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[narrator]
High in the Colorado Rockies,an elite team of engineers is
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taking on a seeminglyimpossible challenge.
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This is gonna be
one for the record books
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and the resume.
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They're racing to buildan extraordinary new mega dam.
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We're under a lot of pressure
to get this done on schedule.
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The clock is ticking.
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A chronic drought putsthe water supply
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for millions of people at risk.
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If we don't do something now,
we will be too late.
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To succeed,they must safely fuse
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70-year-oldconstruction methods
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with cutting-edge engineering.
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This mega dam
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ranks in a league of ambitiousnew engineering wonders that
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are bigger, faster,taller, and more advanced
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than anything everconstructed before.
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This is the inside story ofthe extraordinary challenge of
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building these giants.
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Colorado is facing a crisis.
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It has long relied onmelting mountain snowpack
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for its water supply.
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Climate change is reducingsnowfall and shortening
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the melt season.
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This means more water runs off
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before it can be storedin reservoirs.
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Colorado must capturea greater amount of
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the dwindling snowmelt.
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If these efforts fail,reports suggest the state
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could run out of waterwithin 25 years.
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To meet this challenge,engineers in Colorado are now
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working on a series ofmegastructures to boost
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the state's reserves of water.
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The Gross Dam was builtin the 1950s
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to help supplythe growing population
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of Colorado's statecapital, Denver.
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Constructed from over1,400 concrete blocks,
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it rose toan impressive 335 feet
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and was designed to hold back
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over 13 billion gallonsof water.
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But that's not enough to meetthe demand of the 21st century.
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The plan today is totriple its capacity.
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Jeff Martin leads the teamtasked with making it happen.
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[Jeff] The original Gross Dam is
just an amazing structure.
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Just, unfortunately, now,
it doesn't hold
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as much water as we need.
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So, we're gonna solve
our problem,
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by raising the Gross Dam
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to create more water
storage behind it.
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Engineers must builda completely new dam on top of
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the old one.
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To succeed, they must beatextreme weather,
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tough geology,and a tight deadline
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set by the Federal government.
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The engineers will build upthe height of the dam
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by a third toa colossal 471 feet.
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They will double the length ofthe crest of the dam
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to 2,040 feet,
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and build a brand-new spillwayto release surplus water.
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The team will pour over21 million cubic feet of
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special concrete to makethe wall's 118 steps,
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and expand the width ofthe dam's base to 300 feet.
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The new gross dam will bethe tallest dam in Colorado
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and hold back a staggering38 billion gallons of water.
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This megaproject transformsthe structure from
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a gravity dam intoan arched dam.
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This will be the first time inthe world that engineers
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have attempted to do this.
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Engineer of record,Felipe Garcia, and his team
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have been brought onto make it happen.
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So, the original Gross Dam was
designed as
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a curved gravity structure.
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What I mean by a curved gravity
dam is that it has enough
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weight to maintain stability
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against the pressure
of the reservoir.
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But relying on their sheermass to hold back a reservoir
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makes gravity damsexpensive and inefficient.
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A arch dam achieves
its stable factor of safety by
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transferring the loads from
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the reservoir laterally
towards the abutment.
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And in turn, you're able to
make the arch thinner.
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Not only that reduces
cost and schedule, but it also
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provides a more
sustainable project.
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Engineering teams must buildsolid foundations on both sides
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of the canyon to support
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the greater width ofthe new dam.
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But the geology in this part ofColorado presents
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a big problem.
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What we have here
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is pretty typical of about
90% of the foundation
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of we have
out there at Gross.
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It is very strong rock,
but from this particular slope,
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this material is
highly weathered.
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You see?
I -- I can just peel it
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with my hand -- that means
that it doesn't have
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enough stiffness to support
the loads from the dam.
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So, this material would need to
be removed.
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The teams use a fleet ofexcavators to scrape away
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the loose weathered rock.
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Next, the team pours nearly705,000 cubic feet of concrete
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to build a super strongand perfectly level foundation
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that bonds tightlyto the bedrock.
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It takes around 20 months
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to prepare the canyon wallsfor the new dam.
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The engineers' next task is toprepare the concrete of
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the old dam to make surethat it bonds
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to the concrete ofthe new one.
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[Jeff] A concrete dam moves.
It lives.
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So, the new dam and old dam
have to hold together.
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They have to bond.
They have to move together.
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That's critical to
the performance of the dam.
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One of the first things we need
to do to build this dam is
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roughen up the face of
the old dam
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so we can get the new dam
to stick to it.
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To create this crucial bond,
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a blaster fires water ata pressure of nearly
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20,000 pounds per square inch
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to strip away the top layerof concrete.
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A large saw cuts slices intothe crest of the dam.
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A hydraulic hammerthen breaks up the concrete
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before another water blasterfinishes the job.
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These processes leave the damwith a rough surface to allow
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the new concrete to forma super strong bond.
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[Felipe]
The activity that's going on
right now is what we call doing
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a hydro demolition
of the downstream face
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of the existing dam.
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We're removing the outer layers
of the skin of
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the existing dam,
but we want to make sure
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and be careful not to remove
too much of it
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for a large extended area,
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because at the end of
the day, right,
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we're raising Gross Dam
while it's still in operation.
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While the water blaster roughsup the concrete, a team at
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the top of the dam wrestleswith the next challenge.
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Here is the crest ofthe old dam's spillway,
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the structure that allowsthe safe release
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of excess water.
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It's Casey Dick'sresponsibility to remove it
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before the team raisesthe height of the dam.
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We couldn't just build right
on top of the existing spillway
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as it sits right now,
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because the top of it
is rounded.
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If we tried to just start
placing concrete right on this
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rounded surface,
it would just fall right off
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and we'd never be able to
get it started.
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Deconstructing this criticalpart of the old dam is
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a major operation.
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The concrete is very heavy by
its nature, so if we cut it off
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in one giant piece,
we wouldn't be able to actually
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remove it from the dam.
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So we have to slice it up
into smaller pieces,
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about the size of a vehicle,
so that the cranes can then
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hoist it off one piece
at a time.
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The team deploys a specialcutting system to get
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the job done.
