizontal lift interfaces and reduced per-
meability along lift lines because of excess paste. Use of these mixes also
tends to produce fewer voids and less segregation at the bottom of lifts.
2.2.2 Aggregates
For RCC, like conventionally placed concrete, aggregate quality and
gradation are important factors influencing the final product. Slight
differences have occurred among designers in the selection of maxi-
mum size aggregate (MSA), the proportion of sand in the mix, and the
percentage of fines passing a No. 200 (0.75mm) sieve for RCC mix-
tures when compared with conventional concrete mixtures.
The segregation of coarse aggregate at the bottom of RCC lifts has
led to decisions to reduce the MSA in some cases or to increase the
proportion of sand in the mix in other cases. Most soils-approach RCC
mixes have a greater percentage of fines than conventional concrete
mixes. This is particularly so if the fines are nonplastic, fill voids in
the aggregate, and lead to decreased water demand and improved
compactibility.
In some instances, aggregate produced for applications other than
concrete can be used in RCC. Among them, an available free-draining
gravel produced for a zone in an embankment dam and a gravel base
course and an aggregate produced for asphalt paving have been used
for some small projects. The function of the completed structure and
the minimum required properties of the RCC should determine what
aggregate is chosen.
Rounded river gravels and crushed aggregates have been used for
RCC. At Copperfield Dam, difficulty was encountered maintaining an
24 Chapter Two
2.2.2.2 Grading. Grading for both coarse and fine aggregate (less
than 4.75 mm) and the proportions used have an important effect on
the properties of RCC. Specifications for grading of aggregate have
varied considerably.
Because the goal for concrete approach mixes is to fill all aggregate
voids with paste, a well-graded aggregate designed to produce mini-
mum voids is more important for these mixtures than for soils ap-
proach mixtures. For many of those, the goal has been to use an ac-
ceptable grading that results in the lowest overall cost of the RCC.
The difference in mix design philosophy has produced some differ-
ing trends with respect to specifying aggregates for RCC. This is es-
pecially true with respect to maximum size aggregate (MSA), percent-
age of sand and fines desired, and the number of separate sizes
processed and then combined to produce the desired grading.
For concrete-approach RCC mixes, aggregate requirements are very
Figure 2.6 Characteristics and tests for aggregates for RCC dams.
Test designation
Characteristic Significance (U.S.) Test name
-
Grading Consistency, compactability ASTM Cl36 Sieve Analysis of Fine and Coarse
economy Aggregate
ASTM Cl17 Materials Finer than 75 km (No.
266) in Mineral Aggregates by
Washing
Resistance to abrasion Aggregate quality, wear re- ASTM Cl31 Resistance to Degradation of Small
sistance of surface Coarse Aggregate by Abrasion and
Impact in the Los Angeles Ma-
chine
ASTM C535 Resistance to Degradation of large
Coarse Aggregate by Abrasion and
Impact in the Los Angeles Ma-
chine
ASTM C295 Petrographic Examination of Ag-
gregates for Concrete
Specific gravity-absorption Mix design calculations ASTM Cl27 Specific Gravity and Absorption of
Coarse Aggregate
ASTM Cl28 Specific Gravity and Absorption of
Fine Aggregate
Bulk unit weight or density Mix design calculations ASTM C29 Unit Weight and Voids in Aggre-
gate
Sulfate resistance Soundness against weather- ASTM C88 Soundness of Aggregates by So-
ing and chemical attack dium Sulfate or Magnesium Sul-
fate
Organic impurities Strength gain ASTM C40 Organic Impurities in Fine Aggre-
gate for Concrete
26 Chapter Two
90 SIX % Filssln~
4 I 100
80 3 I 98 - 100
2 in 86- 96
I-1/2in 72- 92
1 I 56- 66
3/4 I 49- 5 9
3/6 I 38-48
No. 4 30- 4 0
No 6 23- 3 3
No. 16 16- 26
Na 3 0 13- 2 3
No. 50 lo- 16
No. 100 7- 1 4
No. 200 i5- 1 0
10
0
3
Gram SILOS. mm
GV.lVd I Sand Slit or clay
Cobbles Fine
Coarse Fins Medium
(a)
2R I 100
2 in 95 - 100
?E 7 0 3 in 60 - 85
.P
% 60 shin 42- 5 4
0
h 50 No 4 30-42
F 40 No. f3 23 - 35
%
; 30 No. 30 10-21
a No. 200 4 - 12
20
0
100 50 10 5 1.0 0.5 0.1 005 001
Gram sizes. mm
GWVd I Sand
coarse 1 Fine 1 coarse 1 Medium Fine
(b)
Figure 2.7 Two RCC aggregate gradation bands. (a) Galesville Dam; (b) Stacy
Dam. [From Oberholzer (1985); Lemons (1988j.J
28 Chapter Two
2.2.3 Water
The only requirement for water in RCC mixes is that it be free from
excessive amounts of alkalis, acids, or organic matter that might in-
hibit proper strength gain. Most RCC mixes require 150 to 200 lb of
water per cubic yard (89 to 119 kg/m31 for MSA greater than 2 in (50
mm).
2.2.4 Admixtures
With little success, air-entraining, as well as water-reducing and set-
retarding, admixtures have been tried in RCC mixtures, with propor-
tions based on soils principles. Due primarily to the dry consistency
and fines content of these mixes, a proper air-void system has not been
established at any application rate using normal batching or propor-
tioning procedures.
There is a better chance for admixtures to be effective in wetter-
consistency mixes associated with the concrete approach. Air-
entraining and water-reducing admixtures are introduced into all
Japanese RCD mixtures. A water-reducing, set-retarding admixture
was used in the RCC for Elk Creek Dam. A relatively high dosage of
14 to 21 oz per hundredweight (0.87 to 1.3 kg per 100 kg) of portland
cement showed good results. Batch water was reduced by 27.5 lb/yd3
(16.3 kg/m31 and the initial design Vebe time was reduced from 20 to
10 s. Mix design investigations revealed that the use of the water re-
Roller-Compacted Concrete as a Material 29
modified Proctor test procedure for soils (ASTM D1557). The test em-
ploys a lo-lb (4.5-kg) hammer that drops 18 in (450 mm) before strik-
ing the surface of the test material. The actual modified compactive
effort equates to 32.55 ft-lb/in3 (2693 kJ/m3).
Lowe used modified Proctor compaction in 1960 to determine the op-
timum moisture content for the rollcrete core of the cofferdam at
Shihmen Dam in Taiwan. A ll-in-diameter (356-mm) compaction
mold was used to perform the tests on the RCC, which was made with
a 3-in (75mm) MSA.
Reeves and Yates later determined that lab specimens compacted
with modified Proctor compactive effort correlated very well with
measured dry densities for the North Loop detention dams at Austin,
Texas, for an RCC made with 1.5-in (38-mm) MAS limestone. The
RCC was placed in the cylinder in six 2-in (50-mm) layers and re-
ceived 122 blows per layer.
More recent tests by Casias, Goldsmith, and Benavidez of the U.S.
Bureau of Reclamation indicate a lower compactive effort may be
more appropriatae than the modified Proctor test procedure. They
found that the modified Proctor compactive effort using the standard
hammer caused too much fracturing of the coarse aggregate. The
amount of aggregate fracturing or gradation change during impact
compaction tests is a function of the particular aggregate. Hard, sound
aggregate should be able to absorb more energy without breakdown.
They concluded that a compactive efort of 13.3 ft-lb/in3 (1100 kJ/m3)
provided better test speciments by impact compaction. This degree of
compaction was obtained by placing the RCC in six 2-in (50-mm) lay-
ers and giving each layer 50 blows.
Wong et al. also noted the breakage of aggregate using the small
sector-shaped hammer associated with the modified Proctor test pro-
cedure. They therefore developed a new rammer contact face consist-
ing of a 5.5-in-diameter (140-mm) flat disk with rounded edges. The
total rammer weight remained at 10 lb (4.5 kg). There was a %-in.
(6-mm) clearance between the disk and the mold. A higher density
was achieved with the modified rammer compared with the standard
rammer for the same 93 blows given to each of three 4-in (lOO-mm)
layers. The tests were done without cementitious materials and the
difference amounted to 1.3 lb/ft3 (20.8 kg/m31 greater density. The
compactive effort used was equal to 12.2 ft-lb/in3 (1,009 kJ/m3).
rigidly clamped to the same vibrating table used in the Vebe test (see
Sec. 2.3.2.2) and filled in three equal layers. A 20-lb (9.1-kg) weight is
placed on top of each layer and the cylinder is vibrated until paste
forms around the edge of the surcharge. After the third repetition, the
excess concrete is struck off and the cylinder is capped for later test-
ing. This method is described in the U.S. Bureau of Reclamation stan-
dard 4906-86. A similar method is used for the RCD method in Japan
except the size of the specimen is approximately 9 in (240 mm) in di-
ameter with a height of 8 in (200 mm).
(a) (b)
Figure 2.9 (a) Kango hammer and (b) Hilti gun to prepare RCC cylinders.
Camp. Camp.
strength, Core strength, Greater
lb/ins dia., in lb/in* strength at
Dam Mix* Age (MPal Age (mm1 (MPal equal age
A. Pole Tamper for Cylinder Preparation
1 . Willow Creek A Iint.1 1 yr 2623 1 yr 8 2300 Cylinders
B (upstr.1 1 yr 3779 1Yr 8 2150 Cylinders
C (down) 1 yr 4146 1Yr 8 3220 Cylinders
6. Asahi Ogawa
are needed. The American Society for Testing and Materials estab-
lished a committee to develop such standards in 1988.
The basic consistency test for no-slump RCC was conceived during
the 1970s by Cannon of the Tennessee Valley Authority. He used a
nonstandard vibrating table, a cylinder filled to the top, and no sur-
charge. Most agencies now use a modified Vebe test. It makes use of
the same %-ft3 (0.0094-m3) container and vibrating table (made by
Dynapac Maskin AB of Sweden) used in the Cannon test. The modifi-
cation is the addition of a surcharge to the loose, leveled concrete. A
weighted Vebe apparatus is shown in Fig. 2.11.
The total weight of the surcharge used varies considerably. In Ja-
pan it is 44 lb (20 kg). The Corps of Engineers uses 27.5 lb (12.5 kg),
and the Bureau of Reclamation uses 50 lb (22.7 kg). As the surcharge
weight increases, the tendency is for the Vebe or VC time to decrease
for the same mix. In the mix design investigations for Upper
Stillwater Dam, a Vebe time of 35 to 45 s was obtained with no sur-
charge. That compared to 25 to 35 s with a 50-lb surcharge for the
same mix.
RCD tests in Japan are done using tables that vibrate at 4000 cycles
per minute (pm) (versus 3600 cpm for the tables initially manufac-
tured in Sweden). Two sizes of containers are used in Japan. The stan-
dard container for RCD has about the same volume as the standard
Vebe container but is about 8 in (200 mm) deep and 9.4 in (240 mm) in
diameter. It is used for preliminary mixture proportioning studies and
for quality control during construction. For tests on mixtures with
Large container
5 0 -
Standard container
OL I I I
110 120
(186.3) (202.5)
Watercontent, kg/m3 (Ib/yd3)
ders prepared for testing at 3, 7, 14, 28,90, 180, and 365 days. If there is
insufficient time to obtain results at later ages, the compressive
strengths can be estimated based on the curve shape for the early ages,
test results from previous projects using the same method , or by accel-
erated test methods. Initial work on accelerated laboratory tests for RCC
mixtures were accomplished by Forbes for Bucca Weir in Australia and
Logie and Oliverson for the not yet constructed Pamo Dam.
The mix design program thus provides a family of curves that indi-
cate the effects of various cementitious contents on compressive
strength at various ages. The cement content can be selected to meet
project requirements with consideration of factors of safety and coeffi-
cients of variation. Once a cement content is selected, additional tests
may be run with varying aggregate types or gradings, especially the
percentage of fines passing the No. 200 (0.075-mm) sieve.
The coefficient of variation of compressive strength of cylinders
from six projects using the lean RCC mix design method and prepared
using pneumatic pole tampers has ranged from 22 to 28 percent. In
addition to material variations, a visual means of determining water
content and the nonstandard means of cylinder preparation are major
factors in producing coefficients of variation of this magnitude.
2.4.1.2 The simplified soils method. RCC mixtures have been propor-
tioned since 1960 using soil compaction principles. The same funda-
mentals have been the basis for determining cement content for soil-
cement mixes for more than 50 years. The basic method is quite
similar to the lean RCC method in that it starts with a fixed aggre-
gate grading and involves a test program of varying cementitious con-
tents and comparing results once a water content is determined. An
aggregate grading band for Stacy Dam in which the mix was designed
using this method is shown in Fig. 2.7.
Rather than a visual determination of water content, the opti-
mum moisture content is determined by the moisture-density princi-
ples described in Sec. 2.1.1, using impact compaction with a standard
hammer or rammer dropped a prescribed number of times. A modified
Proctor compactive effort of 32.55 ft-lb/in3 (2693 kJ/m3) has been used
for most actual projects, although some lesser compactive effort has
been suggested by some researchers (see Sets. 2.3.1.1 and 2.3.1.4). The
number of blows from a lo-lb (4.5-kg) hammer dropping 18 in (450
mm) per unit volume defines the compactive effort.
To solve the aggregate breakage problems encountered by some re-
searchers with the standard modified Proctor rammer, the larger, 5.5-
in-diameter (140-mm) flat disk with rounded edges may be used (see
Sec. 2.3.1.1). The remaining steps in the mix design method are then
identical to those described for the lean RCC method (Sec. 2.4.1.11.
42 Chapter Two
The simplified soils method has been used with a fixed conservative
cementitious content for some relatively small volume dams where
heat generation was not a concern and where time for a longer, more
extensive mix design program was not available. The North Loop de-
tention dams in Austin, Texas (see Sec. 7.2.6.21, used a set 200-lb/yd3
(119 kg/m3) of cement and 80 lb/yd3 (47 kg/m3) of pozzolan in the RCC
mix.
Likewise, this mix design method has been used extensively for the
modification or rehabilitation of existing dams where the primary de-
sign consideration for the exposed RCC has been the durability and/or
erosion resistance of the material. In these cases, the laboratory in-
vestigation can involve varying cementitious contents to achieve a de-
sired level of durability as measured by the loss of weight after 12 or
more cycles of freezing and thawing similar to that developed for soil-
cement. The design mix durability can also be based on the loss of
weight of specimens subjected to high-velocity water jets or on a min-
imum compressive strength. For many of the mixes designed by the
simplified soils approach, the cement and pozzolan contents are ex-
pressed as a percentage of dry weight of aggregate. The percentages
are helpful in the volumetric proportioning of RCC associated with
most pugmill mixing operations.
2.4.2.2 The Japanese RCD method. Criteria for mixes designed for the
RCD method include:
F i g u r e 2 . 1 3 Fklationship b e -
tween cementitious content and
compressive strength with age
f o r T a m a g a m a D a m . [From
Yamauchi et a1.M
Age, days
12. Convert all absolute volumes to batch weights and prepare trial
batches to determine Vebe-time consistency and measured air
content.
13. Adjust the mix as necessary to produce the desired consistency.
ASIA
I I I I
1 . Kengkou 15 101 135 165 0 . 4 7 WRA 0.70 0.57 3.1 1345 2309 36.6
(60) (80) (98) (0.28) (80) (798) (1370)
United States
1 . Willow Creek A (interior mass) - 80 II 32 180 0 1.61 0.29 3 total 3956 (1 size) -
(47) (19) (107) (75) (2347)
B (upstream) - 175 II 0 185 0 1.06 0 3 total 3902 (1 size) -
(104) - (110) (7.5) (2315)
C (downstream) - 175 II 80 185 0 0.73 0.31 3 total 3826 (1 size) -
(104) (47) (110) (75) (2270)
5. Grindstone Canyon (upper portion) - 130 0 200 0 1.54 0 3.5 1361 2500 33.8
(77) - (119) (89) (781) (1531)
7. Lower Chase Creek 20 108 v 67 180 0 1.03 0.38 2.5 1203 2445 33.0
(64) (40) (107) (63) (714) (1451)
8. Upper Stillwater A (interior) 19 134 II 290 171 17 oz. wR4 0.40 0.68 2 1148 2213 34.1
179) (172) (658 cm? (50) (681) (1313)
B (upstream) 15 155 II 343 169 21 oz. wR4 0.34 0.69 2 1162 2128 35.3
(92) (203) (100) (812 cm? (50) (689) (1262)
9. Elk Creek Spring 1987 10 118 II 56 174 41 oz. WRA 1.00 0.32 3.0 1227 2422 33.6
17-21 (70) (33) (103) t set (75) (728) (1439)
retarding
( 1586 cm?
(Continued)
I t
Figure 2.14 RCC mixture proportions for dams. (Continued)
L
Vebe or Cement* Pozzolan Water, MSA, Sand CA 5%
Mix v c lb/yd3 lb/yd3 lb/yd3 Admixtyre, w 2-t in lb/yda Ib/yda sand
Dam designation t i m e , e (kg/m? (kg/m? (kg/ma) lb/yd3 C t P 1C t P (mm) (kg/m? (kg/m31 (by wt.1
NORTH AMERICA
United States
10. Stagecoach - 120 130 233 0 0.93 0.52 2.0 1156 2459 32.0
(11-V)
(711 (77) (1381 (501 (6861 (14591
11. Stacy Spillway 210 105c 259 0 0.82 0.33 1.5 total 3500 (1 size) -
(now S.W. Freese) (125) (621 (1541 (381 (20761
12. Marmot- lo 120 180 175 4 1 oz. WRA 0.58 0.60 3 1270 2060 38.1
Replacement (71) (107) (104) t set (751 (7531 (12221
(1586 cm 1
I I I I retardin5 II II I I
Mexico
1. La Manzanilla 6% by 3
wt. (751
AUSTRALIA
1 . Copperfield A (exterior1 185 II 0 219 0 1.18 0 2 toted 3 5 7 3 (1 size) 4 0 . 0
(1101 - (130) (501 (21201
B (interior) 135 II 51 219 0 1.18 0.27 2 total 3573 (1 s i z e ) 4 0 . 0
(801 (301 (130) (501 (21201
2. Craigbourne 118 II 101 197 0 0.90 0.46 2 total 3 8 3 5 (1 size) 36.0
(70) (601 (1171 (531 (22751
3. Bucca Weir - 152 II 152 185 0 0.61 0.50 1.6 total 3523 38.0
(90) (90) (110) (401 (2090)
AUSTRALIA
4. Wrights Basin - 244 122 266 0 1.00 0.33 1.6 totd 3329 (1 size) -
(145) (72.5) (158) (40) (1975)
EUROPE
Spill
1. Castilblanco de 10s (upper) 38 147 II P 158 185 0 0.56 0.61 1.6 1126 2421 31.7
Arroyos (87) (94) (101) 140) (668) (1440)
(lower) 46 172 II P 144 172 0 0.54 0.57 1.6 1334 2447 31.6
(142) (85.5) (102) (40) (672.5) (1462)
2. Erizana - dike - 152 IP 152 193 0 0.64 0.60 4 930 2798 24.9
(90) (90) (115) (100) (552) (1660)
3. Los Morales (upper) 116 258 170 0 0.45 0.69 1.6 1104 2394 31.6
(69) (153) (101) (40) (655) (1420)
(middle) 121 214 165 0 0.49 0.64 3.1 944 2562 26.9
(72) (127) (98) (80) (560) (1520)
France
1. Les Olivettes 148 R 79 211 0 0.93 0.35 2.5 total 3756 (1 size) -
(88) (47) (125) (63) (2250)
USSR
1. Tashkumy (lower) 20-30 202 IPN - 177 0.51 WRA 0.875 0.25 2 total 3708 30.4
(120) (105) (0.30) (50) (2200)
(upper) 20-30 169 - OAZWRA 0.25 2 total 3708
IP(N)
(100) (0.25) (50) (2200)
(Continued)
Figure 2.14 RCC mixture proportions for dams. (Continued)
AFRICA
South Africa
1. De Mist Kraal - 98 98 177 2.0 oz air 0.91 0.50 3 1241 2918 29.8
Diversion (58) (58) (105) (78 cm3) (75) (736) (1731)
4. Knellpoort 103 239 172 0 0.50 0.70 2.0 1175 2820 29.4
(gravity arch) (61) (142) (102) (50) (697) (1673)
Morocco
SOUTH AMERICA
Brazil
1. Saco de Nova (lower) - 12711P - 284 0 2.24 approx. 3 694 2935 19.1
Olinda (75) (168) 0.20 (75) (410) (1735)
-I
1. Urugua-i - 101 0 111 0 1.75 0 3.0 - - 49.0
IbJ) 1 (0) (105) (75)
NOTE: M S A = m a x i m u m 3
admixture.
*I = ASTM Type I or ordinary ortland cement (OPC) unless noted; IP = ASTM Type IP
Portland-pozzolan cement; II = A 8 TM Type II; V = ASTM Type V.
F = ASTM Class F (low-lime); unless noted C = ASTM Class C (high-lime); N = ASTM Class N
(natural); S = Ground blast-furnace slag (called sla ent in South Africa); unless noted
R = ROLAC (a mixture of 60%. OPC, 35% S & 5%%estone dust).
Includes proportion of pozzolan in portlanh-pozzalan cement.
Passing 4.75mm U.S. or 5.0-mm sieve unless noted.
8
54 Chapter Two
tal direction. Most testing has been performed on cores and cylinders
in only one direction, however, so few data are currently available on
the anisotropic properties of hardened RCC.
/Vibrated
A-
0 I I I I I
2 3 4 5 6 7 8
Calculated moisture carrtent(SSD),%
2.5.1.2 Tensile strength. Tensile strength of RCC for dams can either
be determined by tests to measure direct tension or splitting (indirect)
tension. The splitting tension test is also known as the Brazilian test.
For conventional concrete dams, splitting tension tests of cores show
strengths averaging about 10 percent of compressive strengths. Direct
tension tests of the same cores show tensile strengths at about 5 per-
cent of compressive strengths or about half that of splitting tension.
An analysis of RCC mixes for nine dams, after discarding the high
and low values to obtain a more representative average, shows split-
ting tension to average 13 percent of compressive strength. The range
was from 11.9 to 14.3 percent.
Because of its steep downstream slope, Upper Stillwater is the only
RCC dam constructed to date for which the direct tensile strength of
the RCC was the primary design criteria. A minimum direct tension
of 180 lb/in (1.24 MPa) at one year was required. Laboratory tests of
the proposed high-paste mix using sandstone aggregate produced 220
lb/in2 (1.52 MPa) or 4.4 percent of its compressive strength of 5000 lb/
in2 (34.5 MPa) at one year.
The cohesion is also called the bond stress, whilep tan + defines the
sliding friction resistance. A direct shear test is the usual method for
obtaining cohesion and angle of friction data using various normal
loads. McLean and Pierce have summarized shear strength data for
the RCC parent material and bonded and unbonded RCC joints, and
compared the RCC results with conventional concrete shear values
(see Fig. 2.16). They note that there is significant scatter in the values
because test data are obtained from a variety of mixtures and materi-
als, information sources, and test procedures.
