More cracks have been found in a new $57-million London water reservoir, which will put the botched project three years past its scheduled opening.

The city had hoped to have the reservoir operating by year’s-end at the latest.

The southeast reservoir and pumping station, originally slated to begin operating in May, 2011, failed during testing two months after it was to have opened.

One of two water storage cells sprang a leak, allowing water to seep under the other cell, causing the massive concrete structure to “float,” deflecting support columns and damaging its roof.

Now, as costly fixes near completion, The Free Press has learned additional cracking on sloping floor sections of the original cell have been found. The city hopes they’ll be waterproofed at additional cost to the contractor’s insurer, which has covered the fixes so far.

“We’re working with the insurer to assess whether or not it’s an insurable item,” city engineer John Braam confirmed Monday.

The vast majority of the repair work so far has been covered by the Allianz Global Risks, the insurer for contractor McKay Cocker Construction. The cost for the repairs hasn’t been made public, but the city had said it would cost $15 million to $20 million to replace the damaged section entirely.

Braam said he hopes the city can avoid “out of pocket” expenses for the three years of repairs, but admits he’s “reluctant to say all costs are being borne by the insurer.”

The city added $800,000 more to the $2.8 million-contract of consulting engineer AECOM Canada to monitor the repair job on behalf of the city.

In court documents, the city claimed McKay Cocker or one of its subcontractors damaged “sub-drains” below the base of the reservoir cells, causing them to deform or collapse. Unable to run off, the leaking water lifted one cell upward. The lawsuit filed by the city, to free up insurance money, contains claims not yet tested in court.

In September, Braam had predicted testing would be completed and the reservoir along Highbury Ave. S. in full operation by the end of this year.

But the situation has been more “complex and time consuming” than expected, he said.

“My best estimate of when it’s going to be completed now, hopefully, (is) the spring,” he said. “That’s the latest update.”

The city won’t accept the structure until it passes a week of testing with various loads of water to ensure it’s fully operational.

Insurance will continue “for a period of time” after it becomes city property, he said.

“We’ve been very happy and worked very well with the insurer,” he said. “I can guarantee you this will work.”

Braam promised city council will get a final accounting once the facility, expected to have a lifespan of 100 years, is finally up and running.

chip.martin@sunmedia.ca

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Meanwhile at Springbank Dam . . .

Opened in 1930 to hold back the Thames River for recreational purposes, it remains inoperable after a 2008 test of a $6.8-million repair job.

Bolts snapped during the test, leaving a dam gate open and the river at a low level.

Unlike the reservoir, the city owns the dam and filed a $5-million lawsuit against contractors.

Since the damage, the dam remains wide open.

The case isn’t expected to reach court until 2015.

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Southeast reservoir/pumping station