International Commission on Large Dams (ICOLD) - The specification and quality control of concrete for dams
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ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
I C O L D
COMMITTEE ON CONCRETE DAMS
THE SPECIFICATION AND QUALITY CONTROL
OF
CONCRETE FOR DAMS
MARCH 2006
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
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force de Loi et ne doivent pas être considérées comme un substitut aux
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recommandations à chaque cas particulier.
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l'évolution des techniques et de la science, nous ne pouvons en garantir
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NOTICE – DISCLAIMER :
The information, analyses and conclusions in this document have no legal
force and must not be considered as substituting for legally-enforceable
official regulations. They are intended for the use of experienced professionals
who are alone equipped to judge their pertinence and applicability and to apply
accurately the recommendations to any particular case.
This document has been drafted with the greatest care but, in view of the pace
of change in science and technology, we cannot guarantee that it covers all
aspects of the topics discussed.
We decline all responsibility whatsoever for how the information herein is
interpreted and used and will accept no liability for any loss or damage arising
therefrom.
Do not read on unless you accept this disclaimer without reservation.
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
COMMITTEE ON CONCRETE DAMS
COMITÉ DES BARRAGES EN BÉTON
*
(1997-2006)
Chairman/Président
Canada/Canada/ USA/Etats-Unis R.G. Charlwood (since 1997)
Vice Chairman/Vice Président
France/France J. Launay (since 1997)
Members/Membres
Australia/Australie M. Pegg (to 1996)
B. Forbes (since 1997)
Austria/Autriche H. Ludescher (to 1995)
H. Huber (since 1996)
W Pichler (since 2001)
Brazil/Brésil F.R. Andriolo (1996-2001)
J. Marques Filho (since 2002)
Canada/Canada R. Charlwood (since 1995)
China/Chine Shen Chonggang (to 1998)
Jia Jinsheng (since 1999)
Croatia/Croatie V. Ukrainczyk
France/France J. Launay (to 1999)
M. Guerinet (since 2000)
Great Britain/Grande-Bretagne M.R.H. Dunstan
India/Inde B.J. Parmar
Iran/Iran M.E. Omran (to 1997)
A.A. Ramazanianpour (since 1998)
Italy/Italie M. Berra
Japan/Japon S. Nagataki (to 1997)
O. Arai (1998-2002)
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
T. Uesaka (since 2002)
Norway/Norvège O.J. Berthelsen
Portugal/Portugal A. Camelo
Russia/Russie A.D. Osipov (to 1999)
G. Kostyrya (since 2000)
South Africa/Afrique du Sud J. Kroon (to 2004)
J. Geringer (since 2005)
Spain/Espagne J.M. Gaztanaga (to 1998)
J. Buil Sanz (since 1999)
Sweden/Suède J. Alemo
Switzerland/Suisse H. Kreuzer (since 1999)
USA/Etats-Unis V. Zipparro (1998-2000)
R.G Charlwood (since 2001)
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
ACKNOWLEDGEMENTS
This Bulletin was drafted under the auspices of the ICOLD Committee for Concrete Dams and
the Chairmanship of R.G. Charlwood (Canada/USA).
The lead author of the Bulletin was O.J. Berthelsen (Norway). The first draft of the Bulletin in its
current form was assembled by O.J. Berthelsen utilising a previous draft by J.M. Gaztanaga
(Spain) in 2000. Contributions and reviews were provided by B. Forbes (Australia), H. Kreuzer
(Switzerland), B. J. Parmar (India), Malcolm Dunstan (United Kingdom) and J. Launay (France).
The case histories were provided by B. J. Parmar (India) for Sardar Sarovar, Bruce Bennett
and
James Stiady (United States) for Olivenhain Dam), and A. Camelo (Portugal) for Alqueva Dam.
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
FOREWORD
This Bulletin on the 'The Specification and Quality Control of Concrete for Dams' follows more
than two decades of advances in the construction of concrete dams. The purpose of this Bulletin
is to make available a summary of current practice in the specification and quality control of
concrete for dams. This Bulletin supersedes ICOLD Bulletin Nº47 'Quality Control of Concrete'
published in 1983.
In 1991, the International Commission on Large Dams (ICOLD) directed that its technical
Committee on Concrete for Dams, then under the Chairmanship of J.R. Graham (USA),
undertake the preparation of an update of the existing Bulletin. A sub-Committee of the ICOLD
Committee on Concrete for Dams, chaired by J. Gaztenaga (Spain), prepared a preliminary
version of a new Bulletin. In 1999 the Committee, then under the Chairmanship of R.G.
Charlwood (Canada) agreed to major revisions to the terms of reference proposed by O.J.
Berthelsen (Norway) who was appointed to lead the sub-Committee and proceeded to prepare a
new draft. The new draft was wider in scope and addressed the specification of concrete as well
as practices for quality control.
