Deep Foundation Cut-Off Wall Construction for Hydroelectric Dam Project in South America

A large-scale hydroelectric dam project in the Andean region of Peru required the installation of a 65-meter deep cut-off wall to prevent water seepage through the foundation. The project site presented extreme geological challenges, including highly fractured rock formations, high groundwater pressure, and significant variations in rock hardness ranging from 40 to 120 MPa.

The foundation contractor faced multiple complex requirements:

• Extreme depth requirements: 65-meter continuous wall with strict imperviousness criteria
• Highly variable rock conditions: Alternating soft and extremely hard rock zones
• High groundwater pressure: Hydrostatic head exceeding 45 meters
• Remote location logistics: Limited infrastructure and difficult access for equipment transport

APIE FOUNDATION EQUIPMENT engineered a customized trench cutting solution incorporating:

• Extended cutter mast system designed for 70-meter maximum depth capacity
• Adaptive cutter wheel configuration with interchangeable cutting tools for varying rock hardness
• High-capacity slurry circulation system ensuring stable trench conditions under high hydrostatic pressure
• Remote monitoring and control capability enabling real-time operation oversight from site control center
• Modular transport design facilitating delivery to remote mountain location

The trench cutter commenced operations in March 2023 and completed the 2,800-linear-meter wall section in August 2023, accomplishing the following achievements:

• Total wall length completed: 2,800 linear meters
• Maximum depth achieved: 65 meters (record for the region)
• Average penetration rate: 1.2 meters/hour in hard rock
• Wall imperviousness: Permeability coefficient <10⁻⁷ cm/s (exceeding design requirement)
• Zero safety incidents across 5,600 hours of operation

The trench cutter demonstrated exceptional adaptability to varying rock conditions:

• Soft rock zones (40-60 MPa): Penetration rates up to 2.5 meters/hour
• Medium-hard rock (60-90 MPa): Consistent 1.2-1.5 meters/hour progress
• Hard rock zones (90-120 MPa): Maintained 0.8-1.0 meters/hour without tool failure

• Vertical deviation control: Maintained within 0.12% across entire 65-meter depth
• Wall surface smoothness: Average roughness <5mm, eliminating need for secondary treatment
• Panel joint integrity: Seamless connections between panels ensuring complete imperviousness

• Equipment availability: 94.2% uptime throughout project duration
• Fuel efficiency: Optimized hydraulic system reduced consumption by 28% compared to comparable equipment
• Tool life: Cutter wheel components averaged 180 hours of service before replacement, exceeding manufacturer specifications

The successful completion of the cut-off wall provided the dam project with critical advantages:

• Significant cost savings: Reduced construction time by 22 days, translating to approximately USD 1.8 million in project cost reductions
• Enhanced dam safety foundation: Exceptional imperviousness ensures long-term structural integrity
• Technical credibility: Demonstrated capability to execute challenging foundation works in extreme conditions

This project was awarded the “Outstanding Geotechnical Engineering Achievement” by the Peruvian Society of Civil Engineers, with specific recognition for the innovative application of trench cutting technology in extreme geological conditions.

“APIE’s trench cutter technology was instrumental in overcoming what many considered impossible foundation conditions. The equipment’s reliability, combined with APIE’s exceptional technical support, enabled us to deliver a foundation solution that will ensure the dam’s safe operation for generations. This partnership has set a new benchmark for deep foundation construction in South America.”

— Chief Technical Officer, Andean Infrastructure Development Corporation

• Patented cutter wheel design for superior penetration in all soil and rock conditions
• Intelligent control systems ensuring precise operation and optimal performance
• Environmentally responsible design minimizing noise, vibration, and emissions

• Global service network with rapid response capabilities
• Experienced engineering team providing customized solutions for challenging projects
• Comprehensive training programs ensuring maximum equipment utilization and safety

• Track record of success across 40+ countries on 6 continents
• Industry-leading reliability with equipment availability exceeding 95%
• Innovative solutions for the most demanding geotechnical challenges