Boldt Construction and Manitowoc upgrade Minnesota dam and double its production capacity

• The contractor used two Manitowoc crawler cranes to install new generators producing 4.4 megawatts of electricity per year, doubling the previous capacity of 2.2 megawatts.
• Despite site challenges, Boldt successfully rebuilt the 114-year-old dam powerhouse over several months relying on its own Manitowoc 2250 crawler crane.
• Boldt partnered with Dawes Rigging & Crane Rental to employ a Manitowoc MLC300 VPC-MAX™ to install two new generators on the site.

Boldt Construction, in collaboration with Dakota County and Xcel Energy, successfully upgraded the historic 114-year-old Lake Byllesby Dam in Minnesota with the help of two Manitowoc crawler cranes: a 2250 owned by Boldt and an MLC300 VPC-MAX rented from Dawes Rigging & Crane Rental. The project involved constructing a new powerhouse and installing two generators, doubling the dam’s generation capacity to 4.4 megawatts, which can power approximately 2,400 homes.

The hydroelectric dam upgrade, beginning in the spring of 2021, encountered unique challenges due to the dam’s aging concrete structure and its exposure to water. Over 1.7 million lbs of concrete were removed to lay the foundation for the new powerhouse, requiring precise planning and execution.

The Manitowoc 2250 arrived on-site from the jump and was instrumental in handling various materials throughout construction. Renowned for its reliability, the crane was extensively used to transport materials across the jobsite, which was challenging due to its proximity to a lake and river.

The Manitowoc MLC300 VPC-MAX, brought in August 2023, was used to install the new generators, each weighing over 121,000 lbs. The crane lifted and placed both generators on time, with engineers flown in from India and Boldt’s in-house technical team working together to ensure a smooth process.

“The generators and cranes were positioned at a lay-down site near the pump house,” explained Aaron Utley, project manager at Boldt. “Our crews guided the generators into place while the engineer ensured all connections were secure. Installing each generator took several hours, with the second placed shortly after the first. After completing the lifts, we focused on finalizing any remaining connections and tasks. Our teams were excited and eager to make it all happen.”

The two major lifts were completed over two days of favorable weather, with the cranes operating from a carefully engineered site northeast of the powerhouse.

“Despite the confined space of the dam site, both cranes performed flawlessly, with only minor delays due to high winds,” Utley said. “The project’s success is a testament to the skill of Boldt’s operators and the reliability of Manitowoc equipment. Boldt’s experience with challenging projects and Dawes’ crane expertise ensured a smooth, safe execution.”

As part of the original plan, Boldt has also preserved elements of the original powerhouse, displaying historic turbine equipment in the nearby county park and hiking trails. The effort preserves the dam’s historical significance while modernizing its future and ensuring its continued role in the region’s energy infrastructure.

To learn more about Manitowoc’s range of crawler cranes, click here. To visit Boldt Construction’s website, click here.

CONTACT

Ashley Soverns 
Sr. Manager, Marketing
Manitowoc
T +1 717 593 5167
ashley.soverns@7670f.com