Underwater Constructions and Concrete Repair Works at the Nalubaale Hydro Power
Station
Eng. Kevin Otim, PMP Eng. Anne Nankanja Gitta Eng. Fredrick Wasike
Project Manager Head Civil Section, Eskom Uganda Manager Dam Safety and Water
[email protected] [email protected] Resources, UEGCL
[email protected]
Abstract
The life of concrete dam structure is influenced by the condition of both the above and below water
surface. This necessitates the execution of timely repairs on the entire structure curb any identified
deterioration. Over time dam structures undergo deterioration that results into cracking and
spalling of the underwater surfaces of the dam. These areas of deterioration, if not urgently
addressed result into voids in the dam and seepages through cracks which pose both operational
and dam safety concerns to the structure.
The Nalubaale Hydro Power Plant, commissioned in 1954, consists of a concrete gravity dam with
a maximum height of 30m and 726m in crest length, equipped with six gated low-level sluices to
regulate the river flow and a concrete intake dam immediately downstream of which is located the
indoor surface power station housing ten 18MW generating. The powerhouse structure consists of
several downstream columns 16m in height, 11m of which are normally submerged in water, that
support the tailrace deck on which sits 3 gantry tailrace crane that is used for gate operations. These
columns also bear the downstream gate guides and provide firm foundation for the gates to sit into
the river and allow for water ways maintenance activities.
Following a sonar and dive Inspection surveys of the underwater Draft tube deck Column
structures of the Powerhouse, significant spalling and cracking was observed on the externally
submerged areas of the main and intake dams. The Downstream draft tube support columns had
also been severely affected by deterioration exposing rebars withing the structure. This
necessitated the need for underwater repairs and constructions in the damaged parts to curb further
deterioration on the concrete dam and limit future costly remedial efforts.
This paper discusses the execution of underwater remedial repair and structural strengthening
works at the Nalubaale Power station, the methodologies used, the repair approach of the cracks
and spalled areas, material selection and construction monitoring process. The paper also
documents the key challenges faced in the construction execution especially as relates to ensuring
diver safety at the hydro power plant, in addition to continued hydropower supply from some
generating units, whilst guaranteeing safe work executions at the points of repair.
Key Words
Underwater Construction, Dam Safety, Hydro Power
The Authors
Eng. Kevin Otim, PMP; is a Certified Project Manager, extensively experienced at Engineering design,
problem solving, solution development, Contract, claims and Project management. Most notably Executing
and advising on several high value, challenging remedial and rehabilitation projects at two of the oldest
hydro power stations in Uganda, the Nalubaale and Kiira HPP. He has been involved in administering
complex contracts and providing measures of detailed technical and management acumen, to deliver
engineering roadmaps and solutions, with financial diligence that ensures delivery excellence.
Eng. Anne Nankanja Gitta holds a BEng in Civil Engineering and as over 20 years of professional
experience in monitoring and maintain performance of dams and its appurtenant structures. She is also
extensively experienced in design, dam safety evaluations, refurbishment and construction of dams,
assessment of instrumentation data to determine appropriate remedial measure. Currently working with
Eskom, with the key responsibility of monitoring and maintaining the Nalubaale and Kira Dam aged 68
years and 22 years respectively both located along the river Nile. Most recently involved in the Dam Safety
Review of the Nalubaale and Kira dams, of which Nalubaale has greatly been affected by the Aggregate
Silicate Reaction (ASR).
Eng Fredrick Wasike (MBA). Has extensive experience in Dam maintenance and operations having
worked on Uganda's oldest dams for over a decade. During this time he spearheaded the monitoring and
structural evaluation of the civil structures and apartment structures and participated in a number of
remedial measures to improve/extend expected life expectancy of these structures. He is currently the Dam
safety and Water resources Manager with UEGCL and oversees operations of the concession at NPS and
KPS
1. Introduction & Problem
For most of its life Nalubaale Power station (NPS) has suffered cracking and structural movement
due to a rare construction oddity caused by Alkali Silica reaction (ASR), a chemical reaction
between cement and aggregate that results into concrete expansion. (ASR). This expansion causes
detrimental effects to civil hydro infrastructure including reduction in gate clearances, concrete
cracking, failure of support structures and turbine/generator alignment problems (Otim & Gitta:,
2019).