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To remove the old spillway,
we have this apparatus that
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uses diamond-encrusted rope,
wire rope, so it's really hard
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and it's abrasive,
and as you drag that through
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the concrete, those crystals
are stronger than the concrete
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and it's able to cut right
through the concrete.
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So basically, this rope is just
going through the dam,
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cutting the concrete like
a cheese cutter.
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Over the next two years,the team blasts,
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cuts, and cracks apartthe old dam.
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Now the engineers can startthe next phase,
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an innovative concrete pouringprocess to ensure
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its record-breaking rise.
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Engineers in Colorado areracing to build a mega dam to
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help securethe state's water supply.
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They must raise the height ofthe old Gross Dam by 131 feet
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to triple the capacity ofthe reservoir behind it.
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To do this, engineers mustbuild a supersized wall made
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from 118 giant steps to sit ontop of the existing structure.
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For many largeconstruction projects,
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engineers traditionallypour concrete into
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a steel framework.
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But cutting and weldingthousands of feet of steel for
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the new Gross Damwill significantly raise costs
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and risk delays.
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To stay on schedule,the engineers use a material
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called roller compactedconcrete, or RCC.
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A conveyor belt system deliversconcrete to a fleet of
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specially tracked dump trucksat the base of the dam.
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These tip the concrete intopredetermined positions.
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Bulldozers smooth it out.
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Heavy rollers then compressthis layer
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before an excavator witha vibrating pad compacts it
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tightly together toincrease its strength.
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Each step rises about50 inches by 24 inches.
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The team will build118 steps in total
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to make the new dam471 feet tall.
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It's like watching an orchestra
where there's a conductor
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and the conductor knows what
every single one of
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the musicians are doing,
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and everybody's
doing their part.
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This is a 24/7 operation.
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There's two shifts every day,
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and then there's
seven days continuously.
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The dam extension needs over
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17 million cubic feetof concrete.
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That's over 15% more thanthe old dam.
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It's up to project managerJeff Martin to make sure that
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a steady supply of concretereaches the build
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to keep it on schedule.
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We are gonna create
a massive amount of concrete to
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build the dam itself.
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We have over 300 people here
working every day
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and we need to make sure
we can always have the product
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where our people are to put that
in and build the dam.
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Trucking in building materialswould clog up the narrow
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mountain roads for years
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and put the projectover budget.
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So Jeff and the teambuild their own
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concrete factory on site.
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[Jeff]
We couldn't build this dam
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without having
this concrete plant right here
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next to the dam.
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The plant operates 24/7 tosupply 16,000 cubic feet of
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concrete an hour.
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But building quickly withconcrete creates a problem.
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[Jeff] Any time you mix water
and cement together,
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it creates heat.
Heat creates expansion.
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Once it cools,
it shrinks and cracks.
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These cracks could becomeweak points in the future.
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In a dam, that's critical.
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Water can force its way in,building pressure and weakening
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the structure over time.
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To combat this,
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engineers cool the concrete toaround 50 degrees Fahrenheit.
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This limits heat buildup as itcures, reduces expansion,
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and helps to prevent cracksfrom forming.
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As you can see,
we're in our ice plant now.
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This is where we create all
the ice that we put in
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the concrete --
450 tons of ice a day
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to go into our concrete mix
to keep
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our concrete as
cold as possible.
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With this project, we're using
80% ice in the concrete.
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That's a key ingredient,
a key project recipe
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to keep this
really cold concrete
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that we have to make
for this project.
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It's critical that the concretearrives cold to the site,
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so the team builds a customconveyor system to transport it
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quickly over the dam and downto the waiting dump trucks.
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These tip the concreteonto predesignated spots.
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Bulldozers then spread it,
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and rollers level it.
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Finally, a compactorhammers the concrete.
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[Felipe]
The reason we use a compactor
is to achieve the right density
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that it needs to have
the compressive strength
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and the properties that
we need for the raised dam.
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The compaction process forcesout a cement paste that helps
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to strengthen the layersof the dam.
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00:15:29,367 --> 00:15:32,167
[Felipe] After the compaction,
paste comes up to the surface,
254
00:15:32,334 --> 00:15:33,968
and that paste going to
the surface is what
255
00:15:34,133 --> 00:15:36,767
allows us to,
when we place the next layer,
256
00:15:36,934 --> 00:15:39,267
to get the right bond
between the two
257
00:15:39,434 --> 00:15:41,868
so that it's like
it was placed monolithically.
258
00:15:42,033 --> 00:15:44,000
You can't even tell that it was
placed in two different layers.
259
00:15:49,267 --> 00:15:52,167
The density of the concretemakes the wall of the new
260
00:15:52,334 --> 00:15:54,367
Gross Dam strong enough
261
00:15:54,534 --> 00:15:56,767
to hold backbillions of gallons of water.
262
00:16:00,400 --> 00:16:02,467
But it's vulnerable tothe harsh climate
263
00:16:02,634 --> 00:16:04,100
of the Rocky Mountains.
264
00:16:05,901 --> 00:16:09,367
Roller compacted concrete
itself is not super durable
265
00:16:09,534 --> 00:16:11,667
against freeze-thaw
and the elements.
266
00:16:11,834 --> 00:16:15,100
If we just left the roller
compacted concrete exposed,
267
00:16:15,267 --> 00:16:18,100
over time, moisture would seep
into it, and it would go
268
00:16:18,267 --> 00:16:21,567
through freeze-thaw cycles
during our cold seasons,
269
00:16:21,734 --> 00:16:24,300
and that could degrade
the concrete and chip it away,
270
00:16:24,467 --> 00:16:25,767
and it could break down
over time.
271
00:16:26,901 --> 00:16:29,200
The engineers mustweatherproof this layer.
272
00:16:31,000 --> 00:16:32,968
So, they encase it in a nearly
273
00:16:33,133 --> 00:16:35,400
10-inch-thick layer ofregular concrete.
274
00:16:37,667 --> 00:16:39,467
Workers pourthe weatherproofing layer of
275
00:16:39,634 --> 00:16:42,467
concrete in tandem withthe RCC concrete.
276
00:16:48,701 --> 00:16:52,000
It's critical that every layeris the same thickness.
