TELES PIRES DAM – BENEFITS OF USING METACAULIM HP IN

CONVENTIONAL CONCRETES
F.G.Holanda*, R.V.C.Holanda*, E.R.Holanda*,
*
Holanda Engenharia Ltda
Rua Projetada, 22, Lote A, Jardim das Rosas, Itatiaia – RJ – Brazil - 27580000
e-mail: francisco@holandaengenharia.com.br webpage: www.holandaengenharia.com.br

Keywords: AAR, Hydration Heat, Expansion, Temperature

Abstract. The Teles Pires Hydroelectric Power Plant, in the Teles Pires River Basin, with an
installed capacity of 1,820 megawatts, is among the largest hydroelectric plants in Brazil
considering the installed capacity. The volume of concrete of the project, over 1,100,000 m3,
corresponds to the sum of the massive and structural dam’s concrete.
Several types of concrete were used, from wet mix shotcrete, RCC - (roller compacted
concrete), and conventional concrete pumped for the most diverse applications. Considering
the predominant use of pump concrete, in regions defined in Project where the RCC was not
possible to be placed, it was necessary to make use of several resources, not only the
concrete artificial cooling but also adding material of pozzolanic nature, in this case it was
chosen Metacaulim HP as part of the cementitious material composition of the conventional
concretes applied.
Metacaulim HP as part of the cement was used in concrete mixtures with the initial objective
of contributing to neutralize the alkali-aggregate type reaction (AAR) in the formulated
concrete mixes.
The replacement of part of the cement by Metacaulim HP assisted in the function of reducing
the heat generated by the binder in the concrete mixtures applied in massive zones of the
main concrete structures.
The benefits of using the binder also provided the modification of the concrete W/C ratio for
hydraulic surfaces, based on abrasion studies in the concrete by the test method ASTM
C1138.

1 INTRODUCTION
The Teles Pires Hydroelectric Power Plant is located at the north of the state of Mato
Grosso, as indicated in Figure 1. In addition to the engineering challenges, due to the location
of the work, the logistics of material supply has become a relevant factor for the realization of
this project.
In projects of this magnitude, the economic viability is directly related to the quality of the
region's rock, with the objective of performing the crushing process within construction site,
to obtain the small and large aggregates. Although the potentially reactive aggregate has been
detected, the mitigation of alkali-aggregate reactivity (AAR) can be achieved with the use of
compatible cements, combined with the mineral additions, as in the case of Teles Pires.

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Figure 1 - Teles Pires Hydroelectric Power Plant location

The addition of Metacaulim HP in this case, had the initial objective of neutralizing the
expansions of the AAR, however, other additional benefits were identified as presented in
this work.

2 STUDIES OF ALKALI-AGGREGATE REACTIVITY (AAR)

The AAR mitigation studies were conducted in the laboratory of the Brazilian Association
of Portland Cement (ABCP), in São Paulo - SP as well by Holanda Engenharia Ltda, located
in Itatiaia - RJ.

2.1 Reactive aggregate identification

The AAR phenomenon occurs due to the existence of 3 main factors: reactive aggregate,
cement with high alkali content and moisture, this last one being always present in
hydroelectric plants. The first step in the study of AAR is to verify the reactivity potential of
the aggregate, according to the guidelines of NBR 15577 Brazilian standard. Thus, a test
campaign was carried out with samples of rock collected from different locations (inside the
construction site) and analyzed periodically as the advance of the excavations.
This section summarizes the sequence of tests to evaluate the reactivity potential of the
aggregates for use in the work (Alkali-Silica or Alkali-Silicate Reaction). The Figure 2 below
shows the general flowchart for use of the concrete aggregate according to NBR 15577-1. In
the case of big projects, the classification of the preventive action is considered, making it
mandatory to classify the degree of reactivity according to the flowchart of Figure 3. Thus, as
observed in the flowcharts, it is essential to perform the petrographic characterization (NBR
15577-3 for coarse aggregates and NBR 7389 for fine aggregates) including its mineralogical
description and the potential of AAR as well as the realization of the test by the accelerated
method of the mortar bars (NBR 15577-4), using high alkali standard cement.

