MOBILE DISTRICT

TRUNNION ANCHOR ROD FAILURES

TRUNNION ANCHOR ROD FAILURES
WESTPOINT
POINT DAM
DAM PROJECT,
GA.
WEST
PROJECT,
GA.
RF HENRY LOCK AND DAM, AL
APRIL 2009
11 February 2011

GEORGE V. POIROUX, P.E.

Chief Geotech. Envir. & HTRW Branch
GEORGE V.
POIROUX, P.E.P.E.
DAVOOD
TASHBIN,
Chief Geotech. Envir. & HTRW Branch
Dam
Safety Program Manager

MOBILE DISTRICT

TN
AL
Jamie Whitten L&D

GA

G V Sonny Montgomery Lock

Allatoona
John Rankin Lock
Lake Dam
Fulton Lock
Glover Wilkins Lock
Amory Lock
Aberdeen
John Hollis Bankhead L & D
L&D
Stennis
Holt L& D
L&D
Oliver L & D
Bevil
L& D
Heflin A. I. Selden L & D
L&D

JACKSON
Okatibee
Lake

Demopolis
L&D

Indicates Project
with Post-tensioned
Anchor Rods

Carters
Lake Dam

Buford
Dam

ATLANT
A

West
R.F. Henry Point
Project
L&D
MONTGOMERY

Millers Ferry L & D

Walter F.
George
L&D

Coffeeville
L&D
Claiborne L & D

LA

G. W. Andrews
L&
D

Mobile

Jim Woodruff
L&D

FL

TALLAHASSEE

Gulf of Mexico
MOBILE DISTRICT PROJECTS
2

MOBILE DISTRICT

DAM SAFETY ACTION CODE (DSAC)

R. F. HENRY: DSAC 3
WEST POINT DAM: DSAC 4 (April 2006 - Original Screening)
DSAC 3 (Revised May 2008)

MOBILE DISTRICT

POST-TENSIONED TRUNNION ANCHOR TENDONS

Mandated Design by USACE HQ. (1960s)

COE Standard (EM 1110-2-2702)
Adopted by other Government Agencies and Industry
Offered Advantages over Steel Beam/Girder Designs
Limited Suppliers
Rod Sensitivity
Inability for Inspection / Repair

MOBILE DISTRICT

TENDONS
GROUP

Figure 5-1
EM1110-2-2702

MOBILE DISTRICT

GRIP NUT ASSEMBLY

GROUT HOLE

GRIP NUT

GRIP NUT

DRY PLACED
PLATE

BAR

TAIL

FLEXIBLE
TUBING

SLEEVE

Howlett Grip Nut

6

MOBILE DISTRICT

TRUNNION GIRDER
BASE PLATE
DEAD END
ANCHOR

GRIP NUT

TRUNNION
GIRDER

TAIL

NUT

CONC PIER

FREE LENGTH

MOBILE DISTRICT

Access Challenges

R.F. Henry Lock &

Dam
Near Selma, Alabama
Const: 1968
11 Spillway Gates
42 trunnion rods per pier (462 total)

Spillway Gate Trunnion Piers

8

MOBILE DISTRICT

Broken Trunnion Anchor

Rods (protruding through
cover plates)

Pier #1
Pier #8

MOBILE DISTRICT

Trunnion Rods at RF Henry Dam - Note short tail on rods

Rods 1-1/4 diameter

UTS is 145 ksi
Post-Tensioned to 115.7k

10

MOBILE DISTRICT

WEST POINT DAM & POWERHOUSE

(Near West Point, GA)

11

MOBILE DISTRICT

WEST POINT PROJECT

TAINTER GATE TRUNNIONS
(6 Gates 5 Shared Piers with 2 End Blocks)
Constructed 1969
376 trunnion anchor rods

Pier 9

Pier 10
12

MOBILE DISTRICT

WEST POINT PROJECT

Pier 9

Pier #10 Trunnion Anchor Boxes

West (10W) and East (10E)
March 6, 2008
Pier 10
13

MOBILE DISTRICT

West Point Dam

Trunnion Rods with Cover Removed
Note two rods missing.
Rods 1-1/4 diameter
UTS is 145 ksi
Post-tensioned to 115.7k

14

MOBILE DISTRICT

ACTIONS TAKEN
Visual Inspection of Cover Boxes on all 15 Projects
within Mobile District
Inspection Checklist was developed for each Project
No issues observed at any other Project

