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ASSESSMENT AND STRUCTURAL REHABILITATION WITH POST-

TENSIONING AND CFRP OF A MASSIVE CONCRETE STRUCTURE
SUBJECTED TO DYNAMIC LOADING

Francisco LÓPEZ1 Luis RESTREPO-VÉLEZ2

1
Integral S.A., Consulting Engineers, Colombia. fjlopez@integral.com.co, www.integral.com.co
2
Rose School, University of Pavia, Italy. luis.restrepo@unipv.it, www.roseschool.it

Keywords: Dynamic load, impact load, finite element modelling, structural rehabilitation, post-
tensioning, CFRP, powerhouse, emergency shutdown.

1 ANTECEDENTS

The Guadalupe-IV Powerhouse belongs to the Hydroelectric Development of the Guadalupe

River, located 130km north-east Medellín, Colombia. Initially designed for four generators, it began
operating in 1985 and currently houses three Francis-type units with an approximated generation
capacity of 80MW each. Figure 1 shows the general disposition of one unit inside the building,
indicating some relevant elements, such as the second-stage concrete surrounding the scroll case
and the draft tube.
Due to strategic needs of the energetic market, since 1993 the operational regime of the
Powerhouse changed from a 2-shutdown-a-year basis, for which the generation system was originally
designed, to a new one with an average of 240 shutdowns a year.

Fig. 1. Powerhouse - Transversal section

The every-five-year maintenance program executed in 1995 made evident the occurrence of
significant relative displacements between the first-stage and second-stage concretes, when some
problems during the re-installation of the safety valve to the scroll case were experimented in Unit 2.
From that moment on, the structure was instrumented and monitored, confirming the active nature of
both the related displacements and the cracking present in the second-stage concrete surrounding the
scroll case. Figure 2 presents a typical crack in Unit 2.
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Fig. 2. Active crack in the second-stage concrete

2 FIELD TESTING

With the main purpose of collecting as much information as possible related to the quality of the
second-stage concretes and to the probable corrosion processes in the reinforcing bars, extensive
non-destructive tests were executed. Those tests and their results are briefly described as follows:

2.1 Estimation of concrete strength and crack depth

The concrete strength and crack depth were measured by using an ultrasonic pulse velocity test,
under the norm BS-1881 part 203. The results showed a satisfactory average concrete strength of
30MPa, with a coefficient of variation of 6,6% which implies homogeneity and optimal conditions
during concrete mixing and placement [1]. Besides, measurements of some significant crack depths
were obtained, ranging between 0,20m and 0,45m.

2.2 Estimation of diameters, spacing and coverings of reinforcing bars

The measurements, carried out by means of an electromagnetic sensor under the norm BS-1881
part 204, confirmed that the reinforcing bars disposed in the original designs correspond to those
found in the external faces of the second-stage concrete surrounding the scroll case and the draft
tube, that is, #6 bars spaced 0,3m displayed in both the vertical and horizontal directions, with
fy=420MPa. The average measured coverings of 0,05m satisfied the minimum required covering of
0,04m [2].

2.3 Estimation of corrosion electropotentials

The electropotential field on the concrete surface was measured by means of a cooper/sulphate
half cell connected to a high-electroresistivity voltimeter, under the norm BS-1881 part 201. All the
values observed in the structure ranged between 0 and -200mV, indicating a 90% probability of non-
active corrosion processes in the reinforcing steel.

2.4 Measurement of chloride and moisture content

Laboratory tests executed on concrete powder specimens led to maximum values of 0,065% for
chloride content and 4,14% for moisture content, both of them under the established limits to be
considered potentially dangerous as corrosive agents [3].

2.5 Depth of carbonation test

The test consisted in spraying a sort of pH indicator over the concrete surface. The results in all
the sites tested showed a change in the indicator from colourless to intense pink, indicating pH values
over 9,5. This situation implies the absence of carbonation processes in the concrete.

