Proceedings of Indian Geotechnical Conference

December 15-17, 2011, Kochi (Paper No.Q-077)

GEOTECHNICAL CHARACTERIZATION OF FOUNDATION PREPARATION PRACTICES
IN EARTH AND ROCK FILL DAM- A CASE STUDY


Praveen Kumar Yadav, DGM (FES), KOLDAM HEPP, NTPC Ltd, E-mail: cepy@indiatimes.com
Rama Krishna Adhikari, Manager (Geology), KOLDAM HEPP, NTPC Ltd,E-mail: ramakrishnaadhikari@yahoo.com
Pratik Roy, Sr. Geologist, KOLDAM HEPP, NTPC Ltd, E-mail: geoidpratik@gmail.com


ABSTRACT: The Kol Dam Project (800MW), NTPCs first voyage into hydroelectric power project under construction, a
167m high Earth and Rock fill dam across Satluj River, is situated in a Karstic terrain. Geotechnical characterization of
foundation mainly depends upon the type of rock, frequency of discontinuities and structure to be built on that area. Surface
preparation included excavating overburden; surface cleaning, shaping the foundation surface with dental concrete; treating
faults, shears, or weak zones; filling up of joints with cement mortar etc. Besides surface treatments curtain grouting and
consolidation grouting were also provided as per geological condition of the area concerned for creating seepage barrier and
strengthening the strata. This paper presents the different methods adopted to achieve safety and constructional advantage in
foundation preparation in the Dam body of Kol Dam project.


INTRODUCTION
Kol Dam (location 3123N, 7652E) in Bilaspur District,
Himachal Pradesh, NTPCs first voyage into hydro project is
an Earth and rock fill Dam across Satluj, situated about 6 km
upstream of Dehar Power House (Beas Satluj link project).
Main structures of Kol Dam projects are two diversion
tunnels of 14m finished diameter and 900 (appx.) length each,
a 108.5m wide and 0.42 km long chute spillway and a surface
power house of 800(4x200) MW capacity. The Kol Dam
project has been basically designed as a run-of-the-river
hydro power development scheme with advantage of
additional storage for the first 30 years.

The 167 m. high (above deepest foundation level at El 481)
and 500 m. long (at crest) rock and gravel fill Kol Dam with
impervious central clay core to provide a live storage of 90
million cum. (9000 ha. m.) between full reservoir level (FRL
at El 642) and Minimum Draw Down Level (MDDL at El
636). This paper presents the different techniques/ practices
adopted to achieve safety and constructional advantage in
foundation preparation in Main Dam area of Kol Dam
project.
BRIEF GEOLOGY OF THE PROJECT AREA
The rocks belonging to Shali, Shimla, Sundernagar Groups
and Mandi Darla volcanic constitute the area. The dolomite of
Tatapani, Limestone of Sorgarwari (Shali Group) and
phyllites of Basantpur formation with basic intrusive are the
major lithological units exposed at the locations of major
components of the Kol Dam project (Sanjiv Kumar 2005-06).
In addition two generations of terrace materials are also
present in the project area one is simple river borne terrace
material composed of loose river borne materials like
boulders of Quartzite including the material coming from the
rocks present near the dam site and the other one is terrace
material composed of boulders, pebbles and gravel,
essentially made of quartzite, limestone, dolomite and basic
rock (all the rock materials that present outcrops near the dam
site), in a sandy and highly cemented calcareous matrix. The
rock encountered at the Dam foundation is Limestone,
Dolomite and Limestone-Dolomite transition zone.

Detailed geological mapping of the Main Dam foundation
area has been carried out in 1:100 scale. Pink limestone unit
(Sorgharwari Formation), transition zone and Upper dolomite
unit (Tatapani Formation) with thin (1 to 10 cm thick) shale
interbeds are exposed in the Dam foundation and abutments.
The general trend of bedding joint recorded is N10
0
W- S10
0
E,
which is nearly 20
0
askew to Dam axis, with 70-80
0
dip due
southwest direction. Due to the disposition of bedding the
transition zone crosses the core foundation from left to right
abutment. The Limestone-Dolomite transition zone in the
Dam base foundation & abutment carries numerous open
joint networks, solution cavities, sand pockets and small
sinkholes. A number of erosional cavities formed partly by
solution activities and may be by churning actions has also
been observed while doing the geological mapping. Two
principal families of stress relief joints have been observed
along riverbanks near the dam site; both are striking parallel
to the river, the first one consists of joints parallel to the
abutments slope (dipping 30 to 70 towards the river) and the
second one consists of joints, dipping perpendicularly to the
valley dipping joints. The rock is affected by a minor joint
pattern (in a first approach, two main joint families). Both
families are striking perpendicular to the bedding; the first
one is dipping approximately 50-60 NW, and the other one is
1003


Praveen Kumar Yadav, Rama Krishna Adhikari & Pratik Roy


dipping about 50-60 SE. The broken surfaces usually present
a certain roughness. These joints can present an extension
ranging from some dozen centimeters to some meters. Some
cavities (1 to 3m diameter) have also been surveyed during
the Geological mapping on both abutments.
FOUNDATION PREPARATION AT KOL DAM
The foundation preparation practices in Kol Dam Hydro
electric power project has been characterized into three
different categories such as Slope modifications, Foundation
Grouting and Surface Foundation Treatment.

