Execution Method for Spillway Hydraulic Surfaces: HKO Main Dam’s Spillway
Abstract—HKO Main Dam, the Flip-Buckets Concrete Dam for Houay Ka-ouane Hydropower Project. The
Spillway include 3 block, B4 from KN3-KN4, B5 from KN4-KN5 and B6 from KN5-KN6; 69.60m wide Spillway
structure is 25m long include Piano key weir, ogee and flip bucket, installed on ogee structure. 45,000
m3 concrete is demanded to fulfill project, include 2684.55m3 is required for hydraulic surfaces. Numbers
of methods to accomplish various hydraulic surfaces are including screed pipe and manual trowelling,
moving bar, and slip-form application. Facing technical as well as executive obstacles have brought out of
several worthwhile conclusions. For instance, face has to be controlled in near edge for adjacent concrete
before screed or mold installation. Conformity to proper executive sequences such as preparation, tool
box installation, locating installation place for CJ molds, and then reinforcement has to be considered.
Fulfilled surfaces have to be protected of either impact or any pollutants. Errors have to identify through
comparison of surveys for performed surfaces with that of templates before placement, and then should
be corrected in conjunction with adjacent blocks or next lifts. And to impede bolt displacement or shear
occurrence, first hydraulic lift has to be casted using molds with no consoles.
Index Terms—Ogee and chute slabs, screed pipe and bar, slip-form, trowel operation.
I. INTRODUCTION
Methods to accomplish hydraulic surfaces had already been known and used for several years at
engineering society. However unique structural design and technical attributes for each specified
structure make it necessary to devise appropriate plans and the most proper methods to make
construction more accurate and efficient. HKO spillway is consisted of PKW, ogee, upper face, down face,
flip bucket, drain galleries,core, left wall, right wall (see Fig. 1).
Screed pipe and screed bar usage, trowel job, moving bar, unusual metal template employment, and slip-
form application have been opted methods to execute hydraulic surfaces of different slopes.
Some unforeseen problems were emerged during construction procedure and appropriate proposals,
made favorable reforms in practice.
Proposed reforms were implemented at initial executive sketch and finalized instructions were concluded,
and then were put into practice.
Fig. 1. General view of spillway structures, located on riverbed
A. Spillway Facades
Except for facades provided by formwork, other faces had to smoothly be prepared by skillful persons.
These facades are including;
1) Mallet bar Trowel facade (finishing type U1) Facades which will be permanently buried such as backfill
slabs for left blocks of approach channel which had been leveled and finished using bar trowel. This trowel
is also applied before wood or metal trowel to make surface even in its assigned slop.
2) Slate Trowel facade (finishing type U2) In temporarily buried surfaces like entrance slabs for approach
channel or wall top lifts, backfill slabs of left and right walls in upstream, middle, and parts of downstream
chutes is applied. In which pre-leveled, mallet bar trowel produced surfaces become smoother and deficits
were corrected when concrete has become sufficiently consistent. Slate trowel finishing was continued
until required cement sap was emerged on concrete surface to make finishing job of subsequent metal
trowel efficient, if it was necessary.
3) Metal Trowel facade (finishing type U3) Ogee, upstream chute, and aerator shaft apron are structures
in which metal trowel is needed after slate trowel operation. Metal trowel finishing has to be conducted
by enough pressure to produce a compact, uniform, and smooth surface.
4) Metal Trowel facade (finishing type U4) Middle and downstream chutes as well as flip bucket slab
facades were generally finished in U3 class. However foreseen high velocity streams in these regions make
sort of supplemental finishing, U4 necessary [1].
B. Slabs' Joints
Slabs of spillway floor are benefitted of three joint types, control construction joints (CCJ), construction
joints (CJ), and contraction joints (CTJ) in cross direction. It is noticeable that CJ and CTJ are used at
longitudinal direction as well.
Besides that each slab of left or right chute is divided into five separate screeds all along upstream to
downstream structure (see Fig. 2).
C. Ogee
3-D scheme of ogee can be seen here in Fig. 3.
Fig. 2. Ogee cross section- screeds
Fig. 3. 3-Dimensional (3-D) scheme of ogee hydraulic surface.
