How to build a new RCC Dam for 40% Less - Successful application of the design/build approach at Pine Brook RCC Dam

The design/build approach has been successfully used for the design and construction of many heavy civil construction projects including bridges, highways, and multi-story buildings. One of its first applications in dam construction began when the Pine Brook Water District (Pine Brook), a small water district 2 miles northwest of Boulder, Colorado with only 400 customers, sought to build a dam within the boundaries of its district with an extremely aggressive schedule and budget. Given the District's schedule and budget constraints, Pine Brook believed the best way to design and construct a roller compacted concrete (RCC) dam was to use the design/build process. To meet these challenges, the design/build team implemented a design process, which involved the designer, owner and contractor at the earliest phases of the project. This included the geotechnical aspects, flood hydrology, RCC mix design, dam layout, seepage cutoff and collection, outlet works, instrumentation, and even aesthetics. By working as an integrated team, all parties were able to quickly address design issues and minimize costly studies and evaluation of multiple alternatives. More importantly, we were able to expedite the schedule and begin construction 8 ½ months after initiation of the design process. This paper describes implementation of the design/build approach for the Pine Brook Dam and describes key innovations that resulted in project savings of more than 40 percent. 10 pp., 6 references.