ABSTRACT
Corrosion damage in culverts result in loss of the load carrying capacity of these structures. While in concrete box culverts the damage is normally in the top slab directly below the roadway, the corrosion in Corrugated Metal Pipe (CMP) culverts is typically in the invert. This paper describes different solutions for each of these conditions. Both repair methods utilize Fiber Reinforced Polymer (FRP) products. For concrete box culverts, strips of resin-saturated carbon fabric can be applied to the soffit of the culvert from inside. This will increase the flexural strength of the culvert significantly. The work can be performed from inside while the culvert remains open to traffic. Results from a major repair along interstate I-10 in Phoenix, Arizona is reported. The replacement cost of the two box culverts was $25M and it would have required significant road closure and traffic control. The repairs were completed in 3 months at a cost of $1.4M, resulting in significant savings for the owner. The author has developed an FRP pipe using the sandwich construction method with very high strength to weight ratio. The product, named StifPipe®, received the 2016 ASCE Innovation Award as the world’s first green and sustainable pipe. The pipe can be made near the job site in the desired shape and size and inserted into the host culvert using the slip-lining method. The annular space between the culvert and the new pipe is filled with grout. A project completed in Australia is presented. Repair of such culverts with conventional pipes that are heavy require jacking equipment that adds to the cost. The new lightweight pipe segments were pushed by hand into the deteriorated culvert. The elimination of jacking equipment for such a remote site resulted in significant cost savings.