15

MOBILE DISTRICT

ACTIONS TAKEN
Structural Calculation of Factor of Safety
Analysis used 106.7 kips as working load
West Point Dam
Loss of 7 Rods within the 30 Rod Assembly FS approaches 1.00
Loss of 5 Rods within the 30 Rod Assembly Decommission Gate

RF Henry Lock and Dam

Loss of 4 Rods within the 21 Rod Assembly FS approaches 1.00
Loss of 3 Rods within the 21 Rod Assembly Decommission Gate

16

MOBILE DISTRICT

ACTIONS TAKEN Continued

Video Bore Scope
RF Henry
Possibly 5 rods broken .
Tails 1 to 3 inches long

West Point
Boxes contained several inches of grease
Boxes contained water - 12 inches in some boxes
Possibly 7 rods broken later confirmed that only 5 were broken
Tails 28 to 30 inches long.
17

MOBILE DISTRICT

VIDEO BORE SCOPE RF HENRY DAM

Trunnion Anchor Rods
Powerhouse

Pier

Gate

West

Row 1
Row 2
Row 3
Row 4
Row 5
Row 6
Row 7

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

10

Pier

10

11

11

12

Ab
ut
me
nt

East

West

East

West

East

West

East

West

East

West

East

West

East

West

East

West

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

1
2
3
4
5

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1 1 1
2 2 2
3 3 3
4 4
5 5 5
6 6 6
7 7 7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

West column in a specific

group.

Center column in a specific

group.

East column in a specific

group.

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

East

East

West

1
2
3
4
5
6
7

West

Pier

East

1
2
3
4
5
6
7

East

Gate

1
2
3
4
5
6
7

West

1
2
3
4
5
6
7

1
2
3
4
5
6
7

1
2
3
4
5
6
7

East

Anchor Rod Tension estimated by FHD Dispersive Wave Technology

Anchor Rod has been
removed
Anchor Rod broken in-place - to be remvoed and rod length to be
measured

18

MOBILE DISTRICT

Video Bore Scope WEST POINT Dam

Trunnion Anchor Rod Video Inspection, March 2008

Updated April 2008 as closer inspection revealed that 2 rods previously

previously reported as failed, appear to be functioning as designed.
designed.
(Pier 8, East group, west column, row 8 and Pier 10, West group, west column, row 3)
Gate
1

BLOCK
5
West

PIER
6

Gate
2

Gate
3

PIER
7

Gate
4

PIER
8

PIER
9

Gate
5

PIER
10

Gate
6

BLOCK
E

East

West

East

West

East

West

East

West

East

West

East

West

W E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W E

1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1

2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2

3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3

4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

8 8 8

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

9 9 9

10 10 10

W West
C Center
E East

10 10 10 10 10 10

column in a specific group

column in a specific group
column in a specific group

Pier 9

10 10 10 10 10 10

10 10 10 10 10 10

10 10 10 10 10 10

10 10 10 10 10 10

East

10 10 10

NOTE: In every instance of a failed rod, there was some visual indication on the trunnion
anchor assembly metal cover boxes that a release had occurred.

# Anchor Rod has failed.

# Anchor Rod appears to be functioning as designed.

19

MOBILE DISTRICT

ACTIONS TAKEN Continued

Extracted All Released Rods (5 Total) at West Point Dam
Measured Lengths
Retained rod and grip nuts
Cut rods in 24 to 36 inches pieces to assist handling

Extracted 4 Released Rods at RF Henry Dam

Measured Lengths
Retained rod and grip nuts

Performed Metallurgical Testing

20

MOBILE DISTRICT

R.F.HENRYDAM

DEADEND
ANCHOR

BASE
PLATE

RODP1WC6(BROKE2006)

126
RODP1WC7(BROKE2010)

256

RODP8WW3(BROKE2006)

RODP8WW4(BROKE1994)

10

20

30

40
21

MOBILE DISTRICT

WESTPOINTDAM

BASE
PLATE

RODB5EE6(BREAKDISCOVERED2008)

5
DEADEND
ANCHOR

RODP10WW2(BREAKDISCOVERED2008)

4 1

RODP10EC2(BREAKDISCOVERED2008)

15

RODP10EE10(BREAKDISCOVERED2008)

5 8

RODBEEE3(BREAKDISCOVERED2008)

