Dealing With Tunnel Ageing: GR Basson, M V1Sagie, JG Malan

Dealing with Tunnel Ageing
Report to the
Water Research Commission
by
GR BASSON, M V1SAGIE, JG MALAN
Ninham Shand (Pty) Ltd

In Association with the University of Stellenbosch and
University of Pretoria
WRC Report No. 1088/1/03

ISBN No. 1-86845-905-5
February 2003
WRC Project: Dealing with Tunnel Ageing
EXECUTIVE SUMMARY
South Africa has several inter basin water transfer schemes, as indicated in Figure 1-1, with
the most recent one the Lesotho Highlands Water project (LHWP) transfer tunnels bringing
water under gravity from Lesotho through about 80 km of concrete lined tunnels. South
Africa also has the largest irrigation tunnel in the world, the 5.33 m diameter Orange-Fish
Tunnel, 81 km in length.
EstatJng D a n s and Infterlba&in
l\
Opt*
•
Figure 1-1 Water transfer schemes in South Africa
A concrete lined tunnel can lose as much as 30 percent of its hydraulic capacity over a
period of 30 years. Engineers have a sound knowledge of the hydraulic roughness of new
tunnels, as has been confirmed during the recent (1998) commissioning tests of the LHWP
Transfer and Delivery Tunnels. Furthermore, recently completed research funded by the
Water Research Commission (Pegram and Pennington, 1998) helps to assess the hydraulic
capacity of new tunnels. There is however a need for a better understanding of the tunnel
ageing process in order to plan for the phasing in of future possible new tunnels as water
demands increase.
South Africa will have to rely more and more in future on water transfer schemes. These
tunnels are extremely expensive, with estimated capital costs of about R30 000 /m length.
The main aim of the project was to provide a reliable hydraulically based methodology with
which concrete lined tunnel ageing and the associated decrease in hydraulic capacity can be
predicted. Both the ageing mechanisms of sliming (with sediment deposition) and soft water
corrosive conditions were investigated. This will ensure the timeous phasing in of new
schemes when tunnel ageing decreases the hydraulic capacity.
Furthermore, the aim was to establish whether remedial measures can be implemented to
reverse or contain the tunnel ageing process.
Basson, Visagie & Malan October 2002

Tunnel design and operation guidelines were also developed to limit tunnel ageing.
This study combined laboratory and field test data to obtain a better understanding of the
ageing process in large diameter conduits such as water transfer tunnels. Field tests were
carried out since 1998 at the Orange-Fish Tunnel, Roode Elsberg Tunnel and
Theewaterskloof Tunnel, while laboratory investigations at the Universities of Stellenbosch
and of Pretoria were also carried out on pipes. The following are key findings of this research
project:
• Hydraulic ageing is caused by sediment deposition consisting of fine cohesive

sediment, in some cases also containing some organic material. Manganese
deposition by bacterial action also occur which is difficult to flush out at high discharge.
In the Theewaterskloof Tunnel, sand at the tunnel invert also deposited due to
diversion of Berg River water into the tunnel.
• Soft water corrosion occurred at the Western Cape and LHWP tunnels. The effect is a
softening of the upper 3 mm of concrete, but this was protected by a thin layer of
sediment at all the tunnels investigated. The soft water corrosion can however lead to
deep scour holes and etch marks in the concrete, where a poor quality concrete was
used during construction (Theewaterskloof Tunnel). This is however not expected in
the high strength LHWP concrete lining.
• A relationship was developed and calibrated to determine the effective hydraulic

roughness of a segmentally lined tunnel, including the joint step losses.
• A hydraulic rate of ageing equation was developed and calibrated on UK and South
African data, for conditions where sediment deposition and sliming plays a role. The
pH of the water is a dominant variable.
• An ultimate hydraulic roughness equation was developed and calibrated. A probable

and maximum probable ultimate roughness formulation have been proposed.
• Hydraulic flushing at high flows are effective in reducing the hydraulic roughness by
flushing out sediment deposits from the tunnel. Where bacterial action however plays a
role, one cannot rely on flushing alone and other measures have to be considered.
• Chlorination has been used at a limited scale elsewhere in the world to reduce
roughness, but was found more effective after cleaning of the tunnel. Depending on
the system configuration, there are environmental problems associated with
chlorination.
• Mechanical cleaning of a tunnel in soft water conditions is not recommended since it

damages the tunnel and increase the roughness, no matter how careful you are. In
hard water conditions, high pressure water jets damaged the tunnel surface. Literature
also indicates rapid increase in roughness after cleaning, within one to two years.
• Tunnel linings such as poly-urethane can be considered in conditions of soft water

corrosion, but should preferably be applied during the tunnel construction. These
linings are however expensive and their lifespan is unknown. A good quality concrete
without a lining, designed and operated correctly, should be sufficient for most
conditions.
• Literature reviewed indicates that there are two main factors influencing the
deterioration of the concrete due to soft water attack, namely the aggressiveness of
the water and the composition of the concrete under attack.
Basson, Visagie & Malan » October 2002

No cement extenders were used in the concrete of the Theewaterskloof Tunnel and it
was found that the leaching rate of Ca-ions increase exponentially with an increase in
the water operating velocity in the pipe system. The main chemical process taking
place in the concrete during soft water attack in the Theewaterskloof Tunnel is the
leaching of Ca(OH)2. A maximum and minimum theoretical concrete deterioration
depth rate was determined for the concrete. These rates also increase exponentially
with an increase with water operating velocity in the pipe system. The permeability of
this concrete is very high and therefore the leaching rates are also high.
The concrete mixture of the LHWP linings of the delivery tunnels contains fly-ash as a
cement extender. Two different Ca-ion leaching rates for a specific water operating
velocity were found for the LHWP concrete. It indicates that as a result of the fly-ash
content in the mixture, decalcification of the C-S-H gel takes place at a low rate and
Ca(OH)2 leaching at a higher rate. The theoretical concrete deterioration depth rates
for the LHWP concrete are much lower than the rates for the Theewaterskloof Tunnel.
There are not enough data available at this stage, but it seems that the concrete
deterioration rate increases with an increase of water operating velocity.
Although the soft water attack cannot be stopped with a specific concrete mix design it
is possible to decrease it significantly with an optimum design. The optimum concrete
mixture as designed by Castro & Mclntosh (1994) for the LHWP tunnels will still be the
best mixture for resistance to soft water attack because the Ca(OH)2 content is very
low in this design mix.
• Design and operational guidelines for the determination of tunnel ageing and selection
of tunnel diameter during design, have been proposed. The LHWP Delivery Tunne!
North (DTN) has been used as a case study.
• Prediction of future ageing of the LHWP DTN indicates that under current operating
conditions, the rate of ageing would be relatively small and the ultimate discharge
capacity would be between 80% to 85% of the new tunnel capacity. Previous studies
used a higher ultimate roughness (DWAF, 1999) of ks = 4 mm which resulted in an
aged discharge capacity of about 73% of the original capacity. The current predictions
therefore indicate that it might be possible to implement the next phase of the LHWP
without doubling the tunnels: Low Mashai Dam, that would require a total tunnel
discharge capacity (including phase I flow) of 35,8 m3/s without downtime, or 39,8 m3/s
with 10% downtime.
It is recommended that the design guidelines (Chapter 10) are followed during the design of
a tunnel. Even more important however, is that the tunnel should be operated according to
the design.
• Regular hydraulic tests at say 5 year intervals should be carried out at the LHWP,
Theewaterskloof, Orange-Fish and Roode Elsberg Tunnels to determine the hydraulic
roughness to extend the current data base.
• The theory developed for this study should be calibrated against field data of pipelines
for application in pipe design.
Attention to the following chemical aspects regarding soft water corrosion is necessary:
• More laboratory tests are necessary on the LHWP test section at higher water operating
velocities to determine the relationship between the Ca-ions leaching rates and water
operating velocities.
Basson, Visagie & Maian in October 2002

• Tests on the microstructure of the concrete of the test sections are necessary to calibrate
the rate of the theoretical concrete deterioration depths and to determine the exact
influence of the permeability and porosity on soft water attack.
• Tests on the Theewaterskloof Tunnel core have to be completed to calibrate laboratory
tests.
• A core from LHWP is required to calibrate laboratory tests.
• The aggressiveness of the water actually flowing through the tunnels should be
determined. Laboratory tests with the water from the field will be necessary to confirm
the calibration of the accelerated rate of deterioration in the laboratory with the actual
field behaviour.
• Further tests on concrete mixtures with silica-fume as cement extender will be valuable
to determine a concrete mixture with a higher resistance to soft water attack.
• The effect of soft water in the concrete mix should be studied
• Coatings should be applied in the Delivery Tunnel North to evaluate its long term
performance
• Tunnels should 'not be cleaned by mechanical equipment or water jets, as this will
increase the hydraulic roughness, especially in softwater conditions. Controlled hydraulic
flushing at high discharge is recommended instead.
Basson. Visagie & Malar iv October 2002

Acknowledgements
The study team wishes to thank the South African Water Research Commission and the
Department of Water Affairs and Forestry for sponsoring this research project.
The South African Department of Water Affairs and Forestry (DWAF) played an instrumental
role in the successful completion of this study and especially the field work would not have
been possible without their contribution in terms of financial support and personel.
Thanks are also due to Trans Caledon Tunnel Authority for organising and financing the
transport of LHWP tunnel aggregates to Pretoria.
Finally, the Steering Committee members need to be commended for their role in steering
this project to its successful completion from 1999 to 2002. The project team would also like
to thank Mr David van der Merwe, chair person for the WRC on this project, for the way in
which he managed this final project prior to his retirement, and also for the valuable
contribution that he made on hydraulic and water resources projects in South Africa.
Mr DS van der Merwe Water Research Commission (Chair person)
Mr P D Pyke Department of Water Affairs and Forestry
Mr N J van Deventer Department of Water Affairs and Forestry
Prof SJ van Vuuren University of Pretoria
Prof A Rooseboom University of Stellenbosch
Prof GGS Pegram University of Natal
Mr D Hodgkinson Umgeni Water
MrJRMetcalf Keeve Steyn Consulting Engineers
Mr J McKeivey Keeve Steyn Consulting Engineers
Mr D Trebicki Rand Water
Mr BC Viljoen VKE Engineering (Pty) Ltd
Mr A Tanner Ninham Shand (Pty) Ltd

Table of Contents
LIST OF FIGURES 3
LIST OF TABLES 7
LIST OF SYMBOLS 9
KEYWORDS 10
1 INTRODUCTION 11
2 OBJECTIVES 13
3 METHODOLOGY 14
4 TYPES OF HYDRAULIC AGEING AND CONCRETE

DETERIORATION 16
4.1 Introduction 16
4.2 Physical characteristics of aged tunnels 16
4.3 Concrete deterioration 17
5 HYDRAULIC ROUGHNESS 20
5.1 Boundary layer theory 20
5.2 Friction loss equations 23
5.3 Hydraulic roughness of new conduits 25
5.4 Critical conditions for deposition of sediment 32
5.5 Critical condition for re-entrainment of non-cohesive and cohesive
sediment 33
5.6 Sediment transport in closed conduits 36
5.7 The rate of ageing 38
5.8 Ultimate roughness in tunnels / large conduits 50
6 SOFTWATER AGGRESSIVENESS INDEX 60

6.1 Ageing by soft water (chemical) corrosion 60
7 SOFT WATER CORROSION LABORATORY TESTS 63
7.1 Introduction 63
7.2 Background 63
7.3 Laboratory tests 68
7.4 Conclusions on chemical aspects 93
7.5 Recommendations 94
8 REMEDIAL MEASURES 95
8.1 Hydraulic flushing 95
8.2 Mechanical cleaning 127
8.3 Chlorination 135
1
8.4 Concrete design 136

8.5 Tunnel linings & other materials 137
8.6 Other measures 140
8.7 Tunnel costs 140
9 LHWP TUNNEL RATE OF AGEING AND ULTIMATE

ROUGHNESS PREDICTION 143
9.1 Introduction 143
9.2 Ageing prediction (DWAF, 1999) 145
9.3 Transfer Tunnel 147
9.4 Delivery Tunnel 148
9.5 Proposed operation to minimize rate of ageing 149
9.6 LHWP Tunnel roughness prediction based on findings of this WRC
study 154
10 TUNNEL DESIGN AND OPERATIONAL GUIDELINES
INCORPORATING TUNNEL AGEING 160
11 CONCLUSIONS 162
12 RECOMMENDATIONS 164
13 REFERENCES 165
APPENDICES 167
APPENDIX A 167
SOFTWATER CORROSION LABORATORY DATA 167
APPENDIX B 181
BIOLOGICAL ANALYSIS ON LHWP DTN SEDIMENT 181
Basson, Visagie & Malan 2 October 2002

LIST OF FIGURES

Figure 5.1-1 Variation of A with Re for artificially roughened pipes
Figure 5.1-2 Variation in thickness of laminar sub-layer with Reynolds number
Figure 5.1-3 Laminar sub-layer on smooth boundary
Figure 5.1-4 The transition zone for artificially roughened pipes
Figure 5.1-5 Laminar sub-layer formation at Orange-Fish Tunnel
Figure 5.3.3-1 Segmentally lined Delivery Tunnel North
Figure 5.3.3-2 Roughness height as a function of step height to step length
Figure 5.3.3-3 Segmentally lined tunnels new roughness prediction
Figure 5.5.1-1 Modified Liu diagram (Rooseboom, 1992)
Figure 5.5.1-2 Re-entrainment of sediment with laminar and turbulent boundary
conditions
Figure 5.5.2-1 Critical shear stress for mass erosion of reservoir sediment in open
channel flow
Figure 5.6-1 Head loss as given by Durand-Condolios relation for sand
Figure 5.6-2 FL values (Durand, 1956).
Figure 5.7.1-1 Observed linear roughness increase with time of Thirlmere pipeline
Figure 5.7.3-1 Thirlmere pipeline rate of ageing (Colebrook, 1938)
Figure 5.7.3-2 USA pipeline rate of ageing (Colebrook, 1938)
Figure 5.7.3-3 UK and USA pipeline rate of ageing (Colebrook, 1938)
Figure 5.7.3-4 Relationship between pH and hydraulic ageing for pipes
(Colebrook, 1938)
Figure 5.7.3-5 Relationship between pH and hydraulic ageing for tunnels
(Colebrook, 1958)
Figure 5.7.3-6 Relationship between input stream power, pH and rate of ageing
Figure 5.7.3-7 Observed versus predicted rate of ageing-hydraulic radius ratio values
Figure 5.7.3-8 Predicted and observed discharges based on ageing equation 5.7.3-6
Figure 5.7.3-9 Discharge capacity of new tunnel at ko = 0.03 mm
Figure 5.7.3-10 Typical 30 year aged flow capacity based on rate of ageing equation
and pH = 7.5.
Figure 5.7.3-11 Typical 30 year aged flow capacity based on rate of ageing
equation and pH = 5.5
Figure 5.8.5-1 Relationship between k/R and shear velocity
Figure 5.8.5-2 Relationship between k$/R and energy slope
Figure 5.8.5-3 Relationship between k./R and pH
Figure 5.8,5-4 Ultimate roughness tunnel discharge prediction
Figure 5.8.6-1 Location plan of Roode Elsberg Tunnel
Figure 5.8.6-2 Sediment deposition in Roode Elsberg Tunnel

Figure 6.1-1 Soft water zones in ground water in South Africa

Figure 7.3.2-1 Pipe system at the hydraulic laboratory of the University of Pretoria
Figure 7.3.2-2 The experimental set up in the laboratory
Figure 7.3.2-3 90 ° V-notch at the end of pipe system
Figure 7.3.3-1 Surface of sample after 10 days leaching of Ca (X20)
Figure 7.3.3-2 Inside of sample after 10 days leaching of Ca (X20)
Figure 7.3.3-3 Surface of sample after 10 days leaching of Ca (X5000)
Figure 7.3.3-4 Inside of sample after 10 days leaching of Ca (X5000)
Figure 7.3.3-5 Ca-ions leached from concrete (pilot test section)
Figure 7.3.4-1 Cumulative leaching of Ca-ions at different operating velocities
(Theewaterskloof test section)
Figure 7.3.4-2 Leaching rate of Ca-ions from the concrete for different velocities
Figure 7.3.4-3 Leaching rate of Ca-ions per total volume of water through TWK
test section (Theewaterskloof test section)
Figure 7.3.4-4 Leaching rate of Ca-ions per water volume for different water
velocities (Theewaterskloof test section)
Figure 7.3.4-5 Theoretical deterioration depths of concrete for different water
operating velocities (Theewaterskloof test section)
Figure 7.3.5-1 Cumulative leaching of Ca-ions per day (LHWP test section)
Figure 7.3.6-1 Laboratory hydraulic roughness changes due to softwater at
v = 1.2 m/s: Pilot test section
v = 1.2 m/s and following 3 m/s flushing: Pilot test section
Figure 7.3.6-3 Laboratory hydraulic roughness changes due to softwater:
Theewaterskloof Tunnel test section
LHWP DTN test section
Figure 8.1.2-1 Longitudinal profile of Orange-Fish Tunnel
Figure 8.1.2-2 Orange-Fish Tunnel valve
Figure 8.1.2-3 Orange-Fish Tunnel outlet
Figure 8.1.2-4 Orange-Fish Tunnel flow measurement gauge
Figure 8.1.2-5 Observed maximum annual Orange-Fish Tunnel flows
Figure 8.1.2-6 Localized clay deposition in Orange-Fish Tunnel
Figure 8.1.2-7 Typical hard smooth concrete surface of Orange-Fish Tunnel
Figure 8.1.2-8 Depth gauge at tunnel shaft operated by DWAF personel
Figure 8.1.2-9 Depth recording at Orange-Fish Tunnel Shaft
Figure 8.1.2-10 Ott Water level recorder and Thalimedes data logger
Figure 8.1.2-11 Historically observed hydraulic roughness of Orange-Fish Tunnel
Figure 8.1.2-12 Orange-Fish discharge capacity change over time
Figure 8.1.2-13 Orange-Fish Tunnel shaft 0 to 6 roughness (2001)

Figure 8.1.2-14 Orange-Fish roughness shaft 6 to 7a (2001)

Figure 8.1.2-15 Orange-Fish Tunnel sediment transport 2001
Figure 8.1.2-16 Orange-Fish Tunnel cleaned section roughness 2001
Figure 8.1.3-1 Theewaterskloof Tunnel layout
Figure 8.1.3-2 Longitudinal profile of the Theewaterskloof to Kleinplaas Dam
tunnel
Figure 8.1.3-3 Lowering of the boat at the Theewaterskloof Dam intake shaft
Figure 8.1.3-4 Bacteriological growth between the intake and Berg River,
Theewaterskloof Tunnel
Figure 8.1.3-5 Deep scour hole in soft water corroded concrete, intake to
Berg Riverjheewaterskloof Tunnel
Figure 8.1.3-6 Deep scour in soft water corroded poor quality concrete, intake
to Berg River, Theewaterskioof Tunnel
Figure 8.1.3-7 Exposed coarse aggregate after sediment removal due to emptying,
Banghoek to Jonkershoek, Theewaterskloof Tunnel
Figure 8.1.3-8 Sand deposition , Wolwekioof to Banghoek, Theewaterskloof Tunnel
Figure 8.1.3-9 Typical soft water corrosion underneath sediment deposition,
Figure 8.1.3-10 Tunnel flows and sediment concentrations during 1999 tests
Figure 8.1.3-11 Test flows used during 2001 Theewaterskloof Tunnel tests
Figure 8.1.3-12 Banghoek to Jonkershoek roughness 2001
Figure 8.1.3-13 Wolwekioof to Banghoek roughness 2001
Figure 8.1.3-14 Berg River west to Wolwekioof roughness 2001
Figure 8.1.3-15 Theewaterskloof Dam to Berg East portal roughness 2001
Figure 8.1.3-16 Sediment concentrations flushed out at Jonkershoek
Figure 8.1.4-1 Roode Elsberg Dam
Figure 8.1.4-2 Roode Elsberg Tunnel outfall
Figure 8.1.4-3 Roode Elsberg Tunnel inspection team
Figure 8.1.4-4 Roode Elsberg Tunnel at intake
Figure 8.1.4-5 Lowering of the emergency gate at Roode Elsberg Tunnel
Figure 8.1.4-6 Sediment deposits in Roode Elsberg Tunnel (1999)
Figure 8.1.4-7 Construction equipment left in Roode Elsberg Tunnel
Figure 8.1.4-8 Bypass pipe at Roode Elsberg Tunnel
Figure 8.1.4-9 Sediment transport through Roode Elsberg Tunnel (1999)
Figure 8.1.5-1 Dasbos pipeline before tests started
Figure 8.1.5-2 Dasbos pipe flushing hydraulic roughness test results
Figure 8.1.5-3 Dasbos pipe after testing and cleaning
Figure 8.2.1-1 Tunnel cleaning machine before lowered down shaft into tunnel
Figure 8.2.1-2 Rear view of tunnel cleaner
Figure 8.2.1-3 Side view of cleaner with steel brushes

Figure 8.2.1-4 Tunnel cleaning machine inside Colorado MWD tunnel

Figure 8.2.4-1 Tarraleah pipes ageing after cleaning
Figure 8.2.5-1 Water jet cleaning of Orange-Fish Tunnel (1999)
Figure 8.2.5-2 Cleaning team on truck in Orange-Fish Tunnel
Figure 8.2.5-3 Field measurement at shaft 7a during 2001
Figure 8.2.6-1 Theewaterskloof Tunnel cleaning during 1999
Figure 8.2.6-2 Theewaterskloof Tunnel with locally cleaned section next to
sediment deposits
Figure 8.2.6-3 Theewaterskloof Tunnel after cleaning
Figure 8.2.7-1 Tunnel cleaning at Roode Elsberg Tunnel
Figure 8.3.2-1 Hydraulic roughness change with chlorination at Tarraleah siphons
(Brett, 1980)
Figure 8.7-1 Unit costs of recently completed tunnels
Figure 9.1-1 Layout of LHWP tunnels
Figure 9.1-2 Layout of the LHWP Transfer Tunnel
Figure 9.1-3 Layout of the LHWP Delivery Tunnel
Figure 9.1-4 Intake tower of the LHWP Transfer Tunnel
Figure 9.1-5 Delivery Tunnel North at Ash River
Figure 9.3-1 Simulated hydraulic capacity loss of the Transfer Tunnel
due to ageing (DWAF, 1999).
Figure 9.4-1 Simulated hydraulic capacity loss of the Delivery Tunnel due to
ageing (DWAF, 1999)
Figure 9.5.3-1 Delivery Tunnel capacity with raised Muela Dam
Figure 9.6-1 Segmentally lined Delivery Tunnel North
Figure 9.6-2 Sediment deposition in the DTN (1999)
Figure 9.6-3 Sediment deposition partially covering the joints in the DTN (1999)
Figure 9.6-4 Soft water corrosion in the DTN (1999)
Figure 9.6-5 Predicted ageing of the Delivery Tunnel North (this study)

LIST OF TABLES
Table 5.3.1-1 Recommended new pipe roughness values ks (mm) (HR, 1990)
Table 5.3.2-1 Observed roughness of new (or near new) cast in-situ concrete
tunnels
Table 5.3.3-1 Segmentally lined tunnel data
Table 5.3.3-3 Calibration of segmentally lined tunnel relative roughness (R/ks)
Table 5.3.3-3 Predicted and observed segmentally lined roughness
Table 5.5.2-1 Tunnel shear stress and stream power
Table 5.7.2-1 Roughness values for different sewer pipe material
Table 5.7.3-1 Rate of ageing calibration data
Table 5.7.3-2 Predicted and observed roughness and flow
Table 5.8.2-1 Recommended aged pipeline hydraulic roughness ks (mm)
(HR, 1990)
Table 5.8.4-1 Maximum ultimate roughness prediction by Colebrook (1958)
Table 5.8.5-1 Ultimate tunnel roughness prediction with new equations
Table 5.8.7-1 Predicted discharge based on probable and maximum probable
ultimate roughness
Table 6.1-1 Aggressiveness index interpretation (DWAF, 1996)
Table 6.1-2 Recommended limits for assessing aggressiveness
(Basson, 1989)
Table 6.1-3 Aggressiveness index interpretation (Basson, 1990)
Table 7.2.1-1 The main compounds in Portland cement: (Neville, 1987)
Table 7.2.2-1 Swedish classification of natural waters containing carbon dioxide
(Lea, 1989)
Table 7.3.3-1 Leaching of Ca-ions from pilot test section
Table 7.3.4-1 Chemical composition of cement used for Theewaterskloof tunnel
section
Table 7.3.4-2 Composition and properties of concrete mixture for Theewaterskloof
tunnel section
Table 7.3.4-3 Theoretical concrete deterioration depths
(Theewaterskloof tunnel section)
Table 7.3.5-1 Chemical composition of cement used for LHWP tunnel section
Table 7.3.5-2 Chemical composition of Lethabo fly-ash
Table 7.3.5-3 Concrete mixture for precast linings of the LHWP Delivery Tunnels
from the 1994 records as obtained from DWAF
Table 7.3.5-4 Theoretical depth of deterioration of the concrete for
LHWP tunnel section
Table 7.3.7-1 Mix proportion for LHWP tunnel linings as proposed by
Castro & Mclntosh ((1994)
Table 8.1.4-1 Roode Elsberg Tunnel field test data
Table 8.5.4-1 Coatings for concretes in aggressive water (Basson, 1989)

Table 8.7-1 Historical tunnel costs

Table 9.2-1 Design tunnel roughness for aged condition
Table 9.3-1 Hydraulic capacity of the Transfer Tunnel with ageing (m3/s)
(DWAF, 1999)
Table 9.4-1 Hydraulic capacity of the Delivery Tunnel with ageing (m3/s)
(DWAF, 1999)
Table 9.5.2-1 Transfer Tunnel ageing and related MOL(m) required at Katse
Reservoir for various possible yields (Surge shaft MOL = 1950 m)
(DWAF, 1999)
Reservoir for various possible yields, with doubled surge shaft
(Surge shaft MOL = 1919 m)
Table 9.5.2-3 Hydraulic capacity of the Transfer Tunnel with ageing with reduced
surge shaft MOL (nrVs) (DWAF, 1999)
Table 9.5.3-1 Hydraulic capacity of a doubled Delivery Tunnel

LIST OF SYMBOLS
A A!2O3
AOL Average operating level
C CaO
c Volumetric sediment concentration
c Chezy roughness coefficient
C3A Tricalcium aluminate
c2s Dicalcium silicate
c3s Tricaluum silicate
C4AF Tetracalcium Aluminoferrite
CH Ca(0H2) calcium hydroxide
d Particle diameter
dv/dy Velocity distribution
D Datchet Tunnel
D Open channel flow depth
D Pipe diameter
D Tunnel diameter
DTN Delivery Tunnel North
DWAF Department of Water Affairs and Fc
E Enfield
EO Elyouse Tunnel
F Fe2O3
FSL Full supply level
g Gravitational acceleration
h energy head
h/L Energy slope
H H2O
k0 New tunnel hydraulic roughness
KOp Coefficient of oxygen permeability
ks Effective hydraulic roughness
l Segment length
L Liquid
L Pipe length
LHWP Lesotho Highlands Water Project
M Mixture
MOL Minimum operating level
n Manning hydraulic roughness value
PH Water quality variable

Q Discharge
R Hydraulic radius
Re Reynolds number
Rv Roding Valley Tunnel
s Hydraulic gradient
s Mean step height between joints
ss Ratio of density of solids to that of fluid
S SiO2
Sf Hydraulic gradient
T Years after commissioning
TBM Tunnel boring machine
V mean flow velocity
Vc Critical velocity
w Particle settling velocity
W Walsall Tunnel
WRC Water Research Commission
X Calibrated coefficient
y depth measured from the bottom
yr year
K Von Karman coefficient = 0.4 for clear water
0D Dimensionless sediment parameter
Pi Sediment density
To Bed shear stress

V Flow velocity
V kinematic viscosity of fluid
V* Shear velocity
k friction coefficient
a rate of ageing
S1 Laminer layer thickness
p Dynamic viscosity
Shear stress
KEYWORDS
Tunnel ageing; Water Transfer Tunnel; concrete corrosion; hydraulic roughness; friction
loss; mechanical cleaning; rate of ageing; ultimate ageing; hydraulic flushing; soft water
corrosion.
1
1 INTRODUCTION
South Africa has several inter basin water transfer schemes, as indicated in Figure 1-1,
with the most recent one the Lesotho Highlands Water project transfer tunnels bringing
water under gravity from Lesotho through about 80 km of concrete lined tunnels.
A concrete lined tunnel can lose as much as 30 percent of its hydraulic capacity over a
period of 30 years. This ageing process is mostly due to sediment deposition and
sliming, but soft water corrosion can also play a role. Engineers have a sound
knowledge of the hydraulic roughness of new tunnels, as has been confirmed during
the commissioning tests of the LHWP Transfer and Delivery tunnels. Furthermore,
recently completed research by the Water Research Commission (Pegram and
Pennington, 1998) helps to assess the hydraulic capacity of new tunnels. There is
however a need for a better understanding of the tunnel ageing process in order to plan
for phasing in of future possible new tunnels as water demands increase.
Tunnels are extremely expensive infrastructure, with capital costs in the order of about
R30 000 /m length. South Africa will have to rely more and more in future on water
transfer schemes and this study will provide very important information on long-term
tunnel capacities and possible management of these tunnels to limit the ageing rate.

Weservwe C*paciiy
so- -too m)
(nuilfott
London i oa - 500
Cape tow. I;-, > 500
^ Intctbasdi Tiansters
Basson, Visagie & Malan 12 October 20O2

2 OBJECTIVES
The main aim of this project was to provide a reliable hydraulicaiiy based methodology
with which concrete lined tunnel ageing and the associated decrease in hydraulic
capacity can be predicted. The ageing mechanisms of sliming and soft water corrosive
conditions were investigated. This will ensure the timeous phasing in of new schemes
when tunnel ageing decreases the hydraulic capacity.
Furthermore, the aim was to establish whether remedial measures can be implemented
to reverse or contain the tunnel ageing process. Two methods were considered and
tested in the field: hydraulic flushing and mechanical cleaning.
Guidelines were also developed according to which hydraulic flushing of water transfer
tunnels can be used with safety as management tool under conditions of soft water
concrete corrosion, in order to limit the rate of ageing and ultimate ageing due to
sediment deposition, based on theory calibrated on laboratory data and verified against
field data.

3 METHODOLOGY
The study involved a combination of theoretical hydraulic assessments of the tunnel
ageing process under conditions of sliming or corrosion, as well as laboratory and
fieldwork. The following key aspects were identified at the start of the study and some
were investigated in greater detail than others as the study progressed:
• Literature review of tunnel ageing rates, the processes and variables involved and
remedial measures. International information/data on tunnel roughness and rates of
ageing for conventional concrete linings and segmentally lined tunnels were
obtained. In this regard the Metropolitan Water District of Southern California
(MWD) contributed data on the Colorado aqueducts and tunnels.
• Theoretical analysis which investigated the interrelationship between the ageing

rate and stream power, pH, concrete characteristics, etc., also depending on
available data.
• Laboratory tests on sediment transport in pipes and the theoretical analysis of the
interrelationships between roughness, diameter, sediment concentration, energy
dissipation, deposition and critical conditions for re-entrainment. This theory is
essential when predictions on the effectiveness of tunnel flushing are made. The
theory could be applied to minimize the rate of ageing for specific boundary
conditions.
• Field investigation of the Orange-Fish Tunnel and LHWP Tunnel, and

Theewaterskloof Tunnel and Roode Elsberg Tunnel were carried out. Hydraulic
grade lines for different discharges were measured and the tunnel roughness was
calculated to obtain long-term ageing information necessary for the theoretical
analysis of South African data. A field study at the Orange-Fish Tunnel was carried
out in 1998 and indicated improvement of the hydraulic capacity by hydraulic
flushing. This test was repeated in 1999, to check whether this was a long-term
improvement. Physical inspection of the tunnels was also carried out.
While conditions (hard water) at the Orange-Fish Tunnel are such that slime would
form with sediment deposition, it was also considered necessary to study soft water
corrosion of concrete at other tunnels. The Theewaterskloof Tunnel, Roode Elsberg
and LHWP Tunnel North (DTN) were therefore selected as case studies to provide
long-term information in this regard.
• Hydraulic investigation of remedial measures:
Hydraulic flushing and the effects on decreasing tunnel roughness and increasing
the discharge capacity was carried out. Field tests were carried out at the Orange-
Fish, Roode Elsberg and Theewaterskloof Tunnels.
Mechanical cleaning of the tunnel. Investigation of roughness reduction and

increased discharge capacity, based on literature and the cleaning of a part of the
Orange-Fish, Roode Elsberg and Theewaterskloof Tunnels with measurement of
the hydraulic gradient line and roughness reduction were carried out. The USA
experience was also incorporated in the study.
Other: Chlorination, UV sterilization and relining alternatives were investigated.
• Chemical soft water corrosion tests involved laboratory work, investigating the
different concrete mix designs, flow velocities, rate of soft water corrosion (leaching
of cement) and measurement of the change over time of hydraulic roughness.
Three 5 m test concrete pipe sections were carried out by using distilled water,

running first at low flow velocities. Near the end of the tests, high flushing velocities
were used to investigate possible erosion of the soft concrete surface. If hydraulic
flushing is used as a management tool, it would be essential to have this
knowledge to ensure the flushing discharge is small enough without risk of
damageing the concrete surface with associated increased friction losses.

WRC Projeci: Dealing with Tunnel Ageing
4 TYPES OF HYDRAULIC AGEING AND CONCRETE

DETERIORATION
4.1 Introduction
Increased frictional energy losses in tunnels are often caused by sediment deposition.
The sediment is typically fine clay with silt fractions, with some organic material, and
forms a thin 1-3 mm (LHWP Deliver Tunnel) to a 7 to 10 mm layer (Roode Elsberg
Tunnel), covering the whole tunnel. When rivers are diverted directly into the tunnel,
sand deposition occurs at the invert of the tunnel (Berg-Jonkershoek Tunnel).
Sometimes the sediment has a slimy character which is associated with the water pH.
Bed forms develop in the deposited sediment which leads to increased hydraulic
roughness and reduced discharge capacity.
Sediment deposition can also be beneficial in lowering secondary losses caused by

joints in segmentally lined tunnels. In the LHWP Delivery Tunnel joint openings were
smoothly covered by sediment, two years after commissioning.
Hydraulic ageing can also be caused by erosion of the concrete, leading to higher
frictional losses. Concrete erosion in hydraulic structures are caused by cavitation,
abrasion and/or chemical or biological attack. Of these, chemical attack by mineral free
water or soft water corrosion is of most concern in tunnels, not that it affects the
structural strength much, but rather because of a possible increase in frictional losses
created by an eroded concrete surface. The soft water corrosion effect could however
be masked by a thin layer of deposited fine sediment on the concrete surface, which
limits concrete erosion.
If sediment deposition occurs with biological growth, the hydraulic roughness could
become quite high (Theewaterskloof-Franschhoek Tunnel).
4.2 Physical characteristics of aged tunnels
4.2.1 Cause of ageing: Sediment deposition
(a) International experience
A good description of the characteristics of tunnel ageing as experienced at the MWD-

USA Colorado aqueduct is presented by Horowitz and Lee, (1971). Deposition was
found to consist of about 80 % CaCO3 with the remainder being mostly organic matter.
It was estimated that about one-third of the CaCO3 precipitation in the aqueduct water
is deposited as scale on the aqueduct walls.
"Visual inspection indicates the thickness and composition of the deposits to be

remarkably uniform, suggesting existence of a state of equilibrium between the organic
and inorganic components. Biological analysis of the scale indicates that both bacterial
and higher life forms such as algae and protozoa live in the deposits." (Horowitz and
Lee, 1971). A certain type of worm was also found in the deposits. The worms activity
was found to increase the surface roughness of the scale by the worm's burrowing
action, but on the other had it also made deposits spongy and therefore easy to remove
by mechanical means.
"Age of the conduit surfaces alone does not appear to have a significant influence on
carrying capacity of the aqueduct. Up to a certain point, even the accumulation of some
deposits on the concrete surfaces will lower the coefficient of roughness, thus
increasing flow capacity" (Horowitz and Lee, 1971). (This has also been experienced at
the Hartebeespoort Dam siphon, where the initial estimated roughness of 12 mm was
decreased over time to less than 5 mm, based on an investigation by Hopkins (1978).)

