Concrete Tunnel Closure Solutions

Concrete Tunnel Closure Products from Synthetex

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Concrete Tunnel Closure Products from Synthetex

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Custom cast-in-place (CIP) tunnel closure products from the leading manufacturer of fabric formworks for the casting of concrete.

Sometimes a tunnel closure is required inside a dam facility or around it. Rather than using traditional methods that are difficult to install, rely on a custom-made HYDROCAST armor unit to close the tunnel.

These bags are entirely custom-made to the tunnel’s specifications and can come in different shapes such as cubes, rectangles, or shapes with curves. Unlike normal grout bags, our HYDROCAST armor units have more than two sides, making them an effective tunnel closure tool.

How is HYDROTEX used for spillway protection?

The Problem

Over the lifespan of older infrastructures at power plants, dams, and municipalities, tunnels and pipelines must be closed due to evolving regulatory laws or to prevent collapse that could damage the valuable properties above.

The Solution: HYDROTEX Fabric Forms for the In-Situ Casting of Concrete

Effectively prevent catastrophic collapse by casting a custom-sized concrete bag with HYDROTEX and HYDROCAST fabric formworks. Once filled with concrete, these formworks will create a permanent bulkhead at the ends of tunnels or pipelines. In between the concrete bag bulkheads, the void space can be filled with a flowable fill or grout.

Best HYDROTEX Fabric Forms for Closing Tunnels and Pipelines

HYDROCAST® Armor Units



HYDROTEX® Grout Bags



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Spillway Protection for Dams

A spillway ensures that the dam doesn’t overflow or fail by allowing a controlled amount of water to spill from the dam.

To ensure that the spillway doesn’t experience a loss of soil, dam owners and engineers should factor in a need for an effective erosion control system. A concrete lining such as HYDROTEX fabric-formed concrete will ensure that the spillway continues functioning as it should.

Another solution we offer at dams is embankment protection.

Spillway protection is typically needed for:

Lock and dam

Related Solutions

Spillway Erosion Protection Solutions

Spillway Protection Systems from Synthetex

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Spillway Protection Systems from Synthetex

Get a project estimate today:



HYDROTEX fabric-formed concrete mattresses are the most effective chute spillway protection product.

Aside from providing slope protection at emergency spillways, HYDROTEX fabric-formed concrete provides permanent erosion control at dams, mines, and any other sites with chutes.

HYDROTEX is a highly versatile product and is typically used to protect chute and side channel spillways. It is typically not used to provide erosion protection at straight drop, labyrinth, shaft, ogee, and siphon spillways. However, our engineers can work with you to manufacture a fabric-formed concrete product for your specific needs.

How is HYDROTEX used for spillway protection?

The Problem

Spillways are critical structures in dams for lakes, ponds, and other impoundments. When left unlined, the soil in these structures can erode and compromise the spillway’s integrity. Unwanted vegetation can also propagate, making the spillway less efficient and resulting in high maintenance costs.

The Solution: HYDROTEX Fabric Forms for the In-Situ Casting of Concrete

Keep maintenance costs low by casting a concrete mattress over the spillway with HYDROTEX fabric forms for the casting of concrete. Our products can provide hydrostatic relief, integrate internal concrete reinforcement cables, and offer other features as required. Permanent and maintenance-free, these mattresses effectively prevent the soil from eroding and keeps the spillway from losing the ability to properly channel water.

Best HYDROTEX Fabric Forms for Casting a Concrete Spillway Protection System

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block



HYDROTEX Uniform Section

HYDROTEX® Uniform Section



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Spillway Protection for Dams

A spillway ensures that the dam doesn’t overflow or fail by allowing a controlled amount of water to spill from the dam.

To ensure that the spillway doesn’t experience a loss of soil, dam owners and engineers should factor in a need for an effective erosion control system. A concrete lining such as HYDROTEX fabric-formed concrete will ensure that the spillway continues functioning as it should.

Another solution we offer at dams is embankment protection.

