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ABSTRACT
The RCC design review and construction phase services of the 60m high Tannur Dam in Jordan was carried
out by GHD, Australia.
The 220,000m3 of RCC was placed during February-December 2000; the change to the sloped layer method
was made once the dam reached 15m height. It produced a 50% increase in placing rate and a considerable
saving in costs.
The use of the method is the first known use outside of China, where it was developed during the
construction of the 130m high Jiangya Dam in 1997-8. The sloping of the 300mm thick layers of RCC across
the dam from bank to bank at grades between 5-8% ensures subsequent layers of RCC can be placed within
the initial set time of the lower layer and hence the RCC is monolithic across the lift joint.
This paper briefly describes the project in Jordan and then gives specific details of the use of the sloped
layer method. Typical results from the quality control testing during placement and subsequent coring and
testing of the lift joints are also provided. The benefits of its use in adverse climatic conditions, such as
extreme heat or rainfall and the ways it can be integrated with forming the upstream-downstream slope are
also discussed.
The sloped layer method is a significant advancement, particularly for large structures, where lift joint
cohesion, tensile resistance and RCC placing rates are vitally important.
RCC was transported from the mixing plant to the horizontal joints between layers. The adhesion
dam wall via a system of Rotec conveyors and between layers of RCC is produced by two
discharged with a "swinger". The conveyors were mechanisms, cementitious bond and penetration
relocated progressively as the dam wall rose. The of aggregate from the new layer into the surface
RCC was transported from the swinger to the of the previously placed layer. Layer joints always
dumping point by three-25 tonne Volvo A25C exhibit lower tensile strength, shear strength and
6WD dump trucks. They were fitted with smooth impermeability than the RCC. This is due to
profile tyres which helped to minimise damage to ageing of lift surface concrete, tendency for
fresh RCC surfaces. Chutes were welded to the segregation of the overlying RCC at the joint and
sides of the tray to prevent spillage as the swinger the potential for lower rolled density at depth.
was moved from the full truck to the empty one
In order to achieve homogeneous, monolithic
alongside.
RCC across a layer joint the overlying layer must
Grout enriched RCC (GE-RCC) was used in all be placed within the initial set time of the lower
the upstream face, downstream steps including the layer. It is impossible to achieve the time frame
180m wide stepped spillway section, gallery required to place a horizontal layer from one
walls, waterstop encasement and the interface abutment across the other in major dams.
between the RCC and limestone rock abutments.
The Sloped Layer Method is used to construct lifts
of multiple layers. RCC is placed in layers
approximately 300mm thick for a total lift
3 Development and thickness of 3 to 4m. At Tannur Dam 1.2m lifts
Introduction of The Sloped were used. With the Sloped Layer Method, each
Layer Method layer is placed at an inclination of approximately
1:10 to 1:20 instead of the typical horizontal
The Sloped Layer Method (SLM) of placing RCC orientation. The length of the slope depends on
was first developed and adopted in Jiangya Dam the plant capacity and production rate with typical
in China (Forbes, 1999). A number of projects in slope lengths of 20 to 40m. A sloped layer is
China, such as Mianhuatan and Dachaoshan dams, placed over the full width of the placement and
adopted the sloped layer method after successful the layers progress the full length of the
application of SLM in Jiangya Dam. placement. The primary goal of this method is to
A detailed development and the procedure of the minimise the exposure of fresh RCC lift until it is
Sloped Layer Method has been described by covered with the next sloped layer. Bedding
Forbes (2002). mortar is placed on the mature RCC lift surface
prior to placing the next lift. The Sloped Layer
The interest in RCC dams is driven by economic Method is shown in Figure 4.
considerations and also where speed of
construction is an important element. However Placing a sloped layer generally involves
this often compromises quality and water commencing at the downstream face and moving
tightness, as shown by many RCC dams. A across to the upstream face (or visa versa),
significant difference between a conventionally working on the full height of the layer and
placed concrete dam and a roller compacted compacting up-down slope. At lower elevations,
concrete dam are the number of horizontal where the sloped layer is wide enough, the
construction joints. Horizontal joints are placement area can be roughly divided into sub
inevitable in RCC dams because of the layered areas, placing commencing on the downstream (or
method of construction. Each layer is the upstream) third and progressing through the
thickness of material compacted. In order to central and upstream thirds with the placing –
achieve required compacted densities by roller spreading – compacting operations occurring
compaction, RCC layer thickness is typically accordingly.
