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These are the user uploaded subtitles that are being translated: 1 00:00:01,667 --> 00:00:05,701 [narrator] High in the Colorado Rockies, an elite team of engineers is 2 00:00:05,868 --> 00:00:09,267 taking on a seemingly impossible challenge. 3 00:00:09,434 --> 00:00:10,968 This is gonna be one for the record books 4 00:00:11,133 --> 00:00:12,467 and the resume. 5 00:00:12,467 --> 00:00:16,067 They're racing to build an extraordinary new mega dam. 6 00:00:16,234 --> 00:00:19,467 We're under a lot of pressure to get this done on schedule. 7 00:00:19,634 --> 00:00:20,901 The clock is ticking. 8 00:00:21,067 --> 00:00:23,267 A chronic drought puts the water supply 9 00:00:23,434 --> 00:00:25,567 for millions of people at risk. 10 00:00:25,734 --> 00:00:29,200 If we don't do something now, we will be too late. 11 00:00:29,367 --> 00:00:31,968 To succeed, they must safely fuse 12 00:00:32,133 --> 00:00:34,100 70-year-old construction methods 13 00:00:34,267 --> 00:00:35,467 with cutting-edge engineering. 14 00:00:37,567 --> 00:00:38,901 This mega dam 15 00:00:40,267 --> 00:00:44,467 ranks in a league of ambitious new engineering wonders that 16 00:00:44,634 --> 00:00:49,767 are bigger, faster, taller, and more advanced 17 00:00:49,934 --> 00:00:52,000 than anything ever constructed before. 18 00:00:53,167 --> 00:00:57,400 This is the inside story of the extraordinary challenge of 19 00:00:57,567 --> 00:00:59,300 building these giants. 20 00:01:13,100 --> 00:01:15,634 Colorado is facing a crisis. 21 00:01:18,100 --> 00:01:20,767 It has long relied on melting mountain snowpack 22 00:01:20,934 --> 00:01:21,868 for its water supply. 23 00:01:25,767 --> 00:01:28,801 Climate change is reducing snowfall and shortening 24 00:01:28,968 --> 00:01:30,000 the melt season. 25 00:01:31,200 --> 00:01:33,667 This means more water runs off 26 00:01:33,834 --> 00:01:35,467 before it can be stored in reservoirs. 27 00:01:37,267 --> 00:01:39,400 Colorado must capture a greater amount of 28 00:01:39,567 --> 00:01:40,701 the dwindling snowmelt. 29 00:01:42,567 --> 00:01:45,601 If these efforts fail, reports suggest the state 30 00:01:45,767 --> 00:01:48,501 could run out of water within 25 years. 31 00:01:55,000 --> 00:01:58,467 To meet this challenge, engineers in Colorado are now 32 00:01:58,634 --> 00:02:01,601 working on a series of megastructures to boost 33 00:02:01,767 --> 00:02:03,934 the state's reserves of water. 34 00:02:06,367 --> 00:02:08,767 The Gross Dam was built in the 1950s 35 00:02:09,868 --> 00:02:11,968 to help supply the growing population 36 00:02:12,133 --> 00:02:14,000 of Colorado's state capital, Denver. 37 00:02:16,400 --> 00:02:19,868 Constructed from over 1,400 concrete blocks, 38 00:02:20,033 --> 00:02:23,567 it rose to an impressive 335 feet 39 00:02:23,734 --> 00:02:25,367 and was designed to hold back 40 00:02:25,534 --> 00:02:28,467 over 13 billion gallons of water. 41 00:02:28,634 --> 00:02:31,667 But that's not enough to meet the demand of the 21st century. 42 00:02:34,100 --> 00:02:36,868 The plan today is to triple its capacity. 43 00:02:38,000 --> 00:02:41,400 Jeff Martin leads the team tasked with making it happen. 44 00:02:43,100 --> 00:02:45,667 [Jeff] The original Gross Dam is just an amazing structure. 45 00:02:46,767 --> 00:02:49,868 Just, unfortunately, now, it doesn't hold 46 00:02:50,033 --> 00:02:51,300 as much water as we need. 47 00:02:52,801 --> 00:02:54,667 So, we're gonna solve our problem, 48 00:02:54,834 --> 00:02:56,200 by raising the Gross Dam 49 00:02:56,367 --> 00:02:58,667 to create more water storage behind it. 50 00:03:03,868 --> 00:03:07,100 Engineers must build a completely new dam on top of 51 00:03:07,267 --> 00:03:08,334 the old one. 52 00:03:08,334 --> 00:03:11,000 To succeed, they must beat extreme weather, 53 00:03:12,367 --> 00:03:15,367 tough geology, and a tight deadline 54 00:03:15,534 --> 00:03:17,234 set by the Federal government. 55 00:03:19,667 --> 00:03:22,267 The engineers will build up the height of the dam 56 00:03:22,434 --> 00:03:27,200 by a third to a colossal 471 feet. 57 00:03:27,367 --> 00:03:30,467 They will double the length of the crest of the dam 58 00:03:30,634 --> 00:03:32,100 to 2,040 feet, 59 00:03:33,467 --> 00:03:37,000 and build a brand-new spillway to release surplus water. 