Prop and Thruster Scour Protection Solutions

Permanent Scour Protection

Use HYDROTEX fabric formworks to cast a concrete scour protection system at your port or harbor. Save thousands in installation and machinery costs.

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Permanent Scour Protection (Prop or Thruster Scour)

Use HYDROTEX fabric formworks to cast a concrete scour protection system at your port or harbor. Save thousands in installation and machinery costs.

Get a project estimate today:



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 protect against underwater prop and thruster scour?

The Problem

Ports are prime locations for scour, especially at the base of piers and quay walls. Due to natural waves and the movement created by the props and thrusters of ships coming into the ports, the embankment or subgrade material will scour and potentially compromise existing infrastructure.

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

Effectively prevent critical damage to your port by installing a HYDROTEX fabric-formed concrete mattress that will remediate or fill the scour hole as it happens. When a ship pulls into the port, the water will inevitably move, but the concrete mattress will prevent the sand and sediment from eroding.

Best HYDROTEX Fabric Forms for Casting an Underwater Scour Protection System

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block



HYDROTEX Uniform Section

HYDROTEX® Uniform Section



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HYDROTEX: The Best Prop and Thruster Scour Protection System

When a ship pulls away from a port, the land underwater is subject to localized scour. Protect underwater embankments from propeller action by armoring them with a HYDROTEX fabric-formed concrete mattress custom-manufactured to the embankment. The mattress will ensure that soil movements remain to a minimum and that the underwater land isn’t altered by the passing of ships.

Prop scour protection is typically needed for:

Ship at port

Related Solutions

Pipeline Cover Protection Solutions

Concrete Pipeline Protection

Use HYDROTEX fabric forms to cast a concrete pipeline protection system and save millions in labor and installation costs.

Get a project estimate today:



Concrete Pipeline Protection

Use HYDROTEX fabric forms to cast a concrete pipeline protection system and save millions in labor and installation costs.

Get a project estimate today:



HYDROTEX fabric-formed concrete mattresses are one of the best pipeline protection methods in the industry.

Permanent and custom-made, a HYDROTEX pipeline cover is the most effective countermeasure against corrosion for pipelines underwater and above ground.

Used in conjunction with cathodic protection, HYDROTEX can be installed over, under, and around a pipeline to provide superior erosion protection and prevent soil movement under the pipeline.

How is HYDROTEX used for pipeline protection?

The Problem

Like bridges and piers, pipelines are subject to scour and erosion, which can significantly reduce the longevity of the structure. Such damage can lead to catastrophic failure, costing millions in repair costs.

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

Use HYDROTEX fabric formworks to cast a permanent concrete mattress that will protect the pipeline bed from erosion. With HYDROTEX, you can also cast a permanent concrete structure that will support freespan pipelines, preventing critical failure.

Best HYDROTEX Fabric Forms for Protecting Pipelines

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block



SUBSEA Formworks



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HYDROTEX: The Best Oil Pipeline Protection Product

Oil and gas pipelines must be protected from corrosion and damage with a proper armoring system, ensuring the longevity of the pipe. HYDROTEX fabric-formed concrete is a cost-effective way to cover pipelines, fortifying them and ensuring the ground around them experiences minimal erosion during their lifetime.

Pipeline protection is typically needed for:

Industrial plant
Mine
Ship at port

Offshore Pipeline Cover Protection

Don’t leave an underwater pipeline to the mercy of the ocean’s elements.

The metal is subject to scour and corrosion, which could lead to a failure of the pipeline system. HYDROTEX fabric-formed concrete mattresses can be installed over and around the pipeline to provide much needed protection against scour.

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.

Get a project estimate today:



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.

Get a project estimate today:



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
Mine
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

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.

Get a project estimate today:



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?

Bridge Abutment Scour Protection Solutions

Bridge Abutment Scour Protection Solutions

Without proper protection, bridge abutments can suffer from localized scour, critically compromising the structure’s stability.

A HYDROTEX concrete mat will prevent bed degradation and soil loss around the abutment, diminishing this risk.

Get a project estimate today:



Bridge Abutment Scour Protection Solutions

Without proper protection, bridge abutments can suffer from localized scour, critically compromising the structure’s stability.

A HYDROTEX concrete mat can prevent bed degradation and soil loss around the abutment, diminishing this risk.

HYDROTEX fabric-formed concrete is the top countermeasure for localized scour and erosion at bridges and piers.

We provide best-in-class bridge abutment scour protection solutions for engineering firms, general contractors, and installers looking for a permanent, cost-effective product they can confidently use to bid on a project.

With HYDROTEX, you save money, resources, and time.

How is HYDROTEX used in bridge abutment protection projects?

