This project involved stabilizing a critical dam at the outflow of Lake Lulu in Winter Haven, FL. 

Although small in size, the structure plays a big role for the Southern Chain of Lakes, including: 

• Flood control for surrounding communities
• Water level management for recreational use
• Local water supply support 

During the latest inspection, engineers identified serious structural and geotechnical issues that required immediate stabilization to avoid further deterioration. 

Inspection Findings: 

• Emergency Spillway: Cracks in end walls, holes on the upstream side, and a major void under the downstream apron caused by soil erosion. Without repair, water could flow beneath rather than over the spillway, leading to structural failure.
• Main Spillway: Multiple long cracks extending from crest to waterline, prior failed patchwork, vegetation growth in cracks, exposed aggregate, and joint separation. 

The dam is currently classified as a Significant Hazard Potential structure, meaning that failure would not be expected to cause loss of life but could cause serious property damage, environmental harm, and community disruption.

Constructed in the 1940s, the dam has undergone various repairs over the decades. However, age-related deterioration and recurring seepage have reduced its structural integrity.

While long-term replacement is inevitable, immediate action was needed to stabilize the structure through hurricane season and allow time for engineering and funding of a full replacement.

Helicon developed a dual-phase stabilization program to address both short-term safety and long-term planning needs. These involve polyurethane injections from two different products: 

1. Spillway Grouting (Sealing Cracks & Voids)

• Product: GT500 (one-part hydrophilic chemical grout) 
• Method: Injected into cracks, holes, and voids within the spillways 
• Purpose: Seals leaks, restores concrete integrity, and prevents soil migration 

2. Soil Stabilization & Erosion Protection 

• Product: AP720 (hydrophobic grout) 
• Method: Injected beneath concrete structures where erosion had carved out hidden voids 
• Purpose: Fills subsurface cavities, restores the foundation, and blocks future water intrusion pathways 

The Results 

The program provided: 

• Immediate stabilization of both the emergency and main spillways 
• Void filling and erosion protection, restoring subsurface support 
• Extended service life of the dam until full replacement can be designed and funded 
• Community reassurance, ensuring the structure can safely function through upcoming storm events 

Why Municipalities Choose Helicon for Dam & Spillway Repairs 

Helicon is trusted across Florida for critical infrastructure stabilization, offering: 

• Engineered grouting solutions tailored to aging dams and levees 
• Fast, minimally invasive repairs that extend service life and reduce risk 
• Expertise in hurricane readiness, protecting communities from flood hazards 

Learn more about Helicon’s dam and spillway stabilization services by calling us at 844-Helicon.