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Application of SCC to Dam
Construction
-An Example of Technology and
Business Model Development-
Xuehui AN
Professor
Tsinghua University
1、Background
(Market)
Japanese Popular Magazine
AERA 2004.7.12 No.31
Taking a wedding photo in Shanghai,
there is always a construction crane.
Shanghai Wedding
JP TW KR MYSG TH CN VN
kg/capita
1950 1960 1970 1980 1990 200010
100
1000
10000
Co
nsu
mp
tio
n o
f cem
en
t p
er
cap
ita
From Dr. Ouchi
30 years
1950 1960 1970 1980 1990 2000 2010
Year
10
100
1000
Consum
ptin o
f cem
ent per
capita (
kg)
Japan
China
kg/capita
China, the Largest Concrete Market in the World
World Cement Consumption in 2013: 4,000,000,000 ton
China
58.6%
Japan
1.5%
USA
1.9%
India
7%
five east-west lines
five north-south lines
eight connection lines
The development of the high-speed railway in China
>200km/h
The development of the high-speed railway in China
in 2008.8.1
the first high-speed railway
in 2010.7.1
the mileage number become
NO.1 in the world
The aim
The development
in 2020 ,over 16,000 km
Reached at the end of 2014
6900
33002319
120
7055
13000
Dams to be constructed in China
China, the Largest Concrete Market in the World
Dams to be constructed in China
China, the Largest Concrete Market in the World
TGD
三峡
Bird’s View of TGD under Construction
China, the Largest Concrete Market in the World
TGD（２００２）
World records:
Reservoir ： 39,300,000,000m3
Reservoir length： 650 km
Power Capacity： 18,200,000kw
Concrete： 23,150,000m3
1999: 4,585,300m3
China, the Largest Concrete Market in the World
Needs and Challenges in Dam Construction
Vibrating-compacted concrete
Complicated process with vibrating, cooling
pipe placing, etc. High heat, of hydrationcomplicated temperature control, easy to
crack, high project cost
Masonry & Rubble concrete
Low technology required, low cost,
suitable for small-sized projects. Hard
for quality control with low level of
mechanization. Eliminated gradually
because of increasing labor costs.
Roller compacted concrete
Large working space and heavy
machinery required, only be suitable
for large-sized projects, and hard to be
used for ultra-high dam construction
Urgent need for a new -type concrete construction way
– Simple process, ease for quality control: No vibrating and temperature
control
– High speed, high efficiency: make best use of the mechanical operation
– Low cost, easy to popularization: Low cement required
– Wide adaptation：suitable for different size of working space
2、Technology Development
(R&D)
SCC: to meet the needs Technology of Self-Compacting Concrete
(SCC), developed in concrete lab, University
of Tokyo, Japan.
SCC Family in Japan
SCC was invented in 1980s
More and more Reinforced Concrete projects have been built by SCC due to good workability and high durability
SCC is difficult to use in Mass Concrete due to high price and high adiabatic temperature rise
SCC: Experimental Dam Concrete in Japan
Rock-Filled Concrete: SCC+Rock=Dam
Invented in early 2003 by Tsinghua University
Rock
>300mm
SCC
SCC
RFC RockHardening
Experimental Work
2003~2004
Study on the filling ability of SCC
1h
喷水养护3d
拆模
喷水养护
热缝 冷缝
2005~2007
Study on the compression strength and
permeability by piece-cutting method
Experimental Work
2008~2011
Study on the full-scale integrated property
• Compressive strength ：fc
RFC/fcSCC=1.3~1.5
• Modulus of elasticity ：Ec
RFC/EcSCC=1.3
• Tensile strength：ft
RFC/ftSCC=0.9
• Ultimate tensile strain:
RFC: 97×10-6
SCC: 117×10-6
• Shear strength：f=1.71 c=1.59MPa
• Adiabatic temperature rise
14.2~16.1℃
• Permeability coefficient:
RFC: 10-11m/s,
SCC: 10-12m/s
General-Type RFC Construction
Proposed in the
project with a
large working
space
1. Transportation of
Rock Block
2. SCC Pouring
SCC
pouring
Transportation
of rock block
Working
space
SCC
pouring
Riprap-Type RFC Construction
Proposed in the project with a small working space and a
significant drop in elevation
1. SCC Pouring
2. Rock Block Dumping
SCC pouringRock dumping
Working
space
Employment of RFC
Auxiliary dam of upper reservoir in Baoquan pumped-storage
hydroelectric plant project.
Designed as a 50000 m3, masonry gravity dam, 42.6m high.
