2003 seven mile dam ph 2 presentation, karen and ajay

SONS’, INC.

2 0 0 3

Through Kiewit Fundamentals MAKING ESTIMATE…

Seven Mile Dam Anchor Installation Phase II Karen Eager & Ajay Cariappa Western Canada

Presentation Outline

■ Introduction ■ Construction Methodology & Process ■ Costs ■ Conclusions

Introduction

■ Job Location ■ The Owner’s Objective ■ An Anchor “ What we are building” ■ Work progress

Location

Owner’s Objectives

■ Owner’s Objective ●  Seismic Upgrade ●  Increase Storage ●  Better Power Generation

Job Description

■  Phase I ($800,000 contract value) ●  Kiewit Fabricated and Installed

■  3 Anchors ■  Each anchor 90 Strands ■  Worlds second highest capacity anchors

■  Phase II ($13,000,000 contract value)

●  Kiewit Fabricating and Installing ■  48 Anchors ■  Each 92 Strands - Worlds highest capacity anchors ■  Ultimate strength of each anchor 5.39 million pounds ■  During construction owner added 6 more anchors increasing

contract value to $14,700,000.

An Anchor

■ An Anchor ●  92 Strands ●  7 Wires per strand ● High strength steel strands ● High Density Polyethylene (HDPE) sheathing

An Anchor Cross-Section

Bond Zone in Rock - 50 feet

Free Stressing Length - 135 to 350 feet

Anchor Head Recess

Anchor Head

Note: Drawing Not to Scale

Cross-Section at Free-Stressing Zone

Cross-Section at Bond Zone

Construction Methodology & Process

■ Pier Access ■ Demolition ■ Drilling ■ Anchor Assembly ■ Grouting ■ Stressing

Access Over Upstream Piers

Access Fabrication

Anchor Head Blockout Line Drilling

■  Three types of blockout sizes ranging from 7 yds3

to 14 yds3 in size ■  Each blockout must be

line drilled to provide relief in the concrete prior to demolition

Anchor Head Blockout Demolition

■ Machine Demo - 2 rubber tire backhoes with 1200 ft/# Kent KF9 hoe ram ■ Hand Demo – rivet busters

Completed Anchor Head Recess

■  A concrete leveling pad is placed on the bottom of the recess to allow for a level surface for the drill diverter and rebar cage

■  At this point we are

ready to set up the drill

Drilling

■  Contract ●  Requires us to drill 17,000’ of 16” diameter hole ranging

from 185’ to 410’ in depth through a gravity dam structure and into rock that can range up to 29,000 psi in strength.

■  Drilling ●  Drill Buy ●  Drill setup ●  Survey ●  Hole cleaning ●  Drill hole camera inspection

Casagrande M9-1 Drill

Drill Tooling

■  Drill Tooling ●  450’ of 11” Ø drill

string ●  30’ of 11” Ø stainless

steel drill string ●  2 Numa 125

Challenger Hammers ●  Drill bits and other

components ●  Total cost of over

$1,000,000.00

Drill Set Up

■  3x900 CFM x 350 psi compressors

■  Cyclone ■  Diverter ■ Waste Bins ■  Follower System

Cyclone

Follower

Diverter

Cyclone

Design by Scooter

M13 Autoshot Digital Borehole Survey Tool

■  Purchased from Icefield Tools

■  Specification is 1:300 ■  Our drilling averages 1:450

and our best is 1:2200

410’

8”

1:600

Hole cleaning

■  The hole is filled with water and then flushed out using the air on the drill

■  The air lifting proceeds for about 2 hours in 20 minute intervals until water comes out clean

Water Testing and Inspection

■  Each drill hole is water tested and video taped by BC Hydro to inspect the sidewalls

■  Our custom built deep well pump is used to pump water from the drill hole for easy confirmation of water ingress

Strand Anchors

■  Strand and Component Supply ●  Strand extrusion process

■  Fabrication/Assembly ●  Onsite fabrication yard

■  Strand anchor transportation ■  Installation

Strand and Component Supply ■  Con-Tech Systems of Delta B.C. was contracted to

supply the following:

●  1.8 million feet of Extruded HDPE, 270KSI, low relaxation, 7 wire strand

●  100 tons of steel bearing plate and wedge plates

●  17,000 feet of ½” wall x 12” diameter HDPE pipe

Strand Supply

Strand must be physically opened in order to fully encapsulate the individual wire with Petroplast wax

Wax Injection Process

Petroplast is a petrolatum wax manufactured by Neuber Co. based in Germany

Strand after Petroplast Injection

100% Petroplast wax coverage on outside of steel strand

Extrusion Process at Polyform, Salem, Oregon

Melted HDPE

A 0.06” thick HDPE sheathing is extruded over the wire strand

Waxed Strand

Anchor Assembly Yard

Strand Pusher

Strand Trolley

450’ long carrier machine fabricated by Sierra Mechanical

Outer Corrosion Protection

■  412 McElroy Fusion Machine

■  12” diameter x ½” wall HDPE is welded together

■  100% water tightness is a must

Phase 1 – Anchor Installation

■  Anchor is placed in line with hole and a 45 000# hold back winch is attached to the end

■  Anchor is then let slowly up and over a 15’ diameter installation wheel frame and slowly lowered into the hole

Grouting

The Oberman Grout Plant

Obermann Grout Pump

■  The Obermann is a high speed shear vane mixer that can mix a batch of grout before the empty bag can hit the ground

Andre…What is a circuit breaker????

Phase 1 – Anchor Stressing

■  A total of 176 million pounds will have been added to the dam when all anchors are stressed

Costs

■ Demolition ■ Drilling ■ Anchor Assembly

Demolition Costs

500

600

700

800

900

1000

1100

1200

1300

1400

1500

2-Aug 27-Aug 21-Sep 16-Oct 10-Nov 5-Dec 30-Dec 24-Jan

Date

Pro

duct

ion

($/y

d3)

Daily Actual Production ($/yd3) Budget Production ($/yd3) Todate Actual Production ($/yd3)

Budget = 1187 $/yd3

Actual = 1100 $/yd3

Anchor Drilling Costs

30

40

50

60

70

80

90

100

110

16-Oct 26-Oct 5-Nov 15-Nov 25-Nov 5-Dec 15-Dec 25-Dec 4-Jan 14-Jan 24-Jan

Date

Prod

uctio

n ($

/ft)

Daily Production ($/ft) Budget ($/ft) Todate Production ($/ft)

Budget = 61 $/ft

Actual = 58 $/ft

Assembly Costs

0.00

1.00

2.00

3.00

4.00

5.00

6.00

4-Jan 9-Jan 14-Jan 19-Jan 24-Jan 29-Jan 3-Feb 8-Feb 13-Feb

Date

Mhrs/Strand

To Date (Mhrs/Strand) Budget Daily (Mhrs/Strand)

Conclusion

■ Importance ■ Largest and Highest Capacity Anchors in

the World ■ Future Work ■ The People building the work

The People Building the Work