Hopkins stated: "However as the coating increases in thickness, becomes stringy and
spongy, or both, the carrying capacity of the conduit gradually diminishes with time".
(bi Local experience
Regular inspection of the Orange-Fish Tunnel (hard water conditions) since 1974
revealed the following (Metcalf and Jordaan, 1990):
The lining was slippery and close inspection revealed a thin (<1 mm) coating of slime.
More noticeble was the calcite deposits. " These calcite deposits, whilst soft enough to
gough, are not eroded by tunnel flow. Calcification is inhibited when the tunnel is full,
exfiltration being replaced by infiltration". The impact of calcification on the total
roughness was estimated to be less than 5% however (Metcalf and Jordaan, 1990).
Metcalf and Jordaan (1990) noted: "Silt/slime deposits presented when dry as fawn
concave flakes, are estimated 0.5 mm thick. When wet the deposit is dark brown and
continuous. A mottling phenomenon on the crown appears to be due to local
dampness. When the surface of the dry lining is abraded, it typically yields a cream
coloured powdery coating of calcitic silt. Under the coating, the surface of the concrete,
at the occasional points sampled, exhibited a rough (sand paper) feel".
Most of the calcite deposits in the Orange-Fish Tunnel are attributed to the one year
(1976) of no flows in the tunnel, after commissioning in 1974. During the first 10 years
of operation the flows transfered were less than 10 m3/s, with associated flow velocities
< 0.5 m/s, (relative to the design capacity of 47.6 nrvVs. During later years' operation,
the peak summer flows increased to about 25 m3/s (v = 1.1 m/s). At these low flow
velocities, sediment deposition is expected with related relatively high annual rate of
roughness increase, as observed.
Results from the 1998 tests at the Orange -Fish Tunnel indicate that a short period of
high flow managed to flush the tunnel and that tunnel roughness was decreased in
comparison to that of 1988. This was also experienced to some extent during the 1988
tests.
4.3 Concrete deterioration
4.3.1 Cavitation
Cavitation results from the collapse of vapor pressure bubbles formed by pressure
changes within a high velocity water flow, but is generally not important in tunnels.
4.3.2 Abrasion erosion
Abrasion erosion of concrete is caused by water transported silt, sand and debris.
Ordinarily, concrete in properly designed, constructed, used and maintained tunnels will
undergo years of erosion-free service and due to the relatively low velocities and
generally fine sediment in SA tunnels, abrasion erosion is not a problem in water
transfer tunnels. Damage has however been reported at high head diversion tunnels at
dams, where the tunnel invert is most heavily damaged (Graham, 1998).
4.3.3 Chemical erosion
a) Sources of chemical attack
The compounds present in hardened Portland cement are attacked by water and by
many salts and acid solutions. Fortunately, in most hydraulic structures the deleterious
action on a mass of concrete with a low permeability is so slow that it is unimportant.
However, there are situations where chemical attack can become serious and
Basson, Visagie & Malan 1? October 2002

accelerate deterioration and erosion of the concrete, and possibly also increase the
hydraulic roughness.
Acidic environments can result in deterioration of exposed concrete surfaces. The

acidic environment may range from low acid concentrations found in mineral-free water
to high acid concentrations found in mine water.
Hydrogen sulfide corrosion, a form of acid attack, is common in septic sanitary systems.
b) Erosion by mineral free water (soft water corrosion)
Hydrated lime is one of the compounds formed when cement and water combine. It is
readily dissolved by water and more aggressively dissolved by pure mineral-free water,
found in some mountain streams, such as in the Western Cape and Lesotho Highlands.
Dissolved carbon dioxide is contained in some fresh waters to make the water slightly
acidic and add to its aggressiveness.
Scandanavian countries have reported serious attacks by fresh water, both on exposed
concrete surfaces and interior surfaces of conduits where porosity of cracks have
provided access (Graham,1998). In the USA, there are many instances where the
surface of the concrete has been etched by fresh water flowing over it, where in general
USA raw water typically has a nearly neutral acid-alkaline balance (pH).
In South Africa the Theewaterskloof-Franschhoek Tunnel has in many places been

damaged severely by soft water attack, leaving long etch marks and in some places
deep holes in the concrete.
Decaying vegetation is the most frequent source of acidity in natural waters. Running
water that has a pH as low as 6,5 will leach lime from concrete, reducing its strength
and making it more porous on the surface. If the concrete surface remains intact, the
hydraulic roughness will probably not change. However, high flow flushing could
develop bed forms in the soft concrete surface or erode the sediment, or mechanical
cleaning operation can damage the surface and expose coarse aggregate. During
cleaning oi part of the Roode Elsberg Tunnel as part of this study, cleaning by brooms
by hand actually removed the coarse aggregate leaving 20 to 30 mm diameter holes in
the surface!
The amount of lime leached from concrete is a function of the area exposed, the
volume of concrete, as well as aggressiveness of the water. As the surface mortar is
leached from the concrete, more coarse aggregate is exposed, which naturally
decreases the amount of mortar exposed. With less mortar exposed, less leaching
occurs, and hence major structural problems do not usually result, but the hydraulic
roughness can increase.
4.3.4 Bacterial action
Some anaerobic bacteria are able to reduce the sulfates that are present in natural
water and produce hydrogen sulfides as a waste product. Another group of bacteria
takes the reduced sulfur and oxides back so that sulphur acid is formed. The genus
Thiobaciltus is the sulfur-oxidizing bacteria that is most destructive to concrete.
Sulfur-oxidizing bacteria are likely to be found wherever warmth, moisture, and reduced
compounds of sulfur are present. Generally, a free water surface is required, in
combination with low dissolved oxygen in sewage and low flow velocities that permit the
buildup of scum on the walls of a tunnel or pipe, in which the anaerobic sulfur-reducing
bacteria can thrive.

Newly constructed concrete has a strongly alkaline surface with a pH of about 12. No
species of sulfur bacteria can live in such a strong alkaline environment. Natural
carbonation of the free lime by carbon dioxide in the air slowly drops the pH of the
concrete surface to 9 or less. At this level of alkalinity, the sulfur bacteria Thiobacillus
thioparus generates thiosulfuric and polythionic acid. The pH of the surface moisture
steadily declines, and at a pH of about 5, Thiobacillus concretivorus begins to
proliferate and produce high concentrations of sulphuric acid, dropping the pH to a level
of 2 or less.
The destructive mechanism in the corrosion of the concrete is the aggressive effect of
the sulphate ions on the calcium aluminates in the cement paste (Graham, 1998). The
main concrete corrosion problem in a sewer, therefore, is chemical attack by this
sulphuric acid which accumulates along the crown of the sewer.
Sediment obtained from the LHWP DTN was tested during this study for possible
bacterial action (see Appendix B).

5 HYDRAULIC ROUGHNESS
5.1 Boundary layer theory
Colebrook (1938, 1958) stated that while the boundary layer dominates in new pipes
and tunnels, it is not the case under aged conditions. Field data showed clearly that
aged pipes and tunnels operate in the transitional or rough turbulent zone.
In laminar flow, the friction is transmitted by pure shearing action. Consequently, the
roughness of the solid surface has no effect, except to trap small 'pools' of stationary
fluid in the interstices, and thus slightly increase the thickness of the stationary layer of
fluid.
In a turbulent flow, a laminar sub-layer forms close to the solid surface. If the average
height of the surface roughness is smaller than the height of the laminar layer, there will
be little or no effect on the overall flow.
Turbulent flow is a process of momentum transfer from layer to layer. Consequently, if

the surface roughness protrudes through the laminar region into the turbulent region,
then it will cause additional eddy formation and therefore greater energy loss in the
turbulent flow. This implies that the apparent frictional shear will be increased.
The A - Re curves for artificially roughened pipes are shown in Figure 5.1-1. At the
lower range of Reynolds numbers the curves for the rough pipes merge into the single
smooth pipe curve. Thus, rough pipes can behave like smooth ones at low Reynolds
numbers. This phenomenon is explained by the presence of a sub-layer, formed
adjacent to the boundary, in which the flow is laminar. The presence of such a layer
was also confirmed by the velocity distributions obtained by Nikuradse. At low Reynolds
numbers the sub-layer is sufficiently thick to cover the boundary roughness elements so
that the turbulent boundary layer is, in effect, flowing over a smooth boundary, figure
5.1-2.
Boundary Layers on Flat Plan's and in Ducts
010
008
006
004
= 1/252
= I/MM
002 = I/ION
0 01
iO' 10 s 10"
Re
Figure 5.1-1 Variation of A with Re for artificially roughened pipes
Basson. Visagie & Malan 20 October 2002

'-*• -fhfrfhfMl, ^ TifMM,

a, Smooth turbulent h. Transitional c. Rt>ugh turbulent
Figure 5.1-2 Variation in thickness of laminar sub-layer with Reynolds number
The sub-layer thickness decreases with increasing Reynolds number and at high
Reynolds numbers the roughness elements are fully exposed to the turbulent boundary
layer. At intermediate Reynolds numbers, in the transitional turbulent zone, the friction
factor is influenced by both the relative roughness and Reynolds number.
Figure 5.1-3 shows a sub-layer formed on a smooth boundary beneath a turbulent

boundary layer.
-— — - 5-75 k * — + 5*5
r
Figure 5.1-3 Laminar sub-layer on smooth boundary
In the laminar sub-layer,

dv
(5.1-1
dv r zv
whence — = — and v = -L~
dy pv pv
Where x = shear stress, V= flow velocity, p. = viscosity, y= distance from wall / bed and
p - fluid density. At the upper boundary the velocity of the upper turbulent flow is the
same as in the laminar layer and if these are equated, the laminar layer thickness (51)
can be determined:
<5 =
(5.1-2)

Where \f - shear velocity
Substituting v* = VJ— and introducing flow depth (D) on both sides yields:
S 32.8
Re VI (5.1-3)
The thickness of the laminar layer therefore decreases with Reynolds number. For
rough surfaces the zone of turbulent flow is clearly related to the ratio of the magnitudes
of S and the hydraulic roughness (ks). Since — is inversely proportional to Re-\M ,
the quantity
ReVI ks
will be proportional to — .
D 8
2k
Each of the curves in fig 5.1-1 should therefore deviate from the smooth pipe law at the
ks
same value of — . Thus superimposing all curves by plotting figure 5.1-4, shows that
S
the transition from the smooth law begins when S is approximately 4ks and ends
when k3 is approximately 6<5 (See figure 5.1-4). It is only at the latter condition when
S - ks/6 that the hydraulic roughness is no longer controlled by viscous effects at the
boundary.
Figure 5.1-4 The transition zone for artificially roughened pipes
The boundary layer theory can be used to design operational rules of tunnels. Figure
5.1-5 shows the hydraulic roughness versus required discharge to achieve rough
turbulent flow conditions in the Orange-Fish Tunnel. In the new tunnel with 0.13 mm
roughness, all flow conditions will have a laminar sub-layer, even at the maximum
discharge capacity of 57 m3/s. However, when the roughness reaches say 1.5 mm as
the tunnel ages, the discharge should be less than 27 m3/s to maintain a laminar
boundary layer.

In the case of soft water corrosion, possible damage to the concrete will be limited by
operation with a laminar boundary layer, since the settling velocity of sediment is higher
in laminar conditions than in turbulent flow. In the Orange-Fish Tunnel case, assuming
the water is soft, the tunnel should be operated initially at say 50 m3/s and as the
roughness increases later, the maximum discharge can be decreased to maintain a
laminar layer, but the minimum dominant discharge should not be less than the
discharge associated with the ultimate roughness caused by sediment deposition, to
limit hydraulic ageing. Therefore the ideal condition would be to maintain a laminar sub-
layer when the tunnel is still new and to allow some sediment deposition to occur which
would protect the soft corroded upper layer of the concrete.
In the case of transfer of hard water where damage to the tunnel by the flow is not
possible, the operating discharge should be as high as possible and in the rough
turbulent zone when the tunnel ages, to limit sediment deposition.
Orange-Fish rough turbulent
0.88
Flow
Velocity
1.21
= 1.5
1.55'
g> 1
2.18
MaxSf 3.36
E 0.5
20 40 60 80
Discharge (cumec)
Figure 5.1-5 Laminar sub-layer formation at Orange-Fish Tunnel
5.2 Friction loss equations
One of the earliest attempts at providing a scientific basis for hydraulic channel design
was Chezy's work round about 1775. Many empirical equations have since been
developed, some of which have remained in use to this day. Exponential forms such as
the Manning equation have been the most popular because of the ease of
manipulation. However, most empirical formulae are based on limited data, and, as in
general they have no sound physical basis, extrapolation outside the range of
experimental confirmation may lead to serious error.
When the need for dimensional homogeneity was appreciated, and non-dimensional
parameters such as the Reynolds number were available to represent the relationships
in problems containing many variables, the physics of fluid friction became more
apparent. In the 1930s Von Karman and Prandtl published theories of turbulent flow,
which, coupled with experiments on smooth pipes and on artificially roughened pipes
(Nikuradse), provided the foundation for major advances in design techniques. These
theories were used as basis by Colebrook and White (1937) in their derivation of an
equation describing the frictional resistance of pipes.

The Prandtl- Karman theory of turbulence led to the following flow equations:
Smooth turbulence:
0.8 (5.2-1)
Rough turbulence:
= 2 1 o g — + 1.74 (5.2-2)
2 kt
where
A = friction coefficient, 2gDS/V2
k, -a linear measure of effective hydraulic roughness
D = tunnel diameter
Re = Reynolds number, VD/i'
A rough pipe's resistance follows equation 5.2-2 at high Reynolds numbers when
viscous effects are negligible. The same pipe's resistance, at low velocities or when
carrying a more viscous fluid would deviate further from equation 5.2-2 as the Reynolds
number reduced. Provided its roughness was not excessive, the pipe's roughness
would tend to act increasingly like that of a smooth pipe, approaching equation 5.2-1.
There is a gradual transition between rough-turbulence and smooth-turbulence which
depends to some extent upon the character of the surface. In this region roughness and
viscosity operate jointly in determining resistance over a range of conditions. Most
commercial surfaces follow very similar transition curve, and the equation obtained by
Colebrook reads:
Transitional flow:
1 ( k 2.5 ID )
-T= = -2\om—— + r=\ (5.2-3)
JI \3JD ReVIJ
The transition equation incorporates the smooth-turbulent and rough-turbulent formulae
and is therefore applicable to virtually any surface, conduit size, velocity of flow, or fluid,
While empirical equations such as the Chezy and Manning equations are applicable in
rough turbulent flow, equation 5.2-3 has a wide range of application.
If the nondimensional variables of equation 5.2-3 are replaced by their dimensional

equivalents, the following expression results:
V = -2V(2Ô5]logf-^- + ;;51" . I (5.2-4)
where
V = mean flow velocity

g = gravitational acceleration
Si = hydraulic gradient
?;=kinematic viscosity of fluid

WRC Project: Pealing with Tunnel Ageing
Design charts have been developed in the past to solve problems using equation 5.2-4
(HR, 1990). With modern computers and calculators however, it is quite simple to
determine D or S, and a trial-and-error solution or the use of charts is no longer
required.
5.3 Hydraulic roughness of new conduits
Before one can establish the rate of ageing and ultimate roughness of a tunnel, it is
important to know the initial conduit roughness.
5.3.1 New pipes
Several references give recommended hydraulic roughness values for new pipes.
The Wallingford charts (see Table 5.3.1-1) provide such new pipe data and are widely
used (HR, 1990). The table of surface roughnesses is based on recommendations by
Colebrook (1939), Rouse (1943), Lamont (1954) and Perkins and Gardiner (1982). The
surfaces listed are classified as good, normal and poor examples of their respective
categories, thus leaving it to the engineer's judgement to estimate the actual value to
be used in any particular scheme. The range of roughnesses covered by good and
poor, takes into account not only the quality of the jointing but also the variation of
surface roughness to be found in pipes that are normally of the same material.
Table 5.3.1-1 Recommended new pipe roughness values ks (mm) (HR, 1990)
Classification: Good Normal Poor

Description
Smooth material: Drawn non-ferrous pipes of aiuminium and
copper, and non-metalic pipes of glass, Perspex etc. - 0.003 -
Asbestos-cement 0.015 0.03 -
Metal
Spun bitumen or concrete lined 0.03
Uncoated steel 0.015 0.03 0.06
Coated steel 0.03 0.06 0.15
Galvanised iron, coated cast iron 0.06 0.15 0.3
Uncoated cast iron 0.15 0.3 0.6
Tate relined pipes 0.15 0.3 0.6
Concrete
Precast concrete pipes with "0" ring joints 0.06 0.15 0.6
Spun precast concrete pipes with "0" ring joints 0.06 0.15 0.3
Monolithic construction against steel forms 0.3 0.6 1.5
Monolithic construction against rough forms 0.6 1.5 -
Clayware
Glazed or unglazed pipes with sleeve joints 0.03 0.06 0.15
With spigot and socket joints and " 0 " ring seals: - 0.06 -
dia > 150 mm
Glass fibre - 0.06 -
UPVC
With chemically cemented joints - 0.03 -
With spigot and socket joints, "0" ring seals at 6 to 9 m - 0.06 -
intervals
Basson, Visagie & Matan 25 October 2002

The hydraulic roughness values recommended for new pipeline design as given in
Table 5.3.1-1, are useful when considering the use of different materials in the design
of a new tunnel or where relining is considered. For concrete lined tunnels it is
proposed that observed new tunnel roughness values for South African conditions are
used.
5.3.2 New tunnels: insitu concrete lined
The observed hydraulic roughness of new tunnels, cast insitu, are indicated in Table
5.3.2-1.
Table 5.3.2-1 Observed roughness of new (or near new) cast in-situ concrete
tunnels
Tunnel Diameter (m) Manning n

New large concrete conduits (USBR, 1965) 0.6 m to 14 m 0.0111 to 0.013
Appalachia, USA (Elder, 1956) 5.5 0.0135
Colorado River Aqueduct, USA (Horowitz and Lee, 1971) 6.5 0.011 to 0.012
Sante Eltlah, USA 3.4 0.011
Chicago North, USA Unknown 0.012
Large conduits: US Army Waterways Experimental Station - 0.010 to 0.013

(age 0 to 8
years)
Slayand Inverawe, Scotland (Williams & Partners, 1952, 1964) unknown 0.0125
Glenlec (BW Engineers, 1984) 3.4 0.0137
Fasnakyk (BW Engineers, 1984) 4.5 0.0132
Rheidol, Wales Unknown 0.0125

Orange-Fish 5.33 0.0119
Kendoon, Scotland 1.6 m to 7 m 0.0120

4.35 0.0111 (design:
LHWP Transfer Tunnel
0.0123)
LHWP Delivery Tunnel 4.50 0.0116
5.3.3 New tunnels: prefabricated segmentally lined concrete segments
Segmental linings are being used increasingly for construction of tunnels to carry water
and sewage, yet there seems to be disagreement about the most important measure of
hydraulic performance - hydraulic roughness. As a result, many authorities impose
apparently arbitrary penalties on the use of such linings. For example for a nominal 6 m
diameter tunnel in the USA, an increase of 9 % in diameter was specified if a precast
segmental lining were to be used rather than an in-situ lining (Pitt and Ackers, 1982).

Other factors, such as durability and speed of construction and available construction
equipment, as well as hydraulic performance, can also influence the size and cost of
tunnels. In South Africa, the Delivery Tunnel North (Figure 5.3.3-1) followed the
segmentally lined construction technique. Commissioning test data of this tunnel
indicated a ks = 0.15mm, much less than expected during design. When the
commissioning test data were compared with other international tunnel data, the
general relationship of the equation proposed by Pitt and Ackers (equation 5.3.3-1) was
found, but with a completely different coefficient.
Figure 5.3.3-1 Segmentally lined Delivery Tunnel North
When segmentally constructed tunnels age, the secondary losses created by the panel
joints could actually decrease with time due to sediment deposition and sliming. For
accurate prediction of the ageing rate it is important to know the panel roughness and
the effective roughness caused by the steps between panels.
The Pitt and Ackers (1982) equation related ks to the mean step height Isl (ignoring
sign) and the segment length t. Hydraulic data obtained from 5 tunnels were used by
Pitt and Ackers to calibrate their equation:
k.=k,+x{\s\f!l (5.3.3-1)
with k0 the new panel roughness, calibrated as 0.3 mm, x = calibrated coefficient and ks
in mm. The constant of 0.3 mm is the roughness of the segments only, excluding the
joint losses. The tunnels tested were constructed during the 1970s and the initial
roughness of current in situ and segmentally lined tunnels (panels only) is typically 0.03
to 0.08 mm, based on the LHWP commissioning tests of the Transfer and Delivery
Tunnel North respectively.
The calibration of equation 5.3.3-1 is shown graphically in Figure 5.3.3-2.

T -
20-
L
•
1 0|Soulh|L
• d! North!
t
f .I L
-
0 020 0 0*0 Q060

71-7/
KEY
fa ELTf OUSE
D OATCHET •
nean vaius tsiandafddeviaJion
WALSAtl j
£ ENFIEU1
RQDINGViLLEY
1
Figure 5.3.3-2 Roughness height as a function of step height to step length (Pitt
and Ackers, 1982)
Viljoen and Metcalf (1999) proposed a recalibrated equation, using the DTN
commissioning test data as well as data of the Orange-Fish Tunnel. While the latter
tunnel has been constructed in situ, it has a lining pattern similar to a segmentally lined
tunnel with 1.52 m segments (between shutter joints) and mean step height of 6 mm.
They proposed k0 = 0.03 mm, but calibrated x = 0.65, which is significantly different
from the value proposed by Pitt and Ackers of 60. The British and South African tunnel
data therefore appear to differ, probably because of different hydraulic conditions, and
the s/l relationship on its own does not seem to be a good predictor of the total
roughness.
Viljoen and Metcalf (1999) proposed equation 5.3.3-2 which gives the percentage
increase in head loss (y), over that due to wall friction ks alone, due to mean step size s,
in mm units. Data of only the Orange-Fish Tunnel and the Delivery Tunnel North were
used in the calibration, with k0 = 0.08 mm. A correlation coefficient of only 0.63 was
obtained and the equation is only applicable for tunnel diameters of 4.6 m to 5.5 m.
y = L.75ln[.v]+4.2 (5.3.3-2)
Equation (5.3.3-2) has been calibrated on a small data set and with a fixed segment
length to diameter ratio of 0.3. A new approach based on applied stream power will be
followed here in order to establish a new equation calibrated on British and SA tunnels.

For equilibrium sediment transport conditions under steady, uniform open channel flow
conditions, when the power applied to maintain suspension near the bed is equated
with the power required to suspend a sediment particle, the following relationship is
found:
(5.3.3-3)
where
x = bed shear stress
v = velocity
y = depth measured from bottom
p = sediment density
p = density of water
g = gravitational acceleration
w = particle settling velocity
The left hand side of equation 5.3.3-3 represents applied stream power at the bed and
can be rewritten as:
3QpgSj D^gS^D/Kk^ = {pt -p)gw (5.3.3-4)
where
K = Von Karman coefficient = 0.4 for clear water
D = open channel flow depth
Sf = energy slope
When equation 5.3.3-4 is written in terms of relative roughness, equation 5.3.3-5 is

obtained:
(5.3.3-5)
Simons and Senturk (1992) found through dimensional analysis, that in cobble and
boulder bed rivers with large scale roughness, the Darcy-Weisbach friction factor is
related to the density ratio, the shear velocity and the d50/d84 ratio of the boulders. The
Darcy-Weisbach factor is related to the Chezy C which is a function of D/ks, the left
hand side of equation (5.3.3-5). Although there is no (or limited) sediment transport in
cobble bed rivers and none in the segmentally new tunnels under consideration, the
power is balanced and with a calibrated equation (5.3.3-5) the total hydraulic roughness
of a segmentally lined tunnel can be predicted.
The data considered for the calibration are indicated in Table 5.3.3-1.

Table 5.3.3-1 Segmentally lined tunnel data
Tunnel Type Hydraulic Flow S, (m/m) Observed Mean Step Age pitta
radius velocity new ks step length when Ackers
(X10 3 )
height L(m) tested (1982)
(m) (m/s) (mm)
(mm) (yr) ks calc
Dachet Raw 0.635 1.2 0.47 1.0 2.7 0.6 8 1.03

North water &
full
Dachet Raw 0.635 0.58 0.10 1.0 2.2 0.6 8 0.78

South water &
full
Ely Raw 0.635 0.62 0.11 0.45 2.3 0.6 5 0.83
Ouse water &
full
Enfield Sewer & 0.14 0.8 1.75 1.7 4 0.6 2 1.90
part full
Roding Sewer & 0.145 0.75 1.55 2.1 4.3 0.6 6 2.15
Valley part full
Wallsall River 0.23 1.33 2.11 1.3 3.5 0.6 0 1.53
water &
part full
Orange- Raw 1.33 2.54 0.60 0.13 6 1.52 0 1.72
Fish water &
full
Delivery Raw 1.15 2.95 0.90 0.15 8 1.4 0 2.83
Tunnel water &
North full
Of the 7 tests, the two which yielded the highest values of ks were in sewer tunnels after
2 to 6 years operation, and not new pipelines. It may be argued that hydraulic
resistance was increased as a result of slime on the surface, but inspection showed
that there was little sliming.
The last column of Table 5.3.3-1 shows the calculated ks values based on the Pitt and
Ackers equation, it is clear that the equation cannot predict the hydraulic roughness of
the South African Tunnels, even if the ko value in the equation is adjusted from 0.3 mm
to 0.03 mm.
The calibration of equation 5.3.3-5 was carried in a number of steps, as indicated in

Table 5.3.3-2. Firstly only the UK data were used with the proposed equation 5.3.3-5.
Then a dimensionless parameter R/s was introduced to account for the joint losses and
calibrated on the UK data with good results. An additional dimensionless parameter
was then introduced: Us to account for the suddenness of the joint transitions
(expansion/convergence), and UK and SA data gave an improved calibration 5.3.3-6.
(5.3.3-6)

Table 5.3.3-3 Calibration of segmentally lined tunnel relative roughness (R/ks)
Tunnels V* S R/s Us R/L r2
UK yes yes no no No 0.94
UK yes yes yes no No 0.95
UK&SA yes yes yes yes No 0.98
UK&SA yes yes no no yes 0.98
With V" = , w, K.p.p - constant.
Based on equation 5.3.3-6 k3 decreases when V* increases, when S decreases, when

R decreases, and when L increases.
The mean step heights in equation 5.3.3-6 however cancel out (fron the regression
analysis) and that is why an additional equation 5.3.3-7 was calibrated with a third
parameter R/L to account for the number of joints. Equation 5.3.3-7 gives the same
prediction accuracy as equation 5.3.3-6. Theoretically, it does not make sense that the
step height is not part of the equation, but its unimportance is probably due to the
available data, where step heights to L ratios have a narrow range of values. It is
proposed that equation 5.3.3-6 is recalibrated in future when more data for larger steps
are also available.
-1.79
(5.3.3-7)
The predicted and observed roughness values ks of the calibrated tunnels are shown in
Table 5.3.3-3 and Figure 5.3.3-3.
Table 5.3.3-3 Predicted and observed segmentally lined tunnel roughness
Ti i n n£i 1
Observed Predicted ks with Predicted ks with
i unnci k 5 {mm) eq 5.33-6 (mm) eq 5.3.3-7 (mm)
Dachet North 1.0 0.85 0.85

Dachet South 1.0 0.71 0.71
Ely Ouse 0.45 0.71 0.71
Enfield 1.7 1.81 1.81
Roding Valley 2.1 1.76 1.76
Wallsall 1.3 1.52 1.52
Orange-Fish 0.13 0.12 0.12
Delivery Tunnel North 0.15 0.16 0.16

WRC Project: Dealing wilh Tunnel Ageing
10
ks calculate d (mm)
. . ^ E ^ i d d i n g Valley
s^Dachet N
ElyOyse -r- Dachet S
0.1 ^
0.1 1 10
ks observed (mm)
o New 4 parameter eq C1RIA(1982)

T
Viljoen& Metcalf (1999) 3 parameter-R/L
Figure 5.3.3-3 Segmentally lined tunnels new roughness prediction
The proposed methodology gives reliable ks predictions for UK and South African
tunnels for a wide variety of conditions, for diameters ranging from 1.0 m to 5.33 m, for
full flow and partially full flow conditions, with mean step heights at joints ranging from
2.2 to 8 mm, and with a wide range of new tunnel roughness ks = 0.13 to 2.1 mm. It is
believed that the UK data used in the calibration is less robust that the South African
data, due to the free flow in some, and slightly aged conditions in these tunnels. In
future more commissioning test data should be gathered to refine the calibration.
It is proposed that for larger joint step heights (s > 10 mm), the secondary tosses
created by the joints should be calculated separately by using theory for sudden
contractions and expansions.
5.4 Critical conditions for deposition of sediment
In pipe sediment transport, especially at high sediment concentrations, there is a critical

relationship between velocity, energy slope and concentration. For a specific sediment
concentration, there is a minimum energy slope and when the velocities decrease
further, sediment is deposited at the bottom of the pipe which decreases the flow area
and increases the hydraulic roughness (Figure 5.4-1). The sediment deposition is due
to oversaturated conditions which is not typical what is found in tunnels. Critical
conditions for sediment deposition for tunnels should be based on the discussion on
critical conditions for re-entrainment of non-cohesive sediment and sediment transport.

Figure 5.4-1 Relationship between velocity, energy slope and stream power
Graf, 1971)
5.5 Critical condition for re-entrainment of non-cohesive and cohesive

sediment
5.5.1 Non-cohesive sediment
The re-entrainment of non-cohesive sediment can be determined by using the modified

Liu diagram (Figure 5.5.1-1). When the hydraulic conditions in the tunnel plot above the
line in the graph, sediment transport of a particular size sediment will occur.
1 S
SEDIMENT
MOVEMENT
1\
>5 G
V ^
Ld
0-5 A •
i . .. W
* *
0
10 100 1 000
/gDs.d
Figure 5.5.1-1 Modified Liu diagram (Rooseboom, 1992)

Figure 5.5.1-1 has been used to analyse a case study: Orange-Fish Tunnel. The
calculation is for non-cohesive sediment, while the sediment in the field in this tunnel is
in fact fine and cohesive. The required discharge versus sediment diameter is shown in
figure 5.5.1-2. As the tunnel ages and its roughness increases, the required discharge
to scour a particular sand fraction becomes slightly smaller. When the discharge is less
than 10 m3/s, a laminar sub layer exists and the stream power required for re-
entrainment of the sediment is relatively high. In the rough turbulent zone there is
initially a sharp rise in discharge required to scour 2 mm versus 1 mm diameter
sediment. At the current maximum tunnel discharge capacity, sediment of 20 mm in
diameter will be re-entrained and transported through the tunnel.
Orange-Fish Re-entrainment noncohesive
100
I
10 0.37
CO 0.30
fj
b 0.13
Laminar Turbulent
boundary boundary
0.01 0.1 1 10 100

d 50 (mm)
ks = 0.13 mm new ks = 0.6 mm ks = 1.2 mm
Figure 5.5.1-2 Re-entrainment of sediment with laminar and turbulent boundary

conditions
5.5.2 Cohesive sediment
Critical conditions to scour cohesive sediment is usually expressed in terms of the bed
shear stress. The critical shear stress depends on a number of factors such as the
physical and chemical characteristics of the sediment, the density of the sediment, its
shear strength and percentage clay. Most of the South African tunnels transfer water
from reservoirs after deposition of coarse sediment. It is the fine sediment that is
transported into the tunnels and deposits in uniform layers in the tunnels. Field data
should as far as possible be used in the determination of a critical shear stress for mass
erosion of the cohesive sediment. Data obtained from reservoir sediment deposits (fine
sediments) can however also provide useful information as shown in Figure 5.5.2-1.
The data were obtained from South African and Chinese Reservoirs. The maximum
and minimum lines can be used to scour sediment in hard water conditions or to limit
re-entrainment of sediment in soft water conditions, respectively.

100
OL
M
•
5
s
1 10
•
1
1 -
o
1
100 1000 10000
Dry density (kg/m3)
maximum •• minimum
Figure 5.5.2-1 Critical shear stress for mass erosion of cohesive reservoir
sediment in open channel flow
The field data obtained during this study during tunnel flushing also provide useful
information on critical shear stresses and input stream power in a tunnel, as shown in
Table 5.5.2-1. Unit input stream power (P) is better correlated with sediment transport
than shear stress and is described by
P = pgVSl
where V = mean flow velocity and Sf = energy slope
Table 5.5.2-1 Tunnel shear stress and stream power
Flow Wall Input

Tunnel velocity shear stream Comments on field or
(m/s) stress power laboratory observations
(Pa) (W/m)
Roode Els berg 0.57 6.5 7.4 Some scour = surface erosion
with C = 300 mg/l
Theewaterskloof: 2.0 5.5 12.6 Surface erosion limiting scour

Banghoek to with max. C = 2000 mg/l
Jonkershoek
Orange-Fish 2.2 4.6 7.5 Near maximum discharge;

flushed out most fine sediment
previously deposited
Corrosion lab pipe 1.06 6.9 210 No scour of soft concrete

test: poor quality
concrete 3.0 95 8115 Increased hydraulic roughness
Corrosion lab pipe 2.8 19 1515 No scour of concrete

test: DTN
Dasbos pipe 3.2 72 9133 Almost no scour of sediment

flushing test

Table 5.5.2-1 shows that at between 4.5 and 7 Pa shear stress, cohesive sediment is
scoured by surface erosion. Laboratory tests indicated it would be safe to operate at a
shear stress as high as 19 Pa without damaging good quality concrete in soft water
conditions.
Input stream power values of between 7.4 and 12.6 W/m lead to surface erosion of the
sediment, at observed concentrations of 300 to 2000 mg/l. The maximum stream power
without any scour of soft concrete that should be allowed in soft water corrosion
conditions is 210 W/m with a poor quality concrete, while with a good quality concrete
such as the LHWP tunnels, the stream power could be 1515 W/m.
5.6 Sediment transport in closed conduits
Sediment transport in pipes can be classified as heterogeneous or homogeneous flow,

depending on the sediment characteristics and hydraulic conditions. Fine sediment is
usually transported as homogeneous flow, with a near uniform distribution across the
pipe or tunnel. Coarse sediment however is transported with a higher sediment
concentration near the invert of the pipe, known as heterogeneous flow.
The Durand-Condolios relation (1953) can be used to describe heterogeneous

transport of sand.
-1.5
(5.6-1}
where 0n is a dimensionless sediment-transport parameter (refer to equation 5.6-2),

describing the excess head loss due to the presence of solid particles, V is the flow
velocity, g is the acceleration due to gravity, D is the pipe diameter, d is the particle
diameter and w is the terminal falling velocity of a particle in water.
(5.6-2)
with C = volumetric sediment concentration, L = liquid, M = mixture and h/L the energy
slope.
This equation is empirical and based on 310 test runs, where the pipe diameter varied
between 40 and 580 mm, the sediment diameter varied between 0.2 to 25 mm, and the
concentration varied from 50 g/l to 600 g/l, supplemented with particle relative density
variation of 1.60 to 3.95. Figure 5.6-1 shows the calibration data used by Durand.

•- —
! • ; •
1.
!
1
-;
i •
• • • - .
*0
• •
• . •• •
'
Figure 5.6-1 Head loss as given by Durand-Condolios relation for sand

(Durand and Condolios, 1953)
The lower limit of the equation where sediment deposition is limited was given by
Durand as
===== = FL (5.6-3)

where V c is the critical velocity and ss is relative weight of the sediment-water mixture.
This velocity separates the deposit-free regime from the deposit regime and is indicated
in Figure 5.6-2.
Figure 5.6-2 FL values (Durand, 1956).
The relationships for sediment transport developed by Durand can be used to

determine whether sediment entering the tunnel would be transported through. It is
applicable to sand and gravel fractions.
Suspensions of very fine (0.003 mm to 0.03 mm) sediment particles behave as

homogeneous fluids. Newitt et al. (1955) proposed an equation (5.6-4).
M
AL ALJL
(5.6-4)
where ss is the ratio of the density of the solids to that of the liquid.
5.7 The rate of ageing
5.7.1 Pipelines
Colebrook (1938) presented ageing data of the Thirl Aqueduct in the UK. The
roughness was determined at intervals of a few months over a period of 14 years, and
show the gradual increase in resistance in two tarred cast-iron pipes. Both pipes, with
the largest having a 1.76 m diameter, showed a very clear linear relationship between
hydraulic roughness and time. The data of one of the pipes were plotted by Colebrook
as shown in Figure 5.7.1-1.

