Andre Construction was contracted to perform extensive concrete mitigation and structural rehabilitation work at a power generating station. Due to long-term water leakage and alkali-aggregate reaction, concrete at the site was in a state of significant deterioration.
In addition to removing and repairing deteriorated concrete throughout the dam, the complex rehabilitation work involved the temporary support of large transverse beams, supporting the switchgear building, and modifications to the beam seat at the gantry beam to accommodate future shifting and movement of aggregate in the dam structure.
As lead contractor, the Andre Construction team was responsible for preparing as built CAD drawings, temporary shoring, managing scaffolding and site access, demolition, form work, and placing of the new concrete and grout. The team oversaw subcontractors who completed field checks of the transverse beam saddles to confirm constructability, modifications to reinforced steel, and saddle installation.
The work took place in an active generating station with the main generator deck crane overhead. The proximity of the crane restricted site access and required substantial shoring of the transverse and gantry beams.
Strict coordination with on-site teams was also necessary to ensure the safety of workers and equipment.
No as-built drawings of the site existed and demolition uncovered existing reinforced steel within the transverse beams. The location of rebar conflicted with the proposed saddle redesign and prompted a complete re-engineering of transverse beam saddles. This extended both the budget and on-site schedule.
To mitigate design-related delays, Andre Construction prepared detailed “as-found” CAD drawings of the transverse beams and surrounding structure. This provided the engineers with accurate conditions for the redesign of the transverse beam saddles, eliminated the need for site visits, and reduced design costs.
To minimize downtime costs and maintain progress while waiting for redesign, Andre Construction reallocated their force to other tasks on the contract such as concrete rehabilitation.
Despite changes in schedule due to the transverse beam saddle redesign, the project reached successful completion in June 2026. Andre Construction delivered concrete remediation throughout the plant, and a moving gantry beam that will accommodate future shifts in the concrete due to weather and aggregate growth.
The work demonstrated the team’s commitment to risk management and operational excellence on high-complexity projects within active power generation environments. All deliverables met quality and workmanship expectations.
Challenges with communication highlighted the importance of early talks with engineers and owners. Receiving all critical information prior to starting projects helps reduce inefficiency and downstream delays.
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