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TED-AJ03-560
David A. Dollar
U. S. Army Corps of Engineers
400 West Bay Street, Jacksonville FL 32232 USA
E-mail: David.A.Dollar@saj02.usace.army.mil
Keywords: Heat of Hydration, Cooling Coils, Concrete Aging and Creep, Thermal Induced Cracking
ABSTRACT
Concrete arch dams are typically constructed from
individual cantilever blocks, as illustrated in Fig. 1, using
approximately 10 thick mass concrete placements or lifts
to build up each block. During placement and the initial
curing of a lift, water is circulated through embedded
pipes, as illustrated in Fig. 2, to control the peak
temperatures and thermal gradients. Once the individual
blocks are completed to the crest height, water is again
circulated to contract the blocks and open the contraction
joints between the blocks. The open joints are then
pressure grouted to form a monolithic arch dam. This
type of mass concrete construction has two opposing
design considerations for the thermal behavior due to the
heat of hydration. During the placement of the lifts,
excessive temperatures and thermal gradients must be
controlled to prevent thermal induced cracking.
However, during the final cooling period, an adequate
drop in the mean concrete temperature must be available to
allow the contraction joints to open sufficiently for
BACKGROUND
The U. S. Army Corps of Engineers is designing a
new concrete arch dam for construction on the Portugues
River near Ponce in southern Puerto Rico. The dam is
initially intended for flood control with the possibility of a
height extension to be constructed later for additional
water supply storage. At the maximum section of the
dam, the initial construction will be 220 feet high, 40 feet
thick at the base, and 23 feet thick at the crest. The length
of the arch at the crest is approximately 1300 feet. The
dam will be constructed with individual, cantilever blocks
in 70-foot lengths as measured along the axis of the dam.
Each block is free standing, and abuts its neighbors at a
contraction joint, which has cast-in vertical shear keys in
the plane of the contraction joints to resist movement in
the upstream-downstream direction. Each block is
constructed with a series of 7 to 10 feet thick concrete
placements or lifts with alternating high and low blocks
along the arch. The high blocks precede the low blocks in
height by at least 2 lifts (14 to 20 feet) for the formwork
requirements, and the low blocks are placed against the
sides of the high blocks with forms only on the upstream
and downstream faces. An example of this type of
construction is shown in Fig 1, which illustrates the
alternating high and low blocks, the formwork, and the
shear key at the contraction joints. After constructing
each block to the crest height, the blocks will be cooled
using embedded cooling pipes to open the contraction
joints. The open joints are then pressure grouted to form
a composite structure. The embedded cooling coils will
also be used to limit internal temperatures due to the heat
generation by the concrete hardening process during the
placement of each lift. Figure 2 illustrates cooling coils
that have been installed prior to placing the next lift.
For this type of construction, there are two opposing
design considerations for thermal requirements. The
potential for thermal induced cracking will be greatest
when the peak temperatures due to the heat of hydration
are the highest relative to the seasonal low temperatures.
However, the ability to open the contraction joints
sufficiently for grouting will most likely be compromised
when the peak temperatures are minimized. This is
because the mean temperature of the concrete at the time
of grouting is a fixed design parameter, which is based on
sensitivity studies for design basis loads during the design
of the dam. These issues were first formally addressed
during the construction of the Hoover Dam in the 1930s
[1]. General procedures for evaluating the potential for
thermal induced cracking in massive concrete structures
are identified in the Corps of Engineers Engineering
Technical Letter for Nonlinear, Incremental Structural
Analysis (NISA) [2]. This paper summarizes and
identifies recent advances in the computer modeling used
for analytical investigations in the thermal engineering of
large concrete structures.
The objectives of the
analytical studies are to evaluate the potential for cracking
in a typical cantilever block and to assess the contraction
joint opening behavior during final cooling for grouting.
This study is intended to verify the design parameters for
ANALYSIS RESULTS
For computer resource considerations, the size of the
3-D model must be limited. Since the foundation
provides constraint to the dam, which affects both the
cracking potential and joint opening performance, the
bottom portion of the dam and a portion of the foundation
are modeled.
To include the interaction of the
contraction joints, the full length of a cantilever block
with half of the adjacent blocks on either side is used.
The adjacent blocks are included to provide the
constraints and associated contraction joint interaction
with the center block. Section cuts are taken near the
centerlines of the adjacent block and symmetric boundary
conditions are applied to these cuts to limit the extent of
the 3-D model. Prior to the 3-D analyses to evaluate the
potential for cracking and the performance of the
contraction joints, a series of 2-dimensional analyses were
performed.
Preliminary Analyses
The purpose of these studies is to evaluate the cooling
coil performance under different combinations of
parameters within the design envelope to finalize the
cooling coil parameters for use in the 3-D models. Since
the schedule and budget limits the number of 3-D analyses
that can be conducted, the 2-D models are used to evaluate
the thermal behavior under various cooling coil design
combinations. Also, since the 3-D model only considers
the first 6 lifts of each block, the 2-D analysis is used as a
basis for the boundary conditions to be applied on the top
cut surface of the 3-D model. Figure 4 illustrates the 2-D
model and the results extracted for the boundary
conditions on the 3-D model.
In addition, the 2-D
modeling is used to determine the worst-case material
property variation combination for the 3-D verification
analyses in fulfillment of the intent of the NISA ETL.
Finally, 2-D analyses are used to assess the temperatures
that are likely to occur under nominal heat of hydration
and mean monthly temperature variations as best estimate
predictions. Since the study strives to look at worst-case
conditions, 15% variations in the measured heat of
hydration and extreme ambient temperature ranges are
considered in the 3-D analyses. The best-estimate 2-D
analyses are used to develop the more likely temperature
ranges as an aid for field decisions during the construction.
3-D Analyses
Figure 5 illustrates the 3-dimensional model, viewed
from downstream, that is used for the NISA study of the
Portugues Arch Dam. The bottom 6 lifts and a portion of
the foundation are modeled. The model includes the full
center block and half of the adjacent high blocks on either
side. Gap elements connect the corresponding nodes
across the contraction joints for the displacement normal
to the plane of the joint. Until the elements for the low
block are activated to simulate the placement of the lifts,
the normal displacement of the nodes of these future low
block elements are tied to the normal displacement of the
Figure 4. 2-D Analysis for Thermal Studies and to Define Boundary Conditions on 3-D Model
Figure 6. Illustration of Thermal Response for Summer and Winter Construction Start Analyses