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CFRD 16
ABSTRACT
This paper presents the geotechnical design of La Yesca concrete face rockfill dam (CFRD), currently under
construction that takes into account the index and mechanical properties obtained from laboratory test results and
from rockfill test embankments using the materials with which the dam is being built. Description is made of the
procedure applied to achieve the compaction determined from the rockfill embankments and the behavior of the
dam is analyzed based on the results of the instrumentation installed. Finally, its behavior is compared with other
dams of the same type built in Mexico, namely, Aguamilpa and El Cajn. The behavior of the dams referred to is
analyzed in terms of settlements for the following conditions: end of construction, first filling, and long-term
performance using for this purpose the information resulting from the instrumentation installed at the
embankment and with special emphasis paid to the physical and mechanical characteristics of the geotechnical
zoning of each of the embankment dams as well as to the compaction procedure used in the field, being these
factors directly related to the recorded behavior
Key words: CFRD, Dam, Behavior, Settlements, Rockfill properties
1. BACKGROUND
1.1 Overview
This paper describes some of the most relevant aspects related to the geotechnical design of La
Yesca Hydroelectric Project currently under construction (progress achieved to date, may 2011,
amounts to 82% in the placement of materials in the embankment) and an account of its behavior
during the construction stage is also presented. Brief mention is made too for comparison purposes of
the behavior of two other large concrete face rockfill dam completed in our country, i.e. Aguamilpa
and El Cajn, both located downstream from the hydrological system of the Santiago River in the state
of Nayarit, Mexico.
1.2 Factors affecting the deformability of the CFRDs
Because the materials used in the different zones of a CFRD have in general very good quality, the
slope stability of the dam is no longer a relevant problem but the deformations that can be experienced
by the concrete slab during the construction stage, first filling and accidental loads (earthquakes) are of
serious concern; therefore, the compressibility properties of the different zones, particularly of
material 3B that acts as a support to the concrete face, should be carefully analyzed because the
The Second International Symposium on Rockfill Dams
objective is to achieve an embankment with low compressibility that ensures a suitable behavior of
this element..
The major factors affecting the characteristics of compressibility of the CFRDs are related to the
physical and mechanical properties of the constitutive materials of the various zones of the
embankment, namely: grain size distribution, grain shape, size and mineralogy of the particles
(hardness), relative density (represented by the void ratio or the dry unit weight), tightness or
interlocking, the state of confining stresses, the degree of saturation and the rate of application of the
load. In addition, it is a known fact that the geometry of the valley also affects importantly the
deformations likely to be experienced by the dam because of the arching phenomenon.
Mention should be made that the compaction process used during construction is fundamental in the
values of the module of compressibility that are obtained in order to achieve a suitable behavior of the
embankment and consequently of the concrete face. The more important issues in this process are
related to the type of compaction equipment (usually a vibratory roller compactor, static weight of the
drums compactor, centrifugal force, number of passes, thickness of the layer to be compacted and, for
rockfill, addition of water during compaction (spraying).
1.3 Geometry and zoning of the high CFRD used in Mxico
Cross sections of embankments for concrete face rockfill dams from a stability point of view, pose by
no means a relevant problem and slopes of 1 vertical to 1.3 - 1.5 horizontal have been adopted (Cooke,
1984, 1998; Sherard, 1995). The distribution of the materials within the cross section of the
embankment takes into account the deformability and permeability. In general terms, material 2 with
permeability of about 1x10-3 cm/s, directly supports the concrete slabs, having maximum particle size
from 5 to 7.5 cm, well graded, with percentage of non plastic fines ranging from 7 to 12%, and sand
content of 35% or higher. Immediately adjacent, material (3A) can be found acting as a filter and
separating the former from the main rockfill (3B).
Toward downstream material (3B) is also placed, and it governs the settlements of the concrete slab
and it is typically well graded, with maximum particle sized of 60 cm for alluvium and 80 cm for
rockfill.
To complete the cross section, sound coarser granular materials are placed (T and 3C), generally well
graded and with maximum particle size from 80 to 120 cm. The downstream slope of the embankment
is protected with rock fragments exceeding 100 cm in size (material 4).
The three large dams presented in this paper were designed and constructed with this criterion. See
cross sections in figures 1 to 3.
test embankment was compacted practically dry, after realizing that the addition of water did not
improve its mechanical properties.
The results of these tests are summarized in the table 1.
Gravel void ratio
Layer
thickness
M
Number of passes
Layer
thickness
m
Fluidal
dacite
Porphyritic
dacite
0.60
0.258
0.247
0.233
0.80
0.336
0.361
0.80
0.250
0.25
0.239
1.0
0.331
0.410
1.0
--
0.257
0.292
1.2
0.368
0.422
.Layer thickness
m
0.60
0.80
1.00
1.20
277
256
246
Rockfill 1
Rockfill 2
148
135
126
174
158
150
Table 2 Average deformability modulus for materials used in the test embankments
2.2.2 Laboratory tests
Index tests
Some of the results of tests done on the construction materials are listed in table 3.