- I T>
I r
U
z
A
-, o-1 o . . . _ -
5»
n 'Vssume '! linear
rela ion
O
6 8 1O 12
YFAR5.
Figure 5.7.1-1 Observed linear roughness increase with time of Thirlmere

pipeline (Colebrook, 1938)
Perkins and Gardiner (1982) carried out hydraulic roughness ageing tests on slimed
sewers and found that slime builds up on a sewer very quickly and once this initial
sliming has taken place, there is no evidence of a subsequent continuous increase. The
roughness varies, suggesting that there is a continuous process of slime building and
removal taking place. This is not what is expected in tunnels where sediment availability
limits the rate of ageing and the process is often not dominated by sliming.
5.7.2 Effect of different pipe material
The pipe or tunnel material could have an effect on the hydraulic ageing. During tests
carried out to determine the ageing of slimed sewers, Perkins and Gardiner (1982)
found that slime built up quickly and that the pipe material had an affect on its
roughness as shown in Table 5.7.2-1.
Table 5.7.2-1 Roughness values for different sewer pipe material (Perkins and
Gardiner, 1982)
Roughness values ks (mm)

Material
Hiqh Median Low
Vertically cast concrete 3.8 1.8 1.3
Spun concrete 4.2 2.3 1.8
Asbestos-cement 2.8 1.8 1.2
Clay 2.3 1.1 0.6
uPVC 1.1 0.6 0.6

Note: velocities about 0.75 m/s

5.7.3 Development of a hydraulic predictor of the rate of ageing by sliming and

sediment deposition
a) Colebrook (1938,1958)
Decreased hydraulic roughness with time could be due to the effects of sliming which
has been found to be more severe as pH decreases, or due to corrosion of the concrete
due to soft water attack.
The rate of ageing is usually taken as linear over time in mm/year. If the initial new
tunnel roughness k0 is known, and the rate of ageing a, it is possible to calculate future
aged tunnel roughness using equation 5.7.3-1.
ka = ku + o r (5.7.3-1)
where T is years after commissioning.
This equation was tested against pipe data by Colebrook (1938), first with Thirlmere
pipeline data (Figure 5.7.3-1), and also with typical USA pipeline data (Figure 5.7.3-2).
He also combined the data and plotted them on a logarithmic time scale (Figure
5.7.3-3). The data showed some scatter due to seasonal temperature changes and
chemical variations, superimposed upon the already large experimental errors to be
expected in such work (Colebrook, 1938). The data show clearly that a linear
relationship exist between the increase of roughness with time and age of a conduit,
and that an equation in the form of equation 5.7.3-1 can be used to determine hydraulic
ageing of pipes or tunnels.
1.1 • U l.l IU l l » l l | W I (I •!
• .
1. 11 1.
(O
ACt T; YEARS.
Figure 5.7.3-1 Thirlmere pipeline rate of ageing (Colebrook, 1938)

......
\
•
- —
t
5;.
i
\ \
—»
\ • z^ . A
\
a
1
— - * ~ — _
1
\ _
\
\ _
i
N
\
\
\
IB
s —
.——.
L
b
' 1 H
—
r-
I H
-- -- - •
.-
15
i ', TtAftS
Figure 5.7.3-2 USA pipeline rate of ageing {Colebrook, 1938)
8 2°
7' I !„ :
Figure 5.7.3-3 UK and USA pipeline rate of ageing (Colebrook, 1938)
Colebrook (1958) found a relationship between the rate of ageing of a concrete lined
tunnel and the water pH. He also established a relationship to determine the ultimate
tunnel roughness ks as function of flow velocity and hydraulic radius:
k =0.38/?" :( 'V- 22 (5.7.3-2)

in imperial units, and R = hydraulic radius and V = flow velocity. Equation 5.7.5-2 shows
that tunnel roughness is inversely related to the flow velocity. This would also apply to
the rate of ageing.
In his assessment of pipeline ageing, Colebrook (1938) found that as pH decreases,

the rate of ageing increase, based on UK and USA field data (Figure 5.7.3-4).
Colebrook proposed the use of a preliminary ageing equation 5.7.3-3, but emphasised
that the data showed considerable scatter and that other equally important factors play
a role with pH.
(5.7.3-3)
where « is in inches/year for pipe ageing.

O I
\ ... •(-_
O OO
Figure 5.7.3-4 Relationship between pH and hydraulic ageing for pipes

(Colebrook, 1938)
Colebrook found a similar relationship (Figure 5.7.3-5) in later work in tunnels (1958),
equation 5.7.5-4, and stated that it should be regarded as tentative until further
experimental data becomes available.
(5.7.3-4)
where a is in inches/year for tunnel ageing.

T 1
003
001
v : IS rn
oooe ^
- , — •
OGOt
\
GCO-t
?" U002
Vjrinwy ^
if ^
-ll' : 17
i
£
0001
UOOOU —IVt -
H OUOOi
O
Derwtnt-Kood i!pl«
S go* (hllcrcj onl/) \
16-
\
a
No. 3 \
V
u ooo Oi JB" : I ) >ri
—(pTr,
oixwot
- «' : 16 yn"Y
10
pH-VALUE
Figure 5.7.3-5 Relationship between pH and hydraulic ageing for tunnels

(Colebrook, 1958)
b) Basson(1999)
Using the above observed factors which contribute to tunnel ageing, the following new
calibrated equation was proposed by Basson (1999) to determine the rate of tunnel
ageing a (mm/year): with V = flow velocity (m/s), p = fluid density, g = gravitational
acceleration and Sf = energy slope.
(5.7.3-5)
The relationship between rate of ageing and input stream power is shown in Figure
5.7.3-6. The rate of ageing is lowest at high input stream power and at high pH values.
Equation 5.7.3-5 includes the impact of input stream power which has generally been
found to describe flow and sediment transport characteristics with great accuracy. A
linear regression carried out to calibrate equation 5.7.3-5 had a low correlation
coefficient of only 0.49. The above equation has therefore been calibrated as envelope
curve (conservative high rates of ageing) on only seven data sets, including the
Orange-Fish Tunnel data, and should be used with caution.

10
equation 5.7.3-5
1
55
. /
¥ /
7.5
5.6 *3
a If a
7.5
•
0.01 7
Label: pH
7.23
o nm
1 10 100
pgvs
Figure 5.7.3-6 Relationship between input stream power, pH and rate of ageing
The data used to calibrate the above proposed equation include pH values between 5.5
and 7.5. When ageing field observations obtained at the Orange-Fish Tunnel is used to
forecast possible future conditions at the LHWP tunnels, it is important firstly to have
corresponding pH values. Orange-Fish Tunnel pH values ranged between 7.5 to 8.5 in
1975 at the inlet, while more recent DWAF data indicate a median pH of 7.5, with a
range 5.9 to 8.7 at the tunnel outlet. These values are quite similar to pH values
obtained at Katse Dam before tunnel commissioning, with mean of 8.1 and range 7.0 to
8.8 (based on a small data set of only 23 samples).
Both the equations proposed by Coiebrook (1939) and Basson (1999) showed relatively
poor correlations with the data. This might be attributed to variability in data such as pH,
or the selection of veiocities not representative of typical values experienced in the
tunnels and/or the selection of unsuitable theory. One of the problems with equations
5.7.3-4 and 5.7.3-5 is that they are not dimensionless, which could make predictions
outside the calibration range highly unreliable.
Applied stream power is a maximum at the bed (tunnel wall) and should be able to
describe hydraulic roughness where sediment deposition occurred, perhaps better than
input stream power.
c) Applied stream power and rate of ageing
In section 5.3.3 a new equation was proposed relating applied stream power at the bed
to the power required to maintain suspension. This resulted in a dimensionless
equation 5.3.3-5:
D p-p

WRC Project; Dealing with Tunnel Ageing
If for tunnel flow D is replaced with R, v is assumed = 0.4 for clear water, p = constant
for water transfer tunnels, w = settling velocity = constant, it is possible to calibrate
equation 5.3.3-5 to determine the rate of ageing, with ks replaced by a. The settling
velocity had to be taken as constant since no data were available of the tunnels used
by Colebrook. Based on the description of the nature of the sediment deposition it is
similar to the South African conditions, consisting of clay and silt fractions.
The data used for the calibration of the proposed ageing equation were obtained from
Colebrook (1958) and aged Orange-Fish Tunnel data, as indicated in Table 5.7.3-1.
Tunnel ageing data are extremely limited and are rarely published. When hydraulic
tests are carried out, these are often treated as confidential consultants' reports
internationally. At many tunnels, as long as the hydraulic capacity exceeds the water
demand, no field work is carried out to establish hydraulic ageing.
Table 5.7.3-1 Rate of ageing calibration data
Tunnel Equivalent Age PH s, ks new Flow Aged Rate of

diameter (year) (mm) velocity roughness ks ageing
(m/m)
(m) (m/s) (mm) (mm/year)
Fasnakyle 4.5 4.5 6.5 0.0018 0.3 3.44 0.7 0.09

Mourne 1.68 55 5.6 0.0003 0.3 0.64 3.0 0.05
Apalachia 5.49 10 7.23 0.0017 0.925 3.87 0.62 -0.03
Glenlee 3.35 19 7 0.0021 0.575 3.14 0.73 0.01
Derwent 1.52 25 5.5 0.0005 0.3 0.67 12.5 0.49
Vyrnwy 1.02 17 6.3 0.0005 0.3 0.73 0.85 0.03
Orange- 5.33 13 7.5 0.0001 0.13 0.67 1.1 0.07
Fish 1988
Orange-
5.33 23 7.5 0.0006 0.13 2.24 0.6 0.02
Fish 1998
The Apalachia Tunnel is operated at a high flow velocity which would limit excessive
build up of deposited sediment. The hydraulic roughness has however decreased with
time, giving a negative rate of ageing, which can probably be attributed to the formation
of a smooth thin layer of sediment. The Apalachia Tunnel data were not used because
of the negative ageing impact.
The tunnel ages varied between 4 to 55 years, while the pH values varied between 5.5
and 7.5. In some cases the hydraulic gradient was very steep as much as 0.0021, while
at the Orange-Fish Tunnel during the first 13 years of operation at low flow velocities,
the slope was only 0.0001. The roughness of new tunnels have decreased over the
years as construction techniques improved. The UK tunnels had minimum roughnesses
of 0.3 mm, while the Orange-Fish Tunnel had an original roughness of 0.13 mm. The
recently constructed LHWP Transfer Tunnel had a roughness of only 0.03 mm which is
extremely good for a cast in situ lining.
Often during the operation of a water transfer tunnel the water demand increases over
time which results in higher flow velocities, which again limits sediment deposition. This
has been experienced at the Orange-Fish Tunnel. During the 1998 tests the tunnel
was flushed by running it for a day at maximum capacity which resulted in a
considerable decrease in hydraulic roughness. The averaged rate of ageing over 23
years is therefore much less than the rate over the first 13 years. The question has to
be asked therefore is the rate of ageing linear with time and if this is assumed, what

could be the consequences in terms of the design and future operation of tunnels? This
aspect will be discussed in more detail at the end of this section.
Typically the rate of ageing is less than 0.1 mm/year, but at the Derwent Tunnel the
ageing rate observed was extremely high at 0.49 mm/year, with a final roughness ks
after 25 years of operation of 12.5 mm. The actual rate of ageing of this tunnel might be
less since the new tunnel roughness had to be estimated at 0,3 mm.
Since the rate of ageing is also influenced by the type of lining, the initial roughness-
hydraulic radius ratio was also incorporated in the calibration. The final calibrated
ageing equation is:
-11.55, J.21
(5.7.3-6)
R
The correlation coefficient of equation 5.7.3-6 is relatively high at 0.79, compared with
the methods proposed earlier by Basson (1999) and Colebrook (1958). The rate of
ageing is minimized when S increases, when R decreases, and when pH increases.
The rate of ageing is especially sensitive to the pH of the water. The predicted versus
observed rate of ageing-hydraulic radius ratio values are indicated in Figure 5.7.3-7.
y
0.01
•o
u
••->
0.001
X*
calculc
0.0001
QC
50.0 / m
3
"re
•
111/
1E-05
/ Label: discharge
<m3/s)
1E-06 *
1E-06 1E-05 0.0001 0.001 0.01
alfa/R observed
Figure 5.7.3-7 Observed versus predicted rate of ageing-hydraulic radius ratio

values
Predicted aged ks values calculated with equation 5.7.3-6 are shown in Table 5.7.3-2
and are compared with the observed values. In addition discharge calculated with the
predicted and observed roughness is also given in Table 5.7.3-2.

Table 5.7.3-2 Predicted and observed roughness and flow
Observed Predicted
Observed Predicted
Tunnel discharge discharge
old ks (mm) old ks (mm)
(m3/s) (m3/s)
Fasnakyle 0.7 0.57 54.7 55.6

Mourne 3.0 9.99 1.41 1.2
Glen lee 0.73 0.74 27.7 27.8
Derwent 12.5 4.95 1.2 1.4
Vyrnwy 0.85 0.77 0.6 0.6
Orange-Fish 1988 1.1 0.74 15.0 15.5
Orange-Fish 1998 0.6 0.96 50.0 47.8
Figure 5.7.3-8 shows the observed and predicted discharges of Table 5.7.3-2
graphically. From Table 5.7.3-2 it is clear that equation 5.7.3-6 over and underestimate
the large roughnesses significantly. However, when the Colebrook-White-Darcy-
Weissbach equation is used to calculate discharge from the predicted ks values, the
differences in discharge predicted and observed are relatively small. In fact all the data
fall within the range of 0.84 to 1.19 when the ratio of predicted discharge to observed
discharge is considered, which is extremely good.
50.0
Orange-Fish
Vyrnwy
0.6
Derwent
Tunnel
Glenlee
Apalachia
1 4 ^~-^~~
Mourne
Label: Discharge
Fasnakyle
(m3/s)
08 0. 9 1 1.1 12
Ratio calculated/observed discharge
Figure 5.7.3-8 Predicted and observed discharges based on ageing equation

5.7.3-6

d) Ageing equation application range
Equation 5.7.3-6 is applicable for a wide range of tunnel diameters (1.0 to 5.3 m),
hydraulic gradients and operating velocities. The age of the tunnels used for calibration
varied between 5 and 55 years, with an average age of 23 years, and it is proposed
that it should only be used to make ageing predictions up to 30 years into the future.
e) Typical tunnel ageing design
The calibrated equation 5.7.3-6 can now be used to calculate typical rates of ageing
and flows, for a range of energy slopes and tunnel diameters, as is graphically shown in
Figure 5.7.3-10 for a 30 year aged condition, with k0 = 0.03 mm and pH = 7.5. This
aged condition can be compared with the new tunnel discharge capacity shown in
Figure 5.7.3-9.
In a typical design of a tunnel, the hydraulic gradient St is fixed, discharge is often fixed
based on the firm yield of the water resources system (or demand is fixed), the water
pH is known and for an in situ concrete lined tunnel an initial roughness k0 = 0.03 mm
can be assumed. For a pH of 7.5, discharge = 30 m3/s and say S = 1:1000 one can use
Figure 5.7.3-10 to determine the required tunnel diameter: about 4.4 m. For a new
tunnel the required diameter would be 3.7 m to convey this flow.
The ageing is very sensitive to the pH as can be seen from Figure 5.7.3-11 when
compared with Figure 5.7.3-10, plotted for pH values of 5.5 and 7.5 respectively, which
is also the calibration range. If the ageing calculation above was based on a lower pH
of 5.5, the required tunnel diameter would be much larger at 5.5 m to give the required
capacity after 30 years of operation.
It is clear that once a tunnel diameter has been selected for a specific aged condition
and discharge, the tunnel should be operated for as long as possible at its maximum
capacity every year to limit the rate of ageing. It might be possible to restore some of
the tunnel capacity later after an initial period of flow less than the design discharge by
flushing operation, but efficiency is not guaranteed depending on the critical conditions
to re-entrain deposited sediment from the tunnel wall.

New tunnel flow

100 6 1J .
362
i
i 6 t
312 S52
5 67
2 3S
5 17 39§_—-"" " 2 99 S23
- .? - —
361, 2 08 1j47~^ 1 08
1
M
4
^ ^ ! ?4 ! 18_^——
3P- " ' 0^95
1 02
0 82
0 87
102. 1 07^ - - ^ ^ " OBl

0 71
n I 066
^ • ^ 0.74
1
a
I IS
g
^ ^ 0 59
0
0 Labels: v(m/s)
1 '
2 3 4 5 6
Diameter (m)
— — Sf = 1:500 SF= 1:1000 S f = 1:2000 Sf = 1:5000
S f = 1:10000 • SI = 1:15000 SI = 1:250
Figure 5.7.3-9 Discharge capacity of new tunnel at ko = 0.03 mm
Tunnel flow 30 yr aged
0 44
0 51
CL|1
Labels: v (m/s)
, 0 33
Diameter (m)
Sf = 1:500 Sf = 1:250 Sf = 1:1000 Sf = 1:2000
Sf = 1:5000 Sf = 1:10000 Sf = 1:15000
Figure 5.7.3-10 Typical 30 year age flow capacity based on rate of ageing

Tunnel flow 30 yr aged

100
258
2 45 m
2.32
1.TQ ^ - 13(
2 S 1,25
l 'fl— ' 1 18 081
Z03 0_67_. ———
afe>
"» 0 7 8_^- 0.53
OK
6.51
o> 10 1 3 Q - - 0*96 oa——'^*"^ 0 37 Oil
• ' " • " ^ „
0 35 o5o
c °^5 0 33 0.28
V)
. ^
0 31 °^7
a 038 029
0^5
0 24
0 27
o 0 22 Uihcls: \ diVs)
1
2 3 4 5 6
Diameter (m)
— Sf = 1:500 Sf = 1:250 Sf = 1:1000 Sf = 1 :2000
Sf = 1:5000 - Sf= 1:10000 Sf = 1:15000
Figure 5.7.3-11 Typical 30 year age flow capacity based on rate of ageing
f) Linear rate of change in hydraulic roughness assumption
In deriving equation 5.7.3-6, it was assumed that the rate of change in hydraulic
roughness occurs linearly with time. It might be possible however that under conditions
with an ample supply of sediment being diverted into a new tunnel, bed roughness
would reach equilibrium roughness or ultimate roughness for specific flow conditions
relatively quickly. This could happen within a year or over a period of 5 to 10 years
where after no further increase in hydraulic roughness occurs. So far in this chapter
however, ageing (increase in roughness) has been assumed to continue indefinitely
and this is probably an incorrect assumption. If the hydraulic roughness is determined
by sediment deposition, even if it is a thin layer, the ageing process should be seen as
a non-equilibrium phase in the life of a tunnel until the ultimate roughness (equilibrium
condition) is reached. The ultimate roughness should remain the same as long as the
same boundary conditions apply. If for example the flow velocity is increased in a
flushing exercise, the equilibrium roughness should decrease (if the sediment can be
re-entrained).
5.8 Ultimate roughness in tunnels / large conduits
5.8.1 Background
Tunnel roughness increases, under steady flow conditions, do not continue indefinitely,
but assimptotically approaches an equilibrium long-term ultimate roughness. This
equilibrium would not only depend on the tunnel material, but also the water quality,
flow velocity, etc.
5.8.2 Pipelines
Several sources can be quoted on final aged roughness values to be assumed for
concrete lined tunnels. Many of these are based on experience, with quite often a risk
(margin for error) design roughness incorporated. Some typical ultimate roughness
values recommended for pipelines are indicated in Table 5.8.2-1.

Table 5.8.2-1 Recommended aged pipeline hydraulic roughness ks (mm) (HR,

1990)
Classification: Good Normal Poor

Description (mm) (mm) (mm)
Old tuberculated water mains with the following

degrees of attack:
• Slight
0.6 1.5 3.0
• Moderate 6.0
1.5 3.0
• Appreciable 6.0 15 30
• Severe 15 30 60
(Good: up to 20 years use, normal: 40 to 50 years
use, Poor: 80 to 100 years use)
Slimed gravity sewers
Sewers slimed to about half depth; velocity, when

flowing half full, approximately 0.75 m/s:
• Concrete, spun or vertically cast - 3.0 6.0

• Fibre cement - 3.0 6.0
• Clayware - 1.5 3.0
• UPVC - 0.6 1.5
Sewers slimed to about half depth; velocity, when

flowing half full, approximately 1.2 m/s:
• Concrete, spun or vertically cast - 1.5 3.0

• Fibre cement - 0.6 1.5
• Clayware - 0.3 0.6
• UPVC - 0.15 0.3
(The roughness of a slimed sewer varies con-

siderably during one year. The normal value is that
roughness which is exceeded for approximately half
of the time. The poor value is that which is
exceeded, generally on a continuous basis, for one
month of the year. The value of ks should be
interpolated for velocities between 0.75 m/s and 1.2
m/s.)
Sewer rising mains, all materials operated as
follows:
• Mean velocity 1.0 m/s 0.15 0.3 0.6
• Mean velocity 1.5 m/s 0.06 0.15 0.3
• Mean velocity 2.0 m/s 0.03 0.06 0.15

Table 5.8.2-1 indicates that a wide range of hydraulic roughness values for water mains
are possible and that ultimate roughness increases with older pipes, giving different
values for 50 years and up to 100 years use. It is not clear to what extent the values
given were calibrated against data, but for tunnels the ultimate hydraulic roughness is
expected after say 30 to 40 years, depending on the local hydraulic and water quality
conditions. After the ultimate roughness has been reached further sediment deposition
could occur which would decrease the flow area. This reduction in area could be of
significance in small diameter pipelines, but in tunnels the effect is negligible.
The recommended sewer ageing roughness values indicate that materials with
resistance to chemical and biological corrosion associated with sewerage, have much
lower hydraulic roughness values than a concrete pipe. The build-up of sediment on
adjacent epoxy lined tunnel sections and on concrete sections in the LHWP Delivery
and Theewaterskloof Tunnels, were similar and it is doubtful whether different tunnel
lining material plays a significant role in ageing as with sewers where the dominant
mechanism is sliming.
The recommended roughness data for gravity and rising main sewers in Table 5.8.2-1
indicate that at higher operating flow velocities the ultimate hydraulic roughness
decreases. The difference is quite significant. For example, a rising main's poor
roughness of 0.6 mm at 1.0 m/s, changes to 0.15 mm at 2.0 m/s. The flushing efficiency
improves at higher flow velocities and sediment deposition is limited. Flow velocity on
its own is however not a good hydraulic parameter to use when predicting hydraulic
roughness and instead a stream power approach should be followed. The aged
roughness in sewers flowing full was also found significantly less than with part-full flow,
which might be important for the design of aquaducts not flowing full, although the
ageing mechanism in sewers is completely different.
5.8.3 Aged tunnel data
Aged tunnel data is shown in Table 5.8.4-1, as obtained from Colebrook (1985) and this
study.
5.8.4 Colebrook ultimate roughness theory (1958)
Colebrook (1958) deveped a rate of ageing equation based on the pH of the water
which he calibrated on UK tunnel data, as discussed in section 5.7. The same data
were also used by Colebrook to calibrate an equation for maximum probable ultimate
hydraulic roughness due to sliming, in imperial units (equation 5.8.4-1).
ks = QMR0Z*Vî3 (5.8.4-1)
with ks in ft
Table 5.8.4-1 shows the calculated versus observed ultimate roughness values as
determined by the Colebrook equation using the same data his equation was calibrated
against, as well as Orange-Fish Tunnel data.
Basson, Visagie & Malan S2 October 2002

Table 5.8.4-1 Maximum ultimate roughness prediction by Coiebrook (1958)
Tunnel Tunnel age (year) Observed k5 (mm) Predicted max ks (mm)
Fasnakyle 4.5 0.7 0.6

Mourne 55 3.0 23.7
Apalachia 10 0.62 0.5
Glenlee 19 0.73 0.7
Derwent 25 12.5 20.7
Vyrnwy 17 0.85 15,1
Orange-Fish 1988 13 1.1 29.2
Orange-Fish 1998 23 0.6 1,8
5.8.5 Development of new theory to describe ultimate roughness

The Coiebrook equation for ultimate roughness seems to overestimate ks too much
when a tunnel is operated at low flow velocity. There are also some cases where the
predicted maximum ks is slightly less than the observed value. It is proposed that a new
equation is derived simiiar to the rate of ageing equation proposed earlier that is based
on conservation of applied stream power, such as equation 5.8.5-1.
(5.8.5-1;
ks 30 p \JgSfD
with J^StD - V = shear velocity
By assuming that w and density are constant, the equation can be calibrated against
tunnel data given in Table 5.8.5-1. The relationship between ks/R and the variables on
the right hand side of equation 5.8.5-2 are shown in Figures 5.8.5-1 to 5.8.5-3.
n9
0.15 • Apalachia
• Fasnakyle
• Glenlee
> 0.1
• O-Fish1998
0.05 • Demvent
• Vyrnwy • Mourne
• O-Fish19B8
n
0,0001 0.001 0,01 0.1
ks/R
Figure 5.8.5-1 Relationship between ks/R and shear velocity

0 01
0.001
H Q-Ftshi 99S • Derwent
V
•• Mourns
0 0001
• O-RsH !98S
1E-05
0 0001 0.001 0.01 0-1
kS/R
Figure 5.8.5-2 Relationship between ks/R and energy slope
m
IU
8
• O-FisWBS8=isri 1988
• Apalachia
i 7 • Glenlee
• Fasnakyie
• Vyrnwy
6
• Mourne • Derwent
0.0001 0.001 0.01 0.1

ks/R
Figure 5.8.5-3 Relationship between ks/R and pH
The figures show that ks decreases as V* increases. When considering Sf, increasing
Sf seems to indicate lower ks, but the relationship is not that clear since the SA data
seem to be giving a slightly different relationship than the UK data. The variable pH
gives a clear relationship for all the data with high pH resulting in a small ultimate
roughness.
The initial roughness/R to kg/R relationship was also considered but it was found, as
was expected, that it plays no role in determining the ultimate roughness (based on the
available data).

Equation 5.8.5-1 was calibrated with the data given in Table 5.8.5-1 and a high
correlation coefficient of 0.89 was obtained. Probable ultimate ageing roughness is
based on regression analysis, while it is proposed that maximum probable roughness
should also be determined (envelope line of data). Maximum probable roughness
prediction can be achieved by adjusting the regression constant with a factor of about
2.5. Two equations are therefore proposed to evaluate the probable and maximum
probable ultimate ageing of a tunnel, equations 5.8.5-2 and 5.8.5-3 respectively.
Probable ultimate roughness:
(5.8.5-2)
Maximum probable ultimate roughness:
= 44668 (Sr)" m(pH r*

R (5.8.5-3)
Table 5.8.5-1 shows the observed aged roughness and discharge, predicted probable
ultimate roughness and associated discharge, and predicted maximum probable
ultimate roughness and associated discharge values. The discharge was calculated by
using the Colebrook-White-Darcy-Weissbach equation.
Table 5.8.5-1 Ultimate tunnel roughness prediction with new equations
Predicted Observed Predicted Predicted

Tunnel Predicted maximum
Observed maximum aged probable
Tunnel age probable probable
ks (mm) probable discharge discharge
(year) ks (mm) discharge
ks (mm) (m3/s) (mVs)
<m3/s)
Fasnakyle 4.5 0.70 1.32 3.35 54.7 51.2 46.20
Mourne 55 3.00 5.28 13.38 1.4 1.3 1.14
Apalachia 10 0.62 0.55 1.40 91.5 92.6 84.59
Glen lee 19 0.73 0.54 1.38 27.7 28.6 26.06
Derwent 25 12.50 4.93 12.50 1.22 1.41 1.22
Vyrnwy 17 0.85 1.17 2.97 0.60 0.58 0.52
Orange- 13 1.10 1.02 2.59 15.0 15.0 13.71

Fish 1988
Orange-
Fish 1998 23 0.60 0.53 1.34 50.0 50.5 46.24
It is possible that the Fasnakyle Tunnel data cover too short a period of ageing and that
is why the predicted probable aged condition overestimates the observed values. Due
to the small data base this tunnel was however kept in the calibration data base.
The accuracy with which the probable ultimate discharge can be determined is quite
remarkable, the ratio of predicted to observed flows falling inside a relatively narrow
band between 0.86 and 1.16. This is also shown graphically in Figure 5.8.5-4.

In the past, before the commencement of this study, the ratio (predicted/observed) was
based on estimated Manning n values or ks values with typical prediction observed ratio
range of 0.75 to 1.33 (n-values = 0.012 to 0.016).
50.0
O-Fish1998
1 &:'O
O-Fish1988
Vyrnwy
£ Derwent
c 277__-~-~"~~~
,E Glen lee
Apalachia
Mourne Label: Discharge

Fasnakyle (m3/s)
0.8 0.9 1 1.1 1.2

Ratio calculated/observed discharge
Figure 5.8.5-4 Ultimate roughness tunnel discharge prediction
Ultimate roughness prediction equations have now been derived and calibrated against
field data. There however remains one aspect of concern and this is whether the
calibration data have in fact reached equilibrium roughness conditions. It is believed
that an equilibrium condition is established relatively quickly, if sediment input is
sufficient. Evidence of this quick adjustment can be found where tunnels have been
cleaned mechanically and where the roughness returns to the pre-cleaning state within
a year. The newly calibrated equation that predicts maximum probable ultimate
roughness caters to some extent for the possibility that ultimate roughness has not
been reached in some of the calibration data.
It is important to note that the ultimate roughness and rate of ageing could be
dramatically increased if a tunnel is operated below its design capacity. If in later years
the originally predicted discharge capacity is required, it might not be possible to turn
the ageing process around.
5.8.6 Verification of the ultimate roughness equation against field data
The Roode Elsberg Tunnel was constructed in the late 1960s and transfers irrigation
water from the Roode Elsberg Dam to the Hex River valley (Figure 5.8.6-1). The insitu
concrete lined tunnel is 5.2 km in length and 1.98 m in diameter. The tunnel has mostly
been operated at flow velocities below 0.5 m/s and a 10 mm uniform layer of fine
cohesive sediment deposited on the tunnel wall (Figure 5.8.6-2).

WRC Projecl: Dealing with Tunnel Ageing
•'.y*.i
UViitj
l . \ • • J "•
•"'••, V * f*+B*t*f 0:,,
•» • • > f c
j
' win
si ^r
• «
Figure 5.8.6-1 Location plan of Roode Elsberg Tunnel

Figure 5.8.6-2 Sediment deposition in Roode Elsberg Tunnel
Steady flow tests were carried out in 1999 (see full description in Chapter 8) and at the
dominant peak discharge of 1.5 m3/s (0.5 m/s), the calculated probable hydraulic
roughness is 93 mm (eq. 5.8.5-2). The observed hydraulic roughness is 200 mm. The
maximum probable roughness calculated is however 236 mm, at a pH of 5.5 (eq.
5.8.5-3). These equations were calibrated with a maximum roughness data set of 12
mm and the Roode Elsberg Tunnel therefore falls far outside this range. The calculated
roughness is however in the right order and certainly indicating a high roughness, as
experienced in the field.
5.8.7 Ageing calculation procedure summary
Three new equations have been derived and calibrated with which the following can be
determined:
• Rate of ageing (equation 5.7.3-6)
• Probable ultimate roughness (equation 5.8.5-2)
• Maximum probable roughness (equation 5.8.5-3). (Based on envelope line of
observed data.)
Ail three equations should be applied and ageing should continue until the ultimate
roughness is reached. Engineering judgement should be used when considering
probable or maximum probable roughness, involving a sensitivity assessment and
economic evaluation.
Table 5.8.7-1 provides ultimate ageing data which can be used for tunnel design, based
on the above equations.

Table 5.8.7-1 Predicted discharge based on probable and maximum probable

ultimate roughness
Max Max Max Max

Probable Probable Probable Probable probable probable probable probable
ageing ageing ageing ageing ageing: ageing:
Diameter a ageing: ageing:
Qfor Qfor Qfor Qfor Qfor Qfor
(m) Qfor Qfor
pH=5.5 pH=6.5 pH=7.5 pH=7.9 pH=7.5 pH=7.9
pH=5.5 pH=6.5
<m/m) (nWs) (nWs) (m 3 /s) (m3/s) (m3/s) (m3/s) (rrWs) (rrWs)
6.0 1:500 96.3 114.4 129.6 134.9 85.2 103.5 118.9 124.5
5.5 77.1 91.7 103.8 108.1 68.2 82.8 95.3 99.7
5.0 60.4 71.9 81.4 84.8 53.4 64.9 74.7 78.2
4.5 46.1 54.9 62.2 64.8 40.7 49.6 57.1 59.8
4.0 34.1 40.8 46.1 47.9 30.1 36.7 42.3 44.2
3.5 24.2 28.9 32.8 34.1 21.3 26.1 30.1 31.5
3.0 16.3 19.5 22.1 23.0 14.4 17.6 20.3 21.2
2.0 5.8 6.9 7.8 8.1 5.1 6.1 7.2 7.5
1.0 1.0 1.2 1.3 1.4 0.8 1.1 1.2 1.3
6.0 1:1000 66.4 79.2 89.9 93.6 58.6 71.5 82.4 86.3
5.5 53.1 63.4 72.0 75.0 46.8 57.2 66.0 69.1
5.0 41.6 49.7 56.5 58.8 36.7 44.8 51.7 54.2
4.5 31.8 38.0 43.1 44.9 28.0 34,2 39.5 41.4
4.0 23.5 28.1 31.9 33.2 20.7 25.3 29.3 30.6
3.5 16.7 20.0 22.7 23.6 14.7 18.0 20.8 21.8
3.0 11.2 13.5 15.3 15.9 9.9 12.1 14.0 14.7
2.0 4.0 4.8 5.4 5.6 3.5 4.3 5.0 5.2
1.0 0.7 0.8 0.9 0.9 0.6 0.7 0.8 0.9
6.0 1:2000 45.8 54.8 62.3 64.9 40.2 49.3 57.0 59.8
5.5 36.6 43.9 49.9 52.0 32.2 39.5 45.7 47.9
5.0 28.7 34.4 39.1 40.7 25.2 30.9 35.8 37.5
4.5 21.9 26.3 29.9 31.1 19.2 23.6 27.4 28.7
4.0 16.2 19.4 22.1 23.0 14.2 17.5 20.2 21.2
3.5 11.5 13.8 15.7 16.4 10.0 12.4 14.4 15.1
3.0 7.7 9.3 10.6 11.0 6.8 8.4 9.7 10.2
2.0 2.7 3.3 3.7 3.9 2.4 3.0 3.4 3.6
1.0 0.5 0.6 0.6 0.6 0.4 0.4 0.6 0.6
6.0 1:5000 27.9 33.7 38.4 40.0 24.5 30.2 35.1 36.8
5.5 22.5 26.9 30.7 32.0 19.5 24.2 28.1 29.4
5.0 17.5 21.1 24.1 25.1 15.3 18.9 22.0 23.1
4.5 13.4 16.1 18.4 19.1 11.7 14.5 16.8 17.6
4.0 9.9 11.9 13.6 14.2 8.6 10.7 12.4 13.0
3.5 7.0 8.5 9.7 10.0 6.1 7.6 8.8 9.3
3.0 4.7 5.7 6.5 6.8 4.1 5.1 6.0 6.2
2.0 1.7 2.0 2.3 2.4 1.4 1.8 2.1 2.2
1.0 0.3 0.3 0.4 0.4 0.2 0.3 0.4 0.4

6 SOFTWATER AGGRESSIVENESS INDEX

6.1 Ageing by soft water (chemical) corrosion
While the relatively high pH values and flow velocities in the LHWP tunnels indicate a
relatively slow rate of tunnel ageing, soft water corrosion (leaching) of the concrete
surface could be the dominant ageing factor to consider. The Katse water could be
potentially aggressive to concrete with Langelier index values less than zero (mean = -
0.9), and the Ryznar indices well in excess of 6.5 (which demonstrates a "neutral"
water, neither scale forming nor scale removing). The aggressiveness index formulated
for evaluating corrosion in asbestos cement pipes indicates a value of 11.24, which is
moderately aggressive (DWAF, 1996). (See Table 6.1-1).
Table 6.1-1 Aggressiveness index interpretation (DWAF, 1996)
Aggressiveness index Water property

>12 non-aggressive
10.0 to 11.9 moderately aggressive
<10 highly aggressive
Basson (1989) recommended limits for assessing aggressiveness, as indicated in

Table 6.1-2.
Table 6.1-2 Recommended limits for assessing aggressiveness

(Basson, 1989)
Degree of aggressiveness of water

Property of water
Moderate High Very high Excessive
pH 6.0 to 8.0 5.0 to 6.0 4.5 to 5.0 <4.5
pH minus CaCO3-saturated pH -0.2 to -0.3 •0.3 to -0.4 -0.4 to-0.5 <-0.5

Calcium hardness as mg CaCO3/l 200 to 300 100 to 200 50 to 100 <50
Total ammonium ion as mg NH4/I 30 to 50 50 to 80 80 to 100 >100
Magnesium ion as mg Mg/I 100 to 500 500 to 1000 1000 to 1500 >1500
Total sulphate ion as mg SO4/I 150 to 1000 1000 to 2000 2000 to 3000 >3000
Chloride ion as mg Cl/I 500 to 1000 1000 to 2500 2500 to 5000 >5000
A 4 lh corrosion index was established by Basson (1990) for the Portland Cement
Institute (PCI). Based on the latest water quality data at the Ash River outfall, the PCI
index has a value of about 1700, which indicates a highly aggressive condition (Table
6.1-3).

