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Arrow Montana Demonstration Project: Innovative Culvert Rehabilitation Using Trenchless Technologies

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Final Report June 2009

Final Report June 2009

Table of Contents

List of Figures



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


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.

1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.
4. Title and Subtitle
Montana Demonstration Project: Innovative Culvert Rehabilitation Using Trenchless Technologies
5. Report Date
November 2009
6. Performing Organization Code
7. Author(s)
Ahmad Ardani, P.E., Jagannath Mallela, Gary Hoffman, P.E., R.L.S.
8. Performing Organization Report No.
9. Performing Organization Name and Address
Applied Research Associates, Inc.
100 Trade Centre Drive, Suite 200
Champaign, IL 61820
10. Work Unit No.(TRAIS) C6B
11. Contract or Grant No.
12. Sponsoring Agency Name and Address
Office of Infrastructure
Federal Highway Administration
1200 New Jersey Avenue, SE
Washington, DC 20590
13. Type of Report and Period Covered
Draft Final Report
May 2007—November 2009
14. Sponsoring Agency Code
15. Supplementary Notes
Contracting Officers Technical Representatives: Byron Lord, Mary Huie
16. Abstract

As part of a national initiative sponsored by the Federal Highway Administration (FHWA) under the Highways for LIFE (HfL) program, the Montana Department of Transportation (MDT) was awarded a grant to demonstrate the use of trenchless technologies in rehabilitating 10 deteriorated culverts on U.S. 12 over MacDonald Pass in Powell and Lewis and Clark Counties. This report documents the entire work effort, including the use of two innovative techniques to rehabilitate the corrugated steel pipe culverts. These innovative techniques included a cured-in-place pipe (CIPP) lining and a sliplining system using high-density polyethylene pipe (HDPEP) liners.

The rehabilitation effort was a great success. By using trenchless technologies, MDT was able to perform the work without closing any lanes or interfering with traffic flow. The benefits of using CIPP and HDPE included the following:

  • Virtually eliminated traffic delays and lane closures
  • Provided a safer environment for the traveling public and workers by eliminating exposure to traffic and construction activities
  • Potentially improved quality because work was done in a controlled environment
  • Eliminated costs associated with traffic control and roadway excavation
  • Attained user satisfaction.
17. Key Words
CIPP, cured-in-place pipe, HDPE, high-density polyethylene, Highways for LIFE, innovative culvert rehabilitation, sliplining, trenchless technologies
18. Distribution Statement

No restriction. This document is available to the public through

19. Security Classif. (of this page)
20. No. of Pages
21. Price  

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

Approximate Conversions to SI UnitsApproximate Conversions from SI Units
When you knowMultiply byTo findWhen you knowMultiply byTo find
(a) Length
(b) Area
square inches645.2square millimeterssquare millimeters0.0016square inches
square feet0.093square meterssquare meters10.764square feet
square miles2.59square kilometerssquare kilometers0.386square miles
(c) Volume
fluid ounces29.57millilitersmilliliters0.034fluid ounces
cubic feet0.028cubic meterscubic meters35.32cubic feet
cubic yards0.765cubic meterscubic meters1.308cubic yards
(d) Mass
short tons (2000 lb)0.907megagrams (tonne)megagrams (tonne)1.102short tons (2000 lb)
(e) Force
(f) Pressure, Stress, Modulus of Elasticity
pounds per square foot47.88PascalsPascals0.021pounds per square foot
pounds per square inch6.895kiloPascalskiloPascals0.145pounds per square inch
(g) Density
pounds per cubic foot16.019kilograms per cubic meterkilograms per cubic meter0.0624pounds per cubic feet
(h) Temperature
Fahrenheit temperature(°F)5/9(°F– 32)Celsius temperature(°C)Celsius temperature(°C)9/5(°C)+ 32Fahrenheit temperature(°F)
  1. The primary metric (SI) units used in civil engineering are meter (m), kilogram (kg), second(s), newton (N) and pascal (Pa=N/m2).
  2. In a "soft" conversion, an English measurement is mathematically converted to its exact metric equivalent.
  3. In a "hard" conversion, a new rounded metric number is created that is convenient to work with and remember.


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

ADT average daily traffic
CIPP cured-in-place pipe
CSP corrugated steel pipe
dB(A) A-weighted decibel
DOT department of transportation
FHWA Federal Highway Administration
HDPEP high-density polyethylene pipe
Hfl Highways for LIFE
IRI International Roughness Index
NHS National Highway System
MDT Montana Department of Transportation
OBSI on-board sound intensity
OSHA Occupational Safety and Health Administration
PVC polyvinyl chloride
SAFETEA-LU Safe, Accountable, Flexible, Efficient Transportation Equity Act: A Legacy for Users
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Mary Huie
Center for Accelerating Innovation

Updated: 04/04/2011

United States Department of Transportation - Federal Highway Administration