The Caltrans Culvert Rehabilitation project scope was to rehabilitate 13 culverts along I-8 in Alpine, California, as some of these culverts are more than 50 years old. Some culverts were lined with a Cured-in-Place (CIPP) liner while others were rehabilitated with concrete invert paving.
The work included the following:
Full culvert cleanout (Performed by GC)
Rust removal on corrugated peaks where nelson studs were welded
Grouting/fill of any voids in the flow line
Stud installation
Wire mesh installation
Shotcrete placement (Performed by JWF’s sub)
Contact grout of discovered voids along walls above spring-line
Culverts 3, 5, 8, and 11 were to be lined with steel nelson studs welded to wire mesh for reinforcement and lined with 6000-psi shotcrete. JWF self-performed the reinforcement installation and concrete invert paving, while a subcontractor placed the shotcrete.
JWF was responsible to divert groundwater from the flowline of each culvert with an approved diversion plan. After implementing the diversion plan for the first time on Culvert #5, it was discovered that perched groundwater was still infiltrating the flowline to the point that the Inspector required further measures to be taken. To remove the perched groundwater JWF installed wells 18” below flowline with additional pumps routed to the main diversion line every 50 feet. This was performed on all culverts except #8.
Each culvert only had main access from one portal where all materials and work would only be able to progress from one end. Large equipment was not allowed down to the culverts resulting in having materials delivered offsite and manually brought into each culvert.
Each culvert was different and possessed its own challenges, but all were rehabilitated in the same overall manner. Culvert #3 was the final culvert rehabilitated and was the largest (15’ diameter / 600 LF). This culvert presented many challenges including a significant settlement along the middle 200’.
The project faced many challenges but the JWF team forged forward through each of them. The project from the top down was a success. The estimate package allowed room for creativity and provided multiple options on how to approach the work. The field team’s creativity and superb work ethic were key to finishing the project on time and well under budget.
