SAFETY CONSIDERATIONS IN DESIGN OF CONCRETE-FACE AND EARTH-CORE ROCKFILL DAMS1 By: M. Ibrahim Samoon, Chief Engineer, ACE (Pvt.

) Ltd.2 ABSTRACT Due to their unique features, the safety considerations in design of concrete-face and earth-face rockfill dams are distinctly different. These considerations are discussed with reference to the Beris dam project located in Kedah State of Malaysia, where a 40 m high main dam will be constructed as concrete-face rockfill on hard and strong conglomerate and sandstone foundation and a 27 m high saddle dam will be constructed on relatively softer sandstone and shale foundation as earth-core rockfill. Though slope stability is not a problem for a CFRD, the presence of thin sheared mudstone layers at the interface of conglomerate and sandstone in the foundation of main dam dictated to carry out stability checks and adopt slightly flatter embankment slopes as compared to the conventional slopes adopted for CFR dams. The dynamic analysis of main dam showed that deformations due to earthquake are negligible. The design features to control leaks through main dam are foundation grout curtain, provision of water stops and sealants at concrete slab joints, well anchored toe slab, semi-impervious and filter like fill under the concrete slab and covering of lower part of slab with impervious earthfill. The design considerations for the ECR Saddle dam are stability checks for embankment slopes, the finite element analysis to evaluate hydraulic fracturing potential of earth core and provision of seepage control measures to check piping failure through dam foundation or earth-core.

This paper was published in the Proceedings, Technical Session on Civil Engineering, 37 th Annual Convention held in April 1997 at Lahore during Golden Jubilee Celebrations of Institution of Engineers Pakistan 2 The author was responsible for the design of embankment dams for Beris Dam Project, Malaysia.
1

SAFETY CONSIDERATIONS IN DESIGN OF CONCRETE-FACE AND EARTH-CORE ROCKFILL DAMS By: M. Ibrahim Samoon, Chief Engineer, ACE (Pvt.) Ltd.* Introduction The Beris dam project located in the State of Kedah Darul Aman, Malaysia will create a reservoir with a storage capacity of 122x106 m3. The dam will primarily supplement irrigation and water supply needs of Kedah and Perlis states of Malaysia. M/S Associated Consulting Engineers-ACE (Pvt.) Ltd., Pakistan were responsible for the detailed design and preparation of tender documents for the project. The construction of project is foreseen to commence by the end of year 1997. The salient features of the envisaged project consist of 40 m high main dam in a narrow valley of Beris river, 27 m high Saddle dam at a low ridge along the reservoir periphery, outlet works including a 5 m dia tunnel and 266 m3/sec capacity side channel spillway. The main dam and saddle dam are both rockfill embankments. However, due to distinct difference in foundation conditions at both dams, the design features of both embankments are distinctly different. The main embankment is concrete face rockfill dam (CFRD), whereas the saddle dam has central earth core flanked by filters and supported by rockfill shell on both upstream and downstream. Though general stability considerations for all engineering structures are same but, every structure due to its specific features require special design details. The seepage forces in a CFRD are concentrated at toe slab and are released in the free draining rockfill. Evaluation of seepage forces is simple. The vertical reservoir load on the concrete face increases the frictional resistance of the embankment base. The only problem to the stability of a CFRD can come if weak layers are present in foundation or the strength properties of rockfill material are low. While in an ECRD, besides the strength characteristics of embankment and foundation, the stability of embankment depends on the distribution of pore pressures in the earth core and foundation during construction, under steady seepage condition and during rapid drawdown of the reservoir. The safety of an ECRD is sometimes endangered by piping failure due to concentrated leaks through the earth core or at core-

contact

with

the foundation.

_________________________________________________________________ *The author was responsible for the design of embankment dams for Beris Dam Project, Malaysia. Some of the major problems which CFRD and ECRD may face due to deficient design, problematic foundation or poor quality construction are listed below: Problems which can develop at a concrete face rockfill dam: 1) 2) 3) 4) 5) 6) 7) Opening of joints or development of cracks concrete face slab resulting in leaks. in

Opening of perimetric joint between face slab and toe-slab may develop high leaks if water stops fail. Lifting of toe slab due to high uplift pressures, may cause leaks and foundation undermining. Concentrated leaks under the toe slab through grout curtain windows, foundation cavities and openings. Slips along weak layers in foundation. Slips and sloughs of rockfill. of slopes due to low strength

Deformations due to earthquake can damage upstream concrete slab and reduce the free board margin.

