COASTAL DAMAGE REDUCTION FLOOD DAMAGE REDUCTION NAVIGATION ECOSYSTEM RESTORATIONREGULATORY INTERAGENCY & INTERNATIONAL SERVICES BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | JACKSONVILLE DISTRICT Portugués Dam Portugués and Bucaná Project Portugués Dam Portugués and Bucaná Project 1 Steve Duba, P.E. Chief, Construction Division

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Project Video Project Video

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Project Map Project Map

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Authorization: R&H Act 1970, WRDA 1986 (PL ) WRDA 1986 (PL ) Urban Area Affected: 1,833 Acres Population: - Subject to severe flooding: 40,500 - Subject to severe flooding: 40,500 - Residential Structures: 13,200 - Residential Structures: 13,200 Commercial & Public Structures: - Commercial Area: 5 Million SF - Commercial Area: 5 Million SF - Hospital, Schools, Courts, Police Depts. - Hospital, Schools, Courts, Police Depts. Estimated Project Cost: $300 M Range of Damages Prevented: $400M-$600M (100-year event) Direct Jobs Created: 650 (Peak) Sponsor: Department of Natural and Environmental Resources Environmental Resources Portugués Dam Pertinent Facts Pertinent Facts

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Initial Thin Arch Conventional Concrete Alternative Initial Thin Arch Conventional Concrete Alternative  Nov 93 - Apr 96: Left Abutment Excavation  Dec 96 - Sep 98: Right Abutment Excavation  Oct 97 - Dec 99: Foundation Grouting  Sep 00: Advertised Arch Dam ► One Bid – Outside of Awardable Range After several studies and cost estimates, design was changed to Roller Compacted Concrete and detailed studies and design began for a 5-yr program.

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Goals in Changing to Thick Arch RCC Goals in Changing to Thick Arch RCC  Explore technology initially ruled out due to its newness in the 80’s  Utilize advancements in RCC technology and techniques  Realize savings in construction time  Maximize utilization of investment on site Arch-shaped foundation excavations Installed initial grout curtain  Avoid extensive new excavations mandated by a gravity design  Pursue Optimal Geometry to reduce total quantity of RCC  Ensure utilization of local regular use cement manufacturing  Deliver the final component of a much need flood reduction project

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Thick Arch RCC Design Thick Arch RCC Design  Only 10 in the world (from 17 to 100 meters in height) ► 3 in South Africa ► 7 in China  First Thick Arch RCC by USACE ► USACE did the first Gravity RCC dam in US Willow Creek 1981 (Oregon)

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Thick RCC Design Pertinent Data Thick RCC Design Pertinent Data Dam Height: Crest Length: Spillway Crest Width: Flood Control Storage: Max Pool Area: Dam Crest Elevation: Spillway Crest Elevation: RCC Volume: Thickness: Contraction Joints: Design: 220 ft 1,230 ft 140 ft 9,484 acre-ft 215 acres ft ft 367,000 cy ft base, 30 ft crest Spaced 70 ft. In-house w/ITR & Other Corps

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Hydraulic / Hydrologic Hydraulic / Hydrologic  Normal River Flows Low (less than 50 cfs)  10.5 Square Mile Basin  Outlet Works include Intake Structure with Emergency Sluice/Roller Gates, Two 60-inch Diameter RO’s, Emergency and Service Valves in Valve House, Emergency Spillway.  Emergency Spillway - Ogee Crest with Flip Bucket Designed for PMP (45,000 cfs) 2,800 yr event Durations Used for Scour Evaluation

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Structural Structural  Single Centered Thick Arch Dam  Designed for Static, Dynamic, and Thermal Loading  Thermal Analysis Determined Placing Temperature and Contraction Joint Spacing.  Designed as a 3-dimensional structure  Designed for Closed Contraction Joints  Horizontal Joint Tensile Strength Important During Seismic Events  Extensive RCC Design and Testing Program  Cold Joint Considerations

