Solution & Implementation


Furmanite’s engineered solutions proved successful throughout the multi-phase initiative. As a result of the sophisticated engineering solution implemented by Furmanite, the Jefferson Lakeside Dam has been restored to even better-than-original condition. In fact, the restored dam withstood one the worst rain storms in Richmond’s recent history that included up to 14 inches of rain in six hours during a major Hurricane in 2004.

Case Study: Services Prevent Major Flooding

Furmanite’s Flood Management Solution Keeps Structured Dam Up and Running at Award-Wining Golf Course

Furmanite’s expert concrete repair, leak and valve management services prevent major flooding to golf course terrain

Jefferson Lakeside Country Club boasts an award-winning golf course in Richmond, Virginia. It is considered one of the most beautiful and challenging courses in the area due to the surrounding terrain, lake and numerous creeks. A unique feature of the course is the ability to play golf even after the most torrential rains. This is the result of a structured dam with a 17 mile drainage area built in the 1800s. The dam is critical to preventing major flooding, which could cause millions of dollars in damage.

Over the past 90 years, severe corrosion to the Jefferson Lakeside dam has caused ongoing maintenance issues, as well as significant damage threats to the golf course. To solve ongoing and future problems, the Lakeside Jefferson management team partnered with Furmanite, the world’s first and largest industrial specialty maintenance service company, to design and implement a repair solution for the damaged dam and prevent major flooding.


The Lakeside Jefferson dam is constructed of stone, keyed into existing bedrock with an earthen fill

consisting of indigenous clay compacted during each course. In the early 1900s, concrete covering an approximately four inch area was poured to enclose the structure. Due to natural decomposition and damage caused by hurricanes, flooding and tornadoes, the structure experienced and the occasional failure and numerous repair attempts.

Designing a solution for repairing the dam provided Furmanite with the ultimate challenge in concrete restoration and required all facets of the Company’s repair expertise.

Solution & Implementation


Furmanite’s extensive experience in concrete repair and technical engineering services, including leak and valve management, was the winning factor in Lakeside Jefferson’s selection of the contractor. Ultimately, cs_lakeside1.jpgFurmanite’s engineering solutions were successful in all phases of repair. Furmanite’s flexibility and trained technicians assessed and changed the job scope as needed to ensure a cost effective, timely and complete restructuring of dam.

Furmanite’s highly trained team led by Todd Murphy, Project Manager, engineered solutions for each stage of the project, including repairing both the downstream and upstream wall; filling the void in the dam; repairing the top cap and repairing numerous leaks and valves. Multiple services were incorporated to create the solution including Concrete Restoration and Specialty Coatings, Valve Repair and Motor Operated Valve Installation.

Downstream Wall Repair

The first step for Furmanite’s expert technicians was to prep the damaged old concrete as a result of continuous freezing and thawing due to water intrusion and hurricane damage. The concrete also had vegetation growing in the voids and cracks that further weakened the structure. After removing the vegetation, Furmanite’s technicians jack hammered and used water blasting to clean the surface. Furmanite proceeded to mix and patch areas with Tamms™ and Sika™ products. The next process involved strengthening the structure of large areas along the dam structure.

Upstream Wall Repair

Another challenge was creating a repair solution for damage caused by implosion to the entire middle section of the upstream wall. Furmanite technicians realized that to perform repairs they would have to remove existing debris, which included concrete, mud, rocks, tree limbs and stumps. This posed numerous problems because a rainstorm of significant force could cause a catastrophic failure of the exposed structure. Furmanite then had to excavate small areas at a time (8′ to 12′ depth by 10′ long), completely prep and tie the existing rock structure together with Tamms Red Line. After this process, the technicians formed the structure with rebar and poured an encasement with Tamms Green Line. After the proper cure time, technicians added more rebar line across the area with Sikadur 33 epoxy paste. A void was then poured with Sakcrete 5000 PSI. The process was repeated across the entire area of the structure, approximately 8′ to 12′ feet in depth by 135 feet long.

Void Fill of Dam Structure

Furmanite’s experts then drilled and installed injection piping on the downstream wall of the structure. The process was completed in a grid pattern to measure depth of void at each location to ensure a bottom-to-top fill of void areas. Furmanite also numbered the grid to track the amount of product injected at each grid point. They utilized a polymer modified Sika 212 Grout product to fill these voids and stabilize the structure of the dam.