The break bond shear strength may also be called the peak
strength, and the sliding friction values referred to by McLean and
Pierce denote the residual shear strengths.
Range of values
Break-bond Sliding friction Statistical Evaluation
2.5.3 Permeability
The total seepage through an RCC dam is the sum of the water pass-
ing through the material itself plus that through any cracks or joints
in the structure. Measured seepage through RCC dams in service is
discussed in detail in Chap. 11.
Permeability values for RCC mixtures have ranged from 2 x 10m2
Compressive Creep
Age, strength, E Poissons coefficient
Dam Mix days lb/in (MPa) (X 10s) ratio (X 10-Y
Willow Creek A 7 577C4.0) 1.20 - 1.97
28 1172(8.1) 1.59 0.14 1.09
90 1730(11.9) 1.91 0.17 0.52
B 7 997C6.9) 2.20 0.48
28 1845c12.7) 2.67 0.19 0.34
90 2649c18.3) 2.78 0.18
c 7 1147(7.9) 2.40 - 0.58
28 2056c14.2) 2.91 0.21 0.39
90 3961f27.3) 3.25 0.21 0.31
Middle Fork 28 127Oc8.8) 0.98 0.16
Galesville A 14 mo.* 2095C14.4) 3.23 0.19
B 1 4 mo.* 2000(13.8) 3.29 0.22
Monksville 28 745(5.1) 0.90
Upper Stillwater A 28 0.66
105 3925C27.1) 1.96 0.23
365 5171(35.7) 2.07 0.29 0.53
Les Olivettes 28 1905(12.7)
90 2130(14.7) 2.85
Saco de Nova 7 1.04 2.15
Olinda 28 1.79 1.28
360 - 0.32
*Properties from cores extracted from dam-all other properties obtained from 6 x 12
in (152 x 304 mm) cylinders prepared by pnuematic tamping.
cm/s for the lean mix A at Willow Creek Dam to 4 x lo- lo cm/s for the
high-paste mix A used at Upper Stillwater Dam, as shown in Fig. 5.1.
Dunstan proposes in Chap. 5 that impermeability is the single most
important property of the RCC mix, and impermeability of RCC can
be directly related to its cementitious content, also as shown in Fig.
5.1. This fact is especially applicable to RCC mixtures than conform to
the concrete approach where the paste exceeds the voids in the aggre-
gate. Therefore, greater cementitious contents produce a more water-
tight paste, which controls the permeability of the RCC material. For
soils approach mixes, greater impermeability can be achieved by a
combination of increased cementitious content, greater compaction,
and sufficient well-graded fine aggregate, all of which reduce voids in
the material.
2.5.4 Durability
The durability of RCC is especially important if the material is ex-
posed to weather or severe hydraulic forces. Its durability has been
documented by both laboratory tests and case studies in the field.
Adiabatic rise, F (0
Specific heat, Diffusivity, Conductivity, Coeff. of exp.
BtulIb . F ftzlb Btulftlh . F in/in.F x 10e6 InitiaI
Dam Mix (k Cal/kg. C) (m/h) x 10m3 (k &/m/b . 0 m m / m m . C x lo- T e m p . 3-day 7-day 2%day
ter and cement than conventional concrete, RCC shrinks less in the
hydration process.
Bibliography
Abrams, D. A.: Design of Concrete Mixtures, Bulletin No. 1, Structural Materials Re-
search Laboratory, Lewis Institute, Chicago, 1918.
American Concrete Institute, Roller-Compacted Mass Concrete, Report 207.5R 1988.
American Concrete Institute Standard Practice for Selecting Proportions for Normal,
Heavyweight and Mass Concrete, Report 211.1, 1989.
Bahrner, V.: New Swedish Consistency Test Apparatus and Method, Betong
(Stockholm), no. 1, 1940, pp. 27-38.
Bouyge, B., A. P. Langois, and J. P. Martin, Quality of Works in RCC in France: A
Contractors Solution, Roller-Compacted Concrete II, ASCE, New York, February
1988, pp. 309-322.
Casias, T. J., V. D. Goldsmith, and A. A. Benavidez: Soil Laboratory Compaction Meth-
ods Applied to RCC, Roller-Compacted Concrete II, ASCE, New York, February
1988, pp. 107-122.
Crow, R. D., T. P. Dolen, J. E. Oliverson, and C. D. Prusia, Mix Design Investigation-
Roller-Compacted Concrete Construction, Upper Stillwater Dam, Utah, Bureau of
Reclamation Report REC-ERC-84-15, June 1984.
Dolen, T. P., A. T. Richardson, and W. R. White, Quality ControllInspection-Upper
Roller-Compacted Concrete as a Material 63
Stillwater Dam, Roller-Compacted Concrete 11, ASCE, New York, February 1988,
pp. 277-293.
Dunstan, M. R. H.: A Method of Design for the Mix Proportions of Roller-Compacted
Concrete To Be Used in Dams, Transactions, 15th ZnternationaZ Congress on Large
Dams, (Lausanne 1985), International Commission on Large Dams, Paris, vol. 2, pp.
713-738.
Forbes, B. A., The Development and Testing of Roller-Compacted Concrete for Dams in
Australia, Transactions 16th International Congress on Large Dams (San Francisco,
1988), International Commission on Large Dams, Paris, vol. 3, pp. 89-117.
Hirose, T., and 1. Yanagida, Some Experiences Gained in Construction of Shimajigawa
and Okawa Dams. Proceedines. CZRZA International Conference on Rolled Concrete
for Dams, Construction Industry Research and Information Association, London,
June 1981.
Hirose, T., and T. Yanagida: Burst of Growth Demands Speed, Economy, Concrete ln-
ternational, May 1984.
Hollingworth, F., and F. H. W. M. Druyts, Rollcrete: Some Applications to Dams in
South Africa, Water Power & Dam Construction, January 1986, pp. 13-16.
Hopman, D. R., and D. R. Chambers, Construction of Elk Creek Dam, Roller-
Compacted Concrete 11, ASCE, New York, February 1988, pp. 251-266.
Johnson, H. A., and P. C. Chao: Rollcrete Usage at Tarbela Dam, Concrete
International: Design and Construction, vol. 1, no. 11, November 1979.
Lemons, R. M.: A Combined RCC and Reinforced Concrete Spillway, Roller-
Compacted Concrete 11, ASCE, New York, February 1988, pp. 51-60.
Logie, C.V., and Oliverson, J.E., Roller Compacted Concrete Mix Design for Pamo
Dam, Roller-Compacted Concrete 11, AXE, New York, February 1988, pp. 187-202.
Lorenzo, A., G. L. Oberholtzer, and E. K. Schrader: Roller-Compacted Concrete Design
for Urugua-i Dam, Roller-Compacted Concrete 11, ASCE, New York, February 1988,
pp. 357-368.
Lowe, J., III: Use of Rollcrete in Earth Dams, discussion of Utilization of Soil-Cement
as Slope Protection for Earth Dams by W. G. Holtz and F. C. Walker; First ASCE
Water Resources Engineering Conference, Omaha, Nebraska, 1962 (not published in
proceedings).
McLean, F. G., and J. S. Pierce: Comparison of Joint Strengths for Conventional and
Roller-Compacted Concrete, Roller-Compacted Concrete 11, ASCE, New York, Feb-
ruary 1988, pp. 151-169.
Mageroy, H., RCC Pavement Developments in Norway, Draft paper for publication in
Journal of Construction Division of ASCE.
Neville, A. M.: Properties of Concrete, 3rd ed., Pitman, London, 1981.
Oberholtzer, G. L.: Galesville Project Materials Engineering for Roller-Compacted
Concrete, Roller-Compacted Concrete Seminar, ASCE Southern Idaho Section,
April 1985.
Parent, W. F., W. A. Moler, and R. W. Southard, Construction of Middle Fork Dam,
Roller-Compacted Concrete, ASCE, New York, May 1985, pp. 71-89.
Portland Cement Association: Soil Cement for Water Control: Laboratorv Tests.
Skokie, Ill., 1976, 26 pp.
Portland Cement Association: Design and Control of Concrete Mixtures, 13th ed.,
Skokie, Ill., 1988.
Proctor, R. R.: Fundamental Principles of Soil Compaction, Engineering News-Record,
vol. III, Aug. 31-Sept. 28, 1933, pp. 245-248, 286-289, 348-351, and 372-316.
Quin, J. T., S. P. Rezende, and E. K. Schrader, Saco Dam-South Americas First RCC
Dam, Roller-Compacted Concrete 11, ASCE, New York, February 1988, pp. 340-356.
Reeves, G. N., and L. B. Yates, Jr.: Simplified Design and Construction Control for
Roller-Compacted Concrete, Roller-Compacted Concrete, American Society of Civil
Engineers (ASCE), New York, May 1985, pp. 48-61.
Schrader, E. K., and D. Namikas, Performance of Roller-Compacted Concrete Dams,
Transactions 16th International Congress on Large Dams @an Francisco, 19881, In-
ternational Commission on Large Dams, Paris, vol. 3, pp. 339-364.
Tayabji, S. D., and A. S. Okamoto: Bonding of Successive Layers of Roller-Compacted
Concrete, Construction Technology Laboratories, Skokie, Ill., March 1987.
64 Chapter Two
US. Army Corps of Engineers: Willow Creek Dam Concrete Report, vol. 1 and 2,
Walla Walla. Wash.. October 1984.
U.S. Army Corps of Engineers: Roller-Compacted Concrete, EM 1110-2-2006, August
1985.
U.S. Bureau of Reclamation: Guidelines for Designing and Constructing Roller-
Compacted Concrete Dams, June 1987.
U.S. Bureau of Reclamation: Procedure for Casting No-Slump Concrete in Cylinder
Molds Using Vibratory Table, procedure 490686.
Urlich, C. M., J. D. Deatheridge, J. H. Rahe, and R. E. Dunne, Design and Construc-
tion of Lower Chase Creek Dam, Roller-Compacted Concrete II, AXE, New York,
February 1988, pp. 236-250.
Wong, N. C., J. A. Bischoff, and D. H. Johnson: Strengthening and Raising Gibraltar
Dam with RCC, Roller-Compacted Concrete IZ, AXE, New York, February 1988,
pp. 92-106.
Yamauchi, T., J. Harada, T. Okada, and S. Shimada, Construction of Tamagawa Dam
by the RCD Method, Transactions, 15th International Congress on Large Dams
(Lausanne, 19851, International Commission on Large Dams, Paris, vol. 2, pp. 39-
114.
Chapter
3
Design of
RCC Gravity Dams
3.1 Background
Roller-compacted concrete has been used primarily for gravity-type
dams to date, and the design of gravity dams will be emphasized in
this chapter. The design of a gravity dam using RCC is fundamentally
no different from the design of a gravity dam constructed of conven-
tional concrete. Therefore, many of the principles and formulas for
gravity dam design will not be repeated here. A good reference for ba-
sic dam design is the text Design of Gravity Dams, prepared by the
U.S. Bureau of Reclamation WSBR).
This chapter will focus on the differences between RCC dams and
conventional concrete gravity dams in the design of their sections and
appurtenant structures. Philosophies and details for the lean RCC,
high-paste RCC and Japanese RCD approaches to gravity dam design
are described in Chaps. 4, 5, and 6, respectively. Therefore, this chap-
ter will concentrate on the overall design of RCC dams, keeping in
mind those different design approaches.
References are made to low, moderate-height, high, and very high
dams in this and other chapters in the book. A low dam is defined as
one that has a structural height of less than 100 ft (30 ml, a moderate-
height dam is one ranging from 100 to 300 ft (30 to 90 ml, a high dam
is one from 300 to 500 ft (90 to 150 m), and a very high dam is greater
than 500 ft (150 ml.
65
66 Chapter Three
ever, because RCC costs less per unit volume than conventional mass
concrete, designers have more freedom in optimizing the selection of
the site. They are no longer tied as strongly to a site that minimizes
the volume of concrete in the dam structure.
Designers can now investigate other sites where a larger-volume
RCC dam may be required to maximize the benefits of the entire
project. Those benefits could include increased pool storage, greater
power head, and shorter penstocks for a hydroelectric project.
In preparing preliminary designs and cost estimates for alternative
dam types, the optimum location of an RCC dam may be different
from the optimum location of an embankment dam. This will depend
primarily on the topography and geology of the site. Such was the case
in studies for Pamo Dam, where the optimum location for the RCC
dam was 0.8 mi (1.3 km) downstream from the optimum earthfill dam
site. The downstream RCC site was selected to reduce foundation
preparation and pipeline transmission costs. Also, there was little
need for the RCC site to be located close to the borrow pits for the
earthfill alternative.
of the grout curtain can vary from 40 percent of the head for dense
foundations to 70 percent in poorer-quality rock foundations according
to USBR criteria.
Another guideline suggested by Simmonds is that:
D=$+C
Drain holes are usually provided in rock foundations for all but
some low to moderate-height dams to reduce uplift pressures in the
foundation and improve the stability of the dam. They are usually lo-
cated immediately downstream of the grout curtain and consist of 3-
in-diameter (75-mm) holes spaced 10 ft (3 m) on center. The function
of the drain holes is to intercept and remove any seepage water by-
passing the grout curtain and thus reduce the buildup of hydraulic
pressure (uplift) beneath the dam.
At Upper Stillwater Dam, the grout curtain and drain holes were
drilled from the same line in the gallery, 2 ft (0.6 m) from the
gallerys upstream face. The grout curtain was drilled 5 from ver-
tical upstream, while the drain holes slanted 10 from vertical
downstream.
In addition to using RCC to replace weak foundation material, RCC
or shotcrete can be used for surface foundation improvements to pro-
tect rock that is susceptible to air slaking. It is good practice to exca-
vate the final 1 to 2 ft (0.5 m) of rock just prior to placement of con-
ventional concrete, shotcrete, or RCC to minimize the surface
deterioration of the rock.
Because RCC is invariably less costly per unit volume than conven-
tional concrete, the designer should maximize the use of RCC in the
foundation. However, conventional concrete surfaces generally are
built up first to facilitate the start of RCC placement. The size of the
starting pad for RCC placement can be as small as one roller width by
two roller lengths.
Handheld compactors or small rollers may be used for compacting
RCC or conventional concrete into areas that are inaccessible to the
large rollers used for the remainder of the dam. Thin lifts usually are
required when using such equipment in order to achieve roughly the
same density as the RCC for the body of the dam. Conventional con-
Design of RCC Gravity Dams 71
Figure 3.2 Lower Chase Creek Dam (completed dam, downstream view).
pressures at the heel and toe under normal maximum design load and
thereby reduce the potential for tilting or differential settlement. The
dams section is shown in Fig. 3.3.
1 &in concrete
Glacial outwash
Figure 3.3 Section of Cedar Falls Dam.
Design of RCC Gravity Dams 73
gravity dam concept, and (2) the upstream membrane concept. The
high-paste RCC dam described in Chap. 5 and the Japanese RCD
structure described in Chap. 6 are dams designed using conventional
concrete gravity dam concepts and criteria. The lean RCC dam de-
scribed in Chapter 4 fits primarily into the upstream-membrane ap-
proach. The differences are primarily in the design philosophies
rather than the construction methods.
Concrete philosophy RCC mixes are generally used in dams de-
signed using the conventional concrete gravity dam concept, while
soils philosophy mixes are usually specified for RCC dam designs us-
ing the upstream-membrane concept, Some recent designs indicate
that certain aspects of each concept are being used to produce designs
that fall in between the two concepts as well.
Before proceeding with the final design of an RCC dam, the de-
signer should have project goals clearly in mind and should be famil-
iar with all aspects of the site. Factors that can affect the general con-
cept to be used in the design of the dam include the owners
requirements for cost, speed of construction, appearance, watertight-
ness, and operations and maintenance.
Upstream-membrane concept dams tend to be more economical, es-
pecially for low to moderate-height dams, than those that follow con-
ventional concrete gravity dam concepts. Depending on design details,
however, the cost advantage may be counteracted by disadvantages in
appearance, watertightness, and maintenance. In addition, the in-
creased shear or tensile properties of a concrete approach RCC mix
may be used to produce a steeper downstream slope and, therefore,
less volume in the dam.
The purpose of the dam could encourage a certain design approach
as well. A conventional concrete concept would be favored for a com-
plex hydroelectric dam, for example, while the upstream-membrane
concept seems more logical for a flood-control dam where watertight-
ness may not be a prime consideration. Dams for water storage or
multipurpose reservoirs can be designed in accordance with either
concept.
The location of the dam is another factor affecting the choice of
design concept. If the site is located in a seismically active area, the
greater tensile capacity of a concrete approach mix may be re-
quired.
Whatever design approach is employed, the designer should select
design details and an overall layout that considers the RCC construc-
tion method. The overall design should be as simple as possible in or-
der to take full advantage of rapid construction using RCC. Sugges-
tions about the location and configuration of spillways and conduits
through the dam are noted in Sec. 3.7.
74 Chapter Three
3.3.2.2 High-paste RCC dam. The design of a high-paste RCC dam dif-
fers from the RCD method in that the permeability of the RCC mix is
tied to the dam height as proposed by Dunstan in Chap. 5. The per-
meability requirements define an RCC mix with a minimum
cementitious content, a high percentage of which is fly ash. The
strength of the mix can then be used to define a minimum down-
stream slope for the dam. Design details such as exterior slipformed
facing elements that may lack vertical joints provide simplicity and
the opportunity for rapid construction rates for this type of RCC dam.
3.4.1.2 Loads. The loads that may act on a pavity dam are shown in
Fig. 3.4 and include the following.
1. Horizontal loadings
v2
Maximum ,
\
i I
I
Reaction
I b
The dam should also be analyzed for any other loading combination
the designer feels appropriate, including uplift with drains inopera-
tive.
3.4.1.4 Factors of safety. The factors of safety to be used for the de-
sign of a gravity dam are usually determined by the governmental
agency responsible for regulating the safety of the dam . One pub-
lished guideline is USBR Monograph No. 19, Design Criteria for Con-
crete Arch and Gravity Dams.
In the LJSBR criteria, minimum factors of safety required for foun-
dation stresses are 4.0, 2.7, and 1.3, for the usual, unusual, and ex-
treme combinations of loads, respectively. Similarly, the minimum
factors of safety for stresses applied to concrete within the dam are
3.0, 2.0, and 1.0, for the usual, unusual, and extreme loading combi-
nations, respectively.
Limits are also applied to maximum allowable compressive stresses.
In no case shall the allowable compressive stress exceed 1500 lb/in2
(10.3 MPa) for the usual load combinations. The maximum allowable
compressive stress is increased by 50 percent to 2250 lb/in2 (15.5 MPa)
for the unusual load combinations. For the extreme loading condition,
the maximum allowable compressive stress can be determined in the
same manner, using a factor of safety greater than 1.0.
Concrete is assumed to crack if its tensile strength is exceeded by
the extreme combination of loads, including the loads induced by a
maximum credible earthquake. The dam is then analyzed with crack-
ing included, and if structural stability is assured, the dam can be con-
sidered safe against a sudden release of the reservoir despite the sus-
tained damage.
Not all designers and agencies agree on design criteria and fac-
tors of safety. The two items that have attracted the greatest atten-
tion. and with it some controversy, are whether to take credit for
the tensile resistance of the RCC at lift lines and what factor of
safety to apply for shear resistance. A redefined factor of safety for
shear resistance based only on sliding friction resistance is de-
scribed in Sec. 3.3.3.
The USBR, following its own criteria, designed Upper Stillwater
Dam for a minimum tensile strength of 180 lb/in (1.24 MPa) in the
high-paste RCC and between successive lifts. Most designers do not
allow for the tensile strength of the RCC under usual loading condi-
tions. This may be due to the use of leaner mixes or the possibility
Design of RCC Gravity Dams 79
that poor construction control could lead to a lift surface with no bond
and, therefore, no tensile capability.
CA t ( W - lJ)tan&
SFF =
H
W, V, and H are loads on the dam, while c and + are concrete prop-
erties determined from direct shear tests of specimens prepared from
the design mix or cores extracted from a test section using the same
mix. Figure 2.16 provides a summary of values of c and + derived from
RCC mixes.
The minimum SFF required is determined by the criteria selected.
For the usual combination of loads and USBR criteria, the minimum
SFF within the dam is 3.0. Based on these criteria with a vertical
downstream face, the steepest downstream slope for variable cohesion
c divided by structural height h and coefficients of internal friction
tan 6 are shown later in Fig. 5.5, omitting the influence of drains.
A realization that cohesion on some RCC lift surfaces may be zero
has led some designers to redefine the shear factor of safety. Instead of
taking into account both an average cohesion and a sliding friction re-
sistance on the lift surface, the cohesion resistance is not considered.
The design for shear is then based strictly on the sliding friction factor
or the residual shear resistance of the RCC in conjunction with a re-
defined lower factor of safety (FS).
It may appear that this redefined lower FS is compromising the
overall safety of the structure. This is not the case, however, because
the ultimate shear resistance of the concrete is equal to its residual
strength once the bond (cohesion) is broken, as shown in Fig. 3.5. Sug-
gested values of the redefined FS have ranged from 1.5 to 2.0, which
may be the approximate ratio of the peak to the residual shear
strength.
Where zero cohesion at lift lines and 100 percent efficient drains are
assumed, the downstream slope for various shear-friction factors of
safety and coefficients of friction (tan 4) may be determined by using
Fig. 10.2.
Even with the reduced SFF, some positive cohesion may be required
Design of RCC Gravity Dams 81
3.4.2.2 Stress analysis. For a gravity dam subjected to the usual load
combinations, the maximum compressive stress occurs at the down-
stream toe and the minimum compressive stress or maximum tensile
stress at the upstream heel. Most designers will allow no tensile stress
in an RCC dam under usual load conditions, including uplift pres-
sures.
Once the maximum stresses within the dam are calculated, the con-
crete mixture is designed to provide sufficient strength to withstand
the maximum stress multiplied by an appropriate factor of safety. Fig-
ure 3.6 indicates minimum RCC strength requirements used for the
design of a number of RCC dams.
The maximum compressive stress is usually not a major factor in
design, except for very high dams. Depending on the base width, the
maximum compressive stress is roughly equal to only 1 lb/in2 . ft
(0.025 MPaim) of dam height. Because tests to determine compressive
strength are quite reliable and relatively easy to perform, this param-
eter is usually specified, since other properties can be determined by
their relationship to the concretes compressive strength.
For a dam with a vertical upstream face, Fig. 5.4 can be used to de-
termine a downstream slope for various dam heights without drains
as a function of compressive strength divided by a factor of safety.
The RCC mixture for Upper Stillwater Dam, as noted in Sec.
82 Chapter Three
Figure 3 . 6 Minimum RCC Design Strength (See Fig. 2.14 for RCC mixture proportions
used.)
The following equation basically says that the concrete will not
crack until the hydrostatic pressure exceeds the compressive stress in
the dam plus the tensile capability of the concrete. The equation also
takes into account the effect of drains in reducing hydrostatic pres-
sure. Therefore, the calculated compressive stress at the upstream
face for the usual combination of loads excluding uplift must exceed
Cmin as calculated from the equation.