60 00:03:38,868 --> 00:03:42,567 The team will pour over 21 million cubic feet of 61 00:03:42,734 --> 00:03:48,100 special concrete to make the wall's 118 steps, 62 00:03:48,267 --> 00:03:52,167 and expand the width of the dam's base to 300 feet. 63 00:03:53,167 --> 00:03:57,100 The new gross dam will be the tallest dam in Colorado 64 00:03:57,267 --> 00:04:01,467 and hold back a staggering 38 billion gallons of water. 65 00:04:06,367 --> 00:04:09,100 This megaproject transforms the structure from 66 00:04:09,267 --> 00:04:12,200 a gravity dam into an arched dam. 67 00:04:12,367 --> 00:04:15,601 This will be the first time in the world that engineers 68 00:04:15,767 --> 00:04:16,934 have attempted to do this. 69 00:04:18,901 --> 00:04:21,868 Engineer of record, Felipe Garcia, and his team 70 00:04:22,033 --> 00:04:23,667 have been brought on to make it happen. 71 00:04:25,868 --> 00:04:28,968 So, the original Gross Dam was designed as 72 00:04:29,133 --> 00:04:31,300 a curved gravity structure. 73 00:04:32,367 --> 00:04:35,868 What I mean by a curved gravity dam is that it has enough 74 00:04:36,033 --> 00:04:37,667 weight to maintain stability 75 00:04:37,834 --> 00:04:39,767 against the pressure of the reservoir. 76 00:04:41,868 --> 00:04:45,467 But relying on their sheer mass to hold back a reservoir 77 00:04:45,634 --> 00:04:48,267 makes gravity dams expensive and inefficient. 78 00:04:50,367 --> 00:04:55,100 A arch dam achieves its stable factor of safety by 79 00:04:55,267 --> 00:04:57,167 transferring the loads from 80 00:04:57,334 --> 00:05:01,767 the reservoir laterally towards the abutment. 81 00:05:01,934 --> 00:05:06,267 And in turn, you're able to make the arch thinner. 82 00:05:06,434 --> 00:05:09,601 Not only that reduces cost and schedule, but it also 83 00:05:09,767 --> 00:05:11,767 provides a more sustainable project. 84 00:05:13,767 --> 00:05:17,167 Engineering teams must build solid foundations on both sides 85 00:05:17,334 --> 00:05:19,267 of the canyon to support 86 00:05:19,434 --> 00:05:20,968 the greater width of the new dam. 87 00:05:22,667 --> 00:05:25,267 But the geology in this part of Colorado presents 88 00:05:25,434 --> 00:05:26,467 a big problem. 89 00:05:27,767 --> 00:05:29,501 What we have here 90 00:05:29,667 --> 00:05:33,100 is pretty typical of about 90% of the foundation 91 00:05:33,267 --> 00:05:35,267 of we have out there at Gross. 92 00:05:35,434 --> 00:05:39,267 It is very strong rock, but from this particular slope, 93 00:05:39,434 --> 00:05:41,100 this material is highly weathered. 94 00:05:41,267 --> 00:05:42,467 You see? I -- I can just peel it 95 00:05:42,634 --> 00:05:44,601 with my hand -- that means that it doesn't have 96 00:05:44,767 --> 00:05:48,901 enough stiffness to support the loads from the dam. 97 00:05:49,067 --> 00:05:50,767 So, this material would need to be removed. 98 00:05:52,767 --> 00:05:55,667 The teams use a fleet of excavators to scrape away 99 00:05:55,834 --> 00:05:56,968 the loose weathered rock. 100 00:06:03,000 --> 00:06:07,901 Next, the team pours nearly 705,000 cubic feet of concrete 101 00:06:09,000 --> 00:06:12,701 to build a super strong and perfectly level foundation 102 00:06:12,868 --> 00:06:14,601 that bonds tightly to the bedrock. 103 00:06:20,100 --> 00:06:21,567 It takes around 20 months 104 00:06:21,734 --> 00:06:24,067 to prepare the canyon walls for the new dam. 105 00:06:29,501 --> 00:06:32,767 The engineers' next task is to prepare the concrete of 106 00:06:32,934 --> 00:06:35,467 the old dam to make sure that it bonds 107 00:06:35,634 --> 00:06:38,000 to the concrete of the new one. 108 00:06:38,167 --> 00:06:41,000 [Jeff] A concrete dam moves. It lives. 109 00:06:41,167 --> 00:06:44,000 So, the new dam and old dam have to hold together. 110 00:06:44,167 --> 00:06:46,467 They have to bond. They have to move together. 111 00:06:46,634 --> 00:06:49,367 That's critical to the performance of the dam. 112 00:06:49,534 --> 00:06:51,801 One of the first things we need to do to build this dam is 113 00:06:51,968 --> 00:06:54,467 roughen up the face of the old dam 114 00:06:54,634 --> 00:06:56,801 so we can get the new dam to stick to it. 115 00:07:00,968 --> 00:07:02,567 To create this crucial bond, 116 00:07:04,000 --> 00:07:06,868 a blaster fires water at a pressure of nearly 117 00:07:07,033 --> 00:07:09,000 20,000 pounds per square inch 118 00:07:10,400 --> 00:07:12,567 to strip away the top layer of concrete. 