1

" -- '

C. A. FASSO, A. SIVIERO, R. V1TAUANI

,!
)

THERMAL ANALYSIS OF RCC DAMS.

A COMPARISON OF TWO NUMERICAL
METHODS

".--

Estratto da «Idrotecnica-., n, 2 marzo· aprilc 1991

,

t j
 THERMAL ANALYSIS

THERMAL ANALYSIS OF RCC DAMS

A COMPARISON OF TWO NUMERICAL METHODS

Costantino A. Fass/), Allilio Slvlero, Renato Vltallanl ('j

•

SUMMARY -A method is developed forcalculatingtheheatofhydra~

tion produced by successive layers alcast concrete. Such building proce--
dures are typical of monolithic structures such as gravity dams.
This paper deals with the Sa Stria dam, nearCagliarl in Sardinia, and
the numerical analysis is carried out with a bidimensional finite element pro-
gram. The results are compared with those obtained from two different
monodimensionaJ finite difference analyses, in vertical and horizontal d;rec~
tion respectively, in order to establish the error deriving from the use of a
more straightforward and less expensive method.

1. SUBJECT AND PURPOSE OF THE STUDY
In monolithtc structures such as gravity dams, di~
sposing of the heat of hydration from the cement has
always been a problem.
This problem can be approached in three main
ways:
i) using low~heat cements;
i1) reducing the cement content andlor adding a very
fine filler (fly ash), which also improves impermea~
bility and workability;
iii) casting thin lifts and leaving them exposed to the
air for the first few days, during which time most
of the heat is generated,
Since the pioneering works carried out in the six*
ties, with the construction of the Italian Alpe Gera
[GENTILE 1965] and Quaira della Miniera dams, the
method of placing concrete in thin lifts has been used
in various countries and has been developed as the
technique which now goes by the name of Roller
Compacted Concrete (RCC),
(*) Costantino A. FassO - Professor of Fluid Mechanics, Mi-
lan Polyt~hnic, Italy; Attilio Sivlero - Senior Engineer, Studio di
Ingegnena C.P.C. - Padua, Italy; Renata Vitaliani - Professor of
Structural Analysis, Padua University, Italy.
Calculating the heat of hydration in successive
layers of cast concrete is complicated by the three-
dimensional field and is thus done by approximation.
An approach based on the one-dimensional Fou-
rier equation has recently been developed as part of
the project for the Italian Sa Stria dam, due for con-
struction near Cagliari in Sardinia (CASARA et al.
1989; FASSO' 1989J.
With this method, the calculation is done in two
stages, separately studying two one-climensional heat
of hydration propagation episodes: one vertically, em-
phasising dispersion through the horizontal layers of
setting concrete; the other horizontally, parallel to the
expansion joints (along the thalweg). thus emphasi·
sing heat dispersion through the dam faces,
The two stages are handled in successive cal-
culations and taking the results of the former into ac~
count in calculating the latter: as the phenomenon
is really one and the same. the nature of the calcu-
lation is clearly one of first approximation.
The second approach. proposed by this paper,
integrates the Fourier equation in a twcrdimensional
field.
This method allows different dam configurations
to be studied, such as combinations of concrete el~
83

