CENTRAL WATER & POWER RESEARCH STATION INDUCTION TRAINING PROGRAM

For
New Appointees of Central Water
Engineering Services
30 th
DECEMBER 2016
NWA, PUNE
FACILITIES IN CONCRETE TECHNOLOGY DIVISION
TOWARDS REHABILITATION OF HYDRAULIC
STRUCTURES
CENTRAL WATER & POWER RESEARCH STATION

TYPES OF STUDIES

1.0 LABORATORY STUDIES

I. Assessment of strength parameters of Concrete Hydraulic
Structures through extracted core testing.
II. Evaluation of thermal properties of mass concrete during
construction and strengthening of gravity dams.
III. Suitability Tests on different materials for repair and
rehabilitation of hydraulic structures.
2.0 DESK STUDIES
IV. Estimation of suitable placement temperature, Thermal analysis
and cooling history of dam using mathematical modelling.
3.0 FIELD STUDIES
V. Conducting in-situ tests for assessing effectiveness of repair and
rehabilitation.
VI. Guidance during repair/rehabilitation/strengthening of
hydraulic structures after detailed inspection.
CENTRAL WATER & POWER RESEARCH STATION

MAJOR CAPABILITIES

1.REHABILITATION OF HYDRAULIC STRUCTURES

Hydraulic structures (dam/aqueduct/bridges/power

plants etc.) are built at very high cost and expected to last
for many years. But deterioration render it unfit for its
intended safe use.

Timely action of repairs / restoration for mitigating

distress is necessary to enhance their functionality,
serviceability and life span.
CENTRAL WATER & POWER RESEARCH STATION

MAJOR CAPABILITIES

1.REHABILITATION OF HYDRAULIC STRUCTURES

 Delay / negligence in this respect further deteriorate

structure which may lead to costly strengthening
measures at a later stage or sometimes even may lead
to a disaster.
Hence,
 Rehabilitation has become a specialized field (systematic
approach & solution,
Maintain balance between technology, management and
economy).
CENTRAL WATER & POWER RESEARCH STATION

MAJOR CAPABILITIES

1.REHABILITATION OF HYDRAULIC
STRUCTURES

Concrete division is engaged in conducting studies on

various repair materials by evaluating their properties to
assess their suitability & Suitable repair methodology for the
rehabilitation of the distressed hydraulic structures.

Important studies (Projects)

Starting with grouting of epoxy systems for Koyna dam
(that had developed cracks because of severe earthquake),
CWPRS is dealing with studies relating to
restoration/strengthening/repairs to the damaged hydraulic
structures.
CENTRAL WATER & POWER RESEARCH STATION

REHABILITATION OF HYDRAULIC STRUCTURES

The prominent studies/works, where CWPRS was

associated in are:
•Koyna dam, Hirakud Dam,
•Gannavaram Aqueduct, Tillari Aqueducts,
•Salauli dam, Anjunem dam,
•Jawahar Sagar dam, Upper Indravati project ,
•Chilla Power house, Chiplima Power house,
• Moorum Silli Dam,
• Nathpa Jhakiri H E Project, etc.
CENTRAL WATER & POWER RESEARCH STATION

Temperature control studies on

Mass/Roller Compacted Concrete Dam

•The volumetric change is principally restrained

at the foundations, at abutments and also in the
interior of the concrete mass.
• This restraint sometimes lead to cracking of the
mass, when it exceeds strain capacity of concrete
or in other words when the tensile stresses
developed in the concrete exceed the tensile
strength of concrete.
CENTRAL WATER & POWER RESEARCH STATION

Temperature control studies on

Mass/Roller Compacted Concrete Dam

•Distress in concrete are - cracking, spalling,

honeycombing etc.
•Concrete dams undergo volumetric changes
with time after the placement due to rise in the
temperature on account of heat of hydration of
cement.
• After hardening, the concrete gradually cools
due to the atmospheric temperature variation and
under goes volumetric changes.
CENTRAL WATER & POWER RESEARCH STATION

Temperature control studies on

Mass/Roller Compacted Concrete Dam

•Thus occurrence of thermal cracks is a very common

phenomenon causing distress of the structures,

•If suitable temperature control measures are not

adopted during construction of massive structures like
dams.

