128 168 AN INVESTlGATION OF HARDY DAM Thesis {or the Degree of B. S. MICHSGAN STATE COLLEGE Leo G. Steam: 1948 * IYHYY IYYYY Y «[1me a ~_3 1293_ 01070 0924 SUPPLEMENTARY MATERIAL IN BACK OF BOOK PLACER RETURN BOXtomnmmthckoumomywrm TO AVOID FlNESMumonorbdonddoduo. Wan-9.1 I“! E An Investigation of Hardy Dan .A Thesis Submitted to The Faculty of I CHIGAN STATE COLLEGE of AGRICULTURE AND APPLIED SCIEJCE by Leo G. Sfiearns b‘ Candidate for the Degree of Bachelor of Science June 1948 'WES‘S 20320 L a u :13 should preferably be built on rock founfl;tion2 - good rock 50 111:1 .t .ons - as etfhor izeo by ran and ‘resent exfnri er ce, but as the demand for electric power increase: dams Vill be built on the bee iounditions available Before the Ilardy Jail ”as designed eeverel problems were encountered Freviousl3r ate: power olunts fore built on tho choafect cites le3 leaving SLCH successive size less attractive us an inves2mont unless nev in“ "ore econ-:ical ideue couli be eevioed. Another :roblem ‘ “ ‘ _.< “ . 'I' F! 2' t \HJ' -' "‘ I~ . ' '." :' r1 ‘A ‘r‘ , SWCUUHUGLGQ «do the luct t»"t stein in} aiesel zone 3,0re lad leuuce the lydro—electric fieli to t”at of u“”ly‘1“ tea? “0 r - Thich ~‘I."“ ““ ‘ ." N " “N h r~ Mr av A.“ .J- ‘r1 --, :~ refluiies li1ge -onfis, niin nee e, lur e 1~ chine 3 c; eeluy, &;u yOLHtQ toward back punrin; during sleep periods to supply Water to er for o u 1 l r‘ '0" 9 -*fi ‘.5 ' {4— Q, 0 G {.3 ( .. ’4. 0 L3 {‘3 d. *? p. H 123‘ (7) fi‘ 5 O :3 5. gr! I *1 H' 3...- 'l O a [—3 {D ' ) H o H cl- : o b) O Q 3 O '7 (3 L3: '1) U! {0 \D .‘3 d- r4. p 3.: ‘4: Q I of a porous sen: *bfiagt nt, 1 _O f ot Figb with a flexible concrete 5 a :‘1' 1n 0-7 . n- o. -: . . ~ . come-.all. lHC CO;G~;111 18 get on utOCl sheet—riling drive: into unaerlying PFTVlOHS, :nn ‘e1vy meter boirinz e1uo or“ ”lacial ”rift rerzl “we’red feet t‘ic’: over bed-rock. Three oenetocke 14 feet in di:fieter, VhiCh fire used both for pomer and suilled enter, extend through the bree of the deeo section. Before anything elee is vflfucoi dbout “be 4“? lei ue investféote ite loc tion and dos ~n. sD The Kuoko¢on River fell: 30.9 “”5 feet in 40 wiles of ri.vor / 5/6 RAP/a5 L CDC/1Y7 ’/ ’ M Elm/r: «ow J Iii-.37 U5 /.3/ /< .j/ m. ,4 7W6 , ( fl / ”-37 HARDY 04M C] 0 m: y/I Y (av/0'7 a v "‘- ‘ Z ‘ .‘ k \ .J NtwArw/ 1 . 11A. ozvrou 1 ./'\\ 1004770” 0F HARDY DAM u. i: Lipids an? Croton. Uyst can from ¢i3 Lt“1ou it 110": “ore slofily, through a Ulucr, flaLt er valley, vita few if any economical power sites. Below Croton is a fall of 70; wt throu3h He aygo to Sridgeton, tnen less than 30 feet through some 30 Wiles of sluggiso channel to Luskegon Lake. Surveys started i1 1933 showed ttis s; is ated 40 foot power sites at Croton and losers, which ('5 nation and i1 vere built in lCOS-O7, leaving a 130 foot fall undeveloped between 4-. A a J'oe'ol. ' V Surveys and studies at that tire located two into: mediate s 1363 k]. for the ultimate developeuent of tais 130 feet fall, the lower one 3 V '9 being Oxbow at the ncaa of Croton fond, the urjer ans in3 Erwin at the Irecosta-Jevaygo County Line. w- Investifatien of the 160 foot project was begun n lffd. Progress vas retarded some hat by the in W1 ty to find good foundation condi- ions. Ehe heavy covering of glacial drift ruulookin13 for roc’n Ci- foundation in this area out of the qtzes ti -on, but H1e action of the glaciers, however, did