Rehabilitation of a reinforced-concrete culvert on the A-310 Chelyabinsk – Troitsk road

The structure is based on a reinforced concrete three-barrel circular culvert with a diameter of 1.5 m. The length of each culvert opening is 34.16 m, and the total structure length is 102.48 m (Fig. 2). Repair using the «PipeArm» technology was carried out to eliminate defects and prevent structural deterioration, including defects in joints between sections and the concrete protective layer, exposed reinforcement, longitudinal and transverse cracks, settlement, and separation of the sections.

Rehabilitation of water culverts using the «ПайпАрм» technology on the A-310 Chelyabinsk–Troitsk–border with the Republic of Kazakhstan road section to restore the structural load-bearing capacity by concreting over permanent polymer formwork was carried out using three interconnected technical solutions:

• Installation of a reinforcement cage inside the pipe. The cage is manufactured on site and secured to the walls of the pipe being rehabilitated.
• Installation inside the pipe of a protective polymer liner made of Анкерного листа. The polymer liner is made of high-density polyethylene (ТУ 22.29.29-019-56910145-2019), with a smooth surface and low hydraulic resistance coefficient on one side, and special anchor elements on the other side for securing it in the monolithic concrete layer.
• Monolithic integration of the structure: filling the gap between the existing pipe body and the polymer liner with high-strength concrete mix.

This unifies the structure into a single system with high load-bearing capacity, low hydraulic resistance and resistance to adverse environmental effects, while preserving the maximum useful cross-section of the water culvert. The minor reduction in the culvert's flow cross-section is offset by the low hydraulic resistance of the polymer liner, enabling the structure to retain high flow capacity.