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Construction of the Hungry Horse Dam
Located in northwest Montana, the Hungry Horse Dam releases water from Hungry Horse Reservoir generating power estimated at $57.7 million a year. Other benefits include reduction of flood damage and support streamflow for fisheries (Bureau of Reclamation). Hungry Horse Montana is located in Flathead County. The dam is located north of West Glacier, a popular entrance into Glacier National Park. Columbia Falls and Kalispell are located southwest of the dam site.
The name "Hungry Horse" comes from the tale of two horses (Tex and Jerry) who had wandered away from their logging sled in the winter of 1900-1901. The horses struggled in the deep snow for a month, and needed to be nursed back to health. Loggers nicknamed Tex and Jerry as the “Mighty Hungry Horses.” The nearby town, mountain, and creek were later named “Hungry Horse” and so was this reclamation project. (Bureau of Reclamation, 2022).
During World War II, the proposal to build Hungry Horse Dam envisioned a solution to reduce flooding as well as to generate energy with the release of water through the fall and winter. In July 1948, construction of the dam began with many of its workers being returning war veterans. Once the project was approved, there was a lot of work to be done in the area before construction could start. Two tasks that had to be completed in order to begin construction of the dam were a water diversion away from the construction site as well as building an access road to the dam site (The Story of the Hungry Horse Project, 2022a). To make the construction possible, workers cleared rock, constructed cableways, and poured concrete when the weather allowed. Located in an area that experiences severe winter conditions, construction was halted during winter in Montana. Construction was completed in 1953. (The Story of the Hungry Horse Project, 2022).
Photo at right: Hungry Horse Dam construction where the 2,000,000th yard of concrete is being hauled in. For reference, one yard of concrete covers a 27 square foot area at 1’ thick. The Hungry horse dam is 564’ high, 39’ at the top width, and 330’ wide at the bottom while the crest is 2,115 feet long (Bureau of Reclamation, 2022).
Stages of Construction
Pictured below are different stages of construction throughout 1948-1953. For a 1953 view of the finished dam, please visit the Bureau of Reclamation.
The name "Hungry Horse" comes from the tale of two horses (Tex and Jerry) who had wandered away from their logging sled in the winter of 1900-1901. The horses struggled in the deep snow for a month, and needed to be nursed back to health. Loggers nicknamed Tex and Jerry as the “Mighty Hungry Horses.” The nearby town, mountain, and creek were later named “Hungry Horse” and so was this reclamation project. (Bureau of Reclamation, 2022).
During World War II, the proposal to build Hungry Horse Dam envisioned a solution to reduce flooding as well as to generate energy with the release of water through the fall and winter. In July 1948, construction of the dam began with many of its workers being returning war veterans. Once the project was approved, there was a lot of work to be done in the area before construction could start. Two tasks that had to be completed in order to begin construction of the dam were a water diversion away from the construction site as well as building an access road to the dam site (The Story of the Hungry Horse Project, 2022a). To make the construction possible, workers cleared rock, constructed cableways, and poured concrete when the weather allowed. Located in an area that experiences severe winter conditions, construction was halted during winter in Montana. Construction was completed in 1953. (The Story of the Hungry Horse Project, 2022).
Photo at right: Hungry Horse Dam construction where the 2,000,000th yard of concrete is being hauled in. For reference, one yard of concrete covers a 27 square foot area at 1’ thick. The Hungry horse dam is 564’ high, 39’ at the top width, and 330’ wide at the bottom while the crest is 2,115 feet long (Bureau of Reclamation, 2022).
Stages of Construction
Pictured below are different stages of construction throughout 1948-1953. For a 1953 view of the finished dam, please visit the Bureau of Reclamation.
August 1948, excavation to begin construction of cableway
Excavation in progress at cableway tail tower (top bench) on the north bank with bench approximately at grade
Excavation in progress at cableway tail tower (top bench) on the north bank with bench approximately at grade
August 1948, access road to the top right bank of the dam
Upper access road on right bank at top of dam. Extension of road to provide access to cableway tail tower (top bench) can be seen at far right. Widening of access road in progress (wagon drills, center bench) and cableway excavation in progress at top center.
