Behaviour of Large Underground Cavern during Construction in Himalayas

– A Case Study 124

Behaviour of Large Underground Cavern during Construction in

Himalayas – A Case Study
SRIPAD R N AIK 1 , V R S ASTRY 2
1
National Institute of Rock Mechanics, Bangalore-560016, India
2
Department of Mining Engineering, NITK, Surathkal, Srinivasanagar-575025, India
Email: sripad_naik@yahoo.com, vedala_sastry@yahoo.co.in

Abstract: Construction of large underground caverns in Himalayas is challenging due to complex geological and
in-situ stress conditions. Understanding the behaviour of such caverns during construction stage is possible only
with extensive instrumentation. A case study of a large cavern under construction in Himalayan region in Bhutan is
considered. Results from various types of instruments are discussed in this paper. Instrumentation data shows that
Himalayan rock mass particularly with phyllitic quartzite exhibits large deformations thus requiring careful
selection of support and excavation methodology.

Keywords: Instrumentation, Large Cavern, Wall Convergence, Multipoint Borehole Extensometer, Load Cells,
Himalayas, Rock Bolt Failure.

1. Introduction tunnel going up to the surface on the downstream of

transformer hall. The transverse section of the
There are many large underground caverns under
powerhouse complex is shown in Figure 1.
construction in Himalayan region. Construction of
caverns in this region poses engineering challenges
partly due to varying complex geology and in-situ
stresses. In order to study the behaviour of the caverns
during construction stage, a detailed instrumentation
programme was taken up at one of the caverns in
Himalayas (Naik et al, 2010, 2011). The instrumentation
studies carried out at Powerhouse caverns of Tala
Hydroelectric Project, Bhutan, during the construction
are discussed in this paper. This paper mainly discusses
results from various instruments installed and monitored
during the construction of the machine hall caverns.
Figure 1. Cross Section of Powerhouse Complex, Tala
Tala Hydroelectric Project is a 1020 MW run of the Hydroelectric Project, Bhutan
river scheme in Bhutan on river Wangchu in Chukha
Dzongkagh of Western Bhutan immediately 2.Geological and Geotechnical Details of Powerhouse
downstream of Chukha Hydroelectric Project. The Complex
project utilises 861.5m of head available from Chukha
The powerhouse complex is situated in a hillock with
downstream to Tala Powerhouse. The underground
overburden ranging from 400m - 500m. The host rock is
powerhouse complex consists of two main caverns, the
fresh and hard, inter-banded sequence of quartzite,
machine hall cavern of size 206.4m x 20.4m x 44.5m ,
phyllitic quartzite and amphibolite schist partings. These
and the transformer hall cavern of size 191m x 16m x
rocks are highly puckered and folded into tight synform
24.5m separated by a 40m pillar. Two caverns are
and antiform. Major discontinuity features are mapped
interconnected by three bus ducts of 11m width and
from the exploratory drift of 2m x 2m driven in N37 oW-
8.5m height, one passage tunnel of size 8.1m x 8m
S37oE direction, along the crown of the machine hall
dimensions and another passage tunnel of 4.6m x 5.5m
cavern. In addition to the foliation, another five sets of
dimensions. Machine hall is also connected to 6
joints were identified. The general foliation trend varies
numbers of pressure shaft manifolds of size 4.5m x
from N65oE-S65oW to N70oW-S70oE with 35o to 60o
5.5m each, on the upstream wall and 6 numbers of tail
N25oW to N20oE dips. The details of major
race tunnel manifolds of size 6.5m length and 8m height
discontinuities are listed in Table 1 (Singh et al, 2002).
on the downstream wall. Two tunnels, Main Access
The plunge of the folds recorded at RD16m (25o/270o),
Tunnel and Construction Adit provide access to the
RD 93m (18o/56o), RD 128m (10o/90o), RD 143m
machine hall. There is also one drainage gallery of 3m x
(15o/130o) and at RD 183m (10o/88o). The long axis of
4m surrounding the machine hall. There is a cable
the powerhouse in N37oW-S37oE direction is across the

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 Behaviour of Large Underground Cavern during Construction in Himalayas
– A Case Study 124

strike of foliation. Due to folding, the angle between the long axis of powerhouse and the strike of formation
varies from 150o to 55o.

