016 - MS For Full Scale Shear Pad Rev.B - 09 Mar 11

THE FEDERAL DEMOCRATIC REPUBLIC OF ETHIOPIA
ETHIOPIAN ELECTRIC POWER CORPORATION
salini COSTRUTTORI S.p.A
GIBE III HYDROELECTRIC PROJECT
METHOD STATEMENT
For
RCC Dam Full Scale Trials Phase II

Shear Pads
Document No.
First Issue
520 RCC M SAS 016 B 09 Mar 2011
Section Sub section Work Office Drawing No. Revision Date Description
Technical Department Project Manager
B 09-Mar-11
Rev Date Prepared Verified Approved
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Method Statement RCC Dam Full Scale Trials Phase II: Shear Pads COSTRUTTORI
TABLE OF CONTENTS
1. DOCUMENT SCOPE AND FIELD OF APPLICATION ........................................... 3
2. RESPONSIBILITIES ............................................................................................... 4
3. REFERENCES ........................................................................................................ 5
4. EQUIPMENT ........................................................................................................... 6
5. MATERIALS ........................................................................................................... 7
5.1 Cementitious Materials and Retarder .................................................... 7
5.2 Aggregates .......................................................................................... 7
5.3 Mix Designs ......................................................................................... 8
5.3.1 RCC .......................................................................................................... 8
5.3.2 Bedding Materials ..................................................................................... 8
5.3.3 Conventional Concrete ............................................................................. 8
6. OPERATIVE METHODS AND WORKING PHASES .............................................. 9
6.1 General ............................................................................................... 9
6.2 Classification and Treatment of Lift Joints ........................................... 10
6.2.1 Lift Joint Maturity ..................................................................................... 10
6.2.2 Warm Joints ............................................................................................ 11
6.2.3 Cold Joints Type I ................................................................................... 11
6.2.4 Cold Joints Type II .................................................................................. 11
6.3 Full Scale Shear Pads Construction Program ...................................... 12
6.4 RCC Placing ...................................................................................... 14
6.4.1 Preliminary Activities ............................................................................... 14
6.4.2 RCC Transportation and Depositing ....................................................... 14
6.4.3 Spreading ............................................................................................... 14
6.4.4 Compaction............................................................................................. 15
6.4.5 Curing ..................................................................................................... 15
6.4.6 Placing of Top RCC Layer ...................................................................... 16
6.5 Laboratory Tests ................................................................................ 17
6.5.1 In-situ Testing ......................................................................................... 17
6.5.2 Laboratory Testing .................................................................................. 19
7. QUALITY CONTROL ORGANIZATION ............................................................... 20
8. SAFETY MEASURES ........................................................................................... 20
9. QUALITY RECORDS AND FILING SYSTEMS .................................................... 20
10. ATTACHMENTES ................................................................................................. 21
520 RCC M SAS 016 B, 09 Mar 2011 Page 2 of 21

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1. DOCUMENT SCOPE AND FIELD OF APPLICATION
This document has been prepared to identify and define the activities for carrying out
the RCC Dam Full Scale Shear Pads. The document includes the method of
execution of the activities, the main sequence optimization, and the resources
allocation.
It is understood that this document is a working tool to be considered as a guideline
that may be modified or adjusted, during the implementation of the method of
construction, in accordance with the actual situation on the spot and the actual
progress of the work.
The aim of the document is therefore to give, on the basis of the information available
clear indication of the works, and the most exhaustive indication of the method of
construction foreseen by the Contractor for the execution of the works.
The above is in accordance with the technical specification requirements and within
the contractual program time allocations.
The scope of work covered by this document is presented as follows:
 The construction of the Full-Scale Shear Pads
 The relevant testing program

