French Development Enterprises, LLC (FDE) of North Billerica, Mass., Oldcastle Precast of Littleton, Colo., and GEI Consultants of Woburn, Mass., announced successful construction and assembly of the first prototype “French Dam” — a modular precast impoundment for construction and retrofit of hydroelectric dams, water control systems, and power houses.

FDE’s patented technology for Rapid Dam Construction was funded for $1.7 million in January 2016 by the U.S. Department of Energy (DOE) under funding opportunity “Research and Development of Innovative Technologies for Low Impact Hydropower Development” and was further supported by a grant from the Massachusetts Clean Energy Center.

“The French Dam will be a game changer for the Hydro industry,” said Bill French Sr., president of FDE. “It simply replaces traditional construction methods with offsite manufacturing and onsite installation, making the entire process just-in-time ready and weather independent.”

The 24-foot-long by 16-foot-high prototype, designed by GEI Consultants in cooperation with Oldcastle Precast, consists of six, 27,000-pound concrete 8-foot by 8-foot blocks interconnected with each other forming one monolithic structure. Upon arriving from Oldcastle’s plant in Avon, Conn., the dam was assembled in less than 3.5 hours.

“This technology for precast dams can significantly decrease time, reduce cost, and minimize risk of the civil stage of the construction process, making it more feasible and attractive to investors, developers, and dam owners,” said Lenny Lozinsky, executive vice president, FDE.

Construction of the prototype of the modular hydro dam came three months after the DOE released its Hydropower VISION report, which recommended modular approaches to new in-stream hydropower facilities. In its report, the DOE proposed a “suite of modular components for foundation, generation, and stream passage may be considered and fit together to meet site-specific parameters as well as environmental and power generation objectives.”

“We believe the French Dam has ultimate flexibility and includes a sophisticated and innovative approach, making it adaptable for almost every type of site conditions for construction of new and retrofit small/medium hydroelectric, water control systems, and power houses in the United States,” said Varoujan Hagopian, P.E., senior consultant, GEI Consultants.

“Precast concrete is one of world’s most functional and versatile building materials,” said Bob Kramer, vice president of marketing and product development, Oldcastle Precast. “Manufactured in a controlled environment gives you the end result of a cost-effective and reliable solution. It is exciting to see its application as an innovative technology in the construction of hydro dams.”

Information provided by French Development Enterprises, LLC (; Oldcastle Precast (; and GEI Consultants (