277
00:16:53,000 --> 00:16:55,801
[Casey]
It's really important as we go
that each step is built to
278
00:16:55,968 --> 00:16:59,100
the exact correct dimensions so
that when we get to the top of
279
00:16:59,267 --> 00:17:02,467
the dam, 118 steps up,
that we end up at
280
00:17:02,634 --> 00:17:03,667
the correct elevation.
281
00:17:05,067 --> 00:17:07,667
Using GPS,the team continually
282
00:17:07,834 --> 00:17:09,367
monitors the stepsto make sure
283
00:17:09,534 --> 00:17:11,267
they're constructed atthe correct height.
284
00:17:12,267 --> 00:17:15,467
Nearby, a second team istackling the water storage
285
00:17:15,634 --> 00:17:19,901
problem in a different way,constructing an entirely
286
00:17:20,067 --> 00:17:22,367
new reservoirfrom the ground up.
287
00:17:31,567 --> 00:17:34,901
Engineers in Colorado areracing to secure the state's
288
00:17:35,067 --> 00:17:37,667
water supplies in the face ofcontinued droughts.
289
00:17:41,400 --> 00:17:45,234
Their solution is to store moreof the ice melt every year.
290
00:17:47,667 --> 00:17:51,501
Nearly 30 miles north ofthe new Gross Dam project,
291
00:17:51,667 --> 00:17:53,367
a second team is working on
292
00:17:53,534 --> 00:17:55,734
another mega waterstorage solution.
293
00:17:58,200 --> 00:18:02,067
Engineers here are constructingan entirely new reservoir
294
00:18:02,234 --> 00:18:03,334
from the ground up.
295
00:18:05,567 --> 00:18:07,868
The Chimney Hollow Reservoirwill store over
296
00:18:08,033 --> 00:18:09,767
29 billion gallonsof water,
297
00:18:11,601 --> 00:18:15,167
held back by a unique dam builtfrom rock and asphalt.
298
00:18:16,667 --> 00:18:20,267
Combined with the Gross Dam,this mega build will help
299
00:18:20,434 --> 00:18:22,901
stabilize Colorado's fragilewater supply.
300
00:18:24,801 --> 00:18:27,701
Jeff Drager and Becky Brushlead the project.
301
00:18:29,167 --> 00:18:31,868
There hasn't been anything
done like this before.
302
00:18:32,033 --> 00:18:34,167
Chimney Hollow is the first
reservoir built within
303
00:18:34,334 --> 00:18:38,801
the last 25 years, which is
a pretty incredible feat.
304
00:18:38,968 --> 00:18:42,267
To hold back the vast amountsof liquid, the engineers are
305
00:18:42,434 --> 00:18:48,100
building a dam that's 350 feettall and 3,700 feet long.
306
00:18:50,300 --> 00:18:54,067
First, workers will blastthe weathered rock to expose
307
00:18:54,234 --> 00:18:55,801
the stable bedrock underneath.
308
00:18:57,267 --> 00:19:00,868
Next, they'll lay an18-inch-thick concrete plinth
309
00:19:01,033 --> 00:19:03,501
across the valley.
310
00:19:03,667 --> 00:19:08,667
A giant drilling machine willthen bore 2,000 holes 230 feet
311
00:19:08,834 --> 00:19:11,467
into the bedrock and fill themwith grout to make
312
00:19:11,634 --> 00:19:14,901
a watertight curtain beneaththe ground.
313
00:19:15,067 --> 00:19:18,801
Above it, a special machinewill lay 512 layers of
314
00:19:18,968 --> 00:19:21,667
an impermeable asphalt concrete
315
00:19:21,834 --> 00:19:24,167
to form the core ofthe Chimney Hollow Dam.
316
00:19:25,367 --> 00:19:30,200
Earthmovers will shift over 315million cubic feet of rockfall
317
00:19:30,367 --> 00:19:31,400
to support it.
318
00:19:34,968 --> 00:19:37,767
The first challengethe engineers face is building
319
00:19:37,934 --> 00:19:40,067
a solid foundationfor the megastructure.
320
00:19:42,100 --> 00:19:45,000
The rock here is too tough formachines to dig away.
321
00:19:46,567 --> 00:19:50,767
The excavators can dig rock
that's up to a certain hardness.
322
00:19:51,767 --> 00:19:54,100
But once you get down further
into the rock, it's just
323
00:19:54,267 --> 00:19:56,767
too hard -- an excavator just
can't dig it.
324
00:19:57,901 --> 00:19:59,868
So, Jeff and his team detonate
325
00:20:00,033 --> 00:20:01,567
millions of poundsof explosives
326
00:20:02,601 --> 00:20:04,000
to smash through the rock.
327
00:20:05,968 --> 00:20:08,868
It's a lot of explosions,
probably one a day
328
00:20:09,033 --> 00:20:10,267
for about a year.
329
00:20:10,434 --> 00:20:11,367
[explosion blasts]
330
00:20:12,667 --> 00:20:13,868
[explosion blasts]
331
00:20:18,267 --> 00:20:20,801
Once they've exposedthe bedrock, the engineers
332
00:20:20,968 --> 00:20:22,968
move on to the next challenge,
333
00:20:23,133 --> 00:20:25,667
constructingthe foundation plinth.
334
00:20:25,834 --> 00:20:28,467
This 3,700-foot-long wall
335
00:20:28,634 --> 00:20:31,100
locks the Chimney Hollow Damto the rock.
336
00:20:33,200 --> 00:20:35,267
[Becky]
It's really important to get
the plinth right because that
337
00:20:35,434 --> 00:20:39,000
is the foundation for the main
dam, so everything is built on
338
00:20:39,167 --> 00:20:40,968
top of that,
and if that goes wrong,
339
00:20:42,100 --> 00:20:43,100
the whole dam will be off.
340
00:20:45,000 --> 00:20:47,200
Engineers fabricate boxes from
341
00:20:47,367 --> 00:20:49,167
thousands of feet ofsteel rebar
342
00:20:50,601 --> 00:20:53,701
and place them inside woodenforms that extends
343
00:20:53,868 --> 00:20:55,200
the full length of the plinth.
344
00:20:56,767 --> 00:21:01,033
The boxes are then pumped fullwith super strong concrete.
345
00:21:03,467 --> 00:21:06,300
It takes the team almost twoyears to complete the plinth.
346
00:21:07,701 --> 00:21:11,000
Engineers can now buildthe main dam.