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2. RESPONSIBILITIES
The Project Manager is responsible for the approval of the Method Statement.
The Technical Manager is responsible for the preparation of the Method Statement
and revisions & verifications that may be required. He is also responsible for the
distribution of the document and the flow of all the information relevant to the subject,
which need to be in accordance with the procedures indicated in the “Documents
Management” procedure, doc. n. QA-0520-01.
The Production Manager is responsible for the application of the methods of
execution on site.
The Work Superintendents are responsible for the divulgation and implementation
on site of the Method Statement, which is to be strictly applied and followed for all
the different work sections. They are also responsible for the monitoring of the actual
situation encountered during the execution of the works that may require adjustments
and/or modifications to the Method Statement. This includes modifying and adjusting
any organizational changes, resources adjustments, and requesting clarification of any
items in the Method Statement according to the actual changes to the basic
assumptions and/or physical situation.
The Quality Control Manager is responsible for the checking and confirming of the
results during the implementation of the Method Statement and execution of all works
to ensure the quality of the permanent works, which shall comply with the Technical
Specifications and applicable standards.
The Safety Inspector is responsible for informing all personnel, including Works
Superintendents, Foreman, Craft Workers, Laborers and any other personnel involved
in the works, of all the dangers and safety procedures to avoid accidents in the work
area.
The Laboratory is responsible for carrying out all specified in-situ and laboratory
testing in accordance with the approved methods.
The ER will receive the method statement for his interface.

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3. REFERENCES
This document has been prepared on the following basis and assumptions:
 Quality Assurance Plan
 The Drawings in Contractor’s hand to date
 The Technical Reports in Contractor’s hands to date
 Civil Works Technical Specifications (CWTS) and Materials Specifications
 All the information, clarifications, detailed technical discussions held with the
suppliers on the materials and equipments to be used for the execution of the
works
 Related method statements and reports:
- 321-GEN-R-SA-001-B “RCC Production Method Statement”
- 520-RCC-R-SP-001-A “RCC Trial Mix Tests”
- 520-RCC-R-SA-002-A “Full Scale Trials”

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4. EQUIPMENT
The following machinery has been foreseen to be used in the execution of the works:
Item Description Quantity

1 CAT D6R Dozer with flat blade 1
2 CAT 683 Roller 2
3 SAME Laser 125 Tractor 4x4 2
4 Terex Crane 30T (or equivalent) 1
5 ITALCLEAN PRIMITIVE 234/75 Broom for SAME tractor 1
6 BOSSINI B2-140 Tow Vacuum Tank 1
7 Dynapac LP 750 Duplex Hand Roller 2
8 Dynapac LG 500 Hand Tamper 1
9 Dynapac LG 160 Hand Tamper 1
10 Tyrolit FZ-2ST Circular Saw 1
11 High Pressure Water Pump 74 bar – 318 lt/min 1
12 CPN MC-S Strata Gauge (Nuclear Densimeter) 1
13 Rotec Crater Crane CC200-24 1
14 Conveyor belt 1
15 Astra 64/32 Dumper Truck 4
16 Astra/CIFA Mixer Truck 7-8 m3 2
The designated Crushing Plant is the one located at Temporary Site Installations D.
The Batching Plants are those located at Temporary Site Installations B and D
(Attachment 2).
Adequate lighting will be provided at the RCC construction site to facilitate work at
night.

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5. MATERIALS
5.1 Cementitious Materials and Retarder

The Full Scale Shear Pads will be constructed using Maple Leaf cement CEM I
42.5N, Ulula fly ash and SIKA Plastiment VZ retarder. See Attachment 1 for the
product specifications.
5.2 Aggregates
The aggregates to be used will be Alluvium, Basalt and Ignimbrites. The Alluvium
and Basalt will be crushed and then mixed with the separately crushed Ignimbrites.
The Aggregates will be in SSD condition and the average aggregate distribution is as
follows:
 Alluvium 72%
 Basalt 25%
 Ignimbrite 3%
Four aggregate classes will be produced as shown Table 5.1 below. The allowable
fines content is listed in Table 5.2.
Table 5.1 Aggregates Classes