leave a deposit of finely ground rock flour which new shows up in xfltat are con only called clay beds, or tech- nically called :udstone. v 1 s The location problem was to find tae Jest Hudstone deposit at foundation elevation. Test holes nere drilled across the valley all the way fr 3 the ujper side 0: too .i; Oxbow to a half mile below the site finally selected. anvy rudsto one dejosits Vere evident at the cut banks above river level but onlv thin and so atterin3 or es a. foundation re“ anss on which the inoaie tower and finally located a 20 foot thic over house could be arrantod to best advantage. Tie site bavin3 Valley of the LIuskegon River. been selected, t e po. er h0118~, 3”ill."a and e“oafl1:ment bad to be arranged to best suit the fe u1o.tion and tonorrajhy. Che final I ' o \. r-1 . u o , arran3enent was on tie sevent 11 bise line. ihe :epiretien of intaL and power house, iifferiz3 from all other hydro-electric profieots, ,. _. in. ,i,.- o , i w.._!.' ., p 1:- ..‘,‘ ‘3-- .ae gar iy a matter 0L economy 1d rar':ly a “atiei Cl lounLaJion. , ‘fhe separation of intane and rover house by buried yenstoois lessens and spreads out 3.‘e loa in3 :nl Si':li ies both de31q- and con- H"' .L _I ’.' I ‘1' -M‘ ‘. 0L o (‘ ,1. nLrUCulono ueuolugfiflu is b l but niet exnerience in buildin3 dams on Iichigans glacial drift has shown that all days sethe about two inches durin3 construction 1 ~. - and in proportion as tne load is added. ,- . -v. , J. .- n - .1. °,. . L. 4 .- . 2”,; nalLy settlement, based upon Ulla exper_ence, has eStl.uU8d a three to four inches, With a possible maximum of six inches. Penstocks, ho ever, Tere dcs i3nel Vith flexible joints at 30 foot Q n;aCi 'nj; ooth in the riveted s el lin r and enCised reinforced c+ :3 to concrete shell “bicb transmits tle e oin’vcnt load to the jenetook foundation. Joints betseen intake a.d oenstocks, and where penstocks 10US€ substructure were also made flexible, all permit a sessiole movement of several bites the enje ted six inch taxluun settlement, 'ust as a matter of assuraioe. :‘"0 nt for these joints the intake tower and the rntire TOTE? House block vere each designed as :epar te un-_ts. nctuil settlement records were Rent tbrou3hout constriction Lut“enty points on the core-. ill, t enty- L V . v- 1.“ - ,3- “ J— n - ~ '- K. 4-. . "f‘ five point 8 on 0113 emu:1.ncn , inc t eaty points on one penstoois and foyer house structures. Core- Lll points more carried u' cWMfimMW / #0401444 7 N )flAJ/v’WALL 3970 4066' PO/VD ‘O ’ )r_-~. I «l '_‘ ’ 'X ."”-.',\._‘,_r"-, \ - ’ '\«‘-"\‘\'F.',." Y.\"“\"‘ _ - '\ - (re—«JvAfl/Vfl/A <3”— - l l j I t.‘ xvi-.2“- (‘ .‘ . \Lu . . ’ a. .. _’ ' 1" ' I '. ‘ o " ~- , o I. ’ ' (.7 -\ .‘.' _I ‘ I I . ~I< ‘ . I, ‘ .‘ ° ‘ I‘.,.1._.~‘- -" ;., || . _ ’ / , "n \ .‘- ’ -~.. I I, " I ‘.| . ' ' "...~_ ' I ‘ I _ (. ' j .5..- "' - a I K JI’I l l .l l . I 0 I 3 ‘ I“ Z / r“. l I i I ‘. ‘. .-.. ‘ ‘ \ ,. . a ' I -'-./ I—. (r - --l . ,- , A t . .WW‘ 1m 3 . ‘ ' “:‘mfim MN] l".‘x ' -""- - "I u I I . — . ~ [4~ l I . ’ - ‘ _ f , ~ L 3 ‘ a - - " ‘ - \ ‘r’\ J . ’(v . ’.,. l ‘. “ h \‘ t | ’ I \‘ ' \ \('~ . ‘¢ l l - " 3... 1 mm, . z I :1 "( .-~I’r’. ‘ ' -’ . \ \ " "\c/ \ "‘ ‘ 5“- -‘ ‘s-\ ‘ ‘ ‘ ' ~ 4 I |‘ t . l\.\ s.‘ ‘ ~ . - '1 . ‘ l I?" ‘ ~. ‘ ( ‘ t‘ . 4 ‘1 ‘ ' ‘ ‘ -' ' A 'I , L_ , , ,lv - ., . ‘ ~ , _ . - - ~ l/ /-~ I ' ' K- ‘. ~ ' . ‘ -/ I ._§ , ‘ v 0 . ( l \— I I‘ ’I'l . I. ( n.1" ‘ I . ' a I I l ' \ - . ‘ ,. . I . ‘ -.