10

11 3

20

30

40

22

MOBILE DISTRICT

TRUNNION ANCHOR ROD LAB ANALYSIS

1. Magnetic Particle Test
No cracks or discontinuities observed except on rod
P1WC7 at RF Henry . All failures were similar in
nature.
2. Chemical Analysis
Material similar to AISI 5160
3. Microscopic Test
Fractures had distinct origins. Flat fracture surface.
No evidence of fatigue. No rod deformation.
4. Charpy and Bend Test
Material has little toughness and high notch sensitivity

Failure Mode Brittle Failure

Prediction of Brittle Failure in notch sensitive materials is difficult.
23

MOBILE DISTRICT

WEST POINT ANCHOR RODS

This photograph shows Sample #2 in the as
received condition. The blue arrow indicates the
fracture origin and the white arrows indicate the
crack propagation direction. Note the area circled
in green appears to have been a pre-existing crack
which is more heavily oxidized than the rest of
the fracture surface.

This photograph shows Sample #2 with no visible

necking of the bar near the fracture as would be
seen with a ductile failure.

24

MOBILE DISTRICT

Stress Corrosion Crack

RF Henry Rod P1 W C 7
25

MOBILE DISTRICT

RF Henry Rod P8 W W3

26

MOBILE DISTRICT

ACTIONS TAKEN continued

Engineering Forensics
TYPE: Brittle Failure
Notch Sensitive
NATURE:
Surface defect
Manufacturing defect which caused stress riser
CAUSE:
Age Hydrogen /Calcium
Vibration of spillway gate at higher gate openings
Corrosion due to moisture and loss of corrosion inhibitor
contributor
PREDICTABILITY OF FAILURE: Failure is not Predictable
27

MOBILE DISTRICT

ACTIONS TAKEN continued

Modified All Cover Boxes to Enable Visual Inspection & Testing
Installed Accelerometers for Continuous Monitoring
Placed collar on rod tail exactly 1 inch from grip nut

28

MOBILE DISTRICT

WEST POINT PROJECT

Modified cover boxes for all piers

Pier 9

Pier 10
29

MOBILE DISTRICT

WEST POINT PROJECT

Modified cover boxes

Pier 9

Pier 10
30

MOBILE DISTRICT

RF Henry New Trunnion Rod Cover Box

31

MOBILE DISTRICT

ACTIONS TAKEN continued

Ultrasonic Testing by ERDC-CERL
Non Destructive Test ( NDT) Measure Tension in Each Rod Block E
East (30 Rods) and West (7 Rods) at West Point Dam
Dispersive Bending Wave NDT by FDH, Engineering
Tested Rods in Block E Static and Dynamic Condition at West Point

32

MOBILE DISTRICT

ULTRASONIC
TESTING
(by ERDCCERL)
April 2008

33

MOBILE DISTRICT

ULTRASONIC TEST RESULTS AS % OF AS-BUILTS

120

80

60

40

ee3

ee1

ew3

ew1

we9

we7

we5

we3

we1

wc9

wc7

wc5

wc3

wc1

ww9

ww7

ww5

ww3

20

ww1

%o
fA
s-B
uilts
%
of
As-Builts

100

Ultrasonic Test % of As Built

34

MOBILE DISTRICT

DISPERSIVE BENDING WAVE TEST

by FDH April 2009

35

MOBILE DISTRICT

DISPERSIVE WAVE RESULTS AS % OF AS-BUILTS

120

80

60

40

20

ee
3

ee
1

ew
3

ew
1

w
e9

w
e7

w
e5

w
e3

w
e1

w
c9

w
c7

w
c5

w
c3

w
c1

w
w
9

w
w
7

w
w
5

w
w
3

0
w
w
1

%o%
fA
s-B
uilt
of
As-Builts

100

Dispersive Wave % of As Built

36

MOBILE DISTRICT

ACTIONS TAKEN continued

PROCURING AN ADDITIONAL SET OF SPILLWAY
STOPLOGS FOR RF HENRY AND WEST POINT DAMS
Decommission two gates if needed
PREPARING RESTRICTED RESEVIOR OPERATIONS PLAN
FOR RF HENRY AND WEST POINT DAMS
Water Management Plan for loss of two spillway gates

37

MOBILE DISTRICT

ACTIONS TAKEN continued

PDT performed site inspection and review of As-Built
Documents
A-E Prepared Recommendation Report
Preliminary estimate of tension in each rod by Dispersive Wave
Technology
Site Inspections and analysis
COE and Industry input/solutions
Partner with Industry for Lift-Off Testing
Preliminary Design Solutions
The Path Forward
38

