Evaluation of Construction Methods for Ultra-High Performance Concrete Invert Linings in Corrugated Metal Pipe Culverts

Corrugated metal pipe (CMP) culverts are key pieces of infrastructure in drainage and waterway management, but many are reaching their end of life and require rehabilitation. While existing repair methods have a long track record of success, they can be cost prohibitive and may significantly affect the hydraulic properties of culverts. Ultra-high performance concrete is internally reinforced, stronger, and more durable than conventional concrete, offering a modern solution to culvert deterioration. The seven mockups described include trials with top-formed UHPC, thixotropic UHPC, and a UHPC shotcrete placement. Shotcrete UHPC was not found to be viable at this time due to challenges with maintaining mix consistency and adhesion to the substrate. Top forming and thixotropic UHPC were found to be the best options for building a consistent invert lining for culvert rehabilitation but posed unique challenges in design, construction, and material consistency. This paper describes the methods of construction, challenges during construction, and the results of each test. It is the author’s intent to give owners a new tool for culvert rehabilitation, provide designers with each of the variables in implementation, and help contractors mitigate risks by discussing the challenges encountered for UHPC invert linings.