Table 1. Major Discontinuities in machine hall cavern

S. No Strike Dip Spacing Continuity Nature
Foliation N65°E-S65°W to 35°-60° 10cm - 3m 5 - 12m R.U
N70°W-S70°E N25°W to N20°E
J1 N20°W-S70°E to 40°-80° 1m - 2m 2 - 5m R.U
N15°W-S75°E N70°E to N75°E
J2 N-S to 25°-80° 5cm - 2m 2m - 10m R.U
N30°E-S30°W W to N60°W
J3 N30°E-S30°W to 30°-50° 6cm - 20cm 2m R.P
N20°E-S20°W S60°E to S70°E
J4 N50°W-S50°E to 60°-70° 10cm - 2m 2m - 5m S.P
N30°W-S60°E S40°W to S60°W
J5 N80°E-S80°W to 40°-70° 20cm - 2m 2m - 5m R.P
N70°W-S20°E S10°E to S20°W
RU -Rough Undulating, RP - Rough Planar, SP - Smooth Planar

2.1. Rock Mass Parameters
Mapping of machine hall and transformer hall was
carried out by Tala Project geologists.
Table 2. Properties of intact rock
taken for further design calculations. The physico-
mechanical properties of phyllitic quartzite and quartzite
were determined by National Institute of Rock
Mechanics (NIRM) (Anon, 2001). The properties are
listed in Table 2.

Property Phyllitic Quartzite Quartzite 2.2. In-situ Stress

Dry Saturated Dry Saturated NIRM carried out in-situ stress measurement at the
Density, kg/m3 2650 2650 - - powerhouse drift. The stress measurement indicated
Uniaxial 63.17 51.90 - - following stress regime.
Compressive
Strength, MPa Vertical stress = 10.9MPa (calculated from over burden
Young’s Modulus, 18.35 12.93 70.6 61.24 weight)
GPa Minimum horizontal stress = 9.5MPa (approximately
Poisson’s ratio 0.35 0.36 0.18 0.19 normal to cavern axis)
Cohesion, MPa 18.56 15.71 - - Maximum horizontal stress = 14.2MPa (approximately
parallel to cavern axis)
Friction Angle, deg 28.86 28.33 - -
Hoek and Brown 4.18 4.49 - - 3. Excavation of the Powerhouse Complex
constant ‘m’
3.1. Excavation of Machine Hall Cavern
Joint Normal 10.4 The excavation of Machine Hall started with excavation
Stiffness, GPa/m of 7m wide central gullet. The height of the central
Joint Shear 0.97 gullet was 7.5m with invert level at 531m. The 206.4m
Stiffness, GPa/m long central gullet was completed in 102 days. The
Joint Cohesion, 0 gullet was supported with 6m and 8m long rock bolts of
MPa 32mm diameter at 3m x 1.5m pattern. A layer of Steel
Joint Friction angle, 25 Fibre Reinforced Shotcrete (SFRS) varying in thickness
deg from 50-100mm was applied after installation of rock
bolts. The central gullet was mainly driven through
It was reported that the rock mass is of Fair to Good fresh, hard, moderately jointed (2+R), folded phyllites,
category, with ‘Q’ value ranging from 4.3 to 11 between phyllitic quartzite, quartzite and amphibolite bands. The
RD 0 to 180m, and around 2 between RD 180m and RD rocks are thinly bedded and bedding partings had large
206m. Estimated GSI values along machine hall cavern variation depending on the rock types. The rock mass
drift were found to vary from 44 to 52 with fresh and was showing presence of shear zones generally trending
hard quartzite and phyllitic quartzite constituting about along the foliation. The shear zones were varying in
85-90% of the rock mass. Average GSI value of 50 was thickness from 5-10cm. The material along the shear