Upper access road on right bank at top of dam. Extension of road to provide access to cableway tail tower (top bench) can be seen at far right. Widening of access road in progress (wagon drills, center bench) and cableway excavation in progress at top center.
April 1949 photo including progression on the removal of rocks to beginning of construction
Usual view of north abutment showing north cableway bench including concrete retaining wall and steel trestle extension with travelling tail towers No. 1, 2 and 3 including counterweights. (Top Center). Road immediately below cableway bench is upper access road to dam which will be elevation of completed dam. Fence below road guards "glory hole" spillway driven by Boyles Bros. under sub contract, with keway excavation immediately to left. Form construction to left of keyway is for mixing plant foundations. Mixing plant access road immediately below. Lower portion of picture from right to left shows diversion tunnel intake, weir type cofferdam and diversion tunnel discharge. Main access road to dam area has been relocated over discharge portal of tunnel. Note sluicing operations to remove danger rocks in center of picture. Camera location moved up river from previous shots to show better view of pay area.
Usual view of north abutment showing north cableway bench including concrete retaining wall and steel trestle extension with travelling tail towers No. 1, 2 and 3 including counterweights. (Top Center). Road immediately below cableway bench is upper access road to dam which will be elevation of completed dam. Fence below road guards "glory hole" spillway driven by Boyles Bros. under sub contract, with keway excavation immediately to left. Form construction to left of keyway is for mixing plant foundations. Mixing plant access road immediately below. Lower portion of picture from right to left shows diversion tunnel intake, weir type cofferdam and diversion tunnel discharge. Main access road to dam area has been relocated over discharge portal of tunnel. Note sluicing operations to remove danger rocks in center of picture. Camera location moved up river from previous shots to show better view of pay area.
April 1950 usual photo of early construction of the dam including cableways
Usual photograph of North Keyway. Mixing Plant transfer track has been completed to service extreme travel of cableways. Cableway control tower has been completed (right end of track) and controls transferred. Operators now control cableways from this tower with full view of bucket landing. Note construction of high cofferdam (center right) and penstock installation (lower left). Steel forms (Blaw-Knox) have been placed in service and block differentials are approaching proper relationship for accelerated placing program.
Usual photograph of North Keyway. Mixing Plant transfer track has been completed to service extreme travel of cableways. Cableway control tower has been completed (right end of track) and controls transferred. Operators now control cableways from this tower with full view of bucket landing. Note construction of high cofferdam (center right) and penstock installation (lower left). Steel forms (Blaw-Knox) have been placed in service and block differentials are approaching proper relationship for accelerated placing program.
April 1951 Downstream and upstream views of progression of construction
Usual view of North Abutment with blocks in varying degrees of progress. High block far side form raising in progress. Second high block final preparations in progress. Third high block pour complete. Fourth high block initial preparations in progress. Fifth high block pour complete, initial preparations just starting. Near high block pour in progress. Note bucket landing at mixing plant has been extended to eliminate blind spot. This was accomplished over winter shutdown.
Usual view of North Abutment with blocks in varying degrees of progress. High block far side form raising in progress. Second high block final preparations in progress. Third high block pour complete. Fourth high block initial preparations in progress. Fifth high block pour complete, initial preparations just starting. Near high block pour in progress. Note bucket landing at mixing plant has been extended to eliminate blind spot. This was accomplished over winter shutdown.
April 1951 Downstream and upstream views of progression of construction
Usual view of South Abutment showing stages of construction in greater detail. Start of trashrack construction for the River Outlets can be seen on face of dam. Not height of dam above cofferdam constructed for 1950 flood season.
Usual view of South Abutment showing stages of construction in greater detail. Start of trashrack construction for the River Outlets can be seen on face of dam. Not height of dam above cofferdam constructed for 1950 flood season.