Problems which can develop in a central core rockfill dam: 1) Piping failure due to: Leaks through high permeability zones in earth core due to faulty construction and placement of so called 'blind filters' created by placement of pervious material Leaks through earth core contact with foundation Leaks through joints, cavities and faults in foundation rock and windows in grout curtain Leaks through hydraulic fracturing in central core due to load transfer effects

between -

core and shell under

Development of transverse cracks valley arching action

Development of pipes due to migration of fines from earth core due to defective filters

2)

Overtopping of dam due to insufficient free board, or inadequate spillway or loss in free board due to excessive settlement. Deformations and slides during earthquake. Slope failures: During construction due to development of high construction pore pressures in impervious core Sliding failure of downstream slope under steady seepage condition Sliding failure of upstream slope during sudden drawdown Slip along weak layers in foundation A dependable and safe design must address these problems and provide all necessary measures to safeguard against them. Present paper describes various aspects of safety which were considered to ensure a safe and reliable design of the main and saddle dams. MAIN DAM The 40 m high and 155 m long main dam is a conventional CFRD design (for current design and construction practices in CFRD, see HACELAS & MARULANDA, 1988; COOKE & SHERARD, 1985; and special issues of J. Geotech. Eng. Oct, 1987 and Water Power & Dam Construction, April 1992). It consists of 4 zones of rockfill with upstream concrete slab of 0.35 m uniform thickness with 3 m high parapet wall at top and 4 m wide upstream toe-slab. The foundation water tightness has been ensured by 3 rows of grout curtain all along the upstream toe under toe slab. A typical section of the dam and other design details are shown in Figures 3

3) 4) -

to 9. Embankment Slopes The batters of both upstream and downstream slopes for Beris main dam have been kept at 1V:1.5H. For CFR dams, the normal practice is to provide embankment slopes on 1V:1.3H to 1V:1.4H. However, the selection of design slopes is dictated by the strength characteristics of embankment materials and presence of planes of weaknesses in the foundation. The available dams data show that the slopes of concrete face embankments constructed of softer rocks have been kept at 1V:1.4H to 1V:2H (Winneke Dam, Australia Sugar Loaf Dam, Australia, and Baily Dam, USA, refer COOKE, 1984). Cirata Dam Indonesia (completed in 1987) constructed with andesite rock has been provided slope 1V:1.5H. Nearby Pedu dam located in the state of Perlis, Malaysia, which is bituminous membrane compacted rockfill dam has slopes 1V:1.5H on downstream and 1V:1.7H on the upstream. The flatter upstream slope was adopted for the convenience of laying the bituminous face. Foundation Conditions of Main Dam The design features of Beris main dam are largely governed by the foundation which consists of three types of rock layers, i.e, conglomerate, gritstone and fine sandstone. Pockets, lenses parting and layers of mudstone have been found in conglomerate and at the interface of conglomerate and sandstone. The conglomerate forms the top layer and dominates two abutments. It consists of medium to fine aggregate of sandstone, quartzite, slates and chert within dense siliceous matrix. The underlying sandstones are hard but indicate certain degree of shearing in the central river section, which is manifested in the form of low RQD values and high permeabilities in packer pressure tests. Sheared Mudstone Partings/Layers The stability of the main dam, particularly of its downstream slope is governed by the presence of two well defined sheared mudstone parting/layers at the interface of top conglomerate and the sandstone (see Figure 10). These layers more or less follow the bedding planes (strike N40E and dip 15-35NW) and provide an apparent dip of 10 from upstream to downstream. The nature of these mudstone layers is similar to the weak sheared seams developed in sedimentary rocks which has undergone folding. Two examples of such type of