Table 6.1-3 Aggressiveness index interpretation (Basson, 1990)
Final index Aggressiveness

<350 non- to mildly aggressive
350 to 750 mildly to fairly aggressive
750 to 1000 highly aggressive
>1000 very highly aggressive
The above four indices indicate that the LHWP tunnels would be subject to softwater
corrosion with resultant leaching of concrete, with possible increased roughness and
friction losses in future.
Unfortunately no way of predicting what the degree of deterioration of the concrete lined
portions of the tunnels will be possible without field observations over time at the LHWP
tunnels. Muller (1977) states that the rate of corrosion is a function of the concrete
permeability. Corrosion resistence is increased against natural aggressive waters if the
concrete is well cured, sound and dense, having a relatively high cement content and a
minimum water-cement ratio.
The rate of tunnel roughening of the LHWP tunnels is however expected to be slow
considering the high quality concrete used. Knowledge of two other tunnels in South
Africa in the Western Cape: Theewaterskloof and Roode Elsberg which both convey
aggressive soft water, indicates that silt deposition and some sliming creating a slippery
surface are present, even under softwater corrosion conditions.
Aggressive ground water zones in South Africa are shown in Figure 6.1-1 and provides
an indication of where soft water in surface water can be expected. The water quality of
surface water at a specific tunnel should however be investigated to obtain site specific
data.
Basson, Visagie & Maian 61 October 2002

; A P E F R o >' i ••
Figure 6.1-1 Soft water zones in ground water in South Africa (DWAF, 1999)

7 SOFT WATER CORROSION LABORATORY TESTS

7.1 Introduction
Soft water corrosion in hydraulic structures is defined as the progressive disintegration
of the concrete by chemical reaction with the soft water (ACI 210 R-93, 1998). This
chapter is concerned with the deterioration of the exposed concrete surfaces of the
concrete linings of the Theewaterskloof Tunnel and the Lesotho Highland Water Project
(LHWP) delivery tunnels as a result of soft water attack.
The deterioration of the exposed concrete surfaces of the concrete linings of the
tunnels will influence the hydraulic roughness of the tunnels and therefore an in-depth
look into the corrosion rate and ultimate hydraulic roughness of the concrete linings is
essential.
The objective of this chapter is to give an overview of the mechanism of soft water
corrosion, a discussion on the laboratory tests done, the conclusions on the rate of
corrosion and the roughness change in the water tunnels as well as a recommendation
for a concrete mix design which can best resist soft water attack.
7.2 Background
7.2.1 Mechanism of concrete corrosion in soft water
In mountainous regions where the rock formations are igneous or siliceous or dense
lime stones into which water cannot penetrate and there is almost complete absence of
bases and soluble salts in the surface soils the waters are almost free of dissolved salts
(Ballim, 1993). The drainage waters from these regions are often acidic owing to the
presence of humic acid and also carbon dioxide, which is a product of plant decay. A
saturated solution of humic acid in water has a pH value of 3.6-4.1. Owing to its low
solubility, 0.19 g/f, the amount, which can be carried in water, is small and although it
has some action on concrete, this is much less serious than that of very pure (mineral-
free) waters or of those containing carbon dioxide (CO2). These pure waters are
aggressive to concrete primarily because of their "ion hungry " nature (Lea, 1998).
The dominant raw materials in ordinary Portland cement is: (Lea, 1998)
Notation:
C = CaO
S = SiO2
A = AI2O3
F = Fe2O3
CH = Ca(OH2)
The main compounds in Portland cement can be seen in Table 7.2.1-1

Table 7.2.1-1:The main compounds in Portland cement: (Neville, 1987)
Name of compound Oxide composition Abbreviation

Tricalcium silicate 3CaO.SiO 2 C3S
Dicalcium silicate 2CaO.SiO 2 C2S
Tricalcium aluminate 3CaO.AI 2 O 2 C3A
Tetracalcium aluminoferrite 4CaO.AI 2 O 3 .Fe 2 O3 C 4 AF
The product of hydration of C 3 S is the microcrystalline hydrate C3S2H3 with some lime
separating out as crystalline Ca(OH) 2 ; C 2 S behaves similarly but clearly contains less
lime. Nowadays, the calcium silicate hydrates are described as C-S-H - gel.
The approximate chemical reactions taking place during hydration of ordinary Portland
cement is as follows: (Addis, 1989)
2C3S + 6H —• C 3 S 2 H 3 + 3CH eq. 7.2.1-1
2C 2 S + 4H —• C 3 S 2 H 3 + CH eq. 7.2.1-2
C3A + CH + I 2 H —• C 4 AH 13 eq. 7.2.1-3
C 4 AF + 4CH + 22H — • C 4 AH 13 + C 4 FH 13 eq. 7.2.1-4
The silicates, C 3 S and C 2 S, are the most important compounds, which are responsible
for the strength of hydrated cement paste. At the age of about one year, the two
compounds, mass for mass, contribute approximately equally to the strength of the
hydrated cement. C3A and C 4 AF contribute very little to the strength of the hydrated
cement paste.
The direction of chemical reactions is always towards establishing equilibrium. In the

case of concrete wetted by distilled or very soft water the concentration of calcium
compounds in the cement paste as seen above is many orders of magnitude higher
than that of the dissolved calcium salts in the soft water which is almost zero. The
concentration gradient (the difference in concentrations of calcium compounds between
the concrete and water phases) creates a leaching of the calcium hydroxide (Ca(OH) 2 )
(Basson, 1989).
The hydrated calcium silicates (C-S-H) are stable only in highly alkaline conditions; if
calcium hydroxide Ca(OH) 2 is removed, the pH is lowered and decomposition of some
more hydrated calcium silicates (C-S-H) takes place with the liberation of more Ca(OH) 2
which in turn is removed by leaching. Under favourable conditions these reactions can
continue until most of the hydrated calcium silicates (C-S-H) are decomposed (Muller,
1977).
Any of the hydrated compounds present in the cement can be leached from the
cement, leaving a residue made up of SiO 2 xH 2 O, AI 2 O 3 yH 2 O and Fe 2 O 3 z H 2 O. This
residue performs a protective role against leaching on account of the gel-like nature of
its compounds (Lea, 1989).
The durability of cement-based materials, subject to the action of mineral-free water,

depends essentially on the initial amount of calcium hydroxide (Ca(OH) 2 ) in the paste
(Carde, 1996).

7.2.2 Factors influencing the rate of concrete erosion in mineral-free water
a) The aggressiveness of the soft water
The aggressive action of soft water is increased if it contains carbon dioxide C0 2 in a

free state. Initially carbon dioxide CO2 dissolves in water to form carbonic acid H2CO3
The carbon dioxide CO2 reacts with calcium hydroxide Ca(OH}2 to form insoluble
calcium carbonate, but on further action the much more soluble calcium hydrogen
carbonate Ca(HCO3)2 is formed. This will not dissolve calcium carbonate CaCO3but will
form more calcium carbonate by reacting with calcium hydroxide, according to the
following reactions: (Lea, 1989)
CO2 + H2O —• H2CO3 eq. 7.2.2-1
H2CO3 + Ca(OH)2 _• CaCO3 + H2O eq. 7.2.2-2
H2CO3 + CaCO3 -> Ca(HCO3)2 eq. 7.2.2-3
Ca(HCO3)2 + Ca(OH)2 — • 2CaCO3 + 2H2O eq. 7.2.2-4
It will be seen that equation 7.2.2-3 is reversible, and can proceed to the right or left
depending on conditions. The direction will be to the right for as long as the calcium
hydrogen carbonate Ca(HCO3)2 can remain in solution, and for this some free carbon
dioxide CO;, is required. If any of this is lost, the reaction will reverse to the left and
calcium carbonate CaCO3 will be precipitated until sufficient carbon dioxide CO2 has
been released to stabilize the calcium hydrogen carbonate Ca(HCO3)2 remaining in
solution (Ballim, 1993).
A certain amount of dissolved CO2 is required to stabilize the calcium hydrogen

carbonate Ca(HCO3)2 and therefore only the CO2 in excess of this amount will
contribute to the erosion of concrete (Lea, 1989).
The hardness of water, as it is applied to concrete erosion, is determined by the

temporary hardness, which is a measure of the concentration of the calcium carbonate
CaCO3. This is different from the concept of total hardness, which measures the
concentration of calcium and magnesium cat-ions {Lea, 1989).
The potential aggressiveness of natural water is difficult to assess since it is dependent

on a number of interrelated factors. The discussion above shows that in the absence of
organic and inorganic acids the aggressiveness of soft water is determined by a
combination of the temporary hardness and the concentration of dissolved CO2 as weil
as the natural pH of the water As a guide, water with a temporary hardness of not more
than 50 mg/e of CaCO3 and a pH value not lower than 6,0 is unlikely to cause damage
unless its free CO 2 exceeds 50 mg/7. On the other hand soft water, with a low dissolved
solids content and a temporary hardness of < 3 mgA of CaCO3 can have a marked
solvent action even if the free CO2 content is negligible and the pH value is 7,0 or
higher. Table 7.2.2-1 shows a classification of the aggressiveness of the soft waters
presented by Lea (Lea, 1989).

Table 7.2.2-1: Swedish classification of natural waters containing carbon

dioxide (Lea, 1989).
Class of Temporary hardness Aggressive carbon Degree of aggressive-

water CaCO 3 (mg/i) dioxide (mg//) ness to concrete
I >35 <15 Very slight
II >35 15-40 Slight
3.5-35 <15 Slight
III >35 40-90 Severe
3.5-35 15-40 Severe
<3.5 <15 Severe
IV >35 >90 Very severe
3.5-35 >40 Very severe
<3.5 >15 Very severe
There are other methods such as the Calcium carbonate precipitation/dissolution

potential method and the Langelier saturation index, which are currently used to
determine whether water is potentially aggressive or not (Ballim,1993).
b) Movement of water relative to the concrete
In the absence of any movement of the water layer in immediate contact with the
concrete surface, any erosion action will soon cease because of the depletion of
reactants and establishment of equilibrium conditions. Erosion rates proceed much
more slowly under stagnant conditions than would be the case if the water was in
motion and the interface water layer was to be constantly replenished (Basson, 1989).
The humic acid in some of the mineral-free drainage waters reacts with calcium salts to
form calcium humate, which is practically insoluble in water. These insoluble calcium
salts tend to block the pores of the concrete surface and prevent further loss of calcium
hydroxide from the cement - a protective skin is formed. Flowing aggressive solutions
are more damageing. The reaction products are carried away from the concrete
surface, thus preventing a protective skin (Lea, 1989).
If the concrete is porous and the soft water can percolate through the material the
leaching effect become very serious {Muller,1977).
c) Temperature of the water
Chemical reaction rates are temperature dependant and generally double for every 10-
degree rise in the Kelvin temperature. Warm waters will therefore have higher erosion
rates than cold water (Basson,1989)
On the other hand the aggressive action of water is increased if it contains carbon
dioxide CO2 in a free state but the solubility of CO2 in water increases with a decrease
in temperature. CO2-gasat atmospheric pressure is soluble in water with a temperature
of 18 CC, to the extent of 1.8 g//, giving a solution of 1.0577 g/' carbonic acid (Lea,
1989).

d) Cement extender content in the concrete
Replacement of cement with fly ash, blast-furnace slag and silica-fume respectively
increase the resistance of the cement-based paste to soft water attack. As mentioned
before the durability of cement - based materials, subject to the action of soft water,
depends essentially on the initial amount of calcium hydroxide (Ca(OH)2) in the cement
paste. The beneficial effect of the cement extenders is that they contain much less
calcium hydroxide (Ca(OH)2) compared to the ordinary Portland cement. In some cases
the calcium hydroxide (Ca(OH)2) is consumed during the pozzolanic reaction.
In the case of a paste sample made with an OPC cement which leads to about 20%
content of Ca(OH) 2 , the leaching of this Ca(OH)2 is the essential parameter governing
decrease in strength . The loss of strength due to the decalcification of C-S-H is only 6
% and can be neglected in relation to the loss of strength due to the leaching of
Ca(OH)2. In the case of the use of a paste sample with the admixture of silica fume to
consume all the Ca(OH)2, the decalcification of the C-S-H reduces the strength with
about 30 %. The effect of the decalcification of C-S-H is therefore not negligible (Carde,
1996)
Leaching of concretes with cement extenders occurs on the hydrated calcium silicates
C-S-H only, causing its decalcification and this is a beneficial factor because this
reaction is much slower than the Ca(OH)2 leaching (Carde,1999).
e) Permeability and Porosity of concrete
The rate of leaching of calcium hydroxide (Ca(OH)2) is a function of permeability. It

slows down when concrete is compact and strong. Leaching of Ca(OH)2 increases both
the porosity and permeability of the cement paste and this, in turn, causes a decrease
in the strength and durability of the concrete (Lea, 1989).
Leaching of massive crystals of the calcium hydroxide (Ca(OH)2) creates a macro-

porosity, which has a greater effect on the loss of the strength than on the porosity
increase. The decalcification of C-S-H creates a micro-porosity, which has less
influence on the loss of strength than on the porosity increase (Carde, 1996).
f) Other factors
The nature of the aggregate also plays also an important role, since it was found that
the depth of corrosion of a paste made with limestone was three times higher than that
made with quartz as aggregate (Lea, 1989).
It has been shown that the degree of deterioration of concrete under attack by
aggressive water depends on whether or not the water is replenished, flowing, warm or
pressurized, and is worse if the water flows from a wet surface to dry surface (Muller,
1977).
7.2.3 Conclusion
Concrete wetted by distilled or very soft water is corroded because the difference in
concentrations of calcium compounds between the concrete and water phases creates
leaching of calcium hydroxide (Ca(OH)2). Decomposition of the cement binder takes
place as the calcium hydroxide (Ca(OH)2) is removed and eventually all the hardened
cement can be decomposed.

The main factors influencing the rate of leaching of calcium hydroxide (Ca(OH)2) in
mineral - free water are:
A combination of the CaCO3 content (temporary hardness) and the concentration of

dissolved CO2 as well as the natural pH of the water which determine the
aggressiveness of soft water. The degree of aggressiveness of water with a very high
dissolved CO2 content to concrete is very severe. On the other hand soft water, with a
very low CaCO3 content (< 3 mg//) can have a marked solvent action even if the free
CO2 content is negligible and the natural pH value is 7,0 or higher.
Erosion rates proceed much more quickly if the soft water was in motion relative to the
concrete surface and the interface layer was to be constantly replenished.
Warm waters will have higher erosion rates than cold waters except in the case where
the aggressive action of the water is increased by the carbon dioxide CO2 because the
solubility of CO2 in water increases with a decrease in temperature.
Replacement of cement in the concrete mixture with fly ash, blast-furnace slag and
silica-fume respectively increases the resistance of the cement-based paste to soft
water attack. The beneficial effect of cement extenders is that they contain much less
calcium hydroxide (Ca(OH)2) compared to the ordinary Portland cement.
The rate of leaching of calcium hydroxide (Ca(OH)2) is a function of permeability of the

concrete. It slows down when concrete has a low permeability.
Limestone used as aggregates in the cement paste is more prone to corrosion than
quarts used as aggregates.
7.3 Laboratory tests
7.3.1 Aims
The aim of the laboratory tests was to investigate the rate of concrete deterioration and
ultimate hydraulic roughness in the Theewaterskloof Tunne! and the LHWP pre-cast
linings (without joint effects) of the Delivery Tunnel due to soft water attack.
Soft water attack on concrete is a very slow process and therefore a pilot study was to
be conducted firstly to determine if an accelerated attack on the concrete can be
reached with tests in the laboratory.
The literature review indicates that there are two main factors influencing the
deterioration of the concrete namely the aggressiveness of the water and the
composition of the concrete under attack.
The aim of these tests is to keep the aggressiveness of the water constant by using
very soft (de-ionised, distilled) water to determine the mechanism and rate of leaching
of the Ca-ions from the different concrete mixtures at different water operating
velocities.
With the leaching data and the concrete composition data known, theoretical rates of
concrete deterioration depths can be determined for the different concretes at different
water operating velocities. The aim with these available data is to correlate it with field
data at Theewaterskloof Tunnel and predict the deterioration of the concrete in the
future. In terms of hydraulic roughness, calibration with field data is not possible
because of sediment deposition in the field.
Originally Roode Elsberg Tunnel was also selected as case study for laboratory testing,
but information on the actual concrete mix used was difficult to obtain and the cement
used in the late 1950s to construct the tunnel was quite different from what is currently
available.
The aim with the tests on the LHWP is to predict concrete deterioration in the future and
to recommend a concrete mixture design, which can resist soft water attack to a higher
degree than the mixture at present.
7.3.2 Experimental set up
A 150 mm nominal diameter pipe system was installed at the hydraulic laboratory of the
University of Pretoria. (See Figure 7.3.2-1)
Figure 7.3.2-1: Pipe system at the hydraulic laboratory of the University of

Pretoria
It consists of a straight length of uPVC pipe of about 15 m, and a 5 m concrete test

section. Firstly a pilot concrete test section was cast and thereafter, concrete test
sections representing both the Theewaterskloof Tunnel and LHWP delivery tunnel were
cast. This pipe system has a maximum pump capacity of about 100 f/s, The test
sections were cast in the concrete laboratory of the University of Pretoria and were
transported to the hydraulic laboratory where they were installed in the pipeline.
A test section is made up of two halves: top and bottom cast around a steel pipe 150
mm nominal diameter as mould. The Department of Water Affairs and Forestry (DWAF)
constructed the mould. The two concrete halves weigh close to 0,5 ton each and they
were clamped together and made watertight, while special flanges were used to align
and connect the test section with the pump line (see Figure 7.3.2-2).

Figure 7.3.2-2: The experimental set up in the laboratory
Two submersible pumps with about 30 Us discharge capacity each were connected to
the 150 mm diameter pipeline.
About 7 M of de-ionised distilled water was obtained from Spoornet in Koedoespoort

and was transported to the laboratory. The total Ca-ion content of the water was in the
order of 4 mg/C. The water used for these experiments is much more aggressive than
the actual water flowing through the two tunnels. Soft water attack is a very slow
process and therefore de-ionised distilled water was used to accelerate the chemical
attack on the concrete. The water had to be replenished as a result of evaporation from
the sump. Special precautions had to be taken to ensure that the mineral-free water
does not corrode the pump well by painting it with epoxy paint.
A 90° V-notch was installed at the end of the pipeline to measure discharge. (See
Figure 7.3.2-3)
The head loss across the 5 m test section was measured by two electronic pressure
gauges, immediately upstream and downstream of the concrete pipe.
7.3.3 Pilot test section
During November 2000 a pilot study was carried out to determine if soft water attack
could be simulated in the laboratory. Concrete sections were cast at DWAF and
transported to the University of Pretoria.
No mixture content data were available for the concrete used to cast the 150 mm
diameter pipe and as no cubes were cast and the 28-day strength was not tested. Four
small test cubes had to be cut from the outside of the concrete pipe and put into the
water for experimental purposes.
Distilled (Ionised) water with a Ca-ion concentration of 0.42 mg/l and a pH of 7 was
used as soft water in the pipe system. Appendix A-6 shows the running time of the
pump, the velocity as well as the volume of the water. The temperature of the water

Figure 7.3.2-3: 90 ° V-notch at the end of pipe system
was also noted. The volume of water in the system decreased due to evaporation and
therefore it was necessary to replenish it with distilled water from time to time (see
Appendix A-6).
a) Experimental methods
X-Ray Fluorescence analysis
Two samples - one before leaching of Ca-ions and one after 10 days of leaching of Ca-
ions were tested with the ARL 9400XP+ Wavelength dispersive X-Ray Fluorescence
Spectrometer. No sample preparation was done, the surface of the material was
exposed to the spectrometer and analysed.
Calibration: The wide confidence limit program (QUANTAS) functions by executing

scans over the total wavelength span of the spectrometer using different
crystal/wavelength combinations. The overlap and background corrected peaks are
quantified after application of the NBSGSC program for matrix correction.
Scanner Electron Microscope
A sample was removed for analysis from the water after 15 days of exposure to soft
water and the resultant leaching of Ca-ions from the concrete. Fragments of the surface
of the sample, as well as a fragment of the inside of the sample were investigated by
using the scanner electron microscope. Sample preparation required the fragments to
be placed in a vacuum after which it was imbedded in a thin layer of gold.
Atomic absorption analysis
Water samples were taken in the mornings and in the afternoons. An atomic absorption
analysis of the Ca-ions in the water was done on selected samples.
b) Experimental results
X-Ray Fluorescence analysis
A quantitative assessment of the compounds on the surface of the samples can be

made with this method. In Table 7.3.3-1 it can be seen that approximately two thirds of
the Ca has been leached out of the surface of the sample after 10 days in the water.

Table 7.3.3-1: Leaching of Ca-ions from pilot test section
Sample before leaching of Ca-ions Sample after 10 days leaching of Ca-ions
Elements Normalised concentration Elements Normalised concentration
SiO2 66,2% SiO2 72.8%
CaO 23.7% CaO 8.84%
AI 2 O 3 4.42% AI 2 O 3 5.83%
Fe2O3 1.66% Fe 2 0 3 3.18%
SO3 1.2% so 3 0.17%
MgO 1.16% MgO 1.74%
K2O 0,67% KZO 1.08%
TiO2 0.34% TiO2 0.31%
Na2O 0.24% Na2O 2.57%
SrO 0.20% SrO 0.195%
Scanner Electron Microscope
Figure 7.3.3-1 to Figure 7.3.3-4 give visible evidence of Ca-ions loss as seen by means
of the microscope.

Figure 7.3.3-1: Surface of sample after 10 days leaching of Ca (X20)
Figure 7.3.3-2: Inside of sample after 10 days leaching of Ca (X20)

Figure 7.3.3-3: Surface of sample after 10 days leaching of Ca (X5000)
Figure 7.3.3-4: Inside of sample after 10 days leaching of Ca (X5000)
Basson, Vrsagie & Malan 74 October 2002

Figure 7.3.3-5 shows the rate of Ca-ions (g) being leached from the concrete pipe as
determined by the amount of Ca-ions found in the water. In the first 50 hours the
leaching rate was high, followed by reduced leaching rates.
0 50 100 150 200 250 300 350 400 450
Figure 7.3.3-5 Ca-ions leached from concrete (pilot test section)
From all this data it was found that it is possible to simulate soft water attack on
concrete in the laboratory.
7.3.4 Theewaterskloof Tunnel section
a) Materials used in the concrete mixtures for the 5m-test section
The original materials used to cast the Theewaterskloof Tunnel, such as the coarse and
fine aggregates have been obtained from the field by DWAF to use in the concrete for
the test section.
The cement originally used for the Theewaterskloof Tunnel was produced by De Hoek
cement factory in 1980 and would today be classified as a CEM I 32,5. In 1980 it would
have contained about 4,5% limestone. Today, the De Hoek cement factory produce
cement (not for resale), which is blended with slag for their Surebuild product. This
"UBC" as it is called contains 6% limestone (around 4,5% when blended with slag). This
UBC cement is the closest to the 1980 cement used in the tunnel. A batch of 300 kg of
this cement was obtained from the De Hoek cement factory to use in the concrete
mixture for the test section. The chemical composition of this cement is as indicated in
Table 7.3.4-1:

Table 7.3.4-1: Chemical composition of cement used for Theewaterskloof

Tunnel section
Chemical Mineralogical Composition

Percentage Percentage
according to the Bogue
composition % %
calculation
SiO 2 20,92 Tricalcium silicate (C3S) 63
AI2O3 3.53 Dicalcium silicate (C2S) 11
Fe 2 O 3 3.69 Tricalcium aluminate (C3A) 3.4
Mn2O3 0,06 Tetracalcium Aluminoferrite (C4AF) 11.4
TiO 2 0,17
CaO 63,62
MgO 1,13
S0 3 2,34
K20 0,67
Na2O 0,40
The original concrete mixture used for the Theewaterskloof Tunnel was obtained from
DWAF. The composition and properties of the concrete mixture made in the laboratory
can be seen in Table 7.3.4-2.
Table 7.3.4-2: Composition and properties of concrete mixture for

Theewaterskloof Tunnel section
Composition of mixture
Water 200,5 kg/m3

Cement 401,0 kg/m3
Fine aggregate 729,8 kg/m3
Coarse aggregate 19 mm-9,5 mm 933,4 kg/m3
Coarse aggregate 9.5 mm-4,75 mm 49,1 kg/m3
Properties of mixture
Design 28-day compressive strength 30MPa

Coefficient of oxygen permeability (k0D) 24.57 (m2*10"18)
Porosity 18,2 %
b) Experimental results
The testing on the Theewaterskloof Tunnel section started at the end of May 2001 and
ran 24 h per day until the end of August 2001. Head loss readings, water temperature
readings and water samples were taken in the mornings and afternoons. The operating
velocities were steady at about 1,2 m/s, 1,9 m/s and 2,9 m/s. The temperature of the

water varied between 24 - C and 33 e C. The natural pH - values of the water varied
between 6,7 and 8 with a mean value of 7,4. See Appendix A-1 and A-2 for the data.
c) Observed rate of leaching

The water was analysed for the amount of Ca - ions present in the water by titration
with [EDTA] Concentration of Di-sodium Ethylenediamine Tetra-acetate. See Appendix
A-2 for leaching data.
The observed rate of leaching of Ca-ions from the concrete for water operating
velocities of 1.2, 1.9 and 2.9 m/s can be seen in Figure 7.3.4-1.
120.0 -
•
E 100.0 - 0.B227X+21 596

•o i.z m/s R"= 0.9959
*
g 80.0 y= 1.3175x- 9.0079
.5! y=0.7835x+18.102
to Rz = 0-9935 R2= 0.9509
o 60.0
3 ^ / /
y=0.6421x+12.196
S 40.0 - Water
3=
R z -0.953
• •
| 20.0 -
o 1. 9 m/S 2.9 m/s
0.0 * w W
t) 10 20 30 40 50 60 70 80 90 100
Days
Figure 7.3.4-1 Cumulative leaching of Ca-ions at different operating velocities

It is clear from Figure 7.3.4-1 that during the first three days the calcium hydroxide
(Ca(OH)2) was leached at a much higher rate. It is possible that excess unhydrated
cement was present on the surface of the concrete. When the water was replenished
as indicated on the graph, the leaching rate of the Ca-ions was very high for a day and
then it stabilised at a constant rate for the different water operating velocities.
A linear trendline was added to the graphs and the equation and R-squared value are
displayed on the figure. It seems that the leaching rate of Ca-ions for a specific velocity
is constant.
The leaching rate of Ca-ions from the concrete for different water velocities can be seen
in Figure 7.3.4-2. These leaching rates are for flowing de-ionised distilled water at a
mean temperature of 27 °C and a natural pH - value of about 7. An exponential
trendline was added to the graph and the equation as well as R-squared value is
indicated on the figure. The leaching rate of Ca-ions increases as the operating water
velocity increases.

CO
/
>. 2
I
I '-5
0)
y = 0.2768e°-6093x
j
re R2 = 0.9541
° 0.5
n -0 0.5 1 1.5 2 2.5 3 3.5 '%

Velocity (m/s)
Figure 7.3.4-2 Leaching rate of Ca-ions from the concrete for different
velocities (Theewaterskloof test section)
The leaching of Ca-ions from the concrete for a total volume of water through the test
section can be seen in Figure 7.3.4-3.
A linear trendline was added to the graphs and the equation and R-squared value are
displayed on the figure. It seems that the leaching rate of Ca-ions for a specific volume
of water through the test section is constant. The water operating velocities influence
this leaching rate of Ca-ions.
The leaching rate of Ca-ions per water volume from the concrete for different water
operating velocities can be seen in Figure 7.3.4-4. It seems that the leaching rate of Ca-
ions for a constant volume of water decrease for higher operating velocities but more
research is
necessary.
= 0.2fl36x + 29.173
W = 0.9959
y=0.2701x+25,319
FF = 0.9935
= 0.3504x+12.196
F¥ = 0.953
100 150 200 250 300

Volume (rt^
Figure 7.3.4-3 Leaching rate of Ca-ions per total volume of water through
Theewaterskloof test section
0.4
Q. 0.3
Q.
y = 0.1142x2 • 0.4592X + 0.737
dy/dx = 0.2284 - 0.4592
•5 0.2
(0 minimum for x = 2.01 m/s
.2 0.1
0.5 1 1.5 2.5

Velocity (m/s)
Figure 7.3.4-4 Leaching rate of Ca-ions per water volume for different
water velocities (Theewaterskloof test section)
d) Theoretical concrete deterioration
A literature review indicates that it is not only the aggressiveness of the water that
influences the leaching rate but also the composition of the cement paste. By predicting
the calcium hydroxide (Ca(OH)2) content of the cement paste a relative chemical
vulnerability towards soft water attack can be established {Addis, 1989).
The mineralogical composition of the cement used for the concrete mixture according to
the Bogue calculation (see Table 7.3.4-1) can be used to predict the calcium hydroxide
(Ca(OH)2) content of the hydrated paste at an age of 28-days (Addis, 1989).
According to Table 7.3.4-2 the Portland cement used in the Theewaterskloof Tunnel
contains 63 % C3S, 11 % C2S, 3.4 % C3A and 11.4 % C4AF.
See Appendix A-3 for calculations
100 kg of hydrated Portland cement produces:
(0,750 x 63) + (0,994 x 11) = 58,18 kg C3S2H3
(0,487 x 63) + (0,215x11)- (0,274 x 3,4) - (0,609 x 11,4) = 25,17 kg Ca(OH)2
A maximum theoretical depth of deterioration of the concrete can be determined taking

into account the following assumptions:
e) Assumptions:
The calcium hydroxide (Ca(OH)2) content of the hydrated paste at an age of 28-days is
25,17 % (see above) and is very high, therefore according to a literature search
(Carde,1999) the maximum theoretical depth of deterioration of the concrete is
calculated for Ca(OH)2 leaching only.
The Ca(0H)2 is distributed evenly through the concrete mixture.
The permeability is also a factor influencing the depth of deterioration, but is not taken
into account in this calculation.

The maximum theoretical depth of deterioration of the concrete is for de-ionised distilled
water with a mean temperature of 27 °C and a natural pH - value of about 7. This water
is much more aggressive than the soft water flowing through the tunnel in the field,
therefore the maximum theoretical depth of deterioration of the concrete is for an
accelerated soft water attack.
Operating water velocity of 1,2 m/s
The Ca-ion leaching rate from Figure 7.3.4-4 is 0,64 g / k'
The atomic mass of Ca(OH)2 = 40+16+16+1 +1 = 74
The atomic mass of Ca-ion = 40
74 v
Therefore: — = Ca(OH)2/k< water
40 0,64
x = 1,18 g Ca(OH)2 / kf water is leached per day
The total volume of water is 7 kt
Therefore: The total Ca(0H)2 leached per day is (1,18*7) = 8,29 g
Concrete:
25,17 % of the hydrated cement is Ca(0H)2(see above)

401 kg / m3 of the concrete mixture is cement (Table 7.4)
Therefore: (0,2517 * 401) = 100,25 kg / m3 is Ca(OH)2
The volume of the concrete mixture with 8,29 g of Ca(OH)2
100250K _ 8,29.1?
3
lm v
y = 0,00008269 m3
The area of concrete attacked per day is the surface of the inside of the test section:
0,15 m * IT * 5 m
The total volume attacked per day is therefore:
0,00008269 m3 = 0,15 m * TT * 5 m * dmax
where: d max = maximum theoretical depth of deterioration of the concrete per day
dmax = 35,11 Mm / day
A minimum theoretical depth of deterioration of the concrete can be determined taking

into account the following assumptions:
Assumptions:
The minimum theoretical depth of deterioration of the concrete is calculated by

assuming that the excess calcium hydroxide (Ca(OH)2) in a certain depth of concrete is
leached first and then total decalcification of the C-S-H gel occurs.

The atomic mass of Ca(OH)2 = 40+16+16+1+1 = 74
Therefore: — = 54% Ca-ions in Ca(OH)2
The atomic mass of C3S2H3 is 342
3*40
Therefore: = 35% Ca-ions in C3S2H3
342
For 100 kg Cement:
25,17 kg of the cement is Ca(OH)2
and 58,18 kg of the cement is C3S2H3 (see above)
Therefore the total amount of Ca-ions in 100 kg of cement is:
(0,54*25,17kg) + (0,35*58,18) = 33,956 kg
Concrete:
But 401 kg / m3 of the concrete mixture is cement (Table 7.3.4-2)
Therefore: (0,33956*401) = 136,16 kg / m3 is Ca-ions
Water:
The Ca-ion leaching rate from Figure 7.3.4-4 is 0,64 g / ki
The total volume of water is 7 k(

Therefore: The total mass of Ca-ions leached per day is (0,64 * 7) = 4,48 g
The volume of the concrete mixture producing 4,48 g of Ca-ions is:
Lm3
y = 0,00003290m3
The area of concrete attacked per day is the surface of the inside of the test section:
0,15 m *TT * 5 m
The total volume attacked per day is therefore:
0,00003290 m3 = 0,15 m * TT * 5 m * dmin
where: dmin = minimum theoretical depth of deterioration of the concrete per day
dmin = 13,97 urn / day

Table 7.3.4-3 Theoretical concrete deterioration depths (Theewaterskloof

Tunnel section)
Operating water Maximum theoretical depth Minimum theoretical depth

velocity (m/s) (urn) of deterioration of the (um) of deterioration of the
concrete per day (dmax) concrete per day (dmin)
1,2 35,11 13,97
1,9 40,00 16,07
2,9 71,60 28,48
The actual graph indicating the theoretical depth of deterioration of the concrete per day
lies between the two graphs on figure 7.3.4-5. The factors influencing the depth are the
permeability and porosity of the concrete. The permeability and porosity of the
Theewaterskloof Tunnel concrete are very high (see Table 7.3.4-2), therefore it is
possible that the actual graph will be closer to the dmai(-graph than the dmin-graph.
Leaching of Ca(OH)2 (dmax)
Leaching of Ca(OH)2
and decaicification of C-S-H-gel (dmin)
0.5 1,5 2 2.5 3 3.5 4.5

Operating water velocities (m/s)
Figure 7.3.4-5 Theoretical deterioration depths of concrete for different

water operating velocities (Theewaterskloof test section)
The concrete of the test section has to be tested to determine the actual depth of
deterioration (amount of Ca-ions present) in order to calibrate this model. More
research is also necessary to determine the specific influence of the permeability,
porosity and aggressiveness of the water on the deterioration rate of the concrete.
f) Comparison with field data
A core, 400 mm in diameter and 700 mm in length, was drilled from the concrete of the
Theewaterskloof Tunnel 21 km from the inlet of the tunnel. In the laboratory a 100 mm
diameter core was taken from the original core. The 100 mm diameter core was cut into
+/- 3mm thin slices with a diamond saw. Every sample was crushed into a fine powder.
The powder was tested for the amount of CaO present by using a titration with [EDTA].
The data can be seen in Appendix A-7.
In the first 3mm (on the surface) of the 100 mm diameter core the CaO content was 6,9
%. At a depth of 7mm - 17mm the CaO content was 9,5 % and at a depth of 210 mm -
213 mm the CaO content was about 8 %.