347
00:21:11,167 --> 00:21:13,234
But they face a new challenge.
348
00:21:15,701 --> 00:21:18,701
Most of the dams here in
Colorado are built with
349
00:21:18,868 --> 00:21:20,868
earthwork and rock.
350
00:21:21,033 --> 00:21:24,501
Most of them have
what we call a clay core.
351
00:21:24,667 --> 00:21:27,567
Clay is impermeable,
and it prevents water from
352
00:21:27,734 --> 00:21:29,000
leaking through the clay so
353
00:21:29,167 --> 00:21:30,567
that your dam actually
holds water.
354
00:21:32,067 --> 00:21:35,400
On our site, we don't
have very much clay.
355
00:21:35,567 --> 00:21:39,100
So we needed to find another
way to keep the water from
356
00:21:39,267 --> 00:21:40,434
leaking out of the dam.
357
00:21:41,501 --> 00:21:44,367
Jeff and the team makethe bold decision to build
358
00:21:44,534 --> 00:21:46,167
the core of the damfrom asphalt.
359
00:21:47,400 --> 00:21:49,400
The technique is commonin Europe
360
00:21:49,567 --> 00:21:51,100
but rare in the United States.
361
00:21:52,901 --> 00:21:56,167
My first thought was, I don't
want to do an asphalt core dam.
362
00:21:56,334 --> 00:21:57,467
It's not been done in Colorado.
363
00:21:57,634 --> 00:21:59,567
I don't want to be
a guinea pig.
364
00:21:59,734 --> 00:22:02,767
But over time, I was convinced
that that was a good way to go.
365
00:22:04,200 --> 00:22:05,300
[horn honking]
366
00:22:06,667 --> 00:22:09,100
The engineers bring ina special paving machine
367
00:22:09,267 --> 00:22:10,267
to do the job.
368
00:22:13,567 --> 00:22:16,367
It works like a 3D printer.
369
00:22:16,534 --> 00:22:18,567
As it advances, it lays down
370
00:22:18,734 --> 00:22:20,868
a three-foot band offlexible asphalt
371
00:22:22,267 --> 00:22:25,467
and two bands of gravel oneither side that lock
372
00:22:25,634 --> 00:22:27,267
the waterproof coreinto position.
373
00:22:28,968 --> 00:22:32,567
For almost three years,the machine travels up and down
374
00:22:32,734 --> 00:22:35,601
the dam over 500 times to build
375
00:22:35,767 --> 00:22:38,767
it up to its full heightof 350 feet.
376
00:22:40,701 --> 00:22:43,968
The asphalt and gravel core istoo weak on its own to
377
00:22:44,133 --> 00:22:46,100
hold back billions of gallonsof water.
378
00:22:47,167 --> 00:22:51,267
To make the dam strong,engineers must build two large
379
00:22:51,434 --> 00:22:54,267
rock embankments on either sideof the waterproof core.
380
00:22:58,367 --> 00:23:01,467
To feed the operation,the engineers transform
381
00:23:01,634 --> 00:23:03,067
a part of Chimney Hollow
382
00:23:03,234 --> 00:23:05,567
into one of the largestquarries in Colorado.
383
00:23:08,000 --> 00:23:10,167
At its peak, it produces over
384
00:23:10,334 --> 00:23:14,400
68,000 tons of materialevery day.
385
00:23:14,567 --> 00:23:17,367
Supersized dump trucks haulthe rock to the dam.
386
00:23:19,267 --> 00:23:22,100
The quarrying operationruns 24/7
387
00:23:22,267 --> 00:23:23,801
to keep the dambuilders supplied
388
00:23:23,968 --> 00:23:25,167
with a steady streamof rock.
389
00:23:34,100 --> 00:23:37,067
But the reservoir is just onepart of the water storage
390
00:23:37,234 --> 00:23:38,601
solution in Colorado.
391
00:23:40,801 --> 00:23:44,267
The challenge for engineers isto reliably deliver thousands
392
00:23:44,434 --> 00:23:46,467
of gallons of water towhere it's needed.
393
00:23:47,767 --> 00:23:49,901
The steep terrain ofthe Rocky Mountains
394
00:23:50,067 --> 00:23:52,167
makes that difficult.
395
00:23:52,334 --> 00:23:54,567
So the team buildsa vast new network
396
00:23:54,734 --> 00:23:56,367
of infrastructurearound the dam.
397
00:23:58,567 --> 00:24:02,267
First, they excavatea 2,000-foot-long access tunnel
398
00:24:02,434 --> 00:24:03,467
through solid rock.
399
00:24:09,367 --> 00:24:13,100
This will house the giantpipelines that carry water into
400
00:24:13,267 --> 00:24:15,300
and out of the reservoir.
401
00:24:17,767 --> 00:24:21,167
Next, they construct a valvehouse to control the flow
402
00:24:21,334 --> 00:24:23,367
of water through the system.
403
00:24:25,801 --> 00:24:29,667
The team also builds a hugeconcrete spillway capable of
404
00:24:29,834 --> 00:24:33,067
releasing excess water safelyduring extreme weather.
405
00:24:35,367 --> 00:24:39,100
And because this site sits highin the Rockies, engineers must
406
00:24:39,267 --> 00:24:42,534
construct new roadsand bridges to reach it.
407
00:24:45,000 --> 00:24:47,567
All of these systems mustoperate together.
408
00:24:54,267 --> 00:24:57,767
After four years ofconstruction, the giant dam
409
00:24:57,934 --> 00:24:59,567
and its supportinginfrastructure
410
00:24:59,734 --> 00:25:01,000
are finally complete.
411
00:25:03,267 --> 00:25:06,467
What engineers must now do isprotect the dam from
412
00:25:06,634 --> 00:25:08,767
an unexpectedbut common threat --
413
00:25:10,100 --> 00:25:11,100
flooding.
414
00:25:23,000 --> 00:25:24,801
Engineers are racingto guarantee
415
00:25:24,968 --> 00:25:27,901
Colorado's future water supply.
416
00:25:28,067 --> 00:25:30,601
Rebuilding Gross Dam willincrease the reservoir's
417
00:25:30,767 --> 00:25:33,868
capacity by over 183%.