D. Upstream Chute
E. Middle Chute
Fig. 4. Ogee concrete placement using scape form.
Fig. 5. 3-Dimensional (3-D) scheme of upstream chute hydraulic surface.
Slip-form was opted to perform 9m wide middle slabs of this chute [2].
To accommodate placement of side slabs which are executed on wall heel, a screed pipe 30 cm far from
wall and form as well as a third pipe in between were installed. After concrete placement, surface has
been finished by trowellers seated on planks.
Fig. 6. 3-Dimensional (3-D) scheme of middle chute hydraulic surface.
III. PROPER EQUIPMENT FOR HORIZONTAL AND MODERATE SLOPE HYDRAULIC SURFACES
The most common method for execution of hydraulic surfaces is usage of pipe or profile segments as
template. These segments are fabricated proportionate to surface geometric features. Usually reinforced
made T-shape props are constructed so that, on which template could be fixed in proper spaces, then
final surface could be achieved via pulling an aluminum bar over the section.
Dividing surface into smaller areas, make it possible to ensure flawless, smooth surfaces by plank and
metal trowel application more easily.
Varity of surface types available in HKO spillway structure specifically those with executive obstacles such
as low width sections or surfaces with particular geometric conditions [3], make this method so beneficial.
However insufficient progress speed because of the extent of hydraulic surfaces, necessity of employment
of experienced skillful persons and strict technical tolerances available made us to speculate of other
supplemental options. Thus appropriate bars were planned to resolve problem and facilitate concrete
placement in different curved surfaces as well.
In order to mitigate thermal crack propagation, 1.5m height slabs were transformed into 0.9 and 0.6 m
height lifts for facing. To ease construction and enhance final surface quality as well, following measures
were carried out:
1) Existing anchorage system was used for reinforcement fixation and facade accomplishment as
well.
2) Horizontal reinforcement of beneath network template at corresponding level which is
responsible to ensure proper concrete coverage over main reinforcement, was pointy welded to
reinforcement, mentioned in first article.
3) After beneath reinforcement was fulfilled, formatting and concrete casting of first lift was
performed.
4) Points were determined and perforated by pneumatic rotating hammers, and then reinforcement
bars were planted for anchorage. Anchorage reinforcement was applied as chassis for upper network as
well. Seating for working plank spacers and screed pipes by which final surface will be specified, are
secured as well.
5) Superjacent reinforcement network is completed at this step. Finally slab spacers’ sittings are
installed on columns mentioned in fourth article using weld with the aid of surveying. Slab spacers’ seating
is liable for establishment plank for concrete placing workers as well as required space for screed pipes to
be installed.
6) Before section preparation and resurveying, screed pipes have to be installed as the last
requirement before concrete placement.
For concrete placement of slabs following points are contemplated:
1) In order to put rather confined surface of slab at workers disposal, step method was opted for
concrete placement.
2) Fresh concrete is poured in between screed rails and become compacted. Then an aluminum
screed bar is placed on rails with a person at each end and pulled over the rails until all excess concrete is
removed. First state of finishing job is accomplished by plank trowel afterwards.
3) Surface finishing was complemented in two or three further steps by metal trowel.
4) In an appropriate time during finishing process and before concrete setting time inception, screed
pipes were replaced by fresh concrete.
5) When masons’ labor was fulfilled, whole slab surface was covered by linen or plastic sheets to
prevent fast evaporation. Then water curing has got started in a suitable time afterwards. And finally;
6) Apron spacers have to be taken away of slab concrete when its setting was performed and
residual flaws has to be repaired using concrete repair materials.
A. Establishment Plank Spacer, Screed Pipes, and Manual Trowelling
This method is favorable for apron concrete placement in flat or moderate slope surfaces [4]. Sequences
are as following:
1) In order to install upper reinforcement, establishment plank spacers, screed pipes by which final
surface is specified, and point excavation pattern has to be proposed.
2) Assigned points are pierced by rotating hammer and φ25 reinforcement segments are planted in
as columns, by which reinforcement network is fixed and establishment plank, as well as its spacer holders
are installed Fig. 8.
Fig. 8. Upper network (a), Space holder seat for slab (b).
