Culvert Lining | Hendy, Wales, UK

250m² of CC8^® installed to extend the working life of a culvert

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Project Overview

In January 2021, work began to repair a large culvert that runs under the M4 near junction 48, West of Swansea in Wales.

The original culvert had been installed in the mid part of the 20th century and was in need of upgrade. The invert had corroded, which would eventually lead to undermining of the structure.

Corroded culvert floor, corrugations filled with grout, batten secured to perimeter edge profile

250m²

of CC8^® used to line the culvert

200mm

spacing between mechanical fixings

5 Days

to complete the installation

Solution

Custom mould GRP culvert lining was considered for the works. However, the restricted site access would have posed significant logistical and practical issues. As a result, a remedial lining solution was required to instead repair the existing culvert.

CC was chosen as it would provide a robust lining for the culvert floor and extend the structures operational life

CC batched to required lengths off site

Design & Installation

CC8^® Bulk Rolls specified
Prior to installation, silt build up was removed
Corrugations filled with grout
CC8^® Bulk Rolls cut down into hand portable Batched Rolls
Transverse layup
Stainless steel mechanical fixing joints
Perimeter edges secured behind a batten and filled with grout
Hydrated using water pumped from upstream dam via a flat hose

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Custom length rolls transported to site on a trailer

Summary

A total of 250m² of CC8^® was installed by a team of five during winter when there was an increased flow of water in the small river, which would otherwise have caused complications for alternative solutions.

The preparation of the culvert (removal of silt and filling the inverts) took approximately 2 weeks including site set-up. Installation of the CC8^® material was installed over five days. The material installation itself was completed in the first three days, with the final two days used for grouting the perimeter edges.

In specifying CC8^® to upgrade the culvert, the client has effectively reduced the amount of time spent on site and negated the need for a costly rebuilt or full internal lining while extending the culvert’s operational life.

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