Repair Top Cap

Furmanite then prepared, formed and poured a section across the top cap, approximately 130 feet long by 11 feet wide.

Replacement of Sluice Gate Valve installed in 1960s

The next step involved removing the existing cast iron gate, stem and valve body. Complete prep of the surface area involved water blasting and spall repair with Sikatop 123 before the new valve installation. To strengthen the valve pedestal, Furmanite technicians jack hammered the old concrete, installed rebar, formed and poured two inches of Chockfast™ Red Epoxy. After cure time, Furmanite drilled and anchored the stainless steel valve body in place, installed the SS gate, stem and motor operator. Furmanite also prepared the top cap of the dam for wiring to operate the valve from a remote position.

Water Leak Stoppage – Urethane Injection

After filling the lake, Furmanite’s leak sealing experts identified the multiple leaks, drilled holes in a V pattern at regular intervals along the length of the crack and installed Furmanite Injectors. Then using a high-pressure pump, they injected urethane into the structure creating a molding bonded throughout the length and depth of the crack to stop the water flow. As a result, the final cure of urethane is flexible enough to move with the structure.

Lake Wall and Future Pump Station

The next challenge posed to Furmanite’s technicians was to extend and reconstruct a bank retaining wall. The solution included forming and pouring Tamms Greenline polymer modified concrete. Furmanite also added a screen-box to the sluice gate valve intake tunnel built with Sakcrete 5000 PSI. They also added a concrete vault at the retaining wall to hold a butterfly valve and connected piping for the future pump station.

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On-Line Leak Sealing

Our leak-sealing technology and unrivaled
on-site service help you maximize asset uptime
by sealing leaks online, onsite and under pressure. This means you keep producing the ‘product’ while we solve your leak problems.

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Process Piping System Hot Tap

Hot Tapping

At Furmanite we carry the largest and most diverse inventory of Hot Tapping equipment
in the world. We have a proven record of developing unique and custom Hot Tap solutions for the most complicated scenarios.

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Line Stopping & Plugging

Our Line Stopping services help prevent unwanted shutdowns and keep critical piping
and pipeline systems online during tie-ins, relocations, repairs, retrofits and routine maintenance.

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On-Site Machining

Our portable machining tools deliver the benefits of a fully equipped machine workshop on-site – where our clients need it most. We consistently achieve tolerances and finishes usually only achievable in a machine shop.

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Self Leveling Machines

Furmanite’s Self Leveling Machines deliver precision on-site machining for large circular and irregular shaped surfaces. Our circular and linear machining equipment is portable and ready for global deployment.

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Composite Repair

Our range of composite repair solutions is designed to ensure the ongoing structural integrity and load-bearing capabilities of your assets, improving their longevity whilst minimizing the impact on your productivity.

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Post Weld Heat Treatment

Furmanite offers a full range of heat treatment services through a wide range of temperatures. We manufacture, own and operate the most technologically advanced heat treatment equipment available in the marketplace.

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All Services

We offer a comprehensive range of on-site
and on-line plant and pipeline maintenance services. From standard applications to highly customized solutions our goal is to help you maximize your asset up time.

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Hot Tapping

Furmanite has been manufacturing Hot Tapping equipment for over 50 years. Our Hot Tapping Machines ensure your critical piping systems maintain a continuous flow while installing new tie-ins and branch connections.

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Line Stopping & Plugging

For over 50 years Furmanite’s Line Plugging equipment has been helping clients maintain a continuous flow on critical piping systems while performing repairs, relocations, valve or pump installations and pipe modifications.

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Pipeline Repair Products

We have a wide range of Pipeline Repair
and Integrity products designed to handle emergency leak repairs in high pressure environments and improve the structural integrity and safety of your pipelines.

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Portable Machining Tools

Furmanite’s Silk portable and lightweight machine tools provide high tolerance solutions for a variety of problems. Renowned for their sound engineering, our Silk machines help you deliver precision onsite machining.