The value ofp is 1.0 if no drains are included in the design, and 0.4
if drains are used. The 0.4 represents the ordinate of a triangular
stress distribution that is equivalent to the uplift stress distribution
where the pressure is reduced to 0.33 of the maximum stress at the
line of the drains, assuming no tailwater. (See uplift pressure distri-
bution with drains in Fig. 3.4).
In the case of a dam with no drains, where p = 1.0, f, = 180 lb/ins
(1.24 MPal, and FS = 3.0, the equation indicates that for the first 138
ft (42 m) of water depth, no additional compressive strength is needed
to withstand full hydrostatic uplift pressure. For greater depths, the
whp factor is greater than f,IFS (60 lb/in2 = 0.41 MPa) and the initial
stress analysis must produce a compression on the upstream face
equal to or greater than the Cmin computed by the equation. With
drains included in the design and the 0.4 drain reduction factor ap-
plied, tensile strength of RCC of 180 lb/in2 (1.24 MPa) is sufficient to
withstand the hydrostatic uplift pressure for all but very high dams.
crest. Some details pertaining to the design of the dam section are dis-
cussed in the following sections.
(a)
Figure 3.7 Cross sections for three RCC dams through spillway. (a) Shimajigawa Dam.
t
I
through the entire dam. Once cracks are initiated, the energy re-
quired to propagate these cracks is less, so both restraint conditions
can combine to produce a deeper crack.
upper portion of the dam. Such was the case for Monksville Dam. If
there is a possibility that there will be design changes related to ther-
mal conditions after the start of construction, provision for payment
should be made in the original contract. A modified version of the Uni-
versity of California at Berkeleys thermal analysis program was used
for Saco Dam to analyze surface temperatures and to assess the prop-
erties of both the conventional concrete facing and the lean interior
RCC mix. Drying shrinkage stresses were added to thermal stresses to
predict cracking of the upstream face more accurately.
H/L-@
t-Y
H/L+@
(b)
Figure 3.8 Degrees of restraint for thermal cracking
analysis. (a) External restraint by foundation rock.
(1 = Degree of external restraint at base of concrete,
2 = ratio of height to length of concrete; 3 = ratio of elas-
tic moduli of concrete to foundation rock.) (b) Internal re-
straint. (1 = Degree internal restraint at concrete sur-
face; 2 = ratio of depth where temperature drop occurs in
concrete to length of concrete; 3 = uniform temperature
drop, 4 = transular temperature drop; 5 = parabolic
temperature drop.)
Design of RCC Gravity Dams 93
351.4 Design for crack control. After it has been established that the
dam will crack and the approximate spacing or location of the cracks
has been identified, the designer must now determine a crack control
solution. It is the authors opinion that it is virtually impossible to de-
sign a straight RCC gravity dam without some cracks occurring. One
solution is do nothing about the predicted cracks initially.
At Upper Stillwater Dam where cracks at lOO-ft (30-m) spacing
were predicted, it was decided to provide no crack control in the de-
sign. It was reasoned that if the anticipated cracks proved to be a
problem at a later date, sufficient funds would have been saved on
construction to pay for future crack repairs. Another solution is to in-
stall water-stopped and drained joints partially or completely through
the dam. Upstream facing methods, including those with joints, are
described in Sec. 3.5.2.
It should be remembered that a concrete dam will crack at points of
least resistance and greatest restraint. Cracks will form in notches or
crack inducers placed in the upstream face and at points of sudden
change in foundation contour. By applying these principles, joints
may be located at a few strategic locations, such as where the dam sec-
tion changes.
Vertical transverse cracks do not reduce the stability of an RCC
gravity dam. The problem associated with cracks is the potential for
seepage, which could cause loss of water and unsightliness. The
greater the degree of watertightness required for an RCC dam, the
greater the need for an impermeable upstream face, which may in-
clude waterstopped joints. Another factor in achieving the overall de-
sired watertightness is the permeability of the RCC material as de-
scribed in Sec. 2.5.3.
Thermally induced longitudinal cracks are not considered to be a prob-
lem in an RCC gravity dam. In the thermal study for the 509-ft-high
(155-m) Miyagase Dam, which has a base width of 591 ft (197 m), it was
deterimined that longitudinal contraction joints could be eliminated.
94 Chapter Three
This method was also used for the 253-ft-high (77-m) Urugua-i Dam
in Argentina. For Urugua-i, the thickness of the conventional concrete
downstream panels averaged 2.3 ft (0.7 m). The width of the bedding
mix atop each 16-in-thick (0.4-m) RCC layer varied from 16 ft (5 m)
near the top to 39 ft (12 m) at lower elevations.
Two patents, one for the membrane-lined panels and another for the
method of installing the panels, have been issued in the United
States. Royalty payments are, therefore, required to use this method
in areas where the patent is in-force.
3.5.2.2 Reinforced and jointed concrete face. The spillway for Stacy
Dam was constructed with an M-in (0.46-m) constant-thickness con-
crete face that was reinforced in both directions. Vertical galvanized
steel sheet water-stopped joints were spaced horizontally at 50 to 60 ft
(15 to 18 m) with reinforcing extending across the joint. Construction
joints were spaced at 13 ft (4 m) vertically. See Fig. 3.10 for a detail of
the face, which is attached to the RCC by steel anchor bars placed atop
RCC lifts as construction proceeded upward.
The reinforced upstream concrete face was cast after the interior
RCC. Placement was delayed until internal RCC temperature started
to decrease as a precaution against potential thermal cracking in the
face. The reinforced and jointed concrete face is very similar to the up-
stream face design for a concrete-faced rockfill dam,
Pre-costG%Kwte
Facing panels
with imcwvious
membrbne
72X16it
(2.2 X 5.0m)-
r
4
7ift
(2 2m)
typlcal
The lower RCC surface must be kept continuously moist but with-
out ponding water to assure bond. Excessive surface moisture is det-
rimental to bond development, but drying of the surface may lead to
no bond.
All loose and dry material should be removed from the RCC prior to
placement of the next lift. Additional cleaning, such as by sand-
blasting or washing, produces little or no benefit. At Willow Creek
Dam, wheeled haul vehicles tracked mud and other debris onto the
dam and their turns disturbed the lift surfaces, which contributed to
Design of RCC Gravity Dams 101
the poor bonding and subsequent seepage at the lift lines. Conveyor
transportation of the RCC from the mixing plant to the dam has been
required on some projects to help eliminate some of these surface dis-
turbance problems.
If a compacted RCC lift is covered with the next lift before the lower
lift reaches initial set, satisfactory bond will usually develop. With in-
creased time delay, a cold joint begins to develop with a resulting loss
in bond strength. Many factors, such as RCC mixture proportions, am-
bient temperature, and surface moisture conditions, affect the time at
which the cold joint begins to develop. Set retarders, high-fly-ash-
content mixes, low temperatures and moist curing extend the life of
the lower RCC lift.
One method of expressing the point at which bond strength poten-
tial decreases takes into account two major factors in RCC strength
development, time and temperature. Referred to as joint maturity, it
has been applied to most lean RCC dam designs. Joint maturity is ex-
pressed as the product of the time of exposure and air temperature at
the surface of the lift, the units thereby being degree Fahrenheit-
hours. As an example, a delay of 8 h with an average temperature of
70F is 560 degree-hours. There is no direct metric conversion, except
at a fixed time or temperature.
There has been little agreement among designers on establishing
joint maturity values, which have ranged from 350 to 2000 degree-
hours. For a lean RCC mix and a temperature at the surface of about
70F (21C) a cold joint usually begins to develop at about 4 h and is
close to full development at 6 h. After 6 h, there is no further signifi-
cant decrease in sliding friction shear resistance until after 30 to 48 h
according to Schrader.
Therefore, if a well-bonded joint is desired, a low joint maturity
value should be specified. Similarly, if shear friction resistance is the
main concern, a higher value should be used. When the contractor ex-
ceeds the specified limiting joint maturity value, most specifications
require application of a bedding mix to assure adequate bond or shear
resistance between lifts.
The use of joint maturity values in project specifications encourages
the contractor to place successive lifts rapidly because the application
of beddng mixes is both costly and time consuming. While the bedding
mix is being applied, the RCC-placing equipment and crew usually
are not working, causing additional costs to the contractor.
To aid the contractor in planning construction, especially for small
projects, joint maturity may be expressed strictly in hours. Whatever
value or method is used for joint maturity, it should be based on field or
laboratory studies using the actual RCC mix. In the absence of such
studies, a conservative but not unreasonable value should be specified.
Bond between lifts improves as the volume of paste increases for the
102 Chapter Three
covering RCC as long as the lower compacted lift is still alive and
moist. This applies to all RCC mixes, Since the water content is basi-
cally constant for a certain mix design approach, bond improves with
mixes containing more cement and pozzolan.
Once the lower lift has hardenend, bond depends on the adhesion of
the paste of the covering mix into the pore structure of the lower lift.
In this case, high-paste RCC mixes, those in which there is a greater
volume of paste than voids in the fine aggregate, are required for ad-
equate bond. The joint properties of a high-paste mix can be defined in
terms of paste/mortar ratio. The research by Dunstan indicates that a
minimum paste/mortar ratio of 0.4 by volume for the RCC mix is
needed to fill voids and achieve a good bond between lifts for an expo-
sure time of one day or less.
Compaction of the covering RCC is a factor in achieving bond, at
least to to the extent that high density indicates a reduction of voids
at the lift interface. Poorly compacted or segregated RCC mixtures
produce greater voids at the lift line and, therefore, less potential area
for achieving bond.
3.5.4 Galleries
the construction site. The RCC half of the cofferdam was on the water
side and was subjected to high-velocity flow and wave action from dis-
charges from one of the outlet tunnels. The earthfill on the spillway
plunge pool side was used as an economical forming method for the
vertical face of the RCC section. After the lining of the plunge pool
was completed, the left side of the cofferdam was breached and the
auxiliary spillway was operated. The earthfill portion of the cofferdam
was completely washed away during the first season of spillway oper-
ation but the remaining RCC portion has remained in place even after
being subjected to spillway flows up to 400,000 ft3/s (11,300 m3/s).
RCC has also been used for both the upstream and downstream cof-
ferdams for the conventional-concrete Yantan Dam as well as for ei-
ther an upstream cofferdam or a diversion wall for three other dams in
China (see Fig. 11.2).
At Yantan, a dumped earth-and-rock dike was first constructed in
the Honshui River. Then the RCC cofferdams were quickly placed be-
hind the embankment, allowing the main dam to be constructed dur-
ing the rivers low-flow season. The 172-ft-high (52.5-m) upstream and
132-ft-high (40.2-m) downstream cofferdams for Yantan, requiring a
total of 366,000 yd3 (275,300 m3), are moderately large RCC dams in
themselves.
3.7.1 Spillways
Spillways for any dam must be designed to pass the design flood and
all lesser-capacity flows safely and economically. With ever-in-
creasing hydraulic requirements, the cost of spillways has become a
major economic factor in dam design and construction. Concrete dams
in general and RCC dams in particular can incorporate spillways into
the structure at little additional cost when compared to embankment-
type dams, which usually require separate spillways. A concrete dam,
therefore, shows a greater cost advantage when compared with an em-
bankment dam as the required spillway capacity increases.
Since concrete dams have a high degree of erosion resistance and
structural stability, there is little chance of failure when the dam is
Design of RCC Gravity Dams 107
be located at the upstream face for a dam that has a relatively narrow
crest width, such as at Galesville Dam (see Fig. 3.7b), or downstream of
an entrance apron, as at Upper Stillwater Dam. The ogee can be con-
structed of conventional concrete or shotcrete following completion of
the RCC dam construction.
Three basic designs for the downstream spillway surface have been
used for RCC dams. They are: (1) the traditional smooth, conventional
concrete surface, (2) a stepped spillway of conventional concrete, and
(3) an unformed exposed RCC surface. Copperfield Dam (Fig. 3.151,
Upper Stillwater Dam (Fig. 3.161, and Galesville Dam (Fig, 3.13) are
good examples of the three types of surfaces.
With the traditional concrete spillway, the objective is to provide a
smooth flow surface for the prevention or minimization of cavitational
damage. The stepped spillway design is more widely used in RCC
dams. The rough stepped surface produces a highly turbulent, well-
aerated boundary layer that eliminates negative pressures and pre-
vents cavitational damage.
If an exposed RCC face for the spillway is to be used, the steepness
of the downstream slope is usually limited to the angle of repose of the
RCC material because of construction considerations. This limiting
slope is generally 0.8 H : 1 V, but may have to be further flattened if
rounded river gravel is used as the RCC aggregate. An unformed RCC
slope was constructed at 0.75 H : 1 V at Les Olivettes Dam with the
1
.a
.; 60 -
D
? 50-
Q)
; 40- Downstream
Dam Slope (I-W
10 I I I I I I I I I
0 15 30 45 60 75 90 105 120 135 150
Unit discharge,ft3/s/ft
Figure 3.17 Stepped spillway energy dissipation (2-ft-deep steps). (From Houston,
unpublished.)
3.8.1 Instrumentation
The use of RCC for a dam curved in plan started with Saco de Nova
Olinda Dam, completed in 1986 in Brazil. The dam was curved near
the right abutment strictly to accommodate local site conditions. No
structural credit was taken for the curvature as the 0.8 H : 1 V down-
stream slope was maintained throughout the gravity structure.
Several curved upstream cofferdams have been constructed using
RCC in China since early 1988 to provide greater stability during
overtopping, as noted in Sec. 3.6.2.
The first RCC gravity arch dam was the 164-ft-high (50-m)
Knellpoort Dam completed in South Africa in 1988. (Fig. 3.9) It was
followed by the 230-ft-high (70-m) Wolwedans Dam completed 1 year
later, Both gravity arch dams were designed by the Republic of South
Africas Department of Water Affairs primarily as a means of reduc-
ing the cost of the structures through reduced volume.
Both gravity arch dams have a vertical upstream face and a 0.5 H :
1.0 V downstream slope. Knellpoort has a crest length of 656 ft (200
m) while Wolwedans is 879 (268 m) long at its crest, thus producing a
crest length/height ratio of 4.0 for Knellpoort and 3.8 for Wolwedans.
While it may be possible to construct an RCC arch dam that will not
crack in the moderate climate of South Africa, provision was made in
the design to control cracks should they occur. To maintain arch ac-
tion, provision for possible cracking was made as follows: Crack induc-
ers and waterstops were placed in both conventional concrete faces.
Bibliography
AC1 Committee 224, Control of Cracking in Concrete Structures (AC1 224R-80) Amer-
ican Concrete Institute, Detroit, 1980, 42 pp.
Benson, S. A., Verigin, W. M., and Carney, M. J., Cedar Falls Roller Compacted Dam,
in Roller-Compacted Concrete II, ASCE, New York, February 1988, pp. 39-50.
Boggs, H. L., and Richardson, A. T., USBR Design Consideration for Roller Com-
pacted Concrete in Roller Compacted Concrete, ASCE, New York, May 1985, pp.
123-139.
Bouyge, B., Langois, A. P., and Martin, J. P., Quality of Works in RCC in France: A
Contractors Solution in Roller Compacted Concrete II, ASCE, New York, February
1988, pp. 309-322.
118 Chapter Three
Bureau of Reclamation, Design Criteria for Concrete Arch and Gravity Dams, Mono-
graph No. 19, September 1974.
Bureau of Reclamation, Design of Gravity Dams, Denver, Colorado, 1976.
Campbell, D. B., and Johnson, P. C., RCC Dam Incorporates Innovative Hydraulic Fea-
tures, Proceedings of the Conference Water for Resource Development, Hydraulics Di-
vision, AXE, Coeur dAlene, Idaho, 1984, pp. 138-142.
Cannon, R. W., Design Considerations for Roller Compacted Concrete and Rollcrete
Dams, Concrete International, American Concrete Institute, Detroit, December
1985.
Chonggang, S., RCC Dams in China, ICOLD Sixteenth Congress, San Francisco, June
1988, vol. V, pp. 387-392.
Chugoku Regional Construction Bureau, Construction of Shimajigawa Dam with
Roller Compacted Dam Concrete, Ministry of Construction, Japan, 1981.
Copen, M. D., Lindholm, E. A., and Tarbox, G. S. Design of Concrete Dams, Chap. 8 in
Handbook of Dam Engineering, Alfred R. Golze (ed.), Van Nostrand Reinhold, New
York, 1977, pp. 385-488.
Ditchey, E. J., and Schrader, E. K., Monksville Dam Temperature Studies ICOLD
Sixteenth Congress, San Francisco, June 1988, vol. III, 662, pp. 379-396.
Dunstan, M. R. H., Rolled Concrete for Dams-Construction Trials Using High Fly
Ash Content Concrete, CIRIA Technical Note 106, Construction Industry Research
and Information Information Association (CIRIA), London, May 1981.
Forbes, B. A,, RCC in Dams in Australia, in Roller-Compacted Concrete II, AXE,
New York, February 1988, pp. 323-339.
Fujisawa, T., and Nagayama, J., Cause and Control of Cracks by Thermal Stress in
Concrete Dams, ICOLD Fifteenth Congress, vol. II, Q57, Lausanne, 1985.
Gilbrough, N., Roller Compacted Concrete and Tunnel Boring Machines-Two
Tools for Designers and Planners, Water Power 1985, ASCE, New York, Septem-
ber 1985.
Hirose, T., Nagayama, I., Takemura, K., and Sato, H., A Study of Control of Temper-
ature Cracks in Large Roller Compacted Dams, ICOLD Sixteenth Congress, San
Francisco, June 1988, vol. III, Q62, pp. 119-135.
Hollingworth, F., Druyts, F. H. W. H., and Maartens, W. W., Some South African Ex-
periences in the Design and Construction of Rollcrete Dams, ICOLD Sixteenth Con-
gress, San Francisco, June 1988, vol. III, Q62, pp. 33-51.
Hollingworth, F., Hooper, D. J., and Geringer, J. J., Roller Compacted Concrete Arched
Dams, Water Power & Dam Construction, November 1989.
Hopman, D. R., and Chambers, D. R., Construction of Elk Creek Dam, Roller-
Compacted Concrete II, ASCE, New York, February 1988, pp. 251-266.
Houston, K. K., Hydraulic Model Studies of Upper Stillwater Dam Stepped Spillway
and Outlet Works, Bureau of Reclamation, REC-ERC-87-6, October, 1987.
Jackson, H., The Construction of the Middle Fork and Galesville RCC Dams, Water
Power & Dam Construction, January 1986.
Leliavsky, Serge, Uplift in Gravity Dams-Part Four, Water Power, January 1960,
pp. 244-332.
Lemons, R. M., A Combined RCC and Reinforced Concrete Spillway, Roller-
Compacted Concrete II, ASCE, New York, February 1988, pp. 51-60.
Levy, Maurice, Communication to the French Academy of Sciences, August 1895.
Logie, C. V., Economic Considerations in Selection of a Roller Compacted Concrete
Dam, ASCE, New York, May 1985, pp. 111-122.
Lowe, John III, Roller-Compacted Concrete Dams-An Overview, Roller-Compacted
Concrete II, ASCE, New York, February 1988, pp. l-20.
Membrane-Lined Panels Face New RCC Dam, Highway & Heavy Construction, Feb-
ruary 1985, pp. 64-65.
Molcr, W. A., and Moore, J. F., Design of Seepage Control Systems for RCC Dams,
Roller-Compacted Concrete II, ASCE, New York, February 1988.
Oberholtzer, G. L., Lorenzo, A., and Schrader, E. K., Roller-Compacted Concrete De-
sign for Urugua-i Dam, Roller-Compacted Concrete II, ASCE, New York, February
1988.
Design of RCC Gravity Dams 119
Design and
Construction of
Lean KC Dams
4.1 Background
Many of the RCC dams completed in the world to date have used low-
cementitious-content mixes. These lean mixes have tended to be dry,
but wetter mixes have also been used. By minimizing cement and/or
pozzolan contents, a direct and considerable material cost savings is
achieved. This is complemented by indirect savings that can be sub-
stantial. If no pozzolan or admixtures are used, storage, proportioning,
mixing, material delivery, and coordination are simplified. Lean
mixes also produce concretes with low internal temperatures from
hydration, low elastic moduli, and high creep rates. The combination
of these characteristics results in few or no vertical joints being re-
quired. This is a major indirect benefit of lean RCC because of the
avoided cost and construction complexity of installing contraction
joints.
The trade-off for lean mixes as compared to high-cementitious-
content RCC mixes is a reduction in the quality of the bond along the
lift-to-lift interface of RCC surfaces. Normally, there is adequate mass
and strength for sliding stability and compressive loads in lean RCC
dams. But seepage should be expected unless special measures are
taken to control it.
121
122 Chapter Four
Typically, cohesion and friction factors for lift joints in lean RCC
dams are influenced mostly by the character of the aggregate and the
degree of care used to reduce segregation during construction. Increas-
ing cement contents in lean mixes usually has little effect on the over-
all sliding stability of the completed dam.
Permeability,
Project Cement, Ib/yd3 Fly ash, lb/yd3 ftis, E - 12
Willow Creek 80 52 61
Willow Creek 175 00 312
Willow Creek 175 80 66
Willow Creek 315 135 220
Lost Creek Test Section 94 75 370
Lost Creek Test Section 120 140 42
Lost Creek Test Section 235 00 128
Waterways Experiment 517 00 10
Station Test
NOTE : 1 lb/y@ = 0.59 kg/m3; 1 ft/s = 0.3 m/s.
can also be placed between RCC layers near the upstream face. They
act as waterstops when wetted.
Another approach to seepage is to simply collect and drain it inter-
nally. This can be done with vertical drain holes, gravel drains, or po-
rous concrete placed along the lifts in question. Flexible, hollow tub-
ing that has filter fabric forming the tubes wall has also been used as
a drain between RCC lifts and at the RCC-to-abutment contact.
The most effective seepage and uplift control method used for lean
RCC dams has been to use a heavy-duty PVC or high-density polyeth-
ylene sheet as a liner behind the upstream facing panels. This method
was first used at Winchester Dam and has since been included in the
design of other RCC dams.
The liner is placed between the RCC and precast facing panels,
which act as stay-in-place forms. The liner is attached to the rear face
of the panels when they are cast. Seams are heat-welded during erec-
tion. The liner is keyed into the foundation and abutments and be-
comes a water-stop extending from abutment to abutment. At Win-
chester, this design has resulted in an attractive dam with no seepage
or maintenance to date. The 74-ft-high (23-m) dam was completed in
1984 and typically maintains a full reservoir for water supply.
Precast panels used for the upstream face at Willow Creek Dam did
not have a liner or employ other seepage controls. RCC lift lines were not
drained or effectively bedded to prevent seepage. While the upstream
face is attractive, substantial but tolerable levels of seepage occurred.
Figure 11.4 shows how the Willow Creek seepage compares with other
dams. Construction of Willow Creek Dam is shown in Fig. 4.2.
RCC was placed directly against wooden forms at Copperfield Dam.
This resulted in an economical, effective, and essentially crack-free
upstream face. But it was not esthetically pleasing (see Fig. 11.6).
