WOKA Whitewater Park Water Cutoff Project

Project Overview

The WOKA Whitewater Park, located in the scenic Ozark Mountains, features a 1,200-foot-long and 100-foot-wide channel with eight drop features and was designed to provide an exceptional experience for whitewater enthusiasts. However, during construction, water leaks through cracks and voids in the limestone bedrock posed a significant challenge, requiring an innovative water cutoff and bulkhead stabilization solution to ensure the project’s success. Through creative geotechnical methods, Foundation Specialties Geostructural Construction (FSGC) addressed these obstacles and delivered a stable foundation for this national-caliber whitewater park near the Arkansas-Oklahoma border.

Problem

Constructing the whitewater park along a river presented unique challenges, particularly in managing water intrusion and ensuring the stability of structural elements. During the excavation of the whitewater channel, significant water flow was encountered through cracks and voids in the limestone bedrock. Despite an extensive sheet pile wall built to protect the area from high water levels, an unexpected flooding event in April 2021 submerged the construction site, further complicating efforts to maintain a dry work environment and secure foundational stability.

Solution

To address these challenges, FSGC implemented multiple geostructural solutions, including the use of Terra-Lok™ 24-120:

To combat water flowing from the river through limestone fractures into the excavation area, FSGC applied NCFI’s Terra-Lok™ 24-120 foam to create an effective water cutoff. The polyurethane was injected directly into the existing rock bulkhead, infiltrating fractures and voids within the limestone. Once injected, the foam expanded to fill these crevices, forming a robust, watertight seal that effectively stopped underground water intrusion. This precise sealing process ensured that even the smallest fractures in the limestone were addressed, preventing any pathways for water seepage, reinforcing the structural integrity of the bulkhead itself, and preventing erosion.

The Terra-Lok™ polyurethane’s rapid reaction time was critical in achieving immediate water stoppage, allowing the seal to form quickly upon contact with moisture in the limestone. As the foam expanded, it adhered to both porous and non-porous surfaces within the rock formation, creating a continuous barrier that adapted to the irregular contours of the bulkhead. This adaptability ensured that the seal was comprehensive and long-lasting, even in areas with significant geological variation.

Results

The application of polyurethane grouting played a critical role in stabilizing the rock bulkhead at WOKA Whitewater Park. By reinforcing fractures and voids in the limestone bedrock, the polyurethane injections added strength and durability to the bulkhead, enabling it to withstand increased river flow and the demands of regular use. NCFI’s Terra-Lok™ 24-120 foam provided a reliable solution for enhancing the structural integrity of the bulkhead, ensuring the site’s long-term stability and resilience. Today, WOKA Whitewater Park benefits from a robust foundation and durable infrastructure, supporting its continued role as a premier destination for whitewater activities.

Solution

A six-man JACKCRETE of Virginia crew was called in to deliver a targeted, efficient repair using polyurethane injection. The repair strategy involved a combination of single and dual component polyurethane systems provided by NCFI Geotechnical:

• Terrathane 24-003 Dual-Component Polyurethane was used to fill the subsurface voids and reestablish soil connectivity.
• Terra-Lok 24-120 Single-Component Polyurethane was used to seal leaking joints and water pathways, especially overhead areas. The crew utilized a scissor lift for high point access during overhead injections.

Technicians worked methodically, injecting polyurethane along the full approach to the tunnel, down each wall, and into every visible leak path—including weep holes and known wet spots. In some areas, injection patterns followed a crisscross technique to thoroughly encapsulate the joints and maximize seal effectiveness.

As the polyurethane was injected, water was actively displaced from beneath the structure—what the crew referred to as “chasing the water.” Laser levels were used to monitor slab elevation throughout the process to ensure no unintended lift occurred. The structure itself had not settled; the objective was to seal the tunnel and reconnect it to surrounding soil without disruption to the slab.

Results

The entire tunnel was successfully sealed within just three days—a fraction of the time required by other repair methods under consideration. Despite the scope of the work, the JACKCRETE of Virginia crew was able to reopen the tunnel nightly to accommodate the facility’s around-the-clock operations.

Even more critically, the railroad above remained fully operational throughout the project, ensuring there was no disruption to the company’s essential logistics and coal terminal activity. The completed repair delivered a watertight tunnel that eliminated wintertime hazards, restored safe access, and showcased the speed, precision, and non-invasive benefits of polyurethane injection.

This project was recognized with an SPFA Industry Excellence Award, honoring the outstanding performance, efficiency, and innovation demonstrated by JACKCRETE of Virginia in addressing complex infrastructure challenges.