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Ontario Power Generation and Coral Rapids Power Corporation (a company wholly owned by Taykwa Tagamou Nation) are equity partners in the Peter Sutherland Sr. Generating Station. Named after a respected community elder, the 28 MW hydroelectric power station is remotely located at the confluence of the Abitibi River and New Post Creek within the Taykwa Tagamou Nation traditional territory of northeastern Ontario. A portion of the flows from New Post Creek have been harnessed to provide clean, renewable hydroelectric energy.

KGS Group worked closely with Ontario Power Generation and Coral Rapids Power through the conceptual and preliminary design stages, ultimately acting as the owner’s representative through the design-build construction phase that was performed by Kiewit and Aecon. KGS Group staff were onsite throughout construction assisting and collaborating with the owners and contractor team.

Construction was completed safely, on budget, and ahead of schedule. The project is not only an investment into Ontario’s clean energy future; it is a symbol of reconciliation and the culmination of a strong partnership between Taykwa Tagamou Nation and Ontario Power Generation that will benefit the community for generations.

Project Highlights

• Powerhouse construction with two horizontal‑axis Francis turbines with a total plant capacity 28 MW
• Gated intake structure and approach channel with controlled conveyance from New Post Creek
• 4 m diameter steel penstock 250 m long
• 520 m long embankment dam with a cement-bentonite core
• Two-bay gated spillway

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The Little Long Dam Safety Project was a significant initiative by Ontario Power Generation (OPG) to rehabilitate and enhance the spill capacity at the Adam Creek Sluiceway to meet new dam safety standards. The project increased overall discharge capacity of the Little Long headpond by 40%, significantly increasing the ability to manage large floods at this site.

There were four main components to the project:

1. The addition of four new concrete sluiceway bays to the pre-existing eight bay structure, providing the additional discharge capacity
2. The replacement of 10 existing sluice gates, gate hoist systems and superstructures to improve operational safety and reliability
3. The installation of an upstream splash wall to protect against wave and debris overtopping
4. Post-tensioned anchoring of the existing structures to address stability deficiencies

KGS Group was initially retained by OPG to carry out the concept design for the project, as well as undertake pre-construction geotechnical investigations. The final design and construction phase was executed by OPG under a design-build arrangement with Kiewit as the EPC contractor, where KGS Group’s role transitioned to owner’s engineer. In this role, KGS Group acted as an extension of OPG’s team, contributing to overall project management, contract administration, advisory and technical support. Our responsibilities included review of the contractor and designer’s work for compliance with good practice and the performance specification requirements, carrying out quality assurance and formal quality audits and providing resident engineering services to participate in overall coordination, monitoring, commissioning and turnover.

With careful planning, Little Long GS facilities remained in operation during the project’s four-year lifecycle. Due to the remote site location, the project required setting up a full-service camp to support over 200 workers, complete with all necessary facilities.

Throughout the project, it was a priority to have local Indigenous community members and women contribute to project execution. This helped to build strong relationships with the community and ensure the project and result would benefit all involved.

Project Highlights

• Construction of four new concrete sluiceway bays to increase overall discharge capacity of the Little Long headpond by 40%, from 6,090 CMS to 8,650 CMS
• Replacement of 10 sluice gates, the gate hoist systems and superstructures, which improved operational safety and reliability
• Installation of upstream splash wall which provides protection against wave and debris overtopping to improve emergency access during large wind and wave events
• Continuous plant operation maintained during staged construction over four years
• 20% of hours were worked by local Indigenous community members and 25% of hours were worked by women
• 11% of construction contract value provided by First Nation subcontracts
• Over 2.1 million person‑hours worked
• Enhanced spillway capacity and dam safety compliance, improved operational reliability and increased generation

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KGS Group was retained by the Yukon Energy Corporation to review feasible hydro projects in the territory, which culminated in the selection of the Mayo B project. To develop the $120 million Mayo B, KGS entered into an early contractor involvement alliance partnership, sharing the financial risks and project rewards. This partnership was the first of its kind in the Canadian hydroelectric industry.

We conducted a feasibility study as well as completed the preliminary and final design of a new powerhouse downstream of the existing Mayo hydroelectric development. Reusing the already in-place dam and intake structure, the work also included connecting and conveying water to the new powerhouse through a new 3.8 km tunnel and penstock system.

Overcoming challenging conditions to make way for the new tunnel and “tie it” into 60-year old infrastructure, we used careful mapping and characterization. This helped support concurrent tunnel design and excavation, and slope stabilization. Precision LiDAR 3-D survey techniques and modelling were also integral to the work.

Within a remote, sub-arctic climate, KGS was also responsible for on-site construction management including all contract administration and quality assurance for the civil, mechanical and electrical works, as well as the supply and installation of the turbines and generator equipment.