According to the composition of the cement and the concrete (see Table 7.3.4-1 and
7.3.4-2) the total amount of CaO in the concrete mixture has to be 11 %, therefore it is
possible that the concrete had been affected deeper than 213 mm. More research is
necessary to evaluate the depths to which deterioration took place.
7.3.5 LHWP delivery tunnel pre-cast concrete lining section
a) Materials used in the concrete mixture for the 5m-test section

The original materials used to cast the LHWP delivery tunnel concrete linings such as
the coarse and fine aggregates have been obtained from the field by DWAF to use in
the concrete for the test section.
The cementious materials originally used for the LHWP delivery tunnel concrete linings
are cement CEM I 42.5 from Anglo Alpha's UIco plant in the Northern Cape and fly-ash
from Ash Resources' Lethabo plant. The chemical composition of the cement and fly-
ash is listed in Table 7.3.5-1 and Table 7.3.5-2 respectively.
Table 7.3.5-1 Chemical composition of cement used for LHWP tunnel section
Chemical Mineralogical Composition according to

composition Percentage % Percentage %
the Bogue calculation
SiO2 20,94 Tricalcium silicate (C3S) 68,7

AI2O3 3,99 Dicalcium silicate (C2S) 8,6
Fe2O3 2,59 Tricalcium alummate (C3A) 6,2
Mn2O3 1,11 Tetracalcium Aluminoferrite (C4AF) 7,9
TiO 2 0,23
CaO 65,03
MqO 2,41
SO3 2,22
K2O 0,59
Na 2 O 0.08
Table 7.3.5-2 Chemical composition of Lethabo fly-ash
Lethabo fly-ash Chemical composition %
SiO 2 53,8
AI 2 O 3 34,3
Fe 2 O 3 3,6
Mn 2 O 3 0,1
TiO z 1,6
CaO 4,4
MgO 1.1
SO3 0,1
K2O 0,5
Na 2 O 0,4
P2OS 0,3
LOi 0,8

The concrete mixture used in the LHWP test section is as indicated in Table 7.3.5-3:
Table 7.3.5-3 Concrete mixture for pre-cast linings of the LHWP delivery
tunnels from the 1994 records as obtained by DWAF
Materials (Kg/m3)
Cement OPC, Ulco 360

Cement Extender (PFA) Lethabo 60
Coarse Aggregate-Dolerite @ 19mm 1050
Coarse Aggregate- Dolerite @ 9.5 mm 405
Fine aggregate rivers sand - Caledon river 190
Fine aggregate Crusher dust - Dolerite 385
Admixture - air entrainment (conplast 316) 0.3
Admixture - Superplasticiser (conplast 337) 4
Water 138
Properties of mixture
28-day compressive strength 103 MPa

Coefficient of oxygen permeability (k0D) 6.28(m 2 *10' 1B )
Porosity 13,65%
The test on the LHWP Delivery Tunnel pre-cast concrete lining section started at the
middle of September 2001 and ran 24 h per day until the middle of November 2001.
Head loss readings, water temperature readings and water samples were taken in the
mornings and afternoons. The operating velocities was steady at about 1,2 m/s, 2,3
m/s and 2,73 m/s. The temperature of the water varied between 19 s C and 29 e C. The
natural pH - values of the water varied between 6,9 and 8,4 with a mean of 7,8. See
Appendix A-4 and A-5 for the data. (The mean pH in the field at the tunnel outlet is 7.9).
b) Observed rate of leaching
The water was analysed for the amount of Ca - ions present in the water by using a
titration with [EDTA] Concentration of Di-sodium Ethylenediamine Tetra-acetate. See
Appendix A-5 for leaching data.
The observed rate of leaching of Ca-ions from the concrete for water operating
velocities of 1.9, 2.3 and 2,7 m/s can be seen in Figure 7.3.5-1.
It is clear from Figure 7.5.3-1 that in the first two days the calcium hydroxide (Ca(OH)2)
is leached at a much higher rate. The same happened at the Theewaterskloof test
section therefore it is possible that excess unhydrated cement is present on the surface
of the concrete. The water was replenished every time the operating velocity was
changed. Linear trendlines were added to the graphs and the equation and R-squared
values are displayed on the figure.

70
60
1,9 m/s
:y = 0.6784x +34.164
R2 = 0.9269
50
y = 1.8194x +8.2777
R2 = 0.9562
40 -U
7 = 0.6587* + 19-329
o
A R2 = 0.9682
O 30
a
y = 3.6581 x + 0.3745
I
o
20
10 4 y= 10.222X+ 9.4999
R2 = 0.9891
2,3 m/s
2,7 m/s
2
R -1
10 15 20 25 30 35
Days
Figure 7.3.5-1 Cumulative leaching of Ca-ions per day (LHWP test section).
Two constant leaching rates for a water operating velocity can be observed from Figure
7.5.3-1. From the literature review it is possible that the lower leaching rate is the rate of
decalcification of the C-S-H gel and the higher leaching rate is the rate of Ca(OH)2
leaching. The decalcification rate is similar for both the operating velocities, but the rate
of Ca(0H)2 leaching for the two velocities differs.
The duration of the test run at an operating water velocity of 2,7 m/s was not enough to
determine the leaching rate. More research is therefore necessary to evaluate the
leaching rate of higher operating water velocities.
c) Theoretical concrete deterioration
The literature, which has been reviewed indicates that replacement of cement in the
concrete mixture with fly ash increases the resistance of the cement-based paste to soft
water attack. (Basson,1989) For LHWP 14% of the cement-based paste in the concrete
mixture (see Table 7.5.3-3) consists of fly-ash, which contains much less calcium
hydroxide (Ca(OH)2) compared to the ordinary Portland cement. The theoretical
calcium hydroxide (Ca(OH)2) content of the hydrated paste at an age of 28-days can be
determined by using the mineralogical composition (see Table 7.3.5-1 & 7.3.5-2) of the
cement and the fly-ash used in this concrete mixture.
According to Table 7.3.5-1 the Portland cement used in the LHWP delivery tunnel
contains 68,7 % C3S, 8,6 % C2S, 6,2 % C3A and 7,9 % C4AF.
See Appendix A-3 for calculations:
100 kg of Ulco Portland cement produces:
(0,750 x 68,7) + (0,994 x 8,6) = 60,07 kg C3S2H3

(0,487 x 68,7) + (0,215 X 8,6) - (0,274 x 6,2) - (0,609 x 7,9) = 28,80 kg Ca(OH)2
Potentially: 100 kg of fly-ash reacts with (185 x 0,538) = 99,53 kg Ca(OH)^
to produce (285 x 0,583) = 166,16 kg C3S2H3

1 m3 of the concrete mixture consists of (Table 7.5.3-3):
360 kg Ulco Portland cement, which produces (3,6 x 60,07) = 216,25 kg C3S2H3 and
(3,6 x 28,79) = 103,99 kg Ca(OH)2
The 60 kg fly-ash in the mixture reacts with (0,6 x 99,53) = 59,72 kg Ca(OH)2
to produce (0,6 x 166,16) = 99,69 kg C3S2H3
Therefore the total amount is:
(216,25 + 99,69) = 315,85 kg/m3 C3S2H3 and
(103,99-59,72) = 44,28 kg/m3 Ca(OH)2
Assumptions:
The theoretical depth of deterioration of the concrete is calculated by assuming that the
calcium hydroxide (Ca(0H)2) in a certain depth of concrete is leached at a rate as
determined with the leaching data and then total decalcification of the C-S-H gel in this
volume of concrete occurs at a different rate (see figure 7.3.4-4).
The Ca(OH)2 is distributed evenly through the concrete mixture.
The permeability is also a factor influencing the depth of deterioration but is not taken
into account during this calculation.
The theoretical depth of deterioration of the concrete is for de-ionised distilled water
with a mean temperature of 27 °C and a natural pH - value of about 7.
The atomic mass of Ca(OH)2 = 40+16+16+1 +1 = 74
Therefore: — = 54% Ca-ions in Ca(OH)2
The atomic mass of C3S2H3 is 342
3*40
Therefore: = 35% Ca-ions in C3S2H3
342
Concrete:
But 420 kg / m3 (360 kg / m3 OPC + 60 kg / m3) of the concrete mixture consists of

cement based binder (Table 7.3.5-2)
Therefore: (0,54 * 44,28) = 23,91 kg / m3 Ca-ions in the form of Ca(0H)2 + (0,35

* 315,85) = 110,548 kg / m3 Ca-ions in the form of C-S-H gel
Operating water velocity of 1,9 m/s:
Water:
The Ca-ion leaching rate for decalcification from Figure 7.3.4-4 is 0,66 g / k/
And the Ca-ion leaching rate for Ca(OH)2 is 3,66 g / k'

The total volume of water is 7 k(:
Therefore: The total Ca-ions leached as a result of decalcification is (0,66 * 7) =

4,62 g per day or 0,19 g / hour
And the total Ca-ions leached as Ca(OH)2 is (3,66 * 7) = 25,62 g per day or 1,07g / hour
Concrete:
If a depth of 10 um of the concrete deteriorates, the volume of concrete affected is 0,15

m * TT * 5 m * 0,000010 m = 0,00002356 m3
In 0,00002356 m3 concrete there is:

(0,00002356 m3 "23,911 kg / m3) = 0,563 g Ca-ions in the form of Ca(OH)2 and
(0,00002356 m3 * 110,54 kg / m3) = 2,605 g Ca-ions in the form of C-S-H gel
Time for leaching:

(0,563 g /1,07 g /hour) = 0,60 hour
plus (2,605 g/0,19 g/hour) = 13,71 hour
Total time for 10 um of concrete to deteriorate = 14.31 hours
I Oum x
14.31/; 24/i
x = 16,77
The theoretical depth of deterioration of the concrete with a water operating velocity of
1,9 m/s = 16,77 |jm / day
The total Ca-ions leached as a result of decalcification is (0,68 * 7) = 4,76 g per day or
0,2 g /hour
And the total Ca-ions leached as Ca(OH)2 is (1,82 * 7) = 12,74 g per day or 0,531 g /
hour
Concrete
If a depth of 10 um of the concrete is deteriorated the volume of concrete affected is

0,15 m * TT * 5 m * 0,000010 m - 0,00002356 m3
In 0,00002356 m3 concrete there is:
(0,00002356 m3 "23,91 kg / m3) = 0,563 g Ca-ions in the form of Ca(OH)2 and

(0,00002356 m3 * 110,54 kg / m3) = 2,605 g Ca-ions in the form of C-S-H gel
Time for leaching:

(0,563 g / 0,531g /hour) = 1,06 hour
plus (2,605 g / 0,2 g / hour) = 13,03 hour
Total time for 10 um of concrete to deteriorate = 14,09 hours
WRC Projeci: Dealing with Tunnel Ageing
1 Oum x
14.09/; 24/i
x = 17,03
The theoretical depth of deterioration of the concrete with a water operating velocity of
2,3 m/s = 17,03 Mm/day
There is not enough data available at this stage but according to Table 7.3.5-3 it seems
that the concrete deterioration rate increase with an increase of water operating
velocity. It is clear that the theoretical rate of deterioration depth per day of the LHWP
tunnel with the fly-ash as cement extender is much lower than that of the
Theewaterskloof tunnel section with no cement extender.
Table 7.3.5-4: Theoretical depth of deterioration of the concrete for LHWP

tunnel section
Operating water velocity Theoretical depth of deterioration of the concrete
1,9 m/s 16,77 um/day

2,3 m/s 17,03 |jm/day
7.3.6 Hydraulic roughness and soft water corrosion
a) Test setup and procedure
The hydraulic roughness based on the Colebrook-White equation was determined for
the three concrete test sections. Data on the first test pipe were obtained by running the
test at a steady flow velocity of about 1.2 m/s. At the end of the tests at this flow, the
flow velocity was increased to 3 m/s for one day at a time, and after each high flow the
flow was reduced to test the roughness at 1.2 m/s again. The aim was to test what
happened during steady low flows and whether equilibrium had been reached.
An OPC cement was used and the concrete mix was a general low strength mix. The
original purpose of this test was to finalize the test procedure for the LHWP tunnel and
Theewaterskloof Tunnel sections, but very useful data were obtained. This led to
several changes such as the use of pressure gauges instead of a manometer,
construction of a permanent roof over the pumps, construction of a test section at
University of Pretoria instead of at DWAF Materials Laboratory due to transport
problems with the test section weighing more than a ton.
Concrete for the second test section was based on the Theewaterskloof Tunnel design,
without slagment, with aggregate obtained from Western Cape (Berg River) by DWAF
and transported to Pretoria where the test section was cast at the University of Pretoria.
The tests were carried out for three steady flow periods until hydraulic roughness
equilibrium was more or less reached.
The third and last test section was based on the LHWP Delivery Tunnel segmentally
lined concrete. Aggregate for this test section was obtained from site by TCTA who also
arranged transport to Pretoria. Three steady flows were tested, increasing with time.
The test section was 5 m in length, cast in a top and bottom half around a steel pipe as
mould to get a smooth finish. The test pipe had an inside diameter of 0.14 m.

b) Hydraulic roughness results
The results of the tests carried out on the pilot test pipe are shown in Figures 7.3.6-1
and 7.3.6-2., while the roughness time series of the Theewaterskloof and LHWP DTN
pipe section laboratory tests are shown in Figures 7.3.6-3 and 7.3.6-4. The following is
concluded from the test results:
Pilot test (Figure 7.3.6-1):
• There was a dramatic increase in roughness over the first 5 test days, which is in
agreement with rapid leaching that occurred over the same period (see
Figure 7.3.3-3)
• Near the end of the low flow test period there was again a slight increase in Ca-ions
leaching that corresponds with a slight increase in roughness
• The low flow tests at 1,2 m/s indicated an initial increase in roughness from 1 mm to
about 3 mm, followed by a general scatter of between 1.7 to 3.1 mm. This latter
range of values is due to measurement inaccuracy due to the manometer water
levels varying. Each point however represents the mean value of at least 20
readings taken at the upstream and downstream gauges.
Pilot test (Figure 7.3.6-2):
• The high flow testing at > 3 m/s increased the roughness and doubled it after 2
days. After repairs were carried out to the pump system and the pipe was empty for
several months, high flow testing continued and again after a day the roughness
tested higher at 6 mm. No chemical leaching tests were carried out during these
tests. One last high flow test lasting a day was carried out and while it was expected
that the roughness would stabilise at about 6 mm, this did not happen and instead a
dramatic increase occurred to reach 9 mm. The tests were stopped at that stage
due to leakage, loss of water and time constraints. It is not clear whether the
roughness would have increased with longer duration high flow testing.
The rapid increase in roughness following high flows could not be simulated with
higher strength tunnel concrete such as being used in the other two test sections.
When the pilot test section was opened up after the test, it was found that the seal
between the upper and bottom halves had moved into the flow zone, and this must
have happened prior to the start of the tests. This led to relatively high energy
losses and a secondary loss as function of the velocity head was incorporated in the
analysis to determine ks. In further tests of the tunnel sections no secondary loss
coefficient was used to determine the hydraulic roughness.
The seal material inside the test pipe would create convergence and divergence
losses, but would also be oscillating at high flows, changing the velocity profile,
resulting in excessive erosion of the concrete. Inspection of the inside of the pipe
after tests showed a relatively coarse surface and none of the original smooth finish
area was present. The absolute roughness values obtained from the pilot test
should not, however, be used as absolute values due to the many assumptions that
had to be made and because this was a low strength concrete not typical of tunnel
concrete.

4.50
4.00
Main saltwater cmroson
occurred
3.50
3.00
f 2.50
JS 2.00
1.50
1.00
0.50
0.00
1-OC1-2000 6-Oct-2000 lt-Oci-2000 16-Oc1-2000 21-Oct-2000 26-OC1-2000 31-Oct-2000 5-Nov-2000

v = 1.2 m/s: Pilot test section
10.00
9.00 After high tow (lushing for

day at 3 m/s; following 4
months with no testing
8.00
7.00 \
_ 6.00 \
£ 5.00
After high flow Hushing for
day at > 3 m/s
4.00
3.00
2.00
1.00
0.00
11-Sep- l-Oct-2000 21-Ocl- 10-Nov- 30-Nov- 20-Dec- 9-Jan- 29-Jan- 18-fieb- 10-Mar- 3D-Mar-
2000 2000 2000 2000 2000 2001 2001 2001 2001 2001

v = 1.2 m/s and following 3 m/s flushing: Pilot test section

4.00
3.50
3.00
2 50
E 200
1 50
0 50
O.QP.; ~z
29-May-0i 8-Jun-01 1B-Jun-O1 28-Jun-01 8-Jul-01 18-Jul-01 2B-JUI-01 7-Aug-OI 17-Aufl-Oi 27-Aug-OI
Dale
• 1.2 m/s • 1.94 nVs - • - 2 9 2 nVs

Theewaterskloof Tunnel test section
090
0B0
0 70
030
020
D10
000
27-Aug-01 6-Sep-01 16-Sep-Ol 26-Sep-01 6-Oci-01 lB-Oci-CJl 26-Oci-OI 5-Nov-Ol 15Nov-0! 25-Nnv-OI
Date
-1 3 rtVs -••- 2 3 m/s - • - 2 8 nVs

LHWP DTN test section
Theewaterskloof test results (Figure 7.3.6-3):
• During the first day of testing there was a dramatic increase in roughness, from 1 to
3 mm, which agrees with the Ca-ions leaching rate, and then the roughness
stabilised between 2 to 3 mm. This pattern is similar to what was experienced
during the pilot tests.

• At 1.94 m/s the roughness experienced is much lower at 0.5 mm than at 1.2 m/s.
There was again a small increase in initial roughness as the test started. The rest of
the test at 2.3 m/s showed steady roughness, in agreement with the Ca-ions
leaching rate.
• At 2.9 m/s there was an initial roughness decrease, stabilizing at between 0.1 to 0.2
mm. No deterioration of the pipe leading to high roughness, as experienced during
the pilot test, was experienced, probably due to the higher strength concrete.
LHWP DTN test results (Figure 7.3.6-4):
• Again there is an initial increase in roughness in agreement with a high Ca-ions

leaching rate, but the increase in roughness was not as high as for the
Theewaterskloof test.
• The range of roughness for 1.9 m/s is more or less similar to that of the
Theewaterskloof test, about 0.4 to 0.7 mm. There was however a more definite
decrease in roughness with time at the LHWP test, stabilising at the end.
• At 2.3 m/s an initial rise in ks was observed, but not picked up in the Ca-ions
leaching rate. With time the roughness decreased from about 0.5 mm to reach
roughness equilibrium at 0.33 mm. The Ca-ions leaching however continues after
equilibrium roughness has been reached.
• At the highest flow the roughness decrease rapidly to about 0.11 mm and remained
steady. The Ca-ions leaching rate became very low at the same time. The final
roughness achieved agreed with that at the same velocity of the Theewaterskloof
tests. The bed shear stress at 2.8 m/s in the pipe was 38 Pa, which is generally
higher than that for field conditions.
• An important conclusion from the laboratory tests is that although Ca-ions leaching
occurs and the surface of the concrete softens so that it can easily be damaged by
a hard object, high velocity flow conditions did not increase the hydraulic roughness
when concrete of high quality and strength is used.
7.3.7 Proposed concrete design
According to a paper by Castro & Mclntosh (1994) an optimum concrete mixture was
designed for the pre-cast concrete linings of the LHWP tunnels (see Table 7.3.5-1). A
concrete mixture having a total cementitious content of 360 kg/m3 and a fly-ash content
of 40 % (cement 216 kg/m3 and fly-ash 144 kg/m3) was proposed to ensure a resistance
to soft water attack.
The actual concrete mixture Neumann &True (1994) used in the linings has a fly-ash
content of only 17 % and a total cementitious content of 420 kg/m3 (see Table 7.3.5-2).
The optimum concrete mixture as design by Castro & Mclntosh (1994) will be a mixture
with a higher resistance to soft water attack than the mixture used in the linings,
because the Ca(OH)2 content is much lower.
Supervision at the construction stage of concrete structures is of the utmost importance

because correct placing, compaction and curing will ensure low permeability and low
porosity. These two factors have an influence on the resistance of the concrete mixture
to soft water attack.
Research on the use of silica fume in these mixtures is also necessary, because it will
decrease the permeability of the concrete and also the Ca(OH)2 content.

Table 7.3.7-1: Mix proportion for LHWP tunnel linings as proposed by Castro &
Mclntosh(1994)
Materials Mix (kg/m3)
Cement 216
Cement Extender 144
Coarse Aggregate - 25 mm 820
Coarse Aggregate - 12 mm 385
Fine aggregate rivers sand 370
Fine aggregate Crusher dust 370
Admixture - water reducer 1.8
Admixture - air entrapment 0.7
Admixture - Superplasticiser 3.6
water 180
7.4 Conclusions on chemical aspects
Literature, which has been reviewed, indicates that there are two main factors
influencing the deterioration of the concrete due to soft water attack namely the
aggressiveness of the water and the composition of the concrete under attack.
For the laboratory tests the aggressiveness of the water was kept constant by using de-
ionised, distilled water at a mean temperature of 27 s C and a natural pH value of about
7. The aggressiveness of the water is severe to ensure accelerated soft water attack
on the concrete.
No cement extenders were used in the concrete of the Theewaterskloof Tunnel and it
was found that the leaching rate of Ca-ions increase exponentially with an increase in
the water operating velocity in the pipe system. The main chemical process taking
place in the concrete during soft water attack in the Theewaterskloof Tunnel is the
leaching of Ca(OH)2. A maximum and minimum theoretical concrete deterioration depth
rate was determined for the concrete. These rates also increase exponentially with
increasing water operating velocity in the pipe system. The permeability of this concrete
is very high and therefore the leaching rates are also high.
The concrete mixture of the LHWP linings of the delivery tunnels contains fly-ash as a
cement extender. Two different Ca-ion leaching rates for a specific water operating
velocity were found for the LHWP concrete. This indicates that as a result of the fly-ash
content in the mixture decalcification of the C-S-H gel takes place at a low rate and
Ca(OH)2 leaching at a higher rate. The theoretical concrete deterioration depth rates for
the LHWP concrete are much lower than the rates for the Theewaterskloof Tunnel.
There are not enough data available at this stage but it seems that the concrete
deterioration rate increases with increasing water operating velocity.
Although the soft water attack cannot be stopped with a specific concrete mix design it
is possible to decrease it significantly with an optimum design. The optimum concrete
mixture as designed by Castro & Mclntosh (1994) for the LHWP tunnels will still be the
best mixture for resistance to soft water attack because the Ca(OH)2 content is very low
in this design mix.

7.5 Recommendations
Attention to the following aspects is necessary:
• More laboratory tests are necessary on the LHWP test section at higher water
operating velocities to determine the relationship between the Ca-ions leaching
rates and water operating velocities.
• Tests on the microstructure of the concrete of the test sections are necessary to
calibrate the rate of the theoretical concrete deterioration depths and to determine
the exact influence of the permeability and porosity on soft water attack.
• Tests on the Theewaterskloof Tunnel core have to be completed to calibrate
laboratory tests.
determined. Laboratory tests with the water from the field will be necessary to
confirm the calibration of the accelerated rate of deterioration in the laboratory with
the actual field behaviour.
Further tests on concrete mixtures with silica-fume as cement extender will be valuable
to determine a concrete mixture with a higher resistance to soft water attack.

8 REMEDIAL MEASURES
The following remedial measures have been investigated in this report:
• Hydraulic flushing (field and laboratory tests)
• Mechanical cleaning (field tests)
• Chlorination
• Tunnel lining
• Doubling or new tunnels
• Minimization of secondary losses
8.1 Hydraulic flushing
8.1.1 Introduction
When tunnels are operated at high flow velocities, sediment deposits can be re-
entrained and flushed out of the tunnel, thereby increasing the discharge capacity of a
tunnel. In this chapter hydraulic flushing in field and laboratory conditions was
investigated, in hardwater and softwater conditions.
8.1.2 Orange-Fish Tunnel experience
a) Tunnel description
The tunnel consists of about 81 km of 5.33 m diameter in situ concrete lined tunnel,
constructed during the 1970's and is the longest irrigation tunnel in the world. The
tunnel transfers water mainly for irrigation to the Eastern Cape from Gariep Reservoir.
A longitudinal profile of the tunnel is shown in Figure 8.1.2-1. The tunnel flow is
controlled downstream by 6 large valves (Figure 8.12-2), and the tunnel flow is
measured at a large Parshall flume at the outlet, as well as at pumps and a small flume
at a canal diversion at the outlet at Theebus (Figures 8.1.2-3 and 8.1.2-4).

,—ISHAFTSI — | SHAFT 7
r
R.L. 1 2 S 8 . H INTAKE SHAFT
DETAIL 'B 1
CHANNEL •Q1 • l O m V i MAX.
.TUNNEL
/ WEIR "20ft" PARSHALL FLUME
5,33 Qi
TUNNEL EXIT
GATES PEPPER POT

VALVES PUMP at io.» - i,
" 8 f t " PARSHALL FLUME

DETAIL Q] • O.ImVi
SHAFT 7 DETAIL 'A' FLOW MEASUREMENT
SCHEMATIC LAYOUT OF UNDERGROUND WORKS DETAILS
Figure 8.1.2-1 Longitudinal profile of Orange-Fish Tunnel

Figure 8.1.2-2 Orange-Fish Tunnel valve
Figure 8.1.2-3 Orange-Fish Tunnel outlet
Basson, Visagie & MaSan 97 October 2002

Figure 8.1.2-4 Orange Fish Tunnel flow measurement gauge
b) Historical tests
Commissioning and other subsequent hydraulic tests were carried out during the 1970s
and 1980s. Rapid ageing was observed due to the first 10 years of operation at
relatively low flow conditions. This resulted in sediment deposition in the tunnel,
consisting of clay fractions with a brown colour. The observed maximum annual flows
are shown in Figure 8.1.2-5.
Annual Maximum flows

E C
OD
50
45
40
I 35
o 30
25
20
1R
IO
77 79 8: 83 85 87 89 91 93 95 97 99
Time (year)
Figure 8.1.2-5 Observed maximum annual Orange-Fish Tunnel flows

WRC Project: Dealing with Tunnei Ageing
c) Tunnel inspection 1999
The tunnel was inspected by driving through it in a day. Almost no sediment was
visible. In many places the concrete had the original smooth finish created by the
shuttering. The concrete is hard and the water is not aggressive to concrete (Figures
8.1.2-6 and 8.1.2-7).
Figure 8.1.2-6 Localized clay deposition in Orange-Fish Tunnel
Figure 8.1.2-7 Typical hard smooth concrete surface of Orange-Fish Tunnel

d) Tunnel test 1998
This test involved periods of steady flow, increasing to maximum and then decreasing.
Shaft water levels were gauged by borehole type depth gauges. Static water levels
were also determined. Figures 8.1.2-8 and 8.1.2-9 show a depth gauge used during the
tests. Ott water level recorders were however also installed for continuous monitoring
(Figure 8.1.2-10). These recorders worked at most shafts but difficulties were
experienced at the deep shafts (400 m) and during discharge adjustments when the
surge pulled the float into the tunnel. Figure 8.1.2-11 shows the test results together
with other historical data.
Figure 8.1.2-8 Depth gauge at tunnel shaft operated by DWAF personel

- ••
Figure 8.1.2-9 Depth recording at Orange-Fish Tunnel shaft.
, m
Figure 8.1.2-10 Ott water level reader and Thalimedes data logger

Orange-Fish Tunnel observed ageing

1.2
0.8
>
?
£0.6
J2
0.4
0.2 * • m
10 20 30 40 SO 60
Discharge (cuinecs)
1998 Rising 1988 1975
1998 Falling 1984 1990
Figure 8.1.5-11 Historically observed hydraulic roughness of Orange-Fish

Tunnel
In 1975 the new tunnel roughness was about 0.13 mm for all flows tested up to the
maximum discharge of 57 m3/s. By 1984 the roughness had increased to 0.6 mm, and
during 1988 the roughness varied between 1.2 mm and 0.8 mm at higher flows. This
roughness was confirmed in 1990 tests. During 1998 another comprehensive hydraulic
test was carried out, but this time in discharge increments going up right to the
maximum capacity. The tests started at the same roughness as for the 1990 test, but
as the discharge increased the roughness decreased with ks = 0.5 mm at 53 m3/s. The
flushing effect at high flow however became apparent when evaluating the downward
steps in flows: at 29 m3/s ks dropped from 0.94 mm to 0.6 mm, and at 20 m3/s it reduced
from 0.9 mm to 0.3 mm.
The flushing changed the long-term ageing rate as indicated in Figure 8.1.2-12.

Orange-Fish Tunnel long-term capacity
Figure 8.1.2-12 Orange-Fish discharge capacity change over time
e) Tunnel test 2000
HDPE pipes were installed down shaft 7a (near outlet), ending in the tunnel upstream
of the shaft at 10 m, 160 m, and 310 m distances. The 150 m closest to the shaft was
cleaned by high pressure rotating head water jets by DWAF as part of this study to
investigate the effect of mechanical cleaning on roughness. The cleaned section was
found rougher than the undisturbed tunnel.
f) Tunnel test 2001
During February 2001 a last flow test was carried out to assess what had happened to
the cleaned sections roughness over time, and to flush the tunnel for a longer duration
at a maximum flow of about 48 m3/s. The results are shown in Figures 8.1.2-13 and
8.1.2-14.
For the upstream part of the tunnel, there appears to be a definite decrease over time in
roughness during the maximum flow testing. For the downstream part of the tunnel
downstream of shaft 6, the roughness at high flow is very low.

ks vs Time (Cheiy) - 0,6
i 200
£ l OOO
0.800
0 400
0.200
0000
02-22-01 02-22-01 02-23-01 02-23-01
Time
Figure 8.1.2-13 Orange-Fish Tunnel shaft 0 to 6 roughness (2001)
ks vs Time (Chezy) - 6,7a
3500 60 00
WOO
50 00
2 500
40 00
30 00
1 500
20 00
1 ooo
10 00
'«* 0.00
0222-01 02-22-01 02-22-01 02-23-01 02-23-01 O2-23-O1 0223-01 02-23-01
Time
p * - k s -•-Discharge |
Figure 8.1.2-14 Orange-Fish roughness shaft 6 to 7a (2001)
The sediment concentrations flushed from the tunnel are shown in Figure 8.1.2-15.
Initially some of the values were up to 140 mg/l, but at the end of the tests they
averaged at about 105 mg/l.
The cleaned tunnel section's roughness was again tested during 2001, with results
shown in Figure 8.1.2-16. The 150-10 m section data represent the cleaned tunnel and

they are consistently higher than for the rest of the tunnel. The very low roughness
values of the 300-150 m section also agrees with the roughness from shaft 6 to 7a.
C vs Time
160 CO
140 00
<>
•
*
120 00
• *•
*
• • • • • •
• • •
100 00 * * * •
• * *
* •
* •
*
Si
E 60 00
60 00
0 00
02-22-01 ffi-22-01 02-22-01 02-23-01 02-23-01 02-23-01
Time
Figure 8.1.2-15 Orange-Fish Tunnel sediment transport 2001
k vs time (Chezy)
3 500
3 000
E • • 300-150(01)
E 2 000 • 150-10(011
1 500
• • •
•
* •
1 000
• • • •
*•
• • •
0500 • • • •, 1 *
• *
* • •
0 000 ••"••I ****** *•—•—
2001-02-22 2001-02-22 2001-02-22 2001-02-23 2001-02-23 200102-23 2001-02-23 2001-02-23
Time
Figure 8.1.2-16 Orange-Fish Tunnel cleaned section roughness 2001

WRC Projec!: Dealing with Tunnel Ageing
8.1.3 Theewaterskioof Tunnel experience
a) Tunnel system description
The Theewaterskioof Tunnel as referred to in this report, was completed in 1980. It

consists of an intake at Theewaterskioof Reservoir near Viiiiersdorp, a 4.23 m diameter
tunnel of about 12 km in length to the Berg River, a steel pipe section underneath the
Berg River, and about 12 km tunnel from the Berg River crossing to the Jonkershoek
shaft. This shaft controls the flow through 3 automatic 1.2 m needle valves that are
regulated by water levels in Kleinplaas Dam, which is about 300 m from the
Jonkershoek shaft. Kleinplaas Dam acts as balancing storage from where water is
transferred underneath Stellenbosch Mountain through a 4 km tunnel which is
connected to a pipeline that conveys the water to Cape Town water treatment plants.
The tunnel system is a gravity system and is quite unique in that it transfers water in
both directions: In winter the Banghoek and Woiwekioof shaft intakes along the tunnel,
transfer Berg River catchment water to Theewaterskioof Reservoir, while in summer
when the Berg irrigation and Cape Town water demands are high the water is
transferred from Theewaterskioof Dam.
A layout of the tunnel is shown in Figure 8.1.3-1 and figure 8.1.3-2 shows a long
section.
Figure 8.1.3-1 Theewaterskioof Tunnel layout

310
305
300 Theewoters kloof

Dam inlake
295
£.290
•
2 8 5
|
I 280
UJ
KJeinplaas Dani Berg River
275
270
265 i
260
5000 10000 15000 20000 25000 30000
Chainage (m)
Figure 8.1.3-2 Longitudinal profile of the Theewaterskloof to Kleinplaas Dam

tunnel
Between Theewaterskloof Dam and the Berg River East portal, the Charmaine pump
station (used for dewatering) and the Charmaine air vent are located, on the Southern
side of the Franschhoek mountain. The Berg River releases are made at the Berg
River western portal. Between the Berg River and Jonkershoek shaft, we find the
Wolwekloof vehicle entrance, the Dasbos tunnel junction, air chamber, Wolwekloof
shaft and Banghoek shaft.
b) Tunnel inspection (1999)
During the winter of 1999 the tunnel was dewatered for inspection. The 28 km tunnel
was inspected in two days on foot and by boat, with DWAF. An inflatable boat was
lowered (Figure 8.1.3-3) at the intake shaft and pulled along the tunnel for 4 km to get
past the deep section of the tunnel with standing water.
Basson, Visagie & Maian •07 October 2002

1
*
Figure 8.1.3-3 Lowering of the boat at the Theewaterskloof Dam intake shaft
Variable ageing characteristics were found along the tunnel:
• Between Theewaterskloof Dam and the Berg River where the tunnel has its
largest diameter, the first part contains a slimy bacterial growth (figure 8.1.3-4)
like a mass of worms covering the concrete about 10 mm thick. There are also
many patches of lower strength concrete surface where severe erosion has
occurred, in some places leaving long etch marks. Some erosion holes are quite
deep (1.0 m) (Figures 8.1.3-5 and 8.1.3-6). These patches of poor quality
concrete were caused by ground water intrusion problems experienced during
construction.

Figure 8.1.3-4 Bacteriological growth between the intake and Berg River,
Figure 8.1.3-5 Deep scour hole in soft water corroded concrete, intake to Berg
River,Theewaterskloof Tunnel

Figure 8.1.3-6 Deep scour in soft water corroded poor quality concrete, intake
to Berg River, Theewaterskioof Tunnel
Between Berg River and Banghoek, the sediment deposits are about 7 mm
thick, consisting of fine sediment, with a cohesive nature and black colour.
During tunnel emptying the sediment remained intact, similar to manganese
deposits. In one part where a sediment strip fell from the wall, it removed the
upper 3 mm of concrete with it, exposing coarse aggregate (Figure 8.1.3-7).
Figure 8.1.3-7 Exposed coarse aggregate after sediment removal due to

emptying, Banghoek to Jonkershoek, Theewaterskioof Tunnel

Sand deposits up to 1 m deep were found on the tunnel floor, especially at the air
chamber, originating from the Berg catchment intake shafts (Figure 8.1.3-8).
Figure 8.1.3-8 Sand deposition , Wolwekloof to Banghoek, Theewaterskloof

Tunnel
• The upper layer of the concrete right through the tunnel was soft due to soft
water corrosion and could easily be damaged (Figure 8.1.3-9).
Figure 8.1.3-9 Typical soft water corrosion underneath sediment deposition,


• There are two contraction sections in the tunnel where the roof of the tunnel has
been lowered in the transition, without providing air vents. Patterns against the
tunnel top clearly show that air has been trapped.
c) Flow test of 1999
During May 1999, the hydraulic roughness of the tunnel was determined. Tests were
carried out at steady flows, increasing in steps to the maximum flow, and then
decreasing again. No tests were carried out at commissioning to make ageing
comparisons possible.
The test duration was limited due to water restrictions in the Western Cape. Discharge
had to be calculated by reservoir routing of Kleinplaas Reservoir, taking into account its
infiow, river outflow, Cape Town usage and storage change with time. Flow meters
originally installed at the three needle valves at Jonkershoek did not work. About 30
staff members of DWAF were involved in the field work which was coordinated by the
regional office.
The tunnel flows as calculated from the Kleinplaas reservoir balance are shown in
Figure 8.1.3-10. Figure 8.1.3-10 also indicates sediment concentrations flushed out at
Jonkershoek.
Basson, Visagie & Malan 112 Oclober 2002

Calculated tunnel flow: Jonkershoek

25 0.05
Spillway
20 0.04
o
v
115 0.03
o
10 — 0.02
CO
0.01
08:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 00:00
Tunnel outflow - Parshall Outflow sediment Cone
weighted 5pt weighted 5pt
Figure 8.1.3-10 Tunnels flows and sediment concentrations during 1999 tests

The results of the hydraulic tests indicated that the Berg River to Jonkershoek tunnel
sections had relatively low roughnesses: 3 mm, 0.9 mm and 0.8 mm for the Berg to
Wolwekloof, Wolwekloof to Banghoek, and Banghoek to Jonkershoek Tunnels
respectively. The tunnel diameter is a minimum at Jonkershoek.
In the Franschhoek Tunnel, the roughnesses were 20 mm, 10 mm and 40 mm, for the
Theewaterskloof intake to Charmaine pump station shaft, to Charmaine air vent, and to
Berg River East portal respectively.
d) Flow test of 2001
During 2001 another steady flow test was carried out, this time with acoustic-doppler
flow meters mounted to each of the steel pipes at Jonkershoek to determine an
accurate discharge. The test was carried out over four days, with the first and last days
at about 67 % capacity, and the other two days at maximum flow {at the given
Theewaterskloof Dam water level) (Figure 8.1.3-11). The flushing efficiency in terms of
sediment being flushed out and possible reduction over time in roughness were
investigated.
The tunnel roughnesses determined from the flow tests are shown in Figures 8.1.3-12
to 8.1.3-15. The Banghoek to Jonkershoek section has a roughness in the order of 1
mm, with most values less than 1.5 mm. The third day's roughness is slightly higher
than that for day two, which is difficult to explain. The last day's roughness was slightly
less than for day one, indicating possible cleaning by flushing. The flushing velocity was
1.4 to 2.0 m/s over the four days.
In the Wolwekloof to Banghoek Tunnel, the day one to day four decrease in roughness
was from 1.7 mm to about 0.8 mm.
The Berg River to Wolwekloof readings vary too much to be reliable. The manometer
used at the West portal could be the problem with air having been trapped in the pipe.
The general roughness is less than 20 mm, which is possible due to the sand
deposition, but seems too high compared with Wolwekloof to Banghoek.
From Theewaterskloof to East Portal at Berg River, the roughness varies between 20
and 30 mm, which was expected due to the concrete erosion and slime growth.
The sediment concentrations measured at the three pipes at the Jonkershoek shaft are
shown in Figure 8.1.3-16. (OP in the legend indicates observed sediment concentration
at Eastern Portal, Berg River.) The central pipe's concentrations are in line with those
of the tunnel flows and were the highest. On the first day of tests, 81 tons of sediment
were flushed from the 3.5 m diameter tunnel (from Berg River to Jonkershoek). On the
next days the sediments flushed were 120 ton, 11 ton and 24 ton respectively. If the
sediment had been removed evenly from the 12 km long tunnel, this would be equal to
a layer of 2 mm average thickness. The sediment being flushed out was however
mostly sand from the deposits at the tunnel invert.

