The 1st International Symposium on Rockfill Dams The Construction Techniques of Shui Buya Concrete Faced Rockfill Dam——Construction Compacting Test Zhu Zhijun China Gezhouba Group Corporation, No.8 Jiaohu 2ed Road, Yichang, Hubei Province 443002, [email protected] Abstract: Shuibuya concrete faced rockfill dam with the height of 233m is one of the highest dam worldwide and the highest dam among current dams of the similar type in China. This dam is constructed by cushion materials (Ⅱ A), transition materials (Ⅲ A), the main rockfill materials (Ⅲ B), 3C materials (Ⅲ C), and downstream rockfill materials (Ⅲ D). In order to ensure the dam's construction quality and the availability of the same conditions with engineering construction, the construction site is simulated and site filling compaction tests are carried out to all dam materials adopted, for the purpose of obtaining the best quality control and detection method of dam filling. The test carried out 9 tests with a total of 78 unit tests, detecting 1515 sets of data. This paper introduces equipments, methods, test results of 9 different dam material type roller compaction tests, analyzing the relationship between roller compacted sedimentation rate and rolling times, the relationship between compacted dry density and rolling times as well as the relationship between porosity and rolling times, also including the relationship between filler compaction effect and the grading features before and after dam material filling, seepage properties after filler rolling, the rolling effect and sprinkler volume of different rolling machines. In accordance with the testing results, in the view of different dam materials of Shuibuya Dam filling construction, this paper proposed suggestions about rational construction parameters on sprinkler method, sprinkler volume, charging pattern, the thickness of materials, rolling equipment models and roller compacted layer parameter. Keywords: CFRD,roller compaction test,testing results, analysis 1 Overview Shuibuya concrete face rockfill dam and the highest dam among current dams of the similar type in China. This dam is filled with cushion materials (Ⅱ A), with the height of 233m is one of the transition materials (ⅢA), main rockfill highest dams of similar type in the world materials (ⅢB), sub-rockfill materials -1- The 1st International Symposium on Rockfill Dams rockfill (Ⅲ B) are blasting experiment materials materials (ⅢD). In order to ensure the from Gongshanbao yard and spillway dam's excavation, (ⅢC), and the downstream construction quality and the respectively; sub-rockfill availability of the same conditions with materials (Ⅲ engineering construction, the construction from Qiaogou yard and Changtanghe yard, site respectively; is simulated and site filling C) are holding materials downstream rockfill compaction tests are carried out to all materials(Ⅲ D), are excavation materials adopted dam materials for the purpose of from obtaining the best quality control and excavation, respectively. detection method of dam filling. This test ranging from August in 2002 to March in 3 2003,completed a total of 9 various dam material tests namely two each test on ⅢA、ⅢB、ⅢC、ⅢD filler rolling and one on ⅡA filler rolling and carried out compacting tests with diversity testing parameters , such as sprinkler volume from 0% to 20%, 6 、 8 、 10 rolling times ,compaction thickness of 40 cm、80 cm、120cm , 18t and 25t self-propelled roller and 20t towed vibrating roller, to dam materials in different filling areas . 2 Sources of testing materials The materials adopted for the dam material compacting tests come from the 3.1 Miaobao yard and river bed Technological requirements of compacting test Test site In accordance with the situation of Shuibuya construction site, test site was arranged in Changtanghe holding material yard and a yard with the size of 55×220 M2 was cleaned up in the upper reaches of Changtanghe material yard, divided into the first test site, the second test site, roller test site and cushion material (Ⅱ A) test site, with the site size of 65 × 34M2, 65 × 34M2, 50 × 40M2, 28 × 10M2, respectively. 