119 00:07:14,968 --> 00:07:17,968 A large saw cuts slices into the crest of the dam. 120 00:07:19,868 --> 00:07:22,667 A hydraulic hammer then breaks up the concrete 121 00:07:24,467 --> 00:07:27,100 before another water blaster finishes the job. 122 00:07:28,767 --> 00:07:32,467 These processes leave the dam with a rough surface to allow 123 00:07:32,634 --> 00:07:35,567 the new concrete to form a super strong bond. 124 00:07:41,801 --> 00:07:45,167 [Felipe] The activity that's going on right now is what we call doing 125 00:07:45,334 --> 00:07:48,400 a hydro demolition of the downstream face 126 00:07:48,567 --> 00:07:49,801 of the existing dam. 127 00:07:51,100 --> 00:07:55,167 We're removing the outer layers of the skin of 128 00:07:55,334 --> 00:07:57,667 the existing dam, but we want to make sure 129 00:07:57,834 --> 00:08:00,100 and be careful not to remove too much of it 130 00:08:00,267 --> 00:08:02,267 for a large extended area, 131 00:08:02,434 --> 00:08:03,701 because at the end of the day, right, 132 00:08:03,868 --> 00:08:06,601 we're raising Gross Dam while it's still in operation. 133 00:08:08,467 --> 00:08:11,801 While the water blaster roughs up the concrete, a team at 134 00:08:11,968 --> 00:08:14,300 the top of the dam wrestles with the next challenge. 135 00:08:16,400 --> 00:08:19,400 Here is the crest of the old dam's spillway, 136 00:08:19,567 --> 00:08:21,467 the structure that allows the safe release 137 00:08:21,634 --> 00:08:22,868 of excess water. 138 00:08:24,567 --> 00:08:27,300 It's Casey Dick's responsibility to remove it 139 00:08:27,467 --> 00:08:29,601 before the team raises the height of the dam. 140 00:08:31,367 --> 00:08:34,667 We couldn't just build right on top of the existing spillway 141 00:08:34,834 --> 00:08:36,000 as it sits right now, 142 00:08:36,167 --> 00:08:38,801 because the top of it is rounded. 143 00:08:38,968 --> 00:08:41,167 If we tried to just start placing concrete right on this 144 00:08:41,334 --> 00:08:43,467 rounded surface, it would just fall right off 145 00:08:43,634 --> 00:08:45,200 and we'd never be able to get it started. 146 00:08:46,701 --> 00:08:50,000 Deconstructing this critical part of the old dam is 147 00:08:50,167 --> 00:08:51,501 a major operation. 148 00:08:52,601 --> 00:08:55,968 The concrete is very heavy by its nature, so if we cut it off 149 00:08:56,133 --> 00:08:58,167 in one giant piece, we wouldn't be able to actually 150 00:08:58,334 --> 00:08:59,667 remove it from the dam. 151 00:08:59,834 --> 00:09:01,868 So we have to slice it up into smaller pieces, 152 00:09:02,033 --> 00:09:04,501 about the size of a vehicle, so that the cranes can then 153 00:09:04,667 --> 00:09:07,300 hoist it off one piece at a time. 154 00:09:07,467 --> 00:09:10,100 The team deploys a special cutting system to get 155 00:09:10,267 --> 00:09:11,601 the job done. 156 00:09:11,767 --> 00:09:14,968 To remove the old spillway, we have this apparatus that 157 00:09:15,133 --> 00:09:19,267 uses diamond-encrusted rope, wire rope, so it's really hard 158 00:09:19,434 --> 00:09:21,501 and it's abrasive, and as you drag that through 159 00:09:21,667 --> 00:09:24,367 the concrete, those crystals are stronger than the concrete 160 00:09:24,534 --> 00:09:26,501 and it's able to cut right through the concrete. 161 00:09:28,901 --> 00:09:31,767 So basically, this rope is just going through the dam, 162 00:09:31,934 --> 00:09:34,234 cutting the concrete like a cheese cutter. 163 00:09:36,701 --> 00:09:39,701 Over the next two years, the team blasts, 164 00:09:41,467 --> 00:09:45,367 cuts, and cracks apart the old dam. 165 00:09:47,801 --> 00:09:50,667 Now the engineers can start the next phase, 166 00:09:50,834 --> 00:09:54,167 an innovative concrete pouring process to ensure 167 00:09:54,334 --> 00:09:55,667 its record-breaking rise. 168 00:10:04,567 --> 00:10:08,467 Engineers in Colorado are racing to build a mega dam to 169 00:10:08,634 --> 00:10:10,601 help secure the state's water supply. 