418
00:25:35,567 --> 00:25:38,467
But that createsa major problem.
419
00:25:38,634 --> 00:25:42,367
As the water rises, it couldexploit natural low points in
420
00:25:42,534 --> 00:25:44,467
the surrounding landscape.
421
00:25:44,634 --> 00:25:47,567
If we have a flood
and the reservoir comes up,
422
00:25:47,734 --> 00:25:50,400
the water is actually going to
go out a different area that
423
00:25:50,567 --> 00:25:51,767
we don't want it to go out.
424
00:25:55,567 --> 00:25:58,901
Enlarging Gross Dam will raisethe reservoir's water level
425
00:25:59,067 --> 00:26:01,567
by nearly 140 feet.
426
00:26:04,000 --> 00:26:07,367
A sudden flood could increasethe water level even higher.
427
00:26:13,567 --> 00:26:16,167
There's a risk that the risingwater could escape through
428
00:26:16,334 --> 00:26:18,434
a low point inthe surrounding valley.
429
00:26:20,901 --> 00:26:22,300
To stop that from happening,
430
00:26:22,467 --> 00:26:25,801
engineers build a secondbarrier known as
431
00:26:25,968 --> 00:26:27,300
a saddle dam.
432
00:26:27,467 --> 00:26:30,968
First, crews excavate down tosolid bedrock.
433
00:26:31,133 --> 00:26:34,200
Then they backfill the cut withthousands of tons
434
00:26:34,367 --> 00:26:36,601
of roller-compacted.
435
00:26:36,767 --> 00:26:40,267
The finished structure stands40 feet high and stretches
436
00:26:40,434 --> 00:26:44,167
roughly 590 feetacross the landscape.
437
00:26:44,334 --> 00:26:47,167
Covered with naturalvegetation, the saddle dam
438
00:26:47,334 --> 00:26:50,000
seals the gap to prevent waterfrom escaping from
439
00:26:50,167 --> 00:26:52,100
the reservoir duringextreme floods.
440
00:26:58,167 --> 00:27:01,100
The huge new Gross Damwill be an arch dam.
441
00:27:02,167 --> 00:27:04,367
The curved shape ofthe structure transfers
442
00:27:04,534 --> 00:27:06,467
the pressure of the watersideways into
443
00:27:06,634 --> 00:27:08,000
the surrounding canyon walls.
444
00:27:10,067 --> 00:27:11,767
The saddle dam is different.
445
00:27:13,467 --> 00:27:16,200
So unlike the main dam,
which is an arch dam,
446
00:27:16,367 --> 00:27:20,067
the Saddle Dam is a gravity
structure, so it holds itself
447
00:27:20,234 --> 00:27:21,667
in place under its own weight.
448
00:27:23,100 --> 00:27:24,601
Crews must buildthe saddle dam
449
00:27:24,767 --> 00:27:29,100
from layer after layer ofdense roller-compacted concrete
450
00:27:29,267 --> 00:27:30,767
to give it the strengthit needs.
451
00:27:32,467 --> 00:27:33,901
Right here,
we're transitioning from
452
00:27:34,067 --> 00:27:35,267
one layer to the next.
453
00:27:35,434 --> 00:27:38,100
You can see this layer,
another layer here,
454
00:27:38,267 --> 00:27:41,367
and they just keep coming in
all day long, dumping out
455
00:27:41,534 --> 00:27:45,100
roller-compacted concrete,
spreading it into these layers,
456
00:27:45,267 --> 00:27:47,100
vibrating it,
rolling it into place,
457
00:27:47,267 --> 00:27:49,100
making sure
it's hard and set up.
458
00:27:51,567 --> 00:27:54,067
The saddle dam's locationpresents engineers
459
00:27:54,234 --> 00:27:55,501
with a challenge.
460
00:27:57,267 --> 00:28:00,601
It's over half a mile fromthe on-site plant that makes
461
00:28:00,767 --> 00:28:03,067
the special cold concretethe dam needs.
462
00:28:04,767 --> 00:28:08,167
Their solution is to deploya fleet of dump trucks.
463
00:28:12,467 --> 00:28:15,367
These work in rotation todeliver the concrete
464
00:28:15,534 --> 00:28:16,434
at the correct temperature.
465
00:28:18,501 --> 00:28:20,701
This operation over here
is continuous.
466
00:28:20,868 --> 00:28:23,167
We have one truck right
after another.
467
00:28:23,334 --> 00:28:24,267
One truck is backing in.
468
00:28:24,434 --> 00:28:25,701
There's another truck out there
469
00:28:25,868 --> 00:28:28,701
waiting to back in right behind
them and dump their load.
470
00:28:32,667 --> 00:28:35,167
Once dumped,it's critical that the concrete
471
00:28:35,334 --> 00:28:37,567
is spread quicklyand to the right height.
472
00:28:39,567 --> 00:28:42,367
So, the engineers equip eachbulldozer with a special
473
00:28:42,534 --> 00:28:46,400
GPS system that tellsthe driver where to spread it.
474
00:28:48,100 --> 00:28:49,767
[equipment beeping]
475
00:28:53,467 --> 00:28:57,000
It uses, basically,
satellites to know exactly
476
00:28:57,167 --> 00:29:00,200
where, what elevation they're
at, where they are in space.
477
00:29:00,367 --> 00:29:02,701
Then they can place the
material to exact tolerances.
478
00:29:07,167 --> 00:29:10,300
Next, crewscompress the concrete.
479
00:29:10,467 --> 00:29:15,367
This reduces its volume by 15%and forces out air to create
480
00:29:15,534 --> 00:29:17,200
a dense, impermeable structure.
481
00:29:18,467 --> 00:29:21,400
[Casey]
This piece of equipment here
that rolls it into place,
482
00:29:21,567 --> 00:29:23,601
and then you can see how it
gets smooth.
483
00:29:23,767 --> 00:29:25,868
The concrete is hardenough to walk on
484
00:29:26,033 --> 00:29:27,267
after only a few minutes.
485
00:29:35,267 --> 00:29:38,701
Once complete, the saddle damwill prevent overflow from
486
00:29:38,868 --> 00:29:41,067
threatening the valleybelow the reservoir.
487
00:29:43,200 --> 00:29:45,367
We've been planning this work
for a really long time.