The failure load values obtained from the particle rupture test appear in table 4, where values of El
Cajn dam materials have also been included as a reference.
Material
Material
Test
Absorption
Accelerated
weathering
Abrasion
(Los
Angeles)
Gravel Rockfill 1
Rockfill 2
Rupture load, in kN
Dry
Saturated
< 2.25%
<2.2%
<2.3%
Gravel La Yesca
12
10
< 1%
<9%
<5.3%
3.5
<12.5%
<14%
<17%
4.8
1.9 to 3.3
1.7 to 2.6
Porphyritic dacite La
Yesca
Ignimbrite El Cajn
These results, reflecting the influence of the shape and the hardness of the particles in the
deformability parameters, confirm that the alluvium is much less deformable than the rockfill
embankment, which is consistent with both the experience observed in other dams and the parameter
values measured in the test embankments.
Shear strength and deformability in giant triaxial tests
Consolidated drained (CD) triaxial tests were done in giant rockfill test samples, 30 cm in diameter
and 70-cm high. The results are shown in figure 5. The tests were executed on samples with a
maximum particle size of 38 mm, coefficient of uniformity similar to that on site, and void ratio of
about 0.30.
Fig. 5 Effect of the confining stress on the friction angle and confining stress effect on initial
tangent deformability modulus (Eti)
2.3 Analysis and design
2.3.1 Overview
La Yesca Dam will be the highest of its kind in America and one of the highest in the world. Recently
some high dams of this kind have endured serious cracking in the concrete face, which in turn has led
to large leaks of the order of several cubic meters per second.
It appears that the origin of these cracks is the high deformability of the embankment rockfill placed in
those dams so, in order to avoid these effects at La Yesca Dam, special emphasis was put on the
strain-stress analyses to estimate the displacement and the compressive stress on the concrete face
induced by the embankment deformation. In this way it was possible to define the most adequate
construction specifications.
Therefore, the zoning design of La Yesca Dam was made to meet the following criteria:
Achieve low deformability of the 3B zone in the rockfill embankment
Get a transition zone between the 3B zone material and the 3C zone rockfill at the embankment.
Keep the deformability modulus ratio among adjacent zones in the embankment smaller than 2
in order to avoid stress concentrations.
Attain effectiveness and efficiency of construction materials this is, proper behavior at a
reasonable cost.
It was also considered that the peripheral and tension joints will have barriers against leakage similar
to those used at El Cajn Dam (copper seal both in the lower and upper face of the joint as well as
self-sealing material covering them), installed strictly following the corresponding specifications.
2.3.3 Material properties for numerical analyses
Based on the above information, 3D finite element analyses were carried out to assess the magnitude
of the settlements in the dam. The deformability modulus values were defined according to the
following criteria:
The deformability modulus of a rockfill or gravel-sand embankments depends mainly on the following
factors (Alberro, 2000, Marsal, 1972):
Hardness and shape of grains (measured by the Grain Rupture Load, in kN).
Compactness or degree of arrangement achieved (measured by the Void Ratio).
Grain size distribution (Measured by the Coefficient of Uniformity, Cu = d60/d10).
Maximum particle size.
Wetting of the rockfill before compacting.
Weight of roller used in compaction, layer thickness and the number of passes.
In general, the deformation modulus, Ec, value increases when the grain rupture load of the materials
and the coefficient of uniformity gets larger and both the void ratio and the maximum particle size
decreases.
Figure 6 shows a graph that contains the total population of deformability modulus calculated with the
different field and laboratory tests for the alluvial and rockfill test embankments (Pantoja, 2006 y
2007), as well as the exponential trend line for alluvial, fluidal and porphyritic dacite materials.
Additionally, the vertical, horizontal and estimated octahedral stresses were calculated for dam
materials 3B, T and 3C, by using FLAC 3D software at one third of its total height. With these stresses
and by using the corresponding trend line graph, the corresponding deformability modulus to perform
the 3D the finite element analyses of the dam were determined. Table 6 presents a summary of index
and mechanical properties expected for materials 3B, T and 3C.