SIZE CLASS (mm) MATERIAL
0-10 Ignimbrites
0-10 Alluvium + Basalt
Table 5.2 Liquid Limit and Plasticity Index of Aggregates

LIQUID LIMIT (%)* PLASTICITY INDEX (%)*
Ignimbrite 0-10 mm 22 N.P.
All-Bas 0-10 mm 18 N.P.
All-Bas 10-20 mm 23 N.P.
All-Bas 20-50 mm 27 10
Combined Curve 23,7 N.P.
*Plasticity Index and Liquid Limit tests carried out on the fraction passing Sieve
No. 40 (0.425 mm)

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5.3 Mix Designs

5.3.1 RCC
Two mix designs are foreseen to be used in the trials. Mix design B with a 1-year
characteristic strength 10 MPa, containing 80 kg cement and 80 kg fly ash; and mix
design E with a 1-year characteristic strength 18 MPa, containing 120 kg cement and
120 kg fly ash (Table 5.3). See attachment 7 for the mix designs.
Table 5.3 Characteristics of RCC mixes B and E

RCC Mix Design B RCC Mix Design E
Cement Content 80 kg 120 kg
Fly Ash Content 80 kg 120 kg
Max Aggregate Size 50 mm 50 mm
Design Strength (1-year) 10 MPa 18 MPa
VeBe Time 1 9-15 seconds 9-15 seconds
5.3.2 Bedding Materials
Two bedding materials are foreseen to be tested to see which will produce the better
bonding at the lift joint. The first is a Bedding Mortar containing a maximum
aggregate size of 5 mm. The second is a Bedding Mix containing maximum aggregate
size of 10 mm (Table 5.4). Both mixes include SIKA Plastiment retarder and have a
90-day characteristic strength of 20 MPa.
Table 5.4 Characteristics of Bedding Mortar and Bedding Mix

BEDDING MORTAR BEDDING MIX
Max. Aggregate Size 5 mm 10 mm
Max. Design strength (90-day) 20 MPa 20 MPa
Slump 180-230 mm 130-180 mm
5.3.3 Conventional Concrete
The base layer of the Full Scale Shear Pads has been cast using C25D32 conventional
concrete.

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6. OPERATIVE METHODS AND WORKING PHASES
6.1 General
The purpose of the Full Scale Shear Pads is to study the mechanical characteristics of
the horizontal lift joints. These trials will be used to determine the shear strengths
(cohesion and friction angle) at the horizontal joints under the following conditions:
 Various lift joint maturities (measured in Degree-hours, °C-hrs)

 Various horizontal lift joint treatment methods
 Various horizontal lift joint conditions with rain
Shear tests will be performed on blocks extracted from the shear pads. The results will
be used to determine the in-situ values of cohesion and friction angle between the
horizontal lift joints and a comparison will be made with the current design
parameters (see 520-RCC-R-SA-002-A). If the analyses of the test results indicate
shear strength values which do not comply with the design parameters, the necessary
adjustments will be made.

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6.2 Classification and Treatment of Lift Joints

6.2.1 Lift Joint Maturity
The Lift Joint Maturity (LJM) is used to classify the horizontal lift joint conditions
before placing the subsequent RCC layer. Depending on the conditions, different
types of joint treatments must be applied before proceeding with RCC placement. The
treatments are described in sections 6.2.2 to 6.2.4 below. The criteria for defining the
lift joint conditions are given in Table 6.1 below, in accordance with CWTS 14.10.2.
Table 6.1 Lift Joint Classification Criteria

