Box culvert abandonment project in Northern Virginia using CJFill-Ultra Lightweight cellular concrete, by CJGeo.

Box Culvert Abandonment

Alexandria, VA


This box culvert abandonment project is located in Alexandria, Virginia. The existing single barrel box culvert had insufficient hydraulic capacity, and the discharge end was causing erosion adjacent to occupied structures. The contractor was building a new double barrel structure adjacent to the original one. After the new structure was in place, the 350 foot long original structure had to be filled. Access to the box culvert was only available from one end, and there were multiple sources of active water infiltration into the box culvert.



VDOT standards specify a minimum compressive strength of 50psi for pipe & culvert abandonments. The proposed mix design needed to meet or exceed 50psi.  

The customer wanted lump sum pricing. Therefore, all sources of infiltration (potential leaks during grouting) had to be completely sealed prior to abandonment material placement.

The laydown area was about 100 feet from the opening.


25PCF wet cast density CJFill-Ultra Lightweight mix met the minimum compressive strength requirement and constructibility challenges.

Pumping 100 feet to reach the placement location, and then up to an additional 350 feet to the far end of the culvert wasn’t a problem. 

Prior to abandonment grouting, CJGeo polyurethane grouting crews used CJGrout geotechnical polyurethane to:

  • plug out of service tie-ins
  • seal penetrations for a 48″ HDPE pipe crossing through the existing box
  • grout various leaks at joints & cracks


CJGeo successfully performed the box culvert abandonment using CJFill-UL. CJGeo self-performed all polyurethane grouting for making the structure watertight placed all sacrificial placement pipes and generated and placed the cellular concrete to complete the box culvert abandonment.  

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