INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

Stabilizing Deep Excavation in Foliated Rock for Low Level Spillway:

Case Study from a Hydropower Project in Himachal Pradesh, India
IMRAN SAYEED1 and RAHUL KHANNA2
1
Chief (Geology, Project Investigation Division, NHPC Ltd, Faridabad, Haryana, India
2
Dy.Manager (Geology),Project Investigation Division, NHPC Ltd, Faridabad, Haryana, India
(E-mail of corresponding author: sayeedimran2009@gmail.com)

ABSTRACT:This paper gives an account of 120m deep excavation for locating a spillway. The excavation has
been undertaken in thinly foliated and jointed metavolcanic rock intercalated with weak to moderately strong
bands of chloritic phyllite and chlorite mica schist.Systematic investigations carried out during detailed project
report (DPR) stage helped in delineating extent of weathered zone. Detailed estimation of rock mass quality,
discontinuity characteristics and strength parameters provided input for optimizing safe design of cut slope with
rock supports.Considering space available, well planned and systematic excavation in accordance with design
has been a highlight for excavating the cut slope with vertical to horizontal ratio of 4:1 from EL 1405m
downwards. Berms of 4m width were provided after every 15m of benching. Consolidation grouting had been
undertaken in portions where loose/ fractured rock mass was encountered. Timely and systematic installation of
rock support in form of long rock anchors/ bolts along with wire mesh and shotcrete contributed to stability.
Post–tensioned cable anchors/tendons formed very important part of the support system. A testing program has
been devised before actual installation for verifying various design parameters of cable anchors/ tendons such as
bond strength, bonding length, free length etc. Subsequently, two rows of post tensioned cable anchors/ tendons
of 25m length were installed as per design. Grouting galleries were constructed towards the left abutment and in
the rock spur between dam and spillway in order to undertake curtain grouting along the dam axis. Few minor
incidents of wedge failure has occurred during excavation which were stabilized by adopting timely remedial
measures including spot bolting and slush grouting. Monitoring of the cut slope during and after excavation by
means of geotechnical instruments such as multi point bore hole extensometer and load cell provided valuable
information w.r.t. slope stability.
Deep cuts in foliated or jointed rock strata have got stability issues. Whilst a number of slope have failed in
hydroelectric projects in the Himalayas, this case history demonstrates advantages of adequate investigation and
testing followed by suitable design provisions and effective construction management.

