Stormwater Culvert and Manhole Repairs Using High Density Polyurethane 1 OUTSIDE INSIDE URETEK for External Rehabilitation CentriPipe for Internal Renewal Sewer Rehabilitation “Outside and Inside” Assess · Rehabilitate · Renew GROUNDWORKSSOLUTIONS.COM 2 Polyurethane Grout Structural Polymer for Soil Stabilization GROUNDWORKSSOLUTIONS.COM 3 Polyurethane Grout URETEK Chemistry: Characteristics Rapid Cure Can support loads after 15 minutes; full strength after 24 hours Strength Rigid Structural Polyurethane created as material cools E Modulus, Compressive Strength, Tensile Strength directly proportional to Density Spread is limited due to speed of reaction Weight Lightweight: 4 to 25 pcf (installed density) Water Resistance Hydro-Insensitive Contains water insoluble diluents - can be injected into wet soils and even standing or flowing water Resists water intrusion into the chemical reaction that forms polyurethane GROUNDWORKSSOLUTIONS.COM 4 Polyurethane Grout URETEK Chemistry: Composition Composition Resin & Hardener Mixing Ratio 1:1 Chemical Reaction Exothermic chemical reaction generates C0₂ gas C0₂ gas causes expansion of material, creating lifting pressure/ strength Reaction Time Fast Adjustable – varying injection methods Can be completed in 1 minute Environmental Impact Environmentally benign material: NSF-61 certified and only patented hydro- insensitive polyurethane foam GROUNDWORKSSOLUTIONS.COM 5 East Main Culvert Durham, NC Project Challenges Solution Support Outcome • Aging culvert, originally • Inject URETEK 486Star • Designed injection plans • Work was completed in a few weeks. constructed in 1930s. Polymer to densify the for culvert stabilization. • Culvert was stabilized and restored to surrounding soils and allow for • Oversaw tree removal. • Large tree growing into the functionality. structural repairs to the box • Set up cofferdam and side of the structure. culvert. bypass pumping. • The city of Durham was able to avoid • Actively flowing creek. • Coordinated with multi-million replacement of culvert. • Cofferdam and bypass restoration company on • Soil loss around the structure. pumping. rebar and epoxy. • Structural repairs to culvert, • Performed shotcrete. including rebar and epoxy, • Placed rip rap. crack injection, and shotcrete, GROUNDWORKSSOLUTIONS.COM 6 Cutler Spur Culvert Stabilization Crystal River, FL Project Challenges Solution Support Outcome • Concern of weak soil zones • Inject URETEK polyurethane • Specifications • Minimal downtime: All work underneath a culvert and new from surface to stabilize soils performed in one day • Designed injection points two lane road to create a solid support for the quantity and depth • Stabilized soil: Final roadway culvert • Area is in an environmentally work was able to continue on • Pre-construction meeting with sensitive area known for • Injection points at various schedule contractor, city and L3 natural springs and manatee locations and depths Communications migration • On-site installation GROUNDWORKSSOLUTIONS.COM 7 72” RCP Dam Outfall Pipe Repair Gainesville, GA Project Challenges Solution Support Outcome • 72” RCP dam outfall pipe had • Stabilize and densify • Uretek designed the • Quick Installation: Project took 6 water flowing along the outside of surrounding soils, creating a injection process using hours compared to 4 days to remove the pipe and entering the weak non-permeable layer to stop a hydrophobic 2 part and relay the RCP (would not have pipe joints water movement by use of Star 486 HDP material needed to replace). • Customer did not want to remove / Deep Injection of high density • We were able to fix the • Cost Effective: Project was more replace the RCP because was in polyurethane joints from inside the cost effective than remove/relay and good condition • Inject the Uretek 486 material pipe and did not need to bringing in additional fill material. • Customer tried cementious grout to seal the leaking joints close the road Also, slip lining was not a viable to seal joints and failed (see • Injections made at 5 & 7 option since the water was coming cementious grout attempt in pipe o’clock positions of the pipe from the outside of the pipe. haunch of picture on right) GROUNDWORKSSOLUTIONS.COM 8 NAS – Inflow & Infiltration Restoration Pensacola, FL Project Challenges Solution Support Outcome • Inflow & Infiltration into storm drain • Inject URETEK polymer using • Pre-estimate meeting with • Infrastructure Restoration: system The URETEK Method to NAVFAC URETEK polymer compacted and encapsulate and seal faulted void filled loose surrounding soils • Pavement and manhole structure • Designed injection locations, joints from inflow and infiltration to rehabilitate storm drain system settlement due to loss of bearing quantities and