IDROTECNICA N. 2, MARCH~APRIL 1991
ements with high or low cement content.
The method applies a calculating code developed
by POLIKVA & WILSON [1976J for the thermal analy-
sis, adapted by the authors for implementation on a
PC.
As a case study, both methods were applied to
the Sa Stria RCC gravity dam, which has a maximum
height of 87 m and a crest length of 350 m.
The dam (Fig. 1) comprises an upstream and
downstream facing element made of a conventional
concrete containing 220 kg/m 3 of Class 225 low~
heat pozzolanic cement (to Italian standards) (1) and
a RCC core element made of a concrete with 105
kg/m 3 of Class 325 pozzolanic cement and 105
kglm 3 of fly ash.
The concrete is cast in 30 cm thick horizontal lifts,
each layer being placed in two days. The finished lift
(1) 225 kg/cm 2 (about 22.5 MPa) islhe compressive strength
of a standard mortar test cube.
Mox IMPOUNDING
14.4.70 mS.m, 5.00 146.70 mS.m.
r~ 141.20 mS.m.
"
87.43
,,
Fig. 1.· SA STRIA dam; typical section.
84
r
is left uncovered for two days after placement, sur·
rendering heat by convection from the vast upper sur~
face and from the two upstream and downstream
dam faces, then the next lift is placed. Each lift is the-
refore left in contact with the air for two days, cov~
ered by a single subsequent layer for another two
days, covered by two subsequent layers for a further
two days, and so on.
These placement methods have a definite effect
on the thermo-elastic stress status: there is clearly
far more dispersion of hydration heat during the first
2 days after placement, aided by the high surface-
ter-volume ratio.
For a given lift, the casting of successive lifts on
top of it gives rise to an increasing insulation in the
vertical direction, whereas thermal exchange by con-
vection continues undisturbed along the two dam fa·
ces; this means a rapid cooling of the facing
elements, where the mixture is richer, and a virtually
adiabatic Increase in the temperature of the core.
O~. . . .~'O~====~'O~. . . .~30m
RCC
CONVENTIONAL CONCRETE
POWERHOUSE
,.-_'8.1.:.0_.., f
98.00
7~
 THERMAL ANAL VSIS
Combined with the reduced cement content, this hence:
placement technique therefore has the double advan-
tage of producing less heat and facilitating its di-
spersion.
(1 ')
The two thermal analysis methods are described
and applied to the Sa Stria dam; comparing the re-
sults obtained with the same boundary conditions and where:
material characteristics: thus the error implicit in the •
more straightforward finite differences method is eva- u = _-=a..::lI:;.t_
luated, at least in relation to a given case study. y,,2 (.6.1j)2

KEY TO SYMBOLS b = 11Ce; , =t - 50 (, - 1)

s,x,y space coordinates (m]

T temperature [C) The variable T has been introduced to cater for
t, T time [days] the fact that heat generation from a given lift starts
a thermal diffusivity (m2/hour) from when it is placed and not from the time t "" O.
c specific heat [J/kg'C) The thickness of each lift has been divided into
e density of concrete [kglm3] two equal parts, i.e. adopting a spatial integration fac-
q quantity of heat generated in hydration tor .6.1j "'" 0,5. The time factor adopted was:
of concrete per unit volume (J/m3]
P cement content per unit volume of con- .6.t :: 0.04 days "'" 57.6 minutes""" 1 hour.
crete [kg/m 3 )
C heat generated by the cement per unit The boundary conditions were assumed as
mass [J/kg)
follows:
It conductivity IW/m'°C)
- all lifts made of ACC (no conventional concrete
a transmission coefficient in contact with
at faces and foundation);
the air [W/ m20C)
- constant air temperature: 0 QC (reference tempe-
y" thickness of lifts
rature);
Xo half width of dam cross-section
- initial temperature of each lift: 0 °C;
{3 expansion coefficient (OC-i1
- constant temperature of foundation rock: 0.5 °C;
2. THERMAL ANALYSIS - constant temperature on upper surface of placed
concrete: 0 °C. .
2.1. One dimensional method (finite differences) The last of these conditions implies disregarding
the temperature difference between the surface of
In one-dimensional analytical terms. the conduc- the placed concrete and the air and is therefore ap-
tion equation is: proximate.
OT I'T 1 dq Fig. 2a illustrates the temperature distribution
-= a--+---- (1 ) along the vertical axis of the main cross-section of
Qt OS2 Ce dt the dam for the first 24 lifts (8 m), which led to the
deduction that the behaviour of each lift subsequent
where: to the eighteenth (at 5.4 m) would be virtually identi-
q = PC; a = ",Ce. cal to that of the eighteenth, each with a two-day
delay.
2.1.1. Dispersion through horizontal planes As illustrated by CASARA et al. [19891. the tem-
perature graph for the standard lift presented no si~
When converted into finite differences. using the gnificant changes after day 8, when it was found to
mid-range values with a second-order error for be thermally insulated by the four lifts placed above,
h2Tlos2 and the values beyond with a first-<>rder er- with its thermal conditions thus evolving regardless
ror for oTlot and dq/dt, and assuming s ""'y. equation of subsequent concrete placement.
(1) beccmes:

. 2.1.2. Dispersion through the dam faces

-1-(T(y,t+<l.tl-T(y'\l) "'" ~(T(Y+M,tl-2T(y,t) +
lit (lIy)'
At this stage, the different cement content in the
facing concrete was taken into account in the com~
+ T(y _ 8Y,t») + 1 (q(, + <l.t) - q(ry)
putation of q.
Ce llt
85
 ,
IDROTECNICA N. 2, MARCHwAPRIL 1991
;
I
, ,t-----------------___~----__1
2,
2
•
,
•
d!!
•"•
~, , ,
•\
•,• , ,
,
~
•
,
•
• • . •
-1:"",,, Fro" f'rst \IP-t tdJ
..
20. - ONE-DIMENSIONAL MODEL 2b - P..tO-DIMENSIDNAL MODEL
L;f1:s I'n-1;, ... I'\Y '" R.C.C. L;f'ts I'~tlr .. ly in R.C,C.

" \
T
"
---,-,-,- - -----
"I
~
" " ~
, , --
,
0

•
,
, c------- ~
0
< , , {/X
•"•• ,
1f!7
• ,, ,
5, ,
0 ~ , (fI
,
~
•• • ~
,
, ,
U
,, .
- 0

.. II
tl ..... fro .. First !!ft toll
,
• • -
ti1'll' frOl'l first lift [<I)

2c - TVQ-DIMENSIONAL MODEL 2 cl - TVQ-DIMENSIONAL MODEL

Co,.. .. p ..... t I~ R.C£. , f(lce o.M
Cor .. IXlI"t '" R,C.c. , F.." .. .. l ...... ~ts
Ln cOlw .. rrtroo .. l """,,, ..... t .. fo<.ln<l<:lt!on ,1"'''1'0-1;$ '" c"",,",otlon(l\
"onc.... t,

Fig. 2.· Lifts' temperature along dam axis.

Dispersion through the dam faces was also exam- standard lift).
ined for a lift (considered as the standard) situated It was thus assumed that in equation (1');
half-way up the dam, applying equation (1) along a Xc'" 15 m;
horizontal axis S x parallel to the thalweg, and as--
IIIIE .6. "'" 1.5 m (spatial integration factor);
suming for the sake of simplicity that the temperatu- .6.11'" xix.,,.. 1.5115 0.1 (dimensionless spatial
IIIIE

res from day 1 to day 8. over the entire extent of the integration factor);
lift, are those found in the first stage for lift 18 (the .6.t
IIIIE 0.2 days"", 4.84 hours (time factor);
86
 THERMAL ANALYSIS
Fig. 3 shows the temperature graphs along the hori~ vity and is thus a function of J1. and of the local
zontal axis parallel to the thalweg after 28 and 90 coordinates:
days. 1(t) Is the vector of the system's nodal temperatu~
res at the Instant t;
2.2. Two-dimensional method (tinne elements) t(t) is the vector of the derivatives of the nodal tem~
Without going into an explanation of the method, peratures at the instant t;
which is now in common use, it is worth mentioning Ott) is the vector of the supplementary heat flows to
simply that the finite elements taken into' considera~ the nodes deriving from internal generation,
tion are isoparametric with 4 and 8 nodes. convection, radiation and outside sources at the
In two-dimensional analytical terms, the conduc~ instant 1.
tion equation is: The matrix equation (2) represents a system of
differential equations whose matrix of coefficients is
diagonal, symmetrical and positive definite in the unk~
aT
M=a
[ il'T
ox2 +
O'T
oy2 +
I Ce
1 dq
dt (1 ")
nown nodal temperatures of the finite element mesh.
Disregarding the analytical demonstration, which
is more complex than for the finite differences me-
thod, it is worth noting that the model assumes that
Ott) can be obtained from the combination:
Thus the integral of (1 ") expressed in matrix form
is:
O(t) = O,(t) + O,(t) + O,(t) + O,(t)
C . T(t) + K, . T(t) = Q(t) (2)
where:
which expresses the balance of the heat flows in a
continuum divided into finite elements. 01(t) = supplementary outside flow;
In equation (2): 02(t) = convection heat flow;
C is the matrix of the system's thermal capacity; 03(t) ... radiating heat flow;
~ is the matrix of the system's thermal conducti~ O,,(t) = internally generated heat flow;