Dry, lean RCC mixes honeycomb when they are compacted against a
vertical form. This has little significance below normal reservoir lev-
els where the surface is not visible and is not subjected to alternate
wet-dry cycles, rapid temperature changes, freezing, and wave action.
Above the reservoir level, this shortcoming can be overcome with a
conventional concrete facing that is placed monolithically with the
RCC. This approach has been used on a number of dams, but it must
be done carefully and with a thorough knowledge of all the technical
issues involved. Strength and mass are much less important, for ex-
ample, than strain capacity, creep, low elastic modulus, minimal dry-
ing shrinkage, and minimal adiabatic temperature rise.
If the conventional concrete face is too thick [more than about 15 in
(0.4 m) or average distance from the upstream form to the RCC], it can
develop significant thermal stresses and result in cracks that would
not appear with a thinner facing. In this case, thicker is more expen-
Design and Construction of Lean RCC Dams 125
only near the face. But for simplicity of construction and better bond-
ing of lifts, it may be used for the entire dam. Due to the loss of
strength and/or increase in cement content and cost, the added water
results in a less efficient RCC mix, however.
In both approaches it is imperative that the facing concrete and
RCC be thoroughly compacted or consolidated together so that they
form a monolithic mass.
It is important to note that conventional facing concrete does not
provide seepage control unless it has a thickness of about 8 percent of
the hydraulic head, no cracks, and waterstopped jointing. In fact, al-
though the facing may be attractive, it may aggravate seepage prob-
lems by causing cracks in the RCC that would not have occurred oth-
erwise. The lift lines between RCC lifts are continuous with the lift
lines in the facing concrete. These lines are the source of seepage. At a
desired maximum facing thickness of about 15 in (0.4 ml, the length of
the flow path along the conventional concrete lift line has no signifi-
cant impact on watertightness.
100 lb/in (0.7 MPa) with a friction angle of 45. Poor aggregates such
a friable sandstones and granites can result in lower strengths. Typi-
cal tensile strengths are on the order of 50 to 100 lb/in2 (0.35 to 0.7
MPa), but zones with little or no reliable tensile strength are also com-
mon. When increased strength is needed for tension or shear, a bed-
ding mix between layers will provide the increased shear resistance-
in most cases creating a bond equal to the strength of the compacted
RCC. This can be double the strength at the interface without bed-
ding.
4.2.4 Galleries
Galleries can be incorporated into RCC dams when appropriate, but
they should be technically necessary and justifiable. Most structures
less than 100 ft (30 m) high can be efficiently and safely built with
128 Chapter Four
lean RCC by providing slightly more mass and eliminating the gal-
lery. Winchester Dam in a good example of an RCC dam with no gal-
lery.
A gallery will decrease the mass, provide a weakened zone where
longitudinal cracking could start, may require troublesome and ex-
pensive reinforcing steel, and will slow production by 15 to 50 percent
in the region of the gallery. It also will restrict the placing area be-
tween the gallery and upstream face, often resulting in lower-quality
RCC than otherwise would have been achieved there. The resulting
short seepage path between the gallery and upstream face will require
special treatment such as bedding each layer or the area will become
a source of considerable seepage.
A gallery is justified in higher dams primarily because internal
drains to the gallery allow an economical reduction of the mass and
because of the access provided for foundation drains. When a gallery is
appropriate, its location should be well conceived and coordinated
with the practical aspects of construction. As much as possible, it
should be located at a single level. Multiple galleries should be
avoided if possible. Sufficient space [25 to 30 ft (7.6 to 9.1 m)] should
be provided between the upstream face of the dam and the gallery to
allow equipment to operate.
Conventional gallery construction methods such as wood forming or
precast elements are expensive, time consuming, and disrupt the plac-
ing operation by blocking the access of hauling vehicles. An effective
construction method has been to replace RCC with a noncemented fill
in the area of the gallery as each layer of RCC is compacted. Later, the
loose material is excavated, leaving the void as the gallery. This al-
lows direct inspection of the rough interior RCC mass. Using precast
concrete, slipformed concrete or forms with conventional concrete as
the gallery walls hides the RCC from direct inspection.
4.2.5 Instrumentation
Instrumentation in lean RCC dams should generally be the same as
would be provided for a conventionally placed dam of similar size,
risk, and purpose. When monolith joints are eliminated or greatly re-
duced, it is prudent to place extra instruments for measuring temper-
ature peaks and rates of drop so that predictions used as the basis for
design can be verified. Also, when temperatures are dependent on the
construction schedule and placing rates do not meet that schedule,
temperature monitoring should be provided.
Uplift pressures along lift lines should be monitored if they are an
important aspect of stability.
Seepage and its change with time are especially critical. Typically,
Design and Construction of Lean RCC Dams 129
Lean RCC mix designs include cement, aggregate, and water. In some
cases, pozzolans and admixtures may also be included. Typical cement
contents are on the order of 80 to 125 lb/yd3 (47 to 74 kg/m3), but
higher cement contents have been used in select portions of some
structures or when only poor-quality aggregate was available.
Pozzolans usually are used only if a high cement content is truly
needed and if pozzolan is economically available.
The amount of pozzolan that is optimal depends on each project. In
some cases, adding silt or rock dust has had the same effect as adding
pozzolan. In other cases, replacement of up to 50 percent pozzolan for
cement has resulted in essentially the same strength as the cement-
only mix. In still other cases, the addition of pozzolan has resulted in
a loss of long-term strength below what was achieved with the same
cement content and no pozzolan. Each case is evaluated individually.
The common approach to mix designs for lean RCC has been first to
obtain the most economical smooth aggregate gradation within the
broad overall limits. Two examples of aggregate gradation bands were
shown in Fig. 2.7. The key is to have a good blend with enough sand
and fines to separate the coarse aggregate so that they do not contact
130 Chapter Four
W Split Modulus of
Cement, Pozzolan, Water, CtP Age, Compression, tensile, elasticity E, Poissons
Dam lb/yd3 lb/yd3 lb/yd3 (by wt) days lb/in lb/in lb/in x lo6 ratio
2
w
N
W Split Modulus of
Cement, Pozzolan, Water, ctp Age, Compression, tensile, elasticity E, Poissons
Dam lb/yda Iblyd lblyda (by W days lb/in lb/ix? lb/in x 10 ratio
Zintel Canyon 100 0 200 2.00 3 190 - 0.31 -
7 280 - 0.68 -
28 630 90 1.54 -
90 1090 165 2.15 0.21
365 1550 - 2.57 -
Zintel Canyon 150 0 200 1.33 3 410 - - -
I 620 - - -
28 1100 - - -
90 1550 - - -
365 2530 - - -
Zintel Canyon 200 0 200 1.00 3 680 - 1.35 -
7 990 - 1.54 -
28 1620 200 2.39 -
90 2130 255 2.47 0.20
365 3100 - 3.28 -
Elk Creek 94 38 170 1.29 3 210 - - -
7 270 - - -
28 410 60 - -
90 820 115 1.69 0.19
Tarbela 200 0 - - 3 - - - -
(1982) 7 1110 - - -
with silt 28 1490 - - -
90 1980 - - -
(2 yr) 2760 - - -
Tarbela 235 0 - - 3 547 - - -
(pre-1982) 7 662 - - -
no silt 28 951 - - -
Middle Fork 100 0 1 3 5 (60) 1.35 3 490 - - -
7 540 - - -
28 868 - - -
90 1290 - - -
365 - - - -
Middle Fork 120 0 1 3 5 (180) 1.13 3 565 - - -
7 797 - - -
28 1655 - - -
90 2000 - - -
365 - - - -
Monksville 105 0 205 (122) 1.95 3 487 37 - -
7 650 64 0.35 -
28 745 95 0.90 -
90 - - - -
365 - - - -
Upper 182 210 183 0.47 3 - - - -
Stillwater 7 1360 - - -
28 2130 110 - -
90 3510 150 - -
365 5220 205 1.10 0.13
Upper 121 269 175 0.45 3 - - - -
Stillwater 7 770 50 - -
28 1220 80 - -
90 2150 130 - -
365 4780 200 1.43 0.14
Gmtinued)
E
W Split Modulus of
Cement, Pozzolan, Water, ctp Age, Compression, tensile, elasticity E, Poissons
Dam lbiyd3 lb/yd3 lb/yd3 (by wt) days lb/in lb/in lb/in x 10 ratio
Upper 129 236 180 0.43 3 - - - -
Stillwater 7 1100 55 - -
28 1620 110 - -
90 2770 130 - -
365 4960 220 1.60 0.19
Ncnes: Strengths are for 6 x 12-in. cylinders with t 1%in aggregate removed. The data are
from laboratory mix design studies and/or field cylinders during construction. Actual water
contents used during construction may vary due to field conditions. The water content is based
on saturated surface dry aggregates. 1 lbiyd = 0.59 kg/ma; 1 lb/in3 = 6.9 x lo3 Mpa.
Design and Construction of Lean RCC Dams 135
the values for the same property vary considerably. That is mainly
caused by the broad range of aggregates used to make RCC. This fac-
tor can be used to great advantage if the structural design and mix
design (material property) aspects of a project are mutually under-
stood and coordinated with the economies and practicalities of con-
struction. For example, a dam that can be built with a very economi-
cal low-cement-content mix by slightly increasing the mass can often
result in substantial overall project savings. It can also result in a con-
crete than is much less likely to crack than a more expensive, higher-
strength mix with more cement (or cement plus pozzolan) and greater
laboratory strengths.
samples are from isolated areas in noncritical zones; and require that
98 percent of all tests to be above 95 percent density with the average
of all tests at 97 percent.
If low densities are the result of inadequate compaction, rerolling
lifts within about 15 min of placement can improve the test results.
However, rerolling after the mix reaches initial set should be
avoided because it can damage the concrete even though it increases
the density. Overrolling should also be avoided because it can reduce
density in much the same way that overrolling affects some compacted
embankments.
Mixer test methods, batch or feed-rate accuracies, allowable mixer
variability, and the amount of overdesign needed to account for mixer
variability have been discussed in detail by the author (see Bibliogra-
phy, Schrader 19871. Basically, more cement and higher average
strengths are needed when using plants that produce more variable
mixes. Overall, coefficients of variation for lean RCC projects have
typically ranged from 20 to 28 percent.
Bibliography
Ditchey, E., and Schrader, E. K., Monksville Dam Temperature Studies, ZCOLD Six-
teenth Congress, San Francisco, June 1988, vol. III, Q62, pp. 379-396.
Quin, J., Rezende, S., and Schrader, E. K., Saco Dam-South Americas first RCC
Dam, Roller-Compacted Concrete II, ASCE, New York, February 1988, pp.340-356.
Schradcr, E. K., Behavior of Completed RCC Dams, Roller-Compacted Concrete II,
ASCE, New York, February 1988, pp. 76-91.
- Compaction of Roller-Compacted Concrete, Proceedings of the American Con-
cretk Institute Symposium on Consolidation of Concrete, San Francisco, March 1986.
---, Design for Strength Variability: Testing and Effects on Cracking in RCC and
Conventional Concretes, Lewis Tuthill Symposium, American Concrete Institute,
October, 1987.
-, Roller-Compacted Concrete, The Military Engineer, September-October 1977.
- Watertightness and Seepage Control in Roller-Compacted Concrete Dams,
Roller-Compacted Concrete, ASCE, New York, May, 1985, pp. 11-30.
Schrader, E. K., and Namikas, D., Performance of Roller Compacted-Concrete Dams,
ICOLD Sixteenth Congress, San Francisco, June 1988, vol. III, Q62, pp. 339-364.
Snider, S., and Schrader, E. K., Monksville Dam: Design Evolution and Construction,
Roller-Compacted Concrete II, ASCE, New York, February 1988, pp. 220-235.
Tatro. S. B., and Schrader, E. K.. Thermal Considerations for Roller-Compacted Con-
crete, Journal of the American Concrete Institute, March-April 1985. _
US. Army Corps of Engineers, Willow Creek Dam Concrete Report, Walla Walla,
Washington, 1984.
Chapter
5.1 Background
Roller compaction of concrete for dams has many advantages over the
conventional method of dam construction. However, designers of RCC
dams should still aim to achieve the excellent properties that have
been obtained in conventionally placed concrete gravity dams. Some
designers have expressed concern about seepage between lifts of Wil-
low Creek Dam. This has led to the suggestion that RCC dams should
be designed as embankment dams comparable to rockfill dams with
an impervious upstream membrane. It has even been suggested that
advantage should be made of the permeability between lifts to reduce
internal uplift. Unless this concern about permeability can be re-
moved, some of the potential economy of the RCC method of construc-
tion may be lost.
The central philosophy of the high-paste-content RCC dam includes
the following:
The latter is one of the main advantages of the new method of dam
construction and it can lead to a significant proportion of the potential
economy of RCC over competing methods.
Within these overall concepts, the author proposes that the interior
139
140 Chapter Five
The height, and to a lesser extent the size, of the dam together with
its intended use will dictate a range of acceptable in situ
permeabilities. It is not the permeability of the RCC itself but the po-
tential leakage path along the joints between the layers of RCC that
can cause problems. Willow Creek had unacceptable leakage along
these joints. Because the leakage is localized along lift lines, the po-
tential for deterioration is enhanced.
A number of tests of the overall in situ permeability have been car-
ried out on RCC structures. The results of some of these tests are
shown in Fig. 5.1, which contains data from eight different countries.
The data are derived from published literature and personal corre-
spondence and include some test sections and RCC structures that are
not gravity dams. The permeability measurements were carried out in
a variety of ways-by use of packer tests, by falling-head permeability
tests, by measuring the flow through the whole dam, and by testing of
cores. In spite of the different approaches, there seems to be a rela-
tionship between low in situ permeability and high cementitious con-
tent. This is to be expected, as conventional concrete follows a similar
pattern.
I I I I
-
Milton Brook++
Holbeom Wood
Willow Creek
0 I I I I I
0 100 200 300
Cementitious coti. kg/m3
Figure 5.1 Relationship between permeability and cementitious content.
Design and Construction Concepts of a High-Paste-Content RCC Dam 143
Treatment of surface
of horizontal joint Bedding mix
Willow Creek None Partial
Holbeam Wood None None
Copperfield None Partial
Ohkawa Green cut Full
Shimajigawa Green cut Full
Tamagawa Green cut Full
Upper Stillwater None None
Bishops Stortford None None
Milton Brook None None
The treatment of the lift surface and the use of bedding mixes do not
seem to have a significant effect upon the overall permeability. Some
of those structures shown in Fig. 5.1 used full treatment of the lifts
together with a bedding mix spread over the entire lift surface. Some
used no treatment of the lifts and partial bedding mixes, while others
used no treatment and no bedding mixes, as shown in Fig. 5.2.
It is not possible to differentiate between the RCC lift surface treat-
ment methods based on the permeability test results. The reason may
be that any modification to the method of construction, such as
treatment of the Iift surface or application of bedding mixes, can slow
the rate of construction. Any slowing of the pace of RCC placement
can lead to a reduction in the performance of the bonding between the
layers. Thus the modifications may only counteract the intended effect
of their introduction.
This does not mean that treatment of the RCC surface may not be
necessary in special cases, but it seems unlikely that the general use
of bedding mixes and lift surface treatment improves the performance
of RCC structures in terms of in situ permeability.
5.2.2 Permeability
The author believes that any dam which is to store water should have
a minimum permeability of 10e6 cm/s. Because the total flow through
structures is dependent upon head, a dam which is 165 ft (50 m) high
may need a minimum permeability of 10m7 cm/s; 330 ft (100 m) high,
10-s cm/s; 650 ft (200 m) high, lo- cm/s; and for a dam higher than
that, 10-l cm/s.
These design criteria may be too low. The U.S. Bureau of Reclama-
tion has defined a limit of 1.5 x lo- cm/s as acceptable for conven-
tional concrete dams. Completed concrete dams have generally been
found to have permeabilities ranging from 5 to 50 x 10-l cm/s.
144 Chapter Five
5.2.3 Density
The density of the RCC will also be an important factor in the final
design of the structure. It has been found that the entrapped air con-
tent of RCC placed for existing dams has varied between 8.5 percent to
less than 0.5 percent. A relationship has been proven between the in
situ density [as a proportion of the theoretical air-free (taf) density]
and a factor called the paste/mortar ratio. This relationship is shown
in Fig. 5.3.
h laximum t h e o r e t i c a l 1/
d ensity with fine
a ggregate having a
oid ratio of 0.32
Maximum theoretical
density with fine
aggregate having a
void ratio of 0.4
0 100
200 300 400
Height, ft
Figure 5.4 Relationship between compressive strength
and downstream slope. (From: Boggs and Richardson,
1985.)
I I I
I I I I
0 0.25 0.50 0.75 1.0
Cohesion C I b/in*
---I-, -
Height H ft
Figure 5.5 Relationship between cohesion, coeffi-
cient of friction and downstream slope. (From: Boggs
and Richardson, 1985.)
Design and Construction Concepts of a High-Paste-Content RCC Dam 147
1. Permeability
2. Tensile strength and tensile strain capacity
3. Shear strength at lift surfaces (cohesion and coefficient of friction)
4. Compressive strength
5. Poissons ratio
6. Coefficient of thermal expansion
7. Creep
One of the main criteria for the design of an RCC dam has been simpli-
fication of the method of construction so that there is no reduction in the
placement rate. Any contraction joints between the upstream and down-
stream faces, as are used in the Japanese RCD method, introduces com-
plications that may reduce the speed of placement. It has been shown
that it is feasible to place RCC for considerable lengths without detri-
mental cracking as long as the material is protected from rapid changes
in temperature. Unreinforced concrete that is subject to rapid changes in
air temperature of 36F (20C) or more (depending upon the coefficient of
expansion of the concrete) will generally suffer from thermally induced
cracks, particularly if the concrete is restrained.
For example, cracks between 10 and 16 ft (3 to 5 m) deep are pre-
dicted to penetrate both faces of Upper Stillwater Dam due to the ex-
treme changes in air temperature at the high-elevation site. Most ex-
ternal faces of RCC dams will eventually crack unless the climatic
conditions are very mild.
Therefore, unless some other form of noncementitious upstream
membrane is applied to an RCC dam, the watertight membrane is
best designed to be in the center of the dam where it is protected from
changes in temperature by the facing concrete. It is this concept which
is used for the design of the high-paste-content RCC dam. The faces
are considered to be purely a durable skin protecting the interior
RCC, which is a watertight barrier.
The faces of an RCC dam can be formed by a number of methods.
The main criterion is that construction of the faces should not inter-
fere with the placement of the interior RCC. The method that seems to
be most suited to the larger RCC dams is slipforming of interlocking
facing elements. This was first conceived for the Milton Brook Dam in
the United Kingdom and was used for Upper Stillwater Dam. By
roller-compacting the interior concrete against the facing element as
soon as possible (the minimum can be as little as 4 h) the interior con-
crete bonds well to the facing element. The whole structure can be
considered to be monolithic.
Other methods of forming the face, as described in Chap. 8, are also
perfectly feasible with the use of a high-paste-content concrete. It is
not necessary to design the external face to perform as a watertight
membrane.
Generally, it is desirable to provide drains in all but the smallest
concrete dams. Drains can be provided in a high-paste-content RCC
dam by drilling from a gallery and/or the top of the dam (to intersect
with a gallery) after the dam is completed.
152 Chapter Five
one advantage over the other forms of RCC, in that it is more plastic.
After compaction the concrete will feel like a stiff jelly under foot. This
is because the concrete will consist of aggregate particles suspended in
a stiff paste. The cohesion of the concrete rather than aggregate-to-
aggregate interlock will support the roller. The feel of a lean RCC, and
to a lesser extent the concrete used in the RCD dams, is completely
different. After roller compaction there is no movement in these con-
cretes. Essentially, they are compacted aggregate with paste filling
most of the voids.
This difference is also noticeable during the manufacture of speci-
mens. High-paste-content concrete can be compacted by use of a vi-
brating table alone, although some form of surcharge load is advanta-
geous.
Two tests have been used to control the placement of high-paste-
content RCC: the Cannon test and the loaded Vebe. Both enable mea-
surement of the workability (by measuring the time taken to reach a
certain state) and also the fresh density. If the density and consistency
fall within a definable range, the concrete will be satisfactory.
A relationship can be derived between the water content of the mix
and the Cannon or Vebe, time which measures workability. This rela-
tionship enables the operator of the batching and mixing plant to modify
minutely the water content of the mix to obtain a consistent workability.
Control of the fresh density will also enable the density of the concrete
after roller compaction to be maintained above the desired level.
5.4 cost
The cost of any RCC dam will be very site-specific, depending upon the
local material costs. Nevertheless, although the cementitious content
of a high-paste-content concrete is higher than other forms of RCC, it
has been found that the overall costs of the structure can frequently be
less than the equivalent lean RCC dam because of optimization of the
properties relative to the volume of the dam.
5.5 Conclusions
The overriding criteria for the design of an RCC dam should be to ob-
tain in situ properties at least equivalent to those of a conventional
concrete dam and to simplify the method of construction as much as
possible so that advantage can be taken of the very rapid method of
construction. The economy of the construction of conventional con-
crete dams floundered when complications were introduced in order to
overcome problems such as the heat of hydration. It is important that
154 Chapter Five
RCC dam designers do not follow the same path. It is also important
that the RCC mixture proportions be optimized to obtain the least-
expensive overall solution for any particular dam rather than to ob-
tain the greatest possible materials cost saving.
A relatively high paste content is required if a density near the the-
oretical air-free density is to be obtained. In addition, a certain
cementitious content is necessary in order to obtain a minimum in
situ permeability on a par with that obtained in conventional concrete
dams. It is the permeability between the lifts rather than the parent
material that can constitute a problem. Because there are many more
horizontal lifts in an RCC dam than in a conventionally placed con-
crete dam, considerable care needs to be taken to minimize the risk of
any leakage along lift interfaces.
If the interior concrete is to be a watertight barrier-and it is ar-
gued that this is the only feasible solution for any but the smallest
RCC dams- then a minimum cementitious content probably exceed-
ing 250 lb/yd3 (150 kg/m31 will be needed. By taking advantage of the
properties that can be obtained by use of an RCC with a cementitious
content of this order, it is possible to reduce the cross section of the
dam so that the volume of concrete to be placed can be reduced. Other
advantages such as a reduction in the quantity of excavation and a
reduction in the length of diversion works follow because of the nar-
rower base width.
The cost of the optimized solution can frequently be less than that of
a dam designed to minimize the material costs. Additionally, the over-
all properties of the concrete can be significantly better.
There will be a few cases where pozzolans are not available in any
form near a dam site and an alternative solution will be required.
However, in the majority of cases a high-paste-content RCC with a
high proportion of pozzolan in the cementitious content will be feasi-
ble. It is therefore suggested that for an RCC dam of any reasonable
height, the use of a high-paste-content concrete will usually be the
best solution.
Bibliography
Back, P. A. A., Report of an informal meeting (Dec. 1, 1986), BNCOLD Newsletter, Sum-
mer Edition, London, July, 1987.
Boggs, H. L., and Richardson, A.T., USBR Design Considerations for Roller-Compacted
Concrete Dams, in Roller-Compacted Concrete, AWE, New York, 1985.