1 INTRODUCTION
The excavation of deep cut slope in thinly foliated and fractured rocks of the Lesser Himalayas is always
beset with several challenges such as identification of slumping zone and depth of weathering, shear zones,
stabilization of open joints and rock wedges, prevention of rock slides, effective channelization of surface and
ground water seepage etc. Detailed geotechnical investigationundertaken during the detailed project report
(DPR) stage has played a pivotal role in proper understanding of the prevailing ground condition. Delineation of
weathered /slumped rock zone, determination of rock mass quality, discontinuity characteristic and strength
parameters assist in optimum designing of cut slope especially when very limited space is available to
accommodate other appurtenant structures. Systematic excavation, proper and timely installation of rock support
in accordance with design and monitoring through geotechnical instrumentation ensure the stability of deep cut
slope.
This paper illustrates excavation of deep cut slope in order to accommodate a radial gated two bay spillway
towards the left abutment of the rockfill dam at a hydropower project located near Sainj Village in Kullu district
of Himachal Pradesh. The hydropower project is owned by NHPC Ltd.The excavation has been undertaken in
thinly foliated and jointed metavolcanic rock with intercalation of mica schist and chloritephyllite bands of weak
to moderate strength. The stability of the cut slope was critical in smooth functioning of the project as it overlies
the two intake structures as well as the spillway itself. Significantly, the cut slope also managed to keep an
important access road in working condition most of the time.
The project area lies within the Lesser Himalayan zone exhibiting complex geology where various rock
formations have undergone extensive deformation. The area forms the part of Kullu-Rampur belt which is
separated from Central Himalayan rocks in the north by Main Central Thrust (MCT) and Siwalik rocks by Main
Boundary Fault (MBF) towards the south. Within the project area, rock belonging to Rampur and Larji Groups
of Proterozoic age are present which are separated by Banjar thrust. The geological exploration undertaken
during DPR stage in form of exploratory drill holes and drifts has revealed a loosely jointed, weathered and
fractured rock zone of about 25m depth.Keeping in view the availability of land and forest area it was proposed
to have a steepcut slope with vertical to horizontal ratio of 4:1 with excavation starting from EL 1405m down
toEL 1288m which was the foundation level of spillway. Berms having 4m width were provided after every 15m
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014
of benching.Pre-grouting has been undertaken wherever loose/fractured rock mass were encountered. Longer
rock anchors along withwire mesh and shotcrete formed the basic support system as recommended by design.
Considering the poor ground condition and compulsion of steep cut slope installation of two rows of multistrand
post-tensioned cable anchors of 25m length above every bermhas been proposed by design as an innovative
measure of stabilization of cut slope. Even though the left bank slope excavation witnessed only few minor
incidents of wedge failure wherein the loose rock mass has been supported by providing spot bolts and slush
grouting, the slope has been regularly monitored through geotechnical instrumentation such as multipoint bore
hole extensometers (MPBX), single point bore hole extensometer (SPBX) and load cell etc. which were installed
on the cut slope in accordance with the design recommendations. The provision of drainage arrangements in
form of peripheral catch drains and drainage holes helped in channelizing seepage and precipitation.
One minor incident of wedge failure that occurred on the cut slope has been discussed in this paper. A
comprehensive stability analysis is carried out taking into account the major joint sets forming the sliding wedge
using the computer program SWEDGE version 4.08 developed by Rocscience (2005). The onsite suitability test
undertaken for installation of cable anchors which played a very important role in deciding various design
parameters such as bond length etc along with the assessment of their effectiveness in providing stability to the
rock massof the steep cut slope has also been discussed.
2 GEOLOGY AND SITE INVESTIGATIONS
Low to medium grade metamorphic rocks associated with Green bed member of Banjar formation belonging
to Rampur Group of lesser Himalayas are distributed in the dam area. The left bank slope has been excavated in
slightly weathered meta-volcanics rockshaving intercalations ofthinly foliated mica schist and chloritic phyllite.
The bed rock has been traversed by several tight to open joints showing high persistence upto 12m. Strength
wise the rock mass ismedium strong to strong. At places rock is highly fractureddue to presence of closely
spaced joints and multiple shear seams running parallel & sub-parallel to the foliation joint (S-1). The shear
seams mostly filled with clay, crushed quartz and gougy material having thickness varying between 5mm to
50mm intercepts the rock mass. The major joint sets encountered are described below:

Table 1 Orientation &characteristics of major joint sets

Joint Average Spacing (mm) Persistence Aperture filling Condition
set no Orientation
S-1 060º-080º/55º-70º 60-200 5 to 12m Tight to 50mm open. Rough to Smooth,
(foliation) (<60in phyllite- 5-50mm sheared. Planar to
mica schist) 5-25mmclay/gouge filling Undulatory
S-2 305º-320º/50º-65º 200- 600 3 to 5m Tight to 5cm open. Rough, Planar
5mm-10mm gouge filling
S-3 150º-170º/50º-60º 200-600 3 to 4m Tight to 20mm open. Rough to Smooth,
5mm-20mm gouge filling Planar
S-4 230º-270º/55º-70º >600 3 to 8m Tight to 50mm open. Rough to Smooth,
5mm-50mm gouge filling Planar