MOBILE DISTRICT

THE PATH FORWARD

FOR

RF Henry Lock and Dam

And

West Point Dam

39

MOBILE DISTRICT

The Path Forward

Perform Quality Control Check on Lift-Off Procedures
Testing at Mock-up Pier at FDH
Simulate as-built conditions Various tensions, tail lengths
Perform test on actual rod and grip nut from West Point Dam
Evaluate Processes and results. Define what constitutes lift-off
Document and incorporate Lessons Learned prior to field testing

Perform Lift-Off Test

68 Rods at West Point (added 40 more rods as mod for total of 108)
98 Rods at RF Henry (added 10 more rods as mod for total of 108)
Rods were selected

Obtain Dispersive Wave Tension (DWT) Datasets prior to

and after each lift-off test
40

MOBILE DISTRICT

The Path Forward Continued

Re-tension rods to 106 kips if lift-off is less than 100kips
Re-tension three rods at each project to 115kips
Reuse grip nuts- Original nuts produced by Howlett Machine
(Calif.)
Howlett Machine, (Calif.) contacted but would not sell or give these grip nuts to
SAM. They did say that these nuts can be reused on the bar size designed for.

Extract broken rods

Carefully measure extracted rod lengths and record
Photo broken ends
Retrieve grip nuts from extracted rods, clean-up and store
41

MOBILE DISTRICT

The Path Forward Continued

Working Platforms at each Trunnion Girder
Certified and inspected
Used by PDT

Water Management thru Spillway Gates while work is

being performed
Close gates while work is being performed if possible

Replace trunnion rod cover boxes at RF Henry

Cut old boxes off
Bolt on new box must be waterproof
Provide access hatch on top of box
42

MOBILE DISTRICT

The Path Forward Continued

Validation of Dispersive Wave Tension Estimates
Compare to actual lift-off load
Develop equivalency equations
Level of Confidence with DWT
Estimate of tension in each rod at West Point and RF Henry

COE to re-evaluate Factor of Safety for each Spillway Gate

Original design provided SF 1.25

43

Table 32: FDH NDT Average Load

MOBILE DISTRICT
Average Load
120.000
100.000
Strain Gauge

Kip

80.000

PSI Gauge

60.000

Load Cell

40.000

FDH NDT

20.000
0.000
1

Test

Average Load (Kip)

Test
Strain Gauge
51.220
1
67.088
2
85.167
3

PSI Gauge

59.521
77.930
96.689

Test 1
TT

Load Cell

56.687
74.033
92.173

FDH NDT

55.908
70.065
92.978

Test
1
2
3

Strain Gauge

PSI Gauge

53.860
71.906
98.506

59.442
78.684
106.107

Load Cell

58.220
78.930
105.400

FDH NDT

56.906
71.644
106.132

Test 2

Mock-Up Tests at FDH Engineering

44

MOBILE DISTRICT

RRF Henry Dam

Trunnion Rods

45

MOBILE DISTRICT

West Point Dam trunnion rods to be lift-off

tested
West Point Dam, Georgia
Post-Tensioned Trunnion Anchor Rods
Lift-off Test Schedule

Block

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Pier

Gate

Block

10

West

East

West

East

West

East

West

East

West

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

East

10

10

10

West

East

10

10

10

10

10

10

10

West

East

10

10

10

10

10

10

10

10

10

Anchor Rod has failed

Scheduled Lift-off Test

46

MOBILE DISTRICT

R.F. Henry Dam trunnion rods to be lift-off

tested
Powerhouse

Pier
1

West

Gate
1

Pier
2

Gate
2

Pier
3

Gate
3

Pier
4

Gate
4

Pier
5

Gate
5

Pier
6

Gate
6

Pier
7

Gate
7

Pier
8

Gate
8

Pier
9

Gate
9

Pier
10

Gate
10

Pier
11

Gate
11

Pier
12

East
Abutment

East

West

East

West

East

West

East

West

East

West

East

West

East

West

East

West

East

West

East

West

East

West

East

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

W C E

Row 1

1 1 1

1 1

1 1 1

1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

1 1 1

Row 2

2 2 2

2 2

2 2 2

2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

2 2 2

Row 3

3 3 3

3 3

3 3 3

3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

3 3 3

Row 4

4 4 4

4 4

4 4 4

4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4

4 4 4

4 4 4

4 4 4

4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

4 4 4

Row 5

5 5 5

5 5

5 5 5

5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

6 6 6

6 6

6 6 6

6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

6 6 6

7 7

7 7 7

7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

7 7 7

Row 6
Row 7

7 7 7

# of Tests

107

Anchor Rods To be Lift-Off Tested (Revised 6 Dec 2010)

W

Revision:

West column in a specific group.