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Geotechnical / Geology Geotechnical / Geology  Foundation Block Stability Analyzed for Dam Induced Loads, Water Gravity Loads, Uplift, and Seismic Loads  Grout Curtain utilized to Reduce Seepage and Uplift  Seepage Analyzed and Foundation Drains Designed  Slope Stabilizations  On-site Quarry Source of RCC Aggregate  Foundation Dental Concrete/Treatments

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Main Dam Portugués Dam Design Features Design Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Dam Sections Portugués Dam Design Features Design Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Outlet Works Portugués Dam Design Features Design Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Outlet Works Portugués Dam Design Features Design Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Dam Gallery Portugués Dam Design Features Design Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District  PHASE 1 – $24,465,435  MOBILIZATION, CLEARING, QUARRY OVERBURDEN EXCAVATION, POWERLINE RELOCATION  PHASE 2 – $47,625,652  FOUNDATION EXCAVATION, AGGREGATE PRODUCTION, DENTAL CONCRETE  PHASE 3 – $37,293,763  AGGREGATE PRODUCTION, ½ DAM RCC PLACEMENT  PHASE 4 – $41,061,083  FINAL DAM RCC PLACEMENT, SPILLWAY, INTAKE STRUCTURE  PHASE 5 – $29,672,717  REMAINING ITEMS, VALVE HOUSE, ACCESS ROAD, MECHANICAL, ELECTRICAL. Portugues Dam Project Phasing Project Phasing

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Project Map Project Map

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Quarry Excavation Approx. 567,170 cy excavated

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Aggregate Production and Stockpiling

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Foundation Excavations

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities RCC Production

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities RCC Mix Design Diversion and Care of Water System

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities RCC Mix Design Diversion and Care of Water System

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Diversion and Care of Water Delay-causing Over-toppings: Sep 30, 2010 Oct 4, 2010 Oct 5, 2010 Oct 6-10, 2010 Oct 17, 2010 Delay-causing Over-toppings: Sep 30, 2010 Oct 4, 2010 Oct 5, 2010 Oct 6-10, 2010 Oct 17, 2010

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Diversion and Care of Water

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Foundation Preparation Work Foundation Preparation Work AS- 11/12 : Foundation Excavation Cleanup

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Drilling and Consolidation Grouting

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities RCC Conveying, Spreading, Compaction, Joint Installation

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Gallery Gallery Gallery Formwork

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Construction Activities Construction Activities Dam RCC Work Topped Out

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Gallery Gallery Gallery Finish

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Foundation Preparation Work Foundation Preparation Work Grouting Setup & Grout Curtain Drill

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Instrumentation Instrumentation Stress / Strain Meters & Joint Meters

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Dam Features Dam Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Dam Features Dam Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Dam Features Dam Features

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District Portugués Dam Conclusions Conclusions  QC Process critical and perhaps more involved than Conventional Concrete Need for sound QC planning and preparatory work process Need for qualified and energetic individuals overseeing the process Need for intense tracking of RCC production and placement parameters  Safety a constant challenge due to multiple activities in close proximity Management involvement in Safety is fundamental Production Staff needs to adopt a Safety Culture Accountability is a must Position of Competent Person as defined by OSHA is critical  Choice of Dam type always based on site considerations, but RCC nowadays a hard to beat choice.

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District ContractorsContractors Prime: Main Sub: : Others: Dragados USA José Carro Const. RC Professionals GEHS Environmental EST Electrical HEAT Security JV Geoland ARC Surveying Frank Electric Altol Laboratories CCG Drilling & Blasting Award: Notice to Proceed: Original Completion Date: Final (Actual) Completion: Beneficial Occupancy: 03/14/ /03/ /08/ /27/ /01/2014 Contract Milestones Award Amount: Modifications: Contract Total: $180,118, $36,718, $216,837, Contract Cost Portugués Dam Contract Data Contract Data

BUILDING STRONG ® US ARMY CORPS OF ENGINEERS | Jacksonville District The End