weak layers have been reported by CASINADER (1980) in the foundations of concrete face rockfill Sugar Loaf Dam (Australia) and the buttress type Muda Dam (Malaysia). Similar type of sheared seams were detected in the foundations of the Mangla Dam Pakistan (Binnie et al, 1967) and the Jatiluhur Dam Indonesia (BOHN & HAMON, 1967). It should be noted that existence of weak zones in foundation at all these dams were detected at the time of foundation excavations and necessitated major changes in the design. At Sugar Loaf dam, slopes of 1V:1.5H for upstream and 1V:2.2H for downstream were adopted. Excavations were deepened to decrease the effect of weak seams, and stabilising berms were added at various critical locations. The sliding stability of Muda Dam was ensured by providing extensive system of stabilising anchors. Slopes of Mangla Dam embankments were provided weight berms to ensure the stability. At 105 m high Jatiluhur Dam the sheared seams in foundation required addition of stabilising berm in 2/3 height of the dam, which resulted changing original design slopes from 1V:1.35H to 1V:2.5H, and in certain reaches even to 1V:3.5H. The timely finding of weak mudstone layers in Beris dam foundation lead to major decision of changing type of dam from concrete gravity to concrete face rockfill dam, which due to its wider base width offers comparatively lesser sliding problems as compared to those in case of a concrete gravity dam. The tests on material from mudstone lenses of Beris dam foundation indicated that they are sandy silty in nature and possess a residual angle of friction equal to 18. The mudstone layers provide potential sliding surfaces and require careful consideration in the analysis. Nature of Rockfill Material Another cause of concern is the nature of conglomerate rockfill to be used in the embankment which contains pockets of mudstone. For conglomerate obtained from tropical setup, wide variation in material characteristics, deep weathering and disintegration during compaction could not be ruled out. Nyumba Ya Mungu Dam Tanzania and Pedu Dam Malaysia required major design changes in embankment section during construction stage due to problems posed by rockfill material. The changes in design at construction stage were such that C.L. CLARKE and R.G. TAYLOR had to write a paper titled "Lessons Learned from Two Rockfill Dams in the Tropics" (CLARKE & TAYLOR, 1970). Stability Checks

The stability checks for Beris main dam were carried out using Morgenstern-Price (1965) method. The design parameters for fill and foundation materials were selected from the results of laboratory and field tests. Selection of Shear Strength Parameters For sheared mudstone layers, based on laboratory test results, values of c'=0 and f=18 were adopted. Coincidentally, at Muda Dam, for the sheared mudstone layers same values were used in its design. Relatively lower values were adopted for Jatiluhur dam (f=11) and Mangla dam (f=13 to 18). For foundation conglomerate/sandstone c=80 kPa and f=40 were adopted. For sensitivity study analysis was also carried out for cohesion values equal to 0 and 40 kN/m2. In case of conglomerate rockfill, which gives higher strength values at low stresses, two approaches were adopted. In the first approach Mohr Coulomb model was used adopting f=42 for internal zones and higher value of f=45 for the external zones where stress levels will be low. In the second approach, the curvilinear shear-normal failure envelope of El. conglomerate rockfill given by MARACHI WILSON (1979) was adopted. The limited Beris conglomerate show results closer strength envelope can be relationship for Infiernillo dam et al (1972) and tests carried out on to this curve. The

represented by equation v=2.169d.859. This curve gives following values of friction angle on various levels of normal stress: Normal Stress (kPa) Friction Angle 10 25 50 100 200 400 800 57.0 54.0 51.0 48.5 45.8 43.0 40.0

It may be of interest to note that in design of nearby Pedu Dam the friction angle for rockfill was adopted as 42 (CLARKE & TAYLOR, 1970) whereas for Design of Ahning Dam a friction angle of 40 was used for rockfill (DAVIES & MOSS, 198?).

Main Findings of Stability Analysis Main findings of the stability analyses are as under: 1. For slopes 1V:1.4H, the safety factors are in the range of 1.34, which is less than the minimum recommended value of 1.5. The selected embankment slopes of 1V:1.5H are safe for all loading conditions (minimum safety factor 1.5 without earthquake) and provide margin of safety for cases when foundation may indicate adverse conditions. A factor of safety of 1.38 is available for the most adverse condition assumed when cohesion may be lost by the conglomerate planes and friction of mudstone layers may drop to 15. The earthquake of slopes. loading is not critical for design

2.