3 METHODOLOGY AND ANALYSIS

Following, a detailed description of the methodology and main results from the analyses carried-
out for the vulnerability assessment of the Guadalupe IV Powerhouse are presented.
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3.1 Dynamic loading

An analysis of the mechanical and hydraulic aspects involved in the operation of the generation
units, and the way in which those impose dynamic-loading regimes to the structure were undertook.
Different operational stages such as synchronised machine start-up, regular operation during
generation, normal shutdown and emergency shutdown-restart were analysed.
In order to execute such sort of analysis, a series of accelerometers were installed in the safety-
valve room at level 696. While operating under regular conditions, records of the environmental noise
were obtained with a maximum acceleration of 0,09g, level of vibration considered as ‘normal’ for this
kind of structure under a regular regime of operation.
Taking into account this, a vibration analysis under emergency-shutdown cycles were carried out
in order to know how this operation regime inducts accelerations and forces to the second-stage
concrete surrounding the scroll case. To perform this analysis, real emergency shutdown-restart
cycles with the three units in plenty operation were done, in presence of structural and mechanical
specialists. From the electro-mechanical point of view, an emergency shutdown consists in the
stopping of the directrix buckets of the turbine and the closure of the admission valve, with an
automatic opening of the safety valve and the progressive de-pressuring of the scroll case. From
those tests, it was established that spectral accelerations as high as 0,30g are present at the safety-
valve level, which are considered as ‘normal’ for this kind of structure and event. In Figure 3,
seudoacceleration spectra obtained from emergency shutdown tests are presented.

0.6
SEUDOACCELERATION (g)

0.5

0.4

0.3

0.2

0.1

0.0
0.010 0.015 0.020 0.025 0.030
PERIOD (sec)

Fig. 3. Seudoacceleration spectra - Emergency shutdown tests

The subsequent restart of the system after an emergency shutdown generates a pressure-
equilibrium process through the by-pass of the safety valve, inducing two significant dynamic
solicitations, namely:

• An impact load coming from the slip-type joint installed between the admission valve and the
scroll case. Because of the nature of this sort of joint, the total impact force is transmitted to
the second-stage concrete surrounding the scroll case, adjacent to the admission valve. The
instantaneous force, before considering the amplification factor associated to an impact force,
is about 12.000kN.

• A uniform radial-expansion pressure acting inside the scroll case and therefore pushing the
second-stage concrete through the pipe steel Considering that the mentioned concrete was
cast with the scroll case pressurised at 2,1MPa, and taking into account that the total water
column associated with the level difference to the water reservoir is 560m (generating a
pressure of 5,6MPa), it was concluded that an instantaneous excess pressure of 3,5MPa is
induced to the scroll case.

3.2 Structural modelling

In order to undertake the different analyses necessary for this structural vulnerability assessment,
a 3-D finite element model was constructed, composed of about 10.500 solid, 5.000 shell and 25
mass elements. Both the model and the analyses were carried out by means of the finite element
program Cosmos/M [4]. Figure 4(a) illustrates the complete finite element model for the second-stage
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concrete of one of the units, and Figure 4(b) shows the shell elements representing the scroll case
and the draft tube embedded in the concrete. The shell elements were intended only to properly
define and visualise the complex geometry shape of the structure, without any structural implication.
Restraints, application of forces and obtained stresses on the model are related only to solid
elements.

Fig. 4. Finite element model

3.3 Modal and frequency analyses

Such kind of analyses are necessary for studying the frequency content, response amplification
and resonance effects on the structure, considering the influence of the structure stiffness on the
natural frequency, the mass participation factor of each vibration mode and the effect of the cyclic
component of the electric energy on the response spectra shape. Due to the complexity of the model,
the first 50 modes were included into the analysis to obtain a representative mass participation.