170 00:10:12,400 --> 00:10:17,267 They must raise the height of the old Gross Dam by 131 feet 171 00:10:17,434 --> 00:10:20,367 to triple the capacity of the reservoir behind it. 172 00:10:22,801 --> 00:10:27,267 To do this, engineers must build a supersized wall made 173 00:10:27,434 --> 00:10:32,267 from 118 giant steps to sit on top of the existing structure. 174 00:10:34,567 --> 00:10:36,868 For many large construction projects, 175 00:10:37,033 --> 00:10:39,267 engineers traditionally pour concrete into 176 00:10:39,434 --> 00:10:40,701 a steel framework. 177 00:10:41,567 --> 00:10:44,100 But cutting and welding thousands of feet of steel for 178 00:10:44,267 --> 00:10:47,868 the new Gross Dam will significantly raise costs 179 00:10:48,033 --> 00:10:49,868 and risk delays. 180 00:10:52,300 --> 00:10:55,467 To stay on schedule, the engineers use a material 181 00:10:55,634 --> 00:10:59,267 called roller compacted concrete, or RCC. 182 00:11:03,100 --> 00:11:06,567 A conveyor belt system delivers concrete to a fleet of 183 00:11:06,734 --> 00:11:09,567 specially tracked dump trucks at the base of the dam. 184 00:11:11,667 --> 00:11:14,667 These tip the concrete into predetermined positions. 185 00:11:16,067 --> 00:11:18,234 Bulldozers smooth it out. 186 00:11:20,667 --> 00:11:22,767 Heavy rollers then compress this layer 187 00:11:24,100 --> 00:11:27,300 before an excavator with a vibrating pad compacts it 188 00:11:27,467 --> 00:11:30,734 tightly together to increase its strength. 189 00:11:33,167 --> 00:11:37,067 Each step rises about 50 inches by 24 inches. 190 00:11:40,467 --> 00:11:44,000 The team will build 118 steps in total 191 00:11:44,167 --> 00:11:47,501 to make the new dam 471 feet tall. 192 00:11:56,801 --> 00:12:00,801 It's like watching an orchestra where there's a conductor 193 00:12:00,968 --> 00:12:03,200 and the conductor knows what every single one of 194 00:12:03,367 --> 00:12:04,701 the musicians are doing, 195 00:12:04,868 --> 00:12:06,467 and everybody's doing their part. 196 00:12:10,868 --> 00:12:13,367 This is a 24/7 operation. 197 00:12:13,534 --> 00:12:15,300 There's two shifts every day, 198 00:12:15,467 --> 00:12:17,367 and then there's seven days continuously. 199 00:12:22,267 --> 00:12:24,167 The dam extension needs over 200 00:12:24,334 --> 00:12:26,801 17 million cubic feet of concrete. 201 00:12:27,968 --> 00:12:31,100 That's over 15% more than the old dam. 202 00:12:32,200 --> 00:12:35,200 It's up to project manager Jeff Martin to make sure that 203 00:12:35,367 --> 00:12:37,901 a steady supply of concrete reaches the build 204 00:12:38,067 --> 00:12:39,167 to keep it on schedule. 205 00:12:44,100 --> 00:12:47,000 We are gonna create a massive amount of concrete to 206 00:12:47,167 --> 00:12:48,801 build the dam itself. 207 00:12:48,968 --> 00:12:51,267 We have over 300 people here working every day 208 00:12:51,434 --> 00:12:54,167 and we need to make sure we can always have the product 209 00:12:54,334 --> 00:12:57,734 where our people are to put that in and build the dam. 210 00:13:00,267 --> 00:13:02,868 Trucking in building materials would clog up the narrow 211 00:13:03,033 --> 00:13:05,267 mountain roads for years 212 00:13:05,434 --> 00:13:06,868 and put the project over budget. 213 00:13:08,467 --> 00:13:10,567 So Jeff and the team build their own 214 00:13:10,734 --> 00:13:12,267 concrete factory on site. 215 00:13:14,300 --> 00:13:15,667 [Jeff] We couldn't build this dam 216 00:13:15,834 --> 00:13:19,100 without having this concrete plant right here 217 00:13:19,267 --> 00:13:21,000 next to the dam. 218 00:13:21,167 --> 00:13:26,200 The plant operates 24/7 to supply 16,000 cubic feet of 219 00:13:26,367 --> 00:13:28,901 concrete an hour. 220 00:13:29,067 --> 00:13:31,901 But building quickly with concrete creates a problem. 221 00:13:33,100 --> 00:13:35,601 [Jeff] Any time you mix water and cement together, 222 00:13:35,767 --> 00:13:38,467 it creates heat. Heat creates expansion. 223 00:13:38,634 --> 00:13:41,767 Once it cools, it shrinks and cracks. 224 00:13:41,934 --> 00:13:45,467 These cracks could become weak points in the future. 225 00:13:45,634 --> 00:13:48,167 In a dam, that's critical. 