maintained at 0.3m, whilst for internally vibrated Using this method the final clean up and surface
conventional concrete, layers are typically 1.5m, preparation of the lower lift, including application
i.e. 5 times more layer joints occur with RCC. of bedding mortar, is restricted to a narrow strip
The performance of an RCC dam will almost along the toe of the sloped layer. The width of the
entirely be dictated by the performance of the strip varies with the slope.
could be placed within the initial set time of the quantity of bedding mix required was greatly
RCC. reduced between the slope layers leading to
considerable cost savings to the owner.
The slope layer approach as developed in China
uses a 3m high sloped layer as standard. At Cold joints were cleaned using high pressure
Tannur Dam, a 1.2m high slope layer was chosen air/water jetting once the RCC had gained
to fit in with height of the downstream steps. sufficient strength. Air/water jetting was assisted
by rotary brooming. Old joints were first treated
by scraping with a blade attached to an excavator
bucket. The layers and 1.2m lift surfaces were
inclined at 1.5% from downstream to upstream to
assist in removal of debris and surplus water.
The Sloped Layer Method minimises the area of
fresh RCC exposed to ambient conditions, i.e.
heat gain is reduced when the RCC temperature at
time of placing is lower than ambient and, in the
case of rainfall occurring, a smaller area of fresh
RCC is exposed to damage or required to be
‘roller sealed’ to limit damage; the method
therefore permits tighter control to be exercised
Photo 1 - RCC placement showing sloped layer
during adverse ambient conditions. An added
construction view to upstream
benefit was the fast rate at which RCC layers were
Placing commenced from the left abutment being covered by the next layer, mostly this was
working across to the right abutment where the 30-45 minutes. Heat gain from the atmosphere,
Rotec “swinger” delivery system discharged the which was about 32-36°C during RCC placement,
RCC into the dumpers. Layer slopes commenced was limited. This would not have been the case
with a slope of 1 on 12.5 and, as the dam rose and with horizontal layers which would remained
the width between upstream and downstream exposed for 24 hours or more. The thermocouple
faces reduced with height of dam, the slope was measurements for the dam at the end of
flattened to 1 on 20. Actual time between construction are presented in Figure 5, which
successive lifts was controlled to about 45 correlate well with the results from the thermal-
minutes. structural study (Malkawi 2003) even though the
RCC construction continued into the hot summer.
To overcome aggregate being crushed under the up to 180 days as well as the 24 hour hot-
heavy steel roller in the thinning toe of each cured (60°C water bath) compressive strength
sloping layer, a solution developed at Tannur Dam which provided early confirmation that the
was to thicken this ‘feather’ edge to form a required long term RCC strengths would, or
150mm horizontal ‘foot’ which was then would not, be achieved.
compacted with the smaller Dynapac roller in an
upstream downstream direction, prior to • GE-RCC and bedding mortar test specimen
compaction of the balance of the layer by the 16 manufacture and testing for compressive
tonne Bomag rollers operating parallel to the dam strength.
axis. • RCC temperature as placed and long term (by
The introduction of the Sloped Layer Method led installed thermocouple system) temperature
to an immediate increase in production rates of history.
around 50% percent, mainly because of the • Slump testing of bedding mortar.
reduced clean-up requirements and lift joint
treatment, and the ability to lift the forms earlier. A computer program which GHD developed,
manipulated all the recorded data, prepared
Rapid construction, which is the key to the averages, maintained graphical presentations and
economics of RCC, results in the quality control updated statistical results for continuous
of the concrete constituents and the production monitoring and regular reporting purposes.
facilities to be a most important factor in ensuring
concrete quality. Once the RCC has been Table 1 gives the statistical summary of the RCC
produced and compacted into the dam, it is density (also as a proportion of the Theoretical Air
expensive, and also often unrealistic, to remove Free density) and moisture content and the
the deficient material. Quality control after coefficients of variation as measured by nuclear
production should provide final verification of the and VeBe methods.
concrete properties. Quality control of the fresh Table 2 below gives the RCC and GE-RCC
concrete must emphasise test methods that can statistical summaries of the specimen compressive
give a quick indication of concrete quality and strengths whilst Table 3 gives those for the tensile
identify any minor adjustments required to strengths and elastic modulus.
maintain the concrete within the specification.