Fig. 6 Total population deformation modules obtained in the studies, and trend lines
Unit
Material
Weight
Poissons
ratio
MPa
171
226
240
480
3*
171
342
1*
2*
153
130
169
260
115
230
119
85
129
170
1*
T,
Rockfill
3C,
Rockfill
Ell
MPa
kN/m3
3B, Gravel
Ec
2*
3*
1*
2*
20.7
19.5
18.5
0.2
0.2
0.25
85
170
3*
* Parameters used in the analysis: 1, Trend line; 2, Most probable behavior considering Aguamilpa and El Cajn dams experience; 3,
Conservative viewpoint
In the analysis presented in this report, the existing vertical joints in the concrete face were not
included, resulting in extreme conditions in some aspects, such as, the horizontal tensile stress in the
lateral side of the concrete face and at the joints. In spite of this, based on the experience with other
dams (Alemn et al., 2005, 2007) the results obtained define quite precisely the zones of compression
and tension on the concrete face as well as the order of magnitude of these values.
A linear elastic model for the materials of the dam and the concrete face was used, taking into account,
the differences that arise between the vertical modulus used during construction and the modulus used
during first filling.
Calculated dam behaviour at the end of construction
The maximum vertical stress at Zone T at end of construction was in the order of 3.5 MPa.
The maximum vertical settlement calculated in the embankment was of 0.80 m, approximately at the
center of a longitudinal section. The maximum vertical displacement in a cross-section of the dam was
equal to 0.81 m (see figure 8).
For first filling a maximum total displacement of the concrete face of 0.17 m was calculated,
approximately, at the center of its height and length (see figure 9).
The maximum horizontal displacement in the concrete face, along the dam axis was of 0.03 m.
0.175
Fig. 9 Total displacement contours due to first filling of the reservoir (in m)
The Second International Symposium on Rockfill Dams
The compression and horizontal stresses generated in the concrete slabs due to first filling of the
reservoir were equal to 4.8 MPa or smaller and were located at the center of the slab. The maximum
tensile stress was of 9.8 MPa and occurred in small concentrated areas located at the contact edges of
the slab with the abutments, with a maximum average tensile strength amounts to 3 MPa.
The stresses generated in the slabs due to filling of the reservoir were calculated in the direction of the
dam slope, obtaining a maximum compression of 1.43 MPa at the center of the height and length, and
a maximum tensile stress of 5.47 MPa acting on small concentrated areas near the contact edges of the
slabs with both abutments. Taking into account the average maximum stress in the area near the
abutments, the tensile stress becomes equal to 2.5 MPa.
The horizontal compression stress and tensile zones of the concrete face, where the construction joints
are located, were defined with this information and can be observed in figure 10.
Zone
El
Cajn
La
Yesca
Number
of
passes
Compaction
Type
Aguamilpa
Aguamilpa
El Cajn
and La
Yesca
---
---
Alluvial
0.3
Alluvial Alluvial
0.30
0.3
3B
Gravel
0.6
Rockfill
0.8
Gravel
0.6
10 ton VR Dry
Rockfill
0.6
Rockfill Rockfill
1.0
0.8
10 ton VR Dry
3C
Rockfill
1.2
Rockfill Rockfill
1.2
1.0
10 ton VR Dry
NA
Placed by backhoe
Placed by backhoe
NA
NA
NA
NA
10
||
BOULDERS
GRAVEL
SAND
100
Xibeiku(95m)
% Passing (weight)
90
80
El Cajn (187 m)
70
La Yesca (207 m)
60
Aguamilpa (185m)
50
40
30
20
10
0
1000
100
10
0.1
0.01
Size particule, in mm
Fig. 12 Contours of settlements and modules of deformability determined with hydraulic levels
in La Yesca Dam (April 2011) Courtesy of Structural Safety Department, CFE
95 MPa
140 MPa
70 MPa
Fig.13 Contours of settlements and modules of deformability determined with hydraulic levels at
the end of construction in El Cajn Dam (courtesy of Structural Safety Department, CFE)
The Second International Symposium on Rockfill Dams
11
49 MPa
129 MPa
260 MPa
Fig. 14 Contours of settlements and modules of deformability determined with hydraulic levels
at the end of construction in Aguamilpa Dam (Courtesy of Structural Safety Department, CFE)
In Table 7 the modulus of deformability and maximum settlement measured in the three dams are
showed. We can see that modulus in the gravel of Aguamilpa and La Yesca dams are very similar, and
that the confinement of the material T reduces its deformability. With respect to material 3C, in
Aguamilpa had a high deformability y due to three factors, poor graduation, using layers of 1.2 m and
the dry compaction. In El Cajn and La Yesca, gradation of these materials was improved and
compaction was performed by adding water and using a heavier vibratory roller. This produced a less
deformable rockfill. The extreme case was La Yesca, where for construction reasons the contractor
used the same gradation for T and 3C, making way for modules in the order of 131 MPa in the latter
material, 4 times higher than Aguamilpa.