Lift Joint Condition Criteria
Warm Joint LJM < 500 °C-hr*
LJM > 500 °C-hr*, but time less than 36 hr after
Cold Joint, Type I
compaction
Cold Joint, Type II time is more than 36 hr after compaction
*The LMJ limits between Warm Joint and Cold Joint Type I will be checked and verified by the Full
Scale Shear Pad tests.
LJM is calculated by taking the average of the previous and current surface
temperature of the lift joint surface during each measurement increment of time after
compaction and multiplying it by the elapsed time after compaction in hours. The
time-increment of measurement shall be minimum 1 hour. The calculation formula is
given below:
t  tn
LJM  n i  n,
2
where,
i = time increment
tn-i = previous measurement of average surface temperature (°C),
tn = current measurement of average surface temperature (°C),
n = the time after compaction (hr),
LJM = Lift Joint Maturity (°C-hr).
The following example will demonstrate the calculation of LJM:
tn  i  tn
n (hr) tn (°C) LJM (°C-hr)
2
0.0 25.0 - -
0.5 25.0 25.0 12.5
1.0 30.5 27.8 27.8
1.5 31.8 31.2 46.7
2.0 33.1 32.5 64.9
2.5 33.3 33.2 83.0
3.0 33.5 33.4 100.2
3.5 33.6 33.6 117.4
4.0 33.5 33.6 134.2
The average surface temperature is measured every 30 minutes (i=0.5), and the
temperature after compaction (n=0) is 25°C. After four hours the LJM is 134 °C-hr.

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6.2.2 Warm Joints
A Warm Joint is produced when the compacted RCC has passed the time of initial set,
but has not yet reached a lift joint maturity of 500°C-hrs (to be confirmed by tests).
Dirt, debris and construction traffic will be kept off the joint surface at all times. Prior
to placing the next layer of RCC the joint surface will be cleaned from all loose
materials, laitance and standing or running water. The cleaning operation will be
performed using brooms and air jets. Vacuum equipment will be made available for
the cleaning operation if necessary.
6.2.3 Cold Joints Type I
When the lift joint maturity has exceeded 500°C-hrs (to be confirmed by tests), but the
time after compaction is less than 36 hrs, the joint is classified as a Cold Joint Type I.
Before placing the next RCC layer, the lift joint surface will be cleaned from all loose
materials, laitance, debris and contaminants using air jets and brooms. Finally, a
bedding mix (10-20 mm thick layer) or bedding mortar (10mm thick layer) may be
applied to the surface no earlier than 15 minutes prior to placing the next layer of
RCC. Vacuum equipment will be made available for the cleaning operation if
necessary.
6.2.4 Cold Joints Type II
When the time after compaction is in excess of 36 hrs the lift joint is classified as a
Cold Joint Type II. Before proceeding with the next RCC layer, the joint surface must
be clean from all loose materials, laitance, debris and contaminants using air/water
jets, brooms, shovels and, if necessary, vacuum equipment. The cleaning procedure
shall expose but not undercut the aggregates. 15 minutes prior to placing the next
layer of RCC a bedding mix (10-20 mm thick layer) or bedding mortar (10mm thick
layer) will be applied to the surface.

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6.3 Full Scale Shear Pads Construction Program

The Full Scale Shear Pads will be constructed close to Temporary Site Installations D,
near the Omo Bridge (see Attachment 2). Construction is planned to start on 09 March
2011, and is envisaged to be carried out over an 8-day period. The tentative
implementation schedule is enclosed in Attachment 3.
Five Shear Pad strips will be constructed to an approximate height of 0.8m and a
width of 3.6m, consisting of three layers each. The base layer will be a minimum of
20 cm thick, the first RCC layer 30 cm thick and the second and final RCC layer will
be 30 cm thick. Three strips will be constructed with a length of 15m, and two with a
length of 10m (see Figure 6.1).
Strips A and B will be prepared with RCC mixes B and E, respectively, and the same
lift joint maturities. The purpose of these two strips is to confirm the limit of 500°C-hr
as the definition of a “warm joint”. Three 5m blocks with lift joint maturities of
300°C-hr, 400°C-hr and 500°C-hr, between the first and second layers, will be
produced and tested.
Strip E will be constructed using an RCC mix E in order to simulate the joint
conditions under rain. Three blocks will be produced with maturities of 300°C-hr,
>500°C-hr and >36 hr, and will be treated as “warm joint”, cold joint type I, and cold
joint type II, respectively.
Two more strips (C and D) using the same RCC mix E will be constructed. These to
strips will contain two 5m blocks each, the first strip aimed at testing “cold joint type
I” conditions, and the second aimed at testing “cold joint type II” conditions. In each
strip one block will be treated with bedding mix and the other with bedding mortar.
The Full Scale shear pad program will begin with the construction of strip E. When
strip E has been fully constructed, strips C and D will be executed in parallel. When
these two strips have been completed, strip B and A will be constructed
contemporaneously (see Attachment 3).
The order of construction has been chosen to allow the less experienced crews to be
trained using the “worst” RCC conditions, introducing them to all the different steps
of the process as early as possible. This will allow them to be more adept at placing
RCC before reaching strips A and B which require more skill as the joint surfaces are
more sensitive and the waiting times are shorter.
For more information on the Shear Pads construction program, see Attachment 4.