• Influence of structure stiffness: Frequency analyses for different model restraint disposition
were carried out for the following cases: 1) fully fixed at the base, 2) fully fixed at the base and
the walls between levels 691,6 and 696, and 3) fully fixed at the base, the walls touching the
first-stage concrete and the sides in contact with other unit’s concrete. In Figure 5, the
obtained mass participation factor for each case is presented, for a constant modulus of
elasticity value of 26GPa.

45
40 Restraint Case 1
Restraint Case 2
35
Restraint Case 3
30
MASS %

25
20
15
10
5
0
0 0.01 0.02 0.03 0.04 0.05
PERIOD (sec.)

Fig. 5. Model restraint influence in the mass participation

Besides, the effect of the modulus of elasticity of concrete on the frequency response was
analysed for two values considered as the possible minimum and maximum values,
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Ec1=20GPa and Ec2=26GPa. Figure 6 shows the results of the analysis for the x and z
model directions (y is the vertical direction). The largest mass participation factor for both
modulus of elasticity were found in the x direction, corresponding to the second vibration
mode, and in the z direction corresponding to the third vibration mode.

30
Ec=20GPa - x dir
Third mode Ec=26GPa - x dir
25 Ec=20GPa - Z dir
Ec=26GPa - Z dir
20
Second mode

MASS %
15

10

0
0.000 0.005 0.010 0.015 0.020 0.025
PERIOD (sec)

Fig. 6. Effect of the modulus of elasticity of the concrete in the mass participation

It was concluded that there were no major differences between the behaviour of Cases 2 and
3, but significant between those cases and that observed for Case 1. However, Case 2 is the
one which represents in the most realistic way the restraint conditions of the second-stage
concrete inside the first-stage concrete of the main structure, being the model used for further
analyses in this study. From the point of view of the influence of the modulus of elasticity of
concrete, it was established that the model was not very sensitive to it for the values that were
used.

• Influence of the electric energy frequency in the spectrum shape: In Figure 7,

seudoacceleration spectra for an environmental noise signal and for one of the records
obtained during emergency shutdown test are presented. This graphic confirmed that the
environmental noise reflects the expected 66Hz (T=0,015s) frequency content of the electrical
energy charging the accelerograph. The emergency shutdown spectrum exhibits an important
response for the same frequency, too. It was concluded that significant amplification on the
shutdown spectrum is possible only if the fundamental vibration frequency of the structure is
around 66Hz.

0.50
From shutdown record
0.45
From ambiance noise record
0.40
SEUDOACEELERATION (g)

0.35

0.30

0.25

0.20

0.15

0.10

0.05

0.00
0.010 PERIOD (sec.) 0.100

Fig. 7. Seudoacceleration spectra - Emergency shutdown and environmental noise

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3.4 Structural analysis

In order to represent the actual load regime and the expected resultant stresses in the second-
stage concrete surrounding the scroll case and the draft tube, a structural analysis by means of a finite
element program was carried out. Since both dynamic and static forces were established as
contemporary acting forces in the structure, the resulting stresses in the concrete were found as the
combination of stresses from structural static and dynamic analyses. General considerations taken
into account in the development of the structural analysis were:

- According to current market regulations, continuous emergency shutdown-restart processes

are present, turning this condition (vibrations, impact load against second-stage concrete and
excess pressure of the scroll case) into a regular structural solicitation.
- The 12.000kN impact load as well as the 3,5MPa instant excess pressure inside the scroll
case, both of them resulting from each emergency shutdown-restart cycle, were considered
as static loads with magnitudes as twice as their instantaneous value, that is, 24.000kN and
7MPa respectively.
- Vibrations generated by the emergency shutdown were included in the dynamic analysis as a
spectral excitation obtained from shutdown acceleration records, exciting the model at the
safety-valve level. Apart from the second-stage mass, in the dynamic analysis the mass
contribution from the structure supporting the generator, the generator itself, and the stator
were included.