During the DPR stage, the site has been thoroughly investigated by means of exploratory drilling and
drifting.A vertical drill hole of about 50m depth undertaken at EL 1386.8m above the intake area has indicated
overburden depth of 9m. Massive meta-volcanics with bands of thinly laminated mica schist has been
encountered in this drill hole. Three number exploratory drifts were undertaken towards the left bank slope at
EL’s 1311m, 1340m& 1365m having cumulative length of 186m. The drifts revealed presence of medium strong
to strong & occasionally very strong metabasics with subordinate bands of strong to medium strong mica schist
and weak to medium strong chloritic phyllites. Loosely jointed rock mass has been encountered at least up to
25m depth. The rock mass is traversed by three to four sets of major joint sets as stated above. The percentage of
various rock class intercepted in the drifts is shown in figure1. RMR system of rock mass classificationhas been
adopted as in tunnels after undertaking corrections for tunnel alignment w.r.t. joint orientation.
The above investigations revealed that the slope in general is enveloped with few meters of superficial
vegetal cover followed by presence of loose & slumped insitu rock upto 25m depth into the hill.Based on the
investigation undertaken a geological section given as figure 2 has been developed.In order to determine strength
and deformation characteristics of rock mass encountered towards the left bank slope, laboratory tests
wereconducted on the intact rock samples of meta–volcanics collected from drill holes and drifts. Based on the
Uniaxial compressive strength, the compact and fresh meta-volcanics has been classified as very strong (100-
150MPa) whereas metavolcanics intercalated with chloritic schist falls under strong (50-100 MPa) category.
However, UCS of greenish chloritic phyllite, which are found to be talcose attimes and are thinly foliated, falls
in the range of weak to moderately strong (25-50 MPa) category.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

L-3 35 65

0% 20% 40% 60% 80% 100%

Rock Class (%)

Class- III % Class- V%

L-2 54 29 17

0% 20% 40% 60% 80% 100%

Rock Class ( %)

L-1 20 80

0 10 20 30 40 50 60 70 80 90 100
Rock Class ( %)

Fig. 1 Percentage of rock class encountered in drifts located towards left bank slope of dam

The geotechnical investigations which had revealed the presence of slumping, shear zones, open joints, weak
chlorite schist/phyllite bands, clay seams, three to four joint sets and their intersections/sliding wedges provided
valuable information for designing the cut slope and various support measures. Based on the above results slope
stabilization measures such as removal of slumped rock, treatment of upslope, installation of rock bolts/rock
anchors with shotcrete and wire mesh, longer tendons, pressure relief holes, drainage arrangement has been
considered.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

141 0 N 156 ° N3 36° N1 45° N 325 °

INDEX
?
140 0 RI VERBORNE MAT ERIAL

139 0 SLOPE WASH MAT ERIAL

138 0 ? THINL YF OLI AT ED CHLORI TI CSCHI ST /PHYL LIT E

M ET AVOL CANI CS WIT HINTERMI TT ENT BANDS OF

137 0 CHL ORI TIC SCHIS T S /PHYLLIYES.
DRIF T - 3
FRACT URE /CL OSEL Y JOINT ED Z ONE.
136 0

SHEAR SEAMS 10 - 50 CM.

135 0
SHEAR SEAM <1 0 CM
DR IF T- 2
134 0

ELEVATION( M)
PROBABL E LI MI TOF SLUMPED ZONE
TOP OF DAM 1333M
133 0

132 0

DRIF T-3 (PROJECTEDFROM D/S) 5 0 5 10 15 20 25 m.