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 123 SRIPAD R NAIK and V R SASTRY
zone was gougy to granular. The long axis of the
Machine Hall cavern is oriented along N 37oW-S37oE
and is across the strike of foliation.
On completion of the Central Gullet, widening was
taken up on downstream side initially, followed by
widening on upstream side. Before widening at any
location, 8m long rock bolts were installed at the central
gullet, using couplings (6m and 2m rods coupled
together by couplings), with the help of Boltec Machine.
Concurrent supporting in the widened portion was done
with 6m and 8m long 32mm diameter rock bolts
staggered at 1.5m centre to centre with SFRS of 50-
70mm thickness near the face. The side slashing on the
downstream side continued for 264 days and on the
upstream side the slashing continued for 252 days.
During the progress of excavation work in downstream
side near RD 95m, a roof collapse occurred in the
Machine Hall between RD 120m and RD 135m (Chopra
et al, 2003). It was observed that the bearing plates and
the end anchors were intact in this zone, but the rock
mass in between the bolts fell down. Subsequently, falls
continued for some more time and extended from RD
135m to 160m and then 120m to 90m. It was observed
that in the zone between 135m and 160m, the bolts
sheared off from just above the bearing plate but the end
anchorages were intact. From RD 120m to 90m also, the
bolts were reported to be sheared off from 3m to 4m
from the bottom and they fell along with large chunks of
rock mass with bearing plates still intact at the end. The
shells of the end anchorage found to be open in all these
cases. It was noted that the height of the fall was more
on the upstream side from the central line of the
Machine Hall. It varied from a few meters to 7m. On the
downstream side the height of the fall varied from 1 to
3m. Subsequently, it was decided to support the crown
of the Machine Hall with steel ribs of ISMB 350m x
140mm section at 0.6m spacing and welding 12mm
thick plates on both the flanges at suitable spacing to
enhance the strength of steel ribs. The ribs were
installed for the entire length of Machine Hall. The
space between the rock mass and the ribs was back
filled with concrete. This was followed by grouting to
ensure proper contact with the rock mass.
After completion of the ribs and subsequent back filling,
the benching down of the Machine Hall was started.
First bench was started with excavation of central gullet
of 6.5m widths and 2.6m deep. The central gullet
excavation generally starts with opening of box cuts at
two locations by drilling using jack hammers or crawler
mounted pneumatic drill (41mm blasthole diameter).
The central gullet was advanced on either direction and
benches were formed on both upstream and downstream
side. Benches were excavated with controlled blasting
techniques and by providing the line drilling along the
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contact of the wall rock. At any given time, a maximum
of 9m span was exposed. The exposed wall was
immediately shotcreted with 50mm thick plane
shotcrete (M35 A10). On this surface, welded wire mesh
of 100mm x 100mm x 5mm was fixed by drilling holes
with the jack hammer drills. This was followed by
installation of high strength Dywidag bolts of 12m long
and 32mm / 26.5mm diameter (bolts of 32mm diameter
were used during initial benches) at 1.5m centre to
centre in a staggered manner. The Dywidag rock bolts
of 26mm diameter had yield strength of 1033MPa and
tensile strength of 1122MPa (Singh et al, 2003). The
rock bolts were end anchored with resin capsules for
initial 4m and rest was grouted with cement slurry. The
Dywidag rock bolts were tensioned up to 30t / 12t
(during initial benching a pretension of 30t was given,
however, after the instrumentation observations and
other considerations, the pre tension of Dywidag bolts
was fixed at 12t). A second layer of 50mm plain
shotcrete was applied after installing all the rock bolts in
the exposed area. The third layer of 50mm thick
shotcrete was provided after the setting of second layer
of shotcrete.
In the initial stages, as 12m long Dywidag rock bolts
were not readily available, the Dywidag rock bolts of
8m and 4m were coupled together for use in single hole.
For this purpose a 76mm dia hole was drilled up to a