The load cases taken into account for the structural analysis, leading to the most critic
combination to be used in the vulnerability assessment, are present in Table 1:

Table 1 Load cases and most critic combination.

Load Description

L1 Self-weight of the structure

L2 3,5MPa pressure inside the scroll case
L3 12.000kN impact force in the admission valve - scroll case connection
L4 Weight of the superstructure and the safety valve
L5 Forces resulting from the dynamic analysis
Combination L1 + 2*L2 + 2*L3 + L4 + L5

3.5 Vulnerability assessment

The resulting stresses in the concrete after the study of the conditions in the operation of the
powerhouse and the corresponding structural analysis, led to the establishment of a structural
diagnosis and the proposal of a solution to counteract the structural over-demand of the second-stage
concrete of the units. Figure 8 shows the principal stress distribution for the complete model.

Fig. 8. Principal stresses - Complete model

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Figure 9 presents the principal stress distribution for longitudinal (a) and transversal (b) sections of
the unit.

Fig. 9. Principal stresses - Longitudinal and transverse sections

The resulting principal stresses in the second-stage concrete, for a plant-view at the level of the
scroll case axis, are presented in Figure 10.

Fig. 10. Principal stresses - Plant at the level of the scroll case

Comparing the resulting stresses and the strength provided by the existing reinforcement steel, it
was concluded that the disposed bars upward the scroll case, according to the original design, are
insufficient to counteract the demand under the current solicitations. It was also evident that tensile
stresses present in some particular locations of the walls exceed the concrete tensile strength, and
then cracking at those locations must be expected. It is worth mentioning that, as an outstanding
result of this investigation, the locations in the structure at which cracking is expected and the cracking
orientation according to the results of the structural analysis, fit very well with the cracking patterns
observed in the real structure, implying an adequate loading definition and execution of the structural
analysis.
The initial hypothesis was confirmed. It was established that the progressive deterioration of the
second-stage concrete of the units is caused by repetitive emergency shutdown-restart cycles that
constantly act in the concrete through the admission valve and the scroll case due to the mechanical
behaviour of the slip joint.
According to the observed results, the repair strategy must counteract the acting stresses in the
upper part of the concrete surrounding the scroll case and the tensile stresses in the surface of the
walls. The structural solution must be relatively easy to implement generating an as-less-as-possible
interruption in the powerhouse operation service, and perfectly defined to prevent causing any
damage in the pipelines, instrumentation and other devices embedded in the concrete to be repaired.
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In this way, it was decided to display a series of post-tensioning tendons to attend the stresses in the
internal concrete and carbon fibre reinforced polymer, CFRP mantles, to attend superficial stresses in
the walls and the floor at the safety valve level.
The structural model was used in the definition of tendon designation, by combining the effect of a
certain compressive force provided by the tendons with the current forces used in the previous
structural analysis. Different values of force provided by the tendons were combined, up to a
particular value for which the obtained stresses were less that the concrete tensile strength. For the
design of the CFRP, a tensile stress equal to 60% of the fibre ultimate strength (3.550MPa) was used.

4 DESCRIPTION OF THE FINAL SOLUTION

The adopted solution consisted in the installation of 6 post-tensioning tendons of 8-0,6”, grade
270, according to the ASTM A416 norm, anchored to the non-weathered rock, as shown in Figure
11(a). Each tendon was tensioned to provide an ultimate effective force of 1.500kN, and were
displayed at the generator level as shown in Figure 11(b).

Fig. 11. Post-tensioning tendons - Longitudinal and plant views

The 50-cm width CFRP was recommended to be placed in both the horizontal and vertical
directions, with a number of layers depending on the expected tensile stresses at a particular location.
In Figure 12, pictures illustrating the fibre placing on wall surfaces of Unit 2 are shown.

