At the historic Saluda Hydroelectric Dam, Lucas Concrete played a key role in restoring critical infrastructure while preserving the character of original structures built over a century ago. The project focused on replacing the hydraulic gate housing buildings—towering enclosures that protect 35-ton lifting gate mechanisms used to regulate water flow through the dam.

Originally constructed using structural CMU, brick, and cast-in-place concrete, the gate housings were an impressive engineering feat for their time—rising more than 180 feet above the creek bed. However, when it came time to access and service the gates, the structures proved difficult and dangerous to modify. Their roofs were never designed to be removed, and cutting into them severely compromised the overall integrity.

Lucas Concrete delivered an innovative solution: replicate the historic forms using modern precast construction with a thin brick veneer to match the original aesthetic. Cast-in features mimicked the original capstone elements and were seamlessly integrated into the wall panels. The new precast structures were also engineered with removable roof panels to allow future access to the gate systems.

In the end, the entire project—once projected to take several months using conventional masonry—was completed in less than 15 working days. The result was a faithful, durable reproduction of the original structures that both preserved the visual legacy of the dam and improved long-term functionality.

The Saluda Dam hydraulic gate housings presented a unique engineering and logistical challenge. Originally built over 100 years ago, these cylindrical towers enclosed the gate-lifting mechanisms that regulate the dam’s output. Each structure stood more than 180 feet above the creek bed and was originally constructed using a combination of structural masonry and cast-in-place concrete.

To access and service the 35-ton gates, the original structures needed to be removed or modified. However, they had no removable roof components—cutting into the roof during initial demolition attempts rendered the structures unstable and unsuitable for reconstruction.

The initial plan called for masonry crews to rebuild the housings in place. But given their remote location—more than a mile from the nearest staging area—this presented significant challenges:

• Material delivery and handling were complicated due to access constraints.
• Safety concerns arose from having crews working directly over water in elevated conditions.
• Emergency evacuation planning in case of inclement weather was problematic.
• Project duration for traditional demolition and rebuild was estimated at several months.

Lucas Concrete proposed a precast solution that addressed all these issues. The new housing structures were fabricated off-site using thin brick veneer to match the existing aesthetic. The original capstone detailing was captured in the mold design and integrated directly into the precast wall panels. Most critically, the new buildings were engineered with modular, removable roof sections—allowing for safe future access without structural compromise.

Once delivered to the site, the precast units were installed quickly and efficiently—completing the work in under 15 working days and significantly accelerating the overall project timeline.