-, ‘ . I ‘ .- ‘ . . . - "‘ _ ~ . 0| - l | - O I WA)” WV: _,.| 30'6" 242 28.7 'o" W. JEECJfifT/chmflfir O §\ ) \ / / wzmxmewwmu MM§“§\ N m (#055 .55 C 7 /0/1/ A/VD Jffflfo/VT 0/" HARDY DAM i “ .-. A. n y , ‘J- I.“ -. o L- -' ~ p. -l—JL 7.. ’.1‘ L tne o.se to male CBIoaln .1“ ,rue settlenen. J e p. .- * ..: --.'.~ .- -: A . ,4. 1, .1 can Iron. .16 -)€-_3.1.Zl.';.l_-.i_ LLO OJU '-‘_'1U;. AC L; 7 AICLJA. p w" " “ """~V ‘.‘ .J‘fi ’ ' ‘ I" “ -- -" "‘. I s " ‘W F the cleanigeni i sell. nrlults n;ve 830 n usmt ,Ls core- .il case a :— " . s r“ ‘a ‘- ' ...1.,\ l- «1‘ 1 I. 1 ,- -.--‘ --:-'. - Q t V o :etuled : 1/2 incTes the 413‘. u iit Ci tee -is, *itn a nag un cl . . _ ,.‘ 1 .L‘ -. ‘ v v w \V \- J. ‘ ~ A ‘ . _ a... A‘ -..\ ‘ A ‘1 V. " r_ 4.- Linches, 61.110 :18 s iJuJ.‘ ma, nae incl tag/~61; 311 one nonailg to load -'~ y-v r. v'. ‘, p~ ‘ a A 3-, d.— ‘ A 0 ‘IV fi fi. r‘r .1. . n 7"" r‘.“"~‘-‘ (‘3' . .. (‘0 toward eacn one Ll UJG run. lac coLQOLleation oi enjiulmsnt aLs 1 1/2 inches at the d087€3+ section, t“is snail a.cunt bsiij Hue w r.- r. n . fl 1' vv . -.~ ,v- 'v we ‘4-- 1 9 . :\ to ccn3lete éflm eifective setule'eit drrl13 Ala eteno my sliicllg -1. 7" I \.‘ F4. k7 all embankment fill into er. about three inches under the core-tall, 1 inch at the power house, rnich likewise (1' additional load due ‘ 7 cnlv a small fraction of an J -' 1 C1. 3 l —L‘ b i 0 Before inspe n3 is 1’: .1. -L 1., ’ J v ~ " -r ° ~~ .~ 1. ° A. sone ealtn (ti-.1 13.1an e... was 7313.3, ~— sign of the Hardy Dam let us consi* have been avoid 'Q 3 “dually to l ‘ A t,‘ .w 1 .ncn. '” lne inc~eased the settlement nch, less than expected. C‘I‘ ed b" J, nrorer oeszgn. ‘3? . . :— ,.,.. .1” . ,.. .' ,.. n . ,..LV 3 3 p 0 _, - ~- o3 fax use co “oars: cause oi eLwon can lailnres 13 lacs of yea {*L’ tale 0 of floods. fiilures rCVealefl the fol An anilySis on J. C'in3: rcenta3e of tttil Cause of fa‘lnre F“ chrthpin; - - - - - - — — - - - - Leakage along conduit - - - — - - - Other lenkages - — - - - — — - - _ ~~‘lides ~ - — - - - — - - - _ - - _ - - 1 a i-cellansous - - - - - - - - - - - - x---.‘ fiot stl' ,r a L .39.) I I / ..J . ’13....4- - Y O O A Earth Enbinlzptent, Power House and Intake Tower. in: "ery Dam Show 1' I“. of Vi en's 97“ ‘ I 1‘ J ‘ Y. - 1 - t , .. ,3 '~ ..-., .- ._ .. is prac 'icLl criiaria for too (cairn CL tne mg? 3 uai or an; . ' L- - -L 3-. (‘5' "-3 '-h.,._1_1 “r, x , ‘,‘_ 1 , earth dul nu} oe siateo ori exlly as follc' : An siren yen SJOUlu oe d=si3ned so that; l. The line of saturation is well within tL3 dC'nstrcan toe. 2. There "ill be no engortunity for the free jassage.of ater from the upstream to the dornstreai face. 3. Hater which gasses through ini under the dun must when it rises to the surfs e, have a velocity so small that it is incapable of novin3 any of the meterial of which tbe dam or its fcun‘a Mign is confosed. 4. l.e frecboare must be such that there i: no d njer of overtopginj by rave action. . S. The utstreau and do nstream slopes ”:st be such that vith the natcrixls used in conitl‘uction, they will b3 stable under all conditions 6. The sr ill”ay is so great tin there i; no danger of ovort03ping. an 6 rth ”an designed and built to meet these criteri; will prove as perrancnt as any of the rorks of man if proper attention is given .1. 9 b0 i inortant eesails during construction. (‘13 . V3“. n 0-; .LhJ... .LJ-¢ Line of saturation within do ‘strenm toe. The hydraulic gradient, ' -H N r + .