Attachment H - Comanche RCC Mix Study - Rev102120.pdf

ROLLER COMPACTED CONCRETE MIXTURE

PROPORTIONING STUDY REPORT

Modifications to Comanche Dam Wichita Mountains Wildlife Refuge Comanche County, Oklahoma

Schnabel Reference: 19C35001.01 September 30, 2020 Revised October 21, 2020

September 30, 2020, Revised October 21, 2020 Schnabel Engineering, LLC Project 19C35001.01 ©2020 All Rights Reserved

September 30, 2020 Revised October 21, 2020

Mr. Stephen L. Jamieson, P.E.

W. W. Wheeler & Associates, Inc.

3700 S. Inca Street Englewood, CO 80110-3405

Subject: Roller Compacted Concrete Mixture Proportioning Study Report, Modifications to Comanche Dam, Wichita Mountains Wildlife Refuge Comanche County, Oklahoma (Schnabel Reference 19C35001.01)

Dear Mr. Jamieson:

SCHNABEL ENGINEERING, LLC (Schnabel) is pleased to submit our roller compacted concrete (RCC) mixture proportioning study report for this project. This study was performed to evaluate several RCC mixes that can be compacted either by vibrating rollers or immersion vibrators. This mix concept is referred to as Immersion Vibrated RCC (IV-RCC). This report includes a description of the tests performed, tables and appendices with relevant data collected, and conclusions. This study was performed in accordance with the Task Order Authorization dated July 22, 2020.

EXECUTIVE SUMMARY

This report presents the testing that was performed as part of an RCC materials and mixture proportioning study conducted at Schnabel’s office located in Alpharetta, Georgia. Representative samples of local Oklahoma aggregate, cement, fly ash, and air entraining admixture were used as part of the study. The project technical specification for roller compacted concrete (Section 03 37 23) includes certain limitations on the aggregate properties.

Aggregate was obtained from the Martin Marietta, Inc. quarry located in Snyder, Oklahoma. The initial evaluation of the aggregate found that the gradation was in general agreement with the project specifications, except that it was lacking material on the No. 4 and No. 40 sieves. An accelerated mortar-bar test (ASTM C 1567) was performed as part of the laboratory testing consisting of 50% cement and 50% fly ash. Interpretation of the test results indicate innocuous behavior related to alkali-silica reaction in concrete.

Four separate RCC mixture proportions were prepared and tested. This work included performing field and laboratory tests on the materials, plastic and hardened RCC. The following proportions of cementitious material were evaluated as part of this study:

Modifications to Comanche Dam

September 30, 2020, Revised October 21, 2020 Page 2 Schnabel Engineering, LLC

Mix Portland Cement

Batch Weight (SSD) (lb/cy) Pozzolan

Batch Weight (SSD) (lb/cy)

Mix 1 180 400

Mix 2 (Test Block 2) 220 330

Mix 3 275 275

Mix 4 (Test Block 1) 250 250

Prior to initiating mix design, two trial batches were prepared (about 2 cubic feet each) to evaluate consistency of the freshly mixed RCC and develop the target proportions for the mixes. The trial batches included 180 lb/cy cement and one included 250 lb/cy of fly ash and the other included 350 lb/cy of fly ash. RCC test specimens were not molded from the trial batch mixes. Mixes 1 through 4 were 3.5 cubic feet and included Vebe time and air content testing along with the molding of RCC specimens for compressive strength testing. Compressive test results are relatively consistent in that higher cement contents and greater age produced higher strengths, as expected.

In addition to the mix design, two test blocks were prepared to evaluate the mixes, vibration and compaction methods. With the type of aggregate used in the Mix Design, Mix 2 is recommended. This mix has a Vebe Time of about 8 seconds and an expected compressive strength in excess of 4,000 psi at 180 days. Additionally, an approximately 3” diameter rather than 2” diameter concrete vibrator is recommended for consolidating the IV-RCC. The final mix design proportions, consolidation and compaction methods should be confirmed and/or modified as necessary during the construction test section prior to production placement.

PROJECT DESCRIPTION

Comanche Dam is located in the U.S. Fish & Wildlife Service (FWS) Wichita Mountains National Wildlife Refuge, Comanche County, Oklahoma, approximately 80 miles southwest of Oklahoma City, Oklahoma.

This work is part of the Supplemental Title II Support Services for the Modifications to Comanche Dam being provided by the W. W. Wheeler & Associate, Inc. (Wheeler) Team.

TECHNICAL REQUIREMENTS FOR ROLLER COMPACTED CONCRETE

In accordance with the project specification, Section 03 37 23 RCC, the materials for the Immersion Vibratory RCC must conform to certain requirements. A local Oklahoma aggregate source was selected and used for the development of this mix design plan. The appendices contain results of the aggregate testing obtained from the aggregate supplier and performed by Schnabel and Concrete Research & Testing, LLC (CRT) along with documentation for the cement and fly ash used in the RCC mixtures. The following material and product requirements were obtained from the project specification.

Cement: ASTM C150, Type I, II, low alkali (if locally available)

Fly Ash: ASTM C618, Class F with a LOI not exceeding 3%.

Water: ASTM C94, standard requirements for ready mix concrete

High-range water reducing admixture: ASTM C494, Type F.

September 30, 2020, Revised October 21, 2020 Page 3 Schnabel Engineering, LLC

Set retarding admixtures: ASTM C494.

Air entraining admixture: ASTM C260.