3.2 Chosen types of test machines sources approved and designated by the The roller weight of vibration roller owners ,designers and supervisors at the should be no less than 100Kn and site, and the specific distribution of the vibrating force no less than 200Kn in IIA source materials is as follow: cushion and IIIA zone; the roller weight of materials (Ⅱ A) are artificial materials vibration roller should be no less than processed by San Youping artificial yard ; 160Kn and vibrating force no less than transition materials (Ⅲ A) are carbide slag 320Kn in Ⅲ B, Ⅲ C, Ⅲ from blasting Engsuolan self-propelled vibration roller experiment materials from Gongshanbao is applied in IIA zone, YZ25-type 25t yard respectively; main rockfill materials self-propelled vibration roller made by hole excavation and -2- D zone. 18t The 1st International Symposium on Rockfill Dams Zoomlion and 18t Engsuolan self-propelled vibration roller Engsuolan self-propelled vibration roller in IIIA zone, in the two Ⅲ YZ25-type 25t self-propelled vibration YZ25-type 25t self-propelled vibration roller made by Zoomlion in Ⅲ zone, roller made by Zoomlion and Shaanxi YZ25-type 25t self-propelled vibration Zhongda YZTY20-type towed vibrating roller roller in Ⅲ D zone. made by Zoomlion B and 18t C zones respectively, Mechanical parameters are as follow Equipment Model Full Hydraulic Vibratory Roller YZ25 Manufacturer Zoomlion Performance Quality (t) Vibration Frequency(Hz) Exciting Force(KN) Nominal Amplitude(mm) Vibration Round Static Line Load(N/cm) Rated Power(KW) Velocity(km/h) Roller Width(M) 25 27.5/31 450/300 2.1/1.1 Equipment Name 3.3 Towed Vibratory Roller YZTY20 Shaanxi Zhongda Machine CO.,LTD 19 30 450 Full Hydraulic Vibratory Roller SD175F 729 980 556 141 4.1/10.8 2.16 110 / 2.0 151 6.9/13.8 2.12 Remarks Ingersoll-Rand 18.769 30.4/18.3 320 1.66/0.83 are as follow: Design standards Design standards of compacting test Design standards of dam material compacting test Dam material zoning ⅡA ⅢA ⅢB ⅢC ⅢD Maximum Slice of Compaction (mm) 400 400 800 800 1200 Sprinkler Volume (%) 5、10 10、15、20 15、20、25 15、20、25 15、20、25 Rolling Times 6、8、10 6、8、10 6、8、10 6、8、10 6、8、10 Maximum Particle Size (mm) 80 300 800 800 1200 <5mm Particle Size Content % 35~50 20~30 4~15 <0.1mm Particle Size Content % 4~7 <5 <5 ≤5 ≤5 Dry Density(g/cm ) 2.25 2.20 2.18 2.15 2.15 Porosity(%) 17 18.8 19.6 20.7 20.7 7671864 4348509 1481194 3 Permeability Coefficient(cm/s) Filling Quantity(m3) 1×10-2~ 5×100~5×10-1 5×10-4 465940 683733 -3- The 1st International Symposium on Rockfill Dams 3.4 Bulldozers are used to press flats in the Testing methods Before the test, the foundation should go through 10 times of temper rolling with the thickness of 40~50cm adopting the same filling materials as those used in the test, and the surface smoothness should be no more than 10cm. Then measuring, setting out and recording the site to know its height, and measuring point distance 2m × 2m with the accuracy of ± 1mm. And draw lime lines to the testing areas and testing units, as well as the directional signs of machines entrance and leave. Spreading materials with the methods of occupying progressively. Edge and ultra-trail materials should be excluded when loading materials in blasting sites and materials should be extracted from the material piles by pullshovel or crowd shovel, avoiding extracting planar stratifiedly. Test-type material should be extracted to make particle gradation test before compacting test. test to meet the test requirements of thickness and flatness, and Water-level Meters are adopted to test the thickness for the purpose of ensuring material thickness meet the test requirements. All dam materials are spreading and then measure the exact cushion thickness. There are two sprinkler methods including sprinkling at RCC test site and sprinkling separately at transit stations and RCC test site. According to the actual situations of Shuibuya productive RCC test site, the owners, designers, supervisors and construction units all confirmed to adjust appropriately the sprinkler volume of dam material rolling. Sprinkling should be done before the accomplishment of dam material rolling, and 5 types of sprinkler volume ,namely 0%、5%、10%、15%、20% are adopted according to volume method. Dam material sprinkler adjustment and specific sprinkling methods in different zones are shown in the table below. -4- The 1st International Symposium on Rockfill Dams Table of sprinkler volume of dam material compacting test Material source Dam type Qiaogou HMY ⅢC Gong Shanbao Yard ⅢB Chang Tanghe HMY ⅢC Miaobao Yard ⅢD Jikeng bed-material ⅢD Youan Carbide Slag ⅢA San Youping AY ⅡA Gong Shanbao yard ⅢA Spillway ⅢB Sprinkler Methods Designed Actual sprinkler sprinkler Water addition at Water addition at volume(%)volume(%)water station(%) site(%) 15 5 30 70 20 10 30 70 25 15 30 70 15 0 30 70 20 10 30 70 25 15 30 70 15 0 30 70 20 5 30 70 25 10 30 70 15 5 30 70 20 10 30 70 25 15 30 70 15 10 0 100 20 15 0 100 10 0 0 100 15 5 0 100 20 10 0 100 5 2 0 100 10 5 0 100 10 0 0 100 15 5 0 100 20 10 0 100 15 5 0 100 20 10 0 100 25 15 0 100 Lime lines should be drawn to various testing areas and units as well as marking Remarks raining raining volume and sedimentation rate of different rolling times at each level. track routes of mechanical equipments such Digging in