Underwater Concrete Technologies in Marine Construction Projects_Sam X. Yao

5/27/2018 Underwater Concrete Technologies in Marine Construction Projects_Sam X. Yao

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Underwater Concrete Technologiesin Marine Construction Projects

Sam X. Yao

Ben C. Gerwick, Inc.


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oncrete Production from a Floating Batch Pla


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Conventional Tremie Placement


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Concrete Delivery on Transit Mixers


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Placing Concrete from a Delivery Barge


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Tremie Placement with Suspended Pipes


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Underwater Concrete Construction Technologies

Concrete Mix Proportions

Workability and Rheology

Underwater Concrete Constructio

Concrete Production/Transportati

Concrete Placement Planning

Concrete Placement Procedures

Inspection and Quality Control

Mass Tremie Concrete Properties

Thermal Behavior

Laitance, Bleeding, Segregation

Form Pressure

Strength Development

Finish and Protection


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erformance Requirements for Underwate

Concrete in Structural Applications Flowability and Self-Compaction

Workability Retention within Work Window Cohesion Against Washout, Segregation, and

Laitance Formation Low Bleeding

Low Heat of Hydration

Controlled Set Time

Compressive Strength

Adequate Bond


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Washout Test and Slump Test


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Slump vs. Slump Flow


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Mock-up Tremie Concrete Test


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Mock-up Tremie Concrete Test


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Principal Parameters in Mix Design

Particle Packing Characteristics - SandContent, Gradation, Size, and Shape

The water-to-fine ratio - Enough Fine to Make ItFlowable and Cohesive (0.85-1.0 by volume)

Cementittious Material Content High VolumeFly Ash plus Silica Fume

Dispersion characteristics - Proper Use ofChemical Admixtures HRWR and Set-retarder


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Tremie Concrete Placement Planning An Overview

Concrete Production & Delivery:

Method & Rate

llowable Flow Distance

acement Area Configuration

llowable Work Window

Concrete Placement Sequence

Tremie Pipe Layout

Tremie Placement Rate

& Procedure

Form Pressure

Concrete Flow Pattern

Form Design

Slope, Vent, Laitance Collector

Quality of In-Situ ConcretStrength

Uniformity

Bond

Quality control plan:

Testing, sounding, inspection

ISK FACTORS

rodcution & Delivery

ogistics

oss of Flowability

ashout - Laitanceegregation, Bleeding

rapping of Water

xcessive Disturbance

rosionConcrete Protection


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Initiation of Tremie Placement

Initiation of Placement usingthe Dry Pipe Method with aEnd Plate as the Seal


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Hydrostatic Balance PointcRwc

W

FDWh ++ **

H = (Wch+WwD+FR) / Wc


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Flow Patterns of Tremie Copncrete

Layered Flow -

Excessive Laitance

Bulging Flow -

Minimum Laitance


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Tremie Pipe Spacing

3-5 Times Depthof Tremie Pours


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Placement Sequence

Simultaneous Placement Method Advanced Slope Method


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Removal of Laitance Underwater


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Lower Monumental Dam


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Hydraulic Flow Pattern in Stilling Basin


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Pomona Dam Stilling BasinHydraulic Model Study


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Kinzua Stilling Basin

18 monthsafter repair


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Erosion Damage


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Erosion Damage Repair


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Erosion Repair within a Cofferdam


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Undrewater Repair of a Dam


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Tremie Concrete over Rock Anchor


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Coarse Aggregates

pecific Gravity: 2.85

bsorption: 1.1%

aximum Nominalize: 3/4-inch

ppearance: Cleannd round-shapedith smooth surface

xture


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Fine Aggregates

Specific Gravity: 2.72

Fineness Modulus: 2.9Absorption: 3.0%

Natural River Sand


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Gradations of Aggregates

Grading Curve

0

10

20

30

40

50

60

70

80

90

100

1-1/2"1"3/4"1/2"3/8"#4#8#16#30#50#100#200

Sieve Number

P

ercenta

ge

P

assing

Sand

Gravel

CombinedSand and

Gravel

Volume Ratio ofFine Aggregatesto TotalAggregates: 47%

Volume Ratio ofCoarseAggregates to

Total Solids: 42%


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igh Volume Fly Ash Concrete for Underwater Rep

Reducting the heat ofhydration in mass

concrete Increasing concrete

flowability without

compromising cohesion Facilitating concrete

flowability retention and

extended set time


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Mix Proportions

Mix No. 1 Mix No. 2 Mix No. 3(52% F.A) (25% F.A) (control)

ement Type II, lb./cy 390 580 740

ly Ash, lb./cy 350 160 0icro Silica, lb./cy 40 40 40

oarse Agg, lb./cy 1.625 1,659 1,688

ine Agg, lb./cy 1,367 1,396 1,420

ater, lb./cy 301.8 302.5 303.3

heomac UW, oz/cwt 85.8 85.8 85.8

elvo, oz/cwt 117 117 117

lenium, oz/cy 102.6 156 189


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Compressive Strength Development

0.0

2000.0

4000.0

6000.0

8000.0

10000.0

12000.0

0 10 20 30 40 50 60 70 80 90

Age (days)