-L . P. H - -- ~- ' a . 4- - -: . r" or plane oi saLurition, throu3h sind enbinln nts is rel iivelv 51,5 and is rarned by the sen” ition of iry and s3.tur=ted materiil that is A quite definitely defined. It variee over quite a range in any vertical plane parallel with the face of the dam. If the fill material were truly graded and of known eiee thie eeepage surface would preemnebly be regular. uniform. and determinate by analytical neane. Any ouch graduation of the wide range of random occurrence in economically available borrow pite hae eeened impoeeible although it ie deeired theoretically. Goneequently. the eaturation line repreeente an average of any expert-onto with a Pitot tube in a number of embank- nente. merience hae indicated a cafe generalisation for thie for: and composition of embanhnent. namely. thie plane romaine below a l on 5 elope from head water to tail water. Malamute thue deeigned without drainage. occaeionally have a few den or poeeibly wet epote at the toe. the drain: at Hardy Dem reduce thie percolation factor to 4.25. but the filter bed arrangement around the drain heede re- etreine the material effectively, as compared with a free eurfece. The embankment ie underdrained by none of a downetreen trench drain. conetructed by filling the lower part of a dirt trestle. prop- erly lagged with poles. with cobble etone. out of. which 12 inch tile headere project at 100 foot epacing. All drain outlete are preferably placed above tail water and are arranged eeperately and vieibly for obeerwetiou and neaeurenent. CRITERION 2 and 3 Should be no opportunity for the free pee-age of water. Velocity of water through dame must be too low to cauee piping. lo ouch thing ae an abeolutely impervioue earth dam exiete. Even if a den ie entirely conpoeed of the tighteet. fineet clay. eome water will get through. Indeed. water ie conetantly flowing through and under all earth dam. in a never ending etream. The earth dam eimply interpoeee reeietance to the flow of water and elackene ite velocity. eo that the water decende to Join the ground water before it reachee the downetrean toe of the den. Seepage from headwater through. around and under the embankment ie another major deeign coneideration peculiar to Michigan conditione. With a thickneee of niecellaneoue and unknown water eaturated drift hundrede of feet in thickneee even under river bede. and underground watere moving through deep eand and gravel with coneiderable preeeure and volume. there ie alwaye a poeeibility of underground loee of con- eiderable mgnitude out of a pond. increaeing of couree with head- mbanlunente. even when built with eand. are rude ae tight ae poeeible with a core-wall. The anewer hae been to drive a continuoue eteel eheet pile cut- off beneath the core-wall. full length of the dam. and to a depth depending upon the head and the underground formation. it the Hardy Dan. beneath the deep eection of the embankment. eixty foot heavy arch eection piling wae driven under coneiderable difficultiee. Thie cut-off. intercepting eeveral layere of mudetone in ite full length. hae effectively etopped underground eeepage. The eaet end of the embankment ie Joined into an alnoet eolid clay bank and tightly eealed- The weet end taile out acroee a wide eand and gravel flat where the head is only 25 feet but where seepage is relatively greater than elsewhere at the dam. CRITERIOH 4 Darth dams mist be safe against overtopping. Freeboard is usually defined as the difference in elevation between the top of the spillway and the top of the dam. but as the spillway of the Hardy is covered by almost 100 feet of water. in this case. the freeboard is the difference in elevation between the full pond and the top of the splashwall. 