•Cracks during construction are primarily a result of

thermal effects and the cracks occurring during service
period result from overloads imposed on the structure by
water or earthquake or by temperature variations on the
 Thermal strain in Concrete Dams
CENTRAL WATER & POWER RESEARCH STATION

Relation between the thermal strain and

temperature.
e =  R [ Tp + ( TO – TL ) - Ts ]

= Rt
Where,
 e = thermal (tensile) strain
  = coefficient of thermal expansion
 R = restraint factor
 Tp = placement temperature of concrete
 TO = Adiabatic temperature rise
 TL = temperature loss from lift surface
 Ts = final stable temperature of concrete
(mean annual air temperature)
  t = temperature gradient
CENTRAL WATER & POWER RESEARCH STATION

Temperature control studies on

Mass/Roller Compacted Concrete Dam

Temperature control measures like pre-cooling and post-

cooling of mass concrete with pre selected placement
temperature are adopted which depends upon evaluation
and control of several variables such as
• Temperature rise
• Placement temperature
• Strength and elastic properties of the mix
• Site climatological parameters
• Construction schedule
CENTRAL WATER & POWER RESEARCH STATION

Temperature control studies on

Mass/Roller Compacted Concrete Dam

Concrete division is engaged in determining the thermal,

strength and elastic properties on mass/ rcc mixes and
these properties are then used as input to the in-house
developed computer program for estimating suitable
placement temperature and to develop cooling history of
the dam for a given construction program viz: lift height &
lift interval.
Prominent projects are:-
Sardar Sarovar Dam, Indira Sagar Dam, Omkareshwar
dam, Ghatghar Pumped Storage Scheme, Mass
Concrete barrages across river Godavari, Koyna Dam,
Bham dam, Nilwande dam, Mulla Periyar Dam.
 WORKS UNDERTAKEN
CENTRAL WATER & POWER RESEARCH STATION

Testing of construction materials

Design of Mass Concrete Mixes
Thermal & Creep properties of Mass Concrete
Estimation of lift height, lift interval and placement
temperature of concrete for mass concrete dams
Pre-cooling requirements of concrete ingredients
(Aggregates and water) and ice requirement
Studies on Roller Compacted Concrete mixes
Evaluation of the suitability of repair systems for
rehabilitation of distressed concrete structures and
providing the Technical knowhow/guidance during the
actual application at site.
CENTRAL WATER & POWER RESEARCH STATION
FACILITIES AVAILABLE
Temperature and humidity controlled chamber
 Adiabatic Calorimeter
 Thermal diffusivity test set up
 Thermal expansion test set up
 Triaxial testing machine
 Viscometer.
 Universal Testing Machines.
 Portable High Capacity Core Extracting machine
LUSAS Finite Element Software for Thermal Analysis
 Objectives of Thermal Analysis
CENTRAL WATER & POWER RESEARCH STATION

 Estimation of placement
temperature
 Estimation of final stable Temperature Gradient
temperature
 Pre-cooling requirements of
concrete ingredients (Aggregates
and water) and ice requirement
 Cooling history of dam – to predict
temperature distribution with time
CENTRAL WATER & POWER RESEARCH STATION Thermal Properties

Adiabatic Temperature Rise : 26

Determined by measuring temperature

24 @ ( 8 8 _ 1 3 2 r e v m ix )
22
@
7 0 _ 1 5 0 r e v m ix

of fresh concrete under adiabatic

20
*
G H 3 m ix

T e m p e r a t u r e Cr is e
18

16 # ( 8 8 _ 1 3 2 o r g m ix )