226 00:13:48,334 --> 00:13:52,000 Water can force its way in, building pressure and weakening 227 00:13:52,167 --> 00:13:53,367 the structure over time. 228 00:13:55,000 --> 00:13:57,000 To combat this, 229 00:13:57,167 --> 00:14:00,567 engineers cool the concrete to around 50 degrees Fahrenheit. 230 00:14:01,901 --> 00:14:06,167 This limits heat buildup as it cures, reduces expansion, 231 00:14:06,334 --> 00:14:08,000 and helps to prevent cracks from forming. 232 00:14:14,000 --> 00:14:16,367 As you can see, we're in our ice plant now. 233 00:14:16,534 --> 00:14:19,968 This is where we create all the ice that we put in 234 00:14:20,133 --> 00:14:24,000 the concrete -- 450 tons of ice a day 235 00:14:24,167 --> 00:14:26,167 to go into our concrete mix to keep 236 00:14:26,334 --> 00:14:28,567 our concrete as cold as possible. 237 00:14:28,734 --> 00:14:32,501 With this project, we're using 80% ice in the concrete. 238 00:14:32,667 --> 00:14:36,267 That's a key ingredient, a key project recipe 239 00:14:36,434 --> 00:14:38,467 to keep this really cold concrete 240 00:14:38,634 --> 00:14:40,167 that we have to make for this project. 241 00:14:46,801 --> 00:14:49,767 It's critical that the concrete arrives cold to the site, 242 00:14:51,701 --> 00:14:55,167 so the team builds a custom conveyor system to transport it 243 00:14:55,334 --> 00:14:58,300 quickly over the dam and down to the waiting dump trucks. 244 00:15:02,367 --> 00:15:05,901 These tip the concrete onto predesignated spots. 245 00:15:06,067 --> 00:15:07,801 Bulldozers then spread it, 246 00:15:07,968 --> 00:15:09,868 and rollers level it. 247 00:15:10,033 --> 00:15:12,701 Finally, a compactor hammers the concrete. 248 00:15:14,100 --> 00:15:17,367 [Felipe] The reason we use a compactor is to achieve the right density 249 00:15:17,534 --> 00:15:19,467 that it needs to have the compressive strength 250 00:15:19,634 --> 00:15:22,100 and the properties that we need for the raised dam. 251 00:15:22,267 --> 00:15:25,601 The compaction process forces out a cement paste that helps 252 00:15:25,767 --> 00:15:27,467 to strengthen the layers of the dam. 253 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 concrete makes 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 back billions of gallons of water. 262 00:16:00,400 --> 00:16:02,467 But it's vulnerable to the 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 must weatherproof 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 of regular concrete. 274 00:16:37,667 --> 00:16:39,467 Workers pour the weatherproofing layer of 275 00:16:39,634 --> 00:16:42,467 concrete in tandem with the RCC concrete. 276 00:16:48,701 --> 00:16:52,000 It's critical that every layer is 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 steps to make sure 283 00:17:09,534 --> 00:17:11,267 they're constructed at the correct height. 284 00:17:12,267 --> 00:17:15,467 Nearby, a second team is tackling 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 reservoir from the ground up. 287 00:17:31,567 --> 00:17:34,901 Engineers in Colorado are racing to secure the state's 288 00:17:35,067 --> 00:17:37,667 water supplies in the face of continued droughts. 289 00:17:41,400 --> 00:17:45,234 Their solution is to store more of the ice melt every year. 290 00:17:47,667 --> 00:17:51,501 Nearly 30 miles north of the 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 water storage solution. 293 00:17:58,200 --> 00:18:02,067 Engineers here are constructing an 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 Reservoir will store over 296 00:18:08,033 --> 00:18:09,767 29 billion gallons of water, 297 00:18:11,601 --> 00:18:15,167 held back by a unique dam built from 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 fragile water supply. 300 00:18:24,801 --> 00:18:27,701 Jeff Drager and Becky Brush lead 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 amounts of liquid, the engineers are 305 00:18:42,434 --> 00:18:48,100 building a dam that's 350 feet tall and 3,700 feet long. 306 00:18:50,300 --> 00:18:54,067 First, workers will blast the 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 an 18-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 will then bore 2,000 holes 230 feet 311 00:19:08,834 --> 00:19:11,467 into the bedrock and fill them with grout to make 312 00:19:11,634 --> 00:19:14,901 a watertight curtain beneath the ground. 