Conroe, TX
GeoSpray® Geopolymer: Corrugated Metal Storm Sewer

Project Overview

The community of Walden on Lake Conroe had been experiencing significant growth and the water infrastructure had begun to feel the burden. A 130 linear ft corrugated metal pipe (66 inch in diameter) that conveyed storm water from a local thoroughfare into the lake was severely deteriorated over most of its length with a section closest to lake having completely collapsed. When the city of Conroe began to look at options to repair the structure, they very quickly eliminated the possibility of excavation and replacement of the pipe because its location and diameter would have likely endangered two neighboring residences. So the city decided that a trenchless rehabilitation would have to be the solution.


To begin the process, a new section of the pipe was added at the end of the outfall where the original pipe had completely corroded and failed. Once this repair was complete, the outfall end of the pipe was plugged because of the high lake level. After the pipe was cleared of water and the damaged section by-passed, the contractor cleaned the pipe with a high pressure water treatment. After cleaning, several of the small holes in the pipe were plugged with GeoPlug™ rapid-set mortar to stop active infiltration. The GeoSpray® mortar lining was installed using a mechanical sled in three ½ inch passes. A single pass of the line took less than 2. 5 hrs to complete and all three passes were completed within 12 hrs. The by-pass was released in under 24 hrs and the new monolithic structure was completed.




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Using this method of trenchless technology, we were able to save money and complete the project faster.
-Haynes Utility North Corp.