PRESS RELEASE

Restoring Liberty County’s Lifeline: US FUSION & LJA Engineering Deliver Rapid, Permanent Dam and Bridge Repair at County Road 6494

Dayton, Texas – September 2025 — When severe erosion threatened the structural integrity of the County Road 6494 dam and bridge—the only access route for an entire neighborhood—Liberty County officials knew that failure was not an option. The structure had already sustained significant damage following Hurricane Beryl in 2024, leaving it vulnerable to further collapse. Another major storm could have completely washed out the crossing, stranding dozens of families with no way in or out.

Before Repairs – Severe erosion and undercutting visible along spillway.

For years, temporary fixes and patch repairs had bought time—but not peace of mind. A permanent solution was urgently required. Working closely with LJA Engineering and the Liberty County Commissioner’s Office, US FUSION & Specialty Construction stepped forward with a long-term, cost-effective, and fast-deploying alternative.

A New Solution for an Old Problem

In early 2024, LJA Engineering engaged US FUSION to evaluate the advancing erosion and propose stabilization options. After extensive site evaluation, US FUSION recommended its proprietary PROTEX™ Cast-in-Place Erosion Control System, a flexible concrete-filled fabric mattress designed to protect waterway slopes, dams, and embankments.

Installation Phase – PROTEX™ fabric deployment and alignment.

Unlike traditional rip-rap or precast concrete block systems, PROTEX™ provides long-term durability, hydraulic performance, and installation advantages—with only 4 to 10 crew members and minimal equipment required.

However, as momentum grew, tragedy disrupted the process: the sitting County Commissioner passed away. The project was paused for more than a year.

From Setback to Breakthrough

In March 2025, with a newly appointed Commissioner and a renewed focus on infrastructure integrity, the County resumed discussions. Reassessment revealed that conditions had deteriorated significantly: large voids had formed beneath the dam and spillway. The structure was approaching failure.

Installation Phase – Concrete pumping into PROTEX™ cells.

Working collaboratively, Liberty County, LJA Engineering, and US FUSION redesigned the repair plan using the PROTEX™ AB400 System. This enhanced design would fill the voids, reinforce the upstream face, and protect the spillway from future scour.

Installation Phase – PROTEX™ mattress curing and shaping.

As urgency increased, the Texas Department of Transportation (TxDOT) joined as a funding partner. US FUSION—supported by their trusted manufacturers—prepared technical exhibits and presentations demonstrating PROTEX™ performance on similar infrastructure across the country.

Installation Phase – PROTEX™ mattress curing and shaping.

Delivering Under Pressure

On June 30, 2025, the project was formally presented before the Liberty County Commissioner’s Court. Approval was granted, and a purchase order was issued on July 2.

US FUSION immediately initiated fabrication of the custom PROTEX™ mattresses, designed to fit the exact geometry of the spillway.

Installation Phase – PROTEX™ mattress curing and shaping.

On August 27, 2025, US FUSION mobilized on-site.
Over two days, the team:

• Excavated toe-in trenches
• Placed fabric forms
• Pumped structural concrete using controlled hoses
• Ensured proper curing and anchoring
• Completed installation ahead of schedule and within budget

The resulting structure now offers the County a permanent, low-maintenance defense against erosion.

Completed Surface – Reinforced spillway armoring fully installed. Final upstream protection and spillway stabilization.

Protecting People, Infrastructure, and Peace of Mind

The project restored more than a dam and roadway—it restored community access, safety, and confidence. Thanks to efficient collaboration among Liberty County Precinct 4, LJA Engineering, and US FUSION, the CR 6494 bridge now stands fortified against future storms.

“This was a project that demanded teamwork, innovation, and absolute precision,” said Nick Turner, Construction Manager at US FUSION. “Every decision was made with the safety of the community in mind.”

Project Highlights

Technology: PROTEX™ Cast-in-Place Erosion Control System
Location: CR 6494 Dam & Bridge, Dayton, Texas
Completed: August 2025
Partners: Liberty County Commissioner’s Office | LJA Engineering | TxDOT | US FUSION & Specialty Construction

Key Advantages

• Permanent, low-maintenance erosion protection
• Installs in wet or dry conditions
• Requires a small crew (4–10 people)
• Pumps concrete up to 300 feet away
• Custom fabricated for site-specific geometry
• Fast deployment and cost-efficient lifecycle

About US FUSION & Specialty Construction

Trusted Supplier for All Your Specialty Construction Needs

Since 1989, US FUSION & Specialty Construction has been a trusted industry supplier and installer of advanced specialty construction solutions. The company provides a full range of services, including HDPE, PVDF, polypropylene and other welded plastic piping systems, on-site fusion services, geosynthetics, secondary containment solutions, asset protection and erosion control systems, PROTEX™ liners and mats, and custom HDPE fabrication. With decades of proven expertise and a commitment to precision, innovation, and safety, US FUSION delivers high-performance infrastructure solutions to clients across the United States.
www.usfusion.com

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