Challenging the Status Quo - An Innovative Approach to the Structural Renewal of a Large Box
Culvert
A collaborative paper by:
• Tara Manning (Brisbane City Council)
• Steven Latimer (Interflow)
Case Study – Brisbane Corso Park Fairfield
• Project initiation
• Consideration of Options
• Reference Design Specification
• Tendering
• Design
• Construction
Case
Study
Brisbane
Corso,
Fairfield
Structure
Original Structure
Extension
Current
Structure
Elevation
Condition
Prior to
Relining
Traditional Renewal
Open
Trenching
Possible Trenchless Alternatives to Dig and Replace
Shotcreting over Steel Reinforcement
Shotcreting with Fibre Reinforced
Concrete
Sliplining with Reinforced Concrete
Sections
Sliplining with Glass Reinforced Plastic
Design Basis for Structural Relining of Culvert
Culvert Section to
Relined be
Under Road
Way
Key Design Considerations
Cross Sectional Area Loss
Decay of Existing Structure
Early Structural
Loading
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Environmental Restrictions / Limitations Brisbane Corso Park
• Operational work for temporary waterway barrier works
• Destruction of Marine Plants
• Acid Sulfate Soils (AHD between 1 to 4m)
• Erosion & Sediment Control
• Water quality (discharge limits)
• NALL permit for tree removal
Outlet
Care of workers
& structure
Traffic Restrictions Congestion Reduction
Unit
Finding
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Geotechnical Data – Fill Over Culvert
Tendering
RFP
Proposals
Site Meeting
Request for Proposal from Open Market
Looking for Proposals from the Market, Innovation in Design Solutions for a D&C
Independent Structural Liner
Mandatory Tender Site Meeting
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Temporary Propping & Lead times
• Lead time of Channeline from Dubai was 10 weeks
• Residual life of culvert –6 months
Temporary Propping Plan
Weekly
Monitoring
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Tender Award - Interflow
D&C Contract awarded to Interflow who provided:
• Innovative design using Channeline meeting all the mandatory design criteria
• Construction methodology that limited the risk of environmental harm
• Short construction duration minimising impact to traffic
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Glass Reinforced Plastic (GRP)
Structural Lining Systems
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Channeline Properties
• High Mechanical Properties for Design purposes
• Long Term Flexural Modulus 4,000Mpa
• Hydraulic Performance “n” 0.009, “K” 0.03
• Design life of 100 years
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Design Standards
• AS5100 Bridge Design Code
• AS1170 Structural Design Actions
• AS3571 Plastic Piping System GRP
• Water Research Centre – Sewer Rehabilitation Manual
• TMR’s Bridge Design Criteria & Other
Structures
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Design Submission
• Design developed from first principles by SASTTI JV, Sewer Assessment & Trenchless Technology Specialist Consulting Engineers
• Finite element model created
Figure of the FEA Model Combined Stress due to Soil, Hydrostatic and Vehicular Loads
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Construction Design Drawings
• 11 Channeline Sections –10 x 1200mm + 1 x 900mm
• Gap between outside of liner & inside of liner filled with grout
• Timber packers used to hold segments
• Sacrificial rails at base on culvert for installation
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Confirmation of Site Measurements
Prior to Channeline
Material Order
Styrofoam Cut to Shape of Channeline
Used to Confirm ‘Fit’
on Site
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Weekly Monitoring
Installation of Temporary Propping
• Multi prop MP250’ –min. capacity 65kN
• Timber beams along top of culvert (1200mm lengths)
• Diagonal bracing at each end
• Scaffold tubes at top and bottom of props
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Weekly Monitoring
Delivery of Channeline
Construction
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Rails and Winch Set-up
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Weekly Monitoring
Unloading Channeline at Site
Tyres Used to Protect Channeline Orientate to Installation Position Lowering to Apron
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Weekly Monitoring
Installation into Host Culvert
Lower to Apron Maneuver to Outlet of Culvert Winching into Culvert
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Weekly Monitoring
Continuous Inst alla tion
• Timber packers
• Joints sealed between Channeline segments
• Flush finish between segments
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading Temporary
Propping Plan
Weekly Monitoring
Sealing Ends Prior to Grouting
• Build End Seal with Quadex Hyperform
• Install Grout Feed Tubes
• Install Air Bleed Tubes
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Weekly Monitoring
Grouting Operations
• Grout supplied by Boral
• Grouting operation completed in 3 stages
Grout Profile
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Weekly Monitoring
Practical Completion
• Grout tubes were cut and sealed
• Ends Rendered to match existing profile
Cross Sectional Area Loss
Care of workers
& structure
Early Structural Loading
Weekly Monitoring
Summary
• First time installed in Queensland
• Cost effective alternative to open trench excavation methods
• Less disruptive to residents, traffic and environment
• Confined space suitable
• Overall reduced construction duration
• Construction Duration of 4 weeks (6 days spread over 4 weeks)
• Day 1 - Install rails and Winch, remove Propping, install first section of Channeline and packing, reinstate propping
• Day 2 –Remove propping, install 8 sections of Channeline and packing, reinstate propping
• Day 3 - Remove propping, install last Channeline section, seal ends and install grout and air bleed tubes
• 3 Days for grout installation and final rendering of culvert ends and demobilisation