This Bulletin addresses all aspects of the relationship between the specification of concrete for
dams of all sizes, construction procedures, the properties of the hardened concrete and how
quality control is used. The development of concrete for dams from the conceptual stage to
finished product is described. It presents a holistic approach, recognizing the interrelatedness of
the design and construction process and the roles of both Designers and Constructors in the
production of functional, durable and economic concrete. Both method and performance
approaches to specifications are recognised as well as current options in contracting for
construction including conventional design, bid and construct as well as design-build approaches
(turnkey and EPC).
Case histories are presented for a gravity dam of conventional vibrated concrete (CVC), a roller
compacted concrete (RCC) dam, and a CVC arch dam. Appendices give tables of typical test
frequencies, a sample table of contents listing for a complete specification plus a listing of
specific requirements for control of thermal cracking are given as possible checklists.
This Bulletin presents the present “State of the Art” and does not intend to limit any further
developments.
Robin G. Charlwood
Chairman
Committee on Concrete Dams
March 2006
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
THE SPECIFICATION AND QUALITY CONTROL OF CONCRETE FOR DAMS
Table of contents
Section Page
1 Introduction ...........................................................................................................................1
1.1 Objectives ............................................................................................................................ 1
1.2 The Contents of the Bulletin ................................................................................................ 1
1.3 Quality Control and Quality Assurance.............................................................................. 2
1.4 Definitions ........................................................................................................................... 2
1.5 Related ICOLD Bulletins .................................................................................................... 2
2 The specification and quality control process.....................................................................3
2.1 The Content of Specifications.............................................................................................. 3
2.2 Purpose of Quality Control ................................................................................................. 4
2.3 Purpose of Quality Assurance............................................................................................. 4
2.4 Development of Specifications from Feasibility Stage to Construction.............................. 4
2.5 Approaches to Specification of Concrete ............................................................................ 6
2.6 Approaches to Quality Control, Division of Responsibilities ............................................. 8
2.7 Requirements for Effective Quality Control........................................................................ 9
3 Concrete constituents and concrete manufacture............................................................13
3.1 Material specification and control.................................................................................... 13
3.1.1 Introduction ...........................................................................................................13
3.1.2 Aggregate ..............................................................................................................13
3.1.3 Cementitious materials..........................................................................................16
3.1.4 Mineral Admixtures ..............................................................................................17
3.1.5 Chemical Admixtures............................................................................................18
3.1.6 Water and ice.........................................................................................................18
3.2 Trial mix programmes....................................................................................................... 19
3.3 Full scale trials.................................................................................................................. 20
3.4 Process specification and control ..................................................................................... 20
3.4.1 Stockpiles and silo storage ....................................................................................20
3.4.2 Quality of manufacturing facility..........................................................................21
3.4.3 Batching, charging and mixing, Process equipment .............................................21
3.4.4 Control of water content........................................................................................23
3.4.5 Fresh concrete properties and verification ............................................................23
4 Control of concrete transport and placement...................................................................24
4.1 Transport........................................................................................................................... 24
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
4.1.1 Specification..........................................................................................................24
4.1.2 Quality control.......................................................................................................24
4.2 Delivery and placement..................................................................................................... 24
4.2.1 Specification..........................................................................................................24
4.2.2 Inspection ..............................................................................................................25
4.2.3 Testing at time of placement .................................................................................25
5 Control of strength..............................................................................................................27
5.1 The basis for approving dam concrete.............................................................................. 27
5.2 Variations in strength and statistics.................................................................................. 27
5.3 Other approaches to evaluating acceptable variation...................................................... 29
5.4 Establishment of acceptable failure rate........................................................................... 30
5.5 Strength development over time ........................................................................................ 31
5.6 Dealing with under strength concrete............................................................................... 31
6 Control of cracking .............................................................................................................33
6.1 Introduction....................................................................................................................... 33
6.2 Design of crack control measures..................................................................................... 33
6.3 Specification ...................................................................................................................... 36
6.4 Principal quality control activities.................................................................................... 36
7 Concrete in contact with high velocity water flows..........................................................37
