The George Wallace Tunnel, located in Mobile, Alabama, is a twin tube tunnel that allows east and west travelers on Interstate 10 to pass under the Mobile River. In the winter of 2001, temperatures in Mobile remained below freezing for most of the month of December.

Mobile, located on the Gulf of Mexico, rarely drops below the freezing mark. The abnormal temperature change caused the tunnel to contract more than normal. This caused the gaps within the construction joints, which are located at both ends of the twin tubes, to open farther than ever before. Water from the river above began to leak in at the west end joint, and although the structural integrity of the tunnels was never in question, concern over public reaction and potential ice on the interstate required that this project be worked under emergency status.

The repair plan required Barton Southern crews to utilize special purpose lifts and coordinate with D.O.T. and tunnel engineers to facilitate lane closures. Work was done at night and through the early morning hours to help alleviate traffic problems. The impeding Mobile Mardi Gras celebration that annually brings thousands of people thru the tunnels added urgency to the project.

Barton Southern crews sealed the leaking joints by injecting a combination of hydrophobic and hydrophilic polyurethane grouts into the voids within the joint. The hydrophobic grout was used first to slow down the flow of gushing leaks. Hydrophilic grout was then pumped to effectively seal and fill remaining void space in the joint. This project was successfully completed in less than three weeks and on budget.