Aggregate: Gradation shall meet the following and aggregate fines are to be non-plastic:

Sieve Size Percent Passing

2 inch 100

1-1/2 inch 90 - 100

1 inch 80 - 100

¾ inch 75 – 85

½ inch 55 – 65

#4 40 – 60

#40 15 – 30

#60 8 – 13

#200 4 – 8

RCC Mix Design: The technical specifications indicate that the RCC mix design will be similar to the following, and that the mix may be revised by the Engineer based upon the field mix design performed by the Contractor. The mix will have a Vebe time between 8-12 seconds:

Material

Batch Weight (SSD)

(lb/cy)

Portland Cement 220

Pozzolan 330

Aggregate 3000

Water 270

Set retarder admixture To be determined

Air entrainment admixture 18 oz/cy

RCC MIXTURE PROPORTIONING/TESTING PROGRAM

Schnabel performed the RCC mixture proportioning and testing at their facility located in Alpharetta, Georgia, under the direction of Randy Bass.

Purpose

The intent of this study is to evaluate the consistency of freshly mixed RCC that can be compacted/consolidated either with vibratory roller or an immersion vibrator. This type of RCC is referred to as immersion vibratory RCC (IV-RCC). In addition, perform a comparison of the hardened properties

September 30, 2020, Revised October 21, 2020 Page 4 Schnabel Engineering, LLC of the RCC when utilizing a local Oklahoma aggregate source at different cementitious mixture proportions and water contents to develop an RCC mixture with a Vebe time between 8-12 seconds.

The following sections contain information about the aggregate properties, testing plan, and compressive strength testing of the molded RCC specimens. The testing aided in the evaluation of the aggregate and provided data for use in the development of recommendations for RCC mix proportioning. The results of the laboratory tests are included in the appendices and summarized in the following sections of this report.

Aggregate

The aggregate was obtained from Plant Snyder, owned and operated by Martin Marietta, Inc., located in Snyder, Oklahoma. Appendix A includes aggregate testing results provided by Martin Marietta, Inc.

Approximately 6,785 pounds of aggregate (Type A Base) was delivered to Schnabel’s office located in Alpharetta, Georgia, in super sacks placed on wooded pallets.

Martin Marietta, Inc. provided the aggregate and select test results for the aggregate. Additional tests were performed by Schnabel on the aggregate sample obtained from the Martin Marietta, Inc. quarry in Snyder, Oklahoma to determine the aggregate properties. A sieve analysis was performed in general conformance with ASTM C136. A gradation test report is included in the Appendix B and summarized in the table below and compared to the project criteria. The gradation of the proposed aggregate is in general agreement with the project RCC specification, except for the percent finer for the No.4 and No. 40 sieves.

Summary of sieve analysis performed by Schnabel as compared to RCC project spec.:

Sieve Size Snyder Type A Base

Percent Passing Project RCC Spec. Percent

Passing

2 inches 100 100

1-1/2 inch 100 90 - 100

1 inch 90 80 - 100

¾ inch 78 75 – 85

½ inch 60 55 – 65

#4 36 40 – 60

#40 12 15 – 30

#60 9 8 – 13

#200 5.4 4 – 8

Based on the results, the aggregate used in the study appears to be slightly more coarse than the gradation provided in the project RCC specifications.

Absorption and specific gravity testing of the material was also performed by Schnabel in accordance with ASTM C127. The absorption and specific gravity values were utilized for preparing the various RCC

September 30, 2020, Revised October 21, 2020 Page 5 Schnabel Engineering, LLC mixes. The absorption and specific gravity values from testing performed by Schnabel and results provided by Martin Marietta are listed below:

Property Schnabel Martin Marietta

Bulk S.G. (Oven Dry) 2.60 2.609

Bulk S.G. (SSD) 2.61 2.626

Apparent S.G. 2.64 2.653

Percent Absorption 0.6 0.6

The following is a summary of other aggregate properties based on the testing and information obtained during this study:

Property By Result*

Description Schnabel GW-GM

Atterberg Limits

(ASTM D4318)

Schnabel Non-plastic

LA Abrasion Martin Marietta 26.6

Soundness Martin Marietta 1.0 (average)

Mortar Bar Test

(ASTM C1567)

CRT <0.1% Expansion

*See test reports included in the appendices for details.

Schnabel’s subcontractor, Concrete Research & Testing, LLC (CRT), performed testing on the aggregate, cement, and fly ash in accordance with ASTM C1567, Standard Test Method for Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method). The test report provided by CRT is provided in Appendix C. Cementitious material for the testing consisted of 50% cement and 50% fly ash. The average net length change at 14 days was 0.02%. According to ASTM C1567, expansions of less than 0.1% at 14 days are indicative if innocuous behavior in most cases.

Since the aggregate was in general agreement with most of the project criteria for aggregate properties, Schnabel proceeded with the preparation and evaluation of RCC mixes. It should be noted that there was a lot of flat and elongated aggregate particles.

The water used for mixing was treated local municipal potable water supplied to the commercial office building, where the mixing/testing was performed. Moisture contents of the aggregate were taken at various intervals. The mixing water requirements for the RCC were adjusted based on the moisture content of the aggregate.

Cement

Appendix D includes the Material Certification Report for the Portland cement, Type I-II (low alkali) provided by Holcim from their Ada, Oklahoma plant for the mixes prepared as part of this study. The

September 30, 2020, Revised October 21, 2020 Page 6 Schnabel Engineering, LLC cement meets the specifications of ASTM C150 for Type I-II cement. At the time of this study, the cement supplier indicated that the specific gravity for the Type I-II cement is 3.13.

Fly Ash

Appendix D includes the ASTM C618 testing report for the Fly Ash (Class F) provided by Boral Resources for the mixes prepared as part of this study. The fly ash meets the ASTM limits for Class F. At the time of this study, the fly ash supplier indicated that the specific gravity for the fly ash is 2.4.

High-Range Water Reducing Admixture

High-range water reducing admixture was not used in this study.

