Entire Interior Culvert Lining with Engineered Cementitious Composites

About the report

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.

Supplemental materials can be found at https://library.vdot.virginia.gov/vtrc/supplements.

_{Disclaimer Statement:The contents of this report reflect the views of the author(s), who is responsible for the facts and the accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the Virginia Department of Transportation, the Commonwealth Transportation Board, or the Federal Highway Administration. This report does not constitute a standard, specification, or regulation. Any inclusion of manufacturer names, trade names, or trademarks is for identification purposes only and is not to be considered an endorsement.}

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