3.

Dynamic Deformation Analysis of Main Dam The deformations in the main dam in event of earthquake of magnitude M=8 and peak ground acceleration (PGA) equal to 0.12 g were calculated. The embankment response was analysed using MAKDISI & SEED (1979) method. Deformation were evaluated using a number of methods. The well recognised methods such as MAKDISI & SEED (1978), SARMA (1980) and ESI (BUREAU et al, 1988) showed that with the proposed embankment slopes practically there will be no deformation in the dam crest in event of earthquake (calculated deformations vary from zero to 9 cms maximum).

Measures to Control Leaks at Main Dam Though leaks through a CFRD do not pose any problem to the structural stability of dam, but may affect the utility of structure if increase beyond certain limit. Following features ensure the control of leaks through dam body or foundation: 1. 2. Grout curtain has been provided under toe slab foundation to close openings and provide cut off. The deformations in compacted rockfill are generally very low. However, to reduce the deformations in

rockfill and in turn in concrete face slab, the portion of dam which shall be directly sustaining reservoir load has been placed on fresh to slightly weathered rock. 3. Joints in concrete face slab have been provided with copper water stops. In addition to copper water stops, the perimetric joint and vertical joints towards abutment which can open due to reservoir load has been provided with 'Igas' sealant covered with 'hypalon' membrane. The lower part of concrete slab, where chances of leaks are higher, shall be covered with impervious earthfill. The fill below concrete slab is semi-impervious and its gradation approaches standard filter. Minor leaks through slab shall be controlled by this layer. The filter action will be helpful in closing the eventual leaks by dumping earth from outside. SADDLE DAM The saddle dam is located at about 0.6 km on the right side of main dam. The dam is 27 m high and about 200 m long at crest. The design of saddle embankment is a conventional design of central earth core embankment. Earth core is placed on sound rock, with transition filters supported by rockfill shell on both shoulders. The outer slopes have been fixed as 1V:2H for upstream and 1V:1.8H for downstream. The dam plan, typical section and other design details are shown in Figures 11 to 14. Foundation Conditions The central impervious earth core shall be placed on fresh rock to slightly weathered rock after removal of overburden and highly weathered rock. The bedrock is mainly composed of sandstone and gritty sandstone while on the right abutment bedrock is alternation of shale and fine grained sandstone. A crushed fault zone about 10 m wide runs through middle of the saddle. Another fault having a width of about 3 m exists towards the right abutment. The foundation in general do not pose any problem to the dam. However, two faults can cause leakage problem and can lead to piping failure. An elaborate treatment of faults has been provided to control these effects. The proposed

4.

5.

treatment consists of excavating the fault zone about 2 to 3 m below the fresh rock and backfilling with concrete cap extending from downstream end of the core to upstream toe of dam. On downstream of clay core, the excavated fault zone shall be filled with filter. Stability Analysis Considerations While evaluating the stability of Saddle Dam the which were considered in the design are as under: i) Strength characteristics of clayey earth core, filter zones and foundation mudstone were determined under saturated conditions. Stability of both upstream and downstream slopes was checked for end of construction. The construction pore pressures in earth core were evaluated by HILF (1948) method using consolidation test results. Pore pressure estimates were further verified using FEM analysis by simulating embankment construction. Stability of downstream slope was checked under steady seepage condition when reservoir shall be full. The expected pore pressures were evaluated from the flownet developed by finite element seepage analysis. Stability of upstream slope was checked for full and partial rapid drawdown conditions. The pressures resulting from rapid drawdown were predicted by BISHOP (1954) method. The design parameters for foundation and embankment materials were selected from the laboratory test results. Following strength parameters were used in the analysis: Impervious earth core Fine filter : Coarse filter : Rockfill shell : Foundation fresh rock : c'=20 c'=0, c'=0, c'=0, : c'=0, kPa, f=15 f=35 f=36 f=42 f=35 factors

ii)

iii)

iv)