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Figure 6.1 Full Scale Shear Pads

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6.4 RCC Placing

The RCC will be batched at the plant located at Temporary Site Installations D, near
the Full Scale Shear Pads. Bedding Mortar and Bedding Mix will be batched at the
plant located at Temporary Site Installations B. In order to reduce the RCC
temperature as much as possible, chilled water and ice will be used when batching and
a cover will be constructed over the aggregate stocks. The coarse and medium
grained aggregates will be kept in SSD conditions. For the sand, moisture will be
measured and, depending on the results, water will be added to the RCC mix at the
batching plant.
6.4.1 Preliminary Activities
A layer of conventional C25D32 concrete has been placed as the Base Layer at the
site for the Shear Pads (Figure A2.1 in attachment 2). The base layer will be covered
with polyethylene or a mould release agent prior to the start of placement.
Formwork will be erected to a height of 60 cm on the sides of the shear pads and at
the ends of the shear pads. At the front of the shear pads formwork for the first layer
will be erected to a height of 30cm before the ramp is constructed. The ramp will then
be constructed against the formwork. (Figure A2.2 in attachment 2)
Ramps will be constructed on one side of the Shear Pads to allow the ascending and
descending of construction equipment. The ramps will be constructed using base-
course type material and finally topped with a layer of concrete. During the ramp
construction care will be taken to ensure that the base layer and RCC lift joint surfaces
are not contaminated.
Before the RCC placing begins the working condition of all necessary equipment shall
be check and any oil leakages shall be rectified. The tracks and wheels of equipment
working on top of the RCC layers shall be cleaned of contaminants before being
allowed on the RCC surfaces.
6.4.2 RCC Transportation and Depositing
The RCC will be transported from the Batching Plant using trucks. The trucks will
unload the RCC into the hopper of the Crater Crane. The Crater Crane will then
deposit the RCC on the trial pad in windrows. Each windrow will have an overlap ½
its height with the adjacent windrow.
6.4.3 Spreading
Prior to the start of spreading, the temperature of the RCC will be measured.
Spreading will commence within 10 minutes of the depositing of the RCC. A CAT
D6R Dozer equipped with flat rubber tracks will spread the RCC by full thickness.
Care will be taken so that the thickness of the layer being spread is never less than the
final spreading thickness of 35 cm. Markings on the formwork will be used to ensure
correct thickness during spreading.