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The accelerated method test using standard high alkali cement (NBR 15577-4) and as
shown in Figure 3 is considered to be potentially innocuous when the expansions at the age
of 30 days are less than 0.19%.

Selection of aggregate for

concrete use

Risk analysis of the possibility

of occurrence of AAR in the
structure

Classification of
preventive action
(Table 1)

Unnecessary Mi n i mu m Mo der at e St r o ng

Aggregate with history YES

of occurrence of RAA
(in service or by tests)

NO

Classification of the
degree of aggregate
reactivity
(see Figure 3)

Potentially Potentially
innocuous react ive

Mitigation measures (see Aggregate

Section 7 of the standard) Exchange

Execution of
the work

Figure 2 - General flowchart for use of concrete aggregate (NBR 15577-1)

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 F.G.Holanda, R.V.C.Holanda, E.R.Holanda.

Petrographic
analysis

A cce le ra te d me th o d o f
mo rtar b a rs

Expansion at 30 days Expansion at 3 0 days

³ 0.19 %
<0.19%

L o n g -te rm me tho d o f
co n cre te p risms

Expansion in 1 year Expansion in 1 year

< 0.04 % > 0.04 %

Potentially innocuous (Return to Potentially reactive (Return to

flowchart in Figure 2) flowchart in Figure 2)

Figure 3 - Flowchart for laboratorial classification of the aggregate for the alkali-aggregate reaction (AAR)

If the test results in expansions equal to or greater than 0.19% at 30 days of age, the
aggregate is considered to be potentially reactive, making it necessary to study the
reactivity mitigation by the method of NBR 15577-5 (It should be considered the use of
inhibitors of this reaction in concrete with the addition of pozzolans, fly ash, blast furnace
slag, Metacaulim or Active Silica).
The studies carried out for the Teles Pires Hydroelectric Power Plant classified the granite
rock as potentially reactive, both by the petrographic analysis as well as by the accelerated
test with the standard cement, as shown below:

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Figure 4 - Graph of expansion evolution with cure time in alkaline solution - NBR 15577-4 - Samples of the
right river bank

Figure 5 - Graph of expansion evolution with cure time in alkaline solution - NBR 15577-4 - Samples of the
left river bank

As shown in the previous charts, the reactive aggregate was well above the recommended
limit. In this way the mitigation studies were carried out as presented in the following item.

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2.2 AAR mitigation studies

The evidence of reaction mitigation is obtained when the accelerated test result in mortar
bars is less than 0.10% at 16 days of age (14 days in aggressive solution), performed by the
NBR 15577-5 method.

Figure 6 - Graph of the expansion evolution with cure time in alkaline solution NBR 15577-5 - Samples of the
right river bank

Figure 7 - Graph of the expansion evolution with cure time in alkaline solution NBR 15577-5 - Samples of the
left river bank

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For expansion values equal to or greater than 0.10%, new tests are required in order to
meet the established limit, being it possible to change the cement used or to incorporate or
increase the contents of materials inhibiting the alkali-aggregate reaction (pozzolan, blast
furnace slag, active silica, metakaolin) or even replacing the aggregate.
Although the limits were met at the age of 16 days, the long-term expansion worried. In
addition, the variability of the results presented results very close to the limits, with reduced
safety margin.
From there, additional mitigation studies were performed with the use of Metacaulim,
according to the results presented in the following graph (Figure 8).
In view of the results obtained, the minimum use of 10% of Metacaulim was defined as
replacing the weight of the cement, for all concrete mixtures. This decision was also due to
the variability of the content of pozolana in cement manufacturing, with the objective of
additional guarantee for AAR mitigation.

Figure 8 - Graph of the expansion evolution with cure time in alkaline solution NBR 15577-5 - mitigation with
use of Metacaulim

3 ADDITIONAL BENEFITS

3.1 Hydration Heat reduction

In large works, with many massive concrete structures as in the case of the Teles Pires
HPP, the Hydration Heat is determinant for the definition of layer plans, ice consumption and
execution schedule.
As an indicator of the experiments carried out, the heat generated corresponds to an index
of approximately 0.12 °C/kg/m3 of cement. That is to say, that every 8 kg of cement
corresponds around 1 °C of temperature.
The design mix studies showed that the addition of Metacaulim to partial replacement of
cement results in equivalent characteristics of compressive strength for the age of 28 days.

