At the heart of critical infrastructure projects like the stabilization of Bluestone Dam, automated grouting equipment plays a pivotal role in ensuring precision and reliability. Designed for high-volume, consistent performance, systems like our PD1011H handle the demanding task of injecting thousands of gallons of grout daily, supporting crews as they anchor massive structures to bedrock foundations.

In the rolling hills of southern West Virginia, where the New River meets Summers County, the Bluestone Dam stands as a quiet guardian. Construction of this dam began in 1942 as part of the USACE Flood Control Act of 1936. Standing at 165 feet tall it spans over 2,000 feet and holds back the over 10 mile long New River and Bluestone Reservoir.

This impressive structure has estimated to save billions of dollars in flood damage to its community. The dam’s structure even played a crucial role in the community following the aftermath of hurricane Helene. But like any piece of infrastructure that is over 80 years old, it requires careful reinforcement to ensure it remains effective for the communities downstream. Our automated grouting equipment tackles this epic project, keeping things running smoothly for the operators and team. 

Recently, we visited the site in Hinton, West Virginia, where Brayman Construction is leading a major stabilization effort. The project’s core challenge: securing the dam’s foundation by anchoring it directly to the underlying bedrock. This isn’t a quick fix—it’s a methodical process involving thousands of feet of drilling and grouting to create a network of high-strength ties that distribute loads and prevent movement.

The Scale of the Work

This project is currently in phase 5, with lots of challenges and large milestones. Check out these impressive numbers from the project:

• 90,000 cubic yards of concrete, requiring an onsite concrete batch plant.
• 1,150 additional anchors to be installed all throughout the dam including any new concrete that will be placed. 
• 57,000 cubic yards of rock excavation in the rock basin. This will be for future placement of over 100,000 cubic yards of new embankment material.

Crews coordinate with drillers to bore over 1,000 holes into the dam’s structure, each one a pathway for post-tensioned anchors ranging from 10 to 60 strands of steel cable. These anchors are then tensioned and grouted in place, effectively stitching the dam back to its natural bedrock base. It’s an intensive intensive project navigating the site’s steep slopes and variable weather. All while maintaining the structural integrity of a flood-control asset that protects thousands along the New and Kanawha Rivers.

Grouting is the unsung hero here. On peak days, the teams pump up to 3,000 gallons of cementitious mix through these holes, ensuring a uniform bond that fills voids and locks everything in. The volume alone speaks to the project’s ambition—it’s not just about patching; it’s about rebuilding resilience from the inside out.

A Reliable Partner in the Mix: Penndrill Automated Grouting Equipment

At the heart of Brayman Construction’s grouting operation is one of our PD1011 automated grouting equipment, a workhorse that’s been stationed on this job for over a decade. This unit handles the daily grind without missing a beat. It processes anywhere from 100 to 3,000 gallons per shift, depending on the demands of the anchors being installed.

What sets the PD1011 automated grouting equipment apart in a setting like this is its straightforward reliability. Equipped with integrated flow metering, it is able to run autonomously based on set recipes. These recipes are customizable. Parameters like mixture time, powder weight, water amount, and number of batches are under total control to the operator. This level of control gives the operator and team the confidence  and consistency they need every time. They are able to save up to 100 recipes to recall at any time for different mix conditions. These recipes mix themselves automatically based on flow meter and weigh scale readings.

No guesswork—just verifiable records that ensure each injection meets engineering specs. The system runs on a simple electric over hydraulic setup, drawing from local water sources and silo feeds.

Justin Martin with Brayman, stated that he has been running this particular PD1011 since the early days of the project. “It’s an iron horse,” he said, gesturing to the weathered machine behind him. At over 10 years old, it powers through every workday.

Voices from the Field on our Automated Grouting Equipment

We captured the operator’s perspective in a short video during our visit—an explanation of how the PD1011 fits into the bigger picture. “We’re hoping to see many more years out of this plant,” he noted after the upgrades. It’s a sentiment echoed by the crews: equipment that shows up reliably lets them focus on the anchors, the drills, and the dam itself.

This project underscores why we design our systems the way we do—for longevity in demanding environments. Our automated grouting equipment doesn’t demand attention; it just delivers, batch after batch, helping turn engineering plans into lasting infrastructure.

As Bluestone Dam’s anchors take hold, so does the quiet assurance that comes with proven tools and dedicated hands. We’ll keep following along as the project progresses—stay tuned for more updates from the field.