'l‘he core-wall of the Hardy Dam was moved 30 feet 6 inches upstream from the usual location and was "topped out“ with slope paving to take wave action for any probably drawdown. The splash- wall. slope paving. and core-dwell are all Jointed and water stopped. The water elevation of the full pond is 822 feet and the splasmn elevation is 832 feet. The downstream slope of the dam was sodded to prevent any erosion that might be caused by rainfall. CRITERION 5 Stable sloped required. Downstream slope. The slepe of the downstream face will often be determined by criterion 1. which requires the line of saturation to intersect the base at a point well within the downstream toe. The slope of the downstream face. however. should be flatter than the angle of repose of the material of that part of the dam even if the position of the line of saturation would permit the use of a steeper slope. The downstream slope of the Hardy Dam starts at the top of the dam with a 1 on 2 slope and midway down the bank Energen cy Spillway . the slope becomes a l on 2%. The slope of the upstream face of the dam should generally be de- termined by the underwater angle of repose of the material. Other ‘ things being equal. a material having a high unit weight will stand on a steeper slope under water than one with a low unit weight. The slope of the upstream face should be flatter than that indicated by the experiments as safe. Iron the results of the experiments talnen on the borrow pit soil. a l on 4 slope was finally decided on as a safe slope. Gammon 6 Ample spillway provision. The effect of soil cover and slope on flood discharges is very marked. Thus the watershed of the Huskegon River. which is covered with sand of indefinite depth. has a ground water storage which is tremendous. The result is that for this river the recorded maximum discharge is only two or three times the minimum. Spillway capacity is provided by the three 12 foot diameter butterfly valves controlling bypasses from each penstock to each draft tube. Additional emergency capacity is provided by a concrete overflow weir and paved channel at the west end of the embankment. which is a added safeguard in case of a phenomenal flood. The over- flow weir at the spillway intake is built of short concrete sections of varying thickness and stability. designed to overturn and wash away pregressively so that the spillway overflow will increase as the pond rises. but will never exceed or even equal the inflow into th. Ponds WADWA Y -)-1 a 52:70 ’ .316" I "'l I! -* [-6 L<—— /.’j”—- II #6 +-6 L. fL—f—fi a 82K 0’ A Vifi’fléf ”PP/”é Will? JfIWO/V 0/" lair? .