A Case Study - Installation of Cut-Off Wall In Seyrantepe Dam Project

H.Turan Durgunoglu1, Selim Ikiz2, Sabahattin Eser3, Onder Akcakal4, Melis Sutman5
1

Prof. Dr. P.E., Chairman, Zeta Zemin Teknolojisi A.S., 34794 Istanbul Turkey;
[email protected]
2
CE, Msc., General Manager, Zeta Zemin Teknolojisi A.S., 34794 Istanbul Turkey;
[email protected]
3
GE, Bsc., Site Manager, Zeta Zemin Teknolojisi A.S., 34794 Istanbul Turkey;
[email protected]
4
CE, Msc., Project Engineer, Zeta Zemin Teknolojisi A.S., 34794 Istanbul Turkey;
[email protected]
5
CE, Bsc., Asst. Project Engineer, Zeta Zemin Teknolojisi A.S., 34794 Istanbul Turkey;
[email protected]

ABSTRACT: Due to high energy demand, recently dams are one of the most
encouraged projects by the state in Turkey. Dam locations are determined in order to
obtain maximum energy output and minimum cost to attract the private investors. On
streams alluvial and permeable areas possess special problems for controlling
groundwater seepage under the dam. For this purpose cut-off walls are well known
relatively impermeable groundwater barriers that have been used for decades in
various sizes and types. This paper examines a cut-off wall case study beneath
Seyrantepe Dam Project in Elazig, Turkey. Seyrantepe Dam is planned to be
constructed on alluvial deposits of Peri Stream which discharges into Munzur River.
Maximum 30 meters deep alluvial and slope debris layers exist under the Seyrantepe
Dam site. A slope failure has occured during the initial stage of the construction that
added great difficulty and complexity in construction of seepage barrier. To avoid the
groundwater seepage in the alluvial and slope debris layers, a cut-off wall with 800
mm thickness was planned to be constructed penetrating two meters into relatively
impermeable marl base rock. Mechanical grab and hydrofreze cutter diaphragm wall
machine was used to construct the cut-off wall considering very unfavorable subsoil
conditions given by slope debris containing irregular large size basalt boulders. In
addition systematic grouting of limestone formations was planned in order to control
permeability within of the dam settlement area. The plastic concrete which used in
the cut-off wall was determined based on the hydraulic conductivity tested in the
laboratory. Special permeability tests are also implemented after construction in
order to verify the impermeability of the cut-off. Construction method and
encountered difficulties with special emphasis are discussed in the scope of this case
study.
INTRODUCTION
The number of dam projects which serving for multiple purposes is now increasing
rapidly in Turkey. Dam locations are determined in order to obtain maximum energy
output and minimum cost to attract the private investors and engineers are compelled

to locate dam projects on unfavorable soil condition. Controlling the groundwater

seepage is one of the challenging problem which encountered during design and
construction phase. It is well known that effects of the uncontrolled groundwater
seepage are very important for the dam stability and as well for seepage loss. Ground
water seepage may cause catastrophic results if they are not handled properly.
Results of the uncontrolled ground water seepage can be indicated as economical
problems due to water loss. More seriously, if the velocity of seepage water where it
emerges on the downstream is large, particles of foundation material can be carried
away by the water and thus decrease the resistance to seepage, resulting in an
increase in velocity and greater erosion, ultimately causing the formation of a
channel underneath the dam in the pervious material which may enlarge rapidly and
cause the failure of the structure, namely piping phenomenon (Tanaka and Yahagi,
1956). Impermeable curtains are most common solutions to eliminate these serious
problems in pervious soil conditions under dams. For this purpose, cut-off walls are
well known relatively impermeable groundwater barriers that have been used in the
past in various sizes and types in dam projects. In this manner, dam safety can be
satisfied and water loss could be limited.
Since dam is located on pervious soil profile in this case study, it is compulsory to
build impervious slurry-trench curtain to eliminate seepage problems. Beside the
seepage problems also slope stability failures were encountered in the site during the
initial stage of construction (Vardar and Sans, 2006). Seyrantepe Dam is planned to
be constructed on alluvial deposits of Peri Stream which discharges into Munzur
River. General view of the Seyrantepe Dam Project site is given in Figure 1.