Slope Modifications
To allow earth fill to be compacted and maintain positive
pressure on the abutments, foundation surfaces in both
abutments in Main Dam Clay Core, in particular, has been
flattened to about 0.73:1 to 1.75:1(H:V)in Left abutment
while 0.87:1 to 4.45:1(H:V) in the Right abutment (Clay Core
Area) by excavation (NTPC-EDF 2002)(Fig. 1).




Fig.1 Slope modification to reduce differential settlement &
cracking of core (Sanjiv Kumar 2005)

Foundation Grouting
The principal purpose of grouting is to fill openings in a
foundation and render it impervious to percolating water. It is
also used to improve the strength and elastic properties of the
foundation material into which it is injected. The
methodology of grouting given to the foundation materials as
a whole has been decided depending upon the available
geological formations and features in the near vicinity of Dam
site. Grouting with normal cement grout is also doubtful
value in rocks where permeability value results from a great
number of fine cracks. With normal cement grout it is not
possible to seal cracks which have width much finer than
0.2mm. In Kol Dam as the carbonate sedimentary rock like
limestone and dolomite are inherited by very fine as well as
open joint networks different fillers/accelerators/admixtures
were incorporated in both curtain and consolidation grouting
with variable C:W ratios. The grout mix for all the grouting
operations in Kol Dam has been designed depending upon the
existing site geology. The grouting operation has been carried
out with a variety of grout mixes starting C/W ratio 0.35:1 to
0.6:1 with different admixtures like bentonite, accelerators
like micro silica etc depending upon the geology encountered.
The spacing and the pattern of grout holes has been designed
based on several test sections carried out on the basis of
acceptable permeability of the foundation and the nature of
the Dam. In the test sections different grout materials with
variable C/W ratio were also analyzed for suitability by
observing the performance in terms of viscosity, decantation
and compressive strength. The grout performance in terms of
lugeon value, viscosity, decantation, compressive strength
and ground upheaval were analyzed for achieving the design
criteria. The treatments provided as per encountered geology
has been found satisfactory even during the heavy monsoon.
In addition, as a measure of foundation safety in Kol Dam, 5
no. of drainage galleries are also provided to drain off the
seepage water and thus reduce the uplift pressure in the
abutments which will act after the reservoir impounding.
Foundation grouting adopted in Kol Dam are mainly in two
forms:

1. Curtain Grouting
In Kol Dam two rows of grout curtain with an average depth
from the deepest level of dam foundation has been designed
(Fig. 3). The average depth of the grout curtain is around 70-
80m from 12 grouting Galleries (Fig.2). Two rows of separate
grout curtain has also been provided in the U/S part of the
Main dam left bank clay core abutment (up to 30m from the
foundation) to provide curtain to cutoff/minimize seepage.

2. Consolidation/Blanket Grouting
It is being carried out in the Main Dam clay core abutments
and in the foundation, for filling up the joints/cracks/crevices
etc. and there by making the foundation homogeneous. It
makes upper portions of the bedrock stronger and less
pervious. In Kol dam it is usually restricted to the upper 6 to
12m.

The following observations can be drawn on the basis of
Drilling-Grouting records of Dam foundation in Kol Dam:
1. The intrinsic permeability of the rock in the Main Dam
foundation appears to be low as inferred from the strata
encountered, drilling record & grout intake data of
consolidation as well as curtain grouting and from the pre &
post grout permeability test results (Sanjiv Kumar 2005-06,
07-08).
2. The overall grouting activities in the Dam foundation
depicts that the opening along joints, fractures and fissures is
more in the left abutment as compared with the right
abutment.
3. The concentration of open joint networks/fine
fissures/cavities are more in the near surface condition upto
an average depth of 6-10m as compared to the deeper depth in
general in both the abutments.
1004


Geotechnical characterization of foundation preparation practices in Earth and Rock fill Dam- A case study.
4. In addition, only some rare and little size (2-5 cm) solution
cavities or channels have been observed during drilling
operations or core logging all along the Dam foundations and
below the Dam foundation Galleries. In conclusion, no real
evidence of large scale Karstic phenomena has been observed
at Dam site.

