Concrete Cloth™ Metal Arch Culvert Invert Lining – New Era, MI

WATER/WASTEWATER  STRUCTURAL STRENGTHENING

PROJECT OVERVIEW

On highway M-20, east of New Era, MI, a 70-foot metal plate arch culvert was experiencing moderate to severe section loss in the invert from corrosion and abrasion. The steep decline in condition due to corrosion was attributed to the intermittently flowing creek and the invert’s frequent exposure to oxygen; this was observed in early 2017 by Michigan Department of Transportation (MDOT) personnel. The active creek flow could not be entirely stopped during the placement of the Geosynthetic Cementitious Composite Mat (GCCM) as by-pass over the road was deemed impractical.

SOLUTION

The MDOT had plans to replace the 12’x8’ culvert in 10 to 15 years and desired a repair option that would extend the life of the culvert invert for at least 10 additional years. MDOT’s Grand Region Bridge Engineer, Jonathan Bruinsma, was introduced to Concrete Cloth at the annual Michigan Bridge Conference and learned that the fabric would last the required length of time until replacement as well as provide a protective barrier against further invert deterioration. He contacted Milliken Infrastructure Solutions, LLC and was assured that the state of the invert’s deterioration made Concrete Cloth GCCM an excellent candidate
for the repair.

Installation training and on-site assistance was provided to the Oceana County Road Commission to educate the contracted crew on how to correctly repair the invert using 1,470 square feet of CC8 fabric. The workers secured strips of the CC8 fabric transversely, shingling the seams in the direction of the creek’s flow to prevent water ingress under the fabric. The CC8 panels were then mechanically secured to the invert with a Ramset tool and fasteners due to the culvert wall thickness, and the edges were sealed with a bitumen based sealant to complete the fabric installation. The relative ease of installation enabled the DOT to use local Oceana County crews which saved the MDOT critical maintenance funds.

RESULTS

The complete installation took approximately four (4) hours. The ability of Concrete Cloth GCCM to cure underwater was a key advantage as creek flow continued slightly abated during placement  and ultimately hydrated and hardened the product. The Concrete Cloth GCCM invert protection is expected to extend the lifespan of the culvert 10-15 addition years. The low-cost and quick repair provided the DOT value by extending the life of the culvert and considerably delaying the need for a more expensive replacement. The success and viability of this repair will lead the Michigan DOT to consider the use of Concrete Cloth GCCM on future rehabilitation/repair projects.

PROJECT DETAILS
Application: Metal Arch Culvert Invert Lining
Client: Michigan Department of Transportation (MDOT)
Location: New Era, MI
Installation: September 2017
Contractor: Oceana County Road Commission

Securing CC8 fabric to the culvert invert.
Securing CC8 panels with a Ramset tool and fasteners to invert.
80% of the transverse panels installed and secured.
Completed CC8 invert rehab, with sealed edges.
Existing culvert invert with moderate to severe section loss.
Layout of transverse strips of CC8 fabric at the culvert outlet, shingling in the direction of flow.