0
condition 14

12
*
G H 2 m ix
10 *
G H 1 m ix
8

0
0 10 20 30 40 50 60 70
T im e in d a y s

1.2

1 1
0.9 0.9

PART OF THE ORIGINAL TEMPERATURE REMAINING

1.0 0.8 0.8
0.7 0.7
0.6 0.6

PART OF ORIGINAL TEMPERATURE DIFFERENCE

0.5 0.5
0.4 0.4
0.8
0.3 0.3

REMAINING  /
0.2 0.2
0.6

0.1 0.1
0.4 0.09 0.09
0.08 0.08
0.07 0.07
0.06 0.06
0.05 0.05
0.2
0.04 0.04

0.03 0.03

0.0
0.02 0.02
0 10 20 30 40 50 60
0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.2
TIMEINMINUTES 2 2
VALUEOFh t/D
NONLINEARCUVEFITTINGOFDATAOBTAINEDFROMDIFFUSIVITY STANDARDPLOTOFTEMPERATURECHANGEATCENTREOFCYLINDER)

Thermal Diffusivity : Determined by

conducting cooling test on 203 mm x 406 mm
concrete cylinder

Thermal Expansion : Determined by conducting test on 150mm x 300

mm concrete cylinder
 Creep of Concrete
CENTRAL WATER & POWER RESEARCH STATION

• Creep is time dependant deformation under

sustained load
• Mechanical dial gauges or resistance / vibrating
wire strain gauges are used for measuring
deformation .
• The specific creep and creep coefficient
determined from studies are used for:
 Estimating Tensile strain capacity of
concrete
 Thermal analysis of dams
Fully automatic - Control of temperature (10 0 to 600C)
and Humidity (40 to 95 %) – runs for 180 days
continuously

CREEP SET UP
CENTRAL WATER & POWER RESEARCH STATION KOYNA DAM

STUDIES ENTRUSTED
Determination of thermal properties
of strengthening, closure concrete,
recommending suitable placement
temperature & pre/post cooling
requirements for given construction
schedule.

MERITS OF THE STUDY

Studies indicated that by adopting
pre and post cooling measures,
strengthening concrete with lift
height of 2.3 m. and lift interval of
48 hours can fairly attain stable
temperature within a 24-25 days.
 GHATGHAR PROJECT
CENTRAL WATER & POWER RESEARCH STATION

STUDIES ENTRUSTED
Determination of thermal properties of RCC
mixes and recommending a suitable placement
temperature.
Roller Compacted Concrete (RCC)
methodology of construction
Use of fly ash,(a by product of Thermal
Power Plant) from 50% to 70% by weight
of cement which reduces the temperature
rise.
Small lift heights (30cm) & short lift
intervals (16 to 24 hours)- Speedy
construction.
Adopted first time in India for the
DISTRESSES, REMEDIAL MEASURES AND REPAIR MATERIALS
FOR GRAVITY DAMS

SYMPTOMS OF DISTRESS
 Cracking
 Spalling
 Concrete disintegration
 Seepage

Repair procedures Cracks & Seepage

depends upon crack
location, extent, cause of CAUSES OF DISTRESS
cracking, their current or  Absorption of water
future structural problems  Temperature effects
to accomplish one or  Leaching
 Uplift pressures
more objectives like:
 Construction defects
 Restore and increase  Earthquakes/floods
strength  Cracking
 Improve functional  Shrinkage Leaching

performance  Thermal effect

 Provide water-tightness  Excessive loading
 Improve appearance of  Foundation movements
the concrete surface  Chemical reaction etc.
 Improve durability
DISTRESSES, REMEDIAL MEASURES AND REPAIR MATERIALS
FOR GRAVITY DAMS

REMEDIAL MEASURES
For Masonry Dam-
 Grouting Grouting
 Pointing REPAIR MATERIALS
 Gunitting  Grouts- (Cementitious, Non Shrink,
 Cable Anchoring Inorganic/organic)
 Concrete membrane
 Bonding/coating agents
 Use of Geo-membrane
 Steel Jacketing  Modified concrete/mortar
For Concrete dam-  Protective coatings
Pointing
 Resurfacing  Fibre reinforced/polymer impregnated
 Sealing/plugging/ concrete/mortar
grouting of cracks
 Coating

