The Clear Creek Second Outlet Gate Structure in Seabrook, Texas, is a key flood-control asset operated by the Harris County Flood Control District (HCFCD). After 25 years in a harsh saltwater environment, its six steel gates and lifting systems had deteriorated severely, threatening Clear Lake’s flood protection and water quality control.
Huitt-Zollars engineered a comprehensive solution involving the first-ever complete extraction of all gates from the structure. A phased removal plan using a barge-mounted crane enabled gates to be transported to a controlled fabrication shop, overcoming the limitations of field-applied coatings. The project team developed flexible bidding options that allowed HCFCD to choose between rehabilitation and full replacement. Ultimately, full replacement was selected: six new gates, new cast iron wheels, and upgraded lifting systems were fabricated using modernized USACE drawings. Shop-applied epoxy coatings and stainless steel fittings were incorporated to ensure long-term durability and reduced maintenance. The use of sacrificial anodes for cathodic protection further extended the lifespan of the gates.
This project demonstrates an effective approach to rehabilitating aging flood control infrastructure by integrating historical design knowledge with modern fabrication techniques. The solution delivered enhanced flood protection, reduced operational disruptions, and minimized environmental impact through efficient shop fabrication and barge transport.