depth of 4.5m so that 4m long rock bolt could be
coupled with 8m long rock bolt with a coupler of 61mm
outer diameter. Beyond 4.5m, the hole was drilled using
standard 51mm diameter hole. During the excavation of
the first bench, consolidation grouting was carried out
up to a depth of 11m and after the grout was set, the
holes were re-drilled for installing the Dywidag rock
bolts. The sequence of excavation of the benches and
the duration of excavation of each bench is shown in a
schematic diagram in Figure 2. It may be noted that the
widths of central gullet and benches were varied to suit
the geological conditions. From 6th bench and
downwards, the benching was done between RD 60 and
RD 206.4 only. Eleven benches were excavated up to
EL 499.5.
 Behaviour of Large Underground Cavern during Construction in Himalayas
– A Case Study
Figure 2. Sequence and Period of Excavation at
Machine Hall Cavern
3.1. Excavation of Transformer Hall
The Transformer Hall was excavated on the downstream
side of Machine Hall in the Power House Complex. A
rock pillar of 40m thickness was left between Machine
Hall and Transformer Hall. Dimensions of Transformer
Hall were 191m x 16m x 24.5m. The EL of the crown
was 539m and floor was 514.5m. The springing level
was at 535.5m. The sequence of excavation of the
benches and the duration of excavation of each bench in
Transformer Hall is shown in Figure 3.
Figure 3. Sequence and Period of Excavation at
Transformer Cavern
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124
The excavation of transformer hall started with
excavation of the central gullet of 7.5m height and 7.5m
width. The rock mass of Transformer Hall mainly
consisted of fresh, hard, moderately jointed and folded
phyllites, phyllitic quartzite and quartzite bands. During
excavation of the central gullet, the rock mass was
supported by SFRS and 6m long rock bolts of 32mm
diameter with 1.5m x 1.5m pattern. However, during
side slashing, SFRS of 150mm thickness and rock bolts
of 6m and 8m long, 32mm diameter were placed at
1.25m x 1.25m pattern. The rock mass contained six
foliation joints at 0.5m to 2m spacing and these are 10m
- 20m long. Dip of these foliation joints varied from 40o
to 70o. In addition to these foliation planes, there was a
sub-vertical shear from RD 10m onwards consisting of
1m to 1.5m thick fracture zone with more than 2cm
gouge material which exhibited swelling and pinching
behaviour tending N40oW-S40oE with 75° to 80°easterly
dip, running sub parallel to the axis of Transformer Hall
cavern along the right wall of the gullet. Further, around
RD 85m, a folded body of shattered quartzite of about
1.5m to 2m thick with swelling and pinching behaviour
was encountered at the crown of the Transformer Hall.
Both the mentioned features were adequately supported
with directional rock bolts of 6m length and SFRS of
more than 50mm thickness.
It was found that due to geological features and dripping
conditions, gully formation occurred towards right side
of the crown from about RD 70m onwards and
sheared/crushed quartzite got detached. However,
advance was continued with the help of directional rock
bolts and SFRS till RD 119m. When the face was at RD
102m, the widening/side slashing of central gullet was
started around RD 73m on the downstream (left wall)
side. During blasting at the central gullet face at RD
119m and side slashing at 86m, loosening of the rock
mass was observed soon after the blast from RD 85
onwards and a rock fall took place between RD 85m
and RD 97m. The overbreak was found to extend 4-5m
over the crown in the shape of a wedge. A few rock
bolts also came down along with the rock mass, while
the remaining was hanging with the rock mass. The rock
fall possibly developed tension cracks in the previous
reach due to which the overbreak extended up to about
RD 80m. The gougy material, which fell down, was
reported to be crushed white quartzite. The cavity thus
formed was immediately supported with the help of
thick layer of SFRS and 8m long rock bolts.
Since the shape of the Transformer Hall was already
deteriorated and the cavity was likely to extend further
once widening starts, it was decided to support the
entire cavern using steel ribs of ISMB 300mm x 140mm
section and welding 12mm thick plates on both the
flanges at suitable spacing to enhance the strength of
 123 SRIPAD R NAIK and V R SASTRY