Qtoial vs Time
2500 -,
20 00
1500
ooo
03-26-01 03-26-01 03-27-01 03-27-01 03-28-01 03-28-01 03-29-01 03-29-01 03-30-01 03-30-01 03-31-01
Time
Figure 8.1.3-11 Test flows used
ks vs Time (Colebrook-White)
6
£ I S00
1 000
0 000
03-27 01 03-27-01 03-2B-01 0328-0! 03-29-01 03-29-01 03-30-01 03-30-01 03-31-01
Tims
Figure 8.1.3-12 Banghoek to Jonkershoek roughness 2001

k vs Time (Colebrook- White)
3000 i
3 500
2000 L
-•-27
f • 28
S 1 500 29
30
1 000
0 500
0000
03-27-01 03-27.01 03-28-01 03-28-01 03-29-01 03-29-01 03-30-01 03-30-01 03-31-01
Tlmo
Figure 8.1.3-13 Wolwekloof to Banghoek roughness 2001
k vsTime(CW)
40 000
30 000
~ 26 000
E
15 000
5 000
03-27-01 03-28-01 03-28-01 03-29-01 03-29-01 03-30-01 03-30-01 03-31-01

Time
Figure 8.1.3-14 Berg River west to Wolwekloof roughness 2001

ks vs Time (Colebrook-While)
• • •
• 28
I 25
29
30
03-27-01 03-27-01 03-26-01 03-28-01 03-29-01 03-29-01 03-30-01 03-30-01 03-31-01

Time
Figure 8.1.3-15 Theewaterskloof Dam to Berg East portal roughness 2001
C vs Time
1D000
• •
1000
•
• •
• Lett
• Middle
I 100
O *• *n •
A Right
• - T • OP
i ••
•-••
*•
* <
*
*
oooo i2oo oo oo is oo oooo 12 00 0000 12:00 OOOO 12:00 00:00

Time
Figure 8.1.3-16 Sediment concentrations flushed out at Jonkershoek
In general the roughness values of the 1999 and 2001 tunnel tests are in agreement.

8.1.4 Roode Elsberg Tunnel experience
This tunnel links Roode Elsberg Dam with the Hex River valley. It is 5.2 km in length
and 1.98 m in diameter, and is insitu concrete lined. The diameter is much smaller than
typical tunnel diameters of today of the major water transfer schemes, but its capacity is
much larger than the maximum water requirement. This tunnel has been in operation
since the 1960s. Figure 8.1.4-1 shows Roode Elsberg Dam where the tunnel starts at
the left bank, while the tunnel outfall at the Hex River Valley is shown in Figure 8.1.4-2.
The tunnel was inspected during 1999 by members of the project team and DWAF
(Figure 8.1.4-3). The tunnel is relatively small, especially at the intake section (Figure
8.1.4-4). Prior to shutdown of the tunnel fow for inspection, the emergency gate had to
be lowered which required special equipment (Figure 8.1.4-5).
Inspection during 1999 showed that due to relatively low operating velocities, a slimy
soft sediment deposit had developed, about 10 mm thick. The surface of the sediment
has a waviness which could be due to bedforms (Figure 8.1.4-6). Unfortunately, within
the inner 3 km of the tunnel a lot of the construction equipment such as pipes, cables
and railway tracks, had been left behind which would lead to high effective roughness
(Figure 8.1.4-7).
JW
Figure 8.1.4-1 Roode Elsberg Dam

Figure 8.1.4-2 Roode Elsberg Tunnel outfall
Figure 8.1.4-3 Roode Elsberg Tunnel inspection team

Figure 8.1.4-4 Roode Elsberg Tunnel at intake
•••• • 'hd- i '• / y
Figure 8.1.4-5
i\ is
Lowering of the emergency gate at Roode Elsberg Tunnel

Figure 8.1.4-6 Sediment deposits in Roode Elsberg Tunnel (1999)
Figure 8.1.4-7 Construction equipment left in Roode Elsberg Tunnel
Steady flow tests were carried out on 20 September 1999 to determine the hydraulic
roughness of the tunnel. The tunnel had been operated at relatively low flow velocities
in the past at about 0.5 m/s maximum.
An HDPE pipeline was installed at the downstream end of the tunnel, connected to a
tap at the tee of the bypass pipeline. The static water level was recorded and three
steady discharges were tested: 1.0, 1.47 and 1.77 m3/s, with flows measured at the
three electro-magnetic flow meters. A fourth discharge of about 2.4 m3/s was also
tested by releasing water through the bypass at the outlet (Figure 8.1.4-8). The highest
flow velocity tested was quite small at 0.76 m3/s. The tunnel is however linked directly
to the irrigation distribution system and it is therefore not possible to test higher flows.
Spillage through the bypass is also a loss from the system and the test could therefore
only be carried out when Roode Elsberg Dam was spilling and for a short duration.

' -
gg?. . V
Figure 8.1.4-8 Bypass pipe at Roode Elsberg Tunnel
The head loss in the tunnel could be measured when the bypass pipeline was not in
operation and the observed data are indicated in Table 8.1.4-1.
Table 8.1.4-1 Roode Elsberg Tunnel field test data
Discharge Velocity Total head loss Hydraulic roughness ks

3
(m /s) (m/s) (m) (mm)
1.0 0.32 0.29 1.4
1.47 0.48 3.15 200
1.77 0.57 6.85 390
While the Reynolds number of all the above tests were high and in the turbulent zone,
the first steady flow at 1.0 m3/s was in the transitional zone and laminar boundary
effects could have masked the boundary roughness effects. The low observed
roughness could perhaps also be explained by the bedforms that are in equilibrium at
this low typical discharge, minimizing the stream power. At the higher discharges the
flow is fully rough turbulent and the hydraulic roughness dominates, giving values of
200 to 390 mm which is considerably higher than found at any of the other tunnels
found in South Africa or internationally. Secondary losses at the intake and outlet of the
tunnel, as well as 0.5x the kinetic energy head for construction debris in the tunnel,
were taken into account in the determination of the friction head loss.
At higher discharges than the ones tested, it is expected that the hydraulic roughness
will decrease as the sediment is scoured. The flushing test did scour sediment as
indicated by the observed sediment concentrations, but at the discharge of 1.77 rrvVs,
the sediment availability of the cohesive sediment became limited due to the high shear
stress required to re-entrain the consolidated sediment (Figure 8.1.4-9). At 2.4 m3/s the
shear stress at the wall of the tunnel was about 11.8 Pa. This value agrees with a

critical shear stress for re-entrainment of 12.2 Pa found in rivers with colloidal alluvial
silt (Nalluri and Featherstone, 2001).
During the flow test of 4 h duration, about 5 ton sediment was flushed through the
tunnel. The test duration was relatively too short to identify with reliability changes in
hydraulic roughness associated with the flushing event, but the data seem to indicate
that at 1.77 m3/s, the hydraulic roughness decreased from about 400 mm to 375 mm
over a steady flow period of 45 minutes.
qnfi
f250 2.5
.2 200 2 «
Sediment <;oncentra
co
1 8
o
o
Q
en
0.5
o
n
U
09:36 10:48 12:00 13:12 14:24
Time
Concentration Discharge
Figure 8.1.4-9 Sediment transport through Roode Elsberg Tunnel (1999)
8.1.5 Dasbos pipe laboratory test
a) Background
Flushing tests to try and remove sediment deposits in a laboratory are much easier to
control and monitor than in the field. It is however not possible to rapidly age a pipe
under laboratory conditions by sediment deposition when water quality, sediment
characteristics and possible bacterial growth play a role. In the laboratory higher flow
velocities and longer duration tests can be carried out than in the field, without the risk
of damage to the prototype tunnel.
An aged pipeline connected to the Theewaterskioof Tunnel system was selected for
flushing tests in the Hydraulic Laboratory of the University of Stellenbosch. This pipe is
a 100 mm diameter AC pipe which has been in operation for 20 years since
commissioning of the tunnel. The pipe was connected to the Dasbos Tunnel portal near
Franschhoek, and supplied water for irrigation to local farmers.
Four 4 m lengths of pipe were carefully removed from the field, with the pipe ends
sealed to maintain the moisture content inside, and transported by truck by DWAF to

Stellenbosch during 2001. Assembly of the pipe in the laboratory was carried out on the
same day of delivery and flow tests started the next day.
The laboratory setup consisted of the 4 pipes placed horizontally on the floor, linked
upstream to the laboratory clear water system by a bend, valve and vertical steel pipe.
After slow filling of the pipeline, flow control was by means of a valve at the downstream
end of the pipe, where the water discharges into a large container with a V-notch weir
for flow gauging. The head loss was measured by means of a manometer. The
upstream gauge point was located 5 m downstream of the pipe bend to ensure uniform
flow conditions, with the second one 12 m downstream.
The test programme consisted of a series of steady flows, starting at low flow velocities
and increasing to the maximum velocities that could be generated with the available
12 m laboratory head. After the maximum flow test, the same steps were repeated in
reverse order. Each test was run until equilibrium hydraulic roughness was obtained.
Following these tests some more high flow tests were carried out at longer durations.
b) Characteristics of pipe ageing prior to testing
The pipe had a uniform layer of black deposit, about 3 mm thick, with small bedform
riffles closely spaced. This material had a sticky oily feeling and character, and it was
difficult to damage its surface by hand. When water was applied it however became
easier to remove the sediment layer.
Figure 8.1.5-1 Dasbos pipeline before tests started
The nature of the sediment is similar to that found in the 5.5 m diameter Apalachia
Tunnel, UK (Colebrook, 1958). "...became coated with a 5/16-in. thick layer of black
mucilaginous material in a period of 10 years. This coating was uniform in depth and
surface roughness from end to end of the tunnel. An analysis of the material showed

that it is primarily manganese and is considered that the deposition was probably due to
the absorbtion of the manganese by alga polysaccharides."
A small amount of vegetable binding material was also found in the pipe sediment.
Manganese deposits are common in Western Cape pipes. Manganese bacterial slimes
have also been observed in many Tasmanian hydroelectric conduits (Brett, 1980).
The Dasbos tunnel normally has no flow, apart from the small irrigation release through
the pipeline. Coarse sediment and even silt can therefore not be transported through
the tunnel, and it is probably only organic and colloidal sediments that reached the test
pipe. Bacterial action caused the manganese deposits, mixed with fine sediment. In the
Berg to Jonkershoek Tunnel, similar black deposits have been observed, but with a
more spongy softer character probably due to more fine sediment in the deposit, and it
was not as sticky and difficult to damage as in the pipe. Field flow tests at 2 m/s on the
main Berg-Jonkershoek Tunnel could not remove the cohesive deposited tunnel wall
sediment, but the non-cohesive sand was flushed out.
c) Test results
The observed hydraulic roughness changes with time are shown in Figure 8.1.5-2. The
key finding was that it was not possible to decrease the hydraulic roughness by high
flow flushing, and in fact it increased slightly. At 0.9 m/s flow velocity at the start of the
tests, ks = 1.6 mm, while later after a maximum velocity of 3.2 m/s, the roughness ks at
0.9 m/s was 1.8 mm. At 2.1 m/s, ks = 1.75 mm and 2.1 mm before and after hydraulic
flushing.
During the rising velocity phase of the tests at steady flows of 2.7 m/s and then 3.0 m/s,
the roughness varied considerably, and this can possibly be ascribed to roughness
adjustment of the sediment, or air in the manometer pipes.
The long duration test at 2.7 m/s indicated no further change in roughness from about
2.1 mm. Lower flow tests at 0.6, 0.9 and 1.2 m/s also indicated no change.
A chlorination test was carried out next, after testing it first on a small sediment sample
from the pipe which seemed to indicate that the sediment would fluidise with some
mechanical disturbance. The pipe was first filled with the HTH mixture and left standing
overnight, before the test commenced. A high flow at 3.6 m/s for a duration of 3.5 h,
however, did not change the roughness. The same procedure was also repeated with
Jayes fluid, running it at 3.4 m/s for 4 h, and then at 4.3 m/s for 4 h. The Jayes fluid
definitely decreased the roughness from about 2 mm to 1.8 mm. The decrease was
however small and the visible effect on the sediment was negligible. The final
roughness achieved was the same as at the start of the tests during the rising steady
flow tests, at a velocity of 2.1 m/s.
After several months the sediment inside the pipe dried out and fell from the wall of the
pipe on its own, as a powdery deposit.
The tests indicate that under certain conditions, ageing by sediment deposition where
the cohesive sediment is well consolidated, consisting of manganese deposits, with
bacterial involvement, cannot be restored by hydraulic flushing. One should therefore
not operate the tunnel at first below its design capacity for long durations, since it would
lead to a higher ageing rate and ultimate roughness, and if the sediment consists of
manganese deposits and especially if bacterial growth is involved, high flow flushing or
higher operating velocities later in the life of the tunnel might not be able to decrease
the roughness. From the field inspections bacterial growth and manganese like
deposits were observed in the Theewaterskloof Tunnel. More research is required to
link the biological character of the deposited sediment to the water quality.

5000 600
4 500
400
3 50 * Increase
—»— Decrease
* Steady
3 00
Check 1
a Check2
2.50 • Chack3
CheckSlcIl
200
Checli7
VBlociiy
00
0 500 050
0000 OOO
1000 2000 3000 4000 5000 6000 7000
T (mln)
Figure 8.1.5-2 Dasbos pipe flushing hydraulic roughness test results
Finally, a 0.3 m section of pipe was cut in half for inspection after testing and to clean
one half mechanically by hand using a brush, as shown in Figure 8.1.5-3. The cleaned
surface (pipe on the left hand side in figure) was found to be relatively rough and did
not resemble the original smooth finish of the pipe. Even if hydraulic flushing is able to
re-entrain the sediment, it is doubtful whether a final roughness of below 0.6 mm can be
achieved.
Figure 8.1.5-3 Dasbos pipe after testing and cleaning
Basson, Visagie & Malan 126 Ociober 2002

8.2 Mechanical cleaning
8.2.1 USA experience
The Metropolitan Water District of Southern California (MWD), USA, operates the
400 km long Colorado River Aqueduct. Construction on the concrete lined aqueduct
was completed in 1941. The tunnels have the shape of an inverted horseshoe, 4.9 m
high, and are designed for free surface flow conditions. The water is not aggressive to
concrete.
According to Kelly (1998), MWD periodically uses a tunnel cleaning machine to remove
calcium build-up on the tunnel walls. The tunnel cleaner is an old front loader from
which the bucket was removed and on which a framework and brushes were installed.
The bristles of the brushes are spring steel and were found quite effective in removing
the calcium buildup. No recent specific hydraulic measurements have been carried out
to verify the cleaning efficiency, but a visual observation was that the before and after
conditions were similar to the difference between 40 and 150 grit sandpaper. This
corresponds to a water level drop of 0.25 m in the tunnel after cleaning.
Horowitz and Lee (1971) published an article on their findings of tunnel cleaning
efficiency based on the MWD experience. Manning n-values were found to vary
between 0.0127 to 0.013 before cleaning, while after three passes of tunnel cleaning,
the hydraulic roughness measured as Manning n improved to 0.0113 to 0.0119. This
relates to an average discharge capacity increase of 11 % (5 m3/s) from 46 m3/s to
51 m3/s for the Colorado tunnels.
Without cleaning of the MWD tunnels, hydraulic roughness measured as Manning n

values quickly increased to 0.015. Photographs of the tunnel cleaning machine are
shown in Figures 8.2.1-1 to 8.2.1-4.
Figure 8.2.1-1 Tunnel cleaning machine before lowered down shaft into tunnel

Figure 8.2.1-2 Rear view of tunnel cleaner
Figure 8.2.1-3 Side view of cleaner with steel brushes

Figure 8.2.1-4 Tunnel cleaning machine inside Colorado MWD tunnel
8.2.2 Reidol Tunnel, Wales
At commissioning the Manning n value of the concrete tunnel was assumed to be

0.0125. Twelve years later, after tunnel cleaning, the n value was measured as 0.0134.
Eighteen months later it was measured at 0.0141, indicating the effects of renewed
deposition.
8.2.3 Tarraleah siphon, Tasmania
Brett (1979) reported on the cleaning of two of the 1.93 m siphons after 5 years of
operation and associated change in roughness. The pipe consists of steel and mostly
woodstave. The roughness dropped from 0.46 mm before cleaning, to 0.11 mm after
cleaning in 1964. Within 6 months, however, the roughness increase linearly to
0.33 mm, and over the next 6 months at a slower rate during winter, to reach a
roughness of 0.46 mm at the end of 1965 and the ageing probably continued after that
to reach the pre-cleaning roughness within two years after cleaning.
8.2.4 Tarraleah No. 1 canal valley crossing, Tasmania
The valley is crossed by twin steel pipes 2.26 m in diameter and each 364 m in length.
They were originally coated with horizontal retort tar in 1938. Some cleaning and partial
reconditioning was done in 1952 and 1953. Late in 1966 the first measurements
showed No.1 pipe to have a roughness ks = 1.88 mm, while No. 2 pipe had a
roughness of 1.08 mm. No. 2 pipe was then closed for cleaning and painting with a
coal-tar epoxy. No. 1 pipe was not cleaned or painted until 1974. Head loss
measurements taken during since 1966 have yielded the results shown in Figure 8.2.4-
1. High and low ks values indicated in the figure are the highest and lowest readings
during each year and the fluctuations are due to seasonal growth variation.There is no
explanation why the loss in No. 1 pipe is higher than in No. 2 pipe (Brett, 1979).
Where canal sections of the Tarraleah transfer system were cleaned, deterioration of
the concrete surface was found with loss of cement and fines leaving the dolerite
aggregate proud after the growth is cleaned off. Brett (1979) also states: "It has been

found economic to manually scrape the surface of the canal to remove growth on
occasions to restore capacity, but this has been only temporarily effective because of
the rapid regrowth".
After No 2 pipe
3.50
Before cleaning and reconditioned
painting No 2 pipe
3.00
No 1 pipe cleaned
and painted 1974
2.50
Both pipes cleaned w rth
c 2.00
bristle brush
o>
o
1.50
o
1.00
CQ
0.50
x
0.00
1965 1967 1969 1971 1973 1975 1977
Year
• N o . 1 p i p e k s h i g h ••••-•• N o . 1 p i p e k s l o w
• N o . 2 p i p e k s h i g h •••*•- N o . 2 p i p e k s l o w
Figure 8.2.4-1 Tarraleah pipes ageing after cleaning
8.2.5 Orange-Fish Tunnel
During 1999 a 150 m section of the tunnel was cleaned by using pressurized water jets
with rotating heads. This tunnel section was located 10 m upstream of shaft 7a (surge
shaft at downstream end of tunnel). Although there was no visible sedimentation in the
tunnel, the test was carried out to find out whether this technique is suitable for hard
water conditions and whether the tunnel concrete will not be damaged. The nozzles
were held about 1 m from the concrete which gave a spray diameter of about 0.5 m on
the concrete surface (Figure 8.2.5-1). The cleaning was completed in about one week.
Due to the large diameter of the tunnel, a truck was used as platform to reach the roof
of the tunnel (Figure 8.2.5-2). A control tunnel section of 150 m length was used to
record and compare head loss over time in the cleaned and not cleaned tunnel
sections. The data indicate that the cleaned tunnel is rougher and damaged, and did
not improve with time due to possible sediment deposition. Figure 8.2.5-3 shows the
test pipes at shaft 7a and field measurement during 2001.

Figure 8.2.5-1 Water jet cleaning of Orange-Fish Tunnel (1999)
Figure 8.2.5-2 Cleaning team on truck in Orange-Fish Tunnel

Figure 8.2.5-3 Field measurement at shaft 7a during 2001
8.2.6 Theewaterskloof Tunnel
This soft water corroded tunnel was cleaned by using brooms, wetted with the water at
the tunnel invert, to remove the sediment deposits over a 150 m section upstream of
the Wolwekloof vehicle entrance (Figure 8.2.6-1). This operation was carried out by
DWAF, and HDPE pipes were installed upstream and downstream of the cleaned and a
control section, and taken out horizontally about 300 m and then up the mountain to an
elevation above the Theewaterskloof Reservoir water level. After installation the static
water level was recorded and then steady flows were tested to determine the hydraulic
roughness of the tunnel sections. The cleaned section showed consistently higher
roughness than the control section. It therefore seems that no matter how careful you
are when cleaning a tunnel exposed to soft water conditions, damage to the concrete
surface is highly likely to occur. Figure 8.2.6-2 shows a cleaned section (left hand
side), next to the sediment deposition. Figure 8.2.6-3 shows the tunnel after cleaning
with coarse agggregate on the surface of the concrete.
Basson, Visagie & Malan 132 Oclober 2002

Figure 8.2.6-1 Theewaterskloof Tunnel cleaning during 1999
A ..•-.• . ,' .,
^ •• * ' .
Figure 8.2.6-2 Theewaterskloof Tunnel with locally cleaned section next to

sediment deposits

Figure 8.2.6-3 Theewaterskloof Tunnel after cleaning
8.2.7 Roode Elsberg Tunnel
A tunnel section close to the intake was cleaned by the Hex River Irrigation Board. As
in the case of the Theewaterskioof Tunnel, brooms were used wetted with the invert
water. The cleaning operation is not an easy task in the wet, dark and cold conditions
(Figure 8.2.7-1). HDPE pipes were installed and taken up the shaft, but tests on the
cleaned section could not be performed due to relatively dry winters with little spillage
and excess water available for high enough flow in the tunnel and because the HDPE
pipe connection had to be broken when the emergency sluice gate was raised. Divers
would have to carry out the reconnection by swimming 30 m into the tunnel from the
intake in the reservoir. The water depth in the reservoir was however too deep to use
standard diving equipment and the exercise was abandoned.

Figure 8.2.7-1 Tunnel cleaning at Roode Elsberg Tunnel
During the cleaning operation, however, it was quite clear that the concrete was
damaged by the cleaning operation. Aggregate located on the concrete surface with 20
to 30 mm diameter fell from the tunnel wall, leaving holes.
8.3 Chlorination
8.3.1 USA experience
At the MWD tunnels chlorination is carried out on an annual basis, and seems to be
effective if implemented with mechanical cleaning. The system is however closed. More
details are provided in Chapter 9.5.
8.3.2 Tasmanian tunnels
Flow tests carried out during 1964 and 1965 in siphons of the Tarraleah No. 2 Canal,
Tasmania, revealed some very interesting information with regards to the hydraulic
roughness changes. The hydraulic roughness data are indicated in Figure 8.3.2-1
(Brett, 1979). The project was completed in 1959. The No. 1 siphon is 1.93 m in
diameter with 66 m of steel pipe and 745 m of woodstave pipe. No. 3 Creek siphon has
the same diameter, with 158 m of steel pipe and 594 m of woodstave pipe. The steel
pipe was coated with horizontal retort tar. In one of these conduits experimental
injections of chlorine have been used to prevent slime growth.

The 1964 injections of chlorine did not seem to be as effective in reducing the friction in
a slimed conduit as did the 1965 injections, which prevented slime regowth after
cleaning and kept Manning's n down to 0.0104 (ks = 0.11 mm) in No. 3 Creek siphon,
whereas in No. 1 Creek siphon Manning's n grew from 0.010 (ks = 0.07 mm) to 0.012
(ks = 0.46 mm). Chlorination seemed to have been effective only after cleaning.
In Tasmania, chlorination of tunnels has not been adopted because of possible adverse
effects on the environment (Brett, 1979).
! (REEK SIPHON
1964 !9&S
0-0/5 •
0014
RAJE-QOWd/SMTHS.-
0 013
1 0-012-
0011-
>
& 0
1.1 o
0-0)0-
0-009
3 CREEK SIPHON
0015 -I
0-014 •
U013- • : •
0 012- 11
0011
,. U m ,
=^
0-010-
d1
nninifnHnninnnfiuii
§•009- g ^ INJECVONS
1965
Figure 8.3.2-1 Hydraulic roughness change with chlorination at Tarraleah

siphons {Brett, 1980)
8.4 Concrete design
The first and foremost line of defence against aggressive waters is to use a sound,
dense and impervious concrete, made from the appropriate materials, and properly
compacted and cured (Basson, 1989).
The gradual erosion of the leached mortar can be minimized by use of special cements,
addition of pozzolan to mixes, or use of a variety of protective coatings and sealants
applied to the concrete surface (Graham, 1998).

No portland cement concrete, regardless of its other ingredients, will withstand attack
from water of high acid concentrations. Where strong acid corrosion is indicated, other
construction materials or an appropriate surface covering or treatment should be used.
This may include applications of sulfur-concrete toppings, epoxy coatings, polymer
impregnation, linseed-oil treatments, or other processes, each of which affects acid
resistance differently. Replacement of a portion of the Portland cement by a suitable
amount of pozzolan selected for that property can improve the resistance of concrete to
weak acid attack (Graham, 1998).
The addition of an appropriate amount of silica-fume and a high-range water-reducing

admixture to a concrete mixture will greatly increase compressive strength and
abrasion resistance.
8.5 Tunnel linings & other materials
8.5.1 General considerations
A variety of materials are used for repair of concrete, some are better suited for certain
repairs, and judgement should be exercised in the selection of the proper material.
Consideration should also be given to the time available to make repairs, access points,
logistics in material supply, ventilation, nature of the work, available equipment, and
skill and experience of the local labour force. For example if a surface coating has to be
applied to a concrete tunnel after commissioning, sufficient downtime is limited and one
has to allow for dewatering, drying, surface preparation, applying the coating, and
filling. Such downtime for general maintenance which has been allowed for at the
LHWP is about one month per year. Longer periods would only be available during the
early life of this tunnel when the system yield exceeds the water demand.
8.5.2 Acrylics and other concrete polymer systems
There are three main ways in which polymers have been incorporated into concrete to
produce a material with improved properties as compared to conventional Portland
cement concrete. These are (Graham et al. 1998):
• polymer-impregnated concrete (PIC),

• polymer-portland cement concrete (PPCC), and
• polymer concrete (PC).
PIC is a hydrated portSand-cement concrete that has been impregnated with a

monomer which is subsequently polymerised in situ. By effectively case hardening the
concrete surface, impregnation protects structures against the forces of cavitation and
abrasion. The depth of monomer penetration depends on the porosity of the concrete
and the process and pressure under which the monomer is applied. These materials
are quite costly and some monomer systems could be hazardous to work with if
unskilled workmen are used.
PPCC is made by the addition of water dispersible polymers directly into the wet
concrete mix. PPCC, compared to conventional concrete, has higher strength,
increased flexibility, improved adhesion, superior abrasion and impact resistance, and
improved durability. The most commonly used PPCC is a dispersion of organic
polymer particles in water. Typically, the fine aggregate and cement factors are higher
for PPCC than for normal concrete, and therefore it would have lower resistance to soft
water corrosion.
PC is a mixture of fine and coarse aggregate with a polymer used as the binder. This
results in a rapid-setting material with good chemical resistance and exceptional

bonding characteristics. So far, polymer concrete has had limited use in large-scale
repair of hydraulic structures because of the expense of large volumes of polymer for
binder.
Polymer concretes are finding application as concrete repair materials for patches and
as precast elements for repair of damaged surfaces, and have been used at several
hydraulic structures in the USA such as at Grand Coulee Dam.
8.5.3 Preformed polymeric coatings
Tunnels and conduits that have suffered surface damage due to chemical attack or
bacterial action can be protected from further damage with a non-bonded mechanically
attached PVC lining. Such a lining at the Berg River crossing of the Franschoek-Berg-
Jonkershoek Tunnel scheme was unsuccessful, since it was broken up in pieces over
time and some pieces blocked the Berg River outlet valves, and were very difficult to
remove without dewatering the tunnel.
Polyurethane and neoprene coatings exhibited good resistance to abrasion during high-
head testing (Graham et a!., 1998) and offer good protection against chemical
corrosion. The problem with flexible coatings like these is their bonding to the concrete
surfaces. Once an edge or a portion of the coating is torn from the surface, the entire
coating can be peeled off rather quickly by hydraulic force, and their use in tunnels is
therefore not recommended.
8.5.4 Organic coatings applied as liquids
This category covers a wide variety of materials, ranging from low-performance

bituminous varnishes to highly durable catalysed coatings. Table 8.5.4-1 gives the most
commonly used types, but is by no means an exhaustive list of all possible types
(Basson, 1989).
Table 8.5.4-1 Coatings for concretes in aggressive water (Basson, 1989)
Category Typical examples Minimum coating Remarks

thickness required
Inorganic Extra thickness of base Use under mild to

concrete as sacrificial moderate leaching
allowance 20 to 50 mm conditions only;
typically used in
Plaster coats sewers
Preformed Polyethylene
polymeric liners
Polyvinyl chloride 0.2 to 1 mm
Polychloroprene
Emulsion-based Polyacrylics Tolerant of damp
waterborne surfaces
organics Polyacrylonitriles 150 Mm
Solvent-based Chloronated rubbers High-build, thixotropic

organics lypes available
Vinyls 150 pm
Vinylidenes
Catalyzed Epoxy tars
organics
Solventless and water- 150 to 300 urn Accurate mixing and
based epoxies time scheduling
required
Polyurethanes

Bitumens were widely used in the past but have been omitted here due to their
relatively high permeability and inferior ageing characteristics, as have hot-applied,
high-build, coal-tar enamels as a result of the difficulty of application requiring highly
skilled workers. Underwater materials are specially formulated and should be selected
with the manufacturers technical personnel. If the water that is to be in contact with the
coating is intended to be potable, the manufacturer should guarantee that the material
is free from any toxic substances and has been approved for the purpose.
Preparing concrete surfaces for coating should be carried out carefully to ensure
adequate adhesion. The basic function of any method of surface preparation is to
remove any deleterious contaminants that may be present. Unless otherwise indicated
by the coatings manufacturer, one of the following two procedures should be employed
(Basson, 1989):
• Brush-off blastcleaning. Over-enthusiastic blasting could lead to a rough

abrasive surface, as found at the Orange-Fish Tunnel during this study, when
rotating head, high pressure jets were used to clean a 150 m length tunnel.
• Acid etching is a chemical process by which unwanted contaminants are

removed by means of an acid treatment
Surfaces that have been wetted during surface preparation should be allowed to dry
thoroughly before organic coatings (other than water-borne emulsions), are applied.
Trapped moisture reduce adhesion and leads to blistering. The moisture content of the
concrete before application should be below 5 to 8 % (Basson, 1989).
Cement-based mortars may be trowelled or applied by pneumatic projection

(shotcreting), while liquid organic coatings may be applied by brush, roller, conventional
spray or airless spray. In all cases the manufacturer's directions for thinning, spreading
rate and where applicable, mixing proportions should be carefully followed (Basson,
1989).
Basson (1989) recommended the use of organic coatings in conditions where his
aggressiveness index exceeds 750: highly aggressive (See Chapter 6 classification).
8.5.5 Catalysed organic coatings: Epoxy resins
Resins are natural or synthetic, solid or semisolid organic materials of high molecular
weight. Epoxies are one type of resin. These materials are typically used in preparation
of special coatings or adhesives or as binders in epoxy-resin mortars or concretes.
Epoxies will bond to most building materials and epoxy formulations have been
developed recently which will bond to damp concrete and even bond to concrete under
water. There are case histories of the successful uses of these materials in hydraulic
structures, in the USA as well as the Drakensberg pump storage scheme tunnel where
it was used for patching.
If epoxy is used for patching a very smooth finished surface is obtained, highly resistant
to damage, with the result that the abutting original material erodes away, leaving an
abrupt change in surface geometry and developing a condition worse than the original
damage. This was observed in the Franschhoek-Berg River Tunnel where patching of
poor original concrete that was eroded away was done with high strength concrete.
Within a number of years deep eroded holes developed next to the patched areas,
some measuring 2 m by 1 m in area, and 1 m deep.

8.5.6 Preplaced-aggregate concrete (PAC)
PAC also known as "prepacked concrete", is used in the repair of large cavities and
inaccessible areas. Well graded aggregate is placed in a form and neat cement grout or
sanded grout is then pumped into the aggregate matrix through openings. The grout is
placed under pressure until initial set and the concrete has a low volume change.
8.5.7 Pipe inserts
This method is commonly used for the repair of small diameter pipes to obtain a
jointless, structurally sound pipe inside an existing pipe without excavating the existing
unsound pipe. One such method is to place a plastic pipe inside the deteriorated
concrete pipe and then to fill the annular space between the concrete and plastic liner
with grout. With the proper selection of material for the plastic liner pipe insert, this
repair method can provide a sound, chemically resistant lining.
Another popular method is the installation of a resin saturated fibreglass "hose" into the
pipeline using water pressure. After installation, the hose is filled with hot water to
initiate the chemical reaction of the resin. The hardened resin forms a rigid pipe lining.
8.6 Other measures
Measures to increase the discharge capacity such as doubling or partial doubling,

construction of a new tunnel, minimization of secondary energy losses and pumps
could be considered with other measures listed in this chapter, to provide an
economical and sustainable design solution.
8.7 Tunnel costs
Historical tunnel costs are shown in Table 8.7-1. The unit costs (Figure 8,7-1) are
extremely expensive and everything possible should be done to prolong the life of a
tunnel by limiting the rate of ageing and ultimate roughness, especially if this is possible
through flow control during operation.