Following an ASR driven Finite element assessment of the powerhouse carried out by Hatch
Limited, it was determined that there could be deterioration occurring on the downstream draft
tube deck columns of the power station especially those between Units 5 to 10 (Figure 1). It was
therefore for recommended that an underwater inspection be carried out on the Columns between
Units 5 and 10. The inspection was carried by of divers with high-tech underwater cameras and
sonar equipment along with a wide variety of simple hand tools, physical measurements of defects
were approximated using visual scaling, tape measures, finger sizes and hand span.
The deterioration was observed to be ranging from very light to severe with the greatest amount
of deteriorated concrete was found at the bottom portions of the columns. This had happened over
time, with the damages extending inwards. However, the concrete at the top 6m and the bottom of
the columns appeared sound. The average depth of damage for the moderately and severely
deteriorated columns was 300-400mm on the downstream faces of the columns. Later inspections
revealed that the Columns between Unit 1- 4 were generally in good condition due to the
differences in ASR related concrete in the powerhouse.
Figure 1: Cross section of the Powerhouse highlighting the downstream columns
The cracking and deterioration observed on the downstream draft tube columns was assessed to
be due to factors including the structural rotation caused by the power station expansion and the
effects of ASR and the erosive an abrasive force of water affecting the cracked concrete below the
water surface (Figure 2).
Figure 2: Diver placing hand into crack on one of the unit columns
Schmidt Rebound Hammer tests were used to check the strength of the Column surfaces above the
water and lowest compressive strength was recorded at about 58Mpa quite a good indication that
the general concrete cast was sound. The primary concern then was that local collapse of the deck
would certainly render the affected units inoperable and threaten the functioning of the whole
station.
The findings were not recorded for the first time during this recent assessment, as 1987 Gibb, the
rehabilitation Engineering team at Nalubaale reported that there could be cracking to the
underwater sections of the columns resulting from the same modelled rotation. However, at the
time, Given the generation constraints and the minimal underwater execution advancements, they
opted to limit the amount of underworks, opting to gout in place steel casings installed close to
deteriorated columns, which would be loaded in the event of failure of the downstream columns.
The key challenges to this solution were that the supplementary support columns did not provide
load transfer directly to the foundation but rather through the draft tube roof, which loading paths
were not designed for, at initial construction. The center pier of the draft tube roof and the side
walls were also subject to existing rotational movement and hence the existing shear cracks
potentially leading to overstressing and system failure in event the downstream columns were to
fail shift the load to these steel supplementary sections. The consideration for security of the draft
tube deck operations and surrounding concrete providing foundation for the guides was also an
issue assessed to be of concern.
As such Eskom Uganda Limited, commissioned a project to designed by Hatch Limited to repair
the 18 underwater columns from Unit 5 to 10 of the powerhouse their structural condition and
avert any deterioration as well as possible structural failures. Given the generation requirements
the repair had to only involve partial shutdown of the generating station to allow for both diver
safety and continued electricity generation.
2. Repair option
The best repair of underwater concrete structures is preferably performed in dry conditions after
dewatering the structure upon building a cofferdam or sheet pile structure, however, in several
cases, this is not financially prudent, environmentally acceptable or extensively challenging in
terms of execution. Hence it becomes necessary to appropriate a repair solution under submerged
conditions.
As the deterioration was underwater, any envisioned remediation would likely require the need
carry out extensive under water repair and machine shutdowns in areas where the works are being
undertaken for diver safety.