.. ~~
~-
8 "~,,-"'" ~
"""""",.,,""'" " ,~""~~"'~""-." """"'~"-"'"

dQ" face

\-'
~
7 .
-- - ----
'-"-
1--- -----
. ~

----- ----
-- -
---- 1----
1"-
r-~- ~\,
\

•• 6 "'--""'"'
+---- -""---,- I----~-- ---------
"
0

R
~
.., 5 - ------------- - - ------- r- \
•
~--- ---~-~--- ~
----~.- ~- ~
~- -~~-
~~.
L

(\ 1\ \\ -
L
~•
• 4 '''- """"
L.....

one~"'Mens'onal I~\\
L
v
28 clo.ys \
,•
L
3 "'" "'''-,-"
90 clO,ys
} Moclel
-""'-- "-,~--'"

\\\
~

------- 28 oays}
•",
L
two-diMenSional Moclel
~

2 . -- ------- 90 do.ys
• '''-~

~
··-r·~-
RCC . CONV.C NC, "n \
f'..- dol'l oxls

I
° 0,0 0.1 0,2 0.3 0.4 0,5 0,6 0,7 0,8 0,9
dil'\(?nsloniess Spo.C(? steps

Fig.3 Standard 11ft: temperature variation from dam axis to face.

87
 .IDROTECNICA N. 2, MARCH·APRIL 1991'-_ _ _ _ _ _ _ _ _ _ _ _ _ ._ _ . _ . _ _ _ __
As for the boundary conditions, the temperature
of certain system nodes can be assumed as constant
or subject to a certain time-dependence; a condition
of this kind is similar to the restrictions placed on no-
dal movements in mechanical analyses. This can sj~
mulate contact with elements of high thermal capacity
(rock) or with cooling pipes (embedded in the can·
crete lifts and carrying a flow of cold water· a tech-
nique commonly used in dam-building) and contact
with the air which is sUbject to changes in tempe-
rature.
It is worth noting that the system of differential
equations represented by (2) is linear because it is
assumed that the, thermal properties of the material
do not depend on the temperature.
The conduction equation is thus solved using a step-
by-step integration procedure, assuming a linear tem~
perature variation during the interval At.
The programme thus performs the thermal ana~
lysis, in stationary or variable conditions, of flat or
axially symmetrical, two-dimensional structures with
a geometry varying with time.
It can be used to evaluate the temperatures and
stress status caused by temperature changes in mo-
nolithic concrete structures such as dams, bridges
and large-scale foundations, during and after con-
struction.
Ambient conditions varying in time with respect
to the pre-set temperatures and flows, internal heat
generation, the presence of cooling~pipes and
constant-temperature outside nodes can be taken in~
to account.
Calculating stresses calls for setting constraints
on the movements of some of the structure's nodes.
Three types of element can be used:
1. two-dimensional from 4 to 8 flat or axially
symmetrical nodes;
2. convection;
3, cooling pipes.
For the purposes of this paper, it was particular~
Iy relevant to obtain the temperatures and their maxi~
mum gradients, for comparison with the results of the
method described in para. 2.1. As there is an almost
linear dependence between temperature gradients
and stresses, comparing of results of the thermal cal~
culation wi!! be significant in itself.