FIG. 1. General View of The Seyrantepe Dam

The cut-off (800 mm thickness) wall is designed to be constructed within the
originally failed slope described by Vardar and Sans, 2006. Failed slope contained
erratic large size magmatic origin boulders, creating a great difficulty during
excavation of segments in case of using bentonite slurry and cutter technology.
Special emphasis is given to encountered problems and their consequences during
excavation of cut-off walls segments.

Plastic concrete is designed based on its hydraulic conductivity measured in the

laboratory. Special permeability tests of the core samples taken from the plastic
concrete of cut-off wall are tested in the laboratory to verify the acceptable limits.
SUBSOIL CONDITIONS
Soil profile under the proposed dam site is determined according to the results of
soil investigation works. According to borehole logs, there is slope debris (partly
failed slope due to initial phase excavation) which includes various size large basalt
and agglomerate boulders to a depth of approx. 38 m and base rock is located under
this layer which consists of sandstone and marls. Typical soil profile where the
problems are encountered in excavation cut-off segments is given in Figure 2.
Ground water table is approximately 10 m below the surface.

FIG. 2. Soil Profile

Existance of the soil debris is also emphasized by Vardar and Sans (2006) in the
soil profile of the cut-off wall area due to previous slope failure the area. Slope
failure mechanism and typical section of the dam shoulder is illustrated in Figure 3.
Crown Zone

Creep Zone

Toe Part of the

Landslide

FIG. 3. Failure Mechanism on the Dam Shoulder, Vardar and Sans (2006)
CUT-OFF WALL
Because of the existence of pervious soil layers alluvial and limestone directly
under the dam site and failed pervious slope debris containing large boulders at the
left side of dam long cut-off wall is planned to be constructed both beneath the
alluvial, limestone and slope debris to eliminate the excessive groundwater seepage.

Cut-off curtain wall depth is determined based on 2.0 m minimum socketing into the
relatively impermeable underlying bedrock marl formation.
It is well determined that the limestone formation beneath the dam is
heterogeneous. Water pressure Lugeon values determined during soil
investigations often yield excess Lugeon values. Therefore systematic cement
grouting was planned to be implemented based on observed Lugeon values within
the limestone. Further, systematic cement grouting is also planned to be implemented
prior to cut-off wall construction up to 90.0 m under dam foundation including the
west side. Dam and cut-off wall section is illustrated in Figure 4.
CUT-OFF WALL
(Lmax=31m)

Slope Debris
Bottom Limit

SK-243
SK-242

SK-9

SK-239

SK-240

43
43

SK-2
SK-256

SK-238
SK-231

SK-10

SK-7

32

SK-4
~4

DB-9

CURTAIN INJECTION
BOTTOM LIMIT

Min 2m Socket To
Bedrock

FIG. 4. Cut-Off Wall and Cement Grouting Section

CONSTRUCTION OF CUT-OFF WALL
Because of the heterogenous and difficult subsoil conditions, as explained
previously, it is planned to construct the cut-off wall using both mechanical grab and
hydro-freze cutter diaphragm wall machine. Cut-off wall is constructed in debris
with the mechanical grab wherever possible and hydro-freze cutter (81 kNm max.
Torque per gear box, 30 rpm max. revolution, max cutting depth 53m) was used
where large basalt and agglomerates boulders encountered within slope debris and
for the socketing of cut-off in bedrock. Typical equipment used in this project is
shown in Figure 5. Due to urgency and tight construction schedule, continous two
shifts were employed throughout regardless of the weather conditions as shown in
Figure 6.

FIG. 5. Hydro-Freze Cutter and

Mechanical Grab During Operation

FIG. 6. Construction under

Unfavorable Climate Conditions

Cut-off wall panels are contsructed as primary and secondary units as illustrated
in the Figure 7. Panels are constructed with providing minimum 200mm - 400 mm
overcutting between them.

FIG. 7. Primary and Secondary Panels

PROBLEMS ENCOUNTERED
In the construction phase large size basalt originated boulders within slope
debris are encountered. Unfortunatelly, the size of boulders at the cut-off locations
were larger than the sizes reported during design stage and large cavities are
encountered during diaphragm wall excavation. Boulder size diameter as large as
2.0 m - 3.0 m at various elevations of the walls are observed. A boulder which
extracted with excavator from the top elevations of the slope debris within a cutoff
trench is shown as an example in the Figure 8.