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After spreading, the placing temperature will be measured and a thermocouple will be
installed just under the lift joint surface. Samples will also be collected for the
modified VeBe Time, Unit Weight and Air Content tests.
6.4.4 Compaction
Compaction will be carried out to a final thickness of 30 cm in the centre of the Shear
Pad, using an 18 ton CAT 683 Roller (attachment 9). This will commence
immediately after the spreading has been completed. The Roller will start with 1 static
pass1, followed by a minimum of 6-8 passes in vibratory mode. Finally, the Roller will
perform 1 static pass. During compaction the roller vibration frequency will be
measured with a tachometer.
The borders of the trial pad will be compacted with the Dynapac LP 750, and the two
other hand tampers, to the final compaction thickness. The overlap will be 10 cm. The
rollers are not allowed to be in vibratory mode when standing still, and vibratory
mode shall only be activated when the roller is moving.
After compaction, the density will be measured with the nuclear densimeter. This shall
be carried out at least 30cm away from the area where the Shear Test blocks will be
extracted.
Level 2 Design will define the minimum RCC density to be attained. The mix design
study and the Full Scale Trial Test shall confirm that the designed density can be
attained. The required average wet density per lift shall be achieved at each test
location, or for every 100 m2. Test in situ will be carried out with a two probe
strata’s nuclear density gauge. Three units in good working order shall be available
on site. They shall be calibrated in the factory. In principle, the minimum average
wet density per lift shall be 2.35 kg/m3. (CWTS 14.9.1.3)
This is approximately 97 % of the practical achievable density using good practice

and equipment, and it is approximately 96 % of the theoretical air free density. The
average density at each individual test location shall be determined from readings
taken at the bottom of the lift, the middle of the lift, and approximately 10 cm below
the top of the lift. No individual reading of less than 92 % of the theoretical air free
density will be allowed in any part of any lift. (CWTS 14.9.1.4)
6.4.5 Curing
Curing will be carried out using water mists, keeping the top surface of the RCC layer
in a continuously damp condition until it is covered by the next layer. Curing will be
performed so as to avoid water ponding on the surface, but done in a manner so that
the RCC is continuously wet.
1
1 “pass” is 1 trip across the RCC, and 2 passes is a “round trip”. See CWTS 14.9.1

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6.4.6 Placing of Top RCC Layer
In order to carry out the placing of the subsequent RCC layer, the necessary extension
of ramps must be carried out with base-course type material and concrete as above.
Prior to the ramp construction, a 30cm high formwork will be erected at the front of
the shear pad against which the ramp will be constructed. Another formwork with a
height of 30 cm will be erected between blocks of different maturities to limit the
spreading of the placed RCC. These operations will be carried out so as not to delay
the placing of the RCC, taking care not to contaminate the surface of the existing RCC
layer.
The lift joint treatment will be carried out in accordance with the specified treatment
for Warm Joints, Type I Cold Joints or Type II Cold Joints. Bedding mix and mortar
will be transported by mixer trucks to the Shear Pads construction site. After the
application of the prescribed treatment, the subsequent RCC layer will be placed as
described in the preceding sections.
After placing, the final layer will be allowed to mature before the samples are taken
for the Shear Strength tests. Curing will be carried out continuously during the final
maturation period.

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6.5 Laboratory Tests

Sampling and testing will be carried out by the site laboratory. The tests are divided
into those carried out at the construction site, and those carried out in the laboratory.
For each RCC Placing, the tests/sampling will be carried out in the following
sequence:
1. Measure aggregates temperature;

2. Measure RCC temperature at the batching plant;
3. Measure VeBe Time 1 at the batching plant;
4. Take samples for laboratory testing;
5. Measure RCC temperature before spreading;
6. Measure RCC temperature after spreading;
7. Install thermocouple;
8. Measure Roller vibration frequency during compaction;
9. Measure Surface temperature after compaction, as well as ambient temperature,
and continue to measure ever 30 minutes thereafter, and take readings from
thermocouple as described in section 6.5.1;
10. Measure density with nuclear gauge.
6.5.1 In-situ Testing
The tests which will be carried out at site are as follows:
 Ambient Air Temperature will be measured at the Shear Pads construction

site and readings taken every 30 minutes.
 Aggregates and RCC Temperature will be measured at the aggregate stocks

and batching plant, respectively.
 RCC Temperature before Spreading will be measured.
 RCC layer thickness during spreading shall be controlled by level indications

marked on the formwork. The layer thickness of 30 cm after compaction will
be controlled by level indications marked on the formwork.
 Placing Temperature will be measured after spreading the RCC and prior to
compaction. This temperature is determined by placing a thermometer into the
RCC at the placement site in four different positions.
 Roller Vibration Frequency will be measured by placing a Tachometer on the

lift surface during the compaction.

