Dale Hollow Dam

Preserving Critical Infrastructure: Champion Painting Specialty Services’ Success at Dale Hollow Dam

Introduction

Champion Specialty Services was contracted by Shimmick Construction to recoat the six (6) spillway gates and bridge superstructure located at the Dale Hollow Dam in Celina, Tennessee. Operated by the U.S. Army Corps of Engineers, the Dale Hollow Dam is a vital piece of infrastructure that contributes to flood control, erosion mitigation, and hydroelectric power generation. Maintaining the structural integrity of the dam’s gates, which endure immense water pressure daily, is critical to ensuring their long-term functionality and safety.

Project Overview

The project’s primary objective was to preserve and enhance the durability of the dam’s spillway gates through the application of advanced protective coatings. These gates are essential in regulating water flow from the reservoir, enabling precise control over downstream conditions. Champion’s specialized crews were tasked with providing access via a Safespan platform system and the meticulous surface preparation inclusive of dry abrasive blasting and recoating of the gates to ensure their continued performance under extreme pressure and exposure to environmental elements.

Scope of Work

Champion’s work involved:

1. Surface Preparation
   • Sandblasting (SSPC SP5 White Metal Blast) to remove existing coatings, corrosion, and contaminants, ensuring a clean substrate for optimal adhesion of new coatings.
2. Protective Coating Application
   • Application of a multi-layer protective coating system designed to withstand continuous exposure to water pressure and environmental conditions. This included:
     • One primer coat of Sherwin-Williams Zinc Clad 108 Corps of Engineers Vinyl-Type Zinc-Rich Impacted Immersion Coating at 2.5 mils Dry Film Thickness (DFT).
     • Three coats of Formula V-766E Impacted Immersion Coating, each applied at 2.0 mils DFT.
3. Hazardous Material Abatement
   • Safe removal and disposal of existing lead-based coatings to comply with environmental regulations and safety standards. Champion’s Environmental team also performed asbestos abatement on dated electrical components underneath the road deck within the bridge superstructure.

Challenges and Execution

The project required precise planning and execution to meet stringent safety, environmental, and quality requirements. Crews worked under demanding conditions, managing tight schedules while adhering to regulations set forth by the U.S. Army Corps of Engineers. Champion’s experienced team deployed advanced equipment and techniques to ensure the job was completed efficiently and effectively.

Conclusion

Champion Painting Specialty Services’ work at the Dale Hollow Dam exemplifies their commitment to delivering high-quality, sustainable solutions for critical infrastructure. By preserving the integrity of the spillway gates, Champion has helped ensure the continued operation and safety of the dam, contributing to flood control, erosion mitigation, and the well-being of surrounding communities.