The top 3m,
with a volume
of 3000m3,
was made of
RFC.
1st
Batching and
mixing plant:
mix SCC
Road : used for
transporting rock
blocks to the working
space by dump truckWorking space: construct
riprap by excavators and
bulldozers
Tower Crane:
transport SCC to
the working space
Bucket: load SCC
during transportation
Unit Weight：2401kg/m3
Rock：53.2%
SCC：42.8%
Air：4%
Employment of RFC 1st
Observed temperature history inside RFC
5.0
7.0
9.0
11.0
13.0
15.0
17.0
19.0
07.1.8 07.1.13 07.1.18 07.1.23 07.1.28 07.2.2 07.2.7 07.2.12
T1 T2
Employment of RFC 1st
JSCE
Technical Features
Low cost and
environmental friendly
Low cement and low heat of hydration
Decreased construcntion cost and impoved economic efficiency
Effective recycling of solid waste
Energy saving, reduced CO2 emissions
Safe and high quality
guaranteed
High density and high compressive strength guranteed
Good volume stability, outstanding fracture resistance
Excellent impermeability
Simpified and effective quality control
Simple construction way
High construction speed
Strong shear strength, eliminating surface roughening process
Simplifying temperature control process
Continuous construction, improved efficiency, shorten construction period significantly
3、Applications
(Engineering Solution)
Baoquan Hydropower StationQingyu Reservoir Weitan Reservoir
Jili Hydropower Station
Project Reference
Qiannian Reservoir
Xiaoshixia Hydropower StationGaoche Reservoir
Yangzhuang Levee Sanming LeveeSanwanWater Supply Project
First RFC gravity dam in Beijing
Tunnel lLining in Zhaikou Hydropower Station
Retaining wall of Huixin Highway
Karst Cave Filling in Aikou ReservoirTunnel Lining in Wuyue Reservoir
Project Reference
Cofferdam in Buerjin Hydropower station
Penstock Filling in Zhongliang Hydropower Station
Changkeng Reservoir Curtain Grouting in Xieka Hydropower Station
Open Caisson FillingIn Xiangjiaba Hydropower Statoin
Henshan Reservoir Reinforcement
Retaining wall of Sai-Guo HighwayPenstock Filling in
Dukouba Hydropower Station
Zhaojiayao Reservoir Reinforcement
Minhe Levee
Nahe-2 Hydropower Station
Project Reference
Xianyinhe Hydropower Station Miniu Reservoir
Donshen Hydropower Station
Menshan Reservoir
Shihe Reservoir Reinforcement Meizhou Levee Reinforcement Dalongtan Reservoir Reinforcement
Shuigoukou-2 Reservoir Reinforcement Hutiaoxia Reservoir Pula Reservoir
RFC volume (m3)
Project number
Project Reference
Located in Shanxi Province, total capacity of
reservoir is 2.33 million m3
Concrete gravity dam with height of 42.5m,
top width of 38.3m and length of 203m
Except impervious panel and overflow
section panel were constructed by CVC, all
the other parts of dam are constructed by
RFC
Total concrete quantity: 70,000 m3
Project Profile
Qingyu Reservoir —— Gravity Dam
Site Layout
SCC Plant
Pipe
Road
Rock Blocks
Casting
Project Profile
The first arch dam in the world
Single curvature arch dam with a gravity podium at each side.
Dam height is 24.5m and length is 120m. The length of arched dam part is 62m
All the dam is constructed by C25 RFC with total concrete amount of 12,000 m3
Menshan Reservoir —— Arch Dam
Rock
blocks
Aggregate
Fly ash、cement
Concrete
mixer
Concrete
pump
Tower crane
Menshan Reservoir —— Arch Dam
Changkeng Reservoir —— Dam Rebuilt
Project Profile
Rebuilding project with RFC gravity arched dam. Height of
RFC dam is 24.5m, length of dam is 88m and total capacity
is 1.61 million m3
Rubble demolished from the old masonry dam,
accomplishing resource recycling of solid waste
Rebuilt
Water leakage in old
dam
SCC Manufacture SCC Transportation SCC Pumping
Full-recycle the old dam body as rock material for RFC
Xiangjiaba Hydropower station —— Caisson Backfilling
Project profile
The last cascade hydroelectric station located on Jinsha River. The ten caissons of
this projects was the largest caisson group in China with max backfilling depth of
57.4m
In order to shorten the construction period, Riprap-Type RFC is used for all the
backfilling parts except the ferroconcrete ones.