488
00:29:45,534 --> 00:29:48,267
It's great to see it finished
off so that we can move on
489
00:29:48,434 --> 00:29:49,767
and continue the rest of
the project
490
00:29:49,934 --> 00:29:51,567
and get things
wrapped up around here.
491
00:29:52,667 --> 00:29:56,167
Now, engineers must tacklesomething that could threaten
492
00:29:56,334 --> 00:29:58,601
the stability ofthe entire structure.
493
00:30:09,868 --> 00:30:14,367
Engineers in Colorado aresupersizing the Gross Dam to
494
00:30:14,534 --> 00:30:17,801
help secure the state's futurewater supply.
495
00:30:20,267 --> 00:30:23,701
Reservoirs need a way to safelyrelease excess water when
496
00:30:23,868 --> 00:30:25,501
water levels rise too high.
497
00:30:27,100 --> 00:30:30,400
To do that, engineers buildthem with spillways.
498
00:30:32,267 --> 00:30:35,400
These channels often directflood water down the face of
499
00:30:35,567 --> 00:30:38,367
the dam and safely back intothe river below.
500
00:30:40,100 --> 00:30:43,567
But at Gross Dam,enlarging the spillway creates
501
00:30:43,734 --> 00:30:44,968
a dangerous problem.
502
00:30:46,367 --> 00:30:49,167
The overflowing water strikesthe bottom of the dam,
503
00:30:50,200 --> 00:30:52,400
a zone calledthe stilling basin,
504
00:30:52,567 --> 00:30:54,000
with enormous force,
505
00:30:54,167 --> 00:30:56,767
after it plunges downthe stepped concrete chute.
506
00:30:58,067 --> 00:31:00,868
That energy could threatenthe stability of
507
00:31:01,033 --> 00:31:02,300
the structure itself.
508
00:31:04,100 --> 00:31:07,267
The concern is with the new
steps, the force of the water
509
00:31:07,434 --> 00:31:11,000
could just create too much
energy at the base, which then
510
00:31:11,167 --> 00:31:13,601
erodes the foundation
and creates a hole
511
00:31:13,767 --> 00:31:16,367
right underneath our new dam.
512
00:31:16,534 --> 00:31:19,501
To solve the problem,Gross Dam's designers turn to
513
00:31:19,667 --> 00:31:22,567
hydro engineers atColorado State University.
514
00:31:24,868 --> 00:31:26,567
The team builds a scale model
515
00:31:26,734 --> 00:31:28,767
of the new spillwayand stilling basin.
516
00:31:30,701 --> 00:31:35,000
Then, they simulate extremefloods to measure how the water
517
00:31:35,167 --> 00:31:37,267
behaves as it crashesdown the dam.
518
00:31:38,400 --> 00:31:40,267
The tests reveal a solution.
519
00:31:41,901 --> 00:31:45,400
Engineers must build gianttriangular-shaped concrete
520
00:31:45,567 --> 00:31:49,567
structures called baffle blocksinside the stilling basin at
521
00:31:49,734 --> 00:31:52,000
the base of the spillway.
522
00:31:52,167 --> 00:31:55,100
These structures break upthe flow of water and reduce
523
00:31:55,267 --> 00:31:58,467
its destructive energy beforeit reaches the river below.
524
00:32:00,567 --> 00:32:03,000
We learned from that model how
large to make these
525
00:32:03,167 --> 00:32:05,467
baffle blocks,
how far to space them
526
00:32:05,634 --> 00:32:07,501
from the dam,
how long to make
527
00:32:07,667 --> 00:32:10,467
the stilling basin itself,
and how tall to make
528
00:32:10,634 --> 00:32:13,100
these stilling basin walls so
that all the water would stay
529
00:32:13,267 --> 00:32:15,167
inside this structure.
530
00:32:15,334 --> 00:32:19,467
Now engineers must buildthe system in real life.
531
00:32:19,634 --> 00:32:22,267
First, crews constructthe stilling basin
532
00:32:22,434 --> 00:32:23,667
at the foot of the dam.
533
00:32:25,267 --> 00:32:29,167
Then, they install 11 massiveconcrete baffle blocks
534
00:32:29,334 --> 00:32:30,567
across its floor.
535
00:32:31,400 --> 00:32:35,367
Next, crews pour toweringreinforced-concrete walls
536
00:32:35,534 --> 00:32:36,801
around the basin itself.
537
00:32:38,868 --> 00:32:41,767
To prevent the turbulent waterfrom escaping and eroding
538
00:32:41,934 --> 00:32:44,868
the surrounding ground,the walls must be built
539
00:32:45,033 --> 00:32:47,767
strong enough to withstandthe immense force
540
00:32:47,934 --> 00:32:49,667
of the falling water.
541
00:32:49,834 --> 00:32:51,601
[Casey]
So these walls are what
we're building today.
542
00:32:51,767 --> 00:32:54,200
They're full of reinforcing
steel, and these guys are
543
00:32:54,367 --> 00:32:57,167
pumping conventional concrete
into these walls.
544
00:32:57,334 --> 00:32:58,601
You can see the workers above
545
00:33:00,067 --> 00:33:02,601
vibrating the concrete into
place and making sure it's all
546
00:33:02,767 --> 00:33:06,167
consolidated and properly
installed so that when we pull
547
00:33:06,334 --> 00:33:08,300
this formwork off,
we have a nice,
548
00:33:08,467 --> 00:33:09,667
smooth, finished product.
549
00:33:11,167 --> 00:33:13,968
Together, the spillwayand stilling basin form
550
00:33:14,133 --> 00:33:15,467
a giant safety valve
551
00:33:17,267 --> 00:33:20,467
to protect Gross Dam duringthe most extreme floods.
552
00:33:26,367 --> 00:33:29,300
The safety features of the damextend beyond the spillway.
553
00:33:31,367 --> 00:33:34,100
It's critical that the newextension moves slightly
554
00:33:34,267 --> 00:33:37,701
upstream as the reservoirpushes against the structure.
555
00:33:39,167 --> 00:33:41,100
That movement helpsto lock the dam
556
00:33:41,267 --> 00:33:43,667
into its final super-strongarch shape.
557
00:33:45,267 --> 00:33:49,267
But if the dam moves the wrongway, the concrete could crack.
