Andre Construction was contracted to a multi-year replacement of three ice sluice structures at a power generating station. The existing sluices, originally constructed in the 1950s, measured between 16 and 23 meters in width and held back approximately 5 meters of headwater. In addition, the concrete around the aging steel sluices needed to be removed and replaced.
The project included installing a cofferdam upstream of the sluices, capping a valve intake pipe approximately 55 feet below water level, and performing necessary dewatering efforts. Additionally, we demolished and reconstructed concrete structures, reinforced and repainted an existing crane beam, and upgraded structural steel and grating.
The Challenges
We encountered several challenges over the course of this three-year hydroelectric project:
Extensive permissions were necessary for working in water.
Strict environmental controls were necessary to minimize impact on aquatic ecosystems.
We were required to maintain an eel ladder to accommodate migratory fish.
Generator shutdowns had to be coordinated for safe diving operations.
Water intrusion demanded ongoing management.
The dam needed to be operational throughout the project.
Multiple projects across the dam significantly limited the laydown area, which required constant coordination between the owner and other project stakeholders.
The Solutions
Prior to starting work, our team identified potential risks and created mitigation strategies for winter construction, cofferdam leaking, mass concrete pours, working in water, environmental compliance, and more.
Our laydown area was severely limited throughout the project. To eliminate storage issues and delays, we expertly coordinated with suppliers and developed a precise master schedule that allowed for seamless delivery of materials just in time for installation.
To manage water intrusion at the site, our team designed and built cofferdams on the upstream face of the dam. The closest generator had to be shut down at specific times so divers could safely install the cofferdams. This required meticulous planning and communication to minimize disruptions and maintain project timelines. Once the cofferdams were in place, they held back the water to a depth of five meters, allowing us to maintain appropriate conditions for working with concrete.
With a water-free environment established, the team began work one ice sluice gate at a time. Extensive heating and hoarding of the concrete was necessary for work to continue through the winter months.
The Ice Sluice Gate Replacement project is a testament to strategic planning, technical expertise, and environmental stewardship. The project aligns with best practices in hydroelectric infrastructure maintenance and rehabilitation, ensuring long-term operational efficiency and sustainability.
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