steel ribs. The entire crown portion of the Transformer is shown in Figure 5. In this paper, instruments results
Hall was provided with the steel ribs. The area between in machine hall cavern are discussed.
ribs and rock surface was backfilled with concrete, and
contact grouting was done to ensure proper contact with
the rib surface. The benching operation in Transformer
Hall was started with the excavation of first bench from
EL 533 to EL 530. The second bench was excavated
from EL 530 to EL 527. The procedure of excavation in
Transformer Hall was almost similar to the procedure
adopted in Machine Hall. However, Dywidag bolts of
8m long and 32mm diameter was used in conjunction
with wire mesh and plain shotcrete as the primary
method of support on the walls.
3.3 Excavation of Bus Ducts
Bus Ducts were excavated up to 10m initially from Figure 4. Instrumentation layout at a) Machine Hall
Machine Hall side. The excavation of Bus Ducts which b) Transformer Hall Cavern
were earlier excavated up to 10m from Machine Hall
Side was continued from Transformer Hall side and
excavation was completed.

4. Instrumentation Studies at the Cavern

In this study, both the behaviour of main caverns and

the connecting tunnels was monitored using following
instruments:
a. Magnetic Ring Multi-point mechanical borehole
extensometers (MRMPBX) for measuring the
displacements in the Crown.
b. Anchor load cells for measuring the load on the
rock bolts in crown and walls.
c. Rib load cells for measuring the load in the ribs.
d. Multi-point mechanical borehole extensometers
(MPBX) with 4-5 anchors for measuring the
deformations at various horizons in the walls.
e. Measurement of wall convergence using reflective
Targets/Total Station.
f. Measurement of stress changes along the length of
rock bolts using VW stress meters.
g. Measurement of pore water pressure using
vibrating wire piezometers.
The instrumentation at Machine Hall and Transformer
Hall was carried out in two stages i.e. during the
excavation of crown of the caverns and during
benching. The instrumentation layouts were decided
based on the site geology and conditions. Instruments
were installed at the following locations.
Machine Hall: RD 15, 65,110, 150m at EL 525, 520,515
and EL 506 on upstream and downstream walls
Transformer Hall: RD 14, 60, 114 and 156m at EL 525
and 520m on upstream and downstream walls
The instrumentation layout implemented at Machine
Hall Cavern and Transformer Hall Cavern is shown in
Figure 4. Instrumentation layout for Bus Duct galleries
Figure 5. Instrumentation layout at bus bar galleries
4.1 Instrumentation during Excavation of the Crown
Four sections each along the length of Machine Hall
were selected for instrumentation. Accordingly, Multi
Point Borehole Extensometers of magnetic type were
installed at RD 15m, 80m, 130m, 150m and 174m of
Machine Hall. The instrumentation at Machine Hall
Cavern started after about 120 to 150 days from
completion of excavation of the central gullet (7.5m x
7m). Displacements at the crown and at deeper horizons
were measured with the help of multi-point borehole
extensometers (MPBX) of magnetic type. The deepest
anchor was placed at a distance of 25m inside from the
crown. Anchors were placed at very close distance with
a view to study the separation of rock beds. Some of the
extensometers had as many as 15 to 18 anchors. Load
on the rock bolts installed in crown portion of the
excavation was monitored using vibrating wire anchor
load cells. In the center portion of the crown of central
gullet, extensometers were installed at RD 15m, 80m,
130m, 150m and 174m. Extensometers at the sides of
the crown were installed as and when the side slashing

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 Behaviour of Large Underground Cavern during Construction in Himalayas
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was done. Major observations of MPBX and anchor Results of Multipoint Borehole Extensometers (MPBX)
load cells are presented in the following sections. installed in the center of the crown at RD 15m, RD
80m, RD 130m and RD 150m are shown in Figure 6.
4.1.1 Multipoint Borehole Extensometer

a) at RD 15m, Center of Crown b) at RD 80m, Center of Crown

c) at RD 130m Center of Crown d) at RD 150m, Center of Crown

Figure 6. Displacement versus time at RD 15m, 80m , 130m and 150m Center of the Crown, Machine Hall Cavern

At RD 15m, maximum surface displacement of 115mm Anchor load cells were installed on 8m long full cement
was observed after a period of 216 days. The grouted rock bolts at the crown portion of Machine Hall.
displacement started accelerating after a period of 46 Load cells were installed at RD 15m, 80m, 90m, 100m,
days. The separation at various horizons was found to 110m, 130m and 150m at the centre of the crown and at
initiate at the same time. The maximum rate of RD 80m on the right up side of the crown. The load
displacement was 0.37mm/day during this period. A induced on the bolts at different RD’s is shown in
separation of 41mm occurred between the surface and Figure 7.
0.7m horizon, indicating separation of shotcrete from
the rock surface. It was observed that the bed separation
took place up to a height of 8.7m above the crown,
indicating the ineffectiveness of rock bolts in controlling
the displacement, Figure 6(a). Subsequently, ribs were
put up for the entire length of the cavern.
At RD 80m crown, the separation of beds started after
48 days and the separation was occurring up to a height
of 3.8m above the crown as could be seen in Figure
6(b). The separation was of the order of 22mm. Anchors
between 4.8m and 17.5m horizons showed negative
movement indicating the closure of pre-existing cracks.
Maximum surface displacement observed was 52mm at
the time of installation of the ribs. The displacements
were however restricted after the backfilling. Figure 7. Load on Rock Bolt in the crown versus time at
At RD 130m crown, surface displacement (lowering of different RD’s, Machine Hall
crown) of 18 mm was observed before installation of
ribs and was increased to 23mm after backfilling of the
ribs as seen in Figure 6(c). The separation up to a height
of 9m above the crown was observed. At RD 150m, a
small crown surface displacement of 7mm was
observed.