Air Entrainment Admixture

Appendix D includes information on the air entraining admixture used in the mixes prepared as part of this study. The Sika AEA-14 product meets the requirements of ASTM C260 for air entrainment admixtures.

Set Retarder Admixture

Set retarding admixture was not used in all the mixture proportions evaluated/tested during this study;

however, set retarder admixture was added at a dosage of 16 oz./cy to RCC mixtures prepared for construction of Test Block 2.

RCC Mixture Proportioning/Testing

The RCC mixture proportioning and testing was performed at Schnabel’s facility located in Alpharetta, Georgia. Schnabel contacted local Oklahoma suppliers to obtain samples of aggregate, cement, and fly ash. Samples of the aggregate, cement, and fly ash were shipped from the suppliers to Schnabel’s office.

Mixing of the RCC was accomplished using a nine cubic foot drum mixer. The RCC was allowed to mix for approximately ten minutes after the addition of the water to the cement. We note that this is a longer time than standards practice for conventional concrete laboratory mixes. However, it is our opinion that longer mixing times are necessary in order to compensate for the inefficiency of the drum mixer when producing zero slump concrete. This time did not include time required to remove the occasional buildup of fine-grained material on the inside of the drum. Mechanical mixing was supplemented by a final hand mixing after RCC was removed from the drum. The minimum batch size prepared was two cubic feet and the maximum prepared was four cubic feet. This size was selected based on the number of tests to be performed and number of cylinders to be fabricated.

The proportions were based on volumetric batching, with an assumed air void content of four percent. As can be seen by comparing the mixture proportions to the actual air content test results, actual air void volume was slightly less than what was assumed.

The Vebe test was performed on freshly mixed RCC from each mix. An approximately 29 lb. RCC sample was loosely placed into the Vebe pot. A 27.5 lb. surcharge weight was placed over the RCC sample and the vibrating table was activated. The Vebe time was recorded as the total time required to form a complete ring of paste around the plastic plate attached to the surcharge weight, which is in general conformance with ASTM C1170 Procedure B / CRD-C53. For this study, the target Vebe time was between 8 to 12 seconds. Two trial mixes were prepared to evaluate the consistency of the RCC

September 30, 2020, Revised October 21, 2020 Page 7 Schnabel Engineering, LLC and help determine the water content necessary for a low Vebe time within the target range. Trial batch 1 contained 180 pcy cement and 250 pcy fly ash. Trial batch 2 contained 180 pcy cement and 350 pcy fly ash. Trial batches were two cubic foot and used to evaluate consistency of the freshly mixed RCC and develop the target proportions for mixes. RCC test specimens were not molded from the trial batch mixes. Mixes 1 through 4 were 3.5 cubic foot and included Vebe time and air content testing along with the molding of RCC specimens for compressive strength testing.

An air content test was performed on freshly mixed RCC from each of the mixes. The RCC was placed in the air pot in three layers of approximately equal volume and consolidated utilizing the vibrating table (without the use of surcharge). The air content of the RCC was measured in general accordance with ASTM C231. However, the vibrating table was utilized to consolidate the freshly mixed RCC, as opposed to rodding or using a concrete vibrator. Also, the use of a vibrating hammer with tamping plate, as described in ASTM C1849, was not utilized for these mixes with low target Vebe time.

Thirteen compressive strength specimens (6-inch diameter by 12-inch height) were molded for each of the four mixes (Mix 1 through Mix 4). Molding of the specimens was accomplished utilizing a Vebe table with an approximately 5 ¾-inch diameter surcharge, and assembly with a mass of approximately 20 pounds. The specimens were molded in a split steel 6-inch diameter by 12-inch height mold with a plastic cylinder liner. The specimens were molded in three approximately equal lifts. For each lift, the weight was placed on the concrete, and the concrete was allowed to consolidate under the weight while Vebe table was running. The concrete in the annular space between the edge of the surcharge and the inside wall of the mold was observed until the formation of a mortar ring around the total perimeter of the surcharge. After the final lift of each cylinder was placed, the RCC was struck off level with the top of the mold. The cylinders were molded in general conformance with ASTM C1176.

RCC specimens were cured in a water tank at a temperature within the range of approximately 70 to 77 degrees Fahrenheit. At the desired test age, each cylinder was removed from the curing tank, weighed, measured, and visually inspected for voids at the surface. Prior to testing for compressive strength, the cylinders were capped with sulfur capping compound in general accordance with ASTM C617.

Compressive strength tests were performed on specimens for Mixes 1 through 4 at the age of 3, 7, 28, and 56 days.

In addition to performing the standard curing and compressive strength testing, Schnabel performed an accelerated cure test on two of the test specimens from each of the four (Mix 1 through 4) batches. The purpose of the accelerated cure test is to estimate long term (180 day) strength of the RCC. For accelerated curing, the compressive strength specimens are cured normally for 7 days. After the seventh day, the compressive strength specimens are submerged in water within a sealed container and placed in oven at 160 degrees Fahrenheit for a period of 7 days. The sealed container is removed from the oven and allowed to cool down to room temperature before removing the specimens from the container and testing. The 14-day accelerated curing generally replicates cylinders with a standard curing age of approximately 180 days.

RCC Mix 4 was selected and used to construct a test block by placing and consolidating the RCC in two, 12-inch-thick lifts in a 2-foot-wide by 3-foot-long by 2-foot-high wooden box. The RCC was consolidated with an approximately 2” diameter concrete immersion vibrator and a plate tamper, similar to those required in the RCC specification. After the placed RCC cured for a few days, the formwork was removed and RCC test section was saw-cut in half to observe how well the RCC was consolidated in the wooden

September 30, 2020, Revised October 21, 2020 Page 8 Schnabel Engineering, LLC forms. It was observed that efforts to internally vibrate this mix (Vebe time of 19 seconds) were not very successful, however the compacted lift joints appeared blended together. The formed surfaces showed significant pockets of honeycombing. As such, although not in the original scope of work, a second Test Block was prepared using Mix 2 in order to evaluate the consolidation of a mix with a lower Vebe time.