The stability analysis showed that: 1) Proposed embankment slopes are safe under all loading conditions analysed (safety factor 1.54 for end of construction and steady seepage condition for downstream slope and 1.71 and 1.60 for upstream slope in condition of end of construction and rapid

drawdown respectively). 2) In all cases analysed, the critical slip surfaces pass through rockfill shell. The geometry and strength of central impervious core are such that it does not control the overall stability of embankment slopes. Potential of Hydraulic Fracturing at Saddle Dam The incremental non-linear finite element analysis of saddle embankment was mainly carried out to evaluate the deformations and stresses within the embankment by simulating the construction stages and reservoir filling. The results were used to study load transfer effects between the core and shell and to check the potential of hydraulic fracturing. The analysis showed that ratio of maximum principal stress to the reservoir water pressure on the upstream face of core is always more than unity, the minimum value being 1.74 at 23 m depth. Thus there is no potential of hydraulic fracturing of saddle dam core. This is explainable for small height of the saddle dam, relatively wider earth core and transition fitter zones between shell and the core. Measures to Control Piping Failure at Saddle Dam Leaks through saddle dam, which can occur due to defects in construction or cavities in foundation, can develop into piping failure if migration of particles form earth core and mudstone foundation layer is not checked. The migration of fines shall be checked by the filter flanking the core and the horizontal filter placed on the downstream portion of the foundation. Filter will also help in self healing of leaks.

REFERENCE 1. BINNIE, G. M, CLARK, J. F. F., (SKEMPTON, A. W. (1967), "The Effect of Discontinuities in Clay Bedrock on the Design of Dams in the Mangla Project", Trans. 9th Int. Cong. Large Dams, Istanbul, 1967, Vol. 1. BISHOP A. W. (1954), "The Use of Pore Pressure Coefficients in Practice", Geotechnique, IV, No. 4, Dec. 1954. BISHOP A.W. (1955), "The Use of Slip Circle in the Stability Analysis of Slopes", Geotechnique, Vol. 7, No. 1, March 1955. BOHN, M., & HAMON (1967), "The Djatiluhur Project", Water Power, Aug. 1976. BUREAU, G. et al (1988), "Seismic Analysis of Concrete Face Rockfill Dams", 16th ICOLD, San Francisco, Vol. V. CASINADER, R. (1980), "Systematic Weak Seams in Dam Foundations", Symp. on Problems and Practice of Dam Engineering, Bangkok, Dec. 1980. CLARKE, J. L. & TAYLOR, R. G (1970), "Lessons Learned from Two Rockfill Dams in the Tropics", ICOLD, Montreal, 1970. COOKE, J. B. (1984), "Progress in Rockfill Dams", 18th Terzaghi Lecture, ASCE, J. Geotech. Eng. Vol. 110, No. 10, Oct. 1984. COOKE, J. B & SHERARD, J. L. (1985), Editors of Concrete Face Rockfill Dams - Design Construction and Performance, Proc. Symp., ASCE, Detroit, Oct. 1985. DAVIES, D. R. & MOSS, P. N. S. (198?), "Design and Construction of Sungai Ahning Dam", A Concrete Faced Rockfill Dam for Jabatan Kerja Ray, Kedah, Malaysia. GEOTECHNICAL ENGINEERING, Special Memorial Issue: Concrete Face Rockfill Dam, ASCE, Vol. No. 10, October 1987. 113

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HACELAS, J. E. & MARULANDA, A. (1988),"Rockfill Dams

with Concrete Facing", Report prepared for the ICOLD Committee on Materials for Fill Dams, Bogota, D.E. 13. HILF, J. W. (1948), "Estimating Construction Pore Pressures in Rolled Earth Dams", Proc. 2nd ICSFE, Vol. 3. MAKDISI, F. 1. & SEED, H. B. (1978), "Simplified Procedures for Estimating Dam Embankment Earthquake Induced Deformation", J. Geotech. Eng. Div., ASCE, G17, July 1978. SARMA, S. K. (1980), "A Simplified Method for the Earthquake Resistant Design of Earth Dam", Design of Dams to Resist Earthquake, ICE, London, Oct 1980. WATER POWER & DAM CONSTRUCTION (1992), Special issue on Concrete Faced Rockfill Dams, April 1992.

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