WRC Project: Deahny with Tunnel Ageing
Table 8.7-1 Historical tunnel costs
HISTORICAL TUNNEL COSTS

Signiiicant
Construction Actual cost Year of
Project Phase Start point End point Length (km) Diameter (m) Lining cost
Method (mil Rand) completion
implications
Transfer Maiibamatso Muela Hydro (B|
1 45,00 4.35 In situ TBM 1461 1998 None
Tunnel Intake Power Station
Partial lining
only 30% of
Delivery 5.10 bored (#)
2 Muela Intake Vent Shaft 5 15.00 In situ TBM 397 1998 length. Steel
Tunnel South 4.5 lined
lining at river
crossings
Lesotho Underpassed
Delivery North of 5.10 bored TBM + One-
3 Highlands Vent Shaft 5 2200 Pre-cast 554 1997 two major
Tunnel North Clarens 4.6 lined pass lining
Water Project rivers
4.5 Floor - In situ
4 Matsoku Ha Tsehla Kutha Kutha 5,60 Horse shoe Wall - Fibre Drill and Blast 34 2001 None
shape reinforced
5.30 bored
5 TBM,
Mohale Katse 4.8 lined Hard Rock
Mohale 32.00 Pre-cast 1000 2004
Reservoir Reservoir 6.90 bored Water Fissure
6 TBM;,
6.40 lined
In & Out lets
lined, 2.5km.
Pieter 3.8 bored
7 Midmar Tunnel - Merryvale 6.60 Reinforced TBM 91 1996 None
Maritzburg 3.5 lined
shotcrete and
rock anchors
'"April 1994 Rates
TBM - Tunnel Boring Machine

R 35.000
* R 32,467
• H 31,250
R 30,000
• B 26.467
| R 25.000
a
Z R 20,000
£
^ R 15,000
o • R 13,788
| R 10.000
• R 6,071
R 5.000
R0
3.00 3 20 3.40 3 60 3.60 4 00 4 20 4 40 4 60 4 BO 5.00
Lined tunnel diameter (m)
Figure 8.7-1 Unit costs of recently completed tunnels

9 LHWP TUNNEL RATE OF AGEING AND ULTIMATE

ROUGHNESS PREDICTION
9.1 Introduction
The first phase of the LHWP was completed recently. A layout of the LHWP system
is shown in Figure 9.1-1, while Figures 9.1-2 to 9.1-4 show more detailed profiles of
the Transfer Tunnel, Delivery Tunnel and Intake Tower at Katse Dam respectively.
The Transfer Tunnel conveys water from Katse Dam to the Muela hydropower
scheme in Lesotho, while the Delivery Tunnel transfers water from Muela Dam to the
Ash River in South Africa. The Ash River outfall (end of the Delivery Tunnel North) is
shown in Figure 9.1-5.
\ v..
Figure 9.1-1 Layout of LHWP tunnels

2C 25
SC3J8 Ot Km
Figure 9.1-2 Layout of the LHWP Transfer Tunnel
r i ii
I : iI 'I i i ['
\U II
1 M is i;;
I1
l 4 If:
Figure 9.1-3 Layout of the LHWP Delivery Tunnel

16 1m t Irlake icme:
:
«' T-*I r ^ •' ux
\r
Figure 9.1-4 Intake tower of the LHWP Transfer Tunnel
Figure 9.1-5 Delivery Tunnel North at Ash River
9.2 Ageing prediction (DWAF, 1999)
DWAF commissioned a study during 1999 to investigate the possible future ageing and
hydraulic capacity of the LHWP tunnels. Some typical ultimate tunnel roughness values
being used during the design of the tunnels are indicated in Table 9.2-1.

Table 9.2-1 Design tunnel roughness for aged condition
Description Design new Observed new Aged ultimate design

LHWP Transfer Tunnel n = 0.0123 n = 0.0111 n = 0.016
(ks = 0.03 mm)
LHWP Delivery Tunnel n = 0.012 n = 0.0116 n = 0.016
n = 0.0118 (ks
Orange-Fish Tunnel (5.33 m n = 0.013 design: n = 0.013;
= 0.15 mm)
diameter)
observed 1990:
n = 0.0138 (ks = 0.9);
1998: ks = 0.6 mm
Colebrook (1958) expressed the ultimate tunnel roughness as function of hydraulic

radius and mean flow velocity. Based on this, the long-term ageing rate during the
earlier years of operation of the Orange-Fish Tunnel at low flows is estimated at 0.1
mm/year (0.07 mm/year observed by 1990), with an ultimate roughness of 5.0 mm as
worst scenario. The same equation however indicates that the ultimate roughness could
be as low as 0.2 mm for the Orange-Fish Tunnel if operated at close to 2 m/s flow
velocity. The 1998 tests carried out at similar flow velocities, indicated an Orange -Fish
Tunnel roughness of 0.6 mm, which could possibly still decrease with longer duration
flushing.
During the design phase of the LHWP absolute maximum and minimum possible rates
of roughness increase in the Delivery Tunnel were set at 0.03 mm/year to 0.5 mm/year,
based on an equation by Colebrook (1958), which relates change in roughness to the
pH of the water. The phenomena observed by Colebrook were that acid waters
encouraged algal growth. While the 1988 design assumptions used pH values of 7 to
5.5, CSIR sampling (23 tests) in 1997 indicates pH values exceeding 8. Sampling by
DWAF at the Ash River tunnel outlet (12/11/97 to 12/01/99) also indicates a median pH
= 7.9 (standard deviation = 0.3), based on 47 samples. Even with a maximum pH of 7
the expected rate of tunnel roughening would be no more than 0.03 mm/year based on
the equation of Colebrook. The new ageing equation (DWAF, 1999) predicts an ageing
rate of 0.04 mm/year at the median pH of 7.9.
The CSIR analysis also shows that, notwithstanding the high ("alkaline") pH's, the Katse
water is also potentially aggressive to concrete and some roughening of lining surfaces
over time could be expected. Unfortunately no methodology is available to predict with
accuracy what the degree of deterioration of the concrete lined portions of the tunnel
will be. The Orange-Fish Tunnel does however provide invaluable information in this
regard and based on the 1988 and 1998 tunnel roughness evaluations, it is possible to
adapt similar rates of roughening for the LHWP tunnels, in the order of 0.07 mm/year,
and 0.022 mm/year based on the 1998 tests.
For the DWAF(1999) study, a probable ageing rate of 0.1 mm/year (conservatively
high) has been used and a minimum rate of 0.03 mm/year. The economic analysis was
based on an ageing rate of 0.1 mm/year.
While these values indicate that relatively low final roughness values are possible if the
LHWP tunnels are operated at design flow capacity (or even higher), an assumption
has been made for the study DWAF (1999) that ks = 4 mm (without cleaning), at an
ageing rate of 0.1 mm/year as the most probable scenario (DWAF, 1999).
Basson, Visagie & Maian 146 October 2002

9.3 Transfer Tunnel
Based on the tender assumptions, the minimum, mean and maximum head losses over
the full length of the tunnel were estimated to be 32.3 m, 36.6 m and 45.3 m
respectively, for a tunnel of 4.95 m. I.D., only lined for 6,7 km at 4.35 m I.D. During
construction it was decided to concrete line the complete tunnel at 4.35 m diameter,
which calculations showed should give similar head losses as the tender proposal.
The design flow of the tunnel for water transfer purposes is 32.6 m3/s, while the design
normal maximum discharge (turbines at rated load) is 35.9 m3/s. A review indicated that
medium and long-term friction losses in the concrete lined Transfer Tunnel could be
expected to be 32.8 m and 45.2 m respectively for the medium and long-term friction
losses. These correspond to between 12 and 16 percent of the gross available head
with the Katse Reservoir at full supply level.
Details of the commissioning tests carried out at the Transfer Tunnel have been
obtained from LHC. The new Transfer Tunnel roughness is 0.03 mm (Manning n =
0.0111), which is slightly less than the mean roughness of the Delivery Tunnel of
0.15 mm (Manning n = 0.0116). With the current tunnel roughness which is slightly less
than the "mean Phase 1A typical" Manning n = 0.0123 used during the design of the
tunnel, the discharge capacity is now 11 percent higher than the design discharge at a
design head loss of 36.6 m. Compared to hydraulic tests carried out at other tunnels,
the new tunnel friction loss is relatively small.
The tunnel capacities at various head losses and ageing rates are indicated in Table
9.3-1 and Figure 9.3-1 as determined in a recent study by DWAF (1999). For the
purpose of the assessment the same rate of tunnel roughening as with the Delivery
Tunnel has been assumed.
The analyses indicate that the Transfer Tunnel could, under certain operating
conditions, have sufficient long-term capacity, even at Katse minimum operating level
(MOL), to transfer the Phase II yields.
Table 9.3-1 Hydraulic capacity of the Transfer Tunnel with ageing (m3/s)
(DWAF, 1999)
Capacity at head Current Minimum

Estimated probable ageing at
loss of condition ageing at 0.03
0.1 mm/year
mm/year
Year: 1998 2020 2020 2050
39 m (Katse at
42.2 34.4 30.5 28.6
MOI>
103 m (Katse at 69.8 56.0 49.6 46.6
FSL)
Note: (a) The available energy head is limited by the minimum design operating
level (1950 m) in the surge shaft upstream of the Muela hydro power
station.

50
Minimum iigt-ing 0 0? mm/yr Probable ageing: 0 I mm/yr

45
jnnel capacity (cumec)
40
\
35
30
*• K.. scaiMOL
25
20
19 90 2000 2010 2020 2030 2040 2050
Time (yr)
Figure 9.3-1 Simulated hydraulic capacity loss of the Transfer Tunnel due to
ageing (DWAF, 1999).
9.4 Delivery Tunnel
Various ageing scenarios of the Delivery Tunnel have been investigated, based on the
commissioning tests and a calibrated numerical hydraulic model (DWAF, 1999). The
results are indicated in Table 9.4-1 and Figure 9.4-1.
Allowance has to be made for tunnel maintenance on an annual basis in the order of 10
% of the time. The discharges indicated in Table 9.4-1 are absolute values and do not
include down time.
Table 9.4-1 Hydraulic capacity of the Delivery Tunnel with ageing <m3/s)(DWAF,
1999)
Current Minimum ageing Orange-Fish Estimated

condition at 0.03 mm/year tunnel ageing probable
Description
at 0.07 ageing at 0.1
mm/year* mm/year
Year: 1998 2020 2020 2020
Muela Dam at FSL 37

48 42 39
(1775 m)
Muela Dam at MOL 38 33 30 29
(1759.5 m)
Muela Dam at AOL 47 41 38 37
(1773.5 m)
'Based on 1988/89 tests at the Orange-Fish Tunnel; the recent 1998 tests indicated
ageing at 0.022 mm/year.

NOTE: FSL Full Supply Level,

MOL Minimum Operating Level
AOL Average Operating Level
50
_48
| 46
= 44
>42
| 40
5 38
"36
§34
"~ 32
30
1990 2000 2010 2020 2030 2040 2050
Time (yr)
Probable ageing: 0 1 mm/yr minimum ageing: 0 03 mm/yr
Figure 9.4-1 Simulated hydraulic capacity loss of the Delivery Tunnel due to
ageing (DWAF, 1999)
9.5 Proposed operation to minimize rate of ageing
9.5.1 General
Various operational and structural modifications have been investigated for the Transfer
and Delivery Tunnels in order to maximize the hydraulic capacities, as counter
measures to limit the impacts of tunnel ageing and hydraulic constraints in the system
(DWAF, 1999).
9.5.2 Transfer Tunnel
The options available for increasing the capacity of the Transfer Tunnel are operating
Katse Reservoir at a higher MOL and/or lower the MOL at the surge shaft (upstream of
Muela).
Operation of the Transfer Tunnel at variable flows is possible, and allows water
transfers at high Katse reservoir levels equal to the yield, while at low reservoir levels,
the tunnel discharge capacity (less than the yield), limits the transfer of water, and
would therefore impact on the system yield. This option has been investigated in the
yield analysis. Table 9.5.2-1 shows the required MOL's at Katse Reservoir for three
phase II yields. It is clear from Table 9.5.2-1 that the highest yield would decrease the
live storage in Katse Reservoir considerably.

Reservoir for various possible yields (Surge shaft MOL = 1950 m) (DWAF, 1999)
Year Discharge: 38.4 m3/s Discharge: 44.7 m3/s Discharge:47.9 m3/s

yr2010 2005m 2025 m 2035 m
yr 2020 2012 m 2028 m 2046 m
yr 2030 2017 m 2034 m (2054 m)**
yr 2037 2020 m 2045 m (2059 m)**
yr 2050* 2020 m 2045 m (2059 m)**
Notes: * MOL constant from yr2037 due to ageing equilibrium
Katse FSL = 2053 m
Katse MOL = 1989 m (design)
Table 9.5.2-1 is based on a design surge shaft MOL = 1950 m, and rate of ageing of
the Transfer Tunnel = 0.1 mm/year.
Table 9.5.2-2 provides additional information in the case of a combination of operating

Katse Reservoir at a higher MOL, as well as operating at a lower MOL in the surge
shaft (DWAF, 1999).
Reservoir for various possible yields, with doubled surge shaft
(Surge shaft MOL = 1919 m)
Year Discharge: 38.4 m3/s Discharge: 44. ma/s Discharge:47.9 m3/s

yr2010 1989 m 1994 m 2004 m
yr2020 1989 m 2003 m 2015 m
yr2030 1989 m 2010 m 2023 m
yr2037 1989 m 2014 m 2028 m
yr2050* 1989 m 2014 m 2028 m
Note: * MOL constant from year 2037 due to ageing equilibrium
The design minimum operating water level in the surge shaft at the end of the Transfer
Tunnel is at 1950 m, well above the tunnel. The purpose of such a seemingly high MOL
could be to eliminate negative pressures in the tunnel during startup of the hydro power
plant, or during rapid shutdown. The consequences on the Transfer Tunnel capacity are
however dramatic with the MOL at 1950 m and could be the limiting capacity for the
whole transfer scheme at Katse Dam MOL when phase II flows are considered. The
benefit of this scenario is indicated in Table 9.5.2-3.

Table 9.5.2-3 Hydraulic capacity of the Transfer Tunnel with ageing with
reduced surge shaft MOL <m3/s) (DWAF, 1999)
Current Minimum ageing Estimated probable

Capacity at head loss of
condition at 0.03 mm/year ageing at 0.1 mm/year
Year: 1998 2020 2020 2050
39 m (Katse at MOL)(a) 42.2 34.4 30.5 28.6
103 m (Katse at FSL) 69.8 56.0 49.6 46.6
70 m (Katse at MOL and

surge shaft MOL at
1919m ){b) 57.2 46.1 40.8 38.3
Notes: (a) The available energy head is limited by the design minimum operating
level in the surge shaft upstream of the Muela hydro power station of
1950 m.
(b) Maximum possible if surge shaft MOL could be lowered from 1950 m
(design) to 1919 m (proposed) to maintain positive head on tunnel.
9.5.3 Delivery Tunnel
Several options are available to increase the hydraulic capacity of the Delivery Tunnel
(DWAF, 1999).
a) Raised Muela Dam
The raising of Muela Dam to increase the available hydraulic head of the Delivery
Tunnel could be considered. Any higher tailwater level would of course result in
decreased hydro power generation and efficiency. The long-term Delivery Tunnel
capacity with a raised Muela Dam by 5 m is indicated in Figure 9.4.3-1. The raising of
Muela Dam would however result in a higher hydraulic gradient line at the low cover
Little Caledon River section, exceeding design pressures.

60
|50
I
a
30
1990 2010 2030 2050
Time (year)
Muela FSL & ageing 0.1 mm/yr Mueta FSL & 0.03 mm/yr
cleaning based on USA-MWD(O.Jmm) River crossings doubled
Crossings doubled & Mueia raised Sm
Figure 9.5.3-1 Delivery Tunnel capacity with raised Muela Dam
b) Increase Delivery Tunnel river crossing capacities
The hydraulic gradient line of the LHWP commissioning tests shows clearly that the
river crossings, especially at high flows, create relatively high energy losses (HDTC,
1998). By doubling these river crossings, it would be possible to increase the hydraulic
capacity of the Delivery Tunnel (See figure 9.5.3-1).
c) Mechanical cleaning : LHWP application
The DWAF (1999) study proposed:
"Regular cleaning of the LHWP tunnels with the aid of mechanical equipment would
probably limit the rate of ageing, and while this should probably be tested in the field by
pilot project, it is expected that the long-term Delivery Tunnel capacity could be as
illustrated in Figure 9.5.3-1. This is based on the USA-MWD experience with
roughness coefficients before and after cleaning of ks = 0.43 mm and 0.14 mm
respectively, giving a mean roughness of 0.29 mm (Horowitz and Lee, 1971).
With the current LHWP tunnels, the tunnel capacity is relatively high compared to the
water yield. As future water requirement increase, however, with the construction of a
possible Mashai Dam (after year 2010), the aged tunnel capacity could be limiting the
transfer of water. If regular cleaning is considered, annual shut-down of say one week,
would result in about 2 percent reduction in yield transferred. It would, however, not be
impossible to design an in line automatic cleaning machine which could operate without
shutdown of the tunnel."
However, based on the findings of this WRC study, mechanical cleaning in aggressive
water conditions is not recommended due to possible damage to the concrete.

d) Hydraulic flushing
At high flow velocities, preferably above 2 m/s, it would be possible over time to recover
some of the lost hydraulic capacity due to ageing by flushing out some of the previously
deposited sediments in the tunnel. Metcalf and Jordaan (1990), indicated the impact of
hydraulic flushing during the Orange-Fish Tunnel testing in 1988:
"Whilst there is a large degree of scatter at lower flows, the trend towards ks = 1.0 mm
(n = 0.0139) at the higher flows is clearly discernable. The fact that roughness tended
to fall as flow was increased, and stay at the lower value (ks = 1.0 to 1.1 mm) when the
lower flows were re-established after the tests, suggests a scouring action," (although
maximum flow velocity was 1.8 m/s). During the 1998 hydraulic tests carried out at the
Orange -Fish Tunnel, a longer duration, higher flow test has been carried out
specifically to test the effectiveness of hydraulic flushing as possible remedial measure.
During tests carried out in 1989, Metcalf and Jordaan (1990), observed: "The value of n
(Manning) obtained at the start of the test for the working flow of 21.3 m3/s was at n =
0.0142, about 2 % higher than that recorded at the end (i.e. post-scour) of the previous
years testing, n = 0.0139. On resuming working flows of 21.3 m3/s after the tests 'n'
showed a decrease to 0.0139, i.e., the same as the previous year."
"At the higher test flow of 34.6 m3/s an initial value of n = 0.0141 was obtained which
showed a slow fall during the test." This friction factor at the Orange-Fish Tunnel was
estimated to be about n = 0.0137 (ks = 0.8 mm), once again implying a scouring action
by the above normal flow, and an increased discharge capacity of 3 %. During even
higher flows in the tests carried out during 1998, the tunnel capacity improved by about
5 % within 20 hours. This was achieved after short duration, high flows, and even
higher flushing efficiency would be possible at higher flows (v > 2 m/s), typical of the
LHWP tunnels. (The Colorado River tunnels typically operated at a flow velocity of
2.6 m/s).
Colebrook (1958) also found that pipes operated at higher hydraulic shear stresses
(higher flow velocities), aged slower than tunnels operated at low flow velocities. To
limit the rate of ageing it is therefore important that the LHWP tunnels are operated at
maximum system yield, with perhaps certain periods on an annual basis, running at
maximum tunnel capacity.
e) Chlorination
MWD (USA) uses monthly chlorination during the summer months with sodium
hypochlorite to remove algae build-up in the Colorado Tunnel (Kelly, 1998). They have
about 12 sites where 4500 litres of 5.5 % sodium hypochlorite is applied. The
applications are in early evening and at the inlets to inverted siphons. This maximizes
mixing. In years past, liquid chlorine was used, but MWD found that they could attain
and maintain a higher chlorine residual with the sodium hypochlorite.
Chlorination of the LHWP tunnels would probably not be practical considering the fact
that they discharge into rivers. It would therefore only be an option to consider if the
proposed Rand Water pipelines are constructed, linking the tunnel outfall to the Rand
Water purification plants in a closed system.

f) Relining
Relining of the Transfer and Delivery Tunnels is possible. Relining could be an epoxy
type/poly-urethane coating to be applied in future only on concrete lined sections of the
tunnel. An ultimate roughness of the relined tunnel of 1.5 mm have been assumed
(DWAF, 1999), which would give the Delivery Tunnel a hydraulic capacity of about
43 m 3/s. An ultimate roughness of as low as 0.6 mm would however also be realistic to
use, but one has to take into account the possibility of abrasion and siltation (DWAF,
1999). The assumption that a relined tunnel would have a different ultimate roughness
than a concrete tunnel used in the DWAF (1999) study should however be modified to
be the same.
g) Phased doubling of the Delivery Tunnel
Doubling of the Delivery Tunnel could be considered (or even phased doubling), after
other cheaper options have been considered. Complete doubling of the tunnel would
give the capacities indicated in Table 9.5.3-1.
Table 9.5.3-1 Hydraulic capacity of a doubled Delivery Tunnel
Year Hydraulic capacity (m3/s)
2020 75
2050 71
Note: Table 9.5.3-1 is based on a rate of ageing of 0.1 mm/year.
Phased doubling is possible and doubling has been considered from the Delivery
Tunnel north outfall first, in order to lower the hydraulic gradient line at the Little
Caledon low cover section (DWAF, 1999).
9.6 LHWP Tunnel roughness prediction based on findings of this WRC

study
a) Delivery Tunnel North
During the 1999 tunnel inspection of the Delivery Tunnel North, about 2 years after
operation started, a thin uniform layer of fine sediment was observed in the tunnel. At
the outlet the tunnel dried and the sediment layer was not visible (Figure 9.6-1), but
deeper into the tunnel it completely covered the tunnel wall (Figures 9.6-2 & 9.6-3). The
LHWP water is aggressive to concrete and the upper layer of the concrete (under the
sediment) was found to be soft and could easily be damaged, exposing the coarse
aggregate (Figure 9.6-4).

Figure 9.6-1 Segmentally lined Delivery Tunnel North
Figure 9.6-2 Sediment deposition in the DTN (1999)

Figure 9.6-3 Sediment deposition partially covering the joints in the DTN
(1999)
Figure 9.6-4 Soft water corrosion in the DTN (1999)

The following calculation procedure is proposed to determine the long term roughness
and discharge capacity of the Delivery Tunnel:
• Determine dominant discharge. This could be based on say the discharge that is
exceeded 20 % of the time. The DTN dominant discharge was taken as 35 m3/s at
this stage to be conservative. Typical daily flow vary from 15 to 40 m3/s due to
hydropower generation.
• Obtain pH data and determine the mean, the range and standard deviation, and
select minimum for sensitivity analysis. For DTN the mean is 7.9 with 0.3 standard
deviation, measured at the Ash outfall (Calculation based on data in 1999, but pH
however subsequently deceased). A minimum value of 7.5 was selected.
• Obtain initial roughness of tunnel
• Apply the rate of ageing equation (eq. 5.7.3-6) for the tunnel at mean pH and
selected minimum pH, using the energy slope of the dominant discharge, and
determine ks with time
• Use the ageing ks values determined above and determine the tunnel discharge
capacity by using the maximum available energy slope
• Determine the ultimate roughness for the probable (eq. 5.8.5-2) and maximum
probable roughness (eq. 5.8.5-3), based on the dominant discharge and associated
energy slope, also considering mean and minimum pH values. Then calculate the
ultimate discharge capacity based on the calculated ks values and the maximum
available energy slope, using the Colbebrook White-Darcy Weissbach equation.
The predicted ageing of DTN is shown in Figure 9.6-5, based on a dominant discharge
of 35 nrvVs to calculate the ageing. The ultimate roughness of the three lines indicated
varies between 0.25 mm and 1.31 mm which is much less than the 4 mm used in the
original design of the tunnel and in the DWAF (1999) study where 4 mm was also
considered as the ultimate roughness, corresponding to about 34 m3/s ultimate
discharge capacity. The predicted ultimate discharge capacity is now 41.7 m3/s
(probable ks) with a low value of 38.9 m3/s (maximum probable ks).
• In order to be conservative, it is recommended that the ultimate roughness

minimum should be taken as 0.6 mm due to possible concrete deterioration. The
two lower lines in the graph (Figure 9.6-5) should therefore be used.
The probable ageing is given by the central line, with an ultimate discharge capacity of
85 % of the original capacity. The predicted maximum ageing discharge capacity is
given by the lower line on the graph, with a long term capacity of 80 % of the original
capacity.
The rate of ageing predicted is 0.017 mm/year and 0.032 mm/year for the mean and
minimum pH values respectively. This is now considerably less than the estimates of
the DWAF (1999) report of probable and maximum probable values of 0.03 mm/year
and 0.1 mm/year.

50
Observed aqeinq
10 20 30 40 50
Age (years)
Avg. pH=7.9 Probable ks ult=0.25mm Low pH=7.5 Max prob ks ult=1,31mm
A Avg pH=7.9 max prob ks ult-0.64 mm
Figure 9.6-5 Predicted ageing of the Delivery Tunnel North (this study)
• The critical conditions for re-entrainment (eq. 5.5.1 -1) and transport of non-cohesive
sediment sediment transport (eq. 5.6-1) should be determined to transport say 0.5
mm sediment, the typical median size of sand bedded rivers in South Africa.
• The maximum shear stress should not exceed the maximum value (19 Pa) tested in
the laboratory (Table 5.5.2-1) where no concrete deterioration associated with an
increased roughness occur. The maximum bed shear stress is less at DTN.
The predicted rate of ageing and ultimate roughness has to be refined with more field
data, and the ageing prediction of the Delivery Tunnel and Transfer Tunnel should be
carried out. At this stage, however, these findings indicate that perhaps a next phase of
the LHWP can be implemented without doubling of the tunnels.
Field testing (2002) at the Delivery Tunnel indicates no ageing after 5 years of
operation, with head loss changes of less than 50 mm from the commissioning tests.
Initially the tunnel was operated at regular peak discharges of 35 to 40 m3/s. Since
September 2001 the operation changed to typical peak discharge of 27 m3/s during day
time, dropping to 12 m3/s at night, due to hydropower generation requirements and
system constraints (Figure 9.6-6).
During the first 5 years of operation, the pH of the water discharging from the DTN has
slowly decreased from about 8.0 to about 7.6 (Figure 9.6-6). Since September 2001,
when the peak flows reduced, a large scatter in pH data has been observed, which is
difficult to explain. The predictions of tunnel ageing shown in Figure 9.6-5 are however
based on a range of pH values between 7.5 and 7.9, as observed in the field.

WRC Project Dealing with Tunnel Ageing
9.5
pH dala
40
ss 35
JO
26
5
a
1997/0&19 1996/01/05 1998/0704 1999/02/09 1999/08/28 20OCLTO15 SOOOnWOI 2001(04/13 2001/11/05 2002/05/24 2002'12!0
Date
Figure 9.6-6 Delivery Tunnel North observed discharge and pH data

10 TUNNEL DESIGN AND OPERATIONAL GUIDELINES

INCORPORATING TUNNEL AGEING
The following general calculation procedure is proposed to determine the long-term
hydraulic roughness, rate of ageing and associated discharge capacity of a concrete
lined tunnel:
Design aspects:
a) Determine the dominant discharge, based on say the flow that is exceeded
20 % of the time. Consider changes in future water requirements, daily and
seasonal variation.
b) Determine whether the water is aggressive to concrete (soft water) by referring

to Chapter 6.
c) Calculate the rate of ageing (eq. 5.7.3-6).
d) Calculate the probable (eq. 5,8.5-2) and maximum probable ultimate (eq. 5.8.5-
3) hydraulic roughness. Use the minimum ultimate roughness equal to 0.6 mm
to allow for possible concrete deterioration.
e) Calculate the discharge capacity of the ageing tunnel, also considering pH

sensitivity (standard deviation).
f) Tunnels should not be oversized as this could lead to high ageing rates. Larger
tunnel diameters lead to reduced flow velocities, which accelerates the rate of
ageing and could lead to a relatively high ultimate roughness. A sensitivity
ageing analysis should however be carried out for various tunnel diameters, with
a costing exercise.
Operational aspects:
g) Carry out a sensitivity calculation considering actual operational discharge less

than the design discharge, and neglecting hydraulic flushing, to determine the
ageing discharge capacity.
h) If the water is aggressive to concrete (soft water), the initial operational

discharge should ensure laminar sub-layer formation (Figure 5.1-4) as the
tunnel ages, but with a minimum operational discharge given by the probable
ultimate roughness (eq. 5.8.5-2) calculation or required roughness (capacity).
i) If the water is not aggressive to concrete, make the dominant discharge as high
as possible to limit ageing. The ageing can in some cases be reversed by
hydraulic flushing at high discharge on an annual basis. The flushing operation
should however be seen as a safety factor in the design since it will not work
under all conditions. It is better to make the dominant discharge as high as
possible.
j) Determine the critical hydraulic condition for re-entrainment of non-cohesive

sediment that could enter the tunnel and check whether deposited sand and
gravel could be re-entrained during the dominant discharge (eq. 5.5.1-1).
k) Calculate the sediment transport capacity of the tunnel at the dominant

discharge for non-cohesive sediment (eq. 5.6-1).

I) In soft water conditions, evaluate the maximum bed shear stress ( and stream
power) which should not exceed 10 Pa to prevent damage to the soft concrete
surface (Table 5.5.2-1).
Comments on ageing remedial measures:
m) Mechanical cleaning should not be considered for soft water conditions, and
only soft brushes should be used in hard water conditions to prevent damage to
the concrete surface. Drying of deposited sediment will remove it, but this
should not be carried out in soft water conditions as the surface layer of
concrete will also be removed.
n) Hydraulic flushing should only be considered in hard water conditions. It is

however better to make the dominant discharge as high as possible instead of
allowing excessive ageing at first and then relying on flushing to reverse the
ageing process
o) Relining of concrete tunnels should not be necessary under most conditions, as

long as a good quality concrete is used and the soft concrete is not scoured {in
soft water conditions).
p) When designing a tunnel, limit secondary losses as far as possible, but conduct
a cost analysis. Also consider phased partial or complete doubling of the tunnel.

11 CONCLUSIONS
This study combined laboratory and field test data to obtain a better understanding of
the ageing process in large diameter conduits such as water transfer tunnels. Field
tests were carried out since 1998 at the Orange-Fish Tunne!, Roode Elsberg Tunnel
and Theewaterskloof Tunnel, while laboratory investigations at the Universities of
Stellenbosch and of Pretoria were also carried out on pipes. The following are key
findings of this research project:
• Hydraulic ageing is caused by sediment deposition consisting of fine cohesive

sediment, in some cases also containing some organic material. Manganese
deposition by bacterial action also occur which is difficult to flush out at high
discharge. In the Theewaterskloof Tunnel sand at the tunnel invert also deposited
due to diversion of Berg River water into the tunnel,
• Soft water corrosion occurred at the Western Cape and LHWP tunnels. The effect
is a softening of the upper 3 mm of concrete, but this was protected by a thin
layer of sediment at all the tunnels investigated. The soft water corrosion can
however lead to deep scour holes and etch marks in the concrete, where a poor
quality concrete was used during construction (Theewaterskloof Tunnel). This is
however not expected in the high strength LHWP concrete lining.
• A relationship was developed and calibrated to determine the effective roughness

of a segmentally lined tunnel, including the joint step losses.
• A hydraulic rate of ageing equation was developed and calibrated on UK and SA

data, for conditions where sediment deposition and sliming plays a role. The pH
of the water is a dominant variable.
• An ultimate roughness equation was developed and calibrated. Probable and

maximum probable ultimate roughness formulations have been proposed.
• Hydraulic flushing at high flows are effective in reducing the hydraulic roughness
by flushing out sediment deposits from the tunnel. Where bacterial action
however plays a role one cannot rely on flushing alone and other measures have
to be considered.
• Chlorination has been used on a limited scale elsewhere in the world to reduce
roughness, but was found more effective after cleaning of the tunnel. Depending
on the system configuration there are environmental problems associated with
chlorination.
• Mechanical cleaning of a tunnel in soft water conditions damages the tunnel and
increase the roughness, no matter how careful you are. In hard water conditions,
high pressure water jets damaged the tunnel surface. Literature indicate rapid
increase in roughness after cleaning, within one to two years.
• Tunnel linings such as poly-urethane can be considered in conditions of soft

water corrosion, but should preferably be applied during the tunnel construction.
These lining are however expensive and their lifespan is unknown. A good quality
concrete without a lining, designed and operated correctly, should be sufficient for
most conditions.

• Literature reviewed indicates that there are two main factors influencing the
deterioration of the concrete due to soft water attack namely the aggressiveness
of the water and the composition of the concrete under attack.
No cement extenders were used in the concrete of the Theewaterskloof Tunnel

and it was found that the leaching rate of Ca-ions increase exponentially with an
increase in the water operating velocity in the pipe system. The main chemical
process taking place in the concrete during soft water attack in the
Theewaterskloof Tunnel is the leaching of Ca(OH)2. A maximum and minimum
theoretical concrete deterioration depth rate was determined for the concrete.
These rates also increase exponentially with an increase with water operating
velocity in the pipe system. The permeability of this concrete is very high and
therefore the leaching rates are also high.
The concrete mixture of the LHWP linings of the delivery tunnels contains fly-ash
as a cement extender. Two different Ca-ion leaching rates for a specific water
operating velocity were found for the LHWP concrete. It indicates that as a result
of the fly-ash content in the mixture, decalcification of the C-S-H gel take place at
a low rate and Ca(OH)2 leaching at a higher rate. The theoretical concrete
deterioration depth rates for the LHWP concrete are much lower than the rates for
the Theewaterskloof Tunnel. There are not enough data available at this stage
but it seems that the concrete deterioration rate increase with an increases of
water operating velocity.
Although the soft water attack cannot be stopped with a specific concrete mix
design, it is possible to decrease it significantly with an optimum design. The
optimum concrete mixture as designed by Castro & Mclntosh (1994) for the
LHWP tunnels will still be the best mixture for resistance to soft water attack
because the Ca(OH)2 content is very low in this design mix.
• Design and operational guidelines for the determination of tunnel ageing and
selection of tunnel diameter during design, have been proposed. The LHWP DTN
has been used as a case study.
• Prediction of future ageing of the LHWP DTN indicates that under current
operating conditions, the rate of ageing would be relatively small and the ultimate
discharge capacity would be between 80% to 85% of the new tunnel capacity.
Previous studies used a higher ultimate roughness (DWAF, 1999) of ks = 4 mm
which resulted in an aged discharge capacity of about 73% of the original
capacity. The current predictions therefore indicate that it might be possible to
implement the next phase of the LHWP without doubling the tunnels: Low Mashai
Dam, that would require a total tunnel discharge capacity (including phase I flow)
of 35,8 m3/s without downtime, or 39,8 m3/s with 10% downtime.

12 RECOMMENDATIONS
It is recommended that the design guidelines (Chapter 10) are followed during the
design of a tunnel. Even more important however, is that the tunnel should be operated
according to the design.
• Regular hydraulic tests at say 5 year intervals should be carried out at the LHWP,
Theewaterskloof, Orange-Fish and Roode Elsberg Tunnels to determine the
hydraulic roughness to extend the current data base.
• The theory developed for this study should be calibrated against field data of
pipelines for application in pipe design.
Attention to the following chemical aspects regarding soft water corrosion is necessary:
• More laboratory tests are necessary on the LHWP test section at higher water
operating velocities to determine the relationship between the Ca-ions leaching
rates and water operating velocities.
• Tests on the microstructure of the concrete of the test sections are necessary to
calibrate the rate of the theoretical concrete deterioration depths and to determine
the exact influence of the permeability and porosity on soft water attack.
• Tests on the Theewaterskloof Tunnel core have to be completed to calibrate

laboratory tests.
determined. Laboratory tests with the water from the field will be necessary to
confirm the calibration of the accelerated rate of deterioration in the laboratory with
the actual field behaviour.
• Further tests on concrete mixtures with silica-fume as cement extender will be

valuable to determine a concrete mixture with a higher resistance to soft water
attack.
• The effect of soft water in the concrete mix should be studied.
• Coatings should be applied in the Delivery Tunnel North to evaluate its long term
performance.
• Tunnels should not be cleaned by mechanical equipment (brushes/brooms) or

water jets, as this damages the concrete surface, leading to increased hydraulic
roughness, based on field tests carried out during this study.
• The rate of ageing and ultimate hydraulic roughness predictors developed and
calibrated in this study make use of hydraulic data and pH values. These equations
should however be refined in future by incorporating water quality variables related
to soft water corrosion and sliming.
Bassors, Visagie & Malan 164 October 2002

13 REFERENCES
Addis, B.J. (1989). Predicting the Ca(OH)2 content and chemical vulnerability of pastes
made with different binders and calculating the saturation proportion for fly ash with
Portland cement. Portland Cement Institute TIP No. 169, Midrand, South Africa.
Ballim, Y. (1993). Chemical deterioration processes. Natal branch of the concrete

Society of Southern Africa - Short Course: Durability of concrete
Basson, J.J. (1989). Deterioration of concrete in aggressive waters - measuring

aggressiveness and taking countermeasures. Portland Cement Institute, Midrand,
South Africa.
Basson, G.R. and Rooseboom, A. (1997). Dealing with Reservoir Sedimentation. SA

Water Research Commission , TT91/97.
Brett, T.M. (1979). Head-loss measurements on hydroelectric conduits. J. of Hydr. Div.,

ASCE, Vol. 106, No. HY1.
BW Engineers (1984). In Colebrook (1958).
Carde, C. Francois R. (996) Leaching of both calcium hydroxide and C-S-H from
cement paste: Modelling the mechanical behaviour. Cement and Concrete Research.
Vol.26, No. 8. pp. 1257-1268.
Carde, C. Francois R. (1999). Modelling the loss of strength and porosity increase due
to the leaching of cement paste. Cement and Concrete Research 1997; 21 181-188.
Castro, D.J. & Mclntosh, J. (February 1994). Design of a concrete mix with a high fly
ash content for construction of tunnel linings. Second international symposium Ash - A
valuable Resource Volume 1,.pp 141-154.
Colebrook, C.F. (1939). Turbulent flow in pipes, with particular refence to the transition
region between the smooth and rough pipe laws. J Instn. Civ. Engrs., 11,133.
Colebrook, C.F.(1958). The flow of water in unlined, lined and partly lined rock tunnels.
J. Instn. Civ. Engrs., Paper No. 6281.
Colebrook, C.F. and White, CM. (1937). Experiments with fluid friction in roughened
pipes. Proc. Roy. Soc, A161, 367.
Colebrook, C.F. & White, CM. (1938). The reduction of carrying capacity of pipes with
age. J. Instn. Civ. Engrs., vol. 7, p99.
Durand.R. and Condolios, E. (1956).Donnees Techniques sur le Refoulement

hydraulique des Materiaux solides en Conduite, Rev. I'lndustrie Minerals, Special
Number 1 F.
DWAF. (1996). Water quality guidelines. Department of Water Affairs and Forestry,
South Africa.
DWAF. (1999). Internal Communication, Department of Water Affairs and Forestry,

South Africa. .
Elder, R.A.(1956). Friction measurements in Apalachia Tunnel. Proc. Amer. Soc. Civ.
Engrs., vol. 82 (HY3).