As a result, total hydro power generation capacity went from 5.4 MW to 12 MW, increasing Yukon’s renewable and sustainable electricity generation capability. The on-budget, on-schedule project also displaces diesel generation, offsetting up to $10 million in annual fuel costs and eliminating approximately 25,000 tonnes of greenhouse gas emissions per year.

Project Highlights

• A new downstream powerhouse and 3.8 km tunnel and penstock system
• Integrated new infrastructure with the existing 60-year-old dam and intake infrastructure
• Generation capacity increased from 5.4 MW to 12 MW
• Up to $10 million/year fuel cost offset
• 25,000 tonnes of CO₂ avoided per year
• $120M project completed on time and on schedule

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The Lafleche Dam in southwestern Saskatchewan was originally constructed in 1958. The dam’s reservoir (Thomson Lake) is used for municipal water supply, irrigation and recreation. The dam offers flood protection, and its low level outlet conduit is needed for reservoir management and riparian flow passage.

In 2018, an inspection of the conduit revealed severe deterioration of the pipe which presented a significant dam safety risk due to internal erosion. KGS Group developed a solution using an array of innovative conduit replacement and rehabilitation methods, including trenchless technologies such as slip-lining and Cured in Place Pipe (CIPP) replacement. The work required excavations and other construction activities at the toe of the in-service dam which necessitated a comprehensive dam safety surveillance program. KGS implemented a state-of-the-art instrumentation plan with telemetry to monitor the performance of the dam during critical high risk construction stages.

The project was completed on schedule and within budget just before winter onset, under a relatively short construction season. The low level outlet was returned to full service in September 2022 following final commissioning of the new slide gate equipped with a cathodic protection system.

Project Highlights

• Inspection and assessment, detailed design, construction supervision, dam safety surveillance and real‑time instrumentation with telemetry
• Renewal of low‑level outlet conduit at an in‑service dam and work at the dam toe through a short construction season
• Trenchless methods (slip‑lining, Cured‑in‑Place Pipe), new slide gate, cathodic protection system and state‑of‑the‑art monitoring through critical stages

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Block Dam 2 is one of four embankment dams that contain the Caribou Falls Generating Station reservoir in northwestern Ontario. After 60 years of operation, the dam sustained unexpected slope movements. With KGS Group retained to carryout detailed design and construction supervision, Ontario Power Generation awarded the construction contract to Peter Kiewit Sons Ltd. Together, OPG, KGS and Kiewit reconstructed the dam through most of 2019 and finalized the work in late 2020.

The team applied advanced investigation and laboratory testing techniques, innovative materials, sound engineering judgement and progressive construction methodologies to design and build a new zoned rockfill dam with a cement-bentonite wall (CB wall) core. The design integrated constructability, risk mitigation and schedule saving strategies at the planning level.

Despite unforeseen challenges, all parties persevered using a “One Team” approach. As a result, the project was successfully completed, restoring the dam to modern standards and the station’s generating capacity while preserving the natural surroundings in this wild and beautiful project setting.

Project Highlights

• Detailed design, materials and lab testing, constructability planning, risk management assessments and construction supervision
• Full reconstruction of a 60-year-old structure
• New rockfill dam with cement‑bentonite cutoff wall core
• Progressive construction methodologies and schedule‑saving strategies embedded at planning
• Restored generating capacity and dam service, compliance with modern standards and improved stability and performance

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KGS Group served as owner’s engineer to help the Water Security Agency (WSA) reduce their project backlog and bring consistency to their capital delivery services. Acting as project managers, our team scoped, managed and executed over 20 project procurements on behalf of the WSA.

Our project managers also assisted the WSA with oversight of their larger portfolio of owner’s engineer projects. Our role covered portfolio oversight, procurement leadership and risk and schedule control across multiple projects.

At the start of the contract, KGS mostly worked on process definition, engineering standards development and project engineering. In the later years, KGS was able to progress the work through engineering to construction. Because of this, the WSA spent its full capital allocation, with KGS-managed projects accounting for the majority of the spend, with this trend continuing to this day.

The KGS team accelerated project delivery and budget utilization while establishing a repeatable framework for future projects, enabling continued success for WSA.

Project Highlights

• Managed and executed over 20 project procurements
• Managed over 45 engineering, long‑lead procurement and construction contracts
• $53 million in capital construction delivered (November 2020 – March 2024)
• Helped create a framework enabling consistent, sustainable asset maintenance
• Clearer engagement model for ACEC‑SK members

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The Davis Diversion was built in 1939 near the town of Maple Creek. The main purpose of this canal is to divert unregulated flow to Cypress Lake, the main source of drinking water and irrigation projects in Southwestern Saskatchewan. Operation of the original diversion has, in the past, resulted in stranding of at risk fish species.