313 00:19:15,067 --> 00:19:18,801 Above it, a special machine will 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 of the Chimney Hollow Dam. 316 00:19:25,367 --> 00:19:30,200 Earthmovers will shift over 315 million 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 challenge the engineers face is building 319 00:19:37,934 --> 00:19:40,067 a solid foundation for the megastructure. 320 00:19:42,100 --> 00:19:45,000 The rock here is too tough for machines 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 pounds of 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 exposed the 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 constructing the 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 Dam to 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 of steel rebar 342 00:20:50,601 --> 00:20:53,701 and place them inside wooden forms 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 full with super strong concrete. 345 00:21:03,467 --> 00:21:06,300 It takes the team almost two years to complete the plinth. 346 00:21:07,701 --> 00:21:11,000 Engineers can now build the 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 make the bold decision to build 358 00:21:44,534 --> 00:21:46,167 the core of the dam from asphalt. 359 00:21:47,400 --> 00:21:49,400 The technique is common in 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 in a 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 of flexible asphalt 371 00:22:22,267 --> 00:22:25,467 and two bands of gravel on either side that lock 372 00:22:25,634 --> 00:22:27,267 the waterproof core into 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 height of 350 feet. 376 00:22:40,701 --> 00:22:43,968 The asphalt and gravel core is too weak on its own to 377 00:22:44,133 --> 00:22:46,100 hold back billions of gallons of 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 side of 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 largest quarries 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 material every day. 385 00:23:14,567 --> 00:23:17,367 Supersized dump trucks haul the rock to the dam. 386 00:23:19,267 --> 00:23:22,100 The quarrying operation runs 24/7 387 00:23:22,267 --> 00:23:23,801 to keep the dam builders supplied 388 00:23:23,968 --> 00:23:25,167 with a steady stream of rock. 389 00:23:34,100 --> 00:23:37,067 But the reservoir is just one part 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 is to reliably deliver thousands 392 00:23:44,434 --> 00:23:46,467 of gallons of water to where it's needed. 393 00:23:47,767 --> 00:23:49,901 The steep terrain of the 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 builds a vast new network 396 00:23:54,734 --> 00:23:56,367 of infrastructure around the dam. 397 00:23:58,567 --> 00:24:02,267 First, they excavate a 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 giant pipelines 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 valve house 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 huge concrete spillway capable of 404 00:24:29,834 --> 00:24:33,067 releasing excess water safely during extreme weather. 405 00:24:35,367 --> 00:24:39,100 And because this site sits high in the Rockies, engineers must 406 00:24:39,267 --> 00:24:42,534 construct new roads and bridges to reach it. 407 00:24:45,000 --> 00:24:47,567 All of these systems must operate together. 408 00:24:54,267 --> 00:24:57,767 After four years of construction, the giant dam 409 00:24:57,934 --> 00:24:59,567 and its supporting infrastructure 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 is protect the dam from 412 00:25:06,634 --> 00:25:08,767 an unexpected but common threat -- 413 00:25:10,100 --> 00:25:11,100 flooding. 414 00:25:23,000 --> 00:25:24,801 Engineers are racing to 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 will increase 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 creates a major problem. 419 00:25:38,634 --> 00:25:42,367 As the water rises, it could exploit 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 raise the 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 increase the water level even higher. 