Taum Sauk Upper Reservoir Rebuild Project

In October 2007, AmerenUE awarded Ozark Constructors, LLC, a contract to rebuild the Taum Sauk Upper Reservoir Dam, located approximately 2 and a half hours southwest of St. Louis, Missouri. Ozark Constructors is a venture partnership between Fred Weber, Inc., St. Louis, Missouri and ASI Constructors, Inc., Pueblo, Colorado.

Team Members

Ozark Constructors, LLC
- Fred Weber, Inc., Maryland Heights, MO
- ASI Constructors, Inc., Pueblo, CO
Paul Rizzo Associates, Monroeville, PA
Fall Line Testing & Inspection, LLC, Monroeville, PA

Project Overview

The Taum Sauk Upper Reservoir Rebuild Project primarily consists of the rehabilitation of the existing inoperable rock fill Upper Reservoir with the construction of a modern concrete faced symmetrical Roller Compacted Concrete (RCC) dam. The 2.8 million cubic yard RCC dam replaces the existing concrete lined – rock fill dam, which was built in 1963.

The 6,700 ft. long, 120 ft. tall and 150 ft. base width structure was constructed in a linear fashion by excavating the existing ryolite rock fill dam, repairing the base foundation and placing formed RCC creating the Taum Sauk Hydroelectric Plant Upper Reservoir, which stores in excess of 1 billion gallons of water. By processing and using the existing ryolite for the RCC aggregates and producing the RCC all within the footprint of the reservoir, Ozark Constructors was able to meet the demanding project schedule and provide AmerenUE with a highly cost effective method of construction versus more conventional methods.

Ozark Constructors provided the leadership and project management skills for the fast-track and successful rebuild of the Taum Sauk project. The primary goal was to safely build a high quality RCC dam, utilizing modern dam design, skilled construction techniques and safe work practices within established cost and schedule targets. Taum Sauk is the largest dam constructed in North America, with approximately 2.8 million cubic yards RCC and 0.3 million cubic yards of structural concrete. Foundation excavation and aggregate crushing accounted for nearly 6 million tons. Substantial completion of the project was achieved in Spring 2010.

Ozark Constructors key project management responsibilities included: project engineering, scheduling and cost control, dam excavation, foundation preparation, aggregate crushing, RCC placement, equipment procurement and maintenance, and related facility operations to achieve maximum production at lowest possible cost, while meeting established quality requirements.

Further information regarding the Taum Sauk Upper Reservoir Rebuild Project and related restoration information can be found at www.ameren.com

Click here to view the Taum Sauk brochure