131 0
R OAD SC ALE

130 0

129 0

?
GEOLO GIC AL CROSS SECTION
128 0
OF LEFT BANK SL OPE

127 0

Fig. 2 Geological Section towards left bank slope

3 DESIGN OF CUT SLOPE AND ROCK SUPPORT
The deep cut slope towards the left bank of dam has been proposed by the design engineersafter giving due
consideration to the prevailing rock mass condition. However,a major constrain that has limited the availability
of space for development of slope has been the provision for accommodating radial gated two bay spillwayof
about 28.5m width with stop log arrangement towards the left abutment of the dam. Moreover, due to limited
availability of land and forest area the overhead cut slope could not be extended beyond a certain limit. It has
been carved out from the rock spur consisting of meta-volcanic rock with intercalation of chlorite schist/phyllite.
The excavation of the cut slope has been proposed from EL 1405m above the intake portion with vertical to
horizontal ratio of 4:1down to foundation level of the spillway i.e. El.1288m. After benching of every 15m,
berms of 4m width has been provided at EL 1378m, 1363m and 1348m respectively. Provision of a 7m wide
road at EL 1333m on the cut slope coincided with the top of the dam. This road has been the only means of
transportation towards the higher reaches of the valley.Below the road level, the slope has been excavated down
to EL 1288m with berms of 3m width at EL 1318m and EL1303m respectively. As drainage arrangement, a
peripheral drain has been constructed at the top, extending all along thecut slope collecting storm water from
side drains constructed at every berm. Besides drainage holes of 8m and 14m length were also provided on the
cut slope to drain out seepage from the joints and voids.
The stability has been provided to this cut slope of about 120m depth by means of installation of systematic
rock support and pre and post grouting arrangement. The design engineers have provided the rock support
consisting of long rock bolts/anchors of 9m, 12m, 15m and 18m length having diameter of 36mm at spacing of
2m & 3m c/c staggered at various levels as shown in figure 3. Considering blocky nature of rock mass, presence
of shear/ fracture zones in closely laminated metavolcanics and chlorite schist/phyllite formations and steep cut
slope, 25m long multistrand post tensioned cable anchors or tendons were installed in two rows above each berm
upto road level. Shotcrete of 100mm thickness with single layer of wire mesh has also been installed. All the
rock supports were installed systematically with the exaction.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

LEFT BANK
500 X 500 DRAIN ABOVE CUT SLOPE

1410
25 / 36 Ø 9 M LONG ROCK BOLTS @ 2000 c/c

SCALE
1400 36 Ø 18 M LONG ROCK BOLTS @ 2000 C/C STAGGERED
5 0 5 20 METRES
EL 1394.50
36 Ø 12 M LONG ROCK BOLTS @ 2000 C/C STAGGERED

1390
1 36 Ø 15 M LONG ROCK BOLTS @ 2000 C/C STAGGERED
4

1380 EL 1378.00

1
4
1370 25 M LONG POST TENSIONED ROCKBOLTS / TENDONS @ 3000 C/C STAGGERED

EL 1363.00
36 Ø 12 M LONG ROCK BOLTS @ 2000 C/C STAGGERED
1360 1
4

1350 EL 1348.00
100 TH. SHOTCRETE WITH WIRE MESH
1
4
1340

ROAD DAM TOP EL 1333.00

1330
1 ROCKFILL DAM
36 Ø 12 M LONG ROCK BOLTS @ 2000 C/C STAGGERED 4
25 Ø 6 M LONG ROCK BOLTS @ 2000 C/C STAGGERED
1320 EL 1318.00
1
GROUTING GALLARY 4
25 Ø 9 M LONG ROCK BOLTS @ 2000 C/C STAGGERED
1310 6
36 Ø 15 M LONG ROCK BOLTS @ 2000 C/C STAGGERED
1
EL 1303.00 EL 1303.00 TOP OF CUT-OFF (EL1300)
1300 1
4
25 / 36 Ø 9 M LONG ROCK BOLTS @ 2000 C/C STAGGERED 6
1
GROUTING GALLARY
1290
EL 1288.00
25 Ø 5 M LONG ROCK ANCHORS @ 1500 C/C STAGGERED