4.1.2 Load Cells on Rock Bolts in the Crown

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 123 SRIPAD R NAIK and V R SASTRY

Before installation of the ribs in the crown of the was a marginal increase in the load on the rock bolts
Machine Hall, the rock bolts were the primary mode of indicating some amount of deformation in the rock

supports. Loads induced in the bolts showed increasing mass.

trend. At the time of installation of the ribs, these anchor
load cells were left inside the backfill and monitoring
was continued. After the backfill, the load on rock bolts
buried inside the backfilled area showed stabilizing
trend. The load started decreasing with excavation of
lower benches. It may be noted that in general there was
a reduction of induced load on the rock bolts as they
were shielded behind the effective support of concrete
and the ribs. However, at RD 100m and RD 110m there
4.1.3 Load Cells on Ribs
At the time of installation of ribs, load cells were
provided on the ribs on either side at EL 533m at six
locations in the Machine Hall. The load cells were
installed at normal to the axis of the ribs. Load indicated
by the load cells was the axial load induced on the ribs
and is shown in Figure 8.

Figure 8. Load on ribs on upstream and downstream side at EL 533, Machine Hall Cavern

Maximum load measured on the rib on downstream side

During the benching, instruments were installed at EL
was at RD 173.5m. The maximum load measured at this
525m, 520m, 515m and 506m at RD 15m, 65m, 110m
location was 128.9t. During the period of excavation of
and 150m. The results of monitoring are discussed in
the benches, the rate of increase of load on the ribs
the following sections.
varied from 0.36 to 0.78t/day except at RD 173.5m,
where maximum rate of load was 2.31t/day. The
4.2.1 Anchor Load Cells on Rock Bolts
increase in load on the ribs varied from 17.87t to 55.10t
The anchor load cells were installed on 12m long full
and at RD 173.5m, the increase in load was 110.96t.
grouted Dywidag high tensile rock bolts. Load cells
During the period of excavation of sumps and bus ducts,
were installed at the time of installation of the rock bolt.
the rate of increase of load reduced at many locations.
The designed pre-tension up to 30t was given to the
However, at RD 56.5m, there was an increase in the rate
rock bolt in few sections at higher elevations. Later, the
of load (0.65t/day) and the maximum load recorded was
pre-tension load was reduced to 10 to 12t. Thus the
102.62t. Maximum load measured on the rib on
monitoring of load cells started from the time of
upstream side was at RD 56.5m, with a value of
installation of the rock bolt, which was the main
131.55t. During the excavation of benches, the rate of
supporting element of the side wall. The load cells were
increase of load varied from 0.09 – 0.51t/day except at
installed at EL 529.75m, EL 525m, EL 520m and EL
RD 56.5m, where the maximum rate of increase was
515m and EL 506m. On upstream side, additional load
1.76t/day. The increase in load during the period varied
cells were installed at few selected locations.
from 9.47 to 52.51t. At RD 56.5m, the increase in load
was 101.52t. During the excavation of Sump, Trench
Load Cells at EL 529.75: At this elevation, load cells
and Bus Ducts, the rate of increase of load varied from
were installed at RD 123m downstream wall and 123m
0.11 to 0.50t/day. During this period, maximum load
upstream wall of the Machine Hall. The load cell
was measured at RD 56.5m (131.55t) and at RD 18.5m
observation on both the bolts is shown in Figure 9. The
(34.86t).
upstream side rock bolt was pre-tensioned to 30.59t as
evident from figure.
4.1 Instrumentation during Benching

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 Behaviour of Large Underground Cavern during Construction in Himalayas
– A Case Study 124