Water for Mix 2 was decreased from 280 pcy to 270 pcy for the batch mixes prepared for the construction of Test Block 2 in attempt to increase Vebe time to within the target range of 8 to 12 seconds.

Additionally, set retarder admixture at dosage of 16 oz./cy was added to the three batches prepared for construction of Test Block 2. One cylinder was molded from the third and final batch prepared and tested for compressive strength at approximate age of 21 hours. Internal vibration using an approximately 2-3/4” diameter vibrator was successful, and the formed faces were very similar to that of conventional concrete.

The second Test Block was not sawcut as it was not included in the original scope of work. Results of testing performed during the mixing of batches for Test Block 2:

Vebe time = 8 sec.

RCC Temp. = 84°F Slump = no-slump Compressive Strength at 21 hours = 1,000 psi

Select photo documentation of the RCC equipment utilized in the RCC mixture proportioning study is included in Appendix E. The photo log includes select pictures of the RCC mixing process and testing performed as part of this study along with construction of the test blocks.

RCC Mixtures and Test Summary

The table below summarizes the various mix proportions and test results for the fresh and hardened

RCC.

Mix Identification Mix 1 Mix 2 6 Mix 3 Mix 4

B at ch

M at er ia ls a n d

W ei g h ts

S

S D

) Portland Cement (lb/cy) 180 220 275 250

Pozzolan / Fly Ash (lb/cy) 400 330 275 250

Aggregate (lb/cy) 2950 3000 3150 3225

Water (lb/cy) 1 300 280 280 260

Air entrainment admixture, oz/cy 12 16 16 16

B at ch P ro p er ti es

W:C/FA 0.52 0.51 0.51 0.52

Vebe Time (sec) 2 7 7 10 19

Air Content (%) 3 2.9 3.8 2.8 4

RCC Temperature 82 77 82 81

Slump (in) 4 n/a 0 n/a n/a

Compressive Strength, 3-day psi 5 720 1,450 2,040 1,910

Compressive Strength, 7-day psi 5 1,080 1,680 2,550 2,360

Compressive Strength, 28-day psi 5 1,950 2,830 4,070 3,710

Compressive Strength, 56-day psi 5 2,400 3,790 4,590 4,510

Compressive Strength, Accel. Cure, psi 5 3,170 4,480 5,280 5,100

Test Block n/a 2 n/a 1

September 30, 2020, Revised October 21, 2020 Page 9 Schnabel Engineering, LLC

1. Water was adjusted for batch based on moisture content of the aggregate

2. ASTM C1170 Procedure B / CRD-C53

3. ASTM C231 (general accordance; however, vibrating table utilized to consolidate freshly mixed RCC)

4. ASTM C143 (slump test performed on sample of RCC for Test Block 2 in general accordance with

C143 for Hydraulic-Cement Concrete)

5. Average of two test specimens (ASTM C1176)

6. For Test Block 2, Mix 2 water was reduced to 270 lb/cy and 16 oz./cy set retarder admixture was added; resulting Vebe time was 8 seconds

Compressive strength test results, including tabulated data and charts, are included in Appendix F. As expected, the testing results generally confirm that the compressive strength generally increases with age and greater strengths were achieved at higher cement contents. Chart 1 in Appendix F depicts the compressive strength at different ages for RCC specimens molded at four different proportions. Chart 2 depicts the compressive strength of four different cement contents tested at the different ages.

CONCLUSIONS

Based on the results of the laboratory testing program performed as part of this RCC mixture proportioning study, the use of local Oklahoma aggregate (Martin Marietta Materials, Plant Snyder, Type A Base) would appear to provide a consistent RCC product generally meeting the project specifications.

Based on the results of this RCC mixture proportioning study, we have concluded:

That materials used in the mixes (Portland cement, fly ash, water and aggregate) generally met applicable ASTM standards and project specifications for properties tested in this scope of work.

The compressive strength results are satisfactory and relatively consistent. Average compressive strength results range from 720 psi (Mix 1) to 2,040 psi (Mix 3) at 3 days; 1,950 psi (Mix 1) to 4,070 psi (Mix 3) at 28 days; and 3,170 psi (Mix 1) to 5,280 psi (Mix 3) for the accelerated cure test specimens.

Based on the desired minimum compressive strength of 3,000 psi at 90 days for this project, we recommend that Mix 2 with 220 lb/cy of cement and 330 lb/cy of fly ash be specified for the RCC project mix. Adjustments to the moisture content during RCC placement due to mix and air temperature can be expected to achieve the desired consistency for consolidation of the RCC.

The recommended RCC mixture proportion, based on the testing results from Mix 2/Test Block 2, is listed below:

Material

Batch Weight (SSD)

(lb/cy)

Portland Cement

Fly Ash / Pozzolan

Aggregate

Water

September 30, 2020, Revised October 21, 2020 Page 10 Schnabel Engineering, LLC

Air entrainment admixture, oz/cy 18

Set retarder admixture, oz/cy TBD*

*Contractor to determine during test section phase of project.

For consolidating the IV-RCC, we recommend vibrators with a minimum diameter of approximately 3 inches and a minimum frequency of 12,000 vibrations per minute and the method of consolidation confirmed during the Test Section. A range of plate compactor(s) should be evaluated during the Test Section and one selected based on compaction results.

LIMITATIONS

We based the conclusions and recommendations submitted in this report on the information revealed by the laboratory testing. We attempted to provide for normal contingencies, but the possibility remains that unexpected conditions/results may be encountered during construction.

