Concrete Faced Rockfill Dams

• Geotechnical site investigations, including evaluation

Identifying the need of foundations and identification and testing of
The design and construction of Concrete Faced Rockfill construction materials
Dams (CFRD) has improved substantially during the last 40 • Concept design for new projects or upgrades
years. This type of dam has proven to be a safe structure • Detail design for new CFRDs and upgrades
long term and is well suited to withstand static and dynamic • Construction support
earthquake loading. In some circumstances CFRDs can • Hydrological analysis
offer a cost-effective alternative in both wide and narrow • River diversion
valleys compared to other types of rockfill and concrete • Spillway design
dams.
• Structural analysis
Compared to other types of dams, CFRDs offer advantages • Access layout
that include: • Safety evaluation of CFRD and other dams, spillways,
outlet works, gates, valves, and penstocks
• Foundation grouting does not affect the critical path • Mechanical control equipment for dam outlet works
activities, since the grout curtain is located on the
• Preparation of operation and maintenance manuals
upstream side of the CFRD embankment
and dam safety emergency plans
• CFRDs have historically performed well during • Economic evaluation of installations
earthquakes • Environmental studies and engineering
• Carbon management
• CFRDs with heights exceeding 150 m have been
constructed at numerous sites
Benefits
• CFRDs are able to perform well even if large leakages Our extensive range of capabilities in dam design and
occur through the upstream concrete face related fields allows us to draw on a wealth of experience to
• CFRD construction offers a cost effective solution for satisfy specific project objectives. We have ready access to
many sites a global network of 8500 dedicated professionals. Expect to
have access to the best people for your project.
• Rockfill of various quality can successfully be included
in construction of the CFRD embankment Experience
GHD has worked closely with clients to respond to their
Service offering needs for water projects. Examples of CFRD projects are
GHD can offer the following professional services described below.
associated with CFRD analysis and design:
Kangaroo Creek Dam, Adelaide, South Australia
Kangaroo Creek Dam is a 64.5 m high CRFD with a side channel spillway. The project
involved the design of an upgrade to the dam up to current standards and compliance with
relevant dam safety guidelines. The upgrade comprised providing additional spillway
capacity by increasing the length of the spillway crest and raising the embankment crest level
to safely pass the Probable Maximum Flood, improving the ability to handle leakage through
the upstream concrete face slab, providing a stabilising berm for improved resistance to
extreme seismic loading and extending the existing outlet works.
GHD provided site investigation, detailed design and documentation services including:
• Geological mapping and intrusive site investigations and laboratory testing
• Seepage and stability analysis of the raised rockfill embankment
• Design of extensions to the face slab and new vertical and perimetric joint extensions
• Upgraded waterstop design for the existing vertical and perimetric joints
• Design of the permanent works staging to function as a coffer dam
• CFD and physical modelling of the spillway
• Optimisation of the spillway widening to minimise excavation and concrete volumes
• Assessment of the spillway cut batter slope to optimise excavation and rock support
• 3D finite element analysis of the Left Abutment Block
• Design of the extended outlet works
• Design of a new spillway flip bucket and plunge pool
• Analysis and design of the widened spillway chute
• Design of post tensioned anchors to stabilise the existing spillway crest structure
• Design of new electrical, security and ventilation systems

Baleh Hydroelectric Project Prefeasibility and Feasibility Study, Malaysia

As part of the Sarawak Corridor of Renewable Energy, GHD was engaged to undertake the
prefeasibility and feasibility studies for the Baleh HEP. Based on site investigations, an
options study and an optimisation process, the following arrangement was adopted:
• 220 m high CFRD, or RCC as an alternative
• Diversion works (45 m high upstream coffer dam and twin 12 m dia tunnels)
• An ungated spillway to pass the PMF discharge of approximately 28,900 m³/s
• 100 m high power intake structure
• Five 8 m diameter power tunnels leading to five 259 MW Francis turbines with total
installed capacity of 1,295 MW generating 9,200 GWh/year
GHD was responsible for the geotechnical investigations, flood hydrology, sedimentation
studies, CFRD and RCC dam design alternatives, diversion works design, spillway and
plunge pool design and design of the 100 m high power intake structure and 8 m diameter
tunnels leading to the powerhouse.

Bakun Dam, Sarawak Province, Malaysia

GHD undertook a CFRD dam design for a D&C Contract for the 205 m high Bakun Dam.
The services included:
• Evaluation of site geology and availability of construction materials, including rockfill and
natural filters
• Tender design of the dam, spillway, river diversion works and hydropower intakes
• Review of design, construction feasibility and reliability of power supply
• Assist the Contractor to establish materials quantities, construction methods, etc.

Shanxi Dam, Whenzhou, Zhejiang Province, Peoples Republic of China

The project involved the design and construction of a 135 m high CFRD funded by the Asian
Development Bank for a 200 MW hydro scheme. The works comprised the construction of
3 3
more than 5 million m of rockfill, 3 km of tunnels, roads, power station and a 25,000 m /sec
gated spillway. Housing, village construction and commercial redevelopments were
constructed for the population displaced by the dam.
GHD provided independent audit and review of the design and construction of the project on
behalf of the Asian Development Bank.
Little Para Dam Upgrade, South Australia
Little Para Dam was completed in 1977 and is a 53 m high concrete faced, zoned rockfill
structure located on the Little Para River, 22 km northeast of Adelaide in South Australia.
GHD was engaged by SA Water to undertake a Safety Review incorporating concept design
of upgrade options and subsequent detailed design in 2007 to increase the spillway capacity
and improve stability of the existing spillway structure. The project included:-
• Raising the existing 225 m long dam crest parapet wall by 1 m
• Excavation of a 30 m deep, 360 m long and 52 m wide auxiliary spillway channel
• Construction of a 12 m wide concrete sill with 6.5 m high Hydroplus Fusegates
• A cement grout curtain to control seepage beneath the overflow sill.
• Access roads to cross.