each test unit in ⅡA、ⅢA、 as rollers. After vibration roller vibrating to ⅢB 、 ⅢC 、 ⅢD zone to test compaction the normal working condition outside, density, particle gradation and permeability under the special command, it operates back coefficient after rolling and forth by whole vibration according to set parameters of RCC construction operations. Rolling a cycle is counted twice and wheel tracks overlap should be no less than 10 ~ 15cm. 3.5 Testing Testing sedimentation sedimentation testing : points arranging by using 2.0m×2.0m square grid in the test units esting density:testing pit water injection Measuring the height of filling level after method is adopted, each test unit is rolling, and calculating the subsidence -5- The 1st International Symposium on Rockfill Dams arranged two testing pits, and average times growing bearing the same growth value of results from two testing pits is trend. The highest sedimentation rate is of taken as the 0% sprinkler, followed by 10 sprinkler, compaction dry density the lowest 10%. value of the testing units Testing particle The compaction sedimentation rate in gradation : size distribution testing is carried out in each pit Gongshanbao to get the gradation curve after rolling. increases with rolling times growing, and ⅢA materials yard coefficient : the highest compaction sedimentation rate Permeability tests of each testing units in is in 10% sprinkler pilot areas, the rate of different 0% sprinkler being very close with 15 Testing permeability tests permeability all test adopt and in-situ testing pit sprinkler. water-injection test. 4 The compaction sedimentation rate in Spillway ⅢB material yard increases with Analysis of testing results 4.1 The relationship rolling between compaction sedimentation rate and rolling times The test results of ⅡA material rolling show that the compaction sedimentation rate increases in two different testing areas with 2% 、 5% sprinkler volume respectively as the roaring of rolling times, but the compaction sedimentation rate of the 2% sprinkler volume is higher than that of 5% sprinkler volume. The compacting test results of slag on the right bank show that compaction sedimentation rate increases with the rolling times raised in three test areas with sprinkler volume of 10%、5%、0% respectively and reaches the highest point in the sprinkler volume of 10%。 The compacting test results of Gongshanbao ⅢA materials yard show that the compaction sedimentation rate increases in three pilot areas with rolling times growing, and the compaction sedimentation rate in three pilot areas is close to RCC time relationship curve, but the compaction sedimentation rate is relatively high when it is 5% sprinkler volume. The compaction sedimentation rate in Qiaogou ⅢC material yard increases with rolling times growing, and the rate roars with the sprinkler volume increases The compacting test results of Changtanghe ⅢC material yard show that the ⅢC material compaction sedimentation rate increases with rolling times raised, and the rate reaches the highest point in 0% sprinkler areas ,the rate in 10% and 5% sprinkler areas being very close. The compacting test results of Miaobao ⅢD material yard show that the compaction sedimentation rate increases with rolling times raised in three pilot areas of 5%, 10% and 15% sprinkler -6- The 1st International Symposium on Rockfill Dams volume, and the rate in 10% and 5% pilot times one. The relationship between the areas is very close but have the highest compacted dry density and rolling times compaction sedimentation rate. is shown in the table below: The compacting test results The of compacting test results of river-bed ⅢD material show that the river-bed ⅢD material show that the compaction sedimentation rate increases compacted dry density between 6 times with rolling times raised in both 15% and and 8 times rolling increases, and that of 10% sprinkler volume of 20t towed 8 times rolling is the highest, that of 10 vibrating roller and 25t self-propelled times being lower than design standards. roller, the compaction sedimentation rate The compacted dry density increases of 10% sprinkler volume of 20t towed with vibrating roller is higher than that of 15% Gongshanbao ⅢB material yard, but has sprinkler volume, and the compaction no rules. The compacted dry density in 6 sedimentation rate of 20t towed vibrating rolling times pilot areas does not meet the roller design requirements, and that in 8 and 10 is higher than that of 25t self-propelled roller times 4.2 The relationship between compacted dry density and rolling times as well as the relationship between porosity and rolling times The compacting test results of Sanyouping artificial ⅢD material show that the relationship