Fig. 3 Design of Excavation and rock support towards left bank spillway
4 EXCAVATION METHODOLOGY AND PROBLEMS ENCOUNTERED
The excavation started from the outer periphery towards top of the proposed cut slope at EL±1405m wherein
most of the area has been under superficial cover of soil and overburden material with few scattered rock
outcrops. A small area of slope wash/ debris material of about 60m extent comprising of boulders in semi-
consolidated matrix of gravel and clay has encountered down to EL ±1394m. The rock type encountered
consisted of slightly to highly weathered metavolcanic rock intercalated with moderately to highly weathered,
thinly foliated bands of mica schist and schistose phyllite (figure 4). The rock has been traversed by several open
joints showing high persistence (upto 12m). The joint opening varied from 5mm to 50mm. The rock mass of low
to medium strength has been intersected by closely spaced joints and multiple shear seams running parallel &
sub-parallel to the foliation joint (060-080º/50-70 o). The shear seams were mostly filled with clay & crushed
quartz vein with thickness varying between 5mm to 50mm.Beside foliation three to four sets of discontinuities as
described above were present. The slope has been excavated according to grades envisaged in design.
4.1 Pre-grouting in fractured rock mass
Subsequent to removal of the vegetation cover, thin veneer of soil and overburden material, the exposed
rock mass appeared to be highly fractured and closely jointed (figure 4). As rock mass quality appeared to be
poor, pre-grouting has been undertaken from 5m above the top of the cut slope i.e. from EL: ±1405m continuing
down to first berm before excavation of hill slope all along the peripheryin accordance with the provisions of
technical specifications and the issued construction drawing.
Pre-grouting has been undertaken by gravity flow, otherwise at low pressure of 1kg/cm 2 in case the grout
intake ceased at normal flow. Grout holes of 10 to 12m length and 45mm dia have been drilledat spacing of 3m
c/c in staggered manner and were completely grouted. Grouting in every hole started with water-cement ratio of
2:1, then with 1:1 mix and finally with 0.5:1 for thicker mix up till the refusal. Grout consumption has varied
from 300kg of cement in less jointed/fractured rock condition to 20,000kg of cement in highly jointed/ fractured
rock mass. Leakage of grout material in very limited quantity has been observed during grouting operation
through open joints at lower levels;however it subsequently stopped within few hours.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

Closely jointed and fractured metavolcanics with open joints Pre-grouting undertaken to consolidate fractured and thinly
encountered at the top portion of excavation. Weathered rock mass foliated rock mass along with patches of overburden material at top
has been removed before installation of rock support. of the cut slope.

