A Cost-Effective Solution for Culvert Rehabilitation

Sliplining project prevents shutdown of busy Interstate 465

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The Indiana Department of Transportation needed to rehab a large, corrugated metal culvert under Interstate 465 near Indianapolis and sought a cost-effective, environmentally friendly solution.

“I-465 is a heavily used interstate bypass around Indianapolis, carrying up to 150,000 vehicles per day," says InfraSteel's Cullom Walker. "INDOT ruled out a complete culvert replacement because the effect of a road closure on the traveling public was deemed too high."

The DOT investigated other rehabilitation solutions such as round high-density polyethylene, spray-on poly, spray-on concrete and a spiral-wound coil reinforced with steel mats, Walker says. The manufacturer of the culvert was contacted but the existing culvert shape installed under I-465 was discontinued in the 1970s and was no longer available.

Additionally, adjacent property owners to the I-465 culvert objected to providing space for a lay-down yard, he says. After evaluating all known options, engineers determined that the InfraSteel permanent sliplining culvert rehabilitation system met all structural and environment requirements of the project.

“We wanted something proven, and with steel, you know what you’re getting," says Douglas Dagley, INDOT engineer and project manager. "We wanted a product that could be easily inspected and monitored over time, plus, InfraSteel required no lay-down yard.”

InfraSteel employs an intricate method of measuring and gathering information about the host pipe, providing this information to plant engineers so they can convert the information into a matching liner.

A 15-foot-4-inch by 9-foot-3-inch by 0.875 thick Arch Pipe Liner that could be sliplined into the host structure was determined to be the best solution for the I-465 culvert project. Temple & Temple, the project contractors, ordered the pipe in 8- to 10-foot lengths. These sections are created with inverted bevels so all the welding can be done from inside the InfraSteel liner. The need for a lay-down yard was avoided since the InfraSteel liner was off-loaded from the trucks directly into the pit with a crane. 

Temple & Temple’s ground crew used a forklift to set the InfraSteel liner inside the host structure over the course of four days. During the next 21 days, the sections were welded into place. Within three days, approximately 180 yards of grout were pumped into the annular space through grout tubes. Since the InfraSteel joints were welded and the annular space was completely grouted, joint failure is not a possibility.

The completed I-465 project has a life expectancy of 50 to 100 years.

For more information about InfraSteel’s culvert rehabilitation solutions, contact Walker at 205/613-0072 or visit the InfraSteel website at www.InfraSteel.com.


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