Graham, J.R. (1998). Erosion of concrete in hydraulic structures. ACI 210R-93.
HDTC. (1998). Delivery Tunnel Design Contract TCTA-01. Highlands Delivery Tunnel
Consultants.
Herowitz, H.R. and Lee, (1971). In Horowitz (1990).
Hopkins, D. (1978). Bepaling van die ruheidsmaat k en die wrywingskoeffisient f van 'n
2.5 m deursnee ou betonpyp. Die Siviele Ingenieur in Suid-Afrika.
Horowitz, H.R. (1990). Charts for the hydraulic design of channels and pipes.
Hydraulics Research, Wallingford, 6th ed.
Kelly, (1998). Personal communication. MWD
Lamont, P. A. (1954). A review of pipe friction data and formulae, with a proposed set of
exponential formulae based on the theory of roughness. Proc. Instn. Civ. Engrs., Part 3.
Lea, F. M. (1998) Lea's chemistry of cement and concrete. Fourth Edition, p 59, 329-
334,570-572.
Metcalf, J.R. and Jordaan, J.M. (1990). Hydraulic roughness change in the Orange-Fish
Tunnel: 1975 - 1990. J. South African Civil Engineering.
Muller, J.R. Deterioration of Portland Cement Concrete in Natural Waters. Proc. CSSA
Conference on Concrete in Aggressive Environments. Pretoria, 1977.
Neumann, MJE & Treu, T.P. ( September, 1994) Mix Design & Site Production of Early
Strength and High Durability Precast Concrete Tunnel Lining Segments. Concrete
Society of Southern Africa, Silver Jubilee Commeration.
Neville A.M. & Brooks J.J. (1987). Concrete Technology. Longman Scientific &
technical, Essex, England., p 9 -15.
Pegram, G.G.S. and Pennington, M.S. (1998). A method for estimating the hydraulic
roughness of unlined bored tunnels. Report WRC 579/1/96, Water Research
Commission, Pretoria, South Africa.
Perkins, J.A. and Gardiner, I.M. (1982). The effect of sewage slime on the hydraulic
roughness of pipes, IT 218, Hydraulics Research Station, Wallingford, 1982.
Pitt, J.D. and Ackers, P. (1982). Hydraulic roughness of segmentally lined tunnels,
CIRIA Report 96.
Rooseboom, A.R. (1992). Sediment transport in rivers and reservoirs - A southern

African perspective. Water Research Commission, Report No. 297/1/92.
Rouse, H. (1943). Evaluation of boundary roughness. Proc. 2nd Hydraulic

Conf.,University of Iowa, Bulletin 27.
USBR (1965). In Colebrook (1958).
Williams and Partners (1952). In Colebrook (1958).

APPENDICES
APPENDIX A
Softwater corrosion laboratory data

APPENDIX A-1
Test data on the Theewaterskloof Tunnel section

DOWN-
UP-STREAM DIFFERENCE
DATE TIME TEMPERATURE STREAM
READING IN READINGS
OF WATER (°C) READING
(cm) (cm)
(cm)
Depth at 90a V-Notch = 185 mm (Velocity 1.2 m/s)
28/05/2001 17 72 82 10
29/05/2001 26 100 115 15
30/05/2001 O9H30 25 105 120 15

30/05/2001 13H00 28 106 120 14
31/05/2001 08H30 28 104 118 14
31/05/2001 12H00 29 106 120 14
01/06/2001 08H30 29 104 118 14
01/06/2001 12H00 29 106 120 14

04/06/2001 09H00 29 103 117 14
04/06/2001 12H45 30 104 117 13
05/06/2001 09HOO 30 100 113 13
05/06/2001 12H30 30 101 114 13
06/06/2001 08H15 30 104 117 13
06/06/2001 13H00 30 103 116 13
07/06/2001 8H00 30 104 119 15
11/06/2001 10H15 28 104 118 14
11/06/2001 13H30 29 107 120 13
12/06/2001 10H00 27 104 119 15
12/06/2001 12H45 28 105 121 16
13/06/2001 O8H00 27 106 121 15

13/06/2001 12H00 28 106 120 14
14/06/2001 08H00 27 106 120 14
14/06/2001 12H30 28 106 120 14
15/06/2001 08H00 26 103 117 14
15/06/2001 12H00 28 104 117 13

18/06/2001 09H00 27 105 120 15
18/06/2001 12H30 27 108 122 14
19/06/2001 09H15 27 110 125 15
20/06/2001 10H00 26 108 124 16
20/06/2001 13H30 26 115 130 15

DOWN-
TEMPERATURE STREAM
DATE TIME READING IN READINGS
(cm) (cm)
(cm)
Depth at 90° V-Notcti = 224 mm (Velocity 1.94 m/s)
21/06/2001 09H15 25 180 200 20

21/06/2001 13H45 26 180 201 21
22/06/2001 09H00 25 180 203 23
22/06/2001 12H30 25 185 208 23
Distilled water added
02/07/2001 12H30 25 183 205 22
04/07/2001 08H30 25 179 200 21
04/07/2001 12H30 26 182 205 23

05/07/2001 10H00 25 183 205 22
05/07/2001 12H15 26 187 208 21
06/07/2001 08H30 24 182 204 22
06/07/2001 12H30 25 182 202 20
09/07/2001 09H30 25 182 205 23
09/07/2001 12H00 26 180 202 22
10/07/2001 08H30 26 179 200 21
10/07/2001 13H30 27 183 205 22
11/07/2001 09H30 25 180 202 22
11/07/2001 14H45 28 183 205 22
24/07/2001 09H00 20 178 200 22
25/07/2001 15H00 20 176 196 20
30/07/2001 08H30 21 174 195 21
31/07/2001 08H30 24 170 190 20
01/08/2001 08H00 25 180 202 22
02/08/2001 08H15 25 170 190 20
06/08/2001 13H00 26 172 194 22
07/08/2001 09H30 24 170 190 20
13/08/2001 09H45 25 170 191 21

DOWN-
TEMPERATURE STREAM
DATE TIME READING IN READINGS
(cm) (cm)
(cm)
Depth at 90° V-Notch = 264 mm (Velocity 2.9 m/s)
14/08/2001 15H30 30 350 391 40

15/08/2001 08H30 29 350 390 41
15/08/2001 14H00 32 347 385 38
16/08/2001 11H00 32 344 382 38
16/08/2001 15H45 33 344 383 39
17/08/2001 09H00 30 342 380 38
17/08/2001 14H0O 32 344 376 32
20/08/2001 09H00 32 335 370 35
20/08/2001 13H00 33 333 370 37
21/08/2001 08H30 33 334 370 36
21/08/2001 13H30 34 335 372 37
22/08/2001 08H00 32 338 374 36
22/08/2001 12H30 34 336 370 34
23/08/2001 10H00 32 335 370 35
23/08/2001 14H00 33 336 372 36
24/08/2001 07H45 33 334 370 36
24/08/2001 12H30 34 336 371 35
27/08/2001 10H30 34 337 371 34
27/08/2001 14H30 34 336 373 37
29/08/2001 09H30 32 345 383 38
30/08/2001 14H30 32 345 382 37
30/08/2001 08HOO 32 346 382 36
31/08/2001 13H30 31 350 384 34
31/08/2001 09H30 30 350 385 35

APPENDIX A-2
Leaching of Ca-ions from the Theewaterskloof Tunnel section
Volume Volume
*[EDTA] Ca (g) per Calcium
Date Time of water of *EDTA mol Ca pH-values
moW 50ml of water ppm
sample W
28-May 0.00125 0.05 0.0036 4.5E-06 0.00018 4.0 6.76
29-May 0.0025 0.05 0.0049 1.23E-05 0.00049 9.8 7.33
30-May 0.00125 0.05 0.0104 0.000013 0.00052 11.6 7.03
31-May 0.00125 0.05 0.01395 1.74E-05 0.000698 15.5 7.22
01-Jun 0.00125 0.05 0.0139 1.74E-05 0.000695 15.4 7.21
04-Jun 0.00125 0.05 0.0149 1.86E-05 0.000745 16.6 7.34
05-Jun 0.00125 0.05 0.01595 1.99E-05 0.000798 17.7 7.37
06-Jun 09:00 0.0025 0.05 0.0081 2.03E-05 0.00081 16.2 7.66
06-Jun 0.00125 0.05 0.01655 2.07E-05 0.000828 18.4
07-Jun 0.00125 0.05 0.0172 2.15E-05 0.00086 19.1 7.84
11-Jun 0.00125 0.05 0.0198 2.48E-05 0.00099 22.0 7.55
12-Jun 0.0025 0.05 0.0098 2.45E-05 0.00098 19.6 7.73
12-Jun 09:00 0.00125 0.05 0.0197 2.46E-05 0.000985 21.9
13-Jun 0.00125 0.05 0.0203 2.54E-05 0.001015 22.6 7.58
14-Jun 0.00125 0.05 0.0208 0.000026 0.00104 23.1 7.32
15-Jun 09:00 0.005 0.05 0.0061 3.05E-05 0.00122 24.4 7.64
15-Jun 0.00125 0.05 0.0212 2.65E-05 0.00106 23.6
18-Jun 0.00125 0.05 0.0235 2.94E-05 0.001175 26.1 7.44
19-Jun 09:15 0.00125 0.05 0.0182 2.28E-05 0.00091 20.2 7,52
20-Jun 09:00 0.005 0.05 0.0057 2.85E-05 0.00114 22.8 7.57
20-Jun 0.00125 0.05 0.0194 2.43E-05 0.00097 21.6
21-Jun 0.00125 0.05 0.0188 2.35E-05 0.00094 20.9 7.31
22-Jun 0.00125 0.05 0.0194 2.43E-05 0.00097 21.6 7.42
02-Jul 0.0025 0.05 0.0043 1.08E-05 0.00043 8.6 7.14
04-Jul 0.0025 0.05 0.0045 1.13E-05 0.00045 9.0 7.8
04-Jul 08:30 0.0025 0.05 0.0095 2.38E-05 0.00095 19.0

05-Jul 12:15 0.0025 0.05 0.01 0.000025 0.001 20.0 111
06-Jul 0.0025 0.05 0.0048 0.000012 0.00048 9.6 7.31

06-Jul 08:30 0.0025 0.05 0.0094 2.35E-05 0.00094 18.8
09-Jul 09:30 0.0025 0.05 0.0111 2.78E-05 0.00111 22.2 7.76

*[EDTA] Volume Volume

Ca (g) per Calcium
Date Time of water of *EDTA mol Ca pH-values
mol/f 50ml of water ppm
sample
w
10-Jul 13:30 0.0025 0.05 0.0115 2.88E-05 0.00115 23.0 7.8
11-Jul 14:30 0.0025 0.05 0.0117 2.93E-05 0.00117 23.4 7.92
24-Jul 15:00 0.0025 0.05 0.0167 4.18E-05 0.00167 33.4 7.38
30-Jul 0.0025 0.05 0.0058 1.45E-05 0.00058 11.6 7.74
31-Jul 08:30 0.0025 0.05 0.0117 2.93E-05 0.00117 23.4 7.67
01-Aug 08:00 0.0025 0.05 0.012 0.00003 0.0012 24.0 7.38
02-Aug 08:15 0.0025 0.05 0.0124 0.000031 0.00124 24.8 7.88
06-Aug 13:00 0.0025 0.05 0.014 0.000035 0.0014 28.0 7.38
07-Aug 09:30 0.0025 0.05 0.0146 3.65E-05 0.00146 29.2 7.31
13-Aug 0.0025 0.0045 0.0047 1.18E-05 0.00047 10.4
14-Aug 15:30 0.0025 0.05 0.0122 3.05E-05 0.00122 24.4 7.14
15-Aug 14:00 0.0025 0.05 0.013 3.25E-05 0.0013 26.0 7.28
16-Aug 15:45 0.0025 0.05 0.0134 3.35E-05 0.00134 26.8 7.23
17-Aug 09:00 0.0025 0.05 0.014 0.000035 0.0014 28.0 7.41
17-Aug 14:00 0.0025 0.05 0.0136 0.000034 0.00136 27.2
20-Aug 13:00 0.0025 0.05 0.0166 4.15E-05 0.00166 33.2 7.34
21-Aug 13:30 0.0025 0.05 0.0168 0.000042 0.00168 33.6 7.38
22-Aug 12:30 0.0025 0.05 0.0163 4.08E-05 0.00163 32.6 8.01
23-Aug 10:00 0.0025 0.05 0.0179 4.48E-05 0.00179 35.8 7.37
23-Aug 14:00 0.0025 0.05 0.0173 4.33E-05 0.00173 34.6
24-Aug 12:30 0.0025 0.05 0.0179 4.48E-05 0.00179 35.8 7.59
27-Aug 14:30 0.0025 0.05 0.0218 5.45E-05 0.00218 43.6 7.37
28-Aug 11:00 0.0025 0.05 0.0159 3.98E-05 0.00159 31.8 7.67
29-Aug 14:30 0.0025 0.05 0.0103 2.58E-05 0.00103 20.6 7.12
30-Aug 13:30 0.0025 0.05 0.0089 2.23E-05 0.00089 17.8 7.21
31-Aug 09:30 0.0025 0.05 0.0054 1.35E-05 0.00054 10.8 7.5
03-Sep 14:00 0.0025 0.05 0.0067 1.68E-05 0.00067 13.4 6.99
04-Sep 09:30 0.0025 0.05 0.0066 1.65E-05 0.00066 13.2 7.01
[EDTA] Concentration of Di-sodium Ethylenediamine Tetraacetate

APPENDIX A-3
Extraction from
Portland Cement Institute:
Tip no. 169
Predicting the Ca(OH)2 content and chemical vulnerability of pastes made with
different binders.
B J Addis
February 1989
Assumptions
• The calcium silicate hydrate (C-S-H) is always of the form C3S2H3, no matter
which binder it is derived from.
• The calcium silicate compounds in Portland cement hydrate fully.
Atomic Masses
Ca 40
0 = 16
H (hydrogen) =1
Si — 28
Al - 27
Fe = 56
Therefore: Ca(OH)2 = CH - 4 0 + 16 + 16+ 1 +1 =74
SiO2 = S - 2 8 + 16 + 16 = 60
CaO = C -40 + 16 = 56
H2O = H = 1 +1 + 1 6 = 18
AI2O3 = A = 27 + 27 +16 + 16+16 = 102
Fe2O3 = F = 56 + 56 + 16+ 16 = 160
C3S = 56 + 56 + 56 + 60 = 228
C2S = 56 + 56 + 60 = 172
C3A = 56 + 56 + 56 + 102 = 270
C4AF = 56 + 56 + 56 + 56 + 102 + 160 = 486

Reactions - Portland cement
2C3S + 6H — • C3S2H3 + 3CH
[456] [108] [342] [222]
Therefore 100 kg C3S produces 75 kg C3S2H3 and 48,7 kg CH
2C2S + 4H _ • C3S2H3 + CH
[344] [72] [342] [74]
Therefore: 100 kg C2S produces 99,4 kg C3S2H3 and 21,5 kg CH
C3A + C H + 1 2 H — • CjAH 13
[270] [74] [216] [560]
Therefore: 100 kg C3A consumes 27,4 kg CH
C4AF + 4CH + 22H - * • C4AH13 + C4FH13

[486] [296] [396] [560] [618]
Therefore: 100 kg C4AF consumes 60,9 kg CH
Fly-ash (pozzolanic reaction)

2S + 3CH —• C3S2H3
[120] [222] [342]
Therefore 100 kg of S reacts with 185 kg CH to produce 285 kg C3S2H3

APPENDIX A-4
Test data on the LHWP Tunnel section
TEMPERATURE UP-STREAM DOWN-TREAM DIFFERENCE IN

Date TIME
OF WATER (°C) READING (cm) READING (cm) READINGS (cm)
11-Sep-01 12H00 177 198 21

12-Sep-01 09H00 25 174 197 23
12-Sep-01 12H30 24 175 195 21
13-Sep-01 O9H00 23 174 195 20
13-Sep-01 13H30 19 179 200 21
14-Sep-O1 09H30 18 175 194 19
14-Sep-01 12H30 18 173 193 20
17-Sep-01 09H00 26 169 188 19
17-Sep-01 12H30 27 170 189 19
18-Sep-01 08H30 25 172 190 18
18-Sep-01 14H30 25 173 191 18
19-Sep-01 09H00 24 172 189 17
19-Sep-01 14H00 24 169 18
20-Sep-01 07H30 25 171 189 18
20-Sep-01 14HO0 24 174 192 18
21-Sep-01 07H30 24 172 190 18
21-Sep-01 13H00 25 173 192 19
27-Sep-01 170 186 16

28-Sep-01 10H00 20 185 206 21
15-Oct-01 10H30 225 250 25
16-Oct-01 08H00 26 227 257 30
17-Oct-01 08H00 27 225 255 30
19-OcK>1 08H00 25 225 254 29
22-Oct-01 11H30 28 227 256 29
23-Oct-01 09H00 29 227 255 28
24-Oct-01 08H00 28 225 252 27
25-Oct-01 08H00 29 225 251 26

TEMPERATURE UP-STREAM DOWN-TREAM DIFFERENCE IN

Date TIME
OF WATER (CC) READING (cm) READING (cm) READINGS (cm)
26-Oct-01 12H00 27 227 253 26
29-Oct-01 11H00 25 228 254 26
30-Oct-01 11H30 26 226 251 25

31-Oct-01 14H30 25 227 252 25
O1-Nov-O1 08H00 26 226 252 26
02-Nov-01 08H0O 26 228 254 26

13-Nov-01 370 413 43
Depth at 90" V-Notch = 257 mm (Velocity 2,73 m/s)
14-NOV-01 14H00 25 39J 424 30

15-NOV-01 11H00 26 395 424 29
16-NOV-01 08H00 25 388 417 29
20-Nov-01 10H00 25 287 317 30

APPENDIX A-5
Leaching of Ca-ions from the LHWP Tunnel section
*[EDTA] Volume Ca (g) per

Volume of Calcium
Date of water mol Ca 50ml of pH-values
mol/^ *EDTA (i) ppm
sample water
11-Sep 0.00125 0.05 0.00855 1.06875E-05 0.000428 9.499905

12-Sep 0.00125 0.05 0.01775 2.21875E-05 0.000888 19.72203 7.4
13-Sep 0.00125 0.05 0.0189 0.000023625 0.000945 20.99979 7.39
14-Sep 0.00125 0.05 0.01915 2.39375E-05 0.000958 21.27757 7.52
17-Sep 0.00125 0.05 0.0209 0.000026125 0.001045 23.22199 8.13
18-Sep 0.00125 0.05 0.023 0.00002875 0.00115 25.5553 7.67
19-Sep 0.00125 0.05 0.0256 0.000032 0.00128 28.44416 7.63
20-Sep 0.00125 0.05 0.03015 3.76875E-05 0.001508 33.49967 7.82
21-Sep 0.00125 0.05 0.0165 0.000020625 0.000825 18.33315 7.99
28-Sep 0.00125 0.05 0.0196 0.0000245 0.00098 21.77756 6.98
01 Okt 0.00125 0.05 0.0174 0.00002175 0.00087 19.33314 7.92
15-Oct 0.00125 0.05 0.0232 0.000029 0.00116 25.77752 7.76
16-Oct 0.00125 0.05 0.0244 0.0000305 0.00122 27.11084 111
17-Oct 0.00125 0.05 0.0252 0.0000315 0.00126 27.99972 7.03
19-Oct 0.00125 0.05 0.0155 0.000019375 0.000775 17.22205 7.65
22-Oct 0.00125 0.05 0.0183 0.000022875 0.000915 20.33313 7.84
23-Oct 0.00125 0.05 0.0186 0.00002325 0.00093 20.66646 7.81
24-Oct 0.00125 0.05 0.0173 0.000021625 0.000865 19.22203 7.77
25-Oct 0.00125 0.05 0.0184 0.000023 0.00092 20,44424 7.78
26-Oct 0.00125 0.05 0.0194 0.00002425 0.00097 21.55534 7.92
29-Oct 0.00125 0.05 0.0217 0.000027125 0.001085 24.11087 8.2
30-Oct 0.00125 0.05 0.0231 0.000028875 0.001155 25.66641 8.17
31-Oct 0.00125 0.05 0.026 0.0000325 0.0013 28.8886 8.17
01-Nov 0.00125 0.05 0.0259 0.000032375 0.001295 28.77749 8.15
02-Nov 0.00125 0.05 0.0284 0.0000355 0.00142 31.55524 8.23
14-Nov 0.00125 0.05 0.0206 0.00002575 0.00103 22.88866 7.73
15-Nov 0.00125 0.05 0.0203 0.000025375 0.001015 22.55533 7.76
16-ISIov 0.00125 0.05 0.0194 0.00002425 0.00097 21.55534 8.01
20-Nov 0.00125 0.05 0.023 0.00002875 0.00115 25.5553 8.37
* [EDTA] Concentration of Di-sodium Ethylenediamine Tetraacetate

APPENDIX A-6
Laboratory test pipe corrosion data
Pump running Samples taken Measurements Water volume
Ace Overflow Depth at Water Total

Date Time Duration Temperature Flow (l/s) Velocity
duration height (mm) pump added (I) volume (I)
3-Oct 0:10 22CC 5100.00
2:00 D.08 3.08 23=C 40 0.57 160 5055,01

C
3:00 0.04 3.12 24 C 180 19.81 1.12 5030,48
4:30 0.06 0.18 24=C 186 21.50 1.22 4993.67

C
15:45 D.05 0.23 26 C 185 21.21 1.20 4963.00
4-Oct 8:15 24 C 188 22.08 1.25
12:45 0.19 0.42 26°C 185 21.21 1.20 4852.58
17:00 0.18 0.60 27°C 4748.30
5-Oct 8:00 25°C 185 21.21 1.20
14:45 0.28 0.88 29 : C 4582.67
17:00 0.09 0.97 30C 4527.46
6-Oct 8:20 27°C
12:45 0.18 1.16 30°C 4419.08
18:00 0.22 1.38 32°C 4290.26
7-Oct 11:00 29'C 186 21.50 1.22
17:00 0.25 1.63 30°C 4143.04
8-Oct 10:30 26°C 185 21.21 1.20
18:30 0.33 1.96 26°C 3946.74
9-Oct 8:15 24°C 185 21.21 1.20

|;
12:00 0.16 2.11 28 C 3854.72
17:00 0.21 2.32 29= C 3732.04
10-Oct 8:00
18:00 0.42 2.74 3486.66
11-Oct 7:45
12:00 0.18 2.92 3382.38
18:45 0.28 3.20 3216.75
12-Oct 8:30
17:20 0.37 3.57 3000.00

Pump running Samples taken Measurements Water volume
Date Time Ace Overflow Depth at Water Total

Duration Temperature Flow (l/s) Velocity
duration height (mm) pump added (I) volume (I)
14-Oct 10:00 2100 5100.00

16-Oct 7:30 1.90 5,46 4191.34
18:30 0.46 5.92 3971.66
17-Oct 7:45 0.55 6.47 3707.05
17:00 0,39 6.86 3522.32
18-Oct 7:30 0.60 7.46 3232.75
20-Oct 7:15 27JC 1867.25 5100.00

21-Oct 11:00 1.16 8.62 30°C 185 21.21 1.20 650 4998.15
23-Oct 17:00 2.25 10.37 28=C 177 18.99 1.07 520 4556.80
24-Oct S:00 0.54 11.41 29°C 178 19.26 1.09 460 4353.10
17:00 0.46 11.87 33 °C 4200.00
a
25-Oct 7:45 0.61 12.48 B0 C 178 19,26 1.09 370 4047.55
16:00 0.34 12.83 34°C 3S50.00
r
26-Oct 9:00 0.71 13.53 30 C 178 19.26 1.09 280 3742.00
17:30 0.35 13.89 31 °C 200 3470.40
28-Oct 9:00 25°C 580 1290.1 4760.50

30-Oct 7:30 1.94 15.83 31 °C 179 19.53 1.11 400 4149.40
17:15 0.41 16.23 33°C 4020.00
3
31-Oct 7:00 0.57 16.81 29 C 177 18.99 1.07 310 3843.85
16:30 0.40 17.20 31 °C 3750.00
1-Nov 7:45 0.64 17.84 29°G 176 18.73 1.06 240 3606,20
15:00 3.30 18.14 29°C 3500.00

APPENDIX A-7
CaO content in concrete sample of core drilled at Theewaterskloof Tunnel
Vol
solution Vol Moles CaO/1 OOg
Sample Mass (ml) [EDTA] EDTA CaO CaO (g) sample
1 (0-3mm) 5 250 0.02 0.031 0.0062 0.3472 6.944
2 (7-10mm) 5 250 0.02 0.0425 0.0085 0.476 9.52
3 (14-17mm) 5 250 0.02 0.0425 0.0085 0.476 9.52
4 (21-24mm) 5 250 0.02 0.0375 0.0075 0.42 8.4
5 (28-32mm) 5 250 0.02 0.0358 0.00716 0.40096 8.0192
6 (35-39mm) 5 250 0.02 0.0422 0.00844 0.47264 9.4528
7 (42-46mm) 5 250 0.02 0.0375 0.0075 0.42 8.4
8 (48-53mm) 5.51 250 0.02 0.041 0.0082 0.4592 9.184
9 (56-60mm) 5 250 0.02 0.0449 0.00898 0.50288 10.0576
10(63-67mm) 5.179 250 0.02 0.0358 0.00716 0.40096 8.0192
11 (210-213mm) 5 250 0.02 0.037 0.0074 0.4144 8.288

APPENDIX B
Biological analysis on LHWP DTN sediment
Sasson, Visagie & Malan 181 October 2002

Results and report-back: analyses performed on sediment

sample
Ref. - [Project: WRC tunnels (microbiological and SEM analyses)]
It is my pleasure to inform you of the results obtained after analyses performed on a

sediment sample delivered to me on 28 October 1999 by yourself. The sample was a
dark sediment in the form of a slurry from a concrete pipe.
A) Materials and Methods:
The following analyses were performed on the sample:
Microbiological analyses:
a) total aerobic bacterial count using Nutrient Agar (Merck) with 50 mg/l
cycloheximide to inhibit fungal and yeast growth;
b) total anaerobic heterotrophic count using Reinforced Clostridial Medium (Merck)

with titanium chloride (Merck) as a reducing agent;
c) total yeast and fungal count using Potato Dextrose Agar (Merck) with 250 mg/l
chloramphenicol to inhibit bacterial growth;
d) Sulphate Reducing Bacteria (SRB) using Iron Sulphite agar (Oxoid) with titanium
chloride as a reducing agent;
e) Thiobacillus ferrooxidans count using ferrous sulphate medium (Karaivko ef a/.,

1977);
All counts were performed after incubation for two weeks at room temperature, except
the total aerobic bacterial count and the total yeast and fungal count, performed after
incubation at room temperature for 48 hours.
Scanning Electron Microscopy (SEM):
SEM was performed using standard preparation procedures (2.5% glutaraldehyde as

fixative in 0.075 M Phosphate Buffered Saline (PBS), immobilization of sample on 0.2îm
filter, washing with 0.075 M PBS, drying with ethanol series, critical point drying, coating
with gold).

B) Results and discussion:
Table 1: Results for analyses done on sediment sample.
Analysis Average Standard deviation
Total aerobic bacterial count (cfu/g) 1.52x106 2.53x105
Total anaerobic heterotrophic count (cfu/g) 2.28x10 4 3.77x103
Yeast count (cfu/g) 1.45x103 6.19x102
Fungal count (cfu/g) 5.00x10 3 8.28x102
SRB count (cfu/g) 2.00x10 4 4.08x103
Thiobacillus ferooxtdans count (cfu/g) <100 -
For the SEM work, photos and digital images were obtained. Photo negatives and
contact prints, as well as digital images on a CD-ROM are included with this report.
SEM indicated the presence of at least three kinds of diatoms, as well as yeasts, fungal
hyphae and rod-shaped and coccoid bacterial cells (Figures 1 to 4).
Figure 1: Rod shaped and coccoid bacterial cells.

Figure 2: A yeast cell.
Figure 3: A rod-shaped cell.
Figure 4: A diatom.

Figure 5: Rod-shaped bacterial cells
The aerobic bacterial count was high (1.52x106 cfu/g). At least nine different bacterial
species could be observed macroscopically.
Anaerobic heterotrophic counts (2.28x1015 cfu/g) were almost two log-units lower than the
total aerobic bacterial counts. Anaerobic growth at low dilutions was dominated by
fermenters, with high levels of gas produced. At higher dilutions, non-fermenters
dominated with little gas produced. Microscopic observation indicated the incidence of
rod-shaped spore formers with round to oval sub-terminal spores.
A low incidence of yeasts and fungi was observed (1.45x103 and 5.00x103 cfu/g
respectively). Macroscopically, at least seven fungal and one yeast species could be
observed.
A low incidence of SRB was observed (2.00x104 cfu/g). These organisms are able to
use oxidized sulphur compounds and reduce these to sulfide which can react with metals
to form black precipitates of metal sulphides, thereby causing microbially induced
corrosion.
No growth of Thiobacillus ferooxidans was observed. The incidence of organic material

in the agar used to select for these autotrophic organisms could have inhibited their
growth.
Concrete can be dissolved by thiobacilli, causing major structural damage to highways

and concrete sewage lines (Prescott et a/., 1990). In the presence of sufficient moisture
and pyritic sulphur compounds of lower oxidation state than sulphate, these microbes
produce sulphuric acid, resulting in the dissolution of concrete. Thiobacilli can be
controlled by the selection of cements that do not contain appreciable levels of oxidizable
sulphur compounds, the avoidance of contamination of concrete with soil microbes, and
the use of organic inhibitors.
In general, there was concern over sampling and transport of the sediment sample.
Firstly, it would be advisable to use a sterile container for sampling, as well as using
aseptic sampling techniques. Secondly, samples should be kept in a cold chain of 4°C
until delivery to a suitable lab for analyzing. There were doubts about the two
prerequisites stated above. Also, to get a representative sample of a biofilm in a
concrete pipe, it would be advisable to scrape the biofilm off the top and sides of the pipe
sampled without including interfering sediment in the sample.

With all the points above taken into consideration, there are doubts as to the validity of all
the analyses performed on the sample in regard to biodeterioration of the concrete pipe
and results should be seen only as an indication of conditions inside the pipe as well as
inside the sediment in the pipe. No final conclusions about the role of the sediment itself
should be drawn to the possible biodegradation of the concrete pipe by microbes. Other
phenomena like structural defects as well as speed of water flow, amount of sediment
etc. should also be taken into consideration.
It is likely that not only Thiobacillus ferooxidans and other thiobacilli, but a variety of
organisms selected for in a biofilm could cause biodeterioration of concrete, mainly by
production of secondary metabolites like organic acids by anaerobic metabolism inside
the biofilm (Prescott etal., 1990).
The lack of Thiobacillus ferooxidans does not indicate the absence of other thiobacilli. it
is suggested that more sensitive methods be used in future to indicate the presence of
thiobacilli. These methods include the use of statistical methods to determine the Most
Probable Number (MPN) or molecular probing techniques like Fluorescent In Situ
Hybridization (FISH).
C) Conclusions:
No final conclusions about the role of microbes in the biodeterioration of concrete pipes
must be drawn from the analyses performed on the sediment sample provided. A much
more detailed and in-depth study should be conducted to investigate the possibility of
specific microbes causing microbially induced corrosion of the concrete pipe. The high
microbial numbers in the sediment sample does indicate the possibility of anaerobic
microbes forming part of anaerobic biofilms and, thus, possible biocorrosion of the
concrete pipe. It is also suggested that wash-down of sediment and soil be minimized by
whatever means possible as the presence of sediments in the pipe creates a habitat
suitable for the growth of microbes. Manual cleaning of pipes (for example pigging)
and/or the possible introduction of organic inhibitors or non-ionic biocides can also be
recommended.
DJ Oosthuizen.
D) References:
Prescott, L.M., Harley, J.P. and Klein, D.A. (1990). Microbiology. Wm. C. Brown
Publishers, Iowa.
Karaivko, G.I., Kuznetsov, S.I. and Golonizik, A.I. (1977). The bacterial leaching of
metals from ores. Technicopy, England.
• • • •

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Dealing with Tunnel Ageing

Water Research Commission

GR BASSON, M V1SAGIE, JG MALAN

Ninham Shand (Pty) Ltd

WRC Report No. 1088/1/03

EstatJng D a n s and Infterlba&in

Basson, Visagie & Malan October 2002

• Hydraulic ageing is caused by sediment deposition consisting of fine cohesive

• A relationship was developed and calibrated to determine the effective hydraulic

• An ultimate hydraulic roughness equation was developed and calibrated. A probable

• Mechanical cleaning of a tunnel in soft water conditions is not recommended since it

• Tunnel linings such as poly-urethane can be considered in conditions of soft water

Basson, Visagie & Malan » October 2002

Basson, Visagie & Maian in October 2002

Basson. Visagie & Malar iv October 2002

Mr DS van der Merwe Water Research Commission (Chair person)

Mr P D Pyke Department of Water Affairs and Forestry

Mr N J van Deventer Department of Water Affairs and Forestry

Prof SJ van Vuuren University of Pretoria

Prof A Rooseboom University of Stellenbosch

Prof GGS Pegram University of Natal

Mr D Hodgkinson Umgeni Water

MrJRMetcalf Keeve Steyn Consulting Engineers

Mr J McKeivey Keeve Steyn Consulting Engineers

Mr D Trebicki Rand Water

Mr BC Viljoen VKE Engineering (Pty) Ltd

Mr A Tanner Ninham Shand (Pty) Ltd

Basson, Visagie & Malan October 2002

4 TYPES OF HYDRAULIC AGEING AND CONCRETE

6 SOFTWATER AGGRESSIVENESS INDEX 60

8.4 Concrete design 136

9 LHWP TUNNEL RATE OF AGEING AND ULTIMATE

Basson, Visagie & Malan 2 October 2002

Figure 1-1 Water transfer schemes in South Africa

Basson, Visagie & Malan 3 October 2002

Figure 6.1-1 Soft water zones in ground water in South Africa

Basson, Visagie & Malan 4 October 2002

Figure 8.1.2-14 Orange-Fish roughness shaft 6 to 7a (2001)

Basson, Visagie & Malan 5 October 2002

Figure 8.2.1-4 Tunnel cleaning machine inside Colorado MWD tunnel

Basson, Visagie & Malan October 2002

Basson, Visagie & Malan October 2002

Table 8.7-1 Historical tunnel costs

Basson, Visagie & Malan October 2002

Basson, Visagie & Malan 9 October 2002

y depth measured from the bottom

To Bed shear stress

Basson, Visagie & Malan 11 October 2002

Cape tow. I;-, > 500

Figure 1-1 Water transfer schemes in South Africa

Basson, Visagie & Malan 12 October 20O2

Basson, Visagie & Malan 13 October 2002

• Theoretical analysis which investigated the interrelationship between the ageing

• Field investigation of the Orange-Fish Tunnel and LHWP Tunnel, and

• Hydraulic investigation of remedial measures:

Mechanical cleaning of the tunnel. Investigation of roughness reduction and

Other: Chlorination, UV sterilization and relining alternatives were investigated.