Fig. 4Excavation of cut slope at top level and pre grouting undertaken to consolidate the jointed rock mass and
patches of overburden cover.
4.2 Installation of rock support
The highly jointed rock mass encountered towards the top of the cut slope has been supported with 9m long
25mm dia rock bolts @ 3.0m C/c in staggered manner along with 100mm thick shotcrete with wire mesh. The
overburden material encountered above EL ±1394m has been supported with 6m long grouted soil anchors of
25mm dia at spacing of 3.0m along with wire mesh and shotcrete. By adopting following measures, stability has
been achieved during excavation of otherwise risky cut slope:
1. The rock mass including the overburden portion has been consolidated by pre-grouting before excavation
especially along the periphery at the top of the cut slope as proposed in construction drawings.
2. Proper scaling has been undertaken in highly jointed rock conditions and also in overburden portion before
installing rock bolts such that no loose rock mass/boulders etc remained in hanging position on the slope.
3. In case of highly fractured rock mass with several open joints, slush grout has been provided beside
consolidation grouting so as to fill the open joints more effectively.
4. Timely installation of rock support viz., rock bolts/anchors, wire mesh and shotcrete as proposed in design.
5. Drainage arrangement in form of contour drain at top of cut slope and pressure relief holes in rock portion
and drainage windows in overburden portion has been undertaken simultaneously with ongoing excavation.
4.3 Wedge failure on the excavated cut slope
Even though the excavation of cut slope has been undertaken systematically with timely installation of rock
support,there have been few instancesof rock sliding due to planer and wedge failures in highly fractured and
jointed rock mass. An incident of sliding has taken place on the cut slope above Intake-2 between RD: ± 34 to
38m u/s of dam axis.The sliding has occurred due to detachment of a large rock wedge formed by intersecting
joint sets 076º/62º(foliation joint) and 320º/68º (valley dipping joint)as the excavation reached towards the toe
portion of the wedge below EL: ±1382M(figure5A).Subsequently, the slide got further extended towards higher
elevation due to highly jointed and fractured nature of rock mass resulting in detachment of already installed
rock supports.Continuous rainfall during preceding 2-3 days hadinitiated sliding of rock mass along weak joint
planes. In this paper it has been attempted to undertake stability analysis of this slide by simulating the rock
wedge that has resulted in this failure through SWEDGE ver 4.0 software of Rocscience Inc(figure 6). Joint
properties have been assumed after referring to available literature and simulating with site conditions. Results of
the analysis also indicate the sliding along the foliation plane(S-1). The safety factor of the unsupported wedge
comes out to be 0.9076 (table 2) which answers the failure quite well.In this portion of cut slope, 9.0m long rock
anchors of 36mm dia were installed as per the proposed design. However, considering that much deeper slip
plane has been formed, the installed rock anchors were unable to prevent the detachment of large wedge.
Subsequently, in order to stabilize the cut slope in slide area following remedial measures were adopted:
(i) Considering moderately to slightly weathered rock condition and presence of several open joints in the area,
excavation had continued upto the next bench at EL: 1378M with proper pre consolidation grouting with
12m long holes @ 3.0m as per design. After removing the loose muck, immediately the slide affected area
was shotcreted with dry mix followed by installation of several 15m long spot bolts having 36mm dia.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014
(ii) Concrete was backfilled after erecting shuttering in order to stabilize the area and prevent further slide.
Pressure relief holes were provided as per the design specifications.
(iii) The site of sliding has been monitored for any further deformation by installation of Single point borehole
extensometer (SPBX) as shown below in figure 5B.

TENSION
CRACK
S2
PLANE

S1
PLANE

A B

Fig. 5(A) Sliding along S-1 plane at excavated cut slope due to wedge failure in rock mass. (B) SPBX
installed in slide portion to monitor the post treatment stability of the area.

Table 2 SWEDGE input joint set data & results

INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

Dip C
Joint Plane Dip Direction Ø
Amount (t/m2)
S1 62º 076º 42 28º
S2 68º 320º 36 34º
Upper Face 60º 330º
Slope Face 76º 336º
Slope Properties Tension Crack
Slope Height 30m Dip Amount 58º
Unit Weight 2.6 t/m3 Dip Direction 220º
Trace Length 3m
SWEDGE RESULT
Safety Factor 0.9076
Wedge Weight 120.287 t
Slip along joint S-1