558
00:33:51,267 --> 00:33:53,868
Dam safety engineerErin Gleason
559
00:33:54,033 --> 00:33:56,567
oversees a vast networkof sensors
560
00:33:56,734 --> 00:33:58,267
that monitor both structures.
561
00:34:02,300 --> 00:34:03,868
[Erin]
We have lots of sensors --
562
00:34:04,033 --> 00:34:06,567
hundreds, in the new dam
and the existing dam,
563
00:34:06,734 --> 00:34:08,400
and all of them work together
564
00:34:08,567 --> 00:34:12,267
so that as we construct the new
dam, we're ensuring that
565
00:34:12,434 --> 00:34:15,567
it's compatible with
the existing dam and that at
566
00:34:15,734 --> 00:34:17,567
the end of construction,
we'll have a safe structure.
567
00:34:22,267 --> 00:34:24,367
Joint meters measurethe movement between
568
00:34:24,534 --> 00:34:28,100
the original concrete blocks ofthe old dam.
569
00:34:28,267 --> 00:34:31,267
The engineers expect to seea change as the new dam's
570
00:34:31,434 --> 00:34:33,667
roller compacted concretepushes on it.
571
00:34:35,167 --> 00:34:38,801
So as the RCC is placed
and heats up and cures on
572
00:34:38,968 --> 00:34:40,767
the downstream side of the dam,
573
00:34:40,934 --> 00:34:43,367
that heat expands the concrete
574
00:34:43,534 --> 00:34:46,367
and then pushes
the existing dam upstream.
575
00:34:48,000 --> 00:34:52,367
And so we're trying to figure
out how much of that expansion
576
00:34:52,534 --> 00:34:56,868
and contraction of the joints
is due to the new RCC.
577
00:34:59,300 --> 00:35:01,701
If the joints widen,engineers know
578
00:35:01,868 --> 00:35:05,100
the new extension is pushingthe dam upstream as designed.
579
00:35:07,501 --> 00:35:11,000
If the joints contract,the dam could be moving
580
00:35:11,167 --> 00:35:12,267
in the wrong direction.
581
00:35:14,267 --> 00:35:16,701
[Erin] And that could make it
prone to cracking.
582
00:35:18,267 --> 00:35:20,767
And cracking is not what
we want to see on --
583
00:35:20,934 --> 00:35:22,968
on a arch dam or any dam.
584
00:35:24,868 --> 00:35:27,868
Survey prisms mountedon the dam monitor
585
00:35:28,033 --> 00:35:29,868
vertical movement acrossthe structure.
586
00:35:32,000 --> 00:35:34,100
Any upward shift could indicate
587
00:35:34,267 --> 00:35:36,400
the dam is pulling awayfrom its foundations.
588
00:35:42,567 --> 00:35:45,868
Back in the control room,Erin analyzes the data
589
00:35:46,033 --> 00:35:47,167
in real time.
590
00:35:47,334 --> 00:35:51,067
Over on this screen,
we have the survey prisms,
591
00:35:51,234 --> 00:35:53,467
the vertical movement of
the survey prisms.
592
00:35:55,000 --> 00:35:57,400
And that's showing no movement,
no vertical movement,
593
00:35:57,567 --> 00:35:59,167
which is good.
594
00:35:59,334 --> 00:36:02,667
This specifically is
the joint meter instrumentation,
595
00:36:02,834 --> 00:36:07,567
and it shows that further
upstream movement is occurring.
596
00:36:07,734 --> 00:36:10,300
So that's exactly what
we were expecting to see
597
00:36:10,467 --> 00:36:12,667
and hoping to see,
and so that just confirms
598
00:36:12,834 --> 00:36:16,767
that we have concrete
that is not going to crack.
599
00:36:16,934 --> 00:36:20,267
The readings confirmthe structure remains stable
600
00:36:20,434 --> 00:36:24,267
and the expanded Gross Dam isperforming exactly as designed.
601
00:36:25,968 --> 00:36:30,167
Now, engineers must solveone final problem before
602
00:36:30,334 --> 00:36:32,400
they can complete the project.
603
00:36:32,567 --> 00:36:35,167
Ensuring the dam is watertight.
604
00:36:45,701 --> 00:36:48,267
Engineers in Colorado areracing to finish
605
00:36:48,434 --> 00:36:49,901
the mighty Gross Dam.
606
00:36:51,467 --> 00:36:53,767
They must solveone final problem
607
00:36:53,934 --> 00:36:55,667
before they can completethe project.
608
00:36:58,100 --> 00:37:00,300
The concrete walls of the damare designed to
609
00:37:00,467 --> 00:37:01,501
hold back the reservoir.
610
00:37:03,901 --> 00:37:05,968
But the rock surroundingthe structure
611
00:37:06,133 --> 00:37:07,601
is not completely watertight.
612
00:37:09,901 --> 00:37:12,968
Water can seep throughtiny cracks and fissures in
613
00:37:13,133 --> 00:37:15,234
the canyon wallsbeside the dam.
614
00:37:17,667 --> 00:37:21,667
Over time, that leakage couldweaken the surrounding rock
615
00:37:21,834 --> 00:37:24,267
and threaten the stability ofthe structure itself.
616
00:37:26,167 --> 00:37:28,701
Specialist Jessie Strobelhas been working
617
00:37:28,868 --> 00:37:31,300
on the project for four years.
618
00:37:31,467 --> 00:37:34,267
This is by far the biggest
project I have ever worked on.
619
00:37:34,434 --> 00:37:36,667
I have never seen anything this
big being built.
620
00:37:38,167 --> 00:37:39,601
This is gonna be one for
the record books
621
00:37:39,767 --> 00:37:40,701
and the resume.
622
00:37:44,167 --> 00:37:46,367
The solution is tobuild a giant
623
00:37:46,534 --> 00:37:49,901
underground waterproof barrierinside the rock itself.
624
00:37:52,067 --> 00:37:55,767
Known as a grout curtain,it seals cracks deep beneath
625
00:37:55,934 --> 00:37:59,367
the surface and blocks waterfrom passing through.