Center column in a specific group.

East column in a specific group.

Anchor Rod has been removed

4

Anchor Rod broken in-place - to be removed and rod length to be measured

Proposed lift-off test location

Rod to be retensioned to 60kips

Rod P1 W C7 failed 1 Nov 2010. Extracted 12'-6' long on 17 Nov 2010.

Rod P8 WW3 Extracted 32'-6' long on 12 Jan 2011.

47

MOBILE DISTRICT
WEST POINT DAM LIFT OFF RECORD
Rods
B5WE3
B5EW2
B5EW6
B5EC3
B5EC5
B5EC7
B5EC10
P6WW6
P6WC2
P6WC5
P6WC6
P6WC10
P6WE8
P6EW4
P6EC4
P6EC8
P6EE2
P7WW1
P7WW2
P7WW4
P7WW5
P7WW6
P7WW9
P7WW10
P7WC1
P7WC2
P7WC3
P7WC5
P7WC6
P7WC7
P7WC8
P7WE9
P7EW9
P7EW10
P7EC1
P7EC3
P7EC4
P7EC6
P7EC8
P7EC10
P7EE1
P7EE2
P7EE5
P7EE6
P7EE8
P7EE9
P7EE10
P8WW1
P8WW4
P8WW7
P8WW9
P8WC3
P8WE3
P8WE4
P8WE9

LiftoffPressure
Gauge(psi)

LiftoffForce
Loadcell
(kips)

LiftoffForce
Gauge(kips)

UseLargerLiftoff
Force(kips)

FDHEstimated
Tension(kips)

5100
5100
5100
5130
5100
5100
5100
5130
5120
5120
5130
5140
5100
5250
5208
5184
5120
5419
5100
5100
5100
5459
5425
5100
5100
5100
5100
5100
5100
5100
5370
5100
5100
5100
5100
5100
5400
5400
5100
5100
5428
5375
5100
5400
5100
5400
5438
5308
5413
5436
5412
5070
5100
5100
5500

108.26
110.19
109.6
110.2
108.3
108.47
108.2
108.8
108.85
108.85
108.3
110.1
109.48
109.1
108.76
115.7
108.98
108.9
108.39
1115.7
115.7
107.97
108
109.5
108.01
109.8
107.21
107.76
115.7
107.75
108.26
108.93
108.7
107.58
108.7
115.7
108.17
109
115.7
114.16
108.52
115.7
107.69
115.7
115.7
115.7
115.7
115.7
115.7
110
109.87
108.28
117.4

106.7
106.7
106.7
107.4
106.7
106.7
106.7
107.4
107.1
107.1
107.4
107.6
106.7
109.9
109.0
108.5
107.1
113.4
106.7
106.7
106.7
114.3
113.6
106.7
106.7
106.7
106.7
106.7
106.7
106.7
112.4
106.7
106.7
106.7
106.7
106.7
113.0
113.0
106.7
106.7
113.6
112.5
106.7
113.0
106.7
113.0
113.8
111.1
113.3
113.8
113.3
106.1
106.7
106.7
115.1

NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO

120+
120+
120+
120+
96.7
120+
120+
114.4
120+
120+
120+
120+
120+
120+
120+
120+
114.6
120+
103.8
120+
101.7
98.4
109.1
107.8
120+
120+
120+
117.8
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
112.6
120+
97.0
120+
120+
89.1
120+
118.3
112.9
120+

Rods
P8EW1
P8EW8
P8EE3
P9WW4
P9WW9
P9WC7
P9WC9
P9WE2
P9WE5
P9EW2
P9EW5
P9EE2
P9EE4
P10WC3
P10WC8
P10WE1
P10WE9
BEWW1
BEWW2
BEWW3
BEWW4
BEWW5
BEWW6
BEWW7
BEWW8
BEWW9
BEWW10
BEWC1
BEWC2
BEWC3
BEWC4
BEWC5
BEWC6
BEWC7
BEWC8
BEWC9
BEWC10
BEWE1
BEWE2
BEWE3
BEWE4
BEWE5
BEWE6
BEWE7
BEWE8
BEWE9
BEWE10
BEEW1
BEEW2
BEEW3
BEEW4
BEEC1
BEEC2
BEEC3