Fig. 12. Placing of CFRP on wall surfaces of Unit 2

The sequence followed in the repairing works for each unit consisted in:
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1. Injection and sealing of cracks in the second-stage concrete surrounding the scroll case and
the draft tube.
2. Drilling of ducts for tendon installation
3. Placing and post-tensioning of tendons
4. Grouting of ducts to protect tendons
5. Placing of CFRP mantles on the lateral walls
6. Placing of CFRP mantles on the floor, at level 696
7. Placing of a heavy duty mortar, for protection of the CFRP on the floor al level 696

The structural rehabilitation of the second-stage concrete of the three units of the Guadalupe IV
Powerhouse was undertook during the year 2000, taking advantage of the electro-mechanical
maintenance shutdowns of each unit, keeping the central continuously generating during the works.
The total area of CFRP used was around 720m2. Average length of the tendons ranged between 23
and 25m. Average total time for rehabilitation works in each unit were 30 days, and the total cost
associated with the rehabilitation process of the three units rounded US$350.000. Currently, the
powerhouse operates normally without any structural problem. Some noises and other minor
problems in the mechanical behaviour of the generator, that were usually reported, have been
prevented after the structural rehabilitation.

5 CONCLUSIONS

Studies intended to rehabilitate the second-stage concrete surrounding the scroll case and the
draft tube of each one of the three units of the Guadalupe IV Powerhouse were carried out. The
vulnerability assessment included a series of mechanical and structural analyses, non-destructive
testing and structural design. From those investigations, the following conclusions arose:

• The concrete in the non-cracked zone is homogeneous and has a good quality. The probable
concrete strength ranges from 26MPa to 30MPa. The extensive concrete cracking in
particular locations was not a result of corrosive processes, as determined after analyses of
corrosion electropotentials, measurement of chloride and moisture content and depth of
carbonation.

• Related to the estimation of diameters, spacing and coverings of reinforced bars, it was found
a very good concordance between construction plans and the actual condition of the structure.
Steel bars in the walls correspond to #6 bars displayed in both the horizontal and vertical
directions, spaced 0,30m. Measured coverings of reinforced bars indicate an adequate
protection of the steel from external aggressive agents.

• Although resonance phenomena between the structure and the exciting vibration generated
by shutdown-restart processes certainly exist, the fundamental reason that conducted to
cracking problems is the 12.000kN impact force that the concrete must absorb due to the
absence of a restricted-type joint between the admission valve and the scroll case, as well as
the increasing of the dynamic radial pressure (3,5MPa) into the scroll case. Both solicitations
are originated as a result of the unit restart operation.

• For the original design no previsions for changes in load regimes implying the frequency of
occurrence such as the one currently acting, were taken into account. Furthermore, twenty
years ago the effects on the surrounding concrete due to instantaneous increasing in the
scroll case internal pressure could not be calculated with the available tools. The present
study provided interesting information about the structural behaviour of this kind of massive
concrete structures subjected to different types of loads.

• The proposed and executed structural rehabilitation is considered the only viable solution to
recover the affected concrete of the powerhouse, according to its operation and generation
restrictions and the limiting space to undertake the works. The structural recovery was
successfully implemented in the year 2000, taking advantage of the periods for electro-
mechanical maintenance of the units.
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ACKNOWLEDGEMENTS

The authors wish to express their acknowledgements to Empresas Públicas de Medellín and to
Integral S.A. for making the information used in the analysis of the Guadalupe IV Powerhouse
Structural Rehabilitation available for this paper.

REFERENCES

[1] Integral S.A.: Ultrasonic testing in the concrete surrounding the scroll cases and the draft
tubes in the Guadalupe IV Powerhouse, Medellín,1998.

[2] Integral S.A.: Vulnerability assessment for the Guadalupe IV Powerhouse, Medellín,1999.

[3] Neville, A.M.: Concrete Technology, Instituto Mexicano del Cemento y el Concreto, A.C.,
Mexico City,1977.

[4] Structural Research & Analysis Corp.: Cosmos/M Version 2.0, Santa Monica, 1998.