Dunstan, M. R. H., Rolled Concrete for Dams: Construction Trials Using High-Flyash-
Content Concrete, Technical Note 106. CIRIA. London. May 1981.
- Rolled Concrete for Dams-A Laboratory Study of the Properties of High-
Fly&h-Content Concrete, Technical Note 105, CIRL4, London, May 1981.
- Design Considerations of Roller-Compacted Concrete Dams, Water Power and
Dani Construction (London), January 1986.
Design and Construction Concepts of a High-Paste-Content RCC Dam 155
Lowe, John, III, Roller Compacted Concrete Dams-An Overview, Roller Compacted
Concrete II, AXE, New York, February 1988, pp. l-20.
McConnell, A. D., Discussion to Question 57, ICOLD Congr., 15th, vol. 5, Lausanne,
1985.
Chapter
6
RCD:
The Japanese Approach
6.1 Background
Japanese engineers have taken a conservative approach to roller-
compacted concrete (RCC) dam building in order to meet the difficult
challenges posed by the topography, hydrology, and geology of the vol-
canic island nation. Although RCC is used primarily for only the in-
terior of Japanese dams, the design criteria adopted impose the same
strict demands for watertightness, strength, and durability on the
RCC as it does for traditional mass concrete dams.
The intent of Japanese research and development of RCC is to en-
hance the speed and economy of dam construction. The conservative
design approach and the painstaking execution of RCC placement are
more time-consuming and costly than the methods developed for RCC
dams in the United States. Japanese dams employing RCC so far have
proven to be more watertight than RCC dams built in the United
States and other countries.
Production and economy are enhanced somewhat in the Japanese
approach by layering RCC into thicker lifts than are common in the
United States and elsewhere. However, to prevent thermal stress
cracking, Japanese designers require transverse contraction joints ev-
ery 49 ft (15 m) in all RCC dams. They also restrict RCC placement
rates to avoid heat buildup from the hydration of cement. Completed
lifts are cured for as long as four days. All lift surfaces are treated as
cold joints and bedded with mortar before the next lift of RCC is
placed. Inspection galleries are required in all RCC dams in Japan,
and all RCC dams are encased in conventional concrete for water-
tightness.
A research team organized in 1974 by Japans Ministry of Construc-
157
158 Chapter Six
6.2.2 Uplift
Uplift pressures in RCD dams are controlled to the same degree as
conventional concrete dams by use of a thick upstream facing and by
bedding all lifts. The cross sections of all RCD dams completed to date
have vertical upstream faces and downstream slopes varying from
0.76 to 0.81 H : 1 V with 0.80 H : 1 V being typical. Combined with the
high unit weight of RCD, this section provides sufficient weight to re-
sist overturning forces.
711-8131 3 3 14
9/l-11/30 2 2 10
Figure 6.1 Upper and lower limits for concrete placement at Tamagawa Dam.
162 Chapter Six
will be 509 ft (155 m) high and Gassan Dam will by 410 ft (125 ml high.
Figure 6.2 lists all RCD dams built, under construction or design.
In final design
L4 (1991) Ryumon MCJG 99.5 326 844,000 (1,104,OOO) 91 t 39 = 130 153 t 66 = 219
15 (1991) GaSSaIl MCJG 125 401 1,450 (1,897) 91 t 39 = 130 153 t 66 = 219
L6 (1991) Hattabara MCJG 85 279 500,000 (654,000) 84 t 36 = 120 141 t 61 = 202
17 (1994) Miyagase MCJG 155 509 1,914,ooo (2,503,OOO) 91 t 39 = 130 153 t 66 = 215
*Stilling basin.
Base m a t .
MCJG = Ministry of Construction, Japanese government
DA = development agency
LG = local government
WRDPC = Water Resource Development Public Corporation
RCD: The Japanese Approach 165
Figure 6.3 tialvanizcd crack inducers are vihrated in place at Tamagawa Dam.
eliminated the problem of small cracks discovered near the top of lifts
that were compacted with only vibratory rollers. It also made cleanup
of the lift surfaces easier because there was less loose material to re-
move.
6. After curing, lift surfaces are green-cut with mortar brushes and
water jets. Excess mortar and loose aggregate are removed with motor
sweepers and hand labor. Water jets are used for a final cleaning. The
water is removed and a 0.6-in (15mm) layer of high-slump mortar is
spread over the cleaned lift surface by wheel loader or by hand to bond
it to the next lift of concrete (Fig. 6.4). The bedding also helps to re-
duce segregation at the construction joints. The placing, cutting, and
cleaning of each lane of RCD at Tamagawa took an average of three
days. To prevent loosening of coarse aggregate and washing out of
mortar during green-cutting, the concrete was allowed to cure from 24
to 36 h before water jetting started.
7. Upstream and downstream faces of the dam are formed with con-
ventional immersion-vibrated concrete placed against formwork. To
eliminate construction joints at the interface, the plastic facing mix is
(1) immersion-vibrated with ganged vibrators mounted on a backhoe;
(2) the RCD lane adjacent to the face concrete is placed to its full lift
height and the interface between the two is immersion-vibrated; (3)
the interface area is compacted with six passes of a vibratory roller
166 Chapter Six
6.4.2 Proportioning
Because of the desire for a low heat rise and good workability, the unit
cement and water content of the mix are also important. Typically,
the RCD mix is designed by keeping the unit binder content-the ce-
ment plus fly ash-and the unit water content constant. Trials are
RCD: The Japanese Approach 169
A Consistency + S t r e n g t h + Mix
meter test
I
-1
(Unit water vs. (Sand aggregate (Unit cement
ratio vs. VC content vs.
valve) compressive
I strength)
Determine unit
, water content
I I
Figure 6.6 RCD mix proportioning flow diagram.
6.4.4 Watertightness
Permeability tests done in boreholes at Ohkawa indicate a high de-
gree of watertightness in the lifts and at the bedded joints between
lifts. The results were essentially the same-within a range of 1.7 to
7.4 x 10m6 cm/s.
170 Chapter Six
.$2 2 0 0
3 2
g
E 100
8
0
0 2 8 91 182 365
Age, days
6.5 Benefits
The potential benefits of the RCD method over conventional concrete
dam-building techniques in Japan are lower construction costs; faster
construction; greater worker safety because of uncongested, level
working surfaces; and, because of the possibility of developing more
sites by using an RCD base mat for a conventional dam, greater con-
crete gravity dam design diversity.
Very general comparisons put the overall cost advantage for RCD
over the monolith method in Japan at 10 to 15 percent in ordinary
conditions and at 40 percent for conditions very favorable to RCD, i.e.,
dams in wide valleys with few embedded structures.
Cost savings are realized in labor and materials. Among the inher-
ent advantages of RCD, the number and skill level of crews required
for RCD construction are lower than for conventional concrete dams.
The road-building equipment required to transport, place, and com-
pact the concrete is less costly, more flexibly deployed, and easier to
operate than the specialized materials conveyance systems used for
dams built by the monolith method. In addition, there is a reduction in
the amount of cement used, a large reduction in the total quantity of
forms and no cooling pipes required in the RCD method. At
Tamagawa, cement savings were roughly 10 percent and form savings
were close to 32 percent.
Bibliography
Development Division, River Bureau, Ministry of Construction, Development in Japan
of Concrete Dam Construction by the RCD Method, 1984.
Dunstan, M. R. H., Design Considerations for Roller-Compacted Concrete Dams, Wa-
ter Pouw & Dam Construction, January 1986.
Harada, J., T. Okada, S. Shimada, and T. Yamaguchi, Construction of Tamagawa Dam
by the RCD Method, ICOLD Congr., 15th, Lausanne, 1985
Hirose, T., Research and Practice Concerning RCD Method, ICOLD Congr., 13th, Rio
de Janeiro, 1982.
172 Chapter Six
Hirose, T., and S. Takebayashi, Present State and Problems of Rationalized Construc-
tion of Concrete Dams, Concrete Library of Japan Society of Civil Engineers, no. 2,
December 1983. Hirose, T., and T. Yanagida, Dam Construction in Japan: Burst of
Growth Demands Speed, Economy, Concrete I n t e r n a t i o n a l , May 1984.
International Commission on Large Dams (ICOLD), Roller-Compacted Concrete for
Gravity Dams-State-of-Art, Bulletin 75, 1989.
Kokubu. M.. Develonment in Jaoan of Concrete Dam Construction bv the RCD
Methbd, text of speech, ICOLD hongr., 14th, Tokyo, 1984.
Nagataki, S., T. Yanagida, and T. Okumura, Construction of Recent RCD-Concrete
Dam Projects in Japan, Roller-Compacted Concrete, ASCE, New York, May 1985,
pp. 90-101.
Research Committee on Rationalized Execution of Concrete Dam Construction, Tech-
nical Guide to RCD Construction Method, (Draft, 1981), Technology Center for Na-
tional Land Development, August 1981.
Shimizu, S., S. Jojima, and T. Yanagida, The Development of the RCD Method in Ja-
pan, Water Power & Dam Construction, January 1986.
Takahi, K., The Outline of Design of RCD Dams, presented at Roller-Compacted Con-
crete II, ASCE, San Diego, March 1988 (not published in proceedings).
Chapter
7
RCC Applications
in Embankment Dams
RCC
Year RCC Max. height V&me, MSA, in C t FA,
completed Name of dam country, state OWW/engilWX dam, ft. (ml yd3(m3) (mm) lb/yd3/(kg/m3)
Original design
Foundation improvement
1968 Cochiti U.S.A., U.S. Army Corps of Engineers, 255 58,500 3 167 + 0
New Mexico Albuquerque District (78) (44,700) (75) (107 t 0)
1988 Mount St. Helens U.S.A., U.S. Army Corps of Engineers, 184 15,000 3 320 t 80
sediment retention Washington Portland District (56) (11,500) (75) (190 t 47)
structure
Central Core
1961 Shihmen cofferdam Taiwan Shihmen Reservoir Administration 210 20,000 3 142 t 89
Authorityflippetts-Abbett- (64) (15,300) (75) (84 t 531
McCarthy-Stratton (TAMS)
1970 Karun cofferdam Iran Ministry of Energy/ 164 13,000 4 169 t 0
Campenon Bernard (50) (10,000) (100) (100 t 0)
1975 Al Massira cofferdam Morocco LEtaWCampenon Bernard 66 2490 4 169 t 0
(20) (1900) (100) (100 t 0)
1982 Holbeam W o o d U.K., Southwest Water Authority/ 39 5360 1% t 160 t 0
Devon SWW Land Drainage Group (12) (4100) (40) (95 t 0)
Spillway--gravity section
1984 Dolet Hills U.S.A., Southwestern Electric Power Co./ 35 26,100 350 + 175
Louisiana Freese & Nichols (11) (20,000) (208 t 104)
1986 Bucca Weir Australia, Queensland Water Resources 39 24,300 lY? t 152 t 152
Queensland Commission/Gutteridge, (12) (18,600) (40) (90 t 90)
Haskins & Davey
1988 Stacy (now S.W. U.S.A., Colorado River Municipal Water 156 116,700 1% 210 t 105
Freese) Texas Dist./Freese & Nichols (48) (89,200) (38) (125 t 52)
Overtopping protection
1979 Revelstoke cofferdam Canada, B.C. Hydro 150 9900 1Ys 284 t 0
British B.C. Hydra (48) (7600) (38) (169 t 0)
Columbia
1984 North Loop (2 dams) U.S.A., Trammel1 Crow Co./ 35 & 32 20,700 3 200 t 80
Texas Freese & Nichols (11 & 10) (15,800) (75) (119 + 47)
1985 Great Hills U.S.A., Trammel1 Crow Co./ 41 13,000 lY2 246 t 98
Texas Camp Dresser & McKee (12) (9,900) (38) (146 t 52)
1986 Bucca Weir Australia, Queensland Water Resources 39 7,100 1Ya 152 t 152
Queensland Commission/Gutteridge, (12) (5400) (40) (90 t 90)
Haskins & Davey
Composite darn
1986 Arabie (now Mokgoma South Africa, Lebowa Dept. of Development/ 118 132,000 3 61 t 125
Matlala) Lebowa Theron, Prinsloo, & van Tender (36) (101,000) (75) (36 + 74)
Rehabitation
(Continued)
Figure 7.1 Roller-Compacted Concrete Applicators in Embankment Dams. 6htinued.J
RCC
Year RCC Max. height V&me, MSA, in C + FA, lb/
completed Name of dam country, state Owner/engineer dam, It. (In) yd3tm3 (mm) yd3/Ck@m31
1980 Tarbela (cofferdam for P&iStan Pakistan Water & Power Develop- 470 60,000 6 250 + 0
auxiliary spillway merit Authority/TAMS (143) (36,060) (160) aver.
plunge pool (148 t 0)
construction)
1981 Tarbela (lining of Pakistan Pakistan Water k Power Develop- 470 1,230,OOO 6 260 t 0
auxiliary spillway ment Authority/TAMS (143) (940,000) (150) wer.
plunge pool) (148 t 0)
1982 Tarbela (backfill of PakiStan Pakistan Water & Power Develop- 470 110,060 6 260 t 0
tunnel 4 stilling ment Authority/TAMS (143) @4,000) (150) aver.
basin) (148 t 0)
1983 Tarbela (lining of PEkiStan Pakistan Water & Power Develop- 470 96,000 6 250 t 0
tunnel 4 plunge pool) ment AuthorityflAMS (143) (73,000) (160) aver.
(148 t 0)
1983 Tarbela gravity wall- Pakistan Pakistan Water & Power Develop- 470 175,000 6 250 t 0
powerhouse area) merit Authority/TAMS (143) (134,000) (150) aver.
(148 t 0)
1986 Tarbela (gravity wall Pakistan Pakistan Water & Power Develop- 470 200,000 6 250 t 0
extension-power- ment Authority/Charles T. Main (143) (153,000) (150) aver.
house area) (148 t 0)
Spillway Replacement
1980 North Fork Toutle River U.S.A., U.S. Army Corps of Engineers, 38 18,660 1Ya 600 t 0
debris retention struc- Washington Portland District (12) (13,800) (38) (297 t 0)
ture
Overtopping protection
I Replacement
1985 Kerrville Ponding U.S.A., Upper Guadalupe River Authority/ 21 22,000 3% 200 t 0
Texas Espey-Huston & Assoc. (6.41 (16,800) pit run (119 t 01
(90)
1986 Dryden (2 dams) U.S.A., Chelan Public Utility District I/ 14 4,200 1 400 t 100
Washington CHPM-Hill (4.31 (3210) (251 (237 t 59)
1986 Cedar Falls U.S.A., Seattle City Light/ 34 5500 2 185 t 155
Washington R. W. Beck & Assoc. (10.41 (42001 (501 (110 t 921
1989 Marmot U.S.A., Portland General Electric/ 48 10,300 1% 120 t 180
Oregon Ebasco Services (14.61 (7870) (381 (71 t 1071
178 Chapter Seven
Construction was similar to the mass placement for Cochiti Dam ex-
cept that a dual windrow spreader was used to place the outer cement-
treated material as well as an adjacent untreated pervious zone.
The face of what now would be termed RCC was designed to protect
the dam from wave action. It was not subjected to reservoir water un-
til 1983, when a concrete labryinth spillway was constructed to raise
the level of the lake to coincide with the original soil-cement slope pro-
tection. Nevertheless, the facing has been subjected to numerous
freeze-thaw cycles since 1963 with little noticeable deterioration. In
many areas, the imprint of the rubber-tired roller remains on the
RCC.
When the spillway was raised, an additional 16,000 yd3 (12,200 m3)
of coarse aggregate soil-cement (RCC) was required to protect a dike
at the left abutment. Using basically the same material source, the
Bureau of Reclamation decided to use a l-in (2.5mm) minus material
rather than the 3-in (75-mm) material used in the original construc-
tion. This resulted in an increase in cement content to 9 percent by
dry weight in order to achieve equivalent durability and compressive
strength.
A concrete approach was used by the U.S. Army Corps of Engi-
neers, Portland District, to design the RCC upstream slope protec-
tion for the Mount St. Helens Sediment Retention Structure. Resis-
tance to abrasion and erosion from high volcanic sediment loads in
the Toutle River was the controlling design criterion rather than
freeze-thaw durability. The RCC was placed in 2-ft-thick (0.6-m)
lifts and required 320 lb of cement and 80 lb of class F fly ash per
cubic yard (190 kg cement and 47 kg fly ash per cubic meter) to
meet the compressive strength specification of 3000 lb/in2 (20.7
MPa) at 28 days (see Sec. 7.3.3).
El. 190
-190
-180
-170
-150
ilty river cobble gravel
ter in original design
-140 pervious core in otginal design
-130
Bedrock
Figure 7.3 Cross-section of Shihmen Dam.
t
182 Chapter Seven
cement plus 53 kg/m3 of fly ash). A mix containing 1.5 bags of ce-
ment and one bag of fly ash per cubic yard was used at the begin-
ning of construction.
Using a 14-in-diameter (360-mm) mold and a compactive effort
equivalent to modified Proctor, the 2.5-bag mix at optimum moisture
of 5 percent by dry weight produced a 2%day compressive strength of
2000 lb/in2 (13.8 MPa) in the laboratory.
The RCC was placed in 12-in (300-mm) lifts. Originally, 50-ton
(45 metric-ton) rubber-tired rollers were planned to be used for
compaction. Instead, the dump trucks used to haul the material to
the cofferdam started the compaction, which was finished by sev-
eral passes of a D-8 crawler tractor used to spread the material. The
final properties of the core are unknown because no permeability
tests were done and no cores were extracted after completion of con-
struction.
The use of RCC for the central core of the upstream cofferdam at
Shihmen led designers Campenon Bernard of Paris to design similar
RCC cores for the cofferdams at Karun Dam in Iran in 1970 and AI
Massira Dam in Morocco in 1975. The 164-ft-high (50-m) cofferdam at
Karun was located between the approach channel to the diversion
tunnels and the main dam. At Al Massira, a 66-ft-high (20 ml coffer-
dam was needed to allow construction of three concrete buttresses to
the right of the diversion channel. Lack of space for construction of a
clay-core rock fill led to the selection of RCC for the core of the coffer-
dam, which was subjected to a head of water during the entire period
of construction of the buttresses.
7.2.4 Spillways
The use of RCC for foundation improvement, upstream slope protec-
tion, and the central core of an embankment dam is based on devel-
opmental work done in the 1960s. However, it was not until the initial
work on RCC gravity dams was completed in the early 1980s that the
use of RCC for embankment dam spillways came into use.
Generally, RCC spillways are gravity overflow sections located in
the central portion of a longer earth embankment. Their design is
identical to that for an RCC gravity section, taking into account the
flow over the structure. In each of the three spillway projects de-
scribed here, galleries and foundation drains were not included in the
designs. Hence, the sections had to be designed to accommodate max-
imum uplift pressures.
The scheduling of construction of RCC spillways in relation to the
adjacent sections of embankment is an important consideration. It is
preferable to raise the spillway and embankment together for con-
RCC Applications in Embankment Dams 183
(4
RCC protection
--.. ._.-
El. 16.2
FI 1.52
b
Laver of beddina 1
Conventional maSs
concrete facing
rO.6 steps
concreteNom: 0.3 T-
-A
,-Reinforced El.
, 20 RCC l i f t s =
c I -&riq drains&/ &, 4&E El. 5.3
- I _-
.
z Layer of bedding I
,-^L^-l-
concrete over I
foundation surface
r
I_
Y
s. 23.3 -I
(W
Figure 7.4 RCC spillways. (a) Dolet Hills Dam; (b) Bucca Weir. (1 ft = 0.3m.j
164 Chapter Seven
El. 1564.0
Interior pier -
El. 1517.25
El. 1469.0
w
Figure 7.4 RCC spillways. (c) Stacy Dam. (1 ft = 0.3m.I Khztinued)
7.2.4.1 Dolet Hills Dam. The RCC spillway at Dolet Hills was de-
signed by consultants Freese and Nichols. It has a crest length of
about 200 ft (61 m) and is located near the left abutment of the 2600-
ft-long (790-m) embankment which impounds a makeup water reser-
voir for a coal-fired powerplant near Mansfield, Louisiana. Because of
the gradual slopes of the upstream and downstream flow surfaces, no
forming was necessary to construct the basic 35-ft-high (10.7-m) RCC
structure.
The spillway section is zoned so that a richer RCC mixture was used
for the exterior 6 ft (1.8 m) measured perpendicular to the slope. A
plant-mixed mortar of two parts sand and one part cement was placed
as a bonding mix between lifts at the exterior zones of the section. The
dry mix was hand-broomed over the previously placed RCC lift surface
and then sprinkled with water to form a mortar prior to placement of
the next lift.
The earth embankment was raised at the same time as the spillway
in order to provide access to the RCC work area. Once the RCC con-
struction procedure was established, the contractor had to increase
the rate of fill placement on the embankment to keep up with the pace
of concreting.
RCC Applications in Embankment Dams 185
7.2.4.2 Bucca Weir. The 39-ft-high (12-m) Bucca Weir is about the
same height as the Dolet Hills spillway, but it presented a different
problem for design consultants Gutteridge Haskins and Davey. Lo-
cated between riverbanks, the 426-f&long (130-m) RCC overflow sec-
tion is more than one-half of the structures total length of 735 ft (224
ml.
Earthfill sections abutting the central RCC weir are 8 ft (2.5 m)
higher than the concrete. The earthen sections are designed to be
overtopped by a 1-in-3-year flood. To accommodate this overtopping,
the downstream slope of the earthfill sections and downstream
riverbanks are protected with a lo-ft-wide (3-m) drained zone of RCC.
For floods with an annual exceedance probability of 1 in 10 years or
greater, the entire structure becomes submerged due to the buildup of
backwater. See Sec. 3.4.3.5 for the design of the section.
Stair-stepped conventional concrete placed concurrently with the
RCC is used on the 0.5 H : 1 V downstream slope of the spillway. The
1 H : 1 V upstream face is unformed. A conventional concrete cap on
the crest is designed for the future attachment of a 2-ft-high (610-mm)
inflatable rubber flash board.
A 6.6-ft-wide (2.0-m) zone of bedding concrete was placed between
RCC lifts at the upstream face to reduce seepage. The conventional
concrete facing on the downstream slope is drained by a network of
strip drains made of polypropylene fiber encased in a geotextile.
A 2-ft-wide (610-mm) zone of noncemented RCC aggregate placed
between the RCC spillway and earthfill end sections was included in
the design to provide support for the RCC during construction.
During construction, a flood overtopped the central RCC weir by 3.0
ft (0.9 m). The material was not damaged and the flood was passed
without incident.
7.2.4.3 Stacy Dam. The 568-ft-wide (173-m) spillway for Stacy Dam
(now S.W. Freese Dam) in Texas differs from the uncontrolled Dolet
Hills and Bucca Weir spillways in that it is a gated structure which
combines both overflow and nonoverlow sections. Located in the cen-
tral portion of a 2-mi-long (3.2-km) embankment, the six-bay spillway
has a capacity of 216,000 ft3/s (6120 m3/s).
Both the overflow and nonoverflow sections require different solu-
186 Chapter Seven
tions using RCC. For the overflow ogee section, the RCC as shown in
Fig. 7.4~ is used as interior mass capped with a minimum thickness of
8 ft (2.4 m) of anchored conventional concrete.