Spillway protection is typically needed for:

Lock and dam

Related Solutions

Concrete Scour Aprons

Concrete Scour Aprons

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Concrete Scour Aprons

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Cast a custom concrete scour apron with HYDROTEX fabric forms for the casting of concrete.

Adding scour aprons to any dam, mining, or other facility is easy with custom-made HYDROTEX fabric-formed concrete mattresses.

Our products can also be used to meet other common scour protection requirements such as bridge pier scour protection, prop scour protection, and rubble mound structure foundations.

How is HYDROTEX used to cast scour aprons?

The Problem

Scour can happen anywhere, especially at the base of locks, dams, and port quay walls. Left unattended, such scour can cause damage to the surrounding infrastructure, limiting its effectiveness and lifespan. Don’t leave these vulnerable areas to the mercy of the severe hydraulic events they experience.

The Solution: HYDROTEX Fabric Forms for the In-Situ Casting of Concrete

Effectively prevent critical failure of costly dam, port, or mining infrastructures by casting a concrete scour protection mattress with HYDROTEX fabric formworks for the casting of concrete.

This mattress is placed underwater at the base of locks, dams, and quay walls, permanently remediating and protecting against severe scour.

Best HYDROTEX Fabric Forms for Casting a Scour Apron

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block



HYDROTEX Uniform Section

HYDROTEX® Uniform Section



HYDROCAST® Armor Units



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Scour Aprons for Dams

HYDROTEX fabric-formed concrete mats are perfect to cast scour aprons.

These scour aprons can help you prevent erosion at conduits or anywhere else in or around the dam.

Scour aprons are especially useful at maintaining healthy soil conditions and providing a buffer between the original soil and the dam’s man-made structures. Installation is simple: lay out the geosynthetic panels on the area you’d like to protect, then pump with fine aggregate concrete.

Scour aprons are typically needed for:

Lock and dam
Mine

Related Solutions

Concrete Canal Lining Solutions

Concrete Canal Lining

Synthetex is the manufacturer and supplier of HYDROTEX fabric formworks (fabriform) for casting concrete canal lining systems. By providing a product that requires no heavy machinery or specialized workforce, we save contractors, engineering firms, and project owners thousands of dollars in installation costs.

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Concrete Canal Lining

Synthetex is the manufacturer and supplier of HYDROTEX fabric formworks (fabriform) for casting concrete canal lining systems. By providing a product that requires no heavy machinery or specialized workforce, we save contractors, engineering firms, and project owners thousands of dollars in installation costs.

Get a project estimate today:



Concrete canal lining is simple with HYDROTEX fabric-formed concrete mattresses.

HYDROTEX is the best solution for permanent erosion control at canals and rivers. Cost-effective and custom-made, a HYDROTEX mat requires no specialized workforce or heavy machinery for installation. Aside from canals, it is also apt for use in ditches, channels, rivers, and ponds. Give our team a call at 1-800-225-0023 for a free quote.

How is HYDROTEX used in concrete canal lining projects?

The Problem

An unlined canal is subject to bank erosion. The eroded bank encroaches upon the adjacent roadway, infrastructure, or valuable property, leading to catastrophic collapse.

A stormwater management or irrigation canal may also suffer from a reduced inefficiency of the components. Vegetation growth or bank erosion increases waterlogging and reduces waterflow.

The Solution: HYDROTEX Fabric Forms for the In-Situ Casting of Concrete

Cast a permanent canal liner with HYDROTEX fabric formworks for the in-situ casting of concrete. When pumped in place with fine aggregate concrete, the mattress rises to the designed thickness and permanently protects against bank erosion, protecting valuable adjacent structures or property.

A HYDROTEX concrete liner can also help you manage the efficiency of water flow. You have several customization options, such as incorporating products that can accommodate hydrostatic pressure relief, products that can accommodate revegetation, and products that can prevent vegetation (Uniform Section).

