Earth Dam Failure Protection with SPiRe®+

Innovative FRP Technology to Raise Dam Crests, Prevent Overtopping, and Protect Critical Infrastructure

As climate change, extreme weather events, and rising water levels continue to threaten aging infrastructure, dam owners and agencies are under increasing pressure to improve resilience and prevent catastrophic failures.

One of the most dangerous failure mechanisms for earth dams is overtopping — when water flows over the crest of the dam and rapidly erodes the embankment. QuakeWrap® has developed an innovative solution using patented SPiRe®+ Fiber Reinforced Polymer (FRP) panels that can raise the elevation of existing dams quickly, economically, and with minimal disruption.

The Challenge: Overtopping of Earth Dams

Unlike concrete dams, earthen embankments are highly vulnerable to erosion when overtopping occurs. Once water begins flowing over the crest, rapid erosion can develop, potentially leading to catastrophic breach and downstream flooding.

Traditional mitigation methods often focus on reducing erosion after overtopping begins by mixing chemicals or additives into soil. These approaches can require extensive earthwork, heavy construction equipment, and long installation periods while still leaving the dam vulnerable to overtopping itself.

QuakeWrap® proposes a fundamentally different approach:

Prevent overtopping before it starts.

The High Cost of Dam Rehabilitation

Across the United States, aging dams represent one of the largest unfunded infrastructure challenges facing public agencies and private owners today. Many earth dams were constructed decades ago using design standards that are now outdated, while increasing development downstream has caused many formerly “low hazard” dams to be reclassified as high-hazard structures requiring major upgrades.

According to a 2025 report by the Association of State Dam Safety Officials (ASDSO), the estimated cost to rehabilitate non-federal dams in the United States has now reached:

with approximately:

needed for high-hazard dams where failure could result in loss of human life.

The report notes that the United States has more than 88,600 non-federal dams, many of which are more than 50 years old. By 2025, nearly 70% of dams in the country will exceed 50 years of age.

According to a 2025 report by the Association of State Dam Safety Officials (ASDSO), the estimated cost to rehabilitate non-federal dams in the United States has now reached:

with approximately:

needed for high-hazard dams where failure could result in loss of human life.

The report notes that the United States has more than 88,600 non-federal dams, many of which are more than 50 years old. By 2025, nearly 70% of dams in the country will exceed 50 years of age.

Conventional Dam Raising Is Expensive and Disruptive

Traditional approaches for increasing dam height often involve:

Massive earthmoving operations
Importing and compacting large quantities of fill
Construction traffic on the crest
Major excavation and slope reconstruction
Extensive environmental permitting
Long project schedules
High labor and equipment costs

In many cases, dam owners simply cannot afford these upgrades. ASDSO specifically notes that many owners struggle to finance rehabilitation projects and require grants or loans to reduce the risk of failures.

The report also highlights that rehabilitation costs continue to rise due to:

aging infrastructure,
stricter safety standards,
increased engineering requirements,
escalating labor costs, and
higher material prices.

The SPiRe®+ Solution

SPiRe®+ is a patented Glass Fiber Reinforced Polymer (GFRP) panel system originally developed for structural strengthening and protection of marine and civil infrastructure. The system can now be adapted to raise the effective height of existing earth dams by embedding lightweight FRP panels into a narrow trench cut along the dam crest.

The result is a durable vertical extension that:

Raises the dam elevation
Prevents overtopping
Creates a watertight barrier
Requires minimal excavation
Eliminates corrosion concerns
Installs rapidly with limited site disruption

Unlike conventional embankment raising methods, this system avoids large-scale soil transport, heavy compaction operations, and major construction traffic on the crest of the dam.

Three Products in One System

One of the unique advantages of SPiRe®+ is that it combines three construction elements into a single integrated product:

1. Stay-in-Place Formwork

The panels create the permanent form for the wall and remain in place after installation.

2. Structural Reinforcement

The integrated T-shaped profiles and grit-coated surfaces act as built-in reinforcement with flexural strength equivalent to No. 6 Grade 60 steel bars spaced at 3.5 inches apart.

This often eliminates the need for conventional reinforcing steel.

3. Waterproofing & Corrosion Protection

The FRP surface creates an impervious barrier that resists moisture, corrosion, and harsh environmental exposure.

Exceptional Structural Capacity

SPiRe®+ panels provide remarkable structural strength despite their lightweight construction.

Testing has shown that panels combined with a 3-inch concrete backing can achieve a flexural capacity of approximately:

This capacity is sufficient to:

Raise a dam crest by up to 10 feet with a safety factor of 2.4
Raise a dam crest by 4 feet with a safety factor of 38

The system uses UV-resistant vinyl ester resin and durable GFRP materials designed for long-term performance in harsh environments.

How the Installation Works

The installation process is fast and minimally invasive.

Step 1 — Cut a Narrow Trench

A trench approximately 4 inches wide and 2–4 feet deep is cut along the crest of the dam.

Step 2 — Install SPiRe®+ Panels

The 3-foot-wide panels are placed vertically into the trench and extend above the crest to the desired elevation. Overlapping panel edges are sealed to create a continuous watertight wall.

Step 3 — Fill the Trench with Concrete

Concrete is placed in the trench to anchor the panels and create a stiff foundation system.

Step 4 — Construct the Wall

Temporary forms are attached to the downstream side while concrete is placed to create the final wall thickness. GFRP bars may be added for temperature and shrinkage control.

The result is a durable raised crest that prevents overtopping while requiring minimal maintenance.

Advantages Over Conventional Dam Raising

SPiRe®+ offers major advantages over traditional earthwork-based solutions:

Rapid installation
Minimal excavation and earth moving
Lightweight materials
No steel corrosion
Minimal construction traffic on dam crest
Suitable for remote locations
Reduced environmental impact
Increased reservoir storage capacity
Long-term durability
Impervious water barrier
Reduced labor requirements

Applications Beyond Earth Dams

The same SPiRe®+ technology is already being used in a wide range of infrastructure projects including:

Seawall repair
Bulkhead rehabilitation
Bridge pier walls
Corroded steel sheet piles
Industrial slabs
Marine infrastructure
Rising sea level protection systems in Florida

This broad range of applications demonstrates the versatility and reliability of the system.

Why QuakeWrap®

Founded in 1994, QuakeWrap® is one of the world’s leading innovators in Fiber Reinforced Polymer (FRP) technologies for infrastructure repair and strengthening.

The company was founded by Professor Mo Ehsani, a pioneer in FRP strengthening systems and holder of more than 20 U.S. patents in this field.

QuakeWrap® technologies are used worldwide for repair and strengthening of:

Dams
Bridges
Marine structures
Pipelines
Piles
Industrial facilities
Waterfront infrastructure

Ready for Immediate Deployment

SPiRe®+ panels are stocked at QuakeWrap® facilities in Tucson, Arizona, and can be rapidly manufactured for projects requiring custom sizes or configurations.

Whether you are addressing overtopping risks, rising sea levels, or resilience upgrades for critical infrastructure, QuakeWrap® can help develop a practical and economical solution.