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 RCC Surface Temperature will be recorded just after compaction and at 30

minute intervals thereafter. The temperature will be taken as the moving
average in two areas close to the centre of a block, and will be measured by a
laser thermometer. These values will be used to calculate the Lift Joint
Maturity Index.
 1 Thermocouple will be installed on each block just under the surface of the
joint between the first and second layer. This will be done immediately after
the spreading of the RCC, but before the compaction. Readings will be taken
just after compaction and every 15 minutes thereafter during the first 12-hour-
period. After the first 12 hours, the frequency of the readings may be reduced
to one reading every 30-60 minutes. A total of 13 thermocouples will be
installed in the Full Scale Shear Pads.
 VeBe Time 1 testing will be carried out for each RCC batch at the batching
plant to ensure it is in the required limits of 9 to 15 seconds.
 Density will be measured using a nuclear densimeter (attachment 6). A reading

will be taken in each block in a shear pad after compaction, at least 30 cm from
the area where the test-blocks will be extracted. The measurements will be
taken at three depths: approximately 10 cm, 15 cm and 25 cm from the
surface2. The in-situ wet density will be at least 96% 3of the theoretical air-free
density (TAFD).
The test-sheets for the in-situ tests are enclosed in attachment 5.
2
CWTS 14.9.1.4
3
Ibid.

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6.5.2 Laboratory Testing
Sampling of the RCC mix will be carried out in-situ and brought back to the
laboratory. The following tests will then be performed:
 Standard Cylinder Test samples will be collected for each Shear Pad Block
and cast in the laboratory. For each cylinder the VeBe time, Unit Weight and
Air Content tests will be carried out. 11 samples will be collected in order to
carry out the test program shown in Table 6.2 for each RCC placing.
Table 6.2 Standard Cylinder Testing

N° AGE OF CYLINDER
DESCRIPTION
OF TESTS (days)
2 28
Compressive Strength
2 90
(Stress-strain graph)
2 365
1 28
Tensile splitting test 1 90
1 365
Accelerated Curing 2 equivalent to 365
 Shear Strength tests will be performed on 9 RCC cubes (300mm x 300mm x

600mm) extracted from each block of a Shear Pad strip. These cubes will be
extracted by cutting, using a 1.6m diameter circular Tyrolit saw (attachment 7),
from the centre of the shear pad blocks (attachment XX). The tests to be
carried out on these blocks are listed in Table 6.3 below.
Table 6.3 Shear Strength Tests

CONFINEMENT AGE OF CONFINEMENT AGE OF CONFINEMENT AGE OF
LOAD RCC LOAD RCC LOAD RCC
MPa Days MPa Days MPa Days
28 28 28
0.1 90 1.1 90 2.2 90
365 365 365
 Tensile Strength tests will be performed on 3 RCC cubes (300mm x 300mm x

600mmm) extracted from each block of a Shear Pad strip. These cubes will be
extracted together with the Shear Strength test-cubes.

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7. QUALITY CONTROL ORGANIZATION
The Quality Control Section as well as the Laboratory section will be responsible for
the quality control.
8. SAFETY MEASURES
Refer to the detailed Risk Assessment in attachment 11.
9. QUALITY RECORDS AND FILING SYSTEMS
Reference is made to the QC plan in attachment 10, which is relevant to the Full Scale
Shear Pads construction and testing. The relevant quality records and filing shall be
carried out by the QC section/Laboratory section.

