One stark example was the failure of Minnesota’s century-old Rapidan Dam in June, which succumbed to intense flooding.

This incident is a microcosm of a broader issue: America’s nearly 92,000 ageing dams, most built in the early 1900s, are under increasing strain from extreme weather.

Federal and state officials have reported over 30 dam failures in the Midwest since 2018, as precipitation has risen by 5-15%. A United Nations University study found that 85% of US dams operate beyond their life expectancy, with refurbishment costs estimated at $64 billion (£47bn).

The US Army Corps of Engineers (USACE) oversees 740 dams, ensuring their safety through data-driven management. Borehole data, which reveals subsurface conditions, plays a crucial role in the Corps’ flood control systems, helping identify areas prone to seepage, instability, or erosion.

However, the USACE faced a significant challenge; its data was scattered across 500 disparate database structures, making it difficult to create a unified picture.

Data migration and standardisation

To address this, USACE partnered with Dataforensics, an Atlanta-based firm specialising in subsurface data management, and adopted Bentley Systems’ OpenGround, a cloud-based platform for geotechnical data.

Dataforensics developed a custom data migration application to streamline the transfer of millions of feet of borehole data into OpenGround.

“We enhance platforms like OpenGround, focusing on getting data into the system so it can be used effectively — whether for logging boreholes, lab results, or historical data,” explains Scott Deaton, president of Dataforensics.

The migration application automated data cleaning, standardisation, and transfer into OpenGround. It also generated PDF logs, enabling seamless integration of previously siloed information. The process was further validated using Microsoft Power BI and advanced analytics.

Implementation posed its own hurdles: “Shifting from a paper-based approach to a modern system required significant effort,” Deaton explains. Success depended on collaboration between internal USACE teams, Dataforensics, and Bentley Systems, as well as a focus on ownership and training.

According to Deaton, regional “data champions” were appointed across USACE district offices to oversee workflow management and documentation, ensuring a smooth transition to the cloud-based solution. These champions also acted as internal support for data queries and promoted best practices.

Extensive training played a pivotal role. Over three years, USACE conducted 30 live, multi-day training sessions, reaching more than 400 personnel. Additional online tutorials, webinars, and internal tech support ensured widespread adoption of OpenGround.

Dam fine results

The implementation has yielded transformative results. Deaton estimates that 8,500 projects containing data from 200,000 boreholes have been centralised and standardised in OpenGround, valued at over $500 million.

Automating the migration saved significant time; a process that would have taken 60,000 hours if completed manually was completed in 3,000.

Centralisation has eliminated redundant workflows and fostered cross-district collaboration within USACE, breaking down silos that previously hindered operations. The quality and completeness of data have also improved.

“In the past, subcontractor data, lab results, and test outcomes were often missing or incomplete. Now, all data is imported into a single system, eliminating errors from multiple data entries,” says Deaton.

He adds that reusing historical data has reduced risks, minimised the need for expensive and environmentally damaging redrilling, and enabled faster, more accurate analysis during emergencies.

Averting disaster

The streamlined system has proven invaluable in critical situations, such as a hurricane or dam seepage emergency. Deaton recalls a recent instance when USACE needed to address a life-threatening seepage issue at an ageing dam.

“We located the data within minutes, visualised it with geographic information tools, and provided emergency workers with an actionable understanding of the subsurface conditions,” he explains.

These capabilities are vital as the US confronts the increasing impact of climate change. With most dams over 100 years old and many owned by small municipalities, Deaton predicts that USACE’s expertise will be in high demand for years to come.

The Corps’ transition to a unified, cloud-based geotechnical data platform has enhanced its ability to safeguard critical infrastructure, like the ageing dams. By standardising its data and embracing advanced tools, the army is not just keeping pace with current challenges but proactively preparing for future ones.

As Deaton concludes: “The Corps has transformed how it manages its data, setting a benchmark for modern infrastructure resilience.”

Harnessing the power of hybrid cloud

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