FIGS. 8 Encountered Boulders

Cut-off wall construction with grab was not possible in these areas because of
the existance of large size boulders. In this case hydro-freze machine took over the
operation but with special difficulties due to the large size of boulders compare to
the width of the cut-off wall. Also, basaltic nature of the boulder lithology caused
a significant decrease in the production rate.
During the operation, because of the large cavities between boulders, bentonite
slurry level decreased rapidly and as a result of this situation, segment of trench
collapsed while hydro-freze cutter machine was working at 18.5 m depth from the
working platform. As a result, trench was partically filled with boulders and debris
up to 8.0 m depth. Due to presence of high groundwater level, a special rescue
mission had to be implemented. To rescue the hydro-freze machine, a new
neighbouring caisson trench as shown in the Figure 9 is excavated up to the
elevation which hydro-freze cutter machine was stucked. Because of the high
water level, caisson trench could be excavated together with dewatering using
high capacity pumps. It was a challanging mission ended up pleasently so that
5

hydro-freze cutter machine could be rescued after seven days of struggle without a
major breakdown (Figure 10).

FIG. 9. Caisson Trench Utilized in

Rescue Operation

FIG. 10. Rescued Hydro-Freze

Cutter Machine without Major
Damage

As faced in this case study, the excavation of cut-offs in loose slope debris
containing large boulders under ground water is one of the most difficult and
unpredictable task to be performed in foundation construction.
DESIGN OF PLASTIC CONCRETE
In the scope of the design of plastic concrete, hydraulic conductivity tests are
conducted in the laboratory on the core samples taken from the plastic concrete
from initial cut-off wall as reported by Altun and Mihcakan (2007). Permeability
tests are conducted on the samples under various pressures. Pressure is increased
from 1 bar to 5 bar and it is noted that permeability decreased respectively with
the increasing pressure. Permeability values 10-4 and 10-6 cm/sec are obtained for
the design mixture of plastic concrete and found to be acceptable. Test results are
given in the Figure 11.

FIG. 11. Permeability Test Results in Plastic Concrete

(Altun&Mihcakan, 2007)

CONCLUSIONS
A cut-off wall using mechanical grab and cutter is constructed in order to
prevent seepage under the dam described in this case study. Since bedrock stratum
where the cut-off wall is socketed is heterogeneous, systematic cement grouting is
also implemented based on observed Lugeon values in excess of unity within the
bedrock. Cut-off wall is constructed within slope debris with the mechanical grab
and hydro-freze cutter where very large basalt and agglomerate boulders were
presented. Boulder sizes encountered during construction were larger than the
ones anticipated in the design stage. It is demostrated that loose slope debris
containing large size boulders under groundwater as in this case study is one of
the most difficult and detrimental condition to be faced in cut-off wall
construction using cutters. High groundwater conditions and very high strength of
boulders having basaltic and agglomarete lithology within the failed slope added
greatly to the complexity of the problems. During the operation, one of the
segment of trench collapsed while hydro-freze cutter machine was at a depth of
18.5 m from the working platform due to presence of large size boulders and loose
slope debris. Hydro-freze cutter machine have been rescued in seven days of
struggle without a major breakdown by implementing special rescue operation
employing construction of a special dewatered rectangular caisson shaft. The
construction of the cut-off wall has been completed with success, finally and
giving the possibility to learn great deal and never to forget to ask the critical
question of what could go wrong in such chalenging foundation engineering
problems.
AKNOWLEDGEMENTS
We would like to thank to Seyrantepe Dam Consortium - DARENHES Elektrik
Uretim A.S. for their cooperation throughout the construction. We would also like
to thank Dr. Vardar, Professor of Istanbul Technical University for his valuable
suggestions during the construction of cutoff wall within the slope debris.
REFERENCES
Tanaka H., Yahagi F., (1956). Some Considerations on the Cut-off Wall Length
in the Pervious Rock Foundation. 'Le Bulletin d'Information de l'Association
Internationale d'Hydrologie Scientifique', Hydrological Sciences Journal.
Vardar M., Sans G., (2006), (In Turkish) A Case Study for Seyrantepe Dam Left
Side Landslides Formation, Reasons, Effects and Remedition Studies for
Unstabilities, ROCKMEC-2006 VIII. Regional Rock Mechanics Symposium,
Istanbul, Turkey
Altun G., Mihcakan I.M., (2007), (In Turkish) Seyrantepe Baraj ve HES naat
ZETA Plastik Beton Karmlar Geirgenlik Deneyleri n Deney
almalar, Dahili Rapor