Corella Dam, Queensland, Australia

GHD was the designer of Corella Dam in the 1950s and has had a constant involvement with
the project throughout its operational life. The dam is a 23 m high shotcrete-faced rockfill
dam which was constructed to provide the water supply for the Mary Kathleen uranium mine
and township. More recently, GHD has provided the services including undertaking a safety
review, failure impact assessment, design of upgrade works to provide increased spillway
discharge capacity, advice on repairs for the shotcrete face slab, and five-yearly
comprehensive dam safety inspections.

Cooby Dam, Queensland, Australia

Cooby Dam is a 32 m high concrete-faced rockfill dam constructed in the 1930s. GHD has
been involved in many projects at Cooby Dam over the last 25 years including dam safety
reviews and inspections, advice on repairs for the concrete face slab, failure impact
assessment, assessment of acceptable flood capacity, and concept design of options for
upgrade works to provide increased spillway discharge capacity.

Ruataniwha Water Storage Scheme, New Zealand

The Ruataniwha Water Storage Scheme is a multi-purpose irrigation and hydropower project
proposed for the Hawkes Bay area, North Island, New Zealand. The scheme is to provide a
reliable water supply for 6,000 ha of existing irrigation and an additional 20,000-30,000 ha of
irrigation and a hydropower station with a generating capacity of approximately 6 MW.
GHD was responsible for geotechnical investigations, tender design of the dam, associated
structures (diversion works including coffer dam and tunnel, spillway and intake structure),
river offtakes and irrigation distribution system. Concept designs included clay core rockfill,
CFRD and hardfill dam types for an 83 m high dam. Management of seismic risk was a key
consideration and the project design required that the dam withstand a seismically-induced
foundation displacement of up to 0.5 m and a Peak Ground Acceleration (PGA) of 0.85 g for
the Maximum Design Earthquake (MDE).

Awoonga Dam Acceptable Flood Capacity Upgrade (Gladstone), Queensland

Awoonga Dam is a 50 m high CFRD dam which includes a concrete gravity main spillway, a
low earth saddle dam and a series of natural saddles on the left abutment. GHD was
engaged by Gladstone Area Water Board to undertake an initial failure impact assessment of
the saddle dam on the left abutment which led to an upgrade options assessment of the
various dams and spillway options to meet AFC requirements. GHD was subsequently
engaged to undertake the concept and detailed design of a three stage upgrade works
package.

Borumba dam Upgrade Options Study, Queensland

A study was carried out to identify technical challenges, risks, advantages and comparative
costs of various prefeasibility design options to upgrade the Borumba CFRD Dam. The dam
was to be upgraded to safely pass at least 65% of the required Acceptable Flood Capacity
(AFC) by 2025 and 100% of AFC by 2035. The study compared options to raise the CFRD
with augmentation of the spillway capacity. In addition, replacing the dam with a new RCC
dam and increasing the yield was also considered. Six options were identified, including
raising of the dam crest, widening of the spillway, provision of a new spillway, increasing the
full supply level and replacing the dam with a new dam.
Experienced CFRD Personnel

Peter Ballantine
Peter has 35 years of experience in engineering, mostly related to dams and hydropower projects.
Peter has been involved in the following CFRD Dams:
• 65 m high Berg River Dam, South Africa, design manager for detailed design
• 150 m high Polihali Dam, Lesotho, feasibility study design
• 115 m high Maguga Dam, Swaziland, tender design and specifications

Malcolm Barker
Malcolm has 35 years of experience in dams and hydropower engineering projects. Malcolm has been
involved in the following CFRD Dams:
• 83 m high Ruataniwha Dam, feasibility design
• 200 m high Baleh Dam, feasibility and prefeasibility studies
• 25 m high Corella Dam, Queensland, spillway upgrade, detailed design and specification
• 205 m high Bakun Dam, Sarawak, Malaysia, review of D&C tender stage design
• 145m high Mohale Dam Lesotho, preliminary design
• 63.5m high Mazwikadei Dam, Zimbabwe, preliminary design to determine dam type

Manoj Laxman
Manoj has 35 years of experience in engineering, mostly related to dams and hydropower projects.
Manoj has been involved in the following CFRD Dam:
• 90 m high Mukorsi Dam, Zimbabwe, pre-feasibility study, feasibility study, foundation
investigations, detailed design, specifications and drawings

Bob Wark
Bob has over 50 years of experience in dams engineering projects. Bob has been involved in the
following CFRD Dam:
• 135 m high Shannxi Dam, Peoples Republic of China, independent audit and review of design
and construction on behalf of the Asian Development Bank

Brian Forbes
Brian has over 45 years of experience in dams engineering. Brian has been involved in the following
CFRD Dams:
• 80 m high Mangrove Creek Dam, Australia, design and construction
• 45 m high Awoonga Dam, safety review

John Potts
John has over 40 years of experience in construction engineering of water supply schemes, including
dams and pipelines. John has been involved in the following CFRD Dam:
• 80 m high Boondooma Dam, Australia, construction supervision

Dr Mark Locke
Mark has over 20 years of experience, principally in dam design, safety evaluation and construction.
Mark has been involved in the following CFRD Dams:
• 205 m high Bakun HEP, Tender Design
• 220 m high Baleh HEP, Feasibility Study Design
• Feasibility studies of CFRDs in the Canadian Arctic

To contact our dams service line professionals, visit www.ghd.com/dams