LABORATORY TESTS CONDUCTED

 Grout Systems - Mix viscosity and pot life, Penetrability, Bond strength
with concrete/rock/steel
 Sealing Systems - Usable time, Pressure bearing capacity.
 Mortar and concrete - Design of suitable mix, Density, strength and
elastic properties, bond strength, split tension, flexural strength,
punching shear and Abrasion resistance.
 Cement Grouting- Flow ability test by Marsh Cone, Settlement test,
compressive strength, gelification and pH value.
 IDENTIFICATION OF DIFFERENT REPAIR MATERIAL
LABORATORY TESTS FOR GROUT SYSTEMS

Mix Viscosity & Pot Life Penetrability

 Brookfield Viscometer Extent of travel of the grout made
 Flow cup by conducting penetrability tests

Penetrability
Bond Strength Under Tension
.

Brookfield
Viscometer Flow Cup

Tensile strength
Dumbbell shaped specimen or
briquettes shaped specimen for this
test.
Test Specimen, Bond Strength Under Tension,
Under water grouting and Failed specimen
Double Shear Test
Tensile Strength on
Briquette

Slant Cone Test

Shear Strength
Slant Cone Test
 IDENTIFICATION OF DIFFERENT REPAIR MATERIAL
LABORATORY TESTS FOR EPOXY MORTAR/CONCRETE
Modulus of elasticity
Conducted on cylinders specimen
Abrasion Resistance on prism

Set up for ‘E’ Value

Bond strength with steel under

Dory’s Abrasion testing machine tension and shear
LABORATORY TESTS ON SEALING SYSTEMS TESTS ON ELASTROMERIC SEALANTS

Pressure bearing capacity

Water under pressure is injected in the gap through the hole
provided in one of the cubes. Water pressure is then
gradually increased till the failure of the seal is observed

Bond strength and elongation

Bulging and puncturing of elastomer

CENTRAL WATER & POWER RESEARCH STATION LABORATORY TESTS ON REPAIR MORTARS

Flowability/Workability Test

Enlarged view of sample

Compressive Strength Test Setup for Cube Specimen

CENTRAL WATER & POWER RESEARCH STATION LABORATORY TESTS ON REPAIR MORTARS

Enlarged view of
sample
Enlarged view of
sample
Tensile strength Test Setup for Briquette Test setup for Young’s Modulus of Elasticity
Specimen

Preparation of Specimen for

Direct Punching Shear test
Specimen for Direct Punching
Shear test in UTM
CENTRAL WATER & POWER RESEARCH STATION LABORATORY TESTS ON REPAIR MORTARS

Test setup for Flexural strength of the composite beam specimen setup

Composite cylindrical specimen for

loading under split tension

Split tensile test specimens

CENTRAL WATER & POWER RESEARCH STATION LABORATORY & FIELD TESTS ON REPAIR MORTARS

PORTABLE PULL OUT

ADHESION TESTER

Composite specimen with rock for adhesion/pull out test

Composite specimen with concrete for adhesion/pull out

CENTRAL WATER & POWER RESEARCH STATION LABORATORY TESTS ON REPAIR MORTARS

Extraction of cores from repaired portion

Test setup for assessing imperviousness of repaired concrete

samples

Field application tests on repair mortars

 LABORATORY & FIELD TESTS ON CEMENTITOUS GROUTS
CENTRAL WATER & POWER RESEARCH STATION

Marsh Cone Apparatus

Settlement test for grout system

Grouting of trial blocks.

 LABORATORY & FIELD TESTS ON CEMENTITOUS GROUTS
CENTRAL WATER & POWER RESEARCH STATION

NDT Tests being carried out on masonry blocks.

Extraction of cores
from grouted blocks

Water loss tests being carried out.

REHABILITATION OF HIRAKUD DAM – UNDER WATER EPOXY GROUTING
Location - Burla, Orissa.
River - Mahanadi river.
Length - 4800 m for main dam with two spillways of 402 m &
256 m.
Capacity - 8136 M.Cum.
Purpose - Irrigation, Hydro Power & Flood
Dam type - Composite
Construction - 1957 - 1958.