Total concrete amount is up to 80,000 m3
23000
43000－57400
4400 5200 4400
ＲＦＣ
Concrete mixing plant
9# Caisson
Aggregate field
Rock blocks
Rock blocks cleaning
SCC
Rock
construction area
Construction Site of Riprap-type RFC
Evaluation from xiangjiaba project
department
High compactness, high bulk density and compressive
strength, meeting the design requirements
Low heat of hydration. The max temperature rise
detected is only 7.1 C
High construction speed. The construction period is
shorten to 5-7 days from 20 – 30 days
Simple process, the project cost is less than CVC
Application Effect
Xiangjiaba Hydropower Station —— Caisson Backfilling
Project Profile
Because the security risks caused by dam cracks,
and abutment sliding stability can not meet the
requirements as well as other dam mechanical
properties, the dam began to be reinforced in 2009
Reinforcing the dam downstream. Over 45,000 m3
RFC were concreted. The concreting project was
finished in late 2010
The first double curvature arch dam of China, with 69m in height
Hengshan Reservoir —— Arch Dam Reinforcement
Construction Plan
RFC
Hengshan Reservoir
Thicken the dam body at downstream by using RFC
Reduce the amount of cement, to simplify the construction
process, shorten the construction period
Compared with CVC dam, RFC dam has larger bulk density,
better reinforced stability
Low heat of hydration, greatly reducing the cracks of interface
between the old and new dam, improving reinforcement quality
施工方案
Form work Concrete mixing
Concreting by pump
Constructing rock blocks into
working space by tower crane
SCC transported by mixing truck
Hengshan Reservoir —— Arch Dam Reinforcement
Application Effects
The average temperature rise of RFC is only 10℃
Effectively solve the complex issues
of temperature control, including
cracks happened between the new
and old dams caused by extreme
temperature difference new and old
dam open reinforcement works
Hengshan Reservoir —— Arch Dam Reinforcement
Application Effects
This project has caused wide public concern. In 2010, CCTV specially reports this
projects on “The Light of Science”
High compactness, high compressive strength to meet the
design requirements
Low heat of hydration, simple construction process, lower
project cost.
Low noise and environmental pollution, solving the
problem caused by narrow construction site and influence
to scenic
Hengshan Reservoir —— Arch Dam Reinforcement
4、Business Model
(Company Strategy)
History of RFC Business
2003 Rock-filled Concrete was invented
2005
2008 Company was founded
2009RFC technology was selected into the list of Key Promotion
Technologies of the Ministry of Water Resources of P.R. China
2010 Awarded as National High-Tech Enterprise
2012
• RFC was selected into the list of National Encouraged Technologies,
Techniques and Devices in the field of Circular Economy
• The first RFC arch dam in the world was built up at Menshan
reservoir
The first RFC gravity dam was built up in Beijing
R&D — Solution — Promotion — Service
Beijing Business Center
Beijing, China
RFC R&D Center
Tsinghua UniversityPlant
Engineering Center
Business
Center in
Chengdu
HQ in Beijing
One R&D Center
One Manufacturing Plant
One Engineering Center
Four Business Center
Business
Center in
Changsha
Business
Center in
Kunming
RFC Joint Research Center established
by Tsinghua University and SINOCONFIX
Chief ScientistsPro. Jin FengPro. An Xuehui
SINOCONFIX
National supporting and promotion
Advanced Practical Technology awarded by Ministry of Water Resources of People’s Republic of China (2009)
Key promoting technology of Ministry of Water Resources (2008~2014)
5 sessions of RFC technology seminar held by MWR of P.R. China
Key promotion technologies of Ministry
of Water Resources of P.R. China
1. “Low cement RFC Technology” was selected into the list of
National Encouraged Technologies, Techniques and Devices in
the Field of Cycle Economy
2. Be select into Advanced energy-saving technology awarded by
Beijing Municipal Commission of Development and Reform
3. “Top 100 Environment Friendly Technologies”
National supporting and promotion
Future of RFC
“Technical Guidelines for RFC＆CSG dams” is issued by the Ministry
of Water Resources of China in 2014.
Songlin gravity dam (90m high) in Yunnan Province, the highest RFC
dam will finish construction in 2017.
Songlin Reservoir
77 RFC dams planed to be constructed in China
in near future
International Concern
RFC has been introduced as a
cover story by
<International Water Power &
Dam Construction > in 2008.
ICOLD（International
Commission on Large Dams）：Technical Committee on
Cemented Material Dams (RFC,
CSG, Hardfill and etc. )has been
established in August 2013.
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