Box Culvert Leak Sealing

Alexandria, VA


A new double box culvert was constructed. The original single box culvert needed to be abandoned in place. Access to the box culvert was only available from one end. Box culvert leak sealing was required because there were multiple sources of active water infiltration into the structure, and old tie-ins that hadn’t been completely plugged.


To contain the grout within the box culvert, it had to be watertight before being abandoned. More than 10 water infiltration/potential cellular concrete exfiltration locations were identified.  Additionally, to avoid inducing settlement, the abandonment grout was only 25lb/cuft. Because it could float, there couldn’t be any water in the box culvert during the abandonment grouting work.

CJGeo selected plural component polyurethane grouting for sealing all potential cellular concrete exfiltrations. Sites included RCP pipes terminating in stone beds, a 48″ HDPE culvert extension punched through the walls of the box culvert, and multiple holes in the ceiling covered with steel plates.

Some of the infiltration points were actively leaking water, so the selected material had to set in, and stop active water flows.  


A CJGeo polyurethane grouting crew performed the box culvert leak sealing repairs using CJGrout 35NHV. 35NHV is a normal reaction speed, hydro-insensitive geotechnical polyurethane specifically formulated for void filling applications and water intrusion repair. The cost of sealing the leaks in the culvert to make it watertight was significantly less than the potential losses due to leaks during grouting.

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