Fig. 6 Stability analysis of wedge formed on the

cut slope by means of SWEDGE v 4.0 of
Rocscience.
5 TESTING AND INSTALLATION OF POST TENSIONED CABLE ANCHORS
In order to stabilize the excavated cut slope, considering the blocky and jointed nature of rock mass,
multistrand post-tensioned cable anchors also known as “tendons” has also been installed.Prior to its’ systematic
installation, a suitabilitytest program in accordance with the technical specifications has been designed for
checking the performance of the anchors as well as to ensure that it can sustain a constant load greater than the
design load and the same is transmitted into the rock mass of the cut slope. The procedure is given below:
5.1 Testing of Cable Anchors
Test for suitabilityof two number cable anchors has been conducted by the specialized agency prior to the actual
installation.Thetest area which was located towards the left bank slope at EL: ±1330M about 53m upstream of
dam axisrepresented the geological conditions expected to be encountered at the actual site of
installation.Following objectives were fulfilled:
i. Determination of the strength of the cable anchors (bond between grout and rock in particular)at actual
location of installation.
ii. Determining the optimum bonding length and verifying the adequacy of the fixed length of rock bolts w.r.t.
their working capacities, ground conditions and location.
iii. Verifying the adequacy of the foreseen working procedures including drilling, consolidation grouting and
rock reinforcement work.
iv. To determine the free length of the cable anchors and other design related criteria including creep criteria.
5.1.1Test Methodology:
The specialized agency adopted methodology given below:
Drilling and Lugeon tests: Two test holes of 125mm dia and 26.0m and 25.5 m length respectively were drilled
at about 2.0m spacing using tractor mounted rotatory drilling machine in the exposed rock on the left bank. On
completion of drilling, the holes were subjected to water pressure test using single packermethod in order to
determine the permeability of the bed rock according to IS: 5529(Part-2). Theaverage permeability values
obtained were 5.13L and 13.25L respectively. As the Lugeon values were high, the rock mass was grouted.
Water pressure tests were again conducted in both the holes. Post-grouting maximum permeabilityhas been
2.63L and 1.23L respectively. Both the test holes were then plugged suitably.
Installation and Grouting:At the face of each drill hole the rock surface was smoothed and test pads of
reinforced concrete of Class M30/A20having dimension 45cm x 45cm x 15cm were constructed.Each cable
anchor/tendon of 25m length was in the form of 7-ply strands with 12.7mm dia of each strand. The fixed length
or bond length for anchor-1 and anchor-2has been kept as 10m and 12.5m respectively. The cable anchors were
then inserted and grouted (water-cement ratio of 1:2.8).At the time of testing the grout has achieved the required
strength. The concrete pads had acquired average compressive strength of 62.27MPa, after 28 days of casting.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

Fig. 7Photographs showing the testing of cable anchors

Stressing of the cable anchors: The fixed length(bond length) of first test anchor (cable anchor-1) has beenkept
as 12.5m thus the free length was 12.5m.Initially, the test load was subjected to 80% of guaranteed ultimate
tensile strength (GUTS) which was given as 1200KN. The 80% of GUTS is 960KN or 300.5Kg/cm 2. However
including 4% losses the applied pressure comes to 312.52Kg/cm 2. The maximum test load has been 1023KN or
320kg/cm2. All the strands of the cable anchor were stressed simultaneously using multi strand hydraulic jack as
shown in figure 7. The displacement of the jack represents the elongation which was measured manually.The
stressing was done in steps with datum load of 96 KN (10% of test load) equivalent to 30 Kg/cm 2 pressure on the
manometer. The total elongation obtained was 158mm. After testing for 80% of GUTS, the cable anchors was
detensioned to the datum load. Then again, the anchor was restressed in steps for lock off load which is 60% of
GUTS i.e. 720KN representing 225Kg/cm2of pressure on the manometer. The total elongation obtained in this
case was 92mm. The stepwise stressing is given in table 3 and the elongation curve for both cases is shown in
figure 8 for first test anchor. The step wise loading and elongation of second test anchor is shown below in
figure9. Both the cable anchors were stressed upto the lock off load and elongation in each case has been
measured.The cable anchors which have been stressed in accordance to the procedure given in the technical
specifications for the Acceptance Test were load checked by lift-off test immediately after stressing and again
3-5 days later. For both anchors the residual rock bolt load has been measured to be more than 98% of the lock-
off load.

Table 3 Testing of Cable Anchors

Applied Load Elongation(mm)
Pressure (KN) Cable Anchor-01 Cable Anchor-02
(Kg/cm2) 80% of GUTS 60% of GUTS 80% of GUTS 60% of GUTS
25 80 - - - 65
30 96 52 - - -
50 160 60 118 80 75
100 320 80 135 103 94
150 480 112 168 128 121
200 640 140 - 155 -
225 720 - 210 - 158
250 800 175 - 183 -
280 896 - - 210 -
320 1024 210 - - -
Net Elongation (mm) 158 92 130 93