April 1951 Downstream and upstream views of progression of construction
Usual view of Powerplant construction. Structural steel is in place over Sevice Bay and Unit No. 1. Forms are nearly complete for last pours (intermediate structure) in Unit No. 2. Unit No. 3 is ready for structural steel superstructure and Unit No. 4 is progressing but at a slower rate. Base of Control Bay is to immediate right of Unit No. 4. Note excellent access to job by catwalks, stairways and bridges between blocks. All photographs indicate good "housekeeping".
Usual view of Powerplant construction. Structural steel is in place over Sevice Bay and Unit No. 1. Forms are nearly complete for last pours (intermediate structure) in Unit No. 2. Unit No. 3 is ready for structural steel superstructure and Unit No. 4 is progressing but at a slower rate. Base of Control Bay is to immediate right of Unit No. 4. Note excellent access to job by catwalks, stairways and bridges between blocks. All photographs indicate good "housekeeping".
April 1952 Upstream and downstream views. Downstream views from both left and right banks.
View of upstream face of the dam looking toward the South Abutment. Forms for initial pours in blocks on South Keyway in place. Trashrack construction shown. Lake level at this time approximately El. 3270.
View of upstream face of the dam looking toward the South Abutment. Forms for initial pours in blocks on South Keyway in place. Trashrack construction shown. Lake level at this time approximately El. 3270.
April 1952 Upstream and downstream views. Downstream views from both left and right banks.
View of the downstream face of the dam looking toward the North Abutment. Concrete in blocks is substantially above the elevation of the loading dock. Catwalks and ladders used for cooling and grouting destroyed or damaged by heavy snow and ice during winter have been replaced where necessary. Final roofing underway on service bay of powerplant shown at lower left. Forms in d-line to dam and control bay in place. Note that cableway operators' tower has been relocated and heightened to provide adequate coverage for increased dam height.
View of the downstream face of the dam looking toward the North Abutment. Concrete in blocks is substantially above the elevation of the loading dock. Catwalks and ladders used for cooling and grouting destroyed or damaged by heavy snow and ice during winter have been replaced where necessary. Final roofing underway on service bay of powerplant shown at lower left. Forms in d-line to dam and control bay in place. Note that cableway operators' tower has been relocated and heightened to provide adequate coverage for increased dam height.
April 1952 Upstream and downstream views. Downstream views from both left and right banks.
View of the powerplant, valve house, and downstream face of dam. Roofing activities underway on service bay. At lower center can be seen form for one wall of spillway tunnel portal. Center right shows forms underway for control bay of powerplant. Hollow jet valves on three 8' outlet pipes operating full open and discharging approximately 8,800 c.f.s under present head.
View of the powerplant, valve house, and downstream face of dam. Roofing activities underway on service bay. At lower center can be seen form for one wall of spillway tunnel portal. Center right shows forms underway for control bay of powerplant. Hollow jet valves on three 8' outlet pipes operating full open and discharging approximately 8,800 c.f.s under present head.
August 1952 Downstream view of the Dam
View of the downstream face, showing completed powerplant stucture, valve house, and spillway portal. Outlet valves closed to complete painting of exteriors. Note that the concrete diversion wingwall between the outlet portal and the valve house shown in the previous pictures has been removed. Dam has lost the jagged appearance at top as blocks reach their ultimate height.
View of the downstream face, showing completed powerplant stucture, valve house, and spillway portal. Outlet valves closed to complete painting of exteriors. Note that the concrete diversion wingwall between the outlet portal and the valve house shown in the previous pictures has been removed. Dam has lost the jagged appearance at top as blocks reach their ultimate height.
August 1952 Downstream view of the Dam
View of the downstream face looking toward the right or north abutment. Completed powerhouse at lower left, with roofing complete, all sash installed. Stripping of catwalks below El. 3400 (continuous wide catwalk in picture) underway. These catwalks and ladders no longer required since all cooling, grouting, and patching now complete. Elevator towers (center of picture) in Block 14 (nearest) and 19 underway. Two pours completed in each, with forms in place for 3rd pour on Block 14 tower.