427 00:26:13,567 --> 00:26:16,167 There's a risk that the rising water could escape through 428 00:26:16,334 --> 00:26:18,434 a low point in the 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 second barrier 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 to solid bedrock. 433 00:26:31,133 --> 00:26:34,200 Then they backfill the cut with thousands 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 stands 40 feet high and stretches 436 00:26:40,434 --> 00:26:44,167 roughly 590 feet across the landscape. 437 00:26:44,334 --> 00:26:47,167 Covered with natural vegetation, the saddle dam 438 00:26:47,334 --> 00:26:50,000 seals the gap to prevent water from escaping from 439 00:26:50,167 --> 00:26:52,100 the reservoir during extreme floods. 440 00:26:58,167 --> 00:27:01,100 The huge new Gross Dam will be an arch dam. 441 00:27:02,167 --> 00:27:04,367 The curved shape of the structure transfers 442 00:27:04,534 --> 00:27:06,467 the pressure of the water sideways 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 build the saddle dam 449 00:27:24,767 --> 00:27:29,100 from layer after layer of dense roller-compacted concrete 450 00:27:29,267 --> 00:27:30,767 to give it the strength it 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 location presents 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 from the on-site plant that makes 461 00:28:00,767 --> 00:28:03,067 the special cold concrete the dam needs. 462 00:28:04,767 --> 00:28:08,167 Their solution is to deploy a fleet of dump trucks. 463 00:28:12,467 --> 00:28:15,367 These work in rotation to deliver 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 quickly and to the right height. 472 00:28:39,567 --> 00:28:42,367 So, the engineers equip each bulldozer with a special 473 00:28:42,534 --> 00:28:46,400 GPS system that tells the 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, crews compress 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 hard enough 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 dam will prevent overflow from 486 00:29:38,868 --> 00:29:41,067 threatening the valley below 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 tackle something that could threaten 492 00:29:56,334 --> 00:29:58,601 the stability of the entire structure. 493 00:30:09,868 --> 00:30:14,367 Engineers in Colorado are supersizing the Gross Dam to 494 00:30:14,534 --> 00:30:17,801 help secure the state's future water supply. 495 00:30:20,267 --> 00:30:23,701 Reservoirs need a way to safely release 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 build them with spillways. 498 00:30:32,267 --> 00:30:35,400 These channels often direct flood water down the face of 499 00:30:35,567 --> 00:30:38,367 the dam and safely back into the 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 strikes the bottom of the dam, 503 00:30:50,200 --> 00:30:52,400 a zone called the 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 down the stepped concrete chute. 506 00:30:58,067 --> 00:31:00,868 That energy could threaten the 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 at Colorado 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 spillway and stilling basin. 516 00:31:30,701 --> 00:31:35,000 Then, they simulate extreme floods to measure how the water 517 00:31:35,167 --> 00:31:37,267 behaves as it crashes down 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 giant triangular-shaped concrete 520 00:31:45,567 --> 00:31:49,567 structures called baffle blocks inside 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 up the flow of water and reduce 523 00:31:55,267 --> 00:31:58,467 its destructive energy before it 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 build the system in real life. 531 00:32:19,634 --> 00:32:22,267 First, crews construct the 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 massive concrete 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 towering reinforced-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 water from 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 withstand the 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 spillway and 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 during the most extreme floods. 552 00:33:26,367 --> 00:33:29,300 The safety features of the dam extend beyond the spillway. 