Shoreline Revetment Solutions

Shoreline Revetment Systems from Synthetex

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Shoreline Revetment Systems from Synthetex

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Installing a coastal revetment is simple with HYDROTEX fabric formworks for the casting of concrete.

The best product for armoring shorelines, HYDROTEX is 100% customized to your project’s specifications and requirements.

The geotextile fabric forms are manufactured to fulfill the required designed thickness and allows the mattress to conform to the land as the fabric is pumped with fine aggregate concrete.

Other coastal solutions we offer include rubble mound structure foundations and embankment protection.

How is HYDROTEX used to cast concrete shoreline revetments?

The Problem

Unprotected shorelines or estuaries can erode and encroach upon valuable seaside, lake, or river property such as ports, piers, lighthouses, industrial complexes, and roadways. This can compromise these structures and result in damage that can cost millions of dollars in repairs.

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

Prevent unexpected repair costs by installing a HYDROTEX fabric-formed concrete mattress on shorelines, attenuating erosion as well as scour. Unlike rip rap, our solutions can be customized to a thinner profile while relieving hydrostatic pressure, reducing wave run-up, and resisting shear stresses from hydraulic flow.

Best HYDROTEX Fabric Forms for Casting a Concrete Shoreline Revetment

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block

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HYDROTEX: The Best Shoreline Revetment Product

Coastal and marine engineers should do everything possible to prevent the loss of soil and movement of sediment from shorelines. A HYDROTEX mattress such as Articulating Block will provide the protection required. Both permeable and cable-reinforced, this mattress is the perfect solution to protect shorelines subject to hydraulic friction.

HYDROTEX fabric-formed concrete replaces other methods such as tetrapods, rip rap, and gabions.

Shoreline protection is typically needed for:

Marine facility

Related Solutions

Rubble Mound Structure Foundations

Rubble Mound Structure Foundations

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Rubble Mound Structure Foundations

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Resolve underwater scour issues with HYDROTEX fabric-formed concrete scour protection mattresses.

The best solution for localized scour underwater and on land, HYDROTEX provides superior protection against harsh hydraulic forces under the sea.

How? The geosynthetic panels are laid out underwater at berths, ports, and harbors, then pumped with fine aggregate concrete. The result is a fabric-formed concrete mat that conforms to the scour depth around pier piles, on embankments, and under any marine structure.

How is HYDROTEX used to create a foundation for rubble mound structures?

The Problem

Rubble mound structures (breakwaters, jetties, oyster reefs, etc) are a critical component of any coastal system. They are one of many ways to control water flow and direction as it comes in from the sea, protecting port operations and ecological environments.

Proper foundations are imperative to ensure the long-term performance of these structures. Without a foundation, you risk having to spend millions in repair or replacement costs.

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

Cast a concrete foundation under a jetty with HYDROTEX fabric formworks. The result is a permeable concrete mattress that effectively prevents soil loss beneath the breakwater, preventing differential settlement and improving the structure’s stability and longevity.

Best HYDROTEX Fabric Forms for Casting an Oyster Reef Foundation

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block

grout bags

HYDROTEX® Grout Bags

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Whether used as breakwaters or shoreline protection systems, rubble mound structures play a critical role in coastal civil engineering projects.

Protect your rubble mound structure from underwater erosion and scour by creating a foundation below the structure, minimizing soil movement and counteracting wave conditions that can critically compromise its efficacy and stability.

HYDROTEX fabric-formed concrete is the best solution for such a need, ensuring the longevity of the structure and minimizing erosion of the coast’s shores.

Rubble mound structures are typically needed for:

Marine facility

Related Solutions

Embankment Erosion Protection Solutions

Permanent Erosion Protection for Embankments

Synthetex manufactures HYDROTEX custom-made fabric formworks for the casting of concrete embankment protection systems. Offering cheaper freight costs and minimal labor requirements, HYDROTEX helps you save money and time.

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Permanent Erosion Protection for Embankments

Synthetex manufactures HYDROTEX custom-made fabric formworks for the casting of concrete embankment protection systems. Offering cheaper freight costs and minimal labor requirements, HYDROTEX helps you save money and time.

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With HYDROTEX, embankment slope protection is permanent and easy.

HYDROTEX fabric-formed concrete is the leading embankment protection method for rivers, locks, coasts, harbors, and more. Simply lay out the geosynthetic panels, pump with fine aggregate concrete, and see your custom-manufactured mattress rise to its designed thickness.