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That is, a medium mixture with 360 kg/m3 of cement, having 10% of its weight replaced by
Metacaulim (equivalent to 36 kg), results in 4.5°C of temperature reduction.
This reduction was very significant because the location of the project in a hot climate
region led to high temperature gradients, thus reducing the risks of thermal cracking and
delayed ettringite formation (DEF).

3.2 Concrete abrasion improvement

It is very common in hydroelectric projects to restrict the water/cement ratio (W/C) to
hydraulic surfaces in order to improve the surface abrasion resistance of the concrete. In this
attempt, studies were conducted by ASTM C11381 (Standard Test Method for Abrasion
Resistance of Concrete).
The considerations were based on studies conducted by researcher Tony C. Liu1.
A criterion for the maximum acceptable wear limit was proposed for the Teles Pires HPP,
according to the local water velocity, as indicated in the Project. This criterion was used
successfully in the construction of similar projects, such as the Machadinho Dam and
Dardanelos HPP as main references in Brazil.
The design specifications limited the use of concrete for hydraulic surfaces as a function
of water / cement ratio (w/c), indicating the limit of 0.45 for spillway structures.

ID 969/13 1056/13 1057/13

Cement
285 355 411
(kg/m3)
Metacaulim
17 20 23
(kg/m3)
W/C 0,57 0,50 0,45
Abrasion - Sample
1,67% 1,04% 0,77%
1
Abrasion - Sample
1,43% 1,07% 1,02%
2
Table 1: Results of concrete abrasion resistance tests - % loss (mass) after 72 hours

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Figure 9 - Relationship between aggregate resistance to abrasion and concrete resistance to abrasion-erosion

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It is also observed that the measures and providences adopted had the purpose of
indicating a condition that allowed the execution of the predicted hydraulic concretes, with
the use of cement quantity per m3 of concrete, that at the same time fulfilled with the control
of the action of abrasion / erosion wear, with thermal gradients that would be installed of
such magnitude to minimize the risk of fissures arising by thermal origin, in the slab of the
spillway channel, mainly.
Considering the test results, it was considered sufficient to adopt the abrasion wear limit in
the concrete of 4% (maximum) at the end of 72 hours, tested according to ASTM C1138.
Therefore, based on the test results of the Teles Pires HPP samples, we consider that the A /
C factor ≤ 0.57 has characteristics that comply with the recommended wear limit.
Additionally, it is important to observe some minimum contour conditions as follows:
• Minimum consumption of cement material (cement + additions): 300 kg/m3
• Maximum diameter of large aggregate: 25 mm

3.3 Strategical benefits

Metacaulim is a higher cost material than cement and, for this reason, many questions are
asked about its benefits of use. In the construction-period scenario, the decision to maintain
its use was based on risk analysis.
As shown in this paper, in accordance with the Brazilian standards, the use of Metacaulim
became optional regarding the mitigation of AAR, however, it was decided to maintain the
use of mineral addition as additional security, due to the cement manufacturing variability
and high aggregate reactivity.
The contractor also opted, even if at an additional cost, to maintain the use of the addition
by quality and durability criteria, evidenced in the tests carried out.

12 CONCLUSIONS
The use of Metacaulim is directly associated, as a general rule, with the mitigation of
AAR. As presented in this paper, other additional benefits have been identified.
This type of product should be analyzed not only for the economic aspects but also for the
performance application: less cement content reflects in less Hydration Heat, less retraction
and consequently decreases the incidence of cracks. The concretes used cement of the CP IV
type added of Metacaulim, when associated, confer characteristics of high durability /
structure’s useful life. The possibility of controlling the addition of Metacaulim
independently, allowed to vary its contents as soon as identified a variation in the cement
characteristics, especially its pozzolan content.
The decision to maintain the addition in terms of its benefits to the quality and durability
of the concrete, even if not mandatory by requirement of standard or contract, showed that
the decision of the construction was based on the cost / benefit ratio, showing a high level of
engineering and corporate commitment.

References

[1] C. Liu, Tony (1981) “Abrasion Resistance of Concrete”. Article in Journal of the
American Concrete Institute, September 1981, pages 341-350.

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