Fig.2 Curtain grouting through Grouting Galleries beneath the Dam foundation (NTPC-EDF 2002)





Fig.3 Typical Curtain Grouting in Kol Dam (NTPC-EDF 2002)

Surface Foundation Treatment
Foundation surface preparation practices in Kol Dam includes
excavating overburden; shaping the foundation surface with
dental concrete; filling surface irregularities with slush grout
(usually a cement/water mixture poured in cracks) or dental
concrete (conventional concrete used to shape surfaces, fill
irregularities, and protect poor rock); providing dental
treatments for the exposed faults, shears zones/seams, or
weak zones as directed by the site geologist prior to caulking
and contact grouting. As the Dam is located on Limestone-
Dolomite i.e in Karstic terrain the shear seams/weathered
zones/buried channels/cavities/surface springs were common
in the foundation/abutments. These zones are susceptible to
differential settlement as the in filled material within the
major open joins (>20cm)/shear seams are of different moduli
compared to the bed rock. So, special care has been taken
while doing the dental treatment all through the Dam
abutments in the Clay core and Filter area. Very often the
faults, shear seams or shattered zones met with after
excavation extend to such depths that It is impracticable to
clean them out entirely.

Stress concentrations may occur in the dam due to the
presence of such low modulus zones. To minimize the build
up of stresses in the dam, a portion of the weak zone is
replaced by concrete. The procedure for reinforcing and
consolidating such weak geological features is frequently
called Dental Treatment.

The dental treatments adopted in Main Dam clay core as well
as in the filter area in Kol Dam are as follows (Fig. 4):

a. For Shear Zone/Clay Band
all the material along its length should be scooped. The
excavation depths (d) were decided by the site geologist by
the following formula:

d=3-4w, if w (width of the shear zone/clay band) > 20 cm;
then it is backfilled by concrete and contact grouted all along
the feature cross cutting it up to a depth 3-4m
1005


Praveen Kumar Yadav, Rama Krishna Adhikari & Pratik Roy


or d=1-2w, if w < 20 cm. Then it is backfilled by cement
mortar and then regularized it with concrete (Sanjiv Kumar
2005-06, 08-09).
b. For Weathered Patches
all the weathered material were scooped out until the fresh
rock is encountered. All the uneven surfaces after scooping
out or any irregularities found have been backfilled with
concrete.

c. For Depression/Cavities/Negative Slopes
First cleaned the area with high pressure air-water jet and
then regularized/backfilled with concrete.

d For Joints/Fractures
All the bedding joints/cross joints/sub horizontal joints in the
clay core/filter area in the Main Dam abutments/foundation
has been provided dental excavation as mentioned in the
above formula and then backfilled with cement mortar.




Fig.4 Typical Surface foundation treatment practices adopted
in Kol Dam (Engg. Geology Field Manual, 2
nd
Edition)
The main purpose of cleaning and grouting of surface
fractures/joints is to protect the earth core from possible
erosion caused by seepage of water flowing through the rock
cracks. The above said surface foundation treatments adopted
in Kol Dam will create an impervious skin on the foundation
surface of the rock again which will reduce the total quantity
and pressures of the under seepage through the rock.

CONCLUSIONS
For safe, timely and economical execution of earth and rock
fill dam construction, adequate foundation treatment is
essential to minimize any kind of post construction surprises.
(Fell 1992). An understanding of geotechnical characteristics
of the rock mass to be grouted is also very important for a
successful, economical and timely execution of the
foundation preparation activities in any river valley project.
Though unexpected geological features (open joint
networks/solution cavities/shear seams etc) cannot be ruled
out even with adequate investigations in any Karstic terrain
because of its unpredictable geomorphology, special care
should be taken into the consideration during the design as
well as in the construction stage depending upon the
encountered geology which would result in considerable
reduction in time and cost over runs.

REFERENCES
1. Fell, R., Macgregor, P. & Stapledon, D (1992)
Geotechnical Engineering of Embankment Dams,
Balkema, Rotterdam.
2. Kumar Sanjiv, Kumar Sajin K S.(2005-06 & 2006-07)
Geological Survey of India, Chandigarh, Progress Report
on the Construction Stage Geological Investigation For
the Kol Dam Project(Unpublished),District
Bilaspur,H.P., Vol 5,1-49.
3. Kumar Sanjiv, Kumar Manoj, Mahapatra R.R.(2007-
08,08-09) Geological Survey of India, Chandigarh,
Progress Report on the Construction Stage Geological
Investigation For the Kol Dam Project(Unpublished) ,
District Bilaspur, H.P.Vol 6,7-34.
4. Kumar Sanjiv, Geotechnical problems of Dam
foundation, Training course on Material testing and
Evaluation of Earth and Rock fill Dam, 29
th
August to 2
nd

September, 2005, CSMRS, New Delhi, 149-168
(Unpublished).
5. Engineering Geology Field Manual, U.S. Department of
the Interior Bureau of Reclamation, Second Edition, Vol
II, Chapter 21,321-349
6. NTPC (National Thermal Power Corporation Ltd.)-EDF
(Electricite de France) (2002) Studies and investigation
report; Geological and Geotechnical report of Koldam
Project, (Unpublished); Vol3, 9-94.


1006