Calculations based on the two-dimensional me~
thod were carried out on dam configurations progres-
sively closer and closer to the actual conditions of
_the case in point:
A. mesh involving the dam alone (and not the
ground) with a single type of material (RCC):
boundary conditions being equal, this case can
be compared with the one-dimensional calculation
using the previously described approximations;
B. mesh as above, but with two types of material
(RCe in the core and conventional concrete at the
88
_._---------------
dam faces): by comparison with the preceding ca-
se A, this enables evaluation of the influence of
the dam faces ~ which will be found to be irre~
levant;
C. as above, but with conventronal concrete instead
of Ree for the first 3 m above the foundation rock:
this identifies the greater generation of heat at the
base, an aspect which is of minor concern from
the point of view of cracking because expansion
is prevented by contact with the ground; it also
identifies the significant drop in heat generation
after the first dozen lifts.
Graphs were traced for all three cases described
above and compared with the one obtained from the
one-dimensional calculation.
3. CASE STUDY (SA STRIA DAM)
3.1. Thermal properties of materials
As already mentioned, one of the aspects having
the strongest influence on the dam's stress status
due to temperature is the use of two different con-
crete mixtures, giving rise to different thermal pro-
perties and characteristic resistances.
As we have already pointed out in para. 1, the
concrete in the facing layer is made with 220 kg/m 3
Class 225 pozzolanlc cement, whereas that in the co-
re is made with 105 kg/m 3 Class 325 pozzolanic ce~
ment and with the same amount of fly ash.
The exothermic reaction of hydration in the con w
crete produces a quantity of heat proportional to the
quantity of cement in the mixture and therefore the
heat of hydration in the core (per unit volume) is much
less than in the skin layer.
Because of its low thermal conductivity (p, "'" 2.44
W/m 0c), concrete behaves as an insulator: thus the
innermost parts of the cast concrete reach conside-
rable temperatures, while the outermost areas sur-
render heat to the surrounding environment; the
result is that the skin is subject to tensile stresses
while the core undergoes compressive stresses.
It is also relevant to express the heat of hydra~
tion as a function of time, as it has quite a conside-
rable influence on the thermal gradient and may even
affect the rate at which the dam lifts can be placed.
One law which interpolates pozzolanic cement
data fairly well is given by the following .formulas:
C =: 290 e-1 .lOit for t < 28 days
C =-i.73·1(}-3·f2+ 0.689· t + 255 fort ~ 28 days
where:
t "'" 0 is the time when hydration begins.
Typical values available from the literature Were
assumed for the concrete's other thermal properties.