LiftoffPressure
Gauge(psi)
5190
5100
5100
5100
5100
5100
5100
5100
5100
5100
5100
5100
5100
5100
5100
5100
5016
5544
5241
5449
5436
5452
5267
5471
5409
5328
5286
5457
5427
5407
5391
5470
5330
5444
5249
5440
5326
5482
5324
5449
5300
5440
5367
5395
5362
5459
5361
5378
5396
5319
5365
5322
5438
5407

LiftoffForce LiftoffForceGauge UseLargerLiftoff

Loadcell(kips)
(kips)
Force(kips)
110
107.3
108.3.
106.7
107.22
106.72
105.98
106.6
106.6
107.2
107.39
109.63
107.73
109.18
109.79
108.74
110
115.7
111.56
115.7
115.7
115.7
112.7
115.7
115.7
115.7
115.7
115.7
115.7
115.7
115.7
115.7
112.48
115.7
112.26
115.7
115.7
115.7
112.88
115.7
110.2
115.7
115.7
115.7
113.7
115.7
115.7
115.7
115.7
115.7
115.7
115.7
115.7
115.7

108.6
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
106.7
105.0
116.1
109.7
114.1
113.8
114.1
110.2
114.5
113.2
111.5
110.6
114.2
113.6
113.2
112.8
114.5
111.6
114.0
109.9
113.9
111.5
114.8
111.4
114.1
110.9
113.9
112.3
112.9
112.2
114.3
112.2
112.6
112.9
111.3
112.3
111.4
113.8
113.2

NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
LO
NLO
NLO
NLO
LO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
LO
NLO
NLO
LO
NLO
NLO
LO
NLO
LO
NLO
NLO
NLO
LO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO
NLO

FDHEstimated
Tension(kips)
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
120+
106.6
100.1
120+
120+
120+
116.8
120+
120+
110.9
100.5
96.8
111.1
120+
102.7
120+
98.1
120+
120+
120+
107.5
120+
98.2
120+
120+
120+
120+
91.4
88.3
120+
104.3
120+
120+
112.2
118.7
120+
120+
116.3

48

RFHENRYDAMLIFTOFFRECORD
Rod
Pier1WC5
Pier1WC5
Pier1EW1
Pier1EW4
Pier1EC1
Pier1EC7
Pier1EE3
Pier1EE4
Pier1EE7
Pier2WW1
Pier2WW4
Pier2WW7
Pier2WC1
Pier2WC7
Pier2WE2
Pier2WE3
Pier2WE4
Pier2EW1
Pier2EW4
Pier2EW7
Pier2EC6
Pier2EC7
Pier2EE4
Pier2EE7
Pier3WW2
Pier3WW3
Pier3WW4
Pier3WW7
Pier3WC5
Pier3WE4
Pier3EW4
Pier3EW5
Pier3EW6
Pier3EE1
Pier4WW3
Pier4WW4
Pier4WE1
Pier4WE7
Pier4EW2
Pier4EW6
Pier4EW7
Pier4EE5
Pier5WW4
Pier5WW5
Pier5WC7
Pier5WE2
Pier5EW6
Pier5EE4
Pier5EE5
Pier5EE6
Pier5EE7
Pier6WW3
Pier6WW4
Pier6WW6
Pier6WW1

LO=LiftOff
FDHEst.
RecordedLiftoff ActualLiftoffForce
RamLiftoffForce
NOL=NoLift
Tension(kips)*
PressurexArea(kips)
PressureGauge(psi) Loadcell(kips)
Off
5123
5123
5493
4908
4908
5448
5448
5493
5494
5450
5337
5595
5337
5595
5444
5360
5295

1700
5014
4903
4990
4903
4903
5320
4902
5265
5087
5087
5180
5222
5009
5470
5428
5064
5350
5147
5111
5109
5272
5170
5251
5140
5230
5080
5004
5009
5096
4985

106.7
106.7
115
101.9
102
112.4
112.35
115.7
115.7
115.7
112
115.4
113.98
115.7
115.7
114.6
112.6
115.7
35
110
115.7
104
35.2
106.3
104.7
105.6
104.6
104.7
112.7
98.6
104.2
107.4
109.2
106.3
109
109.9
105.8
115.7
114.4
106.2
113.4
109.6
108.2
108.6
112.8
110.4
110.7
109.8
111.1
108.5
105.5
106.7
107.7
105.3

107.2
107.2
115.0
102.7
102.7
114.0
114.0
115.0
115.0
114.1
111.7
117.1
111.7
117.1
114.0
112.2
110.8