This report has been prepared to aid in the evaluation of a local Oklahoma aggregate source material for consideration in the RCC mix proportioning/design. We based our conclusions on information on the aggregate and RCC specimen test results as described in this report.

We have endeavored to complete the services identified herein in a manner consistent with that level of care and skill ordinarily exercised by members of the profession currently practicing in the same locality and under similar conditions as this project. No other representation, express or implied, is included or intended, and no warranty or guarantee is included or intended in this report, or other instrument of service.

We appreciate the opportunity to be of service for this project. Please call us if you have any questions regarding this report.

Sincerely, SCHNABEL ENGINEERING, LLC

William E. Freeman, PE Senior Engineer

Randall P. Bass, PE Senior Consultant

WEF:RPB:JW

September 30, 2020, Revised October 21, 2020 Page 11 Schnabel Engineering, LLC

Enclosures:

Appendix A: Aggregate Test Reports - Martin Marietta Appendix B: Aggregate Test Reports – Schnabel Appendix C: Aggregate Test Report - CRT Appendix D: Cement, Fly Ash, and Air Entrainment Admixture Data Appendix E: Photo Log of RCC Mixing, Testing, and Construction of Test Blocks Appendix F: RCC Compressive Strength Testing Results

APPENDIX A

AGGREGATE TEST REPORTS - MARTIN MARIETTA

Basic Quality Statistical Summary Reports

APPENDIX B

AGGREGATE TEST REPORTS - SCHNABEL

ASTM C136 - Sieve Analysis of Fine and Coarse Aggregates ASTM D4318 - Liquid Limit, Plastic Limit, and Plasticity Index of Soils

Type A Agg.

0.0

Bulk

WELL-GRADED GRAVEL WITH SILT AND

SAND (GW-GM), fine to coarse gravel, reddish brown (Submitted as Type A aggregate from Martin Marietta - Snyder, OK Quarry)

NP NP 5.4 30.1 64.5 BLAC

Sheet 1 of 1

Boring No.

Summary Of Laboratory Tests Appendix

Description of Soil Specimen

Project Number: 19C35001.01

Notes:

Project:

Sample Depth ft

Elevation ft

US FWS Comanche Dam RCC Mix Design Comanche County, OK

Sample Type

1. Soil tests in general accordance with ASTM standards.

2. Soil classifications are in general accordance with ASTM D2487(as applicable), based on testing indicated and visual classification.

3. Key to abbreviations: NP=Non-Plastic; -- indicates no test performed; ND=Not Detected

D Y

N A

M

IC

L A

B S

U M

M A

R Y

9C

1.

C O

M A

N C

H E

D A

M .G

P J

S C

H N

A B

E L

D A

T A

T E

M P

LA

T

E

0_

R

E V

_1 .G

D T

8/

/2

P er ce n t S an d

P er ce n t G ra ve l

L iq u id

L im it

P as si n g

N o

S ie ve

P la st ic it y

In d ex

T es ti n g L ab o ra to ry

0.0010.010.1110100

6 4 3

GRAIN SIZE IN MILLIMETERS

Test Method

2.713

%Silt %Clay

ASTM C136

PI

12.355

D10

0.294

%Gravel %SandD30

Sample Description

Type A Agg. 41.972.02NPNP

D100 D60

WELL-GRADED GRAVEL WITH SILT AND SAND (GW-GM),

fine to coarse gravel, reddish brown (Submitted as Type A aggregate from Martin Marietta - Snyder, OK Quarry)

NP

Specimen LL PL Cc

JJRDWC

Tested Date Reviewed By Calc By

DWC

Tested By

8/11/20

U.S. SIEVE OPENING IN INCHES

Cu

1.5 6

P E

R C

E N

T F

IN

E

R B

Y W

E

IG

H T

100 14060

Percent Finer

37.5

U.S. SIEVE NUMBERS

1/23/8 4023 3/4

HYDROMETER

GRADATION CURVE

16 20 301

0.0 ft

Testing Lab: BLAC

5.431

Project: US FWS Comanche Dam RCC Mix Design Comanche County, OK

Contract: 19C35001.01D

G

R A

D A

T

IO

N

9C

.0

C O

M A

N C

H E

D A

M .G

P J

S C

H N

A B

E L

D A

T A

T E

M P

LA

T

E

T E

S T

.G D

T

/1 8/ fine coarse

COBBLES SILT OR CLAY

medium fine

SANDGRAVEL

coarse

Sieve Size

% Finer

No. 200

5.4

No. 60

No. 40

No. 4

1/2 in.

3/4 in.

1 in.

1.5 in.

APPENDIX C

AGGREGATE TEST REPORT - CRT

ASTM C1567 - Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

REPORT NO. T-2032

ON

POTENTIAL ALKALI-SILICA REACTIVITY OF

AN AGGREGATE SAMPLE

TO

SCHNABEL ENGINEERING, LLC

ALPHARETTA, GEORGIA

SEPTEMBER 9, 2020

Jason Cummins, Laboratory Manager Concrete Research & Testing, LLC, Columbus, Ohio CRT Report No. T-2032, pg. 1 Issued: September 9, 2020

POTENTIAL ALKALI REACTIVITY OF

Client: Schnabel Engineering, LLC Contact: Will Freeman

Type of Specimen: 1 x 1 x 11 in. bars Date Cast: August 24,2020

Test Procedure: ASTM C1567 – Standard Test Method for Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

Material Tested: Type A Aggregate Snyder, Oklahoma

SCM, %: Class F Fly Ash, 50% Prairie State

Comparator Readings, in.