626
00:37:59,534 --> 00:38:01,300
[Jessie] The old dam did have
a grout curtain
627
00:38:01,467 --> 00:38:03,067
that extended up to
the top of it,
628
00:38:03,234 --> 00:38:05,968
but this dam is going to be
over 140 meters high,
629
00:38:06,133 --> 00:38:08,667
so we have to extend
the grout curtain the rest of
630
00:38:08,834 --> 00:38:11,567
the way up to the top of
the dam so it can hold back
631
00:38:11,734 --> 00:38:13,667
the reservoir water
once it's filled.
632
00:38:16,100 --> 00:38:18,000
To extend the height ofthe grout curtain,
633
00:38:19,000 --> 00:38:21,100
the crews first drill deep into
634
00:38:21,267 --> 00:38:23,834
the canyon wallsaround the dam.
635
00:38:26,300 --> 00:38:31,267
The machine drills holes tens
of meters into the ground to
636
00:38:31,434 --> 00:38:33,868
make sure that we are getting
as far down as we believe any
637
00:38:34,033 --> 00:38:35,601
reservoir seepage
can go through.
638
00:38:35,767 --> 00:38:37,567
Then, after
it's drilled the hole,
639
00:38:37,734 --> 00:38:41,000
it continues to stay in place
and then injects the grout
640
00:38:41,167 --> 00:38:43,067
through tubing all the way in
to make sure that
641
00:38:43,234 --> 00:38:46,501
we are filling those tens of
meters with all of the grout
642
00:38:46,667 --> 00:38:48,934
and really forming
that strong barrier.
643
00:38:51,400 --> 00:38:53,367
We don't know exactly what
all the rocks look like
644
00:38:53,534 --> 00:38:56,100
100 feet down, so we just
keep feeding grout
645
00:38:56,267 --> 00:38:59,267
in through the machine
until it stops taking any more.
646
00:39:00,367 --> 00:39:04,367
Together, these injectionsform a vast underground curtain
647
00:39:04,534 --> 00:39:07,167
designed to stop water fromescaping around the dam.
648
00:39:10,701 --> 00:39:13,000
But seepage creates anotherdanger beneath
649
00:39:13,167 --> 00:39:14,100
the structure itself.
650
00:39:18,167 --> 00:39:21,667
Groundwater can still forceits way underneath the dam.
651
00:39:23,100 --> 00:39:25,100
When you're engineering a dam,
you don't just need to think
652
00:39:25,267 --> 00:39:27,567
about holding the water back
behind the reservoir,
653
00:39:27,734 --> 00:39:30,100
but you also have to think
about how the groundwater is
654
00:39:30,267 --> 00:39:31,567
going to want to move as well.
655
00:39:33,267 --> 00:39:36,567
Because if pressure is put on
the dam from the groundwater,
656
00:39:36,734 --> 00:39:39,968
it's gonna start lifting
the dam up, and that is just
657
00:39:40,133 --> 00:39:42,167
not what you want to be able to
hold back a reservoir.
658
00:39:43,267 --> 00:39:45,467
That movementcould separate the dam
659
00:39:45,634 --> 00:39:47,467
from the bedrockholding it in place.
660
00:39:49,167 --> 00:39:51,167
The resultcould be catastrophic.
661
00:39:53,367 --> 00:39:54,868
The team needsanother solution.
662
00:39:56,400 --> 00:39:59,067
Deep inside the dam,crews construct
663
00:39:59,234 --> 00:40:01,901
a vast drainage systemdesigned to relieve
664
00:40:02,067 --> 00:40:03,400
the pressurebeneath the structure.
665
00:40:05,467 --> 00:40:09,400
From here, crews drill hundredsof long drainage holes deep
666
00:40:09,567 --> 00:40:10,667
into the foundation below.
667
00:40:17,367 --> 00:40:19,868
The drainage holes interceptthe ground water,
668
00:40:20,033 --> 00:40:23,667
and channel it intothe galleries inside the dam.
669
00:40:23,834 --> 00:40:27,400
From here, the dam can releaseit into the river downstream.
670
00:40:28,767 --> 00:40:31,901
The existing Gross Dam was
pretty watertight,
671
00:40:32,067 --> 00:40:34,868
but you could still fill up
a glass of water in about
672
00:40:35,033 --> 00:40:37,667
a minute from the seepage that
was coming through.
673
00:40:37,834 --> 00:40:40,467
So we would hope with
the raised dam, to keep that
674
00:40:40,634 --> 00:40:44,000
same level of watertightness,
but still have some seepage.
675
00:40:44,167 --> 00:40:46,801
So that's why we have
the foundation drains being
676
00:40:46,968 --> 00:40:49,467
built in, it's for any water
that does come in,
677
00:40:49,634 --> 00:40:52,968
it goes where we want it to go
and doesn't start moving around
678
00:40:53,133 --> 00:40:55,100
and moving things that
we don't want to be moved.
679
00:40:56,367 --> 00:40:58,767
This super drainage system,together with
680
00:40:58,934 --> 00:41:01,868
the grout curtain,will help to keep Gross Dam
681
00:41:02,033 --> 00:41:03,567
locked securely to the canyon.
682
00:41:07,300 --> 00:41:10,868
To complete Colorado's megawater projects,
683
00:41:11,033 --> 00:41:13,667
engineers excavated deep inthe Rocky Mountains...
684
00:41:15,000 --> 00:41:16,968
[explosion blasts]
685
00:41:18,467 --> 00:41:21,067
...raised one of the state'slargest dams
686
00:41:21,234 --> 00:41:22,300
to record-breaking heights...
687
00:41:27,667 --> 00:41:30,667
and built a vast new spillwayand underground drainage
688
00:41:30,834 --> 00:41:33,767
systems to protect it fromthe immense pressure of
689
00:41:33,934 --> 00:41:36,100
the reservoir behind it.
690
00:41:36,267 --> 00:41:39,367
What we've created is really
a testament not only
691
00:41:39,534 --> 00:41:42,868
to engineering,
but of construction innovation.
692
00:41:43,033 --> 00:41:47,100
Now, the new and expanded damswill help provide fresh water
693
00:41:47,267 --> 00:41:49,100
for millions ofColorado residents,
694
00:41:51,200 --> 00:41:54,901
and safeguard the state's watersupply against future droughts
695
00:41:55,067 --> 00:41:56,567
for generations to come.
62701
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