The average cube compressive strength of the
Quality control of the RCC at Tannur Dam RCC for the entire dam (all mixes) was 25.7MPa
included the following field and laboratory at 90 days with a coefficient of variation of 10.6%
testing: and a standard deviation of 2.7MPa. The average
cube compressive strength of the RCC for the last
• Loaded VeBe time and maximum (2 minute)
50% was 24.8MPa at 90 days with a coefficient of
VeBe density
variation of 9.8% and a standard deviation of
• Single probe nuclear densimeter density and 2.4MPa. All results exceeded the specified
moisture content testing of the 300mm layers characteristic strength of 20MPa.
measured at 150 and 250mm depths.
The indirect tensile strength of 150x300mm
• Verification of nuclear densities and moisture cylinder test samples averaged 2.24MPa while the
contents by sand replacement density methods direct tensile strength averaged 1.42MPa at 90
(one per 300mm layer) days. The tensile strength therefore is some 7.5%
of the equivalent cylinder compressive strength.
• RCC washed gradings, monitoring in
particular the minus 0.075mm fraction, which The static elastic modulus averaged 23.1GPa with
contained the aggregate fines plus the added a standard deviation of 3.8GPa compared with the
cementitious material, and minus 4.75mm design assumption of 18GPa.
sand fraction, which largely determines the Some limited 150mm diameter coring of RCC and
sensitivity of the RCC to segregation. GE-RCC has been undertaken. Strength testing
• RCC test specimen manufacture and testing has been carried out, which confirms the mortared
for compressive, indirect and direct tensile lift joints (1.2m intervals) are giving direct tensile
strengths at all the usual standard-cured ages strengths which exceed 1MPa, and are similar to
that of the RCC core itself. Shear testing confirms RCC placing method. Additional anchors had
that the lift joint cohesion exceeds 1MPa, and the to be placed into the RCC to hold the forms in
angle of friction is 40 -45°. place when loaded with 1.2m of ‘live’ GE-
RCC and RCC during compaction by the 16
Comparing the test results tabulated above with
tonne vibrating roller. Individual sloped layers
the consistency standards in the draft ICOLD
were placed in 30-40 minutes, well within the
Bulletin “State-of-the-Art of RCC Dams”
retarded initial set time of the RCC, the 1.2m
(ICOLD, 2002), as shown in Table 4, confirms
lifts are thus essentially monolithic and
that the standards achieved at Tannur Dam can be
without evidence of joints between the
classified as being in the “Excellent” to “Good”
300mm layers.
ICOLD ranges.
• Joint treatment is limited to one cold joint
The use of the sloped layer method of
treatment every 1.2m. Such treatment is a
construction in Tannur Dam assisted in speeding
little more difficult than usual insofar as the
up construction and reducing costs. However, a
surface of the layers are more uneven.
certain number of constraints must be taken into
Retaining the traditional crossfall for drainage
account when using this method, these include the
of wash water is a definite advantage.
following:
• “Feather edge” treatment is required.
• Some problems were encountered with the
vertical 3.0m high upstream RMD (Rapid • Survey control using lasers was more difficult
Metal Developments Ltd) forms that had been and the layer profiles were painted on the
designed expecting the usual ‘horizontal’ forms to assist.
Photo 3 - Tannur Dam 1.2m high downstream Photo 4 - Downstream view showing the sloped
form showing survey mark layer construction in progress on the final RCC
lifts in the spillway area
Extract from Table 6.2 ICOLD (2002) (Values for cores not shown above).