The Water Security Agency (WSA) ceased operation of the diversion system while contemplating solutions. KGS Group developed a solution consisting of the design and construction of a new concrete weir with a Coanda fish exclusion screen, combined with a new rock ramp fishway. This structure provides a novel solution for WSA to achieve its water management objectives, while protecting the area’s sensitive aquatic environment and bringing infrastructure into regulatory compliance.

Project Highlights

• Conceptual and detailed design of fish exclusion at diversion intake
• Replacement and modernization of aging water control structures
• Upstream fish passage integrated around the control structure
• Final product was in complete compliance with Fisheries Act and SARA
• Enables resumption of diversion operations to Cypress Lake

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KGS Group served as owner’s engineer to redevelop Calabogie Generating Station, extending its life and increasing its output to 11 MW. We guided the project through feasibility, design and execution phases. The project included constructing a new powerhouse, expanding intake and tailrace channels, rebuilding the forebay dam and adding a new substation and fish habitat compensation features.

In 2006, KGS Group completed a feasibility study to explore options for the site’s refurbishment and redevelopment and was consequently awarded the role of owner’s engineer in 2017. We presented the client with a list of new turbine vendors, developed user requirements and preliminary specifications, supported environmental assessments and assisted with stakeholder consultations, including engagement with Indigenous groups.

Our team then assisted in procuring the contractor for the project who completed the final optimization, design and construction. Key design refinements included a more compact powerhouse, a redesigned forebay dam and a reworked intake channel supported by hydraulic modelling and a physical model. The project also included measures to make the site ready for eel passage and to facilitate future downstream passage.

KGS Group provided oversight, in collaboration with the resident engineer, throughout the project including full-time inspection services, ensuring quality and regulatory compliance, while mitigating risks and following safety standards. We helped complete commissioning and turnover of the project providing consistency and project knowledge from feasibility design to close out.

Project Highlights

• New powerhouse with expanded intake and tailrace channels and a rebuilt forebay dam
• New substation with fish habitat compensation features and a site ready for eel passage and future downstream passage
• Environmental assessments and stakeholder consultations
• Supported contractor procurement, optimized hydraulic and physical modelling
• 3D digital design for multi‑discipline coordination and field execution
• 11 MW output, extended asset life, improved reliability and operability

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The Pointe du Bois Generating Station is the oldest operating hydroelectric plant in Manitoba. Despite extensive upgrades and ongoing maintenance over the years, the original spillway required replacement. The Pointe du Bois Spillway Replacement project included the design and construction of a new remotely operated 7-bay spillway and a new 1km long zoned earthfill dam, complete with an ancillary support building for electrical switch gear and control systems, a backup diesel generator, and other related infrastructure.

As the prime consultant, KGS Group worked collaboratively with Manitoba Hydro as the designer in an early contractor involvement project delivery process. KGS also provided full-time technical support and quality assurance assistance through construction, commissioning and close-out activities.

The final design was carried out entirely within a 3D digital environment, and was paramount for the successful execution of all stages of the project. This innovative approach gave the team the ability to visualize the end product at the design stage and enabled harmonious advancement of the project across multiple disciplines.

The several hundred-million-dollar project was successfully completed without any interruptions to the ongoing operation of the plant, while protecting and preserving established lake sturgeon habitat and restoring the natural landscape in this environmentally sensitive provincial park setting.

Project Highlights

• New remotely operated seven bay spillway, support building and backup diesel generator
• New 1km long zoned earthfill embankment dam
• 3D digital design environment
• The several hundred‑million‑dollar capital program was completed without operational interruptions
• Enhanced safety and control, extended asset life and a more reliable discharge capacity
• Lake sturgeon habitat protected and the landscape in the provincial park was restored

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Boundary Dam Reservoir serves as a source of cooling water for the Boundary Dam Power Station, SaskPower’s largest generating station. KGS Group was retained to perform a dam safety assessment of the Boundary Dam structures.

The dam safety review identified a number of concerns, the most critical of which were insufficient spillway capacity and deficiencies with the condition of the existing spillway. Our team was then retained to design spillway upgrades to extend the life of the 50+ year old structure and to double the discharge capacity of the spillway. We performed preliminary and final design for complete replacement of the spillway chute and basin, while maintaining the reservoir at full supply level. The work also included the installation of over 400, +30-metre-long anchors.

The team overcame complex foundation issues with bentonite seams, coal layers and high groundwater. Another critical site challenge was to design and complete each year’s construction such that the spillway could potentially pass spring flood flows. Despite many challenges, the project was completed on schedule and near budget.

Project Highlights

• Dam safety assessment, spillway upgrade design, construction support
• Complete replacement of spillway chute and basin while maintaining full supply level
• Discharge capacity doubled to improve flood performance and safety
• Installation of 400+ anchors, each over 30 metres in length
• Foundation treatment addressing bentonite seams, coal layers and high groundwater