Figure 9. Load on 12m Dywidag Rock Bolt on Side wall

at EL 529.75

At RD 123m u/s, the load on the rock bolt started

decreasing at a steady rate. For initial 67 days, there was
a reduction in load of 3.57t. Subsequently, the load
further decreased at faster rate and there was a further
reduction of 4.43t during a period of another 30 days.
Thus after a period of 116 days, the load on the rock
bolt was 22.46t (a decrease of 8.13t). During this period,
the excavation of second bench had already begun.
Since, the pre-tensioning of the rock bolts was very
high, the rock mass near the wall surface might have
lost the capacity to transfer the load arising out of the
excavation of the lower bench to rock bolt and allowing
the wall deformation to take place. However, when the
excavation of the 3rd bench started, the load on the rock
bolts was stabilized and there was marginal increase in
the load on rock bolt. The load loss of 8t occurred
during the excavation of 1 st bench and 4t during the
excavation of 2nd bench. There was an increase in load
of 1.22t due to the excavation of the 3 rd bench. The load
increased by only 0.39t during the excavation of 4 th
bench.

The load cell at RD 123m downstream side was pre-

tensioned to only 19.37t. It may be noted that there was
a reduction of 2.45t during the initial 10 days. Later, the
load on rock bolt started increasing. Load on rock bolt
increased by 4.26t during a period of 23 days. There
was an increase of 18.16t (increase from 16.93t to
35.09t) due to the excavation of 2nd bench. There was
an increase of 7.36t (from 28.54t to 35.90t) load on the
bolt due to the excavation of 3rd bench. The increase in
load during the excavation of the 4th bench was 6.13t,
which also suggests the diminishing influence of the
excavation on the rock bolt as it progresses away.

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 123 SRIPAD R NAIK and V R SASTRY

Load Cells at EL 525m: Anchor load cells were installed

at RD 15m, 16m, 69m and 110m on the downstream
wall and RD 16.8m, 62m and 106m on the upstream
wall at EL 525m. The load cell data at EL 525m d/s and
EL 525m u/s is plotted in Figure 10.
Figure 10. Load on 12m long rock bolts on the d/s & u/s wall of Machine Hall at EL -525

At EL 525m, maximum load on the rock bolt was

measured at RD 62m on the upstream side. The
maximum load recorded on this bolt was 43.01t. The
bolt ultimately failed and the load on rock bolt
decreased to 1.58t. At other locations on the upstream,
the load on rock bolt varied from 12t to 30t. During the
excavation period, the rate of increase of load on the
rock bolt varied from 0.15 to 0.93t/day. Most of the
increase in load occurred during the period of benching
of the Machine Hall. The rate of loading reduced to 0.4t
to 0.07t during the period of excavation of Sumps,
Trenches and Bus Ducts.

Load Cells at EL 520m: The load cells were installed on

the rock bolts at RD 15m, 65m, 110m and 150m on both
upstream and downstream side of Machine Hall. The
load cell data recorded in downstream and upstream
sides during and after the excavation of Machine Hall
are shown in Figure11.
Load Cells at EL 515: Load cells were installed at RD
65m, 110m and 150m on both upstream and
downstream wall and at RD 120m and RD 14m2 on the
upstream wall of the Machine Hall. The load cell data
recorded during the excavation of machine hall on d/s
and u/s is shown in Figure12.

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 Behaviour of Large Underground Cavern during Construction in Himalayas
– A Case Study 124

Figure 11. Load on 12m long rock bolts on d/s & u/s wall of Machine Hall at EL -520m

Figure 12. Load on 12m long rock bolts on d/s & u/s wall of Machine Hall at EL -515m

Load Cells at EL 506: The load cells were installed at
RD 65m, 110m and 150m on both upstream and
downstream walls of the Machine Hall. The load cell
data recorded during the excavation of machine hall on
d/s and u/s is shown in Figure 13.
4.2.2 Wall Convergence
The wall convergence of Machine Hall Cavern was
monitored using reflective targets with Total Station
Leica TDA 5005 with angular accuracy of 0.5s.
Reflective targets were fixed on a plate which was held
in position by a rod grouted into the wall to a depth of
0.3m to 1m. The stations were fixed opposite to each
other on upstream and downstream walls. The
cumulative convergence of two walls was computed.
Convergence observations at EL 525m, 520m, 515m
and 506m are shown in Figure 14. It may be noted from
the figure that, convergence in excess of 250mm was
observed at EL 525, 520 and EL 525m and shows
increasing trend.

Figure 13. Load on 12m long rock bolts on the d/s & u/s wall of Machine Hall at EL -506.