553 00:33:31,367 --> 00:33:34,100 It's critical that the new extension moves slightly 554 00:33:34,267 --> 00:33:37,701 upstream as the reservoir pushes against the structure. 555 00:33:39,167 --> 00:33:41,100 That movement helps to lock the dam 556 00:33:41,267 --> 00:33:43,667 into its final super-strong arch shape. 557 00:33:45,267 --> 00:33:49,267 But if the dam moves the wrong way, the concrete could crack. 558 00:33:51,267 --> 00:33:53,868 Dam safety engineer Erin Gleason 559 00:33:54,033 --> 00:33:56,567 oversees a vast network of 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 measure the movement between 568 00:34:24,534 --> 00:34:28,100 the original concrete blocks of the old dam. 569 00:34:28,267 --> 00:34:31,267 The engineers expect to see a change as the new dam's 570 00:34:31,434 --> 00:34:33,667 roller compacted concrete pushes 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 pushing the 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 mounted on the dam monitor 585 00:35:28,033 --> 00:35:29,868 vertical movement across the 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 away from 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 confirm the structure remains stable 600 00:36:20,434 --> 00:36:24,267 and the expanded Gross Dam is performing exactly as designed. 601 00:36:25,968 --> 00:36:30,167 Now, engineers must solve one 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 are racing 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 solve one final problem 607 00:36:53,934 --> 00:36:55,667 before they can complete the project. 608 00:36:58,100 --> 00:37:00,300 The concrete walls of the dam are 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 surrounding the 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 through tiny cracks and fissures in 613 00:37:13,133 --> 00:37:15,234 the canyon walls beside the dam. 614 00:37:17,667 --> 00:37:21,667 Over time, that leakage could weaken the surrounding rock 615 00:37:21,834 --> 00:37:24,267 and threaten the stability of the structure itself. 616 00:37:26,167 --> 00:37:28,701 Specialist Jessie Strobel has 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 to build a giant 623 00:37:46,534 --> 00:37:49,901 underground waterproof barrier inside 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 water from 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 of the 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 walls around 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 injections form a vast underground curtain 647 00:39:04,534 --> 00:39:07,167 designed to stop water from escaping around the dam. 648 00:39:10,701 --> 00:39:13,000 But seepage creates another danger 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 force its 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 movement could separate the dam 659 00:39:45,634 --> 00:39:47,467 from the bedrock holding it in place. 660 00:39:49,167 --> 00:39:51,167 The result could be catastrophic. 661 00:39:53,367 --> 00:39:54,868 The team needs another 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 system designed to relieve 664 00:40:02,067 --> 00:40:03,400 the pressure beneath the structure. 665 00:40:05,467 --> 00:40:09,400 From here, crews drill hundreds of 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 intercept the ground water, 668 00:40:20,033 --> 00:40:23,667 and channel it into the galleries inside the dam. 669 00:40:23,834 --> 00:40:27,400 From here, the dam can release it 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 mega water projects, 683 00:41:11,033 --> 00:41:13,667 engineers excavated deep in the 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's largest 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 spillway and underground drainage 688 00:41:30,834 --> 00:41:33,767 systems to protect it from the 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 dams will help provide fresh water 693 00:41:47,267 --> 00:41:49,100 for millions of Colorado residents, 694 00:41:51,200 --> 00:41:54,901 and safeguard the state's water supply against future droughts 695 00:41:55,067 --> 00:41:56,567 for generations to come. 62701

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