Together with the design Consultants and from a value engineering perspective, the option to
execute using a steel concrete shuttering system placed around the columns that would be grouted
by tremie method was preferred for curbing deterioration, providing strengthening and offering
protection to the gate guide support structures.
The solution targeted filling of any voids within the structure and by implication improving load-
carrying capacity of the element and stopping any further deterioration. The solution ensured there
was minimal impact on electricity generation and short execution schedule.
The key design requirements were
a) The ability of the shuttering -plates to resist the maximum factored shear and moment
stresses. Iterations were made regarding the execution method and staged grouting (1.5m
length stages) was chosen to ensure that the allowable stress is accommodated.
b) Anchor bolt tension capacity to hold the plate in place and resist the maximum net pressure.
It was also conservatively assumed that the concrete strength within the lower areas was
17.2MPa.
3. Materials
Table 1: Details of materials used during the project execution
Material Details
Anchor Bolts Stainless steel bolts designed and selected based on the Hilti catalogue for
HIT-RE 500 V2 adhesive anchor, size 19mm and 255mm embedment.
Steel Plates Structural steel plate thickness was 6mm, steel grade 300W with maximum
(Form work) tributary bolt to bolt width of 500mm.
Grout Sika Grout®-212 is a one-component, ready to mix, free flowing, non-shrink,
cementitious grout with a unique 2-stage shrinkage compensating
mechanism.
Plate edge Sika Hydrotite
sealant
4. Execution.
Site access
To repair the underwater columns, the contractor constructed a floating boat/ pontoon about 6m
by 4m in dimension cable of holding 3 tonnes of load. This would go on to be used as the platform
from which divers would access the repair area. The floating pontoon was also used for temporary
storage of the formwork steel plates, construction equipment, divers launch and Recovery Unit,
diving compressor and receiver tank, diver umbilical with air hose, communication cable, lifeline
and other safety equipment.
During the execution at a particular generating unit, necessary steps were taken to shut down the
generating unit being repaired and the generating Units adjacent on the left and right of the unit
under repair in line with the internal Plant Safety Regulations Procedure. For example, if Unit 5
was being repaired, Unit 4 and Unit 6 were shut down to ensure safe work execution.
Figure 3: Diving platform/boat with temporality stored steel shuttering plates for Unit 8 central column
The adjacent Units were to be then required to return into operation at the close of the workday to
meet electricity dispatch requirements and be shut down at the next workday. The contractor was
therefore responsible and required to ensure that all under works done at the end of a workday are
firmly secured to prevent shifts in the presence of currents from the adjacent units.
Diving Operation
The diving operation used was Manned diving which is more commonly preferred for underwater
inspections and repairs (Figure 4). The diver was supported by breathing gas provided through an
umbilical hose which extended from the surface, and the diver was limited by time and dive depth
for safety reasons. The divers were breathing air through an umbilical hose supplied from the
surface supported by a compressor. The divers were also attached with a communication cable for
voice and videography, a lifeline, and a pneumotachometer.
Figure 4: Diver leaps into the water to continue construction with connected umbilical
Cleaning
Given the age of the underwater concrete elements, there was need to remove all marine growth,
sediment, debris, and deteriorated concrete before repair concrete was placed into a structure. This
was intended to ensure good bonding between the concrete material and the existing concrete.
During the execution, divers cleaned the surface using mechanical scrubbers and hydraulic power
brushes.
Formwork and Steel Plate installation
The repair was designed to cover 11m section of the Columns right from the foundation to the
above surface areas of the column. Due to the weight of the steel plates, the contractor constructed
as 0.75m and 1.5meter high rigid sections of steel covering the three sides of the column to be
repaired based on the designed geometric shape and mould.
These sections were designed to be easily assembled in situ with a slot or locating bolt from plate
to the other. A total of 8 steel sections was used per column to provide the placed-on top of one
another in sequence around the columns and secured to the column using threaded anchor bolts
and drilled into the concrete columns and affixed with specialized Hilti adhesive anchor material.
as illustrated below. Building up to the required protection height
Although formwork is typically sacrificial due to the cost of the steel formwork and the effort
required to remove it post concreting, the steel plates were designed to be left in place after
execution of the works to support as a form of structural exo-skeleton.