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 123 SRIPAD R NAIK and V R SASTRY

Figure 14. Convergence of side walls of Machine Hall Cavern

5.0 Rock Bolt Failures

During the benching down of Machine Hall Cavern,
when the excavation reached EL 504m/501m, i.e. at the
level where pressure shaft manifolds opens into the
Machine Hall Cavern, rock bolts started failing on the
upstream wall. Keeping the failed rock bolts in view,
additional rock bolts were installed in the upstream wall
of the cavern. However, the rock bolt failures continued
even after completion of the excavation of both the
caverns and other connecting tunnels. There were about
162 rock bolt failures on the upstream wall and about 30
rock bolt failures on downstream side. The locations of
rock bolt failures in the upstream wall are shown in Figure 15. Locations of rock bolt failures in upstream
Figure 15. It could be observed from the figure that wall of machine hall cavern
many rock bolts have failed adjacent to each other as the
failure of one bolt puts additional load on adjacent bolt Instrumentation data indicated that many rock bolts are
resulting in overloading, ultimately leading to the failure loaded more than 35t. The convergence recorded in
of bolt. excess of 300mm suggest that phyllitic quartzite rock
mass becomes highly deformable under high stress
conditions and may require flexible support system.
6.0 Conclusions

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ISSN 0974-5904, Vol. XX, No. XX, XXXX 2014, pp. 633-637
 Behaviour of Large Underground Cavern during Construction in Himalayas
– A Case Study 124

The behaviour of large underground cavern in Himalaya [4] Naik, S., Nair, R., Sudhakar, K. and Nawani, P.C.
was assessed using the instrumentation data. The 2010. Need For Systematic Instrumentation In
instrumentation results reveal that rock mass consisting Hydroelectric Projects In Himalayas, International
of phyllitic quartzite exhibit excessive deformation Conference on Accelerated Development of Hydro
under high stress conditions. Although, rock bolts of Power in Bhutan – Opportunities and Challenges,
high strength are effective in controlling the Thimpu, Bhutan. 16-18.
deformations, failure of large number of bolts are
[5] Naik, S., Sudhakar, K and Nair, R. 2011
witnessed. This suggests that flexible supports like cable
Instrumentation – A Key to Stability Analysis of
bolts may work better under such geological conditions.
Large Caverns in Hydroelectric Projects,
Based on the instrumentation data and analysis during
International Conference on International
the construction of large underground cavern in
Conference on Underground Space Technology,
Himalaya, the following conclusions are drawn:
NIRM, Bangalore, India, January, 16-18,
• Instrumentation data and analysis has played vital role
[6] Chopra, V., and Gupta, A. 2003. Roof arch failure of
during the various stages of cavern excavation in
Machine Hall Cavern – Tala Hydroelectric Project,
ensuring stability to the excavation and in assessing
Bhutan. International Conference on Engineering of
the efficacy of the support system.
Dams and Appurtenance Works including
• Instrumentation data is highly useful for taking Powerhouse and Transmission Systems, New Delhi
appropriate measures in case of inadequate support
system by additional strengthening. After taking
remedial measures, instruments were further used to
assess efficacy of these measures.
• Instrumentation data aided the management in taking
appropriate decisions at right time.
• More sections in the caverns need to be instrumented
in order to correctly understand the behaviour of the
multiple caverns.
• Measurement of convergence using optical instrument
rather than using tape extensometer proved useful as
continuous data could be collected during the entire
benching period and during the post excavation period
also.
7.0 References
[1] Anon., 2001. Technical Report on Laboratory Rock
Mechanics Investigations – Tala Hydroelectric
Project, Bhutan, NIRM Unpublished Report
[2] Singh, R., Chowdhry, A.K., Sharma, B.N., Goyal,
D.P., and Khazanchi, R.N., 2002. Wall Support
System for powerhouse cavern of Tala Hydroelectric
Project in Bhutan Himalayas, INDOROCK, New
Delhi. 132-142
[3] Singh, R., Sharma, B.N., Puri, P.K., Gupta, M.,
Goyal, D.P. and Chugh, I.K., 2003 Experience of
long rock bolts in Machine Hall Cavern at Tala
Hydroelectric Project. International Conference on
Accelerated Construction of Hydropower Projects,
Gedu, Bhutan Vol.I 30-39.

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