Though typically not used as a soil stabilization product, HYDROTEX can help stabilize the embankment and provide an extra layer of protection against hydraulic and environmental forces.

How is HYDROTEX used at embankments?

The Problem

Unprotected embankments can erode and cause the soil to recede under roads, infrastructure, and valuable property, leading to the catastrophic collapse of these structures.

How? Left exposed, embankments can erode due to waves, flowing water, or underwater ship thrusters. The optimal embankment protection solution will therefore accommodate different conditions and protect the embankment decades after installation.

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

HYDROTEX fabric formworks are the best way to cast a concrete mattress that effectively prevents the soil from eroding and keeps the embankment intact.

With HYDROTEX, you can take care of any design requirements. For example, you can choose a product that relieves hydrostatic pressure, decreases water velocity, reduces wave run-up, or provides an impermeable liner.

Best HYDROTEX Fabric Forms for Permanent Embankment Erosion Control

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block

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HYDROTEX in Action at Embankments

Embankment Protection for Locks and Dams

Just like any other inland waterway, locks and dams have embankments that need to be protected from erosion.

HYDROTEX fabric-formed concrete is the best solution for this application. A HYDROTEX fabric-formed concrete mat can withstand the hydraulic forces present at dams and prevent soil loss at these fragile areas.

Embankment erosion control services are typically applicable for:

Lock and dam
Marine facility
Wastewater plant
Ship at port
River and canal erosion control
Airport runway
Sediment remediation and capping

Coastal Embankment Protection

Coasts are subject to erosion because of their constant contact with the ocean’s waves. Protect the coast near or around your facility with a HYDROTEX fabric-formed concrete mattress. Our customized fabric formworks can help you cast a mattress of any thickness and configuration.

For example, two different formworks can be sown together, with an impermeable concrete mattress on one end and a permeable concrete mat on the other.

HYDROTEX can also be used as a shoreline revetment product.

River and Canal Embankment Protection

Preventing embankment failure should be a priority for municipal and regional authorities trying to maintain the well-being of bodies of water in their districts. HYDROTEX fabric-formed concrete is the best erosion protection measure at river embankments, providing far superior protection than geocells (cellular confinement), matting, rip rap, and prefabricated concrete blocks.

Embankment Protection at Bridges, Highways, & Railways

Embankment failure is a concern for DOT authorities looking to ensure the sustainability of their municipality’s rivers, canals, and other inland bodies of water. Ensure river embankments are protected by armoring them with HYDROTEX fabric-formed concrete.

Permanent and simple to install, a concrete mattress will relieve hydrostatic pressure and keep the soil protected underneath.

Who is Synthetex?

We are the manufacturer of HYDROTEX® geosynthetic fabric formwork used for the in-situ casting of concrete.

We are not an engineering firm, subcontractor, concrete supplier, or fabriform installer. We are a manufacturer.

As your manufacturer, we work with each of those entities to deliver cost-effective solutions at every stage of your project. Our team will also assist with cost analyses, train installation teams, provide technical assistance, and assist with design and hydraulics.

We’re not just a one-time supplier—we’re your strategic partner for your current project and beyond.

Related Solutions

Marine & Coastal Erosion Control

Marine and Coastal Erosion Control

Synthetex manufactures effective marine and coastal erosion control systems for a wide variety of hydraulic environments.

Whether you need shoreline revetments, embankment protection systems, or rubble mound structure foundations, rely on Synthetex to manufacture a customized erosion control solution for your marine and coastal facility. With over thirty years of experience providing dependable coastal erosion control systems, we are the top choice for your next project.

Why choose HYDROTEX for your marine erosion control project?

HYDROTEX fabric-formed concrete mattresses are the top solution for marine and coastal erosion control projects. Fully customizable and durable, a HYDROTEX mat will provide much-needed scour protection to marine structures and coasts.

Whether you’re an experienced engineer who knows exactly what you need, a consulting firm looking to resolve coastal erosion control issues for a client, or a project owner in need of guidance and advice, we’re here to help. Our civil engineers are experts in marine erosion control, meaning you won’t have to guess during any stage of your project.

Not convinced yet? We’re the original manufacturer of HYDROTEX, which means that you’ll be talking to the team who patented and developed the product. Our state-of-the-art manufacturing facility in Toccoa, GA will produce a mattress that’s entirely customized to your project.