3) To complete overhead reinforcement network, space holder seat for slabs are welded to columns
mentioned in previous clause with surveying inspection.
4) Before section preparation, surveying recheck, and concrete placement in final phase, screed
pipes were installed on space holder seats that are capable to adjust height.
5) After concrete placement and vibration in consecutive layers, workers pull screed bar on screed
pipes and remove excess concrete from top layer in Fig. 9.
6) Then surface is finished via manual trowelling. Further finishing job is performed in two or three
steps by metal trowel, if it was necessary.
7) Screed pipes are brought off the section during finishing procedure and before concrete setting,
and then were replaced by fresh concrete.
8) When masons fulfill their job and concrete completes its setting process, slab is covered by gunny
or plastic sheets and water curing get started afterwards in suitable time.
9) After concrete setting completion, apron space holders are replaced by repair grouts.
This method can be applied for flat or slope surfaces [5]. However low speed progress made it specified
for low width (< 3.5m) apron slabs, adjacent to side and middle walls.
B. Moving Bar, Equipped by Winch and Vibrator
Hinted restriction for first uttered method compelled us to apply latter method for basement of
downstream chute slabs.
Fig. 9. Removing excess concrete and manual trowelling.
Allen bar scheme has been used as our pattern to fabricate this compound moving bar. We've employed
a rather rigid,
10.5 m length, metal truss with authorized deformation to satisfy needs. It's not usual to install this bar
on template, thus for load transmission as well as bar motion in vertical direction in comparison to
concrete surface, proper legs outside two parties of template were devised.
Some executive considerations have to be implemented to satisfy some essential needs including height
adjustments for bar settlement, horizontal ties to provide structural balance, and fabricating proper seat
for bar wheels to settle on rails.
Kind of this, similar to Allen bars along with its accessories was assembled in downstream chute, by which
a block named DLS3-2 was accomplished. However high tolerances available (±15mm) as well as
remarkable time demand to take it apart, transfer to other blocks, and be assembled again made us to
put it aside (see Fig. 10-Fig. 11).
Fig. 10. Block DLS3-2, placed by moving bar and its accessories.
Fig. 11. 3-D Scheme of moving bar and its accessories.
C. Uncommon Metal Formwork Application
Shear key is fundamental in spillway slabs. Passage of top as well as beneath reinforcement networks
along with two water stop layers at joints, make their molding of an unusual nature.
However identical molding sections and necessity of multiple usage of each individual formwork, has
justified fabrication of metal formworks instead of wood forms. That way 4 series of complete section
molds were ordered for hydraulic faces of apron blocks’ formworks in up and downstream chutes in Fig.
12.
Fig. 12. Unusual metal formworks for apron block hydraulic faces.
Fig. 13. Middle chute, underneath stair shaped mass concrete.
IV. PROPER FACILITIES FOR STEEP HYDRAULIC SURFACES: SLIP-FORM APPLICATION
Making use of methods such as screed pipe, screed bar and trowel job for steep surfaces (around 65%)
causes fresh concrete to flow, thus following considerations were implemented to make execution
possible;
1) To ensure an efficient placement, our concrete mix was designed in slump of about 12 to 14 cm.
2) Up-lift motion signifies as concrete constringe in a level higher than final finished surface. To
harness up lift motion, sort of 9 m×1.2 m formwork in accordance with technical recommendations for
similar structures is necessary, thus;
3) A slip-form capable of movement on side rails was ordered to be fabricated.
4) To make slip-form movement in curved surfaces easier, wrought iron rails were constructed for
these sections.
Decision was made to construct middle chute slabs by slip-form, based on geometric characteristics and
slab drawings’ detection [6]. Qualitative considerations as well as appropriate progress speed to satisfy
project schedule have been other arguments to proof of method as the most profitable alternative. This
method requires more particular specialties and its practical constraints have to be regarded as well. Thus
slip form is commonly applied for structures with uniform geometry.
Chute cross section is divided into three 9m wide middle bands as well as two 3.5 and 4 m wide bands
adjacent to side and middle walls’ heel respectively.
Joints in middle bands as well as heel slabs are cut out joints; however other joints are executive ones.