Av

era

e

Com

re

ssive

Stren

th

si

Mix 3

Mix 1

Mix 2


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Workability Test

itial Concrete Slump10 to 10-3/4

itial Slump Flow21 to 26

inimum Requirementr Achieving 1:10lope on Top Surfacef the Concrete Pours10 Slump and 20lump Flow


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Workability Retention Test

lump after 60 minutes10 to 10-3/4

lump flow after 60 min.21 to 26

nticipated work

indow for a truck ofoncrete45 minutes


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Set Time Test

Mix No. 1Set Time > 12 hour

Mix No. 2 and No. 3Set Time = 7 hour

Anticipated Concrete

Placement Duration:12 hours


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remie Concrete Placement at the Dam Si


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Tremie Concrete Placement Sequence


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Tremie Concrete Slump


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Tremie Concrete Placement


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Concrete Cores


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Conventional Dam Construction


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Cofferdam Failure


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Conventional Lock Construction


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Cofferdam Overtopping


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Cleanup After the Flood


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Braddock Dam

B dd k D Ill t ti


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Towing and

Positioning

In Dam .ppt

Braddock Dam - Illustration

Braddock


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Grouting

-In Dam .ppt

Braddock

Braddock Dam Stage 5


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Concrete Infill

-In Dam .ppt

Braddock Dam Stage 5

27.5 River Miles from Fabrication Site to Outfitting Pier


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Mile 11.2

MonongahelaRiver

OhioR

iver

Alleg

henyRiv

er

N3 Miles

Braddock L/D

Mile 12.8

Duquesne RIDC(Outfitting Pier)

Leetsdale(Fabrication Site)

Mile 14.7

Mile 0.0

PittsburghPittsburgh

Mile 6.2

Emsworth L/D

Mile 13.3

ashields L/D

I th W t F d ti P ti


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In-the-Wet Foundation Preparation


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Underwater Foundations

FLOW

PILE DRIVINGBARGE

SCREEDBARGE

Concurrent Operations Dredge/Backfill

Place Base Stone

Screed Stone Install Piers


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Launch

Basin

Segment 1

Segment 2

Fabrication Site

B dd k D


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Braddock Dam

T Sl b F b i ti


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Top Slab Fabrication


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Segment 1 in Launch Basin

Transport of Dam Segment 1


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Transport of Dam Segment 1


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Towing and Setting a Float-in Dam

Braddock Dam


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Braddock Dam

Braddock Dam


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Braddock Dam

Savings:1 Year5 Million

Construction Complete


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Construction Complete

Florida Keys


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Florida Keys

Coral Reef in Florida Keys


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Coral Reef in Florida Keys

One of the Ground Sites


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One of the Ground Sites

Damaged Coral Reef


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Damaged Coral Reef

Repair Design


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Repair Design

Precast Repair Module


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Precast Repair Module

Repair of Corral Reef in Florida Keys


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Repair of Corral Reef in Florida Keys

Setting a Precast Module


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Setting a Precast Module

Floating Batch Plants


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Floating Batch Plants

Adding Nitrogen Cooling Agent


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Adding Nitrogen Cooling Agent

Repair of Coral Reef in Florida Keys


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Repair of Coral Reef in Florida Keys

Pumping Concrete Underwater

Placing Underwater Concrete


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Placing Underwater Concrete

Placing Concrete in Large Holes of Corral


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Placing Concrete in Large Holes of Corral

Finishing Underwater Concrete


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Finishing Underwater Concrete

Project Location


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Project Location

Coachella Canal Engineering Data


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Coachella Canal Engineering Data

Construction period 1938-1948

Length 123 mi

Diversion capacity 2,500 cfs Typical section, earth lined:

Bottom width 40-60 ft

Side slopes 2:1

Water depth 10.3 ft Lining, clay-blanket 12 in

Typical section, concrete lined:

Bottom width 12 ft

Side slopes 1.5 :1

Water depth 10.8 ft

Lining thickness 3.5 in

Salton Sea/Coachella Canal


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Salton Sea/Coachella Canal

The Coachella Canal.

One of numerous geothermal plantson the eastern side of the Salton Sea.

Bombay Beach at Salton Sea.

Coachella Canal Bathers.

Installation of Liner and Concrete Overla


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Installation of Liner and Concrete Overla

Kiewit received a $5.2Million Contract to

Install 1.5 miles testsection at CoachellaCanal.

Paving half of a sectionat a time

Average Speed: 4-ft per

minute

Canal Lining Design


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Canal Lining Design

Trial Testing


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Trial Testing

Liner: 30 mil thick PVCgeomembrane backedwith a nonwovengeotextile

Nonwoven fabricprevent slippage ofconcrete duringplacement andstrengthen the liner

Vibrator on slip form toconsolidate andmaintain concrete flow

Completion of the Lining Construction


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Completion of the Lining Construction

Underwater Concrete Technologies in Marine Construction Projects_Sam X. Yao

Documents

concrete delivery

tremie concrete placement

washout test

fine ratio

work window cohesion

principal parameters

laitance collectorquality

erformance requirements