2003 Seven Mile Dam Ph 2 Presentation, Karen and Ajay
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Transcript of 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