Best HYDROTEX Fabric Forms for Lining Canals with Concrete

HYDROTEX Filter Point

HYDROTEX® Filter Point


Cast a permeable concrete canal liner with HYDROTEX Filter Point fabric formworks (fabriform). This mattress’s distinctive filter points allow water to filter through, relieving hydrostatic pressure while protecting the canal from bank erosion.


HYDROTEX Filter Band

HYDROTEX® Filter Band® Concrete Mattress


For a more permeable alternative to Filter Point, consider lining your canal with HYDROTEX Filter Band. When the Filter Band fabric formworks are pumped with concrete, they give rise to a mattress with concrete tubes running along the sides and bottom of the canal.


HYDROTEX Uniform Section

HYDROTEX® Uniform Section


Need an impermeable canal lining system? HYDROTEX Uniform Section is just what you need. The closest alternative to concrete paving, the HYDROTEX Uniform Section fabric forms give rise to a mattress with an uniform section thickness and a relatively smooth surface.


HYDROTEX® Enviromat®


Sometimes project owners may desire establishing vegetation at their canals while also controlling bank erosion. For that purpose, Enviromat is the best fabric formwork, providing a solution that is visually appealing, effective, and permanent. When laid out and pumped with fine aggregate concrete, the formwork creates a mattress with unfilled fabric squares that can be cut open and seeded.


All HYDROTEX Products


Though these HYDROTEX fabric formworks are the most applicable for canal lining, we can effortlessly customize them by either mixing two of them or opting for another product that aligns more closely with your project goals and budget.


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Permanent Canal Lining to Prevent Seepage

Sometimes a canal needs to be lined on the sides and the bottom to protect against seepage and erosion. In those cases, a HYDROTEX fabric-formed concrete mat is the best choice.

With a diver’s help, the unpumped geosynthetic panel can be dragged across the riverbed. Once pumped with fine aggregate concrete, the mattress will naturally adjust to the soil.

Which industries typically need canal lining services?

Mine
River and canal erosion control
Airport runway

The Better Alternative for Precast Concrete Canal Lining

Unlike pre-cast concrete blocks, HYDROTEX can be easily transported to and from the project site.

No matter how remote or how close the canal is to a major highway, you will have no trouble transporting the geosynthetic panels to the installation site.

Additionally, other lining alternatives such as brick, puddle clay, LDPE plastic, cement, earthen types, or asphalt offer only a temporary solution that requires upkeep or replacement within a few years. HYDROTEX, on the other hand, is permanent and maintenance-free. After installation, HYDROTEX fabric-formed concrete mattresses can last up to thirty years without any intervention.

No Concrete Lining Machine (or Paver) Needed

One of the principal benefits of HYDROTEX is how easy it is to install in rivers and canals.

Rather than needing a concrete paver for canal lining, all you need is a pair of divers to place the geosynthetic panels across the riverbed. You will also need a small team to pump the custom-manufactured mattresses with fine aggregate concrete.

Erosion Control for any Canal

HYDROTEX fabric-formed concrete can be used in irrigation canals, fly ash canals, and drainage canals both big and small. No matter how long or how deep the cross-section, our manufacturing team in Toccoa will weave the perfect HYDROTEX fabric forms for your project’s specifications.


Looking for a different solution?

Erosion Control for Locks & Dams

Erosion Control for Locks and Dams

Synthetex’s fabric-formed concrete mattresses and grout bags are the premier solution for spillway protection and other erosion control needs at locks and dams.

When requiring spillway protection, scour aprons, or any other permanent erosion control solution at a lock and dam, rely on Synthetex to manufacture a concrete system designed specifically for your dam facility.

Apt for use in various shear stress environments, HYDROTEX fabric-formed concrete is a durable, simple-to-install alternative to popular solutions such as rip rap or prefabricated concrete blocks.

All HYDROTEX mattresses come in a variety of thicknesses and dimensions, ensuring that all erosion control requirements at locks and dams will be appropriately met.

We will work with you to come up with the best solution—simply give us a call to get started.

Why choose HYDROTEX for your lock and dam erosion control project?