Looking for erosion control solutions at ports? We offer customized products for that too, allowing you to focus on issues unique to port facilities, such as prop and thruster scour protection and pipeline cover protection.

HYDROTEX: The Best Coastal Erosion Control Method

HYDROTEX is the best measure to control coastal erosion—and we don’t say that just because we manufacture the product. HYDROTEX is easy to install, economical, and permanently effective at armoring coastal embankments, estuaries, and other shorelines.

If you’re ready for a permanent erosion control solution that will protect coasts at your facility, call us at 1-800-253-0561 from 8 AM to 5 PM EST. Our engineers will be thrilled to help.

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How do you control erosion in coasts and marine environments?

Minimizing coastal erosion can be a simple process, especially with HYDROTEX. With the help of a consulting firm or your in-house engineers, determine the areas in your marine facility that require erosion protection.

From there, simply come to us with your concerns and our civil engineers will take a look at your site plans, carry out all required calculations and analyses, and prescribe a permanent solution that will reduce costs in the long term.

The HYDROTEX Advantage

HYDROTEX doesn’t require heavy equipment. The geosynthetic panels are ready to be rolled out and pumped with fine aggregate concrete the moment they are delivered.

For installation, you will only need a small-line concrete pump, an experienced contractor, and a diver. HYDROTEX is not only permanent, it can be quick to install—installation can be finished in as little as one month, depending on the square footage of the installation.

Ready to get started? Call us today at 1-800-253-0561 for a free consultation, or shoot us an email at When it comes to erosion control, we’re always here to help.

How We Can Help

Sea conditions can be rough and can change unexpectedly. Mean sea level and extreme water levels can rise, storms can hit hard and frequently, and dominant wave directions can turn. When these occur, they have devastating effects on coastal and offshore structures, coastlines, low-lying hinterlands and city areas.

When designing and managing the coastal zone, you must consider the increase in flood risk, loadings on structures, changes in sedimentation, changes in erosion, and accretion of coastlines.

Synthetex uses a proven approach with dependable products to maximize value for private and public infrastructure projects for coastal and marine applications. Whether you to need to maintain or improve existing infrastructure, plan new construction to expand capacity or seek to minimize life-cycle costs, Synthetex can provide you with sustainable solutions.

Synthetex implements solutions for the following:

Shoreline revetments, breakwaters
Wave, wind and storm surge protection
Moveable structures
Bulkhead, seawall, wharves and piers
Marinas, boat ramps, offshore terminals and mega yacht facilities
Waterfront parks and recreation

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Subsea Formworks – Mattresses, Supports, Covers, Sleeves, and Shells

Subsea Formworks – Mattresses, Supports, Covers, Sleeves, and Shells

Synthetex installs fabric formed concrete supports, mattresses, covers, sleeves and shells to prevent pipeline damage and scour, and support pipeline freespans.  Jack-up supports can be used to raise a pipeline or structure.  The flexible, high-strength synthetic woven fabric bags are cost effective to make and are easy to deploy by an ROV or diver.

Portland cement fine aggregate grout is mixed on deck, then pumped through a deepwater grout pipe that has been pre-connected to the formwork and lowered to the seabed on a sled.  The formwork is positioned by an ROV or diver and checked for orientation and position and monitored to assure even filling.  Many formworks can be filled in one stage. Due to their size and volume others may require multiple compartments and filling stages.

Freespan Rectification

In order to determine the design and path of underwater pipelines and cables, surveys of seabed topography and investigations of local currents enable engineers to evaluate the potential occurrence of scour and the need for freespan measures.

Eliminating unacceptable freespans, resulting from undulating sea floors, will require pipeline supports that meet the regulatory requirements, following design codes such as DNV-RP-F105 for freespans.  Seabed scour around pipelines and structures will occur as a result of increased velocities caused by localized currents.  Fabric formed concrete mattresses can be designed and installed to protect both new and existing pipelines from the loss of supportive sediment.

Engineers used computer modeling software to identify tens of potential freespans that would need addressing along a recently completed project, in the Bay of Bengal, that required formwork supports for a new 32 in export pipeline and a 14 in intra-field pipeline.

Custom subsea grout bags were designed and manufactured to suit the terrain and height of the freespans.  The large-base grout bags had anti-scour protection skirt sleeves built into them, which slows down the local current and causes suspended particulate matter to settle.  Over time, the skirts become engorged with sediment, reinstating the seabed.