DAMAGES- Cracking, spalling, popout, honey combing,

rough concrete, embedded non-metallic and metallic
objects were identified on the upstream face of the
spillways.
MAIN CAUSES OF CRACKING - Thermal cracks were
developed in the initial stages because of rapid rate of
concrete placement. Seepage through these cracks,
causing ingress of moisture, caused Alkali Silica Reaction
(ASR) which led to manifestation of distress. Gate surface after application of
epoxy mortar
REPAIR MATERIAL - The cracks were grouted with suitable
underwater epoxy systems. Honeycombed areas and Popouts
were patched using epoxy mortar. Damaged Sluice Gates &
Sluice Barrels were resurfaced using epoxy mortar. Epoxy
systems/mortar were selected on the basis of pre-application
tests conducted in CWPRS. The tests involved determination of
mix viscosity, pot life and bond strength with the
substrate under direct tension, shear and flexure simulating
site conditions.
MERITS OF REPAIRS - The structural integrity of the dam was Extracted cores
restored because of epoxy treatment. Cores taken from the
treated area when tested under compression, indicated a
failure away from the bonded plane.
CENTRAL WATER & POWER RESEARCH STATION UPPER INDRAVATI PROJECT
Location - Kalahandi, Orissa.
River - Indravati
urpose - Irrigation & Power
Head - 300m
Power Generation- 150x4 =600MW

DAMAGES: DUE TO FAILURE OF COFFER

DAM AT INTAKE DURING FLOOD IN 1991,
WATER ALONGWITH DISLODGED DEBRIS
ALONG THE PENSTOCK ROUTE ENTERED
FOOT POWER HOUSE.
THE DEBRIS LANDED ON THE AUXILIARY
FLOOR AREA CAUSED EXTENSIVE
CRACKING IN ALL THE 16 BEAMS.
DUE TO CRACKS, CONSTRUCTION WORK
OF POWER HOUSE STOPPED.
ASSESSESMENT OF STRENGTH OF BEAMS
BECAME NECESSARY.
CENTRAL WATER & POWER RESEARCH STATION UPPER INDRAVATI PROJECT
STUDIES CONDUCTED:
 Non Destructive Tests were Conducted on
damaged beams.
 Structural integrity of damaged beams assessed
by full scale load test.

REMEDIAL MEASURES & MERITS OF

REPAIR

 Structural integrity ensured after load test.

 Surface cracks in the beams were grouted
by suitable epoxy system
 Cavities and damaged areas of beams
columns were resurfaced with epoxy mortar.
 Costly alternatives such as external
strengthening of the structure and
reconstruction of the damaged part
of the powerhouse could therefore be
avoided resulting in saving millions of
rupees.
CENTRAL WATER & POWER RESEARCH STATION
MAJOR STUDIES UNDERTAKEN

Assessment & rehabilitation by suitable repair materials:

Hirakud Dam, Gannavaram Aqueduct, Chilla,Chiplima and
Upper Indravati Power house, Jawahar Sagar dam, Moorum
Silli Dam, Salauli dam, Anjunem dam, Koyna Dam, Nathpa
Jhakiri and Ghatghar Hydro Electric Project, Varasgaon
Dam etc.

Thermal analysis of mass concrete & roller compacted

concrete (RCC) dams:
Sardar Sarovar, Indira Sagar, Omkareshwar, Koyna Dam
Strengthening, Ghatghar (RCC) Dams, Barrages on
Godavari river, Gunjawani Dam, Nilwande Dam, Bham
Dam, Fly Ash concrete -Fly Ash Mission programme etc.
CENTRAL WATER & POWER RESEARCH STATION

COMMENTS:
Repair of gravity dams is a cumbersome task and
also uneconomical
Hence all care shall be taken during construction
Identification of repair materials is important
and mandatory and is necessarily to be done by
conducting laboratory tests on different repair
materials
 Diagnosis of causes before undertaking the
repairs is very much essential. Techniques such as
Geophysical investigations, Tracer techniques,
Nuclear logging, NDT tests shall be conducted
before using any repair method.
CENTRAL WATER & POWER RESEARCH STATION