Designers Freese and Nichols devised a unique solution for seepage
control for the 103-ft-high (31.4-m) nonoverflow gravity sections. Bor-
rowed in part from the design of the upstream deck of a concrete-faced
rockfill dam, an H-in-thick (460-mm) reinforced and waterstopped
conventional concrete face was specified. See Sec. 3.5.2.2 and Fig. 3.10
for a description of the upstream face.
7.2.6.2 Austin detention dams. Three dams for the same owner at
Austin, Texas, had basically the same design criteria. Each had to ac-
commodate a four-lane roadway on the crest, retain a l-in-loo-year
flood, and be able to be safely overtopped for any event up to the prob-
able maximum flood.
The design solution by consulting engineers Freese & Nichols for
two of the dams, called the North Loop detention dams, consisted of a
combination earthfill and RCC gravity section as shown in Fig. 7.6.
The upstream zoned earth portion provided the required crest width
for a four-lane roadway while the downstream RCC section provided
the overtopping protection. The 29-ft (8.8-m) height of the dams was
chosen to store the loo-year flood.
Esthetics were important for the dams, which are part of a business
park development. Precast concrete panels were used to form the
188 Chapter Seven
E x i s t i n g ground l i n e
Figure 7.6 North Loop Detention Dam, No. 1. (Note: 1 ft = 0.3 in.)
downstream face of the RCC gravity sections and also to form a three-
level continuous planter across the dams. Vandals have spray-painted
graffiti on the panels, partially ruining the intended effect.
For the third Austin dam, built at Great Hills at the Arboretum,
consulting engineers Camp, Dresser & McKee faced a similar design
problem. In addition to the hydraulic and roadway requirements, the
owner wanted a permanent lake to enhance the development.
An upstream earth embankment would have taken up too much
room in the proposed reservoir at the cramped site. So the designers
decided to compact select fill between two RCC gravity sections, one
having a vertical upstream face and the other a vertical downstream
face. A chimney drain of coarse material was placed behind the up-
stream RCC section to intercept seepage, which was carried to a
drained crushed-rock blanket and perforated drain at the low point in
the select fill (see Fig. 7.7). RCC was also used as a lining for the lake.
1
.Y Select - -
=a
it= embankment J=Ell
/G P -
Figure 7.7 Great Hills at the Arboretum Dam. (Note: 1 ft = 0.3 m; 1 in = 2.54 cm.)
RCC Applications in Embankment Dams 199
None of the three dams has been overtopped since they were com-
pleted in 1984 and 1985.
7.3 Rehabilitation
days, The next flood season was due in six months. During that period,
it was necessary to rebuild the damaged tunnel and to provide side
support for the two adjacent tunnels, 1 and 3.
The material used for the rehabilitation of the eroded rock fill had
to have the ability to support itself and have the properties of a low-
strength concrete. It also had to be placed very quickly. RCC, or
rollcrete, was selected by Tippetts-Abbett-McCarthy-Stratton
(TAMS), the owners design consultant.
A total of 460,000 yd3 (350,000 m3) of RCC was placed in 42 working
days with a peak daily placement of 24,000 yd3 (18,400 m3). In the re-
construction of the tunnel it was possible to reduce the diameter to 36
ft (11 m) because the larger bore was no longer needed for diversion of
the river during construction. The work was completed in time to
safely pass the spring floods.
There was a wide variation in the compressive strength of the RCC
fill material. A g-in (230-mm) minus pit-run aggregate with a poorly
graded sand portion was used in the mix. The strength variation was
caused by known variations in cement and moisture content, aggre-
gate grading, and probably compactive effort as well.
With a cement content in the two-bag range (188 lb/yd3 or 112 kg/
m3), the IO-day compressive strength varied from a low of 1260 lb/in2
(8.7 MPa) to a high of 4970 lb/in2 (34.2 MPa). Thirteen 6-in (150-mm)
cores were taken and averaged 2530 lb/in2 (17.5 MPa).
7.4 Replacement
Due to failure, damage, or aging, a number of embankment dams need
to be replaced each year. The design and construction of an RCC re-
placement dam is no different than for a new dam, with the possible
exception that the old embankment may be used as a cofferdam dur-
ing construction.
194 Chapter Seven
P -i
36tl
6 in
concrete
3511
r
Figure 7.10 Cross section of Kerrville Ponding Dam in service spillway area.
dams. The two structures combined required a total of 4200 yd3 (3210
m3) of RCC.
Working around the clock, the contractor completed the smaller up-
stream RCC section in 24 hours, took a day off, and then built the
downstream dam in 46 hours.
Bibliography
Bush, E. G. W., Rollcrete in Revelstoke Cofferdam, Proceedings of the Construction
Industry Research and Information Association (CIRLA) International Conference on
Rolled Concrete for Dams, London, June 1981.
Cannon. R. W.. Laboratorv Investieations and Full-Scale Trials bv the Tennessee Val-
ley Authority, Proceed&Is of t[e CIRIA International Confeience on Rolled Con-
crete for Dams, London, June 1981.
Catanach, R. B., and T. N. McDaniel, Cement-Stabilized Fill for Conduit Support,
Journal of the Soil Mechanics and Foundation Diuision, AXE, vol. 97, no. SM6, June
1971, pp. 959-963.
Chao, P. C., Tarbela Dam-Problems Solved by Novel Concrete, Civil Engineering,
AXE, December 1980.
Cooke, J. B., RCC Use With the CFRD Dam, ICOLD Sixteenth Congress, San Fran-
cisco, June 1988, vol. V, pp. 465-468.
Forbes, B. A., Roller-Compacted Concrete-Development in Dams in Australia, Con-
crete Institute of Australia, Queensland Branch, Water Retaining Structures Semi-
nar, September, 1986.
Hansen, K. D., and J. W. France, RCC: A Dam Rehab Solution Unearthed, Civil En-
gineering, AXE, September 1986.
Johnson. H. A.. and P. C. Chao. Rollcrete Usaae at Tarbela Dam. Concrete
InteriationakDesign and Constkction, vol. 1, no. ?l, November 1979.
Launay, J., Soil Cement and Roller-Compacted Concrete: Rollcrete, Conference at
LPPE, Casablanca, October 1986.
Leakage No Problem at New RCC Dam, Highway & Heavy Construction, July 1985.
Lemons, R., A Combined RCC and Reinforced Concrete Spillway, Roller-Compacted
Concrete II, AXE, New York, February 1988, pp. 51-60:
Lowe. J.. III. Use of Rolled Concrete in Earth Dams. Discussion to: Utilization of Soil-
Cement as Slope Protection for Earth Dams, ASCE First Water Resources Engineer-
ing Conference, Omaha, May 1962.
- Roller Compacted Concrete Dams-An Overview, Roller Compacted Concrete
II, AXE, New York, February 1988, pp. l-20.
Morsman, D. E., L. E. Lawler, and J. R. Seimears, Construction of Two Spillways Us-
ing Roller-Compacted Concrete, Roller-Compacted Concrete, AXE, New York, May
1985, pp. 62-70.
Portland Cement Association, Soil-Cement Slope Protection at Ute Dam-A Photo-
graphic Construction Report, Chicago, 1964.
RCC Dam Survives Texas Flood, ENR, April 24, 1986.
Reeves, G. N., and L. B. Yates, Jr., Simplified Design and Construction Control for
Roller-Compacted Concrete, Roller-Compacted Concrete, ASCE, New York, May
1985, pp. 48-61.
Rollcrete Repair is Quick, ENR, March 19, 1981.
Verigin, W. M., Benson, S. A. and Carney, M. J.: Cedar Falls Roller-Compacted Con-
crete Dam, Roller-Compacted Concrete II, ASCE, New York, February 1988, pp 39-
50.
Chapter
8
RCC as a New
Construction Method
8.1 .l Scheduling
Construction scheduling for RCC is less forgiving than for mass con-
crete. Although some mix designs can have greater tolerances than
conventional concrete, RCC is still a sensitive concrete and the critical
199
Figure 8.1 Time of placement and production rates for RCC dams.
RCC volume, Days per Shifts No. & type Maximum daily
Dam yda (m3) week (no. x h) mixing units Total time rate, yds (m3)
Willow Creek 433,000 6 2x8 2 drums < 5 months 5800
(331,000) (4460)
Copperfield 183,000 I 2 x 10 2 pugmills < 4 months 3400
(140,000) (2600)
Middle Fork 55,000 I 2 x 10 1 drum 45 days 2000
(42,100) (- 10 days planned (1530)
interruption)
Galesville 210,000 7 2 x 10 1 pugmill 10 weeks 7500
(160,000) (- 10 days planned (5700)
interruption)
Grindstone Canyon 114,500 7 2 x 10 1 drum 55 days ( - 4 days 4800
(87,500) rain shutdown) (3670)
Monksville 289,000 6 2 x 10 1 pugmill ~5 months 7800
(221,000) (5960)
Upper Stillwater 1,471,OOO 7 2x8 2 drums and 10 months 11,000
(1,127,OOO) 2 pugmills (over 3-year period) (8410)
Lower Chase Creek 26,000 7 2 x 10 1 drum 23 days -
(19,900)
Elk Creek 348,000* 7 2 x 10 4 pugmills >3 months 12,390
(266,000) (in 2 placement (9470)
periods)
Stagecoach 44,500* 7 2 x 10 1 drum 37 days 2260
(34,000) (- 2 days shutdown) (1730)
*Plus conventional concrete face or faces.
RCC as a New Construction Method 201
path for placing RCC is focused on completing one lift at a time. There
are no alternate monolithic blocks to form or place while problems are
being analyzed.
To avoid costly delays over disputes on specification compliance, the
authority to resolve engineering problems must be vested in a well-
trained field organization. Lines of communication between the
project engineer and contractor must be clearly established and used
frequently. Clarity, candor, and cooperation are very important in
achieving the speed of placement possible with RCC.
Thorough field and classroom training of construction crews and in-
spectors in the handling and placement of RCC is essential. Lean, dry
RCC mixes resemble damp gravel and are often placed by road-
building or earth-dam crews using earthmoving equipment. However,
all the desired characteristics of the product are those of concrete.
Meeting the specifications requires educating workers to the specific
requirements of RCC as a new construction material requiring spe-
cific construction methods.
Because so much depends on fast, efficient placement of the RCC,
all related activities such as foundation cleanup, access, assembly
of embedded components, and stockpiling of materials must be me-
ticulously planned and scheduled well before construction starts.
Construction of forms and assembly of embedded items should be
planned and scheduled so that as much of the work as possible is
done off the dam, or if necessary, from the top of a lift during shift
changes.
Lift scheduling is often complicated by concerns over heat buildup.
Because the production rate of RCC can be very high, controls to limit
thermal cracking may restrict the season or time of day that place-
ment is allowed as well as the rate of placement.
At Upper Stillwater Dam, all of the RCC was placed during a five-
month weather window each year from May to October and only dur-
ing two 8-h shifts starting at 8 p.m. This was necessary in order to
keep placement temperatures below the 50F (10C) specification
limit. At Willow Creek and Galesville dams, placement was limited to
no more than three and four lifts, respectively, each 24 h.
Conversely, at Elk Creek and Stagecoach dams, the contractor was
encouraged to place RCC as fast as possible. At peak placement, six
1-ft (0.3-m) lifts were placed in a day at Stagecoach. The 150-ft-high
(46-m) dam required 44,500 yd3 (34,000 m3) of RCC which was placed
during 37 days in the summer of 1988 (see Fig. 8.2). To keep place-
ment temperatures low at Elk Creek, the specifications required that
the most massive sections be constructed during the late winter and
early spring.
Chapter Eight
Figure 8.3 All conveyor delivery at Elk Creek Dam. Each conveyor line delivers both
conventional and roller concrete. (Each line has a separate smaller conveyor for con-
ventional concrete:) The conveyor is self-rising on the ventricle pipe stands.
Minimum
allowable Actual
variability variability
Test Average index index*
Figure 8.4 Monksville Dam RCC mixer proficiency test results. [From Snider and
Schrader (1988j.I
208 Chapter Eight
main feed belt; a 75ton (68-t) cement silo with aerators and one vane
feeder; a Davis pugmill with a capacity of 500 yd3/h (382 m3/h); a
stacker belt; and an 13yd3 (14 m3) two-stage surge bin.
The plant could be operated manually or by a computer pro-
grammed to initiate the production sequence starting at the surge
hopper. Sensing devices included a feed-belt scale; tilt gages on each
feed bin; an electronic water flow meter; and a revolution counter for
metering cement through the calibrated vane feeder. Continuous dig-
ital display was available for real-time measurement of aggregate
feed. For aggregate, cement, and water, the system provided cumula-
tive data every 5 min.
layers of the material with dozers before compacting the layers into a
thick lift.
Whatever transport method is used, the intent should be to get the
material in place quickly, as close to its final location in the lift as
possible and with little rehandling or exposure to weather. If haul ve-
hicles are used, bottom-dump trailer trucks or large-capacity, wheeled
tractor-scrapers offer best results. Because of the higher unit weight of
RCC, weight rather than the volumetric capacity of the vehicle will
probably control the amount of material hauled per trip. If batch mix-
ing is used, matching of the capacity of the haul unit to the batch mix-
ers is critical.
Bottom dumps, because of their short discharge drop distance, min-
imize segregation. Scrapers force the mix out of the bowl and place it
in a relatively uniform layer that requires little secondary spreading.
Scrapers have good maneuverability, top load well, and the bowl un-
loads with few problems. But their basic design is for digging and
rough hauling. Consequently, a scraper with the same horsepower as
a truck will not haul material as efficiently. Scrapers are more mobile
than bottom-dump trailer trucks in difficult terrain, however, and
have better distribution of stress under the tires.
Haul roads need to be laid out, constructed, and maintained to limit
damage from turning and to prevent contamination of the RCC lift
surface from mud, old RCC, or cement spillage and any other foreign
material. Tire cleaning may be required as vehicles approach the dam.
In many cases, access roads near the dam need to be surfaced to pre-
vent tracking of the material onto the lift. The use of clean, crushed
rock for the haul roads at Galesville Dam kept the tires of the haul
fleet clean.
At Monksville Dam, the designers originally specified that RCC
hauled to the dam from surge hoppers near the dam or entirely by con-
veyor belt to avoid tracking of contaminants onto the dam. Instead,
the contractor was allowed to use scrapers to haul RCC from the batch
plant to the point of placement provided that:
. All vehicles entered or left the dam surface in a straight line via a
lane parallel to the axis and immediately adjacent to the down-
stream slope.
n Contaminated haul roads were cleaned immediately by a full-time
crew working exclusively on cleanup.
m The contractor repaired all damaged RCC at the entry and exit
points by removing and replacing it.
n All travel on the dam was in one direction without any turns.
210 Chapter Eight
At Middle Fork Dam, a 200-yd3/h (152 m3/h) Ross batch plant and
drum mixers for RCC were situated upstream of the dam on fill com-
pacted behind a sheetpile tieback wall. For the lower elevations of the
dam, a gob hopper discharged RCC onto a stacker conveyor and then
into a 36-in-diameter (0.9-m), enclosed rock ladder. It consisted of a
steel pipe with semicircular steps welded on the inside which kept the
aggregate from segregating as the mix was chuted down a maximum
distance of about 50 ft (15.2 m) to the construction surface.
As RCC placement progressed, sections of the rock ladder were re-
moved and the vertical drop decreased until the conveyor was dis-
charging directly onto the dam. For the uppermost elevations, three
sections of conveyor were used in a scissored arrangement. The final
stacker conveyor was placed atop a tower made of scaffolding. Front-
end loaders were used to catch or pick up the RCC from the chute and
then to spread the mix for most of the lifts. Near the crest, the con-
veyor discharged into 10 yd3 (7.6 m3) dump trucks.
8.5 Compaction
Average PLI 115 min for compacted lifts to 6 in (20.5 kg/cm for lifts to 15
mm)
150 min for compacted lifts over 6 in (27 kg/cm for lifts over
15 mm)
Amplitude 0.025 to 0.035 in (0.63 to 0.89 mm)
Frequency Not less than 1700 vibrations per minute (28.33 Hz)
Rolling speed Not greater than 2 mi/h (3.2 km/h)
plastic surface condition on the lift surface prior to placing the next lift.
Any aspect of the RCC construction process that influences those desired
characteristics must be carefully executed. For insurance, in some cases
a thin layer of cement-rich bedding mix, mortar, or grout is required to
be placed on all or part of a completed lift before the next layer of RCC is
placed. Most RCC designers specify some kind of bedding for part or all of
each lift lane at the upstream face, except for high-paste content mixes.
A %-in (12.7-mm) layer of broomable, sanded mortar was spread
over the entire surface of each of the compacted, 2-ft (0.6 m) lifts at
Elk Creek Dam to fill voids and increase the bond at the interface.
The mortar was spread using a serrated rubber squeegee mounted on
the front of a small farm-type tractor. A test section built in 1985
showed that the biaxial shear strength at lifts treated with mortar av-
eraged from 205 to 270 lb/in2 (1.4 to 1.9 MPa). Surprisingly, the
higher shear strengths resulted when lift surfaces were not cleaned
prior to placing the mortar and the next layer of RCC. Biaxial shear
strengths achieved for test section lifts are shown in Fig. 8.6.
Transporting and placing a bedding mix can be very complex near
the upstream face. Placing the bedding mix is usually combined with
placement of RCC and facing concrete at the same time and in the
same small area. That is particularly true as the dam narrows near
the crest. Detailed planning and scheduling of the various work crews
Average Shear
Confining Pressure Strength
Lift joint No of
treatment lb/in kg/cm tests lb/in kg/cm*
Figure 6.6 Elk Creek Dam biaxial shear strengths, RCC test section, 1985. [From
Hopman and Chambers (1988)J
216 Chapter Eight
Figure 8.7 Miller Formless slip-formers with side-mounted mold-placed curbs at Upper
Stlllwater Dam.
dom, worked fairly well at Upper Stillwater. Most of the problems re-
lated to controlling grade. A self-leveling Spectra-Physics laser, model
945L, was used to control grade. For alignment, a Laser Alignment
model 5000 was used. During the longest runs across the dam, con-
struction dust and the heat from the lamps used to illuminate the
work area tended to distort or scatter the laser beams, causing the
slip-former to run up or down.
The facing concrete tended to squat or settle after being slip-formed,
which made it difficult to hold the prescribed grade. A number of so-
lutions were proposed-slowing the machine or using a longer mold.
In the end, however, the tolerances-l in. horizontal or vertical dis-
placement across the dam-were relaxed to 1%. in and these were met
consistently.
The 16-ft-long and 4-ft-high (1.2 x 4.9 m) tongue-and-groove panels
used for the upstream face at Willow Creek Dam were stacked edge-
to-edge and a cement-enriched RCC mix was placed against them (see
Fig. 8.8). Alignment of the panels was maintained during compaction
of the RCC by use of an exterior strongback system. A 5-ft-long (1.5 ml
threaded coil rod was used to anchor the panels into the compacted
RCC as a New Construction Method
RCC. The rods screwed into inserts in the facing panels and were se-
cured at the other end by a 4-in U02-mm) square washer.
No support was provided for the 0.8 V : 1 H downstream face of Wil-
low Creek. The uncompacted RCC had a tendency to stand on a l-to-l
slope, however, so the contractor placed the downstream side of each
lift with a motor-grader and compacted the material by running the
wheels along the outer edge. Although effective, this method posed
added safety risks and produced a corrugated look rather than a more
desirable smooth surface.
For the downstream face of Middle Fork Dam, conventional con-
crete was placed using 12-in (300 mm) curb forms and stacked in stair-
step fashion. The esthetically pleasing steps were not anchored. In-
stead they were were made monolithic with the RCC by vibrating the
two mixes together.
Scheduling and technical problems resulted at Middle Fork and Ce-
dar Falls dams because the conventionally formed downstream face
was not placed as quickly as the RCC lifts. The lag was two to three
lifts. That caused the RCC to dry out, making it difficult to create a
good bond between the conventional and RCC mixtures.
One solution is to place the conventional concrete ahead of the RCC.
Another is to place the downstream face concrete after the RCC work
is completed. For the Grindstone Canyon Dam spillway, rebar anchors
222 Chapter Eight
Figure 8.9 Grindstone Canyon Dam nearing completion of conventional concrete face
for uncontrolled-overflow spillway.
were set in the RCC before the conventional concrete was placed (see
Fig. 8.9).
At Winchester Dam, a relatively small RCC dam, precast panels
with 65mil-thick (1.65-mm) sheets of PVC liners cast into the back of
them were used to form a permanent watertight barrier on the up-
stream face, Every membrane joint between panels was spliced in the
field and every tieback support or anchor extending through the liner
had to be sealed. The PVC was tied into the foundation by wrapping
the liner under a lift near the base of the dam and tying the plastic
membrane into an RCC cutoff trench. The trained crew heat-welding
the lapped splices between the panels and over the anchor bars was
able to keep up with production. The composite panels have proved to
be an effective water barrier at Winchester.
Schrader has proposed a way of using precast panels to form the up-
stream face, placing RCC behind them and then backing the panels
about 15 in (38 cm) away from the dam for reuse as forms for a con-
ventional concrete cutoff wall. A strongback system with a plate and
double nut arrangement on the threaded anchor rod would position
each panel during RCC placement. The shiplapped panels would be
moved after the RCC had set by pulling them forward on the anchor
rods. All the panels would eventually be repositioned upstream and
RCC as a New Construction Method 223
the space between the completed RCC lifts and panels would be filled
with conventional concrete placed in a continuous operation. This
method has not been used to date.
The upstream faces of Monksville, Copperfield, and other RCC dams
were built with conventional concrete placed against forms and inte-
grated into the fresh RCC by roller compaction at the interface. For
Copperfield Dam, conventional panel formwork placed between sol-
diers anchored with tiebars back into the RCC were used for the
nonoverflow sections on either side of the service spillway. A thin
layer of conventional concrete was placed by transit mixers against
the vertical face at the same time that RCC was being dumped and
spread. Small vibratory rollers and tampers were used to compact the
interface.
The method was not successful at Copperfield, in part because of ex-
treme time limitations imposed by the private owner of the remote
dam and a decision made to sacrifice finishing work for speed. The
facing concrete did not provide sufficient cover for the RCC, and the
upstream face has an exposed, segregated RCC strip at the top of each
lift as shown in Fig. 8.10. Over time, wave action is expected to expose
the fully compacted RCC 4 to 6 in (10 to 15 cm) behind the facing con-
crete. Watertightness is being achieved by the use of a bedding con-
crete between each lift at the upstream sacred zone.
Figure 8.10 Upstream face of Copperfield Dam shows exposed RCC lifts.
224 Chapter Eight
0.02 min
Figure 8.12 Galvanized corrugated metal pipe sections used for arched roof of galleries
at Upper Stillwater Dam. (Courtesy of U.S. Department of the Interior, Bureau of Rec-
lamation, UINTA Basin Construction Office.)