HYDROTEX fabric-formed concrete is a permanent, customizable way to protect a dam’s components without having to worry about maintenance or upkeep. It is easy to install and to access.

By choosing to install a HYDROTEX armoring system or grout bag, you’d be effectively eliminating major logistical concerns, such as shipping costs and site accessibility.

The most important solutions HYDROTEX offers are spillway protection, scour aprons, embankment protection, and tunnel closures.

A dam is a complicated system—Synthetex is here to make it easy. Our engineers will take a look at the facility and recommend a solution customized only for you.

Save money, resources, and time on your next erosion control project. Get a project estimate:

HYDROCAST® Formworks


HYDROCAST® (HC) Formworks



Synthetex specializes in manufacturing engineered, project-specific fabric formworks for the casting-in-place of concrete armor units and structures for a spectrum of underwater applications.  For more than 25 years, engineering, contractor, and government clients around the world have relied on HYDROCAST® to design and fabricate the special concrete formworks they need for their projects.  They know Synthetex will deliver only the highest quality products, materials, and workmanship—guaranteed.

As leading specialists in the fabrication of fabric formworks for underwater casting of concrete structures, Synthetex offers engineered solutions such as custom armor units for spillway aprons, bulkheads, tunnel and pipe plugs, and more.  Our expertise includes working with nearly every component and material used in concrete formworks today, including high-strength polyester and Kevlar® fabrics and sewing threads, and steel and high tenacity polyester reinforcement cables.  With newly expanded manufacturing capabilities, we’re able to offer end-to-end solutions in-house, delivering finished products that are designed and built to perform.

HYDROCAST® fabric formworks provide low-cost in situ concrete alternatives to natural rock and precast concrete where they are not possible or practical.  Cast-in-place, concrete armor units and structures eliminate the requirement for heavy lift cranes for placement, where rock riprap and precast concrete blocks may require lifts of tens of thousands of pounds.  As with our concrete grout bags, HYDROCAST® can be positioned and filled with concrete from the surface in shallow water or by divers in deeper water.  Since the flexible fabric forms are cast-in-place, they intimately adapt to variations in the subgrade or bottom contours.  Installations do not require dewatering, a crucial advantage in emergency repair of scour aprons.

Synthetex worked closely with the U.S. Army Corps of Engineers and Bergmann Associates for the design of fabric forms for the underwater casting of armor units for the scour aprons of two Ohio River locks and dams. The concrete armor units ranged in sizes, up to 36 ft long x 18 ft wide x 6 ft high, and weights in excess of 10 tons each.  The specification of a fabric formwork that can be deployed underwater and then pumped full with concrete avoided the lifting of the massive armor units.

Heavy-duty, puncture-resistant formworks designed to meet pumped concrete pressures were placed into reusable steel frames and lowered into place in rows and columns.  As the frameworks were lowered they were filled with water to offset buoyancy and to inflate the formwork to its rectangular dimensions.  As concrete was pumped into the formwork an equal volume of water was displaced. The flexible bottom allowed intimate contact with the uneven subgrade. And, all of this is performed entirely under water and constructed on a slope.

HYDROCAST® concrete grout bags meet the requirements for a reliable and economical cast-in-place alternative to traditional rock (riprap) and precast concrete for the armoring of sand-filled geocontainers.

Applications for HYDROCAST® custom fabric formed concrete units:

  • Concrete armor units for dam scour aprons
  • Concrete armor units for the main primary protection of breakwaters, levees, and dikes
  • Artificial concrete reefs
  • Concrete armor units as the protection of sand-filled geocontainers
  • Pipeline and tunnel closures
  • Concrete quay walls and seawalls
  • Concrete sealing of large mineshafts and tubes

Ronald Stive, Director of Projects, Maritime and Waterways at Royall Haskoning DHV, has reported a trend toward using sand packed into geocontainers at the core of a breakwater, a solution that could be ten times cheaper than traditional rock.

“What we have noticed in the past ten years in our port and breakwater projects is that all around the world, people are in a hurry,” he noted. “They don’t accept that these types of structures will take years to design and to construct, so they are always looking for alternative ways to do it faster.

