HYDROPOWER DEVELOPMENT

VOLUME NO 11

CONCRETE IN
HYDROPOWER STRUCTURES
by

Erland Kleivan, Gunnar Kummeneje and Alf J. Lyngra

1994
NORWEGIAN INSTITUTE OF TECHNOLOGY
DIVISION OF HYDRAULIC ENGINEERING

CONTENTS
Abbreviations, Acronyms and Definitions .................................................. 8
1 INTRODUCTION ...................................................................................... 9
1.1 Brief review of the use of concrete in the hydropower industry ......... 9
1.2 Highlights in recent development of concrete technology .................. 10
1.3 Design for durability requires knowledge ............................................. 12
2 THE CONSTITUENTS OF CONCRETE ................................................. 13
2.1 Cements and pozzolana .......................................................................... 13
2.2 Aggregates .............................................................................................. 18
2.3 Water ....................................................................................................... 19
2.4 Admixtures .............................................................................................. 19
2.4.1 Definitions ..................................................................................... 19
2.4.2 Plasticizers/water reducers ........................................................... 20
2.4.3 Air-entraining Agents ................................................................... 21
2.4.4 Accelerators .................................................................................. 21
2.4.5 Retarders ....................................................................................... 22
2.4.6 Admixtures for underwater concreting ....................................... 22
3 FRESH CONCRETE CRITERIA FOR MIX DESIGN ....................... 23
3.1 Water/cement ratio ................................................................................. 23
3.2 Type of structure ..................................................................................... 23
3.3 Workability/consistency ......................................................................... 25
3.4 Ambient temperature .............................................................................. 25
3.5 Means and length of transport ............................................................... 26
4 CURING .......................................................................................................... 27
4.1 Need for proper curing ........................................................................... 27
4.2 Methods and means of curing ................................................................ 28
4.3 Plastic shrinkage ..................................................................................... 29
4.4 Prediction of temperature and strength development ........................... 29
5 THE HARDENED CONCRETE
REQUIREMENTS AND PROPERTIES ................................................ 31
5.1 On the criteria for specifying properties ............................................... 31
5.2 Durability. Sources of deterioration and preventive measures
31
5.2.1 Classification of environment .................................................... 31
5.2.2 Preventing corrosion of reinforcement ...................................... 33
5.2.3 Resistance to erosion/abrasion and cavitation ........................... 34

5.2.4 Resistance to chemical attack ................................................. 34

5.2.5 Resistance to freezing and thawing ......................................... 37
5.3 Watertightness .................................................................................. 38
5.4 Structural strength ............................................................................ 39
6 REINFORCEMENT ................................................................................ 43
6.1 Notes on bar reinforcement .............................................................. 43
6.2 Fibres ................................................................................................ 44
6.3 Galvanized reinforcement ................................................................. 44
7 CONCRETE IN DAMS ........................................................................... 45
7.1 General requirements to concrete properties .................................... 45
7.2 Concrete dams .................................................................................. 46
7.2.1 General comments ................................................................... 46
7.2.2 Small gravity structures .......................................................... 46
7.2.3 Large gravity dams .................................................................. 47
7.2.4 Arch dams ............................................................................... 48
7.2.5 Slab and buttress dams ............................................................ 49
7.2.6 Roller-compacted concrete dams ............................................ 51
7.3 Concrete in embankment dams ......................................................... 52
7.3.1 General .................................................................................... 52
7.3.2 Central concrete membranes ................................................... 52
7.3.3 Upstream concrete membranes ............................................... 52
7.3.4 Retaining walls ........................................................................ 53
7.3.5 Other use of concrete in embankments ................................... 53
8 CONCRETE IN WATERWAYS ............................................................ 57
8.1 Tunnels ............................................................................................. 57
8.1.1 General Comments .................................................................. 57
8.1.2 In situ concrete lining .............................................................. 57
8.1.3 Shotcrete ................................................................................. 60
8.1.4 Pavements ............................................................................... 62
8.1.5 Grouting .................................................................................. 62
8.1.6 High pressure plugs ................................................................. 63
8.1.7 Low pressure plugs ................................................................. 69
8.2 Penstocks and other pressure conduits ............................................. 69
8.2.1 General .................................................................................... 69
8.2.2 Surface conduits ...................................................................... 70
8.2.3 Underground conduits ............................................................. 71
8.3 Surge chambers ............................................................................... 73
8.4 Weirs ................................................................................................. 73
8.5 Gates ................................................................................................ 74
8.6 Intakes ............................................................................................. 75
8.7 Canals .............................................................................................. 76
8.8 Culverts ........................................................................................... 77
8.9 Fish ladders ..................................................................................... 77

9 CONCRETE IN POWERHOUSES ........................................................ 79

9.1 Typical underground powerhouses ................................................... 79
9.1.1 General .................................................................................... 79
9.1.2 The cavern ............................................................................... 79
9.1.3 Access and auxiliary tunnels ................................................... 82
9.2 Typical above ground powerhouses .................................................. 84
9.2.1 General .................................................................................... 84
9.2.2 In situ concrete components .................................................... 85
9.3 Prefabricated elements ...................................................................... 87
9.3.1 General .................................................................................... 87
9.3.2 Roof elements .......................................................................... 87
9.3.3 Floor elements ......................................................................... 88
9.3.4 Trash rack beams ..................................................................... 88
9.3.5 Other products ......................................................................... 89
9.3.6 Advantages/disadvantages with prefabrication ....................... 89
10 QUALITY ASSURANCE ..................................................................... 91
10.1 General comments .......................................................................... 91
10.2 Concrete QA for the consultant ...................................................... 91
10.3 Concrete QA for the contractor ....................................................... 93
11 DAMAGE AND REPAIR ..................................................................... 95
11.1 General ............................................................................................ 95
11.2 Diagnosis ......................................................................................... 96
11.3 Repair methods ............................................................................... 97
REFERENCES ............................................................................................ 101
CASE HISTORIES ..................................................................................... 105
Case 1: Planning and implementing concrete works for a large
gravity dam. Forrevatn Dam.............................................................. 107
Case 2: Concrete composition and cooling arrangement for an
arch dam. Virdnejavri Dam ............................................................... 112
Case 3: Design and construction of a high pressure penstock plug. NysetSteggje Power Plant........................................................................... 114
Case 4: Design and construction of a high pressure gated plug.
Mel Power Plant ................................................................................ 116
Case 5: Design and construction of a high pressure barrier plug.
Nedre Vinstra Power Plant ................................................................ 119
Case 6: Concreting of steel penstock in long shaft.
Aurland I Power Plant. Unit 3 (1989) ............................................... 122
Case 7: Concrete work for large-scale spiral case roof.
Solbergfoss II Power Plant (1983) ................................................... 124