RCC as a New Construction Method 227
(0.91-m) curbs for the galleries allowed RCC placement to continue un-
interrupted in the confined areas on either side of the galleries. Galva-
nized corrugated metal pipe sections were used for the arched roof of the
galleries. Results of this method are shown in Fig. 8.12.
Conventional formwork was used to form the inspection and drain-
age gallery within the dam section at Middle Fork Dam. All other con-
struction obstacles were eliminated in the design, however. The pri-
mary spillway and outlet conduits, for example, were combined in a
double-chambered tower placed against the face of the dam and con-
nected to a trench under the dam that led to an outlet structure down-
stream. The outlet works for Elk Creek Dam were incorporated into a
similar intake structure built on the upstream face so as not to inter-
fere with the placement of RCC.
Placement of gravel or sand fill in the gallery cavity as RCC rises
around it, then mining the loose material later is another approach
that has been taken. At Willow Creek Dam, the resulting gallery
walls were left in a rough condition and some of the fill material ad-
hered to the RCC. If desired, wood separators can be placed between
the fill and RCC lifts in order to obtain a smooth finish. At Galesville
Dam, a sledge hammer was used to dislodge the gravel which was
then removed by an industrial-grade vacuum cleaner.
Bibliography
American Concrete Institute, Roller-Compacted Mass Concrete, Report No. 207.5R-
89.
Bureau of Reclamation, Guidelines for Designing and Constructing Roller-Compacted
Concrete Dams, June 1987.
Bureau of Reclamation, Roller-Compacted Concrete: Interagency Forum, Divison of
Research and Laboratory Services, Lakewood, Colo., April 4, 1985.
Campbell, D. B., G. C. Elias, and E.K. Schrader, Monksville Dam: A Roller-Compacted
Concrete Water Supply Structure, ICOLD Congr., 15th, Lausanne, 1985.
Carruth, B., A Study of Construction Related Problems Encountered During the Pro-
duction and Placement of Roller-Compacted Concrete, Masters Research Report,
Colorado State University, Fort Collins, Fall 1984.
Dunstan, G., Continuous Volumetric Metering of Concrete Ingredients: The ARAN
Equipment Approach to Accuracy-How and Why It Works, Brisbane, Australia,
October 1986.
Forbes, B. A., Roller-Compacted Concrete: Design, Construction and Performance of
Copperfield Dam, Institution of Engineers Australia (Queensland Division),
Brisbane, September/October 1985.
Hopman, D. R., and D. R. Chambers, Construction of Elk Creek Dam, Ro&F-
Compacted Concrete II, AXE, New York, February 1988, pp. 251-266.
Hopman, D. R., 0. Keifer, Jr., and F. Anderson, Current Corps of Engineers Concepts
for Roller-Compacted Concrete in Dams, Roller-Compacted Concrete, ASCE, New
York, May 1985, pp. l-10.
International Commission on Large Dams (ICOLD), Roller-Compacted Concrete for
Gravity Dams-State-of-the-Art, Bulletin 75, 1989.
Jackson, H. E., Roller-Compacted Concrete for Dams, Electric Power Research Insti-
tute report AP-4715, Palo Alto, Calif., September 1986.
228 Chapter Eight
McKinnon, R., Roller-Compacted Concrete, World of Concrete, Session l-06, Las Ve-
gas, February 1983.
McTavish, R. F., Construction of Upper Stillwater Dam, Roller-Compacted Concrete
II, ASCE, New York, February 1988, pp. 267-276.
Nagataki, S., T. Yanagida, and T. Okumura, Construction of Recent RCD-Concrete
Dam Projects in Japan, Roller-Compacted Concrete, ASCE. New York. _ May 1985,
pp. 90-101. -
Parent, W. F., W. A. Moler, and R.W. Southard, Construction of Middle Fork Dam,
Roller-Comwacted Concrete. ASCE. New York. Mav 1985. DD. 71-89.
Schexnayder, C. J., and R. F.Stewart, ConstructionTechn&es for Roller-Compacted
Concrete, Transportation Research Record 1062, Transportation Research Board,
National Research Council, Washington, D.C., 1986.
Schrader, E. K., Watertightness and Seepage Control in Roller-Compacted Concrete
Dams, Roller-Compacted Concrete, AXE, New York, May 1985, pp. 11-30.
Snider, S.H., and E.K. Schrader, Design Changes and Constructi% at Monksville
Dam. Roller-Comaacted Concrete. ASCE. New York. Februarv 1988. ~a. 220-235.
Spreader Box Aids RCC Placement; Engineering News-Record,July ii,-1985.
Tucker, G., Elk Creek Dam: Roller-Compacted Concrete Mixing and Placing Study,
Report to Corps of Engineers, Portland District, 1984.
Withrow, H., Compaction Parameters for Roller-Compacted Concrete, Roller-
Compacted Concrete II, ASCE, New York, February 1988, pp. 123-135.
Chapter
9
Construction Control
and Specifications
229
230 Chapter Nine
In order to evaluate the bond between lifts of RCC, the test section
lifts should be placed at the same rate and using the same procedures
as those planned for the actual dam. Tests should be performed on the
completed section to assure that its properties are reasonably close to
those on which the design is based. If not, changes should be made in
the material or construction procedure. To determine the effect of a
proposed change, construction of a smaller, single-factor test section
may be required prior to the start of dam construction.
On a small project, the test section may be used strictly for deter-
mining the contractors construction capability and to establish test
procedures. In this situation, tests for material properties are not
done. The amount of time the mixing plant needs to be on site also is
shortened.
9.2.1 Aggregate
In order to produce a uniform RCC mixture, the grading and moisture
content of the aggregates must be consistent and within specification
limits. The two types of mixes respond differently to variations in
grading and moisture content. Concrete approach RCC mixes are
more sensitive to any change in aggregate grading that increases
voids. If changes occur, paste volumes need to be adjusted so that all
voids are filled. Soils approach RCC mixes achieve their desired
strength properties by maintaining an optimum moisture content, and
therefore are more sensitive to moisture changes in the aggregate.
Minimizing segregation is an important factor for all RCC construc-
tion.
Sieve analysis and wash tests to determine aggregate grading
ahould be an on-site requirement for all projects. Proper sampling of
aggregate per ASTM D 75 is important whether the sample is ob-
tained from large stockpiles, a bin, or a conveyor belt. Of particular
concern in the grading are the percentages of sand and minus #200
(0.075-mm) sieve fines. Changes in these percentages can affect the
232 Chapter Nine
Any hauling unit or other piece of equipment moving from off the
dam to the RCC surface must be checked to ensure that it is not track-
ing mud, clay, or other undesireable substances onto the construction
area. A means of removing the material prior to tracking it onto the
dam is preferred to cleanup of the RCC surface.
Conveyor-belt systems should be checked and modified as necessary
to minimize segregation or drying out of the material. For conveyor
belts carrying different RCC mixes or both RCC and conventional con-
crete, markers in the form of colored tags should be placed at the start
of a new material so it may be visually identified and placed in the
desired location.
9.3.4 Compaction
Consistently achieving required compaction is one of the most impor-
tant requirements of an RCC construction control program. Density
tests, as a measure of compaction or consolidation, provide an indica-
tion of the strength, bonding capability, and permeability of the com-
pacted RCC as well as a confirmation of the unit weight used in the
structural design calculations.
Specifications for compaction can be either prescriptive or require a
desired performance. Prescriptive specifications require a minimum
number of passes by a specified roller, based on its performance on a
test section. Performance specifications require that the contractor
achieve a certain percentage of maximum density for soils approach
mixtures. Concrete approach performance specifications may define
required compaction in terms of an optimum or average maximum
density.
Some specifications combine both types of compaction requirements.
Construction Control and Specifications 237
mum density for a concrete approach mix. The TAF density can be
computed by adding the SSD batch weights and dividing by its corre-
sponding absolute volume, or calculated after extended vibration of
RCC of the desired consistency. The required in-place density should
then be not less than 98 percent of the TAF density.
35F (2C) until covered. RCC surfaces that will be left exposed should
be cured for no less than 7 days and preferably 28 days. Water curing
is preferred over sprayed-on membranes, especially for surfaces that
will receive another lift of RCC, because the curing compound may act
as a bond breaker and because of the dry nature of RCC mixes.
Most specifications do not permit placing RCC when the ambient
temperature drops below 35F (2C). The owners representative may
permit RCC placing at lower temperatures if the mix and the surface
of the compacted RCC stay above 35F. If the ambient temperature
drops below 32F (OC), the surface of any exposed RCC less than 7
days old should be covered with heavy tarps, blankets, or other tem-
porary protection until after the ambient temperature rises to above
35F. Many contractors elect to shut down operations due to the added
cost of cold weather protection and reduced production rates when
nighttime temperatures start to consistently drop below freezing.
Most specifications prohibit RCC placement during heavy rain,
which is defined as more than 0.3 in/h (7.6 mm/h) or 0.03 in (0.76 mm>
in 6 min as defined by the U.S. Weather Bureau Glossary of Meteorol-
ogy. If heavy rain is anticipated, the amount of RCC left uncompacted
should be minimized, as the greatest problem with rain is altering the
uniformity and consistency of the mix. If the rain causes the moisture
content of the uncompacted mix to exceed specification limits, it
should be removed. This was done with considerable success during
the final season of RCC placement at Upper Stillwater Dam in 1987.
Specifications originally required the contractor to repair rain-
damaged lifts, but this proved to be too time-consuming and more ex-
pensive than removing all of the overly wet RCC.
stream slope of the dam, the tolerance for the unformed face could be
from 0 to 12 in (300 mm) as long as the variation in the overbuild is
not excessive.
Minimum frequency
Test Test designation and location
1. Aggregate Grading
Sieve analysis ASTM C 136 Once per shift of aggregate pro-
duction and RCC placement for
each stockpile.
75-pm (#200) sieve ASTM C 117 Once per shift for the combined
fines gradation
9.5.1 Aggregates
When an aggregate grading test is outside of specification limits, a
recheck sample is taken. If the recheck sample fails, the process is con-
sidered out of control and steps are taken to rectify the situation. If
not rectified, aggregate production and RCC placement can be
stopped.
The owner may test for verification of field moisture determinations
made by the contractor using the oven-drying procedure (ASTM C
566) or other means. If a discrepancy exists, steps are taken immedi-
ately to identify the problem and correct it so that accurate and veri-
fiable field moisture determinations are obtained. Changes in water
entering the mix with the aggregates must be adjusted for at the mix-
ing plant.
When tests for material finer than the No. 200 (0.075 mm) sieve in-
dicate an excessive quantity, corrective action must be taken immedi-
ately, either in aggregate production or stockpiling.
If the aggregate does not meet grading limits during production
start-up, the nonspecification material may be used in developing a
base for a stockpile. After that it may possibly be blended with other
material to produce an acceptable aggregate or used for site improve-
ments such as road surfaces.
9.5.5 Density
Low density of compacted RCC usually can be corrected by additional
rolling. If the moisture content of the mixture or another factor is so
far off that required density cannot be achieved no matter how much
rolling is done, it should be removed. Unacceptable material should be
removed quickly before it gains strength or causes a slowdown in RCC
placement. Nonspecification RCC may be allowed to remain at the
owners discretion, but no payment should be made for the material.
Low density can be caused by one or a combination of the following
factors: insufficient rolling, low or high moisture content, an inappro-
priate vibratory frequency or amplitude for the material, a time delay
prior to rolling, poor gradation or segregation of the mixture, or incor-
rect testing.
inders unless they are desired for historical purposes. Cylinders may
not represent the properties of the hardened RCC in the dam, they do
not give an indication of shear resistance or bonding at the lift lines
and they are evaluated well after any corrective action can reasonably
be taken.
A coring program is recommended for major dams as a way of track-
ing the success of the construction control program. Cores give an ac-
curate representation of compaction throughout lifts and the bonding
between successive lifts and material properties. The core diameter
should be as large as practical-6 in (150 mm) is considered the min-
imum-and cores should taken from representative locations within
the dam. Comprehensive construction records, such as when each Lift
was placed and under what conditions, when correlated with the cores
can provide valuable information for subsequent projects.
Because of the importance of recovering bonded lift joints and the
possibility of breakage at the lift lines during coring, a double-tube
core barrel is recommended. The coring program should be conducted
prior to reservoir filling. The core holes may serve a double purpose if
they can be used for drain holes or for the installation of inclinometers
or other instruments. The results obtained from the coring program
should be compared with the original design criteria to confirm the
structural stability of the dam.
Bibliography
American Concrete Institute, Roller Compacted Mass Concrete, Report 207~5R-89.
Bureau of Reclamation, Procedure for Consistency and Density of No-Slump Concrete
with Vibratory Table, Procedure 4905-86.
- Guidelines for Designing and Constructing Roller-Compacted Concrete Dams,
1987.
- Procedure for Determining Cement Content of Soil-Cement (Heat of Neutral-
ization Method)-Preliminary, 1988.
DeGroot, G., Soil-Cement Short Course-Quality Control and Field Testing Lecture
Notes and Example, U.S. Bureau of Reclamation, 1985 (unpublished).
Lawrence, D. J., Operations Guide and Modification Analysis for Use of the CE Con-
crete Quality Monitor on Roller-Compacted Concrete and Soil-Cement, U.S. Army
Corps of Engineers Civil Engineering Research Laboratory Technical Report M-854/
06 (Revised), July 1985.
Portland Cement Association, Concrete Pavement Construction-Inspection at Batch
Plant and Mixer, EB 084.OlP, revised 1980.
U.S. Army Corps of Engineers, Technical Provisions, Elk Creek Dam, Section 03660,
Corps if Engineer; Portl3ShCt.
Chapter
10
Preliminary Design
and Cost Estimates
24.5
246 Chapter Ten
1. There is zero cohesion at the lift lines and at the dam foundation
contact. A redefined factor of safety of 1.5 is suggested for this con-
dition, which depends on the residual sliding strength of the RCC
for shear resistance.
2. The unit weight of RCC is 150 lb/ft3 (2403 kg/m31 or greater and
the unit weight of water is 62.4 lb/ft3 (1000 kg/m3).
3. Drains that are 100 percent efficient are located at approximately 10
percent of the cross-sectional base width in from the upstream face.
The drains reduce the uplift hydrostatic pressure to one-third the dif-
ferential head between the headwater and tailwater pressure.
-8
r-
IIt
Axis of dam
Tc
r
H
Sl.0
l-s, -I
Preliminary Design and Cost Estimates 247
Wide V-shape
_ LB _1
r
40.00-
I I
%
A
35.00 -
r
= 3 0 . 0 0 -
8
ln
3
9 25 OO-
g cost = 1221
ro A A
Ox A
A
L A
i$ 20.00- \
%
t
s
15 oo-
Figure 10.5 Costs of RCC per cubic yard. (Note: 1 yd3 = 0.76 ma.)
Facing Added
RCC volume concrete cost
Height, as bid, yd3 Added cost cost per per fts
Dam Location ft (m) (kg/m3) Type of face per yd3 RCC yd3* face
1. Winchester Kentucky 74 32,000 Precast concrete panels with $10.04 $ 8.50
(23) (24,500) 65-mil PVC membrane plus +2.34 $ so.00 t 1.98
18-in concrete backing
2. Galesville Oregon 162.5 210,500 Average 18-in-thick concrete 5.88 117.85+ 6.54
(50) (160,800) plus sprayed on membrane t 1.50
3. Grindstone Canyon New Mexico 139 114,500 Average 24-in-thick concrete 5.46 107.a1+ 7.99
(42) (87,500)
4. Monksville New Jersey 157 289,000 Average 24-in-thick concrete 5.38 95.69+ 7.09
(48) (221,000)
5. Upper Stillwater Utah 294 1,357,ooo Horizontal slip-formed 3.88* 58.47+ 4.03:
(91) (1,037,500) elements---al-average (both faces)
6. Elk Creek Oregon 249 999,000 Average 36-in-thick concrete 4.91 71.64+ 7.96
(76) (763,800) plus waterstopped joints t 0.58 jts.
7. Stacy spillway Texas 103 103,800 18-in concrete-reinforced 4.23 110.29+ 8.04
(31) (79,400) plus waterstopped joints
*Includes cement and pozzolan (if used).
Includes cost of forming the face.
Not considered as water barrier-added cost of high-paste RCC must be considered in cost
evaluation.
NOTE: Costs presented were submitted by the low bidder and have not been escalated to 1987 or later
cost levels. See Fig. 10.4 for bid date.
Preliminary Design and Cost Estimates 253
The cost of the concrete dam section can then be determined by mul-
tiplying the volume determined from the equations in Sec. 10.4 by the
unit RCC cost from Fig. 10.5 plus $6 per cubic yard to account for the
cost of the upstream facing method. In this preliminary design and
cost estimate, the volume of the RCC in the section displaced by the
facing has not been reduced and the cost of applying a bedding con-
crete between successive RCC lifts has not been added. These and
other items can be considered once the design is refined at the feasi-
bility level of study.
For dams with less than 100,000 yd3 (76,500 m3) of RCC, the cost of
the upstream face can be considerably more expensive when expressed
as an added cost per cubic yard of RCC. As noted in Fig. 10.6, this
added cost for the membrance-faced concrete panel system at Win-
chester Dam amounted to an increase of $12.38 per cubic yard in the
basic RCC cost.
At the 145-ft-high (44-m) Stagecoach Dam, which was built in a
narrow canyon, alternate bids were taken in 1987 for a formed con-
ventional concrete face averaging 24 in (0.61 ml thick and for a
membrane-faced concrete panel backed by an average of 18 in (0.45
m) of conventional concrete. In this case the cost of the formed con-
ventional concrete reflected an added $16.68 per cubic yard for the
43,500 yd3 of RCC or a 57 percent increase from the basic cost of
$29.34 per cubic yard for the RCC. For the now-patented panel sys-
tem, the added cost was $21.98 per cubic yard of RCC, or a 75 per-
cent surcharge.
(b)
Figure 10.6 Layout of a RCC gravity dam. (a) Plan; (b) profile
developed along axis looking downstream. (Note: 1 ft = 0.3
m.) (from Tarbox and Hansen)
Bibliography
Bureau of Reclamation, Construction Cost Trends, Denver, Colo. October 1989.
Tarbox, G. S., and Hansen, K. D., Planning, Design, and Cost Estimates for RCC
Dams, Roller-Compacted Concrete II, AXE, New York, February 1988, pp. 21-38.
Chapter
11
Data and Performance
of Completed RCC Dams
259
Figure 11.1 Completed roller-compacted concrete dams.