LOAD VS ELONGATION( FOR 80% of GUTS) LOAD VS ELONGATION (For 60% of GUTS)
250
250
200
200
ELONGATION(MM)
ELONGATION (MM)

150 150

100 100

50 50

0
0
96 160 320 480 639 799 1023 160 320 479
LOAD(KN) LOAD (KN)
ELONGATION ELONGATION
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

Fig.8 Elongation of Cable Anchor 1 at 80% of GUTS and 60% of GUTS or Locking Load

LOAD VS ELONGATION (FOR 80% OF GUTS) LOAD VS ELONGATION (For 60% of GUTS)

250 180
160
200 140

ELONGATION (MM)
120
ELONGATION(MM)

150
100
100 80
60
50 40
20
0 0
160 320 479 639 799 895 80 160 320 479 719
LOAD(KN) ELONGATION LOAD (KN) ELONGATION

Fig.9 Elongation of Cable Anchor 2 at 80% of GUTS and 60% of GUTS or Locking Load

Subsequent to the suitability tests the fixed or bond length of 12.5m was confirmed for 25m long post
tensioned anchors. The anchors were installed as per the above at each berm at EL’s 1378m, 1363m, 1348m &
1333m respectively in two rows with spacing of 3m through specialized agency. Monitoring of cable anchor
with load cell subsequent to installation assured that residualrock bolt load is more than 98% of the lock-off load
as shown in figure 10 below:

LOAD CELL INSTALLED ON CABLE ANCHOR TO

MONITOR POST INSTALLATION RESIDUAL ROCK LOAD

Fig. 10 Post tensioned cable anchors installed on the actual cut slope
6 GEOTECHNICAL INSTRUMENTATION
The left bank slope has been continuously monitored by means of instrumentation during and after
completion of excavation. As proposed in the construction drawings the left bank has been monitored at different
levels covering the entire slope through 21 multipoint borehole extensometers, 18 single point bore hole
extensometers, 3 nos. load cells of 120 ton capacity installed on cable anchors and 3 nos. load cells 30 ton
capacity installed on rock bolts. During the ongoing excavation some deflections within allowable limits were
observed in instrumentation data as a result of blasting during benching.Subsequently after completion of
excavation no appreciable movement has been observed indicating the stability of the cut slope.
INDOROCK 2014:Fifth Indian Rock Conference 12 –14Nov 2014

BERM AT EL 1378M

BERM AT EL 1363M

BERM AT EL 1348M

ROAD ( EL1333M)
INTAKE-2 INTAKE-1 SPILLWAY

DAM AXIS
SPILLWAY GUIDEWALL

Fig. 11 The left bank cut slope after excavation and support installation

7 CONCLUSION AND RECOMMENDATIONS

The excavation of deep cut slope in thinly foliated, fractured and closely jointed rocks which are often traversed
by several shear zones of variable thickness is very challenging. Recently several cut slope located in the
Himalayas have failed during construction due to reasons such as inherent geological conditions, improper
construction methodology and agencies not adhering to the recommended design. Here an attempt has been
made to highlight various issues which are mandatory for successful execution of deep cut slope in Himalayan
rocks and for providing long term stability to the structures involved. The recommendations of this work are
summarized below:
(i) Detailed and comprehensive investigation play a pivotal role in delineating the extent of weathered/slump
rock zone beside providing information with respect to rock mass characteristics, joint properties etc.
(ii) The inputs from site investigation and geological details help in optimizing the cut slope design and
deciding the type and amount of rock support.
(iii) Excessive cutting of slope may be avoided and systematic excavation and timely installation of rock support
as per the recommendation of the design lower the possibility of slope failure.
(iv) Ground improvement measures such as pre and post grouting and proper drainage arrangement to take care
of storm water and ground water seepage.
(v) Installation of long anchors especially post tensioned cable anchors provide stability to deep and steeply cut
slope and prevent instances of rock slides due to large rock wedges etc.