ICS 27.

140
P59

Record No.: J4172005

Electric Power Industry Standards of the People's Republic of

China

F DL I T 5207 -2005

Technical specification for abrasion and cavitation

resistance of concrete in hydraulic structures

Published on 14/02/2005; Implemented on 01/06/2005;

Issued by People's Republic of China's National Development and Reform
Commission
 DL I T 5207 -2005

Contents

Preface ..........................................II
1 Scope...............................................1
2 Normative references .....................2
3 Terms and definitions............................3
4 General ........................................4
5 Hydraulics and hydraulic project design ...................5
6 Materials......................................................................9
7 Construction ..........................................................12
8 Maintenance and repairs .......................................15
9 Quality control and approval .....................................18
Annex A (normative) Abrasion resistance test method.....................21
Annex B (information type) sediment flushing structures initiative cavitation number
estimation.............25
Annex C (normative) Cavitation resistance test method....................31
Annex D (normative) Hydraulic concrete iron ore aggregate quality requirements ..34
Annex E (Normative) Hydraulic concrete cast stone aggregate quality requirements .35
Notes................................................37
DL/T 5207 -2005

Preface

The Standards is developed according to previous Notice of Electricity Industry Standard

Formulation and Revision Plan issued by the State Economic and Trade Commission (Electricity [2001]
No. 44).
Sediment flushing structures in hydraulic and hydropower projects are important architectures
that concerns project safety. The sediment flushing structures that have been built so far in China are
generally safe, but due to high speed water flow, abrasion and cavitation against those structures often
occur, directly and indirectly influence safe operations of projects, and maintenance and repair coast are
huge. Based on decades' experience in the technical aspects of abrasion and cavitation resistance of
China's sediment flushing structures, together with relevant standards and literature from abroad, the
Standards is developed after necessary tests.
Annexes A, C, D, E are normative and Annex B is information type.
The Standards is proposed by Federation of China Electricity Enterprises.
Electricity Industry Hydropower Construction Standardization Technical Committee is
responsible for interpretation of the document.

The document is mainly developed by Nanjing Hydraulic Science Research Institute.

Participating unit: Guiyang Investigation and Design Institute, China Hydropower Engineering
Consulting Group
Main authors: Lin Baoyu, Zhen Zhi, Cai Yuebo, Wang Yi, Lu Hong, Li Yajie, Zhang
Yuanzhu.
 DL / T 5207 -2005

1 Scope

The Standards sets up principles of designing, construction, maintenance and operations

of abrasion and cavitation resistance in hydraulic structures.
The technical specifications are for water flow velocities < 40m/s.
DL I T 5207 -2005

4 General

5.2 Abrasion resistance design

5.2.1 When designing sediment flushing structures, in rivers full of silt and sand shall collect data
on sand concentration, sand particle shape, size and hardness, mineral composition, law of density
current movement etc. Bed load river shall collect data on bedload number, particle size and its
movement pattern. Where there is ice in the flow, data on size of ice and its movement pattern shall
be collected to analyze its impact on wearing out concrete surface.

5.2.2 For water intake structures that has bedload rivers of low import, sediment trapping and flow
drainage guiding measures should be set in the upstream.

5.2.3 Avoid disposal in the vicinity of the entrance to sediment flushing structure and by the bank of the
head of the reservior. There shall be design for dismantling of the upstream and downstream cofferdams,
to prevent the abrasion of carbide slag against concrete and causing cavitation.

5.2.4 Desilting facilities should be set up near the entrance of sediment flushing structures built in silt
laden rivers.

5.2.5 Protection shall be set up for the side slope of sediment flushing structure and the slope of exit
bank to prevent stones from dropping or rolling into the tank, and to prevent severe abrasion of
whirlpool and circular flow containing sand and stones caused to stilling basin, apron, plunge pool,
tailrace (tube) and other structures.

5.2.6 The backplane of dam gate outlet structures built in bedload and sediment-laden rivers shall
adopt the form of rapids geosyncline that links the slope and the apron. Stilling basin for underflow
energy dissipation should be the apron of non-supplementary dissipater.

5.2.7 Where the angle between the direction of sand-laden high speed flow and side wall plane of
structures is greater than 10 degrees, you should raise the strength level of the side wall's concrete.

5.2.8 Thickness of abrasion resistant concrete steel protective layer shall not be less than l0 cm, and
steel bar near the surface should be parallel to the flow direction.

5.2.9 Thickness of anti-abrasion concrete side wall shall not less than 20cm, and thickness of
bottom plate should not be less than 30cm.

5.2.10 Where the velocity of bedload flow is greater than 10m/s or suspended load matter
concentration is greater than 20kg/m3 (average during main flood season) and the water flow
velocity is greater than 20m/s, at least one test method in Annex A shall be used, according to the
project conditions, to carry out concrete abrasion resistance test, and compared to select abrasion
resistant materials.
Optimizing tests shall be conducted to determine each proportion of the materials including silica
fume, fly ash, and ground slag.

6.3.2 For projects with abrasion from bed load, the choice of strength classes of concrete can be
based on the maximum velocity and average sediment concentration, accompanying with
optimization tests for abrasion resistance.

Table 6.3.2 Strength classes of bed/suspended load abrasion resistance concrete

Flow cavitation >1.5 1.5~ > 0.6 0.6~0.3 < 0.3F
coefficient
Flow velocity m/s <15 15~25 >25~35 >35
Sediment >2 2 >2 2 >2 2 >2
concentration
kg/m3
Strength Class C35~C40 C35 C40~C50 C40 C50~C60 C60 C60
Note:
1. for sediment flushing structure, the choice of concrete strength grades shall be based on the case
when sediment concentration is > 2kg/m3
2. When suspended load is > 2kg/m3, concrete strength shall be 1~2 levels higher (every 5MPa as a
level).