Bridge abutment before HYDROTEX installation

The Problem

Water velocity, wind, and/or wave run-up cause soil loss and bed degradation at bridge abutments.

When soil is lost underneath the abutment, the structure will settle downward, causing a difference in elevation and forming cracks that will lead to irreparable damage and structural failure.

Bridge abutment after HYDROTEX installation

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

Prevent failure by using HYDROTEX fabric forms for the in-situ casting of concrete. With a custom-made HYDROTEX fabric form, you can cast a permanent mattress or grout bag that conforms to the scour depth and stabilizes the abutment.

One principal benefit of our product is that it can be installed under water. It’s also much easier to install in low head clearance conditions. Rip rap, for example, isn’t as easy to install in such conditions.

Best HYDROTEX Products for SCOUR PREVENTION AT BRIDGE ABUTMENTS

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block Fabric Forms (Fabriform)


Cast an articulating block concrete mattress to protect an abutment with HYDROTEX Articulating Block fabric forms. We manufacture the fabric forms with internal revetment cables that aid articulation and permit flexibility. Once cast in place with fine aggregate concrete, you’ll get a custom mattress that remediates and prevents scour. This is the most popular product for bridge abutment protection projects.


HYDROTEX® Grout Bags for Bridge Abutment Protection


Easily cast a grout bag with a custom-made HYDROTEX grout bag fabric form. Another popular choice for bridge abutment protection projects, a grout bag will fill the scour hole and prop the abutment back up if the local scour has already effected a difference in elevation. Grout bags are made with 100% custom width and height for any type of bridge abutment.


Have a pressing question? Want a consultation or project estimate?

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Why choose HYDROTEX for Scour Prevention at Bridge Abutments?

HYDROTEX is easy to install underwater and requires no excavation, making it superior to grouted riprap, gabion baskets, retaining walls, and reinforced soil systems.

The geosynthetic panels are delivered to the project site ready-to-pump, and installation requires no heavy machinery or specialized workforce.

Not convinced? HYDROTEX is permanent, durable, and maintenance-free. Once installed, it is there to stay.

Which industries typically need abutment protection services?

A bridge going over water
Mine

What type of bridges can be protected by HYDROTEX?

Bridges that cross over any body of water—including river bridges, railroad bridges, and highway bridges—can be protected by HYDROTEX fabric-formed concrete.

Because HYDROTEX is custom-manufactured according to the bridge’s specifications, it can provide a level of protection that surpasses that of mass-manufactured scour protection solutions.

Have more questions? Unsure whether this is the right solution for you? Call 1-800-225-0023 for a free consultation with our engineers. We would be happy to help.

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.


Looking for a different solution?

Bridge Pier Scour Protection Solutions

Bridge Pier Scour Protection & Remediation Products

Synthetex provides leading bridge pier scour protection solutions by manufacturing a custom fabric-form that is placed at the base of the pier and pumped with concrete, permanently remediating and preventing scour.

Get a project estimate today:



Bridge Pier Scour Protection & Remediation Products

Synthetex provides leading bridge pier scour protection solutions by manufacturing a custom fabric-form that is placed at the base of the pier and pumped with concrete, permanently remediating and preventing scour.

Bridge pier scour protection is simple with HYDROTEX fabric-formed concrete mattresses.

Don’t run the risk of leaving bridge piers to the mercy of local scour and wave run-up. Instead, protect them with a HYDROTEX fabric-formed concrete mattress. The most effective countermeasure against bridge scour, HYDROTEX is easy to access, cost-effective, and designed for underwater installation. Call our team today at 1-800-225-0023 for a project estimate.

How is HYDROTEX used in bridge pier protection projects?

The Problem

Local scour at bridge piles (piers) can leave the foundation exposed, causing irreparable structural damage to the bridge. Such damage may necessitate tearing down the whole bridge and re-building it, costing millions of dollars to departments of transportation and municipal authorities.

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

Prevent and remediate scour by casting a permanent mattress or grout bag with HYDROTEX fabric forms for the in-situ casting of concrete. These mattresses and bags will conform to the scour depth and stabilize the bridge pile.

Unlike pre-cast products, HYDROTEX can be installed underwater with more ease and is suited for installation sites with low head clearance conditions. Additionally, the HYDROTEX mattress is customized to accommodate the shape and size of the bridge pile, ensuring optimal scour prevention performance.

Best HYDROTEX Products for Scour Prevention and Remediation at Bridge Piers

Articulating Block Concrete Mat on Slope

HYDROTEX® Articulating Block


Use HYDROTEX Articulating Block fabric-forms to cast a cable-reinforced articulating concrete mattress. One of the most suited HYDROTEX products for bridge pier scour prevention, the articulating block mat conforms to the subgrade around and under the bridge pile as it is being pumped with fine aggregate concrete.