7.1 Specification of properties ................................................................................................ 37
7.1.1 Strength .................................................................................................................37
7.1.2 Properties of fresh concrete...................................................................................37
7.1.3 Surface finish.........................................................................................................37
7.1.4 Concrete for sediment-laden flows .......................................................................37
7.2 Specification of placement and finishing .......................................................................... 38
7.3 Quality control .................................................................................................................. 39
8 Case histories .......................................................................................................................40
8.1 SARDAR SAROVAR DAM ................................................................................................ 40
8.1.1 Introduction:..........................................................................................................40
8.1.2 Evaluation of Aggregates......................................................................................40
8.1.3 Cement and Pozzolan............................................................................................41
8.1.4 Concrete Properties: ..............................................................................................42
8.1.5 Concrete Production and Placement .....................................................................42
8.1.6 Quality Control System during Dam Construction:..............................................42
8.1.7 Concrete Mix design .............................................................................................43
8.1.8 Documentation ......................................................................................................44
8.1.9 Process Control .....................................................................................................44
8.1.10 Tests and Inspection:.............................................................................................47
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
8.1.11 Non Conformity Control and Statistical Techniques ............................................47
8.1.12 Test Equipment Control ........................................................................................47
8.1.13 Statistical Analysis of field compressive strength of concrete..............................47
8.1.14 References .............................................................................................................49
8.2 OLIVENHAIN ROLLER COMPACTED CONCRETE DAM............................................ 50
8.2.1 Introduction ...........................................................................................................50
8.2.2 Specification of concrete.......................................................................................50
8.2.3 Project delivery system .........................................................................................52
8.2.4 Quality control system ..........................................................................................52
8.2.5 Official reporting...................................................................................................56
8.2.6 Tracking of concrete strength................................................................................56
8.2.7 References .............................................................................................................56
8.3 ALQUEVA DAM ............................................................................................................... 58
8.3.1 Introduction ...........................................................................................................58
8.3.2 Aggregate evaluation.............................................................................................58
8.3.3 Mix design and specification of concrete.............................................................60
8.3.4 Concrete production ..............................................................................................61
8.3.5 Project delivery system .........................................................................................62
8.3.6 Quality Control System during dam construction.................................................63
8.3.7 Organization and responsibilities (communication) .............................................63
8.3.8 Quality Control planning.......................................................................................64
8.3.9 Process control (concrete production, placement and cure)..................................65
8.3.10 Tests and inspection ..............................................................................................65
8.3.11 Non conformity control.........................................................................................65
8.3.12 Test equipment control..........................................................................................68
8.3.13 Quality control reports and statistical analyses.....................................................68
8.3.14 Activity reports......................................................................................................68
9 References ............................................................................................................................69
FIGURES
F
IGURE
1
T
YPICAL
QC
SYSTEM FOR A CONVENTIONAL CONSTRUCTION CONTRACT
............................................... 9
F
IGURE
2
T
YPICAL
QC
SYSTEM FOR AN
EPC
CONSTRUCTION CONTRACT
............................................................. 10
F
IGURE
3
Q
UALITY CONTROL OF AGGREGATE PRODUCTION
................................................................................. 14
F
IGURE
4
S
CHEMATIC DIAGRAM OF QUALITY CONTROL OF CEMENT
..................................................................... 17
F
IGURE
5
I
NFLUENCE OF QUALITY CONTROL ON REQUIRED MEAN STRENGTH
....................................................... 28
F
IGURE
6
Q
UALITY CONTROL CHART FOR THE INTERIOR CONCRETE OF AN ARCH
-
GRAVITY DAM WITH RATHER
POOR STANDARD OF CONTROL
............................................................................................................... 30
TABLES
T
ABLE
1
T
YPICAL TESTS FOR AGGREGATE
.............................................................................................................. 14
T
ABLE
2
T
YPICAL QUALITY CONTROL ACTIVITIES AT CONCRETE BATCHING STATIONS
........................................... 22
T
ABLE
3
T
YPICAL QUALITY CONTROL ACTIVITIES AT THE CONCRETE MIXING PLANT
............................................. 22
T
ABLE
4
S
TANDARDS FOR
C
ONCRETE
C
ONTROL
(ACI
214) ...................................................................................29
T
ABLE
5
M
AXIMUM ALLOWABLE TEMPERATURE DROPS AS A FUNCTION OF BLOCK SIZE AND LOCATION IN DAM
... 34
ICOLD Bulletin **: The Specification and Quality Control of Concrete for Dams
Revision 7.2 March 15, 2006
APPENDICES
APPENDIX
1 TABLES
OF
TYPICAL
TEST
FREQUENCIES
T
ABLE
A1-1 TYPICAL
QUALITY
CONTGROL
TESTS
T
ABLE
A1-2 T
YPICAL TEST FREQUENCIES FOR
M
EDIUM SIZE
RCC
DAM
T
ABLE
A1-3 T
YPICAL TESTING STANDARDS FOR A LARGE
RCC
DAM
T
ABLE
A1-4 T
YPICAL TEST FREQUENCIES FOR
L
ARGE
RCC
DAM
T
ABLE
A1-5 T
ESTING STANDARDS AND FREQUENCIES FOR A CONVENTIONAL MASS CONCRETE
DAM
APPENDIX
2
EXAMPLE
OF
OUTLINE
SPECIFICATION
FOR
CONCRETE
WORK
APPENDIX
3 REDUCTION
OF
RISK
OF
THERMAL
CRACKING:
ITEMS
WHICH
MAY
BE
SPECIFIED
APPENDIX
4 REDUCTION
OF
RISK
OF
THERMAL
CRACKING:
PRINCIPAL
QUALITY
CONTROL
ACTIVITIES