Entire Interior Culvert Lining With Engineered Cementitious Composites

Details

• Creators:
  Arce, Gabriel A. ; Sharifi, Mary ; Ozyildirim, Celik ; Kassner, Bernard L.
• Corporate Creators:
  Virginia Transportation Research Council (VTRC)
• Corporate Contributors:
  Virginia. Department of Transportation
• Subject/TRT Terms:
  Cement Chemical Sprays Composite Materials Corrosion Corrugate Metal Pipe (CMP) Cost Effectiveness Culverts Engineered Cementitious Composite (ECC) Engineered Materials Spray Applied Pipe Lining (SAPL
• Publication/ Report Number:
  VTRC 26-R44
• Resource Type:
  Tech Report
• Geographical Coverage:
  United States ; Virginia
• Edition:
  Final Report: 8/1/2022–1/31/2026
• Corporate Publisher:
  Virginia Transportation Research Council (VTRC)
• Abstract:
  Corrugated metal pipes make up a significant portion of Virginia’s culvert inventory and are prone to deterioration from corrosion and abrasion, particularly at the invert. In early stages, invert rehabilitation techniques such as invert paving are sufficient. However, at advanced stages of distress, full interior repair becomes necessary. In such cases, spray-applied pipe lining offers a cost-effective alternative. For spray-applied pipe lining, achieving adequate fresh-state workability of the cementitious lining material is critical to ensure pumpability and sprayability while allowing the material to build the required thickness without slumping. Previous research developed engineered cementitious composites (ECCs) for invert repair, but these mixtures required a biaxial geogrid for stability and were not optimized for full interior lining. This study builds on prior work by evaluating ECCs as a trenchless rehabilitation solution for the entire interior culvert lining. Sprayable ECC mixtures were developed and tested in the laboratory using readily available materials, moderate fiber contents, and simplified compositions—including coal ash-based and slag cement-based systems—to enhance field practicality. In addition, a parametric study assessed existing liner thickness design methodologies, and field inspections were conducted to evaluate the performance of conventional cementitious liners and ECC-repaired culvert inverts. Laboratory results showed that ECCs incorporating air entrainment to leverage the Temporary High Initial Air Content concept achieved consistency suitable for pumpability, sprayability, and thickness buildup, while maintaining strength, deflection-hardening, and durability. The parametric study highlighted the need for more consistent design guidance and indicated that a 1-to 2-inch ECC liner thickness is sufficient to restore the structural capacity of most corrugated metal pipes. Field inspections revealed excellent performance of ECC-repaired inverts, with no cracking or debonding after up to 6.5 years in service, whereas conventional cementitious liners exhibited significant cracking within 3 to 4 years. Overall, these findings demonstrate that properly designed ECCs can provide superior crack control and durability, offering the Virginia Department of Transportation a robust and practical solution for trenchless corrugated metal pipe rehabilitation.
• Format:
  PDF
• Funding:
  122144
• Collection(s):
  US Transportation Collection
• Main Document Checksum:
  urn:sha-512:e653b59148937396fba53424ec4aa77c18a013399250a2e17bb7fc5b3a5f2344a171d31123d7b910d55c0b53f971311eb58ba618472b1c46085a22abe48cb4b3
• Download URL:
  https://rosap.ntl.bts.gov/view/dot/91931/dot_91931_DS1.pdf
• File Type:
  [PDF - 4.04 MB ]