The concrete's thermal conductivity, specific
heat and diffusivity, and the transmission coefficient
in contact with the air, were assumed as the mean
values obtained from those provided by Stucky and
Derron (1957]:
It "" 2.44 W/m °C
c "'" 921.1 JIg °C
a "'" 0,004 m2/h
a "'" 34,89 W/m2 °C
The density of the conventional concrete was as~
sumed as e == 2390 kg/m 3 and as e m 2350 kgfm 3
for the low-cement concrete.
The thermal expansion coefficient was assumed,
for both types of concrete, as fJ = 12 . 1(}-6 °C-1,
which corresponds to ambient conditions with a re-
lative humidity of 40%.
For the foundation rock, conductivity was assu~
mad as 1.75 W/m·C (IPPOLITO at ai, 1985), typical
of metamorphic sandstone (like the cornubianite un~
derlying the Sa Stria dam) and density was assumed
as e = 2700 kg/m 3 , The same values as for the
concrete were assumed for the other parameters.
3.2. Comparison of results
For the configuration of Case A described in pa~
ra. 2,2, Fig, 2a illustrates the temperature trend as
a function of time, in the axis of the dam, for the first
24 lifts of RCC, calculated using the one-dimensional
method,
For the same configuration, Figure 2b illustrates
the corresponding result calculated using the two~
dimensional method.
Comparison of Figs 2a and 2b shows that the two
methods lead basically to the same results,
In fact the temperature of the lifts calculated
using the two methods is virtually the same in the long
term, whereas it differs in the first two days, when
the cast concrete is exposed to the air.
This stems from the different way in which heat
exchange with the air is simulated in the two me~
thods. For the sake of algorithmic simplicity and in
view of the dubious accuracy of the convection coef~
ficient determined for a concrete surface during cu~
ring, the one-dimensional method assumes that heat
exchange with the air (on an imaginary concrete lift
at t = 0 °C) is governed by the expression of con~
duction, not of convection which (At being equal)
would enable a greater heat exchange.
The finite elements programme, on the other
hand. also considers the heat exchange by convec~
tion for the final lift, tentatively assuming a coefficient
typical of an already-cured concrete surface (this is
not entirely correct because the surface is still in the
curing stage).
This means that the two-dimensional calculation
THERMAL ANALY$I$
gives lower temperature value~ ~han the one-
dimensional method for the two days while the caw
sting is exposed to the air, so the subsequent place~
ment is laid on a colder surface.
This circumstance produces a greater heat ex~
change by conduction between the new casting and
the previous lift, which therefore returns to temperaw
tures closer to those calculated with the one-
dimensional method,
Comparison of Figs 2a and 2b therefore shows
that the long-term thermal status is not significantly
influenced by an error in the choice of convection
coefficient, nor even by disregarding this factor and
replacing it with the conduction value,
Figure 2c is similar to Figure 2b, but in this case
(in the two-dimensional model) the dam faces were
considered as made of conventional concrete and the
core of RCC: clearly the dam faces have absolutely
no influence on the thermal status of the core,
Figure 2d illustrates results with the same mo-
del as in Figure 2c, but with conventional concrete
for the first ten lifts (3 m); this difference clearly in-
fluences the first 12 lifts, after which the envelope of
temperature peaks decreses,
A finite differences one-dimensional model there~
fore suffices for calculating the temperature of a
dam's RCC core, even when convection from the sur-
face layer is disregarded, and this is due to the parti w
cular geometry of the case in point and to the casting
times involved for the concrete lifts.
As for the temperature trend near the dam faces,
Figure 3 illustrates the progressive temperature chan w
ges between the dam faces and the core, calculated
by means of both one-dimensional and twow
dimensional methods applied as explained in para,
2, Comparing the 28-<:1ay and 9O-day temperature
gradient curves shows that the results of the two me-
thods follow a very similar pattern.
So, here again, the approximate one-dimensional
method thus applied for calculating the temperature
gradient at the dam faces fairly accurately reprodu~
ces the results of the more sophisticated two-
dimensional method.
Obviously it must be borne in mind that t~ese re~
suits may not be taken as valid in general terms; as
they were found in relation to a given case study.
ACKNOWLEDGEMENTS
The authors wish to thank Dr. Ermanno Picchio~
ni, Mr, Georges Touma and Mr. Giovanni Zivelonghi
for their assistance in the development, verification
and application of this new version of the F,E.M, pro-
gramme.
89
IDROTECNICA N. 2, MARCH-APRIL 1991
REFERENCES

CASARA F" FASSO C.A., S!VIERO A.,. Problemi lermici della digs di Monti Nit!ddu - AII·ITAICOLD: Symposium "La tecnologla de!
ealcestruzzo ruUato per la costruzione del!e dighe a gravitS" - Cagliari. Sap. 1989.
FASSO C. A. - In Sardegna if primo esemplo Italiano dJ Pfogetto df sbamummto in catcestruzzo rul/ato - AH·!TAICOI,.O: Symposium
"La tecnologia del calcestruzzo ruliato per fa costruzlone delle dighe a graviUl" _ CagUai'i, Sap. 1989.
GENTILE G. - Gllimplanti della Valma/enco e la dlfi8 di Alpe Gera ~CostruzIoni .. Apr. 1965
IPPOLITO F., NICOTERA P., LUCINI P, CIVITA M., DE AlSO R. Geologia Tscnica, 1955.
STUCKY A., DERRON M. H. - Probfem8S thermiques pos8s par la construction des barrages. reservoirs. Losanna, 1957.

90