depths soils • The Deep Injection Process at 4 • In-situ Technology: Restored • Pre-construction and safety distinct elevations to fill voids and and increased soil load-bearing • Surface depressions due to soil meeting onsite with crew densify weak base soils to capacity at depth in two days with migrating into storm drain system prevent additional pavement and • On-site installation minimal disruption • Manhole, joint, and lateral line structure settlement encapsulation and sealing GROUNDWORKSSOLUTIONS.COM 9 USAF – Andrews Air Force Base Joint Base Andrews, MD Project Challenges Solution Support Outcome • Runway settlement caused a • Seal pipe and densify • Specifications • Sustainable Solution: work dip 11 years before scheduled compacted soils sustained until scheduled • Designed injection port quantity replacement replacement took place. • Lift runway back to original and depth • Settlement was caused by elevation • Minimally Invasive: work • Pre-construction meeting faulted joints in 60” reinforced performed allowed USAF to avoid concrete pipe beneath runway • On-site installation under strict ripping up the runway for repair security and avoid delays in its operations • USAF wanted to avoid rip & replace due to downtime GROUNDWORKSSOLUTIONS.COM 48” RCP Pipe Rehab Video 11 Hwy 61 – Emergency Sinkhole Repair Natchez, MS SHIFTED RCP BINDING AGGREGATE CRACKED RCP Project Challenges Solution Support Outcome • Sinkhole formed on HWY61 in • Mechanically align the pipe utilizing • Specifications • Sealed and rehabilitated Natchez, MS a trackhoe stormwater drainage system • Utility locates • 24” RCP misaligned due to a leaky joint • Stabilize and seal the pipe utilizing • Stabilized support soils: • Pre-construction meeting that degraded the support soils and URETEK’s Deep Injection method bound #57 aggregate to form a caused voids beneath the pipe • MDOT construction solid monolithic mass below • Fill excavated area with #57 stone support highway • The RCP shifted and caused a sinkhole aggregate and stabilize the that shut down a portion of the highway aggregate at every 4-5ft of fill • Emergency Response • Quick Installation: Project was route to a nearby hospital completed over 2 Days GROUNDWORKSSOLUTIONS.COM 12 AL DOT 4th Division SR22 Alexander City, AL Before Before Water flow is underneath culvert Water flow is underneath culvert After After Upstream Downstream Water flow is through Water flow is culvert through culvert Project Challenges Solution Support Outcome • Extensive voids and • Inject hydro-insensitive URETEK • Designed injection points • Minimal downtime: All work extremely weak soil zones polyurethane through floor quantity and depth performed in 6 hours underneath a culvert and two surface of culvert surface to • Pre-construction meeting with • Stabilized soil: Final roadway lane road cutoff flow of water, fill voids, DOT and local authorities to work was able to continue on and stabilize soils to create a • Water flowing completely minimize disruption schedule solid support for the culvert under rather than through • On-site installation with no • No Road Closure: Traditional culvert • Lift culvert and pavement full bypass required repair methods would created 50 2.5” to original elevation • Culvert & road settled 2.5” mile detour to closest river crossing GROUNDWORKSSOLUTIONS.COM 13 Jackson Lakes Box Culvert Lift Pensacola, FL Project Challenges Solution Support Outcome • Significant undermining and • Inject using The Deep Injection • Designed injection points quantity • 24” Lift of quadruple soil displacement from under Process to lift and realign the and depth barrel box culvert culvert caused by a flood event southwest corner of culverts. • Pre-construction meeting with • 25% the cost of rip and April 2014 of rain over 20” in 2 • Inject on 4’ grid using a string Escambia County Engineering replace days. line to void-fill, stabilize and Department. • Typical flow of Jackson • Voids and lose of supporting ensure a uniform lift. • Holland Pump assisted with Creek and overflow of soils caused approx. 2’ of • Onsite testing identified an dewatering. rainwater restored. settlement at the southwest average of a 2’ void across all corner of culvert. • H2O Environmental completed four barrels. masonry repairs. GROUNDWORKSSOLUTIONS.COM 14 Sealing and Stabilizing Rehabilitate the OUTSIDE Before After Without proper void fill, the structure and road are not supported to the originally designed weight-bearing capacity GROUNDWORKSSOLUTIONS.COM 15 City of Dunlap – I&I Mitigation Dunlap, TN Project Challenges Solution Support Outcome • Excessive groundwater • Seal leaking pipe collars and • Public Works Director • Fast Repair: Work inflow identified at two pump cracks. attended URETEK technical performed in