Length of Exposure Zero† 2 days 7 days 9 days 14 days

Bar 1 0.0050 0.0058 0.0060 0.0064 0.0068

Bar 2 0.0049 0.0057 0.0059 0.0061 0.0064

Bar 3 0.0063 0.0070 0.0071 0.0073 0.0075

†The ‘zero’ comparator reading was taken at 48 hours, following a 24 hour cure and 24 hours in a 80°C ±2°C (176°F ±3.6°F) water bath.

Net Length Change, %

Length of Exposure 2 days 7 days 9 days 14 days

Bar 1 0.008 0.010 0.014 0.018

Bar 2 0.008 0.010 0.012 0.015

Bar 3 0.007 0.008 0.010 0.012

Average 0.01 0.01 0.01 0.02

Notes: The aggregate, portland cement, and fly ash samples were provided by Schnabel Engineering, LLC. The aggregate was crushed (as needed) and graded in accordance with ASTM C1567. The portland cement is from Holcim; the cement is a Type I/II low alkali portland cement with a total alkali content of 0.54% and an autoclave expansion of 0.00%. The fly ash is a Class F fly ash from Prairie State and comprised 50% of the cementitious material.

Interpretation of Results (from ASTM C1567 Appendix)

• Expansions of less than 0.10% at 14 days are indicative of innocuous behavior in most cases.

• Expansions between 0.10% and 0.20% at 14 days include aggregates that are known to be both innocuous and deleterious in field performance.

• Expansions of more than 0.20% at 14 days are indicative of potentially deleterious expansion.

Jason Cummins, Laboratory Manager Concrete Research & Testing, LLC, Columbus, Ohio CRT Report No. T-2032, pg. 2 Issued: September 9, 2020

POTENTIAL ALKALI REACTIVITY OF

Client: Schnabel Engineering, LLC Contact: Will Freeman

Type of Specimen: 1 x 1 x 11 in. bars Date Cast: August 24,2020

Material Tested: Type A Aggregate Snyder, Oklahoma

SCM, %: Class F Fly Ash (50%) Prairie State

Interpretation of Results (from ASTM C1567 Appendix)

• Expansions of less than 0.10% at 14 days are indicative of innocuous behavior in most cases.

• Expansions between 0.10% and 0.20% at 14 days include aggregates that are known to be both innocuous and deleterious in field performance.

• Expansions of more than 0.20% at 14 days are indicative of potentially deleterious expansion.

0.05

0.1

0.15

0.2

0.25

0.3

0 2 days 7 days 9 days 14 days

Ex pa ns io n, Length of Exposure, days

Potential Alkali Reactivity of Aggregates

>0.2% Expansion = Potentially Deleterious

<0.1% Expansion = Innocuous (in most cases)

Between 0.1% & 0.2% Expansion = Inconclusive (Innocuous or Potentially Deleterious)

APPENDIX D

CEMENT, FLY ASH, AND AIR ENTRAINMENT

ADMIXTURE DATA

Holcim – Portland Cement, Type I-II, Low Alkali, Material Certification Report Boral Resources – Fly Ash, Class F, ASTM C618 Test Report Sika AEA-14 – Air Entrainment Admixture Product Data Sheet

APPENDIX E

PHOTO LOG OF RCC MIXING, TESTING, AND

CONSTRUCTION OF TEST BLOCKS

(room for additional notes)

MODIFICATIONS TO COMANCHE DAM

FWS WICHITA MOUNTAINS REFUGE

WHEELER TEAM

PROJECT NO.: 19C35001.01

© Schnabel Engineering 2020 All Rights Reserved

PHOTO 1

DATE TAKEN: 8/12/2020

COMMENTS:

View of lab where the RCC trial mixture proportioning and testing was performed.

PHOTO 2

Vebe test on freshly mixed RCC from Trial Batch 2; Vebe time = 14 sec.

PHOTO 3

View of cylinder mold secured to vibrating table in preparation for making a test cylinder with freshly mixed RCC from Mix 1.

PHOTO 4

DATE TAKEN: 8/13/2020

Adding material into nine cubic foot mixer for Mix 2.

PHOTO 5

Nine cubic foot mixer being utilized to prepare Mix 2.

PHOTO 6

Using concrete immersion vibrator to evaluate consolidation of Mix 2 in wheelbarrow.

PHOTO 7

Performing Vebe test on freshly mixed RCC from Mix 2; Vebe time = 7 sec.

PHOTO 8

View of Vebe mold on vibrating table following the Vebe test.

Note the mortar ring along inside mold wall. During test, mortar fills the annular space between the outer edge of the plastic plate attached to the surcharge (not shown) and the inside mold wall.

PHOTO 9

Performing air concrete test on freshly mixed RCC from Mix 2;

Air content = 3.8%

PHOTO 10

View of completed 6” x 12” test cylinder for Mix 3 prior to removing it from reusable steel mold and placing flat plastic lid over top of the specimen in plastic cylinder mold.

PHOTO 11

View of Vebe mold following the Vebe test on freshly mixed RCC from Mix 4; Vebe time = 19 sec.

PHOTO 12

DATE TAKEN: 8/14/2020

View of formwork ready for construction of Test Block 1 using Mix 4.

PHOTO 13

View of Test Block 1. Concrete immersion vibrator being used to consolidate the RCC at form along one side.

PHOTO 14

Second lift of Test Block 1 completed. Plate tamper utilized to consolidate the RCC.

PHOTO 15

DATE TAKEN: 8/17/2020

View of Test Block 1 prior to saw cutting.

PHOTO 16

DATE TAKEN: 8/18/2020

Saw cutting Test Block 1. The test block was cut into four pieces.

PHOTO 17

DATE TAKEN: 8/18/2020

View of the inside of Test Block 1 after saw cutting into four pieces.

