Weldon, NC
GeoSpray® Geopolymer: CMP Culvert Repair

Project Overview
The NC DOT was looking for a challenging project to complete a first state project with GeoSpray mortar. Along the banks of the Roanoke River in the city of Weldon, NC, the North Carolina DOT (NCDOT) was faced with significant issues of culvert failure and bank erosion that were beginning to threaten private homes. A 108 inch diameter CMP pipe approximately 85 feet in length connects incoming streams to the Roanoke River. The pipe is buried 25 feet below ground under the only access road to a commercial water treatment plant and a cotton and soy bean farm. The NCDOT had already repaired and stabilized the bank on the river side of the culvert with a steel embankment and was now confronted with the problem of extending the life of the failing culvert.

The GeoSpray technology was selected over the open cut method. The 20 day
disruption to the community would have been a significant hardship to the local residents and industries. In addition, using GeoSpray mortar provided a long term structural solution at a fraction of the system cost. Once the decision was made to proceed, the NC DOT lowered the level of the Roanoke River in order to reduce flow through the culvert (often this culvert is completely submerged). After the water level was lowered, the north embankment was repaired by a DOT crew and the culvert rehabilitation was scheduled.

The project was completed with little to no disruption of the private and commercial neighbors while on-time and on-budget.

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Using the GeoSpray system provided a long term structural solution at a fraction of the system cost. The project was completed on-time and on-budget.