110.0
35.3
107.0
104.9
102.6
104.4
102.6
102.6
111.3
111.6
102.6
110.2
106.5
106.5
108.4
109.3
104.8
114.5
113.6
106.0
112.0
107.7
107.0
106.9
110.3
108.2
109.9
107.6
109.5
106.3
104.7
104.8
106.6
104.3

NLO
NLO
LO
LO
LO
LO
LO
NLO
NLO
NLO
LO
LO
LO
NLO
NLO
LO
LO
NLO
NLO
NLO
NLO
NLO

LO
LO
LO
LO
LO
LO
LO
NLO
NLO
LO
LO
LO
LO
LO
LO
LO
LO
LO
LO
LO
LO
LO
NLO
NLO
NLO
NLO
LO
LO
LO
LO

107.5
107.5
108.0
110.4
109.4
108.1
107.7
108.6
106.2
111.0
107.9
105.4
107.0
107.6
109.3
108.4
108.5
109.1
0.0*
105.5
109.6
108.7
0.0*
105.7
97.8
98.6
102.7
100.2
96.7
101.3
106.9
97.9
99.8
101.7
101.2
102.5
104.3
101.8
102.6
106.5
105.1
106.1
102.6
101.2
106.7
104.1
103.4
102.3
102.2
103.3
105.2
99.4
101.4
104.1
105.7

Rod
Pier6EW6
Pier6EW7
Pier6EC1
Pier6EC6
Pier6EE1
Pier6EE3
Pier7WW3
Pier7WE1
Pier7WE3
Pier7WE6
Pier7EW6
Pier7EW7
Pier7EC3
Pier7EE7
Pier8WW3
Pier8WE4
Pier8WE7
Pier8EW2
Pier8EW3
Pier8EW6
Pier8EE2
Pier8EE5
Pier8EE6
Pier8EE7
Pier9WW2
Pier9WW7
Pier9WE4
Pier9WE5
Pier9EW7
Pier9EE1
Pier9EE4
Pier9EE6
Pier10WW4
Pier10WW5
Pier10WE4
Pier10WE6
Pier10WE7
Pier10EW1
Pier10EW2
Pier10EW3
Pier10EC5
Pier10EE6
Pier11WW5
Pier11WE2
Pier11WE7
Pier11EW1
Pier11EW4
Pier11EW5
Pier11EE1
Pier11EE2
Pier12WW5
Pier12WW7
Pier12WE1
Pier12EC3
Pier12EC4

FDHEst.
RecordedLiftoff ActualLiftoffForce RamLiftoffForce LO=LiftOff
PressureGauge(psi)
Loadcell(kips) PressurexArea(kips) NOL=NoLiftOff Tension(kips)*
5380
5247

113.6
110.6

112.6
109.8

LO
LO

5127
5265
5263
5112
5215
5153
5268
5392
5350
5310
5212
Noload
5500
5200
5406
4186
5406
5406
4960
5440
5140
5366
5278
5400
5266
5014
5102
5430
5230
5325
5325
5319
5490
5370
5170
5233
4986
5106
5238
5149
4996
5086
5377
5430
5428
5455
5455
5433
5530
5183
5401
5087

108.4
112.4
111.7
108.6
110.6
109.6
111.9
115.7
115.7
113.4
111.8

107.3
110.2
110.2
107.0
109.1
107.8
110.3
112.9
112.0
111.1
109.1

LO
LO
LO
LO
LO
LO
LO
NLO
LO
NLO

N/A
N/A
115.7
87.2
115.7
115.7
106
115.7
109.6
115.7
112.8
115.7
113.3
107.6
109/8
115.7
111.9
112.4
112.4
112
115.7
114.3
109.3
111.5
104.8
107.6
110.4
108.8
105.8
107.5
113.6
115.7
115.7
115.7
115.7
115.7
115.7
109.2
113.4
107.1

115.1
108.8
113.2
87.5
113.2
113.2
103.8
113.9
107.6
112.3
110.5
113.0
110.2
104.9
106.8
113.7
109.5
111.5
111.5
111.3
114.9
112.4
108.2
109.5
104.3
106.9
109.6
107.8
104.5
106.4
112.5
113.7
113.6
114.2
114.2

NLO
LO
NLO
LO
NLO
NLO
LO
NLO
LO
LO
LO
NLO
LO
LO
LO
NLO
LO
LO
LO
LO
NLO
LO
LO
LO
LO
LO
LO
LO
LO
LO
LO
NLO
NLO
NLO
NLO
NLO
NLO
LO

