Revolutionizing Culvert Rehabilitation: The Power of Polyurea Coatings and Trenchless Technology

Our world is moving fast, and we need quick, cost-effective solutions for maintaining and rehabilitating our aging infrastructure. A recent culvert rehabilitation project in York Region used innovative polyurea protective coatings and trenchless application technology. As experts in chemical-related building materials, IMC/Nukote Canada aims to provide eco-friendly and reliable solutions for underground asset rehabilitation.

Challenges for the York Region Culvert Rehabilitation Project

The primary challenge was rehabilitating a fully deteriorated ellipse CSP (corrugated steel pipe) culvert under a busy four-lane road and bridge. The goal was to restore the culvert’s structure while causing minimal traffic disruption. There were also concerns about flow impact due to liner thickness and environmental concerns from Fisheries and Oceans Canada.

The culvert was about 3.5 meters under the roadway, so traffic loads were important. For the project design it was assumed that the existing deteriorated corrugated steel pipe would not contribute to carrying loads and all dead and live loads would be applied directly to the PP 300 structural liner.

Culvert Before Rehabilitation:

Culvert Before Rehabilitation

Innovative Solutions from IMC – Nukote Canada

IMC – Nukote Canada provided the right innovative solution. Their fully structural SAPL (spray-applied lining) system was crucial for a ductile, durable, and long-lasting result.

Choosing the Right Coatings

Nukote PP300, a high-performance spray applied polyurea/polyurethane hybrid coating, was chosen for its combination of ductility, tensile strength and load-bearing capabilities. Nukote ST was applied over the PP300 to enhance corrosion and impact resistance.

Application Process

Before applying the coatings, the culvert’s interior was cleaned. Areas with screws were striped for added reinforcement. The Nukote PP300 and Nukote ST PW were applied utilizing Nukote’s 360 Ringtech RCOSH System. This robot applies the coatings precisely and efficiently.



Robotic Application:

Advantages of Polyurea Protective Coatings

Polyurea protective coatings offer several benefits in culvert rehabilitation projects.

  • Eco-Friendly (No VOCs): Polyurea protective coatings are eco-friendly, containing no volatile organic compounds (VOCs), no solvents, no styrene, and meet ANSI/NSF-61 certification for direct contact with potable water. This is important because native species of animals often travel through culverts or reside in waterways alongside them.
  • Increased Flow Capacity: Another advantage is the enhanced flow capacity of rehabilitated culverts. Due to the liner’s smooth surface, for this application calculations demonstrated a 5% increase in flow, the concerns about flow impact were addressed.
  • Versatile and Durable: Polyurea coatings provide high resistance to a broad range of chemicals and offer excellent thermal stability, abrasion resistance, and impact resistance. This versatility makes polyurea coatings ideal for a variety of applications, ensuring long-term protection for underground assets.

The Nukote Polyurea Coating Systems are versatile and suitable for a wide range of underground vertical and linear asset rehabilitation projects, including pipes, culverts, sewers as well as manholes.

The Impact of Trenchless Technology

Trenchless technology has revolutionized the field of underground asset rehabilitation. By minimizing excavation and disruption to traffic flow, this method offers a cost-effective alternative to traditional replacement techniques. It also increases efficiency and extends the service life of the underground asset.

In the York Region culvert rehabilitation, trenchless technology allowed for the successful application of the Nukote SAPL system without significant disruption. The use of robotics and other innovative equipment enabled precise and efficient application of polyurea coatings.

Also Read: Revitalizing Failing Culverts: Trenchless Solutions for Structural Rehabilitation

Client Feedback: Regional Municipality of York

The client, the Regional Municipality of York, was satisfied with the project’s outcome. They appreciated the effectiveness of the polyurea coatings and trenchless technology in rehabilitating the culvert.

Conclusion: A Successful Culvert Rehabilitation Project

The successful rehabilitation of the culvert in York Region demonstrates the power of polyurea protective coatings and trenchless technology in underground asset rehabilitation. By embracing these innovative solutions, IMC/Nukote Canada and its authorized applicators were able to address the unique challenges of the project while minimizing environmental impact and ensuring long-lasting results.

Culvert Complete:

culvert rehabilitation completed

Learn More: Download the PDF Case Study

For a more detailed overview of this project, including a step-by-step description of the process, Download the PDF Project Description available on our website. Discover how polyurea protective coatings and trenchless technology can revolutionize your next culvert rehabilitation or underground asset rehabilitation project.

Download the PDF Project Description

Karli Logan is the Owner and President of IMC Distributors which is the exclusive partner of Nukote Coating Systems in Canada. With a B.Sc and M.Sc, as well as a demonstrated history of working across a number of industries, she has a passion to drive significant gains and benefits for IMC’s clients.