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BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville DistrictBUILDING STRONG® US ARMY CORPS OF ENGINEERS | JACKSONVILLE DISTRICT

Portugués DamPortugués and Bucaná Project

Portugués DamPortugués and Bucaná Project

1

Steve Duba, P.E.Chief, Construction Division

BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Project Video


Portugués Dam Project Map


Authorization: R&H Act 1970, WRDA 1986 (PL 91-611)Urban Area Affected: 1,833 Acres Population: - Subject to severe flooding: 40,500 - Residential Structures: 13,200Commercial & Public Structures: - Commercial Area: 5 Million SF - Hospital, Schools, Courts, Police Depts.

Estimated Project Cost: $300 MRange of Damages Prevented: $400M-$600M (100-year event)

Direct Jobs Created: 650 (Peak)

Sponsor: Department of Natural and Environmental Resources

Portugués Dam Pertinent Facts


Portugués Dam Initial Thin Arch Conventional Concrete Alternative

Nov 93 - Apr 96: Left Abutment Excavation Dec 96 - Sep 98: Right Abutment Excavation Oct 97 - Dec 99: Foundation Grouting Sep 00: Advertised Arch Dam

► One Bid – Outside of Awardable Range

After several studies and cost estimates, design was changed to Roller Compacted Concrete and detailed studies and design began for a 5-yr program.


Portugués Dam Goals in Changing to Thick Arch RCC

Explore technology initially ruled out due to its newness in the 80’s

Utilize advancements in RCC technology and techniques

Realize savings in construction time

Maximize utilization of investment on site

Arch-shaped foundation excavations

Installed initial grout curtain

Avoid extensive new excavations mandated by a gravity design

Pursue Optimal Geometry to reduce total quantity of RCC

Ensure utilization of local regular use cement manufacturing

Deliver the final component of a much need flood reduction project


Portugués Dam Thick Arch RCC Design

Only 10 in the world (from 17 to 100 meters in height)► 3 in South Africa► 7 in China

First Thick Arch RCC by USACE► USACE did the first Gravity RCC dam in US

• Willow Creek 1981 (Oregon)


Portugués Dam Thick RCC Design Pertinent Data

Dam Height:

Crest Length:

Spillway Crest Width:

Flood Control Storage:

Max Pool Area:

Dam Crest Elevation:

Spillway Crest Elevation:

RCC Volume:

Thickness:

Contraction Joints:

Design:

220 ft

1,230 ft

140 ft

9,484 acre-ft

215 acres

534.6 ft

512.75 ft

367,000 cy

110.6 ft base, 30 ft crest

Spaced 70 ft.

In-house w/ITR & Other Corps


Portugués Dam Hydraulic / Hydrologic

Normal River Flows Low (less than 50 cfs) 10.5 Square Mile Basin Outlet Works include Intake Structure with Emergency Sluice/Roller

Gates, Two 60-inch Diameter RO’s, Emergency and Service Valves in Valve House, Emergency Spillway.

Emergency Spillway - Ogee Crest with Flip Bucket Designed for PMP (45,000 cfs) 2,800 yr event Durations Used for Scour Evaluation


Portugués Dam Structural

Single Centered Thick Arch Dam Designed for Static, Dynamic, and Thermal Loading Thermal Analysis Determined Placing Temperature and

Contraction Joint Spacing. Designed as a 3-dimensional structure Designed for Closed Contraction Joints Horizontal Joint Tensile Strength Important During Seismic Events Extensive RCC Design and Testing Program Cold Joint Considerations


Portugués Dam Geotechnical / Geology

Foundation Block Stability Analyzed for Dam Induced Loads, Water Gravity Loads, Uplift, and Seismic Loads

Grout Curtain utilized to Reduce Seepage and Uplift Seepage Analyzed and Foundation Drains Designed Slope Stabilizations On-site Quarry Source of RCC Aggregate Foundation Dental Concrete/Treatments


Main Dam

Portugués Dam Design Features


Dam Sections



Outlet Works



Dam Gallery



PHASE 1 – $24,465,435 MOBILIZATION, CLEARING, QUARRY OVERBURDEN EXCAVATION,

POWERLINE RELOCATION

PHASE 2 – $47,625,652 FOUNDATION EXCAVATION, AGGREGATE PRODUCTION, DENTAL

CONCRETE

PHASE 3 – $37,293,763 AGGREGATE PRODUCTION, ½ DAM RCC PLACEMENT

PHASE 4 – $41,061,083 FINAL DAM RCC PLACEMENT, SPILLWAY, INTAKE STRUCTURE

PHASE 5 – $29,672,717 REMAINING ITEMS, VALVE HOUSE, ACCESS ROAD, MECHANICAL,

ELECTRICAL.

Portugues Dam Project Phasing


Portugués Dam Project Map


Portugués Dam Construction Activities

Quarry Excavation

Approx. 567,170 cy excavated



Aggregate Production and Stockpiling



Foundation Excavations



RCC Production



RCC Mix DesignDiversion and Care of Water System



Diversion and Care of Water

Delay-causing Over-toppings:

Sep 30, 2010Oct 4, 2010Oct 5, 2010Oct 6-10, 2010Oct 17, 2010



Diversion and Care of Water


Portugués Dam Foundation Preparation Work

AS- 11/12 : Foundation Excavation Cleanup



Drilling and Consolidation Grouting



RCC Conveying, Spreading, Compaction, Joint Installation


Portugués Dam Gallery

Gallery Formwork



Dam RCC Work Topped Out


Portugués Dam Gallery

Gallery Finish


Portugués Dam Foundation Preparation Work

Grouting Setup & Grout Curtain Drill


Portugués Dam Instrumentation

Stress / Strain Meters & Joint Meters


Portugués Dam Dam Features


Portugués Dam Conclusions

QC Process critical and perhaps more involved than Conventional Concrete

Need for sound QC planning and preparatory work process

Need for qualified and energetic individuals overseeing the process

Need for intense tracking of RCC production and placement parameters

Safety a constant challenge due to multiple activities in close proximity

Management involvement in Safety is fundamental

Production Staff needs to adopt a Safety Culture

Accountability is a must

Position of Competent Person as defined by OSHA is critical

Choice of Dam type always based on site considerations, but RCC nowadays a hard to beat choice.


Contractors

Prime:Main Sub:

Others:

Dragados USAJosé Carro Const.

RC ProfessionalsGEHS EnvironmentalEST ElectricalHEAT SecurityJV GeolandARC SurveyingFrank ElectricAltol LaboratoriesCCG Drilling & Blasting

Award:Notice to Proceed:

Original Completion Date:Final (Actual) Completion:

Beneficial Occupancy:

03/14/200804/03/200803/08/201312/27/201306/01/2014

Contract Milestones

Award Amount:Modifications:

Contract Total:

$180,118,650.80$36,718,962.90

$216,837,613.70

Contract Cost

Portugués Dam Contract Data


The EndThe End

coastal damage reduction flood damage reduction navigation ecosystem restorationregulatory...

Documents

arch dam

gravity rcc dam

thick arch rcc goals

rcc technology

dam crest elevation

rcc volume

project cost

gravity design