A structural failure at Demopolis Lock & Dam in Alabama stopped barge traffic on the Tennessee-Tombigbee Waterway. The U.S. Army Corps of Engineers (USACE), R&D Maintenance, and J.F. Brennan Company (Brennan) quickly united to respond. Colonel Jeremy Chapman described the breach as “a hole the size of a school bus.” The failure halted commercial navigation across two major waterways. It also threatened millions of dollars in monthly economic losses.
Mobilizing Fast: A United Emergency Response
The emergency repair required underwater demolition, complex concrete work, custom formwork, and heavy marine construction. Brennan and its partners completed the work under intense pressure while maintaining strict safety standards.
“We’re essentially building a brand-new dam surface, and we’re doing it at record pace.“
— Colonel Jeremy Chapman, U.S. Army Corps of Engineers
Diving into the Challenge: Working Below the Surface
Divers worked in near-zero visibility throughout the repair. They removed more than 600 tons of damaged concrete before installing a new underwater sill system.
“Measurements were critical. With divers unable to see, we developed templates that allowed for precision and verification at every step.”
— Pat Rude, Brennan Superintendent
The repair also required two specialized concrete mixes. One self-consolidating mix supported underwater placement. A traditional mix reinforced the surface.
Engineering the Fix: Concrete, Formwork, and Collaboration
“This isn’t a fix you get to be part of often. It’s rare to help solve a problem this vital to the country’s infrastructure. Everyone—from our dive teams to our engineers—stepped up.”
— Robert Wheeler, Brennan
Brennan, USACE, and R&D Maintenance worked together to keep the project safe and on schedule.
“There were no egos out here. Everyone worked toward one goal: getting this lock back online.”
— Pat Rude
What Success Looks Like: Infrastructure Back Online
This emergency repair demonstrates the value of teamwork, technical expertise, and innovative problem-solving. Brennan and its partners restored critical infrastructure under extraordinary conditions. Together, they helped reopen the nation’s waterways and support commercial navigation.
We thank every Brennan team member for supporting the Demopolis Lock & Dam emergency repair. Special thanks to the U.S. Army Corps of Engineers, Mobile District, and R&D Maintenance for making this project possible.
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