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Valve Products

The Wilson Snyder Switch Valve has provided proven reliability for over 80 years in Coker Switch Valve applications. Wilson Snyder Switch Valves have the lowest steam consumption in the industry.

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Health & Safety Products

We offer a wide range of proprietary Safety, Environmental and Maintenance products designed to eliminate injuries and improve pipeline safety. At Furmanite, your ongoing safety is our number one priority.

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Chocking Prevention

Furmanite’s SmartShim™ is a truly effective and state-of-the-art conductor analysis and chocking solution that will ensure your offshore production site remains productive, powerful and profitable.

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All Products

Furmanite has been a trusted resource for sophisticated engineering products for over
75 years. From Hot Tapping to Line Stopping, we have a wide range of products to meet your pipeline repair and maintenance needs.

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Furmanite is a world leader in the provision of on site services to clients in the mining, petro-chemical, off shore, oil & gas, powergen, marine, pulp & paper and general engineering industries globally.

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Furmanite - Innovative since 1920

Leak Sealing process developed leak-sealing-developed_thumb 01/01/1920

Furmanite Leak-Sealing process is Developed The under pressure Leak Sealing process is developed by Eugene Clay Furman at the Newport …

First DIY Leak-Sealing Kit old-furmanite-leak-sealing-equipment 01/01/1924

First DIY Leak-Sealing Kit The first do-it-yourself Leak Sealing kits were developed and marketed by Clay Furman and while they …

Long Standing Relationships Sales-Brochure-1926_thumb 01/01/1926

Long Standing Relationships US customer reference list that includes individual war ships in the US Navy, US steel companies and …

1st Patent is filed in 1927 furmanite-patents1 01/01/1927

1st Patent is filed in 1927 The Furmanite patent for the leak sealing process filed in 1927 was the first …

Furmanite moves Overseas Liverpool-Exibition_thumb 06/01/1927

Furmanite moves Overseas First overseas agents appointed to market the leak Sealing kits including in the United Kingdom and Euro…

Costs of a steam leak Sales-Brochure-1926-pg-8_thumb 06/01/1928

Price List from 1926 Table detailing costs of allowing a steam leak based on $4 per ton for “Long coal”. …

Furmanite is thinking global furmanite-the-skys-the-limit_thumb 01/01/1929

Furmanite is thinking global A brief history of the United Kingdom Company written by A W Forsyth (OBE) in September 1973 …

Technology Development leak-sealing-diagram 11/22/1934

Technology Development Furmanite Expands Engineering on Leak Sealing Technology. Photographs taken from a 1934 sales brochure together with schematics of …

Growing Furmanite purchase-letter_thumb 05/01/1960

Growing Furmanite Letter from the Chairman of Furmanite Engineering based in Birkenhead, England to his lawyer requesting information on a …

New Direction New-Technology_thumb 01/01/1966

New Direction Alan Forsyth, acting as a consultant to Furmanite Engineering (1929) advised the Board to move from selling low …

Never compromise on the high quality Company-History-July-1979_thumb 07/01/1979

Never to compromise on the high quality A brief history of the United Kingdom Furmanite organisation written by Joyce Hainsworth, the …

Best in the business were called NASA---Discovery-Team_thumb 09/01/1988

Best in the business were called Furmanite successfully seals nitrous oxide leakage on the Space Shuttle “Discovery” pre launch September …

Start of Modern Furmanite company-overview 11/22/1991

Start of Modern Furmanite The common shares of Furmanite were acquired by Kaneb Inc on 24th January 1991. Furmanite remains …

Acquisition-GSG Division Acquisition-GSG-Division_thumb 01/13/2006

Acquisition of Flow-Serve GSG Division Furmanite as part of Xanser Corporation acquired the General Services Group (GSG) of Flow-Serve corporation …

Corporate Name Change Corporate-Name-Change_thumb 01/13/2007

Corporate Name Change Xanser Corporation (NYSE:XNR) changed the company’s name to Furmanite Corporation, and the company’s shares were traded on …

Acquisition of SLM Acquisition-of-SLM_thumb 04/13/2011

Furmanite Corporation Acquires Self Leveling Machining Technology Furmanite expanded  its global on-site machining capabilities through the acquisition of Self Leveling …


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