between compacted dry density and rolling times is not obvious, and the compacted dry density of 6 times and 8 times rolling is terribly close with the value of 2.280g/ cm3 exceeding design standards ,but that of 10 times rolling is relatively lower meeting the design requirement of 2.220g/ cm3 The river-bed compacting ⅢD the test material results show of that compacted dry density in the two pilot areas each of 6 times and 8 times rolling is close. The compacted dry density of 10 times rolling is bigger than that of 8 and 6 rolling pilot times areas growing exceeds in design requirements, the compacted dry density in 8 times pilot areas being higher than that in 10 times areas. The relationship between the compacted dry density and rolling times is shown in the table below: The compacted dry density of spillway ⅢB material is generally lower than design standards, only the compacted dry density of one set testing material being higher The Qiaogou compacted holding dry ⅢC density material of yard increases with the rolling times growing under the condition of 5% sprinkler volume, but show no rules of increasing obviously with 10%~12% sprinkler volume. The compacting test results of ChangtTanghe ⅢD material yard show that the compacted dry density in all pilot -7- The 1st International Symposium on Rockfill Dams areas is generally higher than design The particle gradation of carbide slag standards, and it increases between the ⅢA materials changes a lot after rolling, interval of 6 times and 8 times rolling. but there is little change of 5mm The compacted dry density of 8 times and fine-grained content before and after 10 times is very close but that of 10 rolling. The gradation curve before and rolling times is a little lower than that of after rolling is mainly included in the 8 rolling times. designed envelop curve. The rolling effect of Miaobao ⅢD The particle gradation of material is not as good as expected, the Gongshanbao ⅢA material is close before compacted dry density being lower than and after rolling, but that of design standards, and sky phenomenon is material before and after rolling goes far found during testing pit process. The beyond designed envelop curve. ⅢA compacted dry density test results also There is little change happened to the show that the compacted dry density is particle gradation of Gongshanbao ⅢB relatively lower and that of 8 times is material in 0% sprinkler areas, but close to design standards. obvious changes happened to the In order to improve river bed ⅢD sprinkler areas. the Fine-grained content material gradation, some fine materials of ⅢB increases with rolling times from river bed excavation are added when growing after rolling, and fine-grained filling ⅢD materials. The compacting test content of <0.1、<5、<20mm all meets results show that the compacted dry the design requirements. There are big changes happened to density is close in 20t towed vibrating roller areas with 6 and 8 rolling times. particle The average compacted dry density of 20t materials before and after rolling in towed vibrating roller is higher than that different of 25t self-propelled roller, so the fine-grained content is included in the compaction effect of the first one is better designed envelop curve, but not the than that of the latter one majority of gradation. 4.3 Gradation before and after dam material filling There is no big change happened to particle gradation before and after rolling Sanyouping artificialⅡA materials and gradation curve before and after rolling does not go beyond designed envelop gradation pilot of areas, spillway and ⅢB < 20mm There are obvious changes happened to particle gradation of ⅢB materials from Qiaogou holding material yard before and after rolling, the composition of fine-grained content increases with the sprinkler volume and rolling times growing after rolling. The particle gradation of ⅢA material curve. -8- The 1st International Symposium on Rockfill Dams from Changtanghe material yard is close and the results of testing pit watering test before and after rolling, and there is no show that rockfill materials in each obvious change of gradation fine-grained testing unit have a free permeability. content after rolling, but the percentage of The seepage parameter of ⅢB various rough-grained content increases construction materials from Gongshanbao obviously. has little change with the value of 10-01 The Miaobao ⅢD blasting materials and the gradation after rolling is not as good as expected, with and rockfill materials in each testing unit perform partially permeability The < 20mm fine-grained content less than 20%. seepage parameter of ⅢB materials from spillway has little change, There are obvious changes happened