Portugus Dam COASTAL DAMAGE REDUCTION FLOOD DAMAGE REDUCTION

Portugués Dam COASTAL DAMAGE REDUCTION FLOOD DAMAGE REDUCTION NAVIGATION ECOSYSTEM RESTORATION Chief, Construction Division REGULATORY Steve Duba, P. E. INTERAGENCY & INTERNATIONAL SERVICES Portugués and Bucaná Project 1 BUILDING STRONG®® US ARMY OF ENGINEERS | Jacksonville District US ARMY CORPS OFCORPS ENGINEERS | JACKSONVILLE DISTRICT

Project Video BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Project Map BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Pertinent Facts 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, 200 Commercial & Public Structures: - Commercial Area: 5 Million SF - Hospital, Schools, Courts, Police Depts. Estimated Project Cost: $300 M Range of Damages Prevented: $400 M-$600 M (100 -year event) Direct Jobs Created: 650 (Peak) Sponsor: Department of Natural and Environmental Resources 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 BUILDING STRONG® After several studies and cost estimates, design was changed to Roller Compacted Concrete and detailed studies and design began for a 5 -yr program. US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Goals in Changing to Thick Arch RCC q Explore technology initially ruled out due to its newness in the 80’s q Utilize advancements in RCC technology and techniques q Realize savings in construction time q Maximize utilization of investment on site ü Arch-shaped foundation excavations ü Installed initial grout curtain q Avoid extensive new excavations mandated by a gravity design q Pursue Optimal Geometry to reduce total quantity of RCC q Ensure utilization of local regular use cement manufacturing q 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: 220 ft 1, 230 ft 140 ft Flood Control Storage: 9, 484 acre-ft Max Pool Area: 215 acres Dam Crest Elevation: 534. 6 ft Spillway Crest Elevation: 512. 75 ft RCC Volume: 367, 000 cy Thickness: 110. 6 ft base, 30 ft crest Contraction Joints: Spaced 70 ft. Design: 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 - 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

Portugués Dam Design Features Main Dam BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Design Features Dam Sections BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Design Features Outlet Works BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Design Features Outlet Works BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Design Features Dam Gallery BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugues Dam Project Phasing q PHASE 1 – $24, 465, 435 MOBILIZATION, CLEARING, QUARRY OVERBURDEN EXCAVATION, POWERLINE RELOCATION q PHASE 2 – $47, 625, 652 FOUNDATION EXCAVATION, AGGREGATE PRODUCTION, DENTAL CONCRETE q PHASE 3 – $37, 293, 763 AGGREGATE PRODUCTION, ½ DAM RCC PLACEMENT q PHASE 4 – $41, 061, 083 FINAL DAM RCC PLACEMENT, SPILLWAY, INTAKE STRUCTURE q PHASE 5 – $29, 672, 717 REMAINING ITEMS, VALVE HOUSE, ACCESS ROAD, MECHANICAL, ELECTRICAL. BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Project Map BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Construction Activities Approx. 567, 170 cy excavated Quarry Excavation 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 Diversion RCC Mix Design and Care of Water System BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Construction Activities Diversion RCC Mix Design and Care of Water System BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Construction Activities Delay-causing Over-toppings: Sep 30, 2010 Oct 4, 2010 Oct 5, 2010 Oct 6 -10, 2010 Oct 17, 2010 Diversion and Care of Water 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 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 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 Features BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Features BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Features BUILDING STRONG® US ARMY CORPS OF ENGINEERS | Jacksonville District

Portugués Dam Conclusions q QC Process critical and perhaps more involved than Conventional Concrete ü Need for sound QC planning and preparatory work process ü Need for qualified and energetic individuals overseeing the process ü Need for intense tracking of RCC production and placement parameters q Safety a constant challenge due to multiple activities in close proximity ü Management involvement in Safety is fundamental ü Production Staff needs to adopt a Safety Culture ü Accountability is a must ü Position of Competent Person as defined by OSHA is critical q 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

Portugués Dam Contract Data Contractors Contract Milestones Award: Notice to Proceed: Original Completion Date: Final (Actual) Completion: Beneficial Occupancy: 03/14/2008 04/03/2008 03/08/2013 12/27/2013 06/01/2014 Contract Cost Award Amount: Modifications: Contract Total: BUILDING STRONG® $180, 118, 650. 80 $36, 718, 962. 90 $216, 837, 613. 70 Prime: Dragados USA Main Sub: José Carro Const. Others: RC Professionals GEHS Environmental EST Electrical HEAT Security JV Geoland ARC Surveying Frank Electric Altol Laboratories CCG Drilling & Blasting US ARMY CORPS OF ENGINEERS | Jacksonville District

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