PHOTO 18

DATE TAKEN: 8/26/2020

Mixing RCC for the construction of Test Block 2.

PHOTO 19

View of Vebe mold following the Vebe test on freshly mixed RCC for Test Block 2; Vebe time = 8 sec.

PHOTO 20

Slump test performed on freshly mixed RCC for Test Block 2;

Slump = no-slump.

PHOTO 21

View of completed Test Block 2 prior to removing the forms.

PHOTO 22

DATE TAKEN: 8/27/2020

View of completed Test Block 2 after removing the forms.

APPENDIX F

RCC COMPRESSIVE STRENGTH TESTING RESULTS

Chart 1: Compressive Strength vs Age Chart 2: Compressive Strength vs Cement Content Summary Tables of Compressive Strength Testing Results

0 20 40 60 80 100 120 140 160 180

C o m p re ss iv e St re n gt h , p si

Age, days

Chart 1: Compressive Strength vs Age

275 pcy cement (Mix No. 3)

250 pcy cement (Mix No. 4)

220 pcy cement (Mix No. 2)

180 pcy cement (Mix No. 1)

150 170 190 210 230 250 270 290

C o m p re ss iv e S tr en gt h , p si

Cement Content, pcy

Chart 2: Compressive Strength vs Cement Content

180‐day (AC‐est.)

56‐day

28‐day

7‐day

3‐day

RCC Mixture Proportioning Study for Comanche Dam

Compressive Strength Test Results

Mix No.

Cylinder

ID

Date

Made

Weight**, lbs.

L1, in. L2, in. L3, in.

Avg. L, in.

D1, in. D2, in.

Avg. D, in.

Volume, ft3 Density, lbs./ft3 Date

Tested

Age, Days Area, in.2

Max.

Load, lbs.

Compr.

Str., psi

Avg. Compr.

Str., psi

Failure

Type

3a 28.57 12.212 12.212 12.211 12.212 6.016 6.028 6.022 0.201 141.9 08/15/20 3 28.48 20253 710 3

3b 28.61 12.201 12.252 12.219 12.224 6.028 6.021 6.025 0.202 141.9 08/15/20 3 28.51 20536 720 3

7a 28.72 12.227 12.258 12.257 12.247 6.006 6.022 6.014 0.201 142.6 08/19/20 7 28.41 30728 1080 3

7b 27.95 12.054 12.032 12.066 12.051 6.001 6.019 6.010 0.198 141.3 08/19/20 7 28.37 30287 1070 3

28a 28.67 12.242 12.269 12.228 12.246 6.014 6.009 6.012 0.201 142.5 09/09/20 28 28.38 56624 2000 3

28b 28.55 12.227 12.238 12.202 12.222 6.019 6.012 6.016 0.201 142.0 09/09/20 28 28.42 53645 1890 3

56a 28.41 12.220 12.198 12.189 12.202 6.021 6.032 6.027 0.201 141.0 10/07/20 56 28.52 68418 2400 3

56b 28.53 12.182 12.234 12.177 12.198 6.022 6.028 6.025 0.201 141.8 10/07/20 56 28.51 68208 2390 3

ACa 28.57 12.198 12.206 12.185 12.196 6.013 6.018 6.016 0.201 142.4 08/26/20 14 28.42 93381 3290 3

ACb 28.53 12.228 12.281 12.222 12.244 6.035 6.016 6.026 0.202 141.2 08/26/20 14 28.52 86732 3040 3

* 180 pcy cement/400 pcy fly ash

** Weight of cylinder prior to capping with sulfur compound.

Note: Accelerated cure (AC) test specimens were placed in standard cure tank for 7 days, then submerged in water within a sealed container in oven at 160 degrees Fahrenheit for a period of 7 days.

Mix No.

Cylinder

ID

Date

Made

Weight**, lbs.

L1, in. L2, in. L3, in.

Avg. L, in.

D1, in. D2, in.

Avg. D, in.

Volume, ft3 Density, lbs./ft3 Date

Tested

Age, Days Area, in.2

Max.

Load, lbs.

Compr.

Str., psi

Avg. Compr.

Str., psi

Failure

Type

3a 28.74 12.217 12.222 12.218 12.219 6.034 6.001 6.018 0.201 142.9 08/16/20 3 28.44 43582 1530 4

3b 29.20 12.282 12.260 12.264 12.269 6.028 6.010 6.019 0.202 144.5 08/16/20 3 28.45 38624 1360 3

7a 28.72 12.076 12.085 12.065 12.075 6.000 6.022 6.011 0.198 144.8 08/20/20 7 28.38 51765 1820 3

7b 28.74 12.142 12.204 12.127 12.158 6.009 6.025 6.017 0.200 143.7 08/20/20 7 28.43 43555 1530 3

28a 28.76 12.167 12.164 12.175 12.169 6.019 6.019 6.019 0.200 143.5 09/10/20 28 28.45 84667 2980 3

28b 28.99 12.294 12.274 12.217 12.262 6.013 6.012 6.013 0.201 143.9 09/10/20 28 28.39 76142 2680 3

56a 28.73 12.192 12.168 12.179 12.180 6.010 6.012 6.011 0.200 143.6 10/08/20 56 28.38 106299 3750 3

56b 28.88 12.217 12.225 12.204 12.215 6.023 6.023 6.023 0.201 143.4 10/08/20 56 28.49 108813 3820 3

ACa 28.97 12.243 12.258 12.249 12.250 6.017 6.004 6.011 0.201 144.0 08/27/20 14 28.37 125844 4440 3

ACb 28.93 12.212 12.228 12.256 12.232 6.002 6.015 6.009 0.201 144.1 08/27/20 14 28.35 127840 4510 3

* 220 pcy cement/330 pcy fly ash

** Weight of cylinder prior to capping with sulfur compound.

Note: Accelerated cure (AC) test specimens were placed in standard cure tank for 7 days, then submerged in water within a sealed container in oven at 160 degrees Fahrenheit for a period of 7 days.