The plates were abrasively blasted to near white (SSPC-SP10) and well painted with appropriate
corrosion proofing No paint was applied on the inside surface. They were then then affixed with
finger tight anchors into the existing columns for interior anchors and half turn tight anchors for
exterior anchors.
The steel plate covers were then lowered to the divers and positioned onto the columns using a
pulley system and boom lift installed on the floating boat. Once the plate was lowered and
positioned over the columns, it was fully supported by the divers and the lift pulley to allow the
drilling team drill through the concrete, affix bolts and secure the plate in place. Once the steel
plate covers were positioned and secured in place using the temporary installation supports the
anchoring holes were drilled into the column, through and guided by the pre-drilled holes in the
steel plate cover.
The edges of the plates were affixed with hydrotite, a hydrophilic water stop with expansive
capabilities to limit loss of grout through edges of the columns.
Grouting method
Following the completion of the plate installation, the Cementitious grout was then used to fill the
60mm space between the concrete and the formwork. This was done in 6 stages for each column
staged manner from the bottom section of the column to the top sections (Figure 6).
The grouting was done by tremie method from the deck of the draft tube by gravitation, with the
mouth of the tremie remaining embedded in the concrete to prevent concrete from dropping
directly through water and washing away. In certain areas doses of anti-washout admixtures were
used to limit cement washout from the concrete during the execution
The edges of the concrete columns were continuously monitored by the divers for leakages and
whenever a leakage emanated, it was blocked by use of foam to stop the out flow.
Figure 5: As built cross section of each unit center column
Quality Control and Post Inspections
One of the core challenges in this execution was management of quality and supervision by the
project team as the works were majorly done under water. To ensure the appropriate verification
and supervision was achieved the Contractor kept a live video feed on the floating boat and was
required to provide video recording of the live feed and captured images on a daily basis
throughout the entire execution. This was reviewed by both the Client Engineer and consulting
teams to ensure that that the appropriate execution methodology was adhered to.
The steel plate samples were also taken for tensile tests giving a minimum yield stress is 509 MPa
which significantly exceeds the required 300 MPa demonstrating that the steel plate complies with
the design specification.
Onsite grout modification was also performed with anti washout in cylinders to check the most
appropriate level of mix that could ensure fast setting and minimal washout during the execution.
The selected choice of concrete Sika 212 is a remixed specialised concrete that allows for
achievement of consistency during the entire execution of the works.
Figure 6: Grout tremie approaches the top of the column
5. Challenges
Underwater executions of concrete works typically present significant challenges, although the
repair procedures are like that outside water. There were limitations regarding the time a diver
could spend underwater due to prevent decompression sickness. The execution was hampered in
some areas by poor visibility, strong currents from generating machinery away from the execution
site.
During the initial drilling stages of the project, the gearing systems of the hydraulic drills failed
due to the strength of the columns once the new drills arrived from Germany the team altered the
drilling process by drilling to 10 mm pilot holes, then 14 mm, then 16 mm and finally the 20 mm
hole to ease pressure on the drills.
Challenges were also faced around the hopper pipe being used for the tremie as it got blocked on
a few occasions. This was addressed by increasing the pipe size to 45mm to for free flow of grout.
6. Conclusion
The execution of the underwater repairs on the Columns of the Nalubaale power station was a
success executed on time, within budget and without any safety incidences.
As such hydraulic structures play a pivotal role in Country’s economy inspecting and rehabilitating
them cannot be optional. With innovations in execution methodologies, researching into advanced
materials and newer technologies such as ROVs to inspect under water areas, it is vital that
engineers responsible for such infrastructure evaluate and apply timely repairs so as to increase
durability of such infrastructure and deliver our sustainable development goals.