HYDROTEX® Grout Bags


Remediating and preventing scour with a HYDROTEX Grout Bag is a simple application. Place the grout bag fabric form around the pile, then pump with fine aggregate. Synthetex takes pride in simplifying your process.


Have a pressing question? Want a consultation or project estimate?

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Scour Prevention, Your Way

Providing scour protection and remediation at bridges is one of the primary applications of HYDROTEX fabric-formed concrete.

Entirely custom-made to your requirements, a HYDROTEX geosynthetic panel can be easily unrolled at the base of a bridge’s piles, then pumped with fine aggregate concrete with a small pump. Heavy equipment or complicated machinery is not necessary.

Looking for something different? HYDROTEX can offer other scour protection solutions at bridges and piers. These include abutment protection and other custom services.

Which industries typically need bridge pier scour protection services?

A bridge going over water
Mine
Ship at port

Prevent Local Scour at Ports with HYDROTEX

Bridge piers at ports shouldn’t be left to the will of the sea’s hydraulic forces.

Protect them with a HYDROTEX fabric-formed concrete articulating block mattress or an especially-designed grout bag.

Rather than relying on grouted riprap, prefabricated concrete blocks, and gabions, depend on HYDROTEX to effectively fill scour holes and prevent further damage. Regardless of the scour depth, our team can find a solution for you.

Need help? Give us a quick call at 1-800-225-0023 to chat with our engineers.

Who is Synthetex?

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

With our highly skilled team of engineers, Synthetex creates an easier process for you.

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 are more than a one-time supplier—we are your strategic partner for your current project and beyond.


Looking for a different solution?

Ports & Harbors Scour Protection

Scour Protection for Ports and Harbors

HYDROTEX fabric-formed concrete is the most effective countermeasure against prop and thruster scour, pier scour, and embankment erosion at ports and harbors.

Permanent erosion control and scour protection at ports doesn’t have to be complicated.

HYDROTEX has been used in more than a hundred ports around the world. It’s the leading product for scour protection and erosion control both on land and underwater. One hundred percent customizable, HYDROTEX fabric forms will create a concrete armoring system that will last for decades.

Don’t use a temporary product that won’t provide the protection your port needs. Chat with one of our engineers to get a quote for your project.

Why is HYDROTEX the top choice for your port and harbor erosion control project?

HYDROTEX is cheaper to transport and easy to install, making it the better choice for hard-to-reach areas at ports and harbors regardless of whether they’re underwater or on land.

It is also entirely customizable, which means that if you need a unique solution or need to protect a specific area, you can rest easy. The HYDROTEX fabric-formed concrete panels will be manufactured to your project’s unique specifications.

Whereas rip-rap and prefabricated concrete blocks are purchased in bulk and then designed around the specifications of your facility, HYDROTEX is a specialized product that is entirely custom-made from the start.

The geosynthetic fabric will be woven and cut to contour specific piers, embankments, and underwater pipelines, then delivered to your project site ready-to-fill. During installation, you won’t be left alone. Our engineers will help you find an experienced contractor and will be available for on-site technical assistance at your port.

HYDROTEX can be installed at the following port facilities:

  • Container and general cargo terminals
  • Dry bulk terminals
  • Liquid bulk terminals
  • Intermodal facilities
  • Passenger, cruise and ferry terminals
  • Shipbuilding and repair facilities
  • Coastal structures

Why choose us?

The demands of today’s ports, harbors and waterways are changing. To adjust, improvements and expansion of port infrastructure need to occur, which requires informed strategies and thoughtful planning to achieve success.

In a time of increasingly stringent land, regulatory and environmental requirements, Synthetex provides clear solutions to help our clients meet their scour and erosion prevention requirements.

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

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.

Enviromat®

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.

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HYDROTEX® Uniform Section

Uniform Section (US) Concrete Linings

Uniform Section (US) Concrete Linings


Uniform Section (US) Concrete Linings are similar to traditional concrete slope paving.  They create a solid, high-quality concrete lining with a relatively low hydraulic resistance and uniform cross-section.  Uniform Section linings are used to reduce the infiltration or exfiltration of aggressive waste and chemical fluids into or out of open channels and basins.  They are also used to reduce exfiltration in arid regions where open channels and basins require watertight linings.

Uniform Section Concrete Linings are resistant to leachate and most chemicals.  They protect geosynthetic liners from mechanical damage, exposure to UV light, and freeze-thaw cycles.  These self-supporting, high-strength linings permit construction on steep side slopes and replace the conventional use of clay or sand as liner protection. Placement of the forms and concrete filling can be performed without the use of equipment on the liner.  The tensile strength and abrasion resistance of the fabric protect the liner from the pumped concrete.

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