— pping a View of An interesting item would be to find at what elevation the weir would wash away. RESISTIHG MOMENT: (1.25) (.5) (150) :- (9s.75) (.534) =- 75.1 (1) (1.25) (150) : (157.5) (.525) = 117. (.75) (3.25) (150) = (355.) (1.525) = 595. H (.5) (.25) (150) (18.75) (1.415) = 26.5 (.5) (.5) (150) = (57.5) (1.75) =, 55.5 (.25) (.75) (150) : (25.1) (2.125) a 59.7 931.9% When the overturning moment is slightly larger than the resisting moment the weir will overturn. (x) (2) (g) (63-4) : 931.9+(.75) (52.4) (x .4) (1.575) 10.4.3"5 = 87'.fo- 581.9 x = 4.55 feet Therefore when the pond level rises to 829.55 feet. the weir washes away and the spillway entrance elevation drops from 825 feet to 821 feet. Other systems could have been used to Judge the above but one method is enough to show how the weir was supposed to have worked. Since the time this thesis was started. certain changes have taken place in the design of the weir. This can be shown by looung at the photograph of the weir which reveals the fact that a concrete section has been placed in such a position that the weir is prevented from ever washing away. The regular spillway under the dam is capable of handling 30.000 cfs: this includes the passage of water through the generator turbines. If the emergency spillway has to be used this capacity will be doubled. Embanlnnent totaling some 1.400.000 cubic yards was placed at the rate of 6.000 yards each day. a total of 55.000 cubic yards of con- crete was poured. including some 8.000 yards of corewall beneath which about 1200 tons of steel sheet piling were driven for cut—off. Total cement used was 50.000 barrels and total reinforcing steel 1600 tons. The fullpond creates a lake with a length of 20 miles and a maxim width of 13- miles backing onto Rogers him a few feet to permit drawdown without loss of head. Its area is about 4000 acres. its volume is 160.000 acre feet. equivalent to 250 feet deep on a square mile. Hidier earth embankments alone have been built. but either on rock foundation or seperate from power house and penstock structures. is far as known no adamant of this height has been built on earth foundation and containing through penstocks and power house in the deep section. Because of this certain theories have been developed that can be used in designing future structures. These are: (1) Coarse sand. gravel. or glacial mudstone river bottm foundations Import loads satisfactorily if such loading is graduated gently to a maximum of 18.000 pounds per square foot. with an average allowable settlement of 1 inch per 5000 pounds per square foot of loading. (2) The perfor-nce of this type of foundation indicates the probabil- ity that tests my develop still greater load carrying ability without excessive settlement or other difficulties. (3) Settlement is essentially proportional to lead and takes place as the lead is applied; it practically ceases thereafter. (4) Sand embankments. composed of river valley and glacial outwash material. settle in permanent position and form when washed to place with water. any subsequent consolidation is too slight to effect upstream paving that has been properly detailed and laid on a 1 on 2* slope. (5) This available embankment.material is deficient in fines for the usual impervious earth core designs. and must be supplemented by some impervious element forming a,part of the embankment. .alkali treatment should be investigated. (6) hbanlments of this material. on good sand and gravel foundation. can.probab1y be constructed satisfactorily for heads in excess of 100 feet. by re-arranging the foundation cut-off and.impervious members to better structural advantage. and with improved economy. 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