Face of dam
RCC RCC Total Upstream Downstream Spillway
ClIl- State or Ht. ft Length, volume, volume,
Dam/river oleted orovince Owner/Designer h-d ft Cm) yds (ms) yds (ms) Slope Typo Slops Typo Slope Type
ASIA
Japan
Shimaiicrawa/ 1980 Yamarmchi Jaean Ministry of 292 181 216,000 415.000 v/ (1) 0.80 (11 0.80 (11
ShimLjy Construction~tJMC) (89) (2401 (165,000) (317,000) 0.30
Tamagawa/Tama 1986 Akita JMC 328 1448 944,000 1,509,000 VI (1) 0.81 (11 0.81 (11
(1001 (441.51 (757,000) (1,154,000) 0.60
Mano/Mano 1987 Fukushima Fukushima Prefecture 226 104 135,000 286,000 V (1) 0.80 (1) 0.80 (11
(69) (239) (103,0001 (219,000)
Pirika/ 1987 Hokkaido JMC + Hokkaido Develop- 131 2966 212,000 471,000 VI (11 0.80 (11 0.80 (11
Shiribeshitoshibetsu ment Bureau (401 (9101 (162,000) (360,000) 0.80
Shiromizugawai 1988 Yamagata Yamagata Prefecture 179 1204 186,000 412,000 V (11 0.80 (11 0.80 (1)
Shiromizu (54.51 (3671 (142,OOOl t315,0001
Asahiogawa/O 1988 Toyama Toyama Prefecture 276 863 217,000 472,000 Vi (11 0.80 (11 0.80 (1)
(841 (2601 (160,000) (361,000) 0.80
NunomelNunome 1989 Nara Water Resources Develop- 236 1056 144,000 492,000 Vi (1) 0.76 (1) 0.76 (11
ment Corp. (721 (3221 (110,000) (370,0001 0.40
China
KengkouEingshan 1 9 8 6 Fujian Fujian Provincial Dept. 186 402 56,000 78,500 v (61 0.75 (9) 0.76 (1)
of Water Conservancy & (571 (1231 (43,000) (60,000)
Hydropower/Fujian Water
Conservancy &
Hvdrooower Investiaation
&De&n Institute -
Tianshengqiao 2/ 1988 Guizhou & Guishou & Guangxi 193 1542 171,000 421,000 V (1) 0.75 (9) 0.75 (11
Nanpan Guangxi ProvincesiGuiyang (59) (4701 (131,000) (322,000)
Hydroelectric Power
Investigation & Design
P Institute
Mahui/ Jialing 1989 Sichuan Sichuan Province/Sichuan 75 463 196,000 327,000 V (11 - 1.18 (11
Water Conservancy 84 (231 (1411 (160,0001 (250,000)
Hydropower Investigation
L IbrAn Tnat.it.nts
Longmentatiuxi 1989 Fujian Dehua County, Fujian 189 515 95,000 132,000 V/ (81 0.75 (9) 0.75 (11
Province/Fujian Water (581 (1571 (73,000) (101,0001 0.30
Conservancy &
Hydropower Investigation
Xc Design Institute
Tonljiezi/Dadu 1989 Sichuan Sichuan Province/Chendu 285 3310 589,000 3,544,ooo v (11 0.75 (9) 0.75 (11
Hydroelectric Power (87) (10091 ( 4 5 0 , 0 0 0 ) (2,710,OOOl
Investigation & Design
Institute
PajiakoulLuanhe 1989 Hebei Bureau of Panjiakou 80 801 27,000 39,000 v (11 0.60 (9) -
Control Worksflianjin (24.5) (2441 (21,OOOl (30,000)
Prospecting & Design
Institute
NORTH AMERICA
United States
-
Willow Creek/Willow 1982 Oregon U.S. Army chps of 169 1780 433,000 433,000 (21 0.80 (41 0.80 (41
Creek EngineersWaIla WaIla, (521 (543) (331,0001 (331,000)
Washington District
Winchester (now Carroll 1984 Kentucky Winchester Municipal 74 1192 32,000 35,000 (31 1.00 (41 1.00 (11
E. E&ml/ Upper Utilities/Palmer (231 (3631 (24,500) (27,000)
Howards Creek Engineering & Parrett,
Ely. & Hurt
Middle Fork/Middle 1984 Colorado Exxon Co. U.S.A.1 124 410 55,000 60,000 (11 0.80 (11 Conduit
Fork of Parachute Morrison-Knudsen (38) (1251 (42,000 (45,OOOl Stepped
Creek Engineers
GaIesville/Cow Creek 1985 Oregon Douglas County/ 162.5 950 210,000 223,000 (1) 0.80 (41 0.80 (11
Morrison-Knudsen (501 (290) (161,OOOl (170,0001
Engineers
Grindstone Canyon/ 1986 New Village of Ruidoso/ 139 1416 115,000 126,000 (1) 0.75 (11 0.75 (11
Grindstone Creek Mexico Boyle Engineering (421 (4321 038,000) (96,000) Stepped
Monksville/Wanaque 1986 New Jersey No. Jersey Dist. Water 157 2200 287,000 304,000 (11 0.78 (41 0.78 (11
Supply Comm. & (481 (6701 (219,000) (232,OOOl Stepped
Hackensack Water Co./
OBrien & Gere
Lower Chase Creek/ 1987 Arizona Phelps Dodge Morenci, Inc. 64 400 18,000 29,000 (11 0.70 (11 0.70 (11
Lower Chase Creek + Sumitomo Metal Min- (201 (122) (13,800) (22,200) Stepped Stepped
ing Arizona/Dames Xc
Moore
Figure 11.1 Completed roller-compacted concrete dams. IContinued)
Face of dam
RCC RCC Toted upstream Downstream Spillway
COTI- State or Ht, R Length, volume, volume,
Dam/river &ted province Owner/Designer (ml ft (ml yd cm31 yds (msl Slope Type Slope Type Slope Type
Upper Stillwater/Rock 1987 Utah U.S. Bureau of 294 2673 1,471,oop 1,675,OOO V (7) 0.32/ (7) 0.321 (7)
Creek Reclamation (90) (815) (1,125,OOOl (1,281,OOOI 0.60 0.60
Stepped
Elk Creek/ Elk Creek 1988 Oregon U.S. Army Corps of 83 1197 348,000 455,000 V (1) 0.80 (71 0.80 (1)
Engineers (as halted) (25) (365) (266,000) (348,000)
Portland District (as 249 2580 1,041,000 1,100,100
planned1 (76) (7861 (796,000) (841,000)
Stagecoachfllampa 1988 Colorado Upper Yampa Water 150 380 44,000 50,500 (1) 0.80 (1) 0.80 (1)
Conservancy District/ (461 (115) (34,000) (38,500) Stepped Stepped
Woodward Clyde
Consultants
Stacy (now SW. Freesel 1989 Texas Colorado River Municipal 103 568 117,000 209,000 (11 0.831 (1) 0.831 (1)
Spillway/Colorado Water District/Freese & (31) (1731 (89,000) (160,000)
Nichols
Marmot (replacement)/ 1989 Oregon Portland General Electric/ 50 194 10,300 13,000 (11 0.80 (11 0.80 (1)
Sandy Ebasco Services (15) (59) (8,000) (10,000)
Mexico
L a Manzanilla/Ibarilla 1987 Leon Secretaria de Agriculture 118 492 65,400 V/ (1) 0.80 Ill 0.80 (11
y Recursos Hidraulicos (361 (1501 (50,000) 0.24
(SARH)
AUSTRALIA
Copperfield/ Copperfield 1984 Queensland Kidston Gold Mine, Ltd./ 131 1115 183,000 205,000 V (1) & 0.901 (4) 0.80 (1)
Gutteridge, Haskins & (401 (3401 (140,000) (157,000) (51 0.80
Davey
CraigbourneiCoal 1986 Tasmania Tasmanian Rivers & 82 810 29,000 29,000 v (21 1.00 (41 Separate
Water Commissionl (251 (2471 (225001 (22,500)
Gutteridge, Haskins, &
Bucca Weir/K&n 1987 Queensland Queensland Water 39 420 31,400 39,300 1.00 (4) Spillway 0.60 (1)
Resources Commission/ (12) (124) (24,000) (30,000) Stepped
Gut&ridge, Haskins, &
Davey
Wrights Basin/Point 1989 Australian Australian Capitol 59 282 11,900 11,900 v (2) 1.0 (4) Conduit
Hut Creek Capital Territory Government/ (18) (86) (9,100) (9,100)
Territory Willing & Partners
EUROPE
Spain
Castilblanco de 10s 1985 Seville Junta de Andalucia/Hydro- 82 404 18,000 26,000 V (1) 0.75 (1) 0.75 (1)
ArroyosiRivera de Cala graphic de Guadalqvirir (25) (123) (14,000) (20,000)
Erizana (dike) 1987 Galicia Confederaci6n Hidraulica 50* 361 15,700 85,000 -
de1 Norte de Espana (15) (110) (12,000) (65,000)
Los Morales/Morales 1987 New Confederacibn Hidro- 92 656 29,000 V (1) 0.75 (5) 0.75 (1)
Castile grafica de1 TajoiOCISA (28) (200) (22,000) stepped
Santa EugeniaiXallas 1988 La Corwia Sociedad EspaAola de 281 935 286,000 306,000 0.05 (5) 0.75 (5) 0.75 (1)
Carburos Metzilicos S.A./ (85.5) (285) (219,000) (234,000) Stepped
INARSA
France
Les Olivettesi 1987 Bas Rhone Conseil General 118 837 105,000 111,000 v (1) 0.75 (10) 0.75 (1)
Tributary of Herault delHerault/ Compagnie (36) (255) (80,000) (85,000) Stepped
Nationale du Bas Rhone
et du Langueduc
(CNARBRL)
USSR
IashkumiriNarin 1988 Kirgizia Gidroproject 246 1050 111,000 - V (1) 0.75 (1) 0.75 (1)
(75) (320) (85,000)
AFRICA
South Africa
De Mist Kraal 1986 Cape Department of Water 98 984 46,000 85,000 V (1) 0.60 (1) 0.60 (1)
Diversion/Little Fish Affairs (30 (300) (35,000) (65,000) SkPPed Stepped
Arabie (now 1 9 8 6 Lebowa Department of Coopera- 118 1493 132,000 185,000 V (1) 0.751 (1) 0.75 (1)
Mokgoma Matlala/ tive DevelopmenVTheron, (36) (455) (101,000) (141,500) 0.50
Oliphants Prinsloo, & Van Tonder Stepped
(Continued)
Figure 11 .l Completed roller-compacted concrete dams. (Continued)
Face of dam
RCC RCC T&d upstream Downstream Spillway
com- State or Ht, ft Length, volume, volume,
Dam/river pleted province Owner/Designer (ml ft (m) yd (m3) yds (ms) Slops Type Slope Typo Slops Type
A F R I C A (Continued)
South Africa (Continued)
ZaaihoeWSlang 1987 Natal Department of Water 154 1729 127,000 175,000 v (1) 0 . 6 2 (1) 0.62 (1)
Affairs (47) (527) (97,000) (134,000) Stepped Stepped
Knellpoort (gravity 1988 South Department of Water 164 656 59,000 77,000 v (1) 0 . 6 0 (1) 0.60 (1)
arch)/Rietspruit Eastern Affairs (50) (200) (45,000) (59,000) Stepped Stepped
Wohvedans (gravity 1989 Cape Department of Water 230 819 (196,000) (221,000) v (1) 0 . 5 0 (1) 0.50 (1)
arch)/Great Brak Atfairs (70) (268) (150,000) (169,000) Stepped StePPad
Morocco
Ain Al Koreima/ 1988 Rabat Direction des 85 407 34,700 39,000 0.20 (1) 0.60/ (2) 0.75 (1)
Akruech Amenagements (26) (124) (26,500) (30,000) 0.75 (5) Stepped
Hydrauliques
RwedatJ- 1988 Rabat Direction des 76 410 33,000 (35,000) 0.40 (11) 0.40 (11) 0 . 4 0 (11)
Amhmgemente (23) (125) (25,000) (27,000) StePpad Stepped Stepped
Hydrauliques
SOUTH AMERICA
Brazil
Saco de Nova Olinda/ 1986 Paraiba State of Paraibailcoplan 184 755 173,000 187,000 V (1) 0.80 (4) Separate
Gravata (56) (230) (132,000) (143,000)
Argentina
Urugua/Urugua-i 1989 Misiones Electricidad de Misiones 249 2254 772,000 819,000 V (3) 0.80 (4) 0.80 (1)
Sociedad Anonimal (76) (687) (590,000) (626,000)
Inwnas
NOTE : Type of face for dam: (1) conventional concrete; (2) precast concrete panels; (3) precast concrete panels with membrane plus conventional concrete;
(4) unformed RCC; (5) RCC against forms; (6) precast concrete panels plus asphalt mortar; (7) conventional concrete slip-formed or extruded elements; (8)
Conventional concrete-expansive cement; (9) precast concrete blocks; (10) mechnically compacted unformed RCC; (11) RCC with wire netting.
*Main gravity dam is 148 ft (45 m) high and 591 ft (186 m) long.
-
Figure 11.2 Completed roller-compacted concrete cofferdams.
I
RCC RCC
com- Country/ Ht, Length, volume
pleted Dam/River province Owner/designer (ml ft. (m) yd (ma) Remarks
-
1980 Tarbela spillway Pakistan/ Pakistan Water & Power 30 850 50,000
repairs/Indus District Development Authority/ (9) (263 (38,000)
Abbottabad Tippetts-Abbett-McCarthy-
Stratton (TAMS)
1987 Sir/- upstream/ Turkey Cukuroya Elektrik S.A. 131 344 52,000
Ceyhan (40) (105) (40,000)
1988 Yantan upstream/ China/ Guangxi Bureau of Electric 172 1220 216,000 Curved
Hongshui Nanning Power IndustrylGuangxi (53) (372) (165,000) upstream
1988 Yantan downstream/ China/ Hydroelectric Investigation 132 144,000
Hongshui Nanning & Design Institute (40) (3201 (110,000)
1988 Geheyan upstream/ China/ Hubei Province/Yangtze 132 558 178,000 CUNd
Qingjiang Hubei Valley Planning Office (40) (170) (136,000) upstream
1988 Shuikou diversion China/ Fujian Electric Department/ 82 656 371,000
walI/Minjiang Fujian East China Hydroelectric (25) (200) (284,000)
Power Investigation &
Design Institute
1989 Dongfeng upstream/ China/ Guizhou Hydropower 295 26,200
Wujiang Guizhou DepartmenUGuiyang (90) (20,000)
Hydropower Investigation
& Design Institute
266 Chapter Eleven
12. High-paste RCC dam: Upper Stillwater Dam, United States, 1985.
11.2.2 Seepage
This section deals with measured overall seepage through RCC
dams and their foundations as contrasted to permeability values of
the RCC material. Permeability of RCC mixtures is discussed in
Sec. 2.5.3 and initial permeability values for certain RCC dams are
plotted in Fig. 5.1. Seepage in this discussion refers to the total
measured volume of water passing through the dam and adjacent
foundation material. Leakage is water passing through joints and
cracks in the structure.
To evaluate overall seepage through or around an RCC dam and its
foundation properly, information on the designed seepage collection
and seepage control system is listed in Fig. 11.3 for the dams discussed
in 11.2.2.2.
The measured seepage is an indication of the performance of the de-
signed seepage control system. The total measured seepage can con-
sist of the following items: (1) leakage through joints and cracks, (2)
seepage through a conventional concrete face if used and the RCC ma-
terial itself, and (3) seepage through foundation materials. The water
passing through the RCC depends upon the void characteristics of the
mixture in addition to construction-related voids, such as those pro-
duced by segregation of large aggregate at or near the bottom of the
lift and possibly inadequate compaction of a lift.
Most measurements of seepage have been from weirs located in the
gallery, at the downstream gallery entrance tunnel, or at a point in
the waterway downstream of the dam. Some seepage that may proceed
through the dam has been measured by weirs at the intersection of the
dam with the abutment just prior to the water being deposited into the
stilling basin or other waterway.
Max.
hydraulic Max. wetted
Dam PuIpCLse head, ft (m) area, Its (mc) Seepage control system Seepage collection system
Shimajigawa Flood and river 246 89,300 Upstream facing concrete, 10 ft (3m) Drain pipes downstream of water
control (75) (8290) thick stops in contraction joints
Municipal water Double waterstop in contraction Drainage gallery
storage joints through entire section at 49 ft Foundation drainage curtain
(15 m) on center
Bedding concrete entire lift
RCC interior
Foundation grout curtain
Willow Creek Flood control 141 149,000 Zoned RCC Bedding concrete 1 ft (0.3 Drainage gallery
(43) (13,900) m) wide upper portion of dam Foundation drainage curtain
Copperfield Industrial water 95 62,100 Thin wedge of conventional concrete Drainage gallery
storage (29) (5,770) (not full height of lift) Geofabric drain tubes
Zoned RCC Internal and foundation drainage
Three PVC waterstopped joints at curtain
key locations Geofabric strip drain every fourth
Foundation grout curtain lift near downstream face connected
to voids produced by form jacking
pipes
Middle Fork Flood control 94 16,800 Upstream facing concrete +1.5-R- Drainage gallery/tunnel
C29) (1560) thick (0.46 m) Internal and foundation drainage
Partially caulked crack-inducer curtain
grooves 12 ft (3.7 m) on center Geofabric drain tubes near
Bedding concrete 6 ft. (1.8 m) wide downstream face below gallery
RCC elevation
Foundation grout curtain Porous concrete zone hear
downstream face
Winchester Municipal water 61 29,600 PVC lined (65-mil = 1.65-mm) precast Geofabric/crushed rock toe drain
(now Carroll storage (19) (2750) concrete upstream facing panels
E. Ecton) Conventional concrete
f 1.5~R-thick (0.46 m) downstream of
panels
RCC
Pl.nrl.tin mm,,+ f.llrtSi
Facing concrete + 2 ft (0.6 ml thick
Bedding concrete 6 ft(1.8 ml wide
Zoned RCC
Foundation grout curtain
Grindstone Municipal water 128 90,400 Upstream facing concrete f 2 ft Drainage gallery
Canyon storage (39) (0400) (0.6 m) Internal and foundation drainage cur-
Partially caulked crack-inducer tain
grooves 16 ft(4.9 ml on center
Bedding concrete
RCC
Foundation grout curtain
Monksville Municipal water 141 131,000 Upstream facing concrete + 1.8 ft. (0.55 Partial drainage gallery
storage (431 (12,lOOl ml thick Internal and foundation drainage
PVC waterstops in crack inducers at curtain
20-R (6.1-m) and 40-R (12.2-m) spac-
ing
Contraction joints through dam at
120~ft (3.7-m) spacing upper 40 ft
(12.2 ml
Bedding concrete 8 R (2.4 ml wide
plus hydrophytic rubber strip at end
RCC
Foundation grout curtain
Arabic (now Agricultural and 98 Upstream facing concrete 22.5 ft (0.76 hainage sallery
Mokgoma municipal water (301 ml thick Internal and foundation drainage
Matlalal strage PVC waterstops in crack inducers at curtain
3.9 ft(12 ml on center
Bedding concrete H/4 wide
RCC
F o u n d a t i o n grout curtain
!O
IO
8
7
I I
Middle Fork
I
- ,- _
I I
I-..,_ hht
nnmc
Shimoivxwa-
I
..-. Plnitf=Y-l
- - -
I I
it
L
6 Willow Creek (after grouting)
d
c Initial unit seepage = 42 h
in- Grindstone
).l I I I I I I I I 0.22
0 6 12 18 24 30 36 42 48 54
Months (after statiof initial filling)
facing and the leakage increased to 533 gal/min (33.6 L/s). It was then
decided to empty the reservoir to allow for repair of these joints and
cracks during 1989. It was reported that the original joint sealant
used in the dummy joints spaced 16 ft (4.9 m) on center was not of the
type recommended for underwater placement and was not applied to
\
the depth specified.
9. Monksuille Dam. The initial filling of this municipal-water-
supply reservoir started in July 1987. Full pool producing a hydraulic
head of 141.5 ft (43 m) was reached in April 1988, at which time a
maximum total seepage of about 250 gal/min (15.8 L/s) was measured
in weirs located in the gallery, and at both abutments. Of this total,
the measured seepage from the gallery which extends only 300 ft (91
m) across the dam and corresponds to the spillway width, was 61 gal/
min (3.8 L/s). During the next five months, total seepage had de-
creased to 120 gal/min (7.6 L/s) and that from the gallery to 25 gal/
min (1.6 L/s). With the advent of cold winter weather, the total
seepage increased to 290 gal/min (18.3 L/s) in March 1989. Of that, the
flow collected in the gallery rose to 55 gal/min (3.5 L/s). Three months
later the total seepage had reduced to 150 gallmin (9.5 L/s). Wet spots
were noticeable on the exposed RCC downstream faces of the
nonoverflow sections soon after filling and remain visible two years
later.
The overall low permeability of this dam was attributed to design
response to a refined thermal analysis and improvements in the RCC
mix design to provide reduced permeability. When it was determined
a delay in construction due to warmer weather would produce higher
peak temperatures than predicted in the original design, the design-
ers decided to increase the number of waterstopped joints for the up-
per 40 ft (12 m) of the dam. The basic watertightness of the RCC ma-
terial was aided by a reduction in the maximum size aggregate from
the usual 3 in (75 mm) to 2 in (50 mm) and by using a 40 percent sand
fraction in the mix. Both of the mix design factors tended to reduce the
potential for segregation and minimize voids for an RCC dam that had
a low cement content of 105 lb/yd3 (63 kg/m3).
10. Arabie (now Mokgoma Matlala) Dam. Reservoir filling for this
dam started in early 1987 and measured total seepage has not ex-
ceeded 16 gal/min (1 L/s). The low amount of seepage has been attrib-
uted to design of an improved seepage control system as well as the
dam being located in a warm area. At this location in Lebowa, there
was a low-temperature drop from the peak RCC temperature in the
mass to the annual average ambient temperature, thus minimizing
the potential for thermal-induced cracking.
The seepage control system includes waterstops installed down-
Data and Performance of Completed RCC Dams 279
*pH is a measure of the hydrogen ion concentration of solutions, with the pH of neu-
tral water being 7.0. Values less than 7.0 indicate acidity and those above 7.0 indicate
alkaiinity.
Data and Performance of Completed RCC Dams 281
n 11. Initially, the volume of seepage from the dam was nearly as
at as the receiving waterway. As a result, rapid dilution of the al-
inity does not occur. Instead, precipitation of calcium and some
gnesium carbonate occurs. This mineral precipitation was aggra-
ed by the fact that the water in the first stream downstream of the
n was already supersaturated with calcium carbonate. Water soft-
ng by pH adjustment is another way of explaining the phenomena.
lile the white-colored bottoms of the streams produced an unnatu-
visual effect, there was no indication of either aquatic or terres-
11 biological damage.
.he immediate solution to the problem was to pump a majority of
seepage water collected in the stilling basin back into the reser-
r. The small amount of water that was proceeding down Grindstone
:ek was then rapidly diluted when it entered larger flows of down-
earn creeks. The mitigation measure effectively stopped the down-
earn carbonate precipitate problems and no long-term detrimental
rironmental effects are expected. Pumping the seepage water back
o the reservoir did increase the pH of the total reservoir storage,
educing a hard water and caused a fine precipitate which gives the
ter a distinctive turquoise color.
although the pump-back scheme produced immediate positive re-
ts, the most effective long-term solution was to reduce the volume
;eepage passing through the dam. As noted in Sec. 11.2.2.1, the res-
roir was emptied in early 1989 for the purpose of repairing cracks
d resealing joints.
deports on the performance of Copperfield, Craigbourne, and Mid-
I Fork dams provide added insight into the calcium hydroxide leach-
; and calcium carbonate buildup phenomena. At Copperfield Dam,
alysis of seepage water varied from a high pH value of 11.6 for a
w leak to 7.45 through a crack, with an average of 9.3 for a flow
wnstream of the dam of 160 gal/min (10.3 L/s). Thus, water passing
ickly through a crack has less opportunity to dissolve the calcium
droxide than water slowly seeping through the RCC mass that
nes into contact with more cemented surfaces.
4 greater amount of calcium carbonate effluorescence appeared on
: exposed downstream face of Craigbourne Dam (see Fig. 11.7) than
Copperfield. This was attributed primarily to a more porous RCC at
s location, due mainly to greater difficulty in compacting the outer
ge to achieve a high density.
4x-1 unusual situation occurred at Middle Fork Dam where initial
emical analysis of seepage water confirmed that calcium hydroxide
ts being leached from the dam and precipitating to calcium carbon-
3 within the gallery and downstream of the dam. Within a few hun-
ed yards of the dam, sufficient dilution had taken place and the
282 Chapter Eleven
11.2.5 Cracking
Cracking in any nonreinforced concrete dam can be expected. From a
design standpoint, joints or crack inducers may be installed in the
dam to help control cracking or the dam can be constructed with no
crack relief as discussed in Sec. 3.5.1.4. Cracks that extend below the
waterline and have sufficient width to pass water are of greatest con-
cern to dam designers. Therefore, leakage and cracking performance
are directly related. Cracks in gravity dams are generally vertical and
transverse to the dams axis and pose no threat to the structural sta-
bility of the dam.
11.2.6 Durability
The durability of RCC dams is directly related to the properties of the
exposed concrete, whether placed conventionally or by the RCC
method. For RCC, greater strength of the mix and aggregates produce
greater durability. The same applies to conventional concrete, except
that the addition of air entrainment to the mix significantly improves
freeze-thaw resistance.
ibliography
mson, S. A., Verigen, W. M., and Carney, M. J., Cedar Falls Roller Compacted Con-
crete Dam, Roller Compacted Concrete II, ASCE, New York, February 1988, pp. 39-
50.
unstan, M. R. H., Recent Developments in Roller Compacted Concrete Dam Con-
struction, Water Power & Dam Construction Handbook, 1989.
nbes, B. A., RCC Dams in Australia, Roller Compacted Concrete II, AXE, New
York, February 1988, pp. 323-339.
uzina, B. J., Uzelac, S., Savic, M., Application of Roller Compacted Concrete at Ap-
purtenant Hydraulic Structures of a Large Dam, ICOLD Sixteenth Congress, San
Francisco, June 1988, vol. III, Q62, pp. 515-534.
ansen, K. D., Roller Compacted Concrete Dams Worldwide, Water Power and Dam
Construction Handbook, 1988.
opman, D. R., and Chambers, D. R., Construction of Elk Creek Dam, Roller-
Compacted Concrete II, AXE, New York, February 1988, pp. 251-266.
kckson, H. E., Thermal Cracking in Roller Compacted Concrete at Galesville Dam,
ICOLD Sixteenth Congress, San Francisco, June 1988, vol. 5, pp. 462-465.
cDowel1. T. E.. Grouting of Willow Creek Dam and Foundation, USCOLD Newslet-
ter, November 1985. -
oler, W. A., and Moore, J. F., Design of Seepage Control Systems for RCC Dams,
Roller-Compacted Concrete II, ASCE, New York, February 1988, pp. 61-75.
agayama, I., and Yamanaka, T., Watertightness of the RCD Dam-Monitoring
Shimajigawa Dam, Engineering for Dams, Japan Dam Engineering Center, vol. 4,
no. 1, 1986.
ichardson, A. T., Upper Stillwater Dam-Design, Construction and Performance,
U.S. Army Corps of Engineers Structural Conference, St. Louis, June 1988.
:hrader, E. K., Watertightness and Seepage Control in Roller Compacted Concrete
Dams, Roller-Compacted Concrete, AXE, New York, May 1985, pp 11-30.
:hrader, E. K., and Namikas, D., Performance of Roller Compacted Concrete Dams,
ICOLD Sixteenth Congress, San Francisco, June 1988, vol. 3, 662, pp. 339-363.