Printable version of this report (.pdf, 2.2 mb)

Final Report June 2009

Table of Contents

• Introduction
  • Highways for LIFE Demonstration Projects
  • Report Scope and Organization
• Project Overview and Lessons Learned
  • Project Overview
  • Data Collection
  • Economic Analysis
  • Lessons Learned
  • Conclusions
• Project Details
  • Background
  • Project Description
• Data Acquisition and Analysis
  • Safety
  • Construction Congestion
  • Quality
  • User Satisfaction
• Economic Analysis
• Appendix A: User Satisfaction Survey

List of Figures

• Figure 1. View of the project site.
• Figure 2. Existing condition of a typical culvert at the project site.
• Figure 3. Cleaning and removal of debris from the existing CSP.
• Figure 4. View of the pipe fuser apparatus.
• Figure 5. View of the preheated iron during the fusion process.
• Figure 6. View of the welded pipes and spacers.
• Figure 7. View of the welded HDPE pipe liner ready for installation.
• Figure 8. Pulling the HDPE liner and PVC tube into the existing pipe.
• Figure 9. View of the pumping apparatus.
• Figure 10. Fully installed HDPE pipe and the cementitious materials.
• Figure 11. View of the refrigerated truck and the liner.
• Figure 12. Closeup view of the nonimpregnated polyester liner.
• Figure 13. Inserting a circular hole into the liner using a heated core.
• Figure 14. View of the inversion apparatus.
• Figure 15. Closeup view of compressed air application and fully inverted liner
• Figure 16. Fully exited liner at the outlet end.
• Figure 17. Fully deflated liner at the outlet.
• Figure 18. View of the rubber plug with air and steam lines connection.
• Figure 19. View of steam exiting at the intake end of the culvert.
• Figure 20. View of a fully cured CIPP
• Figure 21. View of a fully installed CIPP liner.
• Figure 22. Remote monitoring and inspection.
• Figure 23. Typical CIPP liner installation.

LIST OF TABLES

• Table 1. CIPP and HDPE site locations

Foreword

The purpose of the Highways for LIFE (HfL) pilot program is to accelerate the use of innovations that improve highway safety and quality while reducing congestion caused by construction. LIFE is an acronym for Longer–lasting highway infrastructure using Innovations to accomplish the Fast construction of Efficient and safe highways and bridges.

Specifically, HfL focuses on speeding up the widespread adoption of proven innovations in the highway community. "Innovations" is an inclusive term used by HfL to encompass technologies, materials, tools, equipment, procedures, specifications, methodologies, processes, and practices used to finance, design, or construct highways. HfL is based on the recognition that innovations are available that, if widely and rapidly implemented, would result in significant benefits to road users and highway agencies.

Although innovations themselves are important, HfL is as much about changing the highway community's culture from one that considers innovation something that only adds to the workload, delays projects, raises costs, or increases risk to one that sees it as an opportunity to provide better highway transportation service. HfL is also an effort to change the way highway community decisionmakers and participants perceive their jobs and the service they provide.

The HfL pilot program, described in Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users (SAFETEA–LU) Section 1502, includes funding for demonstration construction projects. By providing incentives for projects, HfL promotes improvements in safety, construction–related congestion, and quality that can be achieved through the use of performance goals and innovations. This report documents one such HfL demonstration project.

Additional information on the HfL program is at www.fhwa.dot.gov/hfl.

Notice

This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for its contents or use thereof. This report does not constitute a standard, specification, or regulation.

The U.S. Government does not endorse products or manufacturers. Trade and manufacturers' names appear in this report only because they are considered essential to the object of the document.

Form DOT F 1700.7 (8–72) Reproduction of completed page authorized

Acknowledgments

The project team would like to acknowledge the invaluable insights and guidance of Federal Highway Administration Highways for LIFE Team Leader Byron Lord and Program Coordinators Mary Huie and Kathleen Bergeron, who served as the Technical Panel on this demonstration project. Their vast knowledge and experience with the various aspects of construction, technology deployment, and technology transfer helped immensely in developing both the approach and the technical matter for this document. The team also is indebted to Jeff Patten of the FHWA Montana Division for his effective coordination effort, and to Montana Department of Transportation Project Manager Jim Divies and Craig Abernathy Research Project Manager, who provided construction information that shaped this report and was instrumental in making this HfL project a success.

Abbreviations and Symbols