DAM
Height
Maximum
modulus,
settlement at
A/H2
H, m
3B
e
T
E
MPa
the end of
3C
E
MPa
construction,
MPa
in m
AGUAMILPA
185
3.92
0.19
250
0.29
118
>0.40
35
1.7
CAJON(1)
186
3.21
0.32
95
0.36
140
0.39
70
0.8
LA YESCA
207
2.38
0.18
240
0.28
176
0.30
131
0.75(2)
12
100
200
300
400
500
600
0
Material 3C
Dynamic Elasticity modulus (cross hole test), MPa
200
400
600
800
1000
1200
1400
1600
Material T
1800
50000
Material 3B
Material 3C
10
100000
Material T
Material 3B
150000
20
depth, m
30
40
200000
250000
300000
350000
50
400000
60
450000
70
500000
a)
b)
0.5
in kPa.
We can see that the value of K2 are smaller than the reported in the technical literature for rockfills,
and are near to values for dense sands.
3.2 Behavior during first filling
Currently, La Yesca Dam is in under construction, and is expected to begin first filling in second
quarter of 2012. However, based in its behavior during construction, it is considered that the
displacement of the concrete face will be those predicted in the analyses made (less than 20 cm), so it
will not present cracking problems.
13
Fig.16 Settlement contours at Aguamilpa Dam as of October 2010 (first filling is included)
Courtesy of Structural Safety Department, CFE
With respect to El Cajn, the maximum long term settlement has occurred in the crown of the dam
with a value of 25 cm (see figure 17). Mention should be made that the highest rates of deformation
were recorded at the time period covering from the starting date of the first filling to February 2007
when the rate of deformation began to decrease. Currently the rate of settlement is very slow, which
indicates that this phenomenon has practically stopped.
Fig.17 Settlement contours as of November 2010 measured at El Cajn Dam (first filling is
included). Courtesy of Structural Safety Department, CFE
14
4. CONCLUSIONS
Geotechnical studies and designs allowed to define the site requirements and the use of materials for
the dam, as well as to obtain information about the strength and deformability parameters of the
gravels and rockfill used to construct the embankment.
The results of the analyses made it possible to establish the importance of using transitions in the
zoning of the dam to prevent sudden changes in the module of deformability of materials that could
induce undesirable stress concentrations and lead to tensions and cracking in the concrete face.
It was found that, in high dams, the use in the 3B zone of very well compacted and well graded gravel
or rockfill, with layer thickness less than 60-80 cm It will ensure a proper behavior of the concrete
face by keeping the maximum displacements in values less than 30 cm, and maximum compression
stresses at the central concrete face at lower than permissible values.
There is no doubt that the characteristics of compressibility of the materials constituting La Yesca
dam, their geometry and the compaction procedures adopted in the field have been determinant in the
magnitudes of the settlements measured as of to date and of those to be expected in the long term.
To get a rockfill with low deformability, we need to use a sound rocks, well-graded grain size
distribution curves, addition of water during compaction, layer thickness less than 0.8 m in 3B zone
and less than 1.2 m in 3C zone, and a heavy vibratory roller compactor (12.2 t of mass in the drum).
Addition of water during rockfill compaction also reduces the long term settlement of the
embankment.
It seems that the K2 constant used to calculate dynamic shear modulus in seed and Idriss equation has
values between 20 to 34, substantially lower than those recommended in the literature.
ACKNOWLEDGEMENTS
The authors thanks Ing. Reginaldo Hernndez for allowing us to use the figures of the contours of
displacements developed in the Department of Safety of Structures of CFE.
REFERENCES
[1]
[2]
Alemn, JD et al, 2006, Studies and geotechnical design of El Cajn Dam. Proceedings of the
International Symposium of Dams, ICOLD-SPANCOLD Barcelona, Spain, Vol. 1
[3]
Alemn, JD et al, 2007, El Cajn Dam. Analysis of its behavior during construction and first
filling. Proceedings of 5th International Conference of Dam Engineering, LNAE, Lisbon,
Portugal, 2007
[4]
[5]
Cooke, JB 1998, Empirical Design of CFRD, Hydropower & Dam, Issue six, 1998
15
[6]
[7]
Pantoja, A, et al, 2006, Informe No. 06-62-SGM/S. P.H. La Yesca. Informe del pedrapln de
aluvin. Diciembre de 2006. Subgerencia de Geotecnia y Materiales, GEIC, CFE.
[8]
Pantoja, A, et al, 2007, Informe No. 07-05-SGM/S. P.H. La Yesca. Informe de los pedraplenes
de enrocamiento. Marzo de 2006. Subgerencia de Geotecnia y Materiales, GEIC, CFE.
[9]
Marsal, RJ, 1972, Resistencia y deformabilidad de enrocamientos y gravas, Informe No. 306,
Instituto de Ingeniera, UNAM, Mexico.
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