“Secondly, there is a trend to go into deeper water, and into areas where you don’t have quarries nearby and you may have problems where the seabed isn’t stable enough or there’s seismic activity. In these remote areas, you have to look for alternative designs to the traditional rubble mound type of breakwater, because of the fact that the materials are too far away or too costly to bring in.”

HYDROTEX® Articulating Block

Articulating Block (AB) Concrete Linings

Articulating Block (AB) Concrete Linings


Articulating Block Mats form cable-reinforced concrete block mattresses that resist erosive forces. They are often constructed where a revetment is exposed to frontal attack by wave action.

AB Mats are typically used to protect coastlines, canals, rivers, lakes, reservoirs, underwater pipelines, bridge piers, and other marine structures from propeller wash, ship wakes, wind waves, currents, and high velocity flows. They are also used in environmental construction for landfill caps, down chutes, and collector channels.

The AB fabric form consists of a series of compartments linked by an interwoven perimeter. Grout ducts interconnect the compartments, and high-strength revetment cables are installed between and through the compartments and grout ducts.

Once filled, the AB Mats become a mattress of pillow-shaped, rectangular concrete blocks. The interwoven perimeters between the blocks serve as hinges to permit articulation. The cables remain embedded in the concrete blocks to link the blocks together and facilitate articulation.

Gallery



Submit a Request for an Articulating Block Specification

We’ll get back to you within 1-2 business days. All specifications are available in both nylon and polyester configurations.

Submit a request for a technical specification

We’ll get back to you within 1-2 business days. All specifications are available in both nylon and polyester configurations.





HYDROTEX® Filter Point

HYDROTEX Articulating Block

HYDROTEX Uniform Section

HYDROTEX Filter Band

HYDROTEX Enviromat

Emsworth Lock and Dam, Back Channel Left Abutment Stabilization and Scour Protection


Emsworth Lock and Dam, Back Channel Left Abutment Stabilization and Scour Protection



Allegheny County, Pennsylvania, USA


Emsworth Locks and Dams are located on the Ohio River immediately downstream from the city of Pittsburgh, Pennsylvania. The back channel dam and locks are located on Neville Island, Pennsylvania, at river mi 6.4. The dam length is 960 ft (293 m) and the water depth exceeds 30 ft.

During low-flow conditions the loss of the pools of the Ohio, Monongahela and Allegany Rivers, at the point of Pittsburgh, would cease all navigation. Shippers using Emsworth had estimated that loss of the dam would increase transportation costs by $130 million annually.

The $32 million U.S. Army Corps of Engineer’s Contract W911WN08B0007 was awarded to Trumbull Construction in July of 2008. Synthetex was brought into the project, working closely with the U.S. Army Corps of Engineers and Bergmann Associates for the design of formworks for the underwater casting of armor units for the scour aprons on both the Main and Back Channels of the Emsworth Locks and Dams. The concrete armor units ranged in sizes up to 32 ft x 18 ft x 6 ft and weights in excess of 15000 lb each. Prior to the installation of the HYDROCAST® Concrete Bag Scour Protection downstream of the dam, there were 10 ft (3.0 m) deep scour holes and 65% of the existing stone scour protection was in a failed state. Due to the extreme corroded state of the dam gates, failure of any one of seven lift gates would most likely cause a portion of the stilling basin to fail and possibly undermine the dam. The dam had been categorized as Dam Safety Action Class 1, urgent and compelling.

The scour protection measures consisted of grading, placing bedding stone, and installing HYDROTEX® concrete-filled bags downstream of the existing dam for six individual bays.  During the project, approximately 10000 yd³ (7600 m³) of concrete was placed in more than 200 individual armor units with no lost time for more than three years.


Owner:U.S. Army Corps of Engineers
Engineer:U.S. Army Corps of Engineers / Bergmann Associates
Contractor:Trumbull Construction
Installation:2008 – 2014
Products:HYDROCAST

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