6. Go through optimization test. In the test, one shall use fly ash, silica fume and ground slag.
Maximum recommended dosages of them shall not exceed those shown in the following
table.
Concrete > C50 shall use Grade I fly ash, but can also use Grade II fly ash (with Water
demand ratio 100%, fineness 15%, and loss on ignition < 3%)

Table 6.3.3 Active supplementary admixtures (maximum content)

Active admixtures % of cementitious materials weight
Fly ash 25
Ground slag 50
Silica fume 10
fly ash + Ground slag + silica fume 50
fly ash + silica fume 35
 Annex A
(Normative Annex)
Test Method for Abrasion Resistance

A.1 Underwater steel ball abrasion test method

Refer to DL/T 5150 Concrete Abrasion Resistance Test (underwater steel ball method)

A.2 Sand-blasting gun abrasion test method

Refer to DL/T 5150 Concrete Abrasion Resistance Test (Sand-blasting gun method)

A.3 Silt-laden water flow test method

Refer to DL/T 5150 Concrete Silt-laden Water Flow Erosion Resistance Test (Ring method)

A.4 Abrasion test against water sand

A.4.1.1 Aim and Scope: to measure the abrasion resistance capacity of concrete against high speed
sand-laden water flow, to evaluate abrasion resistance performance of concrete and other materials.
A.4.1.2 Rationale: when water body that contains a certain amount of sand goes through water
pumping vane, helical vane and splitter vane, it will form high speed sand-laden flow. The flow
ejects onto the surface of test piece and cause abrasion against the material.

A.4.2. Main test device

A.4.2.1 Rotary water sand abrasion machine: structure as shown in A.1
 1 Rotating shaft, 2 test piece, 3 splitter vane, 4 helical vane,
5 water absorbing tube, 6 water pumping vane
A.1 Schematic graph of rotary water sand abrasion machine

A.4.2.2 Main technical parameters of the device are as follows:

1 Rotating shaft: standard rotating speed: 1320r/min. Use mechanical or electrical means if needed
to change rotating speed so as to change sand-laden water flow abrasion speed.

2 splitter vane: four vanes vertically fixed onto the rotating shaft, radius of outer edge is 208.6mm.
When rotating shaft reaches a speed of 1320r/min, circumferential tangential velocity of the sand-
laden water flow (abrasion speed) is 28.8m/s.
3 helical vane: fixed onto the rotating shaft, diameter 80mm, interval spacing 30mm.
4 water absorbing tube: diameter 110mm, height 350mm.
5 electric motor: 4.0kW, rated rotation speed 1440r/min, connected to rotating shaft via V-belt

A.4.2.3 Scale: weight 10kg, sensitivity 0.1g

A4.2.4 Abrasion material: Fujian Pingtan hard smelt quartz sand, particle size range:0.63mm-
0.16mm
A.4.2.5 concrete test piece: height 150mm, thickness 96mm, radius of internal arc 212mm, arc
length 111mm. Height of test piece being abrased 90mm, area of each test piece being abrased 100
cm2.
Three concrete test items as a group, each time can conduct four groups test. Test items shape and
distribution are shown in A.2

1 test items, 2 rotating vane, 3 splitter vane,

4 segregating ring for test items, 5 water absorbing tube
A.2 Schematic graph of concrete test items and distribution

A.4.3 Procedures
A.4.3.1 For how to mix concrete mixtures and mold and maintain test items, refer to relevant
stipulations in DL/T 5150.
A.4.3.2 Two days before test age, test items were put into water so as to be soaked fully.
A.4.3.3 Fill water and abrasion material into the test machine.
Normative rate of sand contained in the abrasion material = sand for abrasion / (water + sand for
abrasion) = 3.0%
the rate of sand contained can be adjusted according to need, but the rate shall not exceed 6%, and
shall be noted in the report.
A.4.3.4 While testing, take test items out of water, use wet towel to wipe away water on the surface.
Weight to exact to 0.1g. Note down as weight prior to abrasion.
A.4.3.5 Put test items on segregating ring, and keep the arc surface close to internal edge of the
ring. Adjust the evenness of the internal arc surface. Fix screws tightly and cover ruber pad and
screw lid tight.
A.4.3.6 Start electric motor and record the starting and finishing times of abrasion test.
A.4.3.7 For evry 60min' abrasion, stop the machine and take out test items. Flush clean with water
and wipe away water on the surface. Weight it to exact to 0.1g. Note down weight after the
abrasion. Measure the width and depth caused by abrasion, and record them.
A.4.3.8 Change abrasion material (change both water and abrasion sand). Repeat the test 10 times
(i.e. Accumulative abrasion 10h), and test ends. If the depth caused by abrasion is no less than 5
mm, you can end the test too. You can increase test times if needed and note down in the report.

A.4.4 Test results

A.4.4.1 Abrasion rate of concrete against sand-laden water flow is caculated as below
N = (M0 Mt) / St (A.1)
where,
N Abrasion rate, weight be abrased over a unit area within a unit time, kg/(h.m2);
M0 weight of test items prior to abrasion test, kg;
Mt weight of test items after t h of abrasion test, kg;
t accumulative duration of abrasion, h;
S abrasion area of test items, m2; for normative test items, abrasion area is 0.01 m2.
A.4.4.2 Abrasion strength of concrete against sand-laden water flow R (hm2/kg), i.e., hours needed
to abrase away 1kg per unit area, is caculated as below:
R = 1/N (A.2)
A.4.4.3 Test result is the arithmetic mean of values taken from three test items as a group. When the
difference between a test value and average exceeds 15% of average, this test value shall be
removed, and average two test values as the final result. If in a group less than two values is
adopted, then the test shall be redone.