to with the value of 10-0~10-01 , and rockfill the particle gradation of river bed ⅢD materials in each testing unit perform materials rolled by 20t towed vibrating partially permeability. roller and 25t self-propelled roller, but The seepage parameter of ⅢC little to <5mm fine-grained content before materials from Qiaogou holding material and after rolling. Compared with that of yard. The seepage parameter is relatively 25t self-propelled roller, the gradation little in the testing unit with 10%~12% curve of 20t towed vibrating roller of sprinkler volume, and the rockfill dam changes a lot before and after rolling. materials perform partially permeability 4.4 Seepage properties of rockfill materials after rolling The seepage parameter of artificial ⅡA materials in Sanyouping is between 10-03 and 10-04 ,all meeting the design requirements. The seepage parameter of carbide slag from holes changes violently ranging from 100 to 10-03, and the results of testing pit watering test show that rockfill materials can have a free permeability horizontally, and bear partially permeability vertically. The seepage parameter of ⅢA construction materials from Gongshanbao changes peacefully with that of each testing unit ranging from 10-01 to 10-02, or free permeability in the testing unit with 5% sprinkler volume. The seepage parameter of ⅢC materials from Chang Tanghe changes violently, with the value of 10-01~10-03 and the results of testing pit watering test show that rockfill materials in each testing unit perform free permeability The seepage parameter of ⅢD material from Miaobao material yard ranging from 10-01 to 10-02, and the results of testing pit watering test show that rockfill materials permeability both perform free horizontally and vertically. The seepage parameter of ⅢD materials from river bed has little change, -9- The 1st International Symposium on Rockfill Dams with the value of 10-03 because of some the highest point in the pilot area of 2% fine-grained materials from river bed sprinkler volume, and the compacted dry excavation being added to rockfill ⅢD density increase with the roaring sprinkler materials, and the results of testing pit volume which has a stronger effect on the watering test show that rockfill materials compacted dry density than rolling times. The compacting test results of ⅢA can have a free permeability horizontally, and bear partially permeability vertically 4.5 Rolling effect of various rolling machines ⅢA、ⅢB、ⅢC roller compaction of 25t self-propelled roller as well as ⅡA、ⅢA、 ⅢB 、 ⅢC roller compaction of 18t self-propelled roller can basically meet the design construction requirements parameter ,but the ⅢB 18t of self-propelled roller must get 8 rolling times, while 6 times is enough to 25t self-propelled roller The compaction effect of ⅢD materials rolled by 20t towed vibrating roller is far better than that rolled by 25t self-propelled roller, but dam materials from different sources distinct from each other after self-propelled being rolled roller leading by 25t to the compaction dry density of most testing units losing to meet the design requirements. carbide slag from holes show that the compacted dry density increases with the sprinkler volume growing in each pilot area, and that in the 0% sprinkler volume area loses to meet the design standards, but that in both 10% and 15% sprinkler volume area exceeds far from the design standards with the highest compacted dry density in 10% sprinkler volume area. The compacting test results of ⅢA construction material from Gongshanbao show that the average compacted dry density reaches the highest point in the 5% sprinkler volume area, lowest in the 10% sprinkler volume area and that in the 0% sprinkler volume area fails to meet the design requirements. The compacted dry density of ⅢB construction material from Gongshanbao increases with the sprinkler volume growing in each pilot area with an obvious raising trend. The testing results show that the compacted dry density stops 4.6 The relationship between the rolling increasing when the sprinkler volume is 10%. effect and sprinkler volume The compacted dry density of ⅢB The compacting test results of ⅡA material from spillway is generally lower artificial materials from Sanyouping show than design standards, only with one set that the compacted dry density increases of compacted dry density higher. with the rolling times growing, reaching 4.6.6The compacted dry density of ⅢC - 10 - The 1st International Symposium on Rockfill Dams materials from Qiaogou holding material 15% sprinkler volume area is higher than yard increases with the sprinkler volume that in the 10% sprinkler volume area, far growing with a strong raising trend. The lower than the