Dams are complex engineering structures for storing, diverting, and controlling water. Their construction integrates geotechnical engineering, mass concrete, hydraulic steelwork, water resources management, and asset operation. Controlled interventions in rock and concrete are crucial for planning and execution—for example, rock removal for the foundation, creating construction joints, or repairs to concrete components. In these steps, precise, low-vibration methods such as hydraulic rock and concrete splitters and concrete pulverizers are frequently used; they operate in conjunction with Power Units and play a central role in dam construction with respect to safety, quality, and workflow.
Definition: What is meant by dam construction
Dam construction refers to the planning, erection, repair, and retrofit of structures that run across a valley or watercourse to impound, regulate, or divert water. These include dams and weirs with components such as the embankment body, dam wall, spillway, bottom outlet, foundation and inspection galleries, and operating installations. Dam construction covers the entire project cycle—from geological investigation and foundation works through concrete construction and hydraulic steelwork to operation, monitoring, and later specialist deconstruction.
Structure types and construction methods in dam construction
Dams are built as gravity, arch, or buttress concrete dams, as well as earth and rockfill dams with an impervious core or internal sealing. The choice of structure depends on topography, geology, hydrological loads, material availability, and schedule. Regardless of the system, precise rock and concrete work is required: exposing and profiling rock at the abutments, forming the contact joint, installing drains and grout curtains, making joint cuts, concrete edges, and fitting embedded components. In all these phases, controlled cutting and splitting methods are needed to achieve tight tolerances with low vibration.
Geotechnics and rock removal: controlled splitting instead of blasting
The quality of the foundation determines a dam’s durability. In the area of rock demolition and tunnel construction, it is essential to free rock blocks to precise dimensions, level the contact joint, and avoid voids. Hydraulic wedge splitters and concrete splitters as well as hydraulic wedge splitter cylinders enable non-explosive rock release along defined split lines. This reduces vibrations and protects sensitive structures such as existing works, instrumentation points, or natural habitats. Splitting techniques also support profile-true construction of galleries, shafts, and recesses for embedded parts.
Use in hard-to-access areas
In steep terrain or confined excavations, equipment access is often restricted. Compact splitting technology with suitable energy supply from hydraulic power packs can be deployed in a targeted manner here—for example, when reprofiling abutments or enlarging inspection passages. This special operations context requires careful sequencing so that dewatering, occupational safety, and material logistics interlock smoothly.
Noise and vibration management
When working near sensitive infrastructure or in protected areas, a minimal emission level is essential. Compared with impact and blasting methods, splitting produces lower vibrations and airborne sound. This protects instruments, prevents cracking in existing structures, and facilitates compliance with requirements without sacrificing cutting performance.
Concrete works on dams: new build, modification, and deconstruction
In the mass concrete of dam walls, weirs, and associated components, precise separation cuts, opening components, and concrete demolition and specialist deconstruction are regularly required—for example, for joint adjustments, edge formation, local recesses, or repairs. Concrete pulverizers enable controlled downsizing of concrete with defined piece size and limited crack propagation. Combination shears and Multi Cutters handle the separation of reinforcement, anchor bars, or smaller steel sections, while hydraulic power packs provide the required energy.
Specialist deconstruction during repairs
Selective interventions are required when renewing embedded parts, modifying the spillway, or adding cut-off walls. Concrete pulverizers and splitting techniques allow removal of individual concrete layers without damaging adjacent components. This way, existing joints can be exposed, ducts opened, or anchor heads made accessible—with high control over removal rates and component geometry.
Strip-out and cutting in galleries
In inspection and maintenance galleries, cross-section enlargements, utility retrofits, and opening niches are typical tasks of strip-out and cutting. Handheld or compact hydraulic shears and cutters work safely and efficiently here, especially when access and ventilation are limited.
Hydraulic steelwork: gates, closures, and penstocks
Steel components such as gates, trash racks, closure segments, and penstocks are integral to dam operations. During modification, dismantling, or renewal, precise cutting of thick plates and sections is necessary. Steel shears cut sections and reinforcement, Multi Cutters cut pipes and fittings, and tank cutters are used to open large tanks or pipe sections. These methods support the safe removal of embedded items and facilitate transport through restricted access points.
Construction phases: from excavation to commissioning
Dam construction follows a clearly structured sequence. From geological investigation through excavation support and dewatering to concrete placement and installation of hydraulic steelwork, many disciplines interlock. Controlled splitting, downsizing, and cutting accompany many phases—when exposing competent rock, working the contact joint, touching up formwork, and fitting embedded items. Before commissioning, functional tests, leak-tightness checks, and instrumentation calibration follow.
Rehabilitation, retrofit, and operation
Over their service life, dams are maintained, retrofitted, or strengthened. Typical measures include adding drains, renewing gates, seismic verification with structural adaptations, or optimizing the spillway. For pinpoint interventions, concrete pulverizers and hydraulic wedge splitters and concrete splitters have proven effective, as they open components step by step and in a controlled manner. This reduces downtimes and protects adjacent areas that remain in operation.
Safety, environment, and permits
Safety and environmental requirements are particularly stringent in dam construction. Dust, noise, and vibration management; water quality and sediment controls; and the safe handling of hydraulic energy are integral parts of site organization. Legal requirements vary by country and project and should be considered at an early stage. Non-binding principles include working with low-emission methods, recording vibrations, and maintaining a record of protective measures and limit values.
Logistics and energy supply for the tools
Hydraulically powered cutting and splitting technology requires a coordinated energy supply. Hydraulic power packs are matched to the tool and task in terms of pressure, flow rate, and duty cycle. Short hose runs, secure couplings, and clear start/stop signals increase occupational safety and efficiency. In confined areas and shafts, modular power packs simplify transport and positioning.
Methodology: selecting the appropriate cutting and splitting method
The choice of method depends on material, thickness, reinforcement content, accessibility, permissible emissions, and required sequencing. The following guiding questions help with the decision:
- Does the material structure allow controlled splitting (rock, brittle concrete), or are downsizing/cutting more effective?
- What limits apply regarding vibration, noise, and dust—for example, near sensitive instrumentation points or existing structures?
- How are access, escape routes, and media management (hydraulics, dewatering, ventilation) organized?
- What piece size facilitates transport and reinstallation/disposal?
- Which hydraulic power packs safely cover continuous and peak loads?
Quality assurance and documentation
Documenting separation cuts, split lines, removal volumes, and measured values (vibration, noise, dust) is a key element of quality assurance. Mock-up areas and test fields help optimize parameters such as split pressure, gripping forces, and cut sequence. The result is reproducible workflows that reliably achieve dimensional accuracy, surface quality, and schedule targets.
Typical application examples in dam construction
- Profiling rock foundations at abutments using hydraulic wedge splitters and concrete splitters to create a flat contact joint.
- Selective opening of concrete sections with concrete pulverizers for installing or renewing instrumentation points and drains.
- Dismantling and downsizing of concrete-embedded components in the spillway area with combination shears and Multi Cutters to separate reinforcement.
- Cutting steel components on gates and trash racks using steel shears; opening thick-walled pipe sections with a tank cutter.
- Work in inspection and pressure tunnels during rock excavation and tunnel construction with compact splitting technology and a suitable hydraulic power pack.
- Special boundary conditions in special operations, for example in protected areas or near sensitive buildings, using low-noise and low-vibration methods.