115.8
108.5
113.0
106.5

105.1
101.3
104.7
101.9
103.7
106.6
103.0
104.0
100.2
106.4
105.3
100.7
104.0
114.2
108.6
94.3
104.1
102.7
103.3
104.1
100.8
105.9
102.4
105.6
103.8
104.9
104.2
102.2
103.9
105.6
103.7
104.7
105.2
106.7
107.7
107.6
107.2
103.0
102.0
103.0
104.1
105.4
103.3
102.9
103.5
105.6
103.2
104.5
103.8
104.0
104.4
104.8
103.8
103.3

MOBILE DISTRICT

GRIP NUT ASSEMBLY

MECHANICAL
CLAMP

GROUT HOLE
DRY PLACED
PLATE

GRIP NUT

FLEXIBLE
TUBING
1

Visual Inspection Clamp

Length(ft)

34

3.00E+07

Load(k) Diameter(in) Elongation(in)

115.7

1.25

1.282

36

3.00E+07

115.7

1.25

1.358

38

3.00E+07

115.7

1.25

1.433

40

3.00E+07

115.7

1.25

1.508

42

3.00E+07

115.7

1.25

1.584

44

3.00E+07

115.7

1.25

1.659

46

3.00E+07

115.7

1.25

1.735

Lengthof Rod

LoadforVarious
Deformations
(lbs)

34

36

38

40

42

44

46

0.125

11279.3

10652.6

10092.0

9587.4

9130.8

8715.8

8336.9

0.25

22558.5

21305.3

20184.0

19174.8

18261.7

17431.6

16673.7

0.375

33837.8

31957.9

30275.9

28762.1

27392.5

26147.4

25010.6

0.5

45117.1

42610.6

40367.9

38349.5

36523.4

34863.2

33347.4

50

MOBILE DISTRICT

Dispersive Wave Estimate vs Lift-Off Loads

Project

Number of tests

Accuracy (%)

Mock-up

3.3%

West Point Dam

7.4%

R. F. Henry Dam

69

3.9%

51

MOBILE DISTRICT

The Path Forward Continued

Develop Repair Designs
Repair methods per Recommendation Report
Temporary Repair Design
100% Design. Three to five year measure
West Point structurally replace 5 rods/assembly (10 /pier)
RF Henry - structurally replace 3 rods/assembly (6 rods/pier)

Permanent Repair Design

95% Design.
West Point replace 30 rods/assembly (60 /pier)
RF Henry - replace 21 rods/assembly (42 rods/pier)
52

MOBILE DISTRICT

Conclusions
1. Lift-off test provides actual load on the trunnion rod. High risk,
high cost
2. Dispersive bending wave technology can estimate load on rod.
Calibrate with lift-off test until technology has matured.
3. Rods can fail by sudden breakage, ie brittle failure which is
unpredictable.
4. Rods can fail by the release of the grip nut.
5. Re-tensioning of rods can be achieved with shims.
6. Rods should be monitored and inspected.

53

MOBILE DISTRICT

Future Considerations
1.

Monitor the maturing of the Dispersive Bending Wave

Technology - tool in our tool-box.

2.

Develop technology to test trunnion rods for cracks.

3.

Develop technique to inject rust inhibitor around rods.

4.

Consider update of EM 1110-2-2702. Design of Tainter

Gates .

54

MOBILE DISTRICT

Project Delivery Team

George Poiroux
Mike Thompson
Allen Davis
Anthony Perkins
Leon Cromartie
Mike McCray
Bob Fulton (Retired)
Tracy Hendren
David Schaaf
Chris Westbrook
Larry Dorsey
Dr. Donald Bruce
Dr. Darren Holt
Dr. Mark Cesare
Jeff Peek
Jack Granade
Mike OBrien
Dr. Kendall Clark
Ross Woodbury
Mike McInerney

SAM
SAM
SAM
SAM
SAM
LRH
SAD
SAD
USACEHQ
USACEHQ
A-E
A-E
A-E
A-E
A-E
A-E
A-E
A-E
LRN
ERDC-CERL-IL

Project Engineer
Structural Engr
Structural Engr
OP Engr
OP Engr
Anchor Expert
DSPM
DSPM
DS CoP
HSS Cop
A-E PM
Anchor Expert
NDT Testing
NDT Testing
NDT Testing
Structural Engr
Lift-Off Engr
Metallurgical Engr
Mechanical Engr
Research Engineer
55