design standards. testing results show that the compacted dry density can meet the design 5 requirements under the condition of 6 Conclusion and suggestion The compacted dry density and rolling times and 5% sprinkler volume, seepage properties of ⅡA materials can while the sprinkler volume reaches 10% meet the design requirements, the rolling difficulty seizes site filling construction times slightly affect the rolling effect, and and the soft-rock features such as sprinkler volume has direct agglutination in the surface of filling relationship with rolling effect. Yard materials come out. sprinkler method is better to sprinkler The compacting test results of ⅢC operation and all should be done before materials from Changtanghe show that and the density sprinkler volume should be controlled in reaches the highest point in the pilot area 5%,and be adjusted with the rainfalls. of 5% sprinkler volume, lowest in the The 10% sprinkler volume, while the sprinkler parameter of ⅡA materials is to adopt volume exceeds 10%, difficulty seizes backward site filling construction and soft-rock method with 6 rolling times , 40cm features such as agglutination in the thickness and 5% sprinkler volume. average compacted dry after spreading suggestions materials. for elimination The construction as spreading Whether ⅢA materials rolled by 25t surface of filling materials come out. The compacting test results of ⅢD or 18t self-propelled roller, it can always construction material from Miaobao show meet the design requirement. If the that the compacted dry density is close in gradation curve of blasting materials from the 5% and 10%sprinkler volume areas, Gongshanbao is not beyond the design both lower than design standards, but it envelope curve, the rolling effect would reaches the highest point in the 15% be much better. The suggestions for sprinkler volume area closing to the construction parameter of ⅡA materials is design standards. to adopt hybrid method as spreading The compacting test results of ⅢD method with 6 to 8 rolling times , 40cm material from river bed show that the thickness and 5% to 10% sprinkler compacted volume dry density of 25t towed The rolling effect of ⅢB materials vibrating roller changes slightly with the rolled by 25t self-propelled roller differs different sprinkler volume, and that in the due to the various dam material sources. self-propelled roller and 20t - 11 - The 1st International Symposium on Rockfill Dams The compacted dry density of blasting at adding water station. Filling rolling test materials from Gongshanbao can construction techniques and criterion of meet the design requirements after rolling, quality controlling of soft rock materials but that of blasting test materials from should be made as consultations during spillway the filling rolling construction. is lower than its design specifications, with the gradation curve of The rolling effect of ⅢD rolled by 25t two blasting tests differing from the self-propelled roller can not meet the design envelope one. The suggestions for design requirements, and only the testing construction parameter of ⅢB materials is parameters in the two units of river bed to excavation adopt method of occupying satisfy the requirements, progressively as spreading method with 8 leaving that of excavation materials from rolling times , 80cm thickness and 5% to Miaobao losing to meet the requirements. 10% sprinkler volume and watering is But the good rolling effect of river bed expected before excavation materials is found while spreading materials and adding water adopting towed vibrating roller with the stations. compacted dry density higher than the to be completed Ⅲc materials rolled by 25t or 18t design specifications. The suggestions for self-propelled roller can meet the design construction parameter of ⅢD materials is requirements with the compacted dry to use 25t self-propelled roller and adopt density higher than design specifications. the method of occupying progressively as The construction spreading method while with 8 to 10 parameter of ⅢB materials is to use 18t rolling times, 100cm thickness and 10 to self-propelled roller and adopt method of 20% sprinkler volume under the condition hybrid method as spreading method with of 6 to 8 rolling times, 80cm thickness and excavation 5% 25t self-propelled roller with 4 to 6 rolling self-propelled roller with 6 rolling times, times, 120cm thickness and 10 to 15% 100cm sprinkler suggestions sprinkler thickness for volume, and 5% and sprinkler volume and watering is expected to be successive condition. completed while spreading materials and - 12 - gradation materials, volume and under curve of use 20t the same
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