View of the downstream face looking toward the right or north abutment. Completed powerhouse at lower left, with roofing complete, all sash installed. Stripping of catwalks below El. 3400 (continuous wide catwalk in picture) underway. These catwalks and ladders no longer required since all cooling, grouting, and patching now complete. Elevator towers (center of picture) in Block 14 (nearest) and 19 underway. Two pours completed in each, with forms in place for 3rd pour on Block 14 tower.
October 1952, top view of the dam as well as the spillway
Photo shows view of spillway and top of the dam from the right abutment. The spillway ring gate is raised about 3 feet to permit completion of painting on the gate. The shed showing near the center of the spillway houses a hoist which carries a finishing jumbo for the inclined shaft of the spillway. The hoist sits on top of the control pier on the perimeter of the spillway, not in the spillway as the photo angle suggests. Near the center of the dam roadway, trashrack sections are being installed. All of the forms for the dam parapets and elevator towers have been stripped. The 125-ton Gantry crane shows in the upper center. The 3-story building on top of the dam in lower right is the cableway operators' tower.
Photo shows view of spillway and top of the dam from the right abutment. The spillway ring gate is raised about 3 feet to permit completion of painting on the gate. The shed showing near the center of the spillway houses a hoist which carries a finishing jumbo for the inclined shaft of the spillway. The hoist sits on top of the control pier on the perimeter of the spillway, not in the spillway as the photo angle suggests. Near the center of the dam roadway, trashrack sections are being installed. All of the forms for the dam parapets and elevator towers have been stripped. The 125-ton Gantry crane shows in the upper center. The 3-story building on top of the dam in lower right is the cableway operators' tower.
President Truman flipped the switch for the dam to begin producing stored energy on October 01, 1952
President Harry S. Truman and daughter Margaret were presented with appropriately decorated hard hats at the Hungry Horse Power Plant. President Truman is on the left, Construction Engineer C.H. Spencer is in the center, and Congressman Mike Mansfield is on the right. The Presidential motorcade arrived at the power plant at approximately 8:55 A.M.
President Harry S. Truman and daughter Margaret were presented with appropriately decorated hard hats at the Hungry Horse Power Plant. President Truman is on the left, Construction Engineer C.H. Spencer is in the center, and Congressman Mike Mansfield is on the right. The Presidential motorcade arrived at the power plant at approximately 8:55 A.M.
The Spillway
The Hungry Horse Dam spillway is a unique structure that is specific to the Hungry Horse Dam. According to The National Park Service, the Hungry Horse Spillway drops over 490’ and is the highest in the world. The spillway acts as a giant drain for the reservoir (Montana: Hungry Horse Dam (U.S. National Park Service), 2017).
A view of the spillway under construction
View of spillway tunnel. Note class bore and limited amount of overbreak.
View of spillway tunnel. Note class bore and limited amount of overbreak.
Top of the spillway shaft
View of top entrance to spillway shaft with fencing around part of the hole.
View of top entrance to spillway shaft with fencing around part of the hole.
An expanding steel form that will take the place of the wood forms in the spillway
Photograph of expanding steel form being assembled at top of spillway shaft. This will eliminate wood forms used in 1950 and should greatly expedite completion of the spillway shaft lining. Note taper to form as shaft expands from 24"-6" diameter at bottom to 33"-0" diameter at existing concrete.
Photograph of expanding steel form being assembled at top of spillway shaft. This will eliminate wood forms used in 1950 and should greatly expedite completion of the spillway shaft lining. Note taper to form as shaft expands from 24"-6" diameter at bottom to 33"-0" diameter at existing concrete.
Concrete for the top of the spillway being poured in April 1952
View of crest structure of spillway, with initial two pours complete and forms nearly complete for following pour. Note flared intake for spillway. Relocated cableway operator's tower in background. Stiffleg derrick services operations at crest structure, and provides direct delivery of concrete from bucket landing dock to crest structure.
View of crest structure of spillway, with initial two pours complete and forms nearly complete for following pour. Note flared intake for spillway. Relocated cableway operator's tower in background. Stiffleg derrick services operations at crest structure, and provides direct delivery of concrete from bucket landing dock to crest structure.