The grout bags required filling in two or more stages due to their volume.  This was achieved by injecting grout into the lower section of the bag and allowing it to cure to provide a stable support for the grout injected in the upper sections.  The formworks were installed in water depths up to 186 m across a 90-day campaign.

Deepwater Pipeline Separation

There are other subsea applications for fabric formworks, such as jacking or separating crossing pipelines.  Jack-up supports protect the lower pipeline.  An ROV will remove the formwork from the deployment sled and maneuver it into position.  With the pre-connected grout pump already attached, fine aggregate supports are filled with fine aggregate concrete.

Ordinary Portland cement (OPC) grout is mixed on deck, then pumped to the grout bag via a deepwater grout umbilical, connected to the formwork deployment sled.  After sufficient grout has entered the formwork to stabilize the bag, checks are made to ensure that the bag orientation and position is still correct and that it is filling evenly.

The crossover grout bag is designed to be filled in three stages due to its size and volume.  The lower compartment is filled and allowed to cure sufficiently to support additional grout in the upper compartments.

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.”


Enviromat® (EM) Concrete Linings

Enviromat Concrete Linings are installed to provide protection against periodic high flows. After installation, vegetation can be planted within the open structure of the lining to create a more natural appearance. Enviromat Concrete Linings are used in drainage ditches and on the upper slopes of channels, canals, lakes, reservoirs, rivers, and other water courses as well as for embankments subject to heavy run-off.

Enviromat Linings are comprised of concrete-filled elements and unfilled areas that allow for the establishment of vegetation.  Once the concrete sets, the defined unfilled and interwoven areas are opened by cutting the fabric and are planted or are filled with topsoil and seeded.  Within a growing season a vegetated cover will normally extend over the lining, resulting in an erosion control system with the hydraulic, ecological and aesthetic features desired.


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.


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

Turkey Point Nuclear Generating Station (Units 3 and 4)

Turkey Point Nuclear Generating Station (Units 3 and 4)

Homestead, Florida, USA

Turkey Point Nuclear Generating Station is owned by Florida Power & Light Co. (FP&L). In addition to the two nuclear pressurized water units (Units 3 and 4) Turkey Point operates two 400-megawatt oil/natural gas-fired generation units (Units 1 and 2). Units 3 and 4 each supply steam to one high-pressure and two low-pressure turbines with a power output rated at 693 MW for each unit. In 2007, Turkey Point added the 1150 MW combined-cycle gas-fired Unit 5.

Turkey Point serves the entire southern portion of Florida. With a combined capacity of 3330 MW, the site is the largest generating station in Florida and is the sixth largest power plant in the United States.

In 2010, Florida Power & Light received regulatory approval for the storage of spent fuel cells in dry casks. FP&L designed a 125000 ft² elevated storage area to be protected by a HYDROTEX® 12 in Articulating Block (AB1200) fabric formed concrete perimeter revetment.

Owner:Florida Light & Power Co.
Engineer:Florida Light & Power Co.
Contractor:Dickerson Construction, LLC
Products:HYDROTEX Articulating Block (AB1200)

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

Marine Corps Air Station Camp Pendleton

Marine Corps Air Station Camp Pendleton

Oceanside, California, USA

Marine Corps Base Camp Pendleton is the major West Coast base of the United States Marine Corps. It is located north of San Diego, California, and is a United States Marine Corps airfield.

Camp Pendleton was commissioned in 1942 and is currently home to Marine Aircraft Group 39. The base’s diverse geography and more than 125000 acres (506 km²) serve as the location for year-round training for Marines and other branches of the U.S. military. The base’s 17 mi (27 km) of coastline offers ample opportunities for amphibious and sea-to-shore training.

In 1998, more than $100 million in damage from flooding occurred when a levee burst, sending a 6 ft wall of water onto the airfield.

The Department of the Navy commissioned Winzler & Kelly to design the 9559 ft long levee repair at MCAS airfield. The project specifications called for a 6 in thick fabric formed concrete erosion protection for the levee’s 1h:1v side slope. Reyes Construction, the project’s general contractor, selected HYDROTEX® Uniform Section US600 for the protective cover.

Owner:Department of the Navy
Engineer:Winzler & Kelly
Contractor:Reyes Construction
Products:HYDROTEX Uniform Section US600

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