Since aerator block is located in KM: 255 to 263, form movement and concrete placement have been
divided into upstream and downstream aerator. Thus 9m bands were placed in several separate steps.
To provide continuous placement, technical items were surveyed and all longitudinal joints along direction
of slip-form locomotion were eliminated.
Underneath mass concrete had already been placed in stairs Fig. 13 thus minimum thickness is occurred
at each stage edge. Nevertheless 70 cm corresponding thickness available is satisfied minimum technical
requirement.
Due to cross section shape, 8 m3 fresh concrete is required per one meter length.
Execution procedure for slip-form usage is as following;
A. Cleaning of Placement Surfaces
Stair cleaning as a global prerequisite removes every detrimental materials of previous surface, including
dead concrete, slurries, and etc. To provide more adhesion in between fresh and previously casted
concrete, surface was scratched. Debris is removed by water jet and surface is dried by air jet
application afterwards.
B. Template Considerations
Template preparation is accomplished in two phases. Sine a longitudinal water stop is planned 30 cm
under final surface, formwork is installed from stairs’ surface to beneath water stop level at first. In
second phase molds are installed on water stop up to required height, using Iranian planks.
C. Face Reinforcement
Face reinforcement according to executive drawings is performed in two networks. First one is carried
out 10 cm beneath final surface in arrangement of about Φ25 @ 200*200 and second network in Φ25
@ 400*200 arrangement, 30cm below upper reinforcement.
Because of complete access available to whole slip-form sections, reinforcement was totally
accomplished in advance. Then concrete placement and form movement get started afterwards in Fig.
14. Whereas common usage of slip form to execute vertical sections is different.
Fig. 14. Middle band, complete face reinforcement.
D. Rail Installation
Since section is 9m wide and root of waiting reinforcement bar for adjacent block is protruded, thus
space and level for rail installation should be accurate enough to prevent any conflict with adjacent
reinforcements.
That way 50 cm far from side formwork and above reinforcement level, rail cantilevers are installed and
fixed.
Two perforated hot rolled beams with U-shaped cross section were plugged in apron concrete in front
of each other in an appropriate distance.
In between U-shaped beams multiple bars were installed by which rail legs are fasten in node shapes.
Rail Legs are fabricated by height-adjustable pipes.
Clockwise and anticlockwise screws at middle make rails capable of height adjustment in 1 mm
tolerance.
This operation is fulfilled and finalized by an installer, a welder, a worker, and surveying group during
installation procedure in Fig. 15.
Fig. 15. U-Shaped beams and rail preparation.
E. Slip-Form Assembling
After rail installation, slip-form has to be assembled.
Main body is consisted of two hollow trapezoid shaped prisms in 4.4m length which are connected to
each other using connecting plate in mean.
Formwork contacts to concrete surface via a 68 cm chord. To facilitate form slide on concrete surface, it
was designed 10 cm less wide than section width (9m) at each side.
Thus form is 8.8 m wide and remaining 10 cm at each side has to be finished using bar and hand trowel.
To resist Up-lift pressure a container inside template has been filling in water, that way aside from 3.8
tons of template weight itself, 2.7 tons are added as well.
By taking advantage of plate and resistant bolts, form is seat on carriage and then on rails.
These resistant bolts are responsible for another basic obligation to regulate form height of concrete
surface.
It is noticeable that whole process is conducted under inspection of surveying group.
F. Power Supply
Required power for template movement could be supplied of hydraulic, pneumatic, electric, or manual
jacks among whom hydraulic jacks are the most economic ones.
Networks of hydraulic jacks are connected to a central reservoir via oil lines and required energy is
supplied by electric pump. Each individual jack is calibrated so that, it rises 20 cm in each activation step
of electric pump,” Fig. 16”.
Pump pressure should be adequate enough to insure required rise for complete jack network, when it
runs. Otherwise template basement turns to an uneven position and formwork will lose its vertical
direction. During formwork assembling procedure as well as its movement, presence of an electrician
and hydraulic technician is necessary.
G. Concrete Placement
Two mixes were designed for face concrete in Table I.
Concrete has been transferred to section by pump, mobile pump, or tower crane and bucket for
different conditions (see Fig. 17- Fig. 18).