A view of the spillway above ground in June 1952
View of crest structure of spillway, with initial two pours complete and forms nearly complete for following pour. Note flared intake for spillway. Relocated cableway operator's tower in background. Stiffleg derrick services operations at crest structure, and provides direct delivery of concrete from bucket landing dock to crest structure.
View of crest structure of spillway, with initial two pours complete and forms nearly complete for following pour. Note flared intake for spillway. Relocated cableway operator's tower in background. Stiffleg derrick services operations at crest structure, and provides direct delivery of concrete from bucket landing dock to crest structure.
Support Structures
The construction of the dam lasted from 1948-1953. Throughout that time supporting structures were also constructed in order to streamline the building process. The cableways made it possible to transport concrete from cement plants to the dam site. Some cement plants were built very close to the cable way and dam site. Another cement plant was built in Coram, Montana which is a short distance from the site. The cement from Coram was hauled in trucks to the site to be used. Nearby there has also been a machine shop built that acted as carpenters’ shop and automotive shop that aided in the progress of the dam.
Top mixing plant to transport concrete
General view at top mixing plant showing dump structure where bulk cement and pozzolan trucks (semi-trailers) are unloaded by gravity into hoppers directly below, from which point the cement and pozzolan are delivered to their respective silos by covered conveyor belts. (Cement storage is 7000 bbl., and pozzolan storage 5000 bbl). Delivery from silos to mix plant is also by conveyor belt with additional storage of 2000 bbl. of cement and 2000 bbl. of pozzolan available. Size of rescreen plant is apparent from comparison with 52 foot diameter mix plant upon which it is built. Thirty-six inch aggregate delivery belt is also seen ready to operate.
General view at top mixing plant showing dump structure where bulk cement and pozzolan trucks (semi-trailers) are unloaded by gravity into hoppers directly below, from which point the cement and pozzolan are delivered to their respective silos by covered conveyor belts. (Cement storage is 7000 bbl., and pozzolan storage 5000 bbl). Delivery from silos to mix plant is also by conveyor belt with additional storage of 2000 bbl. of cement and 2000 bbl. of pozzolan available. Size of rescreen plant is apparent from comparison with 52 foot diameter mix plant upon which it is built. Thirty-six inch aggregate delivery belt is also seen ready to operate.
Cement plant at Coram (north of the dam site) during construction
Second view of Coram Silos to show construction details. Local piling used for posts are set on reinforced concrete base. This view from rear of bins.
Second view of Coram Silos to show construction details. Local piling used for posts are set on reinforced concrete base. This view from rear of bins.
Cement plant at Coram (north of the dam site) after completion
Cement and Pozzolan unloading plant at Coram.
Cement and Pozzolan unloading plant at Coram.
Machine shop looking up river
View of the Carpenters' Shop and Framing Yard area with Automotive Shop and Tire Shop (Quonsets) in left center, November 1948
View of the Carpenters' Shop and Framing Yard area with Automotive Shop and Tire Shop (Quonsets) in left center, November 1948
Created by: Tawnie Tribby
Photo Credits:
ImagineIF Libraries - Kalispell
University of Montana Mansfield Library
Bibliography
Bureau of Reclamation. (2022a). The Story of the Hungry Horse Project. Retrieved August 2, 2022, from https://www.usbr.gov/pn/project/brochures/hungryhorseproject.pdf
Bureau of Reclamation. (2022b, April 29). Hungry Horse Damn History. Retrieved August 2, 2022, from https://www.usbr.gov/pn/hungryhorse/history/index.html
Montana: Hungry Horse Dam (U.S. National Park Service). (2017, January 13). National Park Service. Retrieved August 2, 2022, from https://www.nps.gov/articles/montana-hungry-horse-dam.htm
Stene, E. A. (1995). Hungry Horse Project. Bureau of Reclamation, 1–17. https://www.usbr.gov/projects/pdf.php?id=125
Construction of the Hungry Horse Dam. Montana History Portal, accessed 26/09/2023, https://www.mtmemory.org/nodes/view/94846
