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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
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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.
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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)
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Main Dam
Portugués Dam Design Features
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Dam Sections
Portugués Dam Design Features
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Outlet Works
Portugués Dam Design Features
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Outlet Works
Portugués Dam Design Features
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Dam Gallery
Portugués Dam Design Features
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Quarry Excavation
Approx. 567,170 cy excavated
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Aggregate Production and Stockpiling
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Foundation Excavations
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
RCC Production
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
RCC Mix DesignDiversion and Care of Water System
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
RCC Mix DesignDiversion and Care of Water System
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Diversion and Care of Water
Delay-causing Over-toppings:
Sep 30, 2010Oct 4, 2010Oct 5, 2010Oct 6-10, 2010Oct 17, 2010
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Diversion and Care of Water
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Foundation Preparation Work
AS- 11/12 : Foundation Excavation Cleanup
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Drilling and Consolidation Grouting
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
RCC Conveying, Spreading, Compaction, Joint Installation
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Gallery
Gallery Formwork
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Construction Activities
Dam RCC Work Topped Out
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Gallery
Gallery Finish
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Foundation Preparation Work
Grouting Setup & Grout Curtain Drill
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
Portugués Dam Instrumentation
Stress / Strain Meters & Joint Meters
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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.
BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District
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