(220/330)* 8/13/20

(180/400)* 8/12/20

Mix No.

Cylinder

ID

Date

Made

Weight**, lbs.

L1, in. L2, in. L3, in.

Avg. L, in.

D1, in. D2, in.

Avg. D, in.

Volume, ft3 Density, lbs./ft3 Date

Tested

Age, Days Area, in.2

Max.

Load, lbs.

Compr.

Str., psi

Avg. Compr.

Str., psi

Failure

Type

3a 28.87 12.184 12.162 12.158 12.168 6.024 6.005 6.015 0.200 144.3 08/16/20 3 28.41 59073 2080 4

3b 29.18 12.230 12.215 12.214 12.220 6.023 6.023 6.023 0.201 144.8 08/16/20 3 28.49 57084 2000 3

7a 29.31 12.164 12.228 12.205 12.199 6.001 6.004 6.003 0.200 146.7 08/20/20 7 28.30 73045 2580 3

7b 29.14 12.148 12.145 12.184 12.159 5.998 6.032 6.015 0.200 145.7 08/20/20 7 28.42 71574 2520 3

28a 29.26 12.199 12.215 12.251 12.222 6.023 6.024 6.024 0.202 145.2 09/10/20 28 28.50 118080 4140 3

28b 29.22 12.323 12.356 12.333 12.337 6.038 6.008 6.023 0.203 143.6 09/10/20 28 28.49 114076 4000 3

56a 29.16 12.121 12.141 12.147 12.136 6.004 6.025 6.015 0.200 146.1 10/08/20 56 28.41 130783 4600 2

56b 29.45 12.206 12.221 12.289 12.239 6.038 6.032 6.035 0.203 145.4 10/08/20 56 28.61 130932 4580 2

ACa 29.21 12.212 12.203 12.214 12.210 6.006 6.023 6.015 0.201 145.5 08/27/20 14 28.41 147848 5200 4

ACb 29.30 12.384 12.391 12.317 12.364 6.033 6.014 6.024 0.204 143.7 08/27/20 14 28.50 152539 5350 2

* 275 pcy cement/275 pcy fly ash

** Weight of cylinder prior to capping with sulfur compound.

Note: Accelerated cure (AC) test specimens were placed in standard cure tank for 7 days, then submerged in water within a sealed container in oven at 160 degrees Fahrenheit for a period of 7 days.

Mix No.

Cylinder

ID

Date

Made

Weight**, lbs.

L1, in. L2, in. L3, in.

Avg. L, in.

D1, in. D2, in.

Avg. D, in.

Volume, ft3 Density, lbs./ft3 Date

Tested

Age, Days Area, in.2

Max.

Load, lbs.

Compr.

Str., psi

Avg. Compr.

Str., psi

Failure

Type

3a 29.13 12.151 12.219 12.148 12.173 6.015 6.014 6.015 0.200 145.5 08/16/20 3 28.41 53797 1890 3

3b 29.17 12.172 12.158 12.155 12.162 6.014 6.032 6.023 0.201 145.5 08/16/20 3 28.49 54997 1930 3

7a 28.91 12.207 12.161 12.141 12.170 6.012 6.008 6.010 0.200 144.7 08/20/20 7 28.37 66283 2340 3

7b 28.79 12.084 12.050 12.080 12.071 6.033 6.000 6.017 0.199 145.0 08/20/20 7 28.43 67313 2370 3

28a 29.28 12.216 12.232 12.157 12.202 6.018 6.026 6.022 0.201 145.6 09/10/20 28 28.48 105582 3710 3

28b 28.99 12.142 12.162 12.198 12.167 6.013 6.000 6.007 0.200 145.3 09/10/20 28 28.34 104883 3700 3

56a 29.40 12.197 12.148 12.144 12.163 6.018 6.021 6.020 0.200 146.8 10/08/20 56 28.46 131249 4610 3

56b 29.14 12.140 12.092 12.132 12.121 6.021 6.028 6.025 0.200 145.7 10/08/20 56 28.51 125730 4410 3

ACa 28.73 12.006 12.091 12.085 12.061 6.013 6.006 6.010 0.198 145.1 08/27/20 14 28.36 145926 5140 2

ACb 29.21 12.199 12.196 12.175 12.190 6.022 6.004 6.013 0.200 145.8 08/27/20 14 28.40 143675 5060 3

* 250 pcy cement/250 pcy fly ash

** Weight of cylinder prior to capping with sulfur compound.

Note: Accelerated cure (AC) test specimens were placed in standard cure tank for 7 days, then submerged in water within a sealed container in oven at 160 degrees Fahrenheit for a period of 7 days.

(250/250)* 8/13/20

(275/275)* 8/13/20

Mix No.

Cylinder

ID

Date

Made

Weight**, lbs.

L1, in. L2, in. L3, in.

Avg. L, in.

D1, in. D2, in.

Avg. D, in.

Volume, ft3 Density, lbs./ft3 Date

Tested

Age, Days Area, in.2

Max.

Load, lbs.

Compr.

Str., psi

Avg. Compr.

Str., psi

Failure

Type

(220/330)* 1*** 8/26/20 28.56 12.036 12.060 12.055 12.050 6.025 6.008 6.017 0.198 144.1 08/27/20 1 28.43 28391 1000 1000 3

* 220 pcy cement/230 pcy fly ash (Block 2/Mix 2)

** Weight of cylinder prior to capping with sulfur compound.

*** Cylinder tested at approximate age of 21 hours.