Because of low speed concrete placement mere two truck mixers were employed. Two layers of upper
reinforcement available in structure face, necessitate more accurate handwork concrete vibration [7].
TABLE I: CONCRETE MIX DESIGNS, USED FOR HYDRAULIC SURFACES
Con. Slump Cement (0-5) (5-9.5) (9.5-19) Plasticizer
Mix Name W/C
Class (cm) (Kg/m3) (Kg/m3) (Kg/m3) (Kg/m3) (Kg/m3)
T3 19/
12 0.37 380 824 287 805 3.8Reobild
18 40
T3 19/ 2.4Pozolith
14 0.38 400 821 237 766
06 40 LD21
Fig. 16. Hydraulic jack (a), electromotor for electric pump (b).
Fig. 17. Concrete transference by mobile pump.
Fig. 18. Concrete transference by tower crane and bucket.
Fig. 19. Concrete placement underneath formwork.
Concrete was placed and vibrated in an appropriate thickness. When underneath template was filled
and initial setting was completed, slip get started (see Fig. 19-Fig. 20).
As a whole, slip speed depends on concrete slump, weather condition, and resulted in setting time.
Average speeds of about 40 and 70 cm/hour were recorded in cold and hot seasons respectively.
During 24 hour per day-execution procedure, finished surfaces as well as rails were checked by
surveying group continuously.
H. Concrete Surface Facade
When form slips over concrete, provided surfaces were finished by metal, plank, or plastic trowels.
An establishment plank or platform was hanged under formwork and skillful masons were stand on to
make concrete surface smoothly finished using trowel in Fig. 21 and Fig. 22.
Fig. 20. 24 Hour Concrete placement, slip, and surface finishing operation
Fig. 21. Hanged platform and finishing operation by trowel.
Fig. 22. Slip- Form forehead- connecting winches for workers plank.
This platform is connected to formwork and moves by making use of handwork winches. When finishing
is completed, surface was protected of evaporation by moist gunny fabrics and curing process was
continued to an assigned satisfactory period.
V. CONCLUSION
Since hydraulic surfaces are of utmost importance, following hints are beneficial and have to be
implemented:
1) Formwork, final surface, and water stop position have to be controlled by executive as well as
survey inspectors at each section accurately.
2) Water stop has to be accurately located according to shop drawings. It has to be fixed so that its
bulb could be seen at mold axis from template inside.
3) Final surfaces, on which prospective traffic is probable, have to be protected by sand coverage.
4) Before every screed or template installation, face control at least in 10 cm of near edge is
necessary for adjacent concrete.
5) We have to conform to executive sequences such as preparation, anchor and tool box
installation, and locating installation place for CJ molds before apron as well as face reinforcement
preparation according to shop drawings.
6) Some inferior template bolts were failed during concrete placement, and then template and
hydraulic surfaces of f4 type have been exposed to unfavorable displacement. Thus purchased bolts
have to be tested for tensile strength before usage.
7) Edges as well as horizontal and vertical hydraulic faces should be surveyed before formwork
installation. Then existent errors have to be calculated and appropriate decisions were made.
8) Accomplished surfaces should be sufficiently protected of every impacts and massive vehicles’
traffic. For instance sand materials are qualified for mutual obligations; impact defense and protecting
surface of slurries or fresh concrete.
9) Enough reserved concrete pumps are required to prevent cold joints at each block.
10) Surveys of executed sections have to be compared with that of molds before concrete
placement. Then probable errors can be identified and corrected in conjunction with adjacent blocks
and next lifts for current block itself.
In order to prevent mold displacement and conform to authorized tolerances for f4 molds, following
points should be considered:
1) Bracket foot has to be completely settled in beneath lift concrete. Mold foot should have
minimum overlap of about 10 cm with beneath lift concrete.
2) Horizontal metal props have to be in same direction to connect two panels.
3) Seamless wood beams are so beneficial.
4) Requirements for conic in lifts as well as panels’ conformity to each other according to
dimensions of blocks have to be provided.
5) Thorough consistency between template assembling group and executive team is essential.
6) In order to prevent displacement or shear occurrence for bolts in hydraulic formwork, first hydraulic
lift has to be accomplished using molds with no consoles.