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10. ATTACHMENTES
Attachment 1: Cementitious Materials & Retarder

 Maple Leaf Cement Certificate
 Ulula Fly Ash Certificate
 SIKA Plastiment VZ Data Sheet
Attachment 2: Location
 Drawing: 502 SIT D SAS 122 F, Site Installations General Layout
 Photograph: Site Installations D and Position of Shear Pads
Attachment 3: Implementation Schedule

 Tentative Implementation Schedule
Attachment 4: Full Scale Shear Pads Construction Details

 Attachment 5.1 – Strip A
 Attachment 5.2 – Strip B
 Attachment 5.3 – Strip C
 Attachment 5.4 – Strip D
 Attachment 5.5 – Strip E
Attachment 5: Laboratory In-situ Test-Formats

 Fresh RCC Tests Format
 RCC Surface Temperature Format
 Nuclear Gauge Density Format
 RCC Thermocouples Temperature Format
 Aggregates and RCC Temperature Format
Attachment 6: Nuclear Densimeter

 Nuclear Densimeter Calibration Procedure and Results
 Nuclear Densimeter Data Sheets
Attachment 7: Mix Designs

 RCC Mix Design B
 RCC Mix Design E
Attachment 8: Tyrolit Circular Saw

 Tyrolit FZ-2ST Circular Saw Data Sheets
Attachment 9: CAT 683 Roller

 CAT 683 Roller Technical Data Sheets
Attachment 10: Quality Control

 Quality Control Plan
Attachment 11: Risk Assessment

 Spot Job Safety Analysis

016 - MS For Full Scale Shear Pad Rev.B - 09 Mar 11

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016 - MS For Full Scale Shear Pad Rev.B - 09 Mar 11

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THE FEDERAL DEMOCRATIC REPUBLIC OF ETHIOPIA

ETHIOPIAN ELECTRIC POWER CORPORATION

salini COSTRUTTORI S.p.A

GIBE III HYDROELECTRIC PROJECT

RCC Dam Full Scale Trials Phase II

Technical Department Project Manager

8. SAFETY MEASURES ........................................................................................... 20

9. QUALITY RECORDS AND FILING SYSTEMS .................................................... 20

10. ATTACHMENTES ................................................................................................. 21

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1. DOCUMENT SCOPE AND FIELD OF APPLICATION

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Item Description Quantity

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5.1 Cementitious Materials and Retarder

Table 5.1 Aggregates Classes

Table 5.2 Liquid Limit and Plasticity Index of Aggregates

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5.3 Mix Designs

Table 5.3 Characteristics of RCC mixes B and E

5.3.2 Bedding Materials

Table 5.4 Characteristics of Bedding Mortar and Bedding Mix

5.3.3 Conventional Concrete

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6. OPERATIVE METHODS AND WORKING PHASES

 Various lift joint maturities (measured in Degree-hours, °C-hrs)

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6.2 Classification and Treatment of Lift Joints

Table 6.1 Lift Joint Classification Criteria

The following example will demonstrate the calculation of LJM:

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6.2.2 Warm Joints

6.2.3 Cold Joints Type I

6.2.4 Cold Joints Type II

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6.3 Full Scale Shear Pads Construction Program

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Figure 6.1 Full Scale Shear Pads

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6.4 RCC Placing

6.4.1 Preliminary Activities

6.4.2 RCC Transportation and Depositing

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This is approximately 97 % of the practical achievable density using good practice

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6.4.6 Placing of Top RCC Layer

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6.5 Laboratory Tests

1. Measure aggregates temperature;

6.5.1 In-situ Testing

The tests which will be carried out at site are as follows:

 Ambient Air Temperature will be measured at the Shear Pads construction

 Aggregates and RCC Temperature will be measured at the aggregate stocks

 RCC Temperature before Spreading will be measured.

 RCC layer thickness during spreading shall be controlled by level indications

 Roller Vibration Frequency will be measured by placing a Tachometer on the

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 RCC Surface Temperature will be recorded just after compaction and at 30

 Density will be measured using a nuclear densimeter (attachment 6). A reading

The test-sheets for the in-situ tests are enclosed in attachment 5.

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