AbstractA structurally spray-applied pipe lining (SAPL) is a trenchless method to inhibit further deterioration and structurally renew deteriorated pipes, culverts, and drainage structures. The primary SAPL materials generally fall into two broad categories of cementitious and polymeric materials. SAPLs can be a key strategy in extending service life and managing the future issues expected from the aging network of gravity pipes and culverts. However, currently no standard design methodology exists for SAPL. Most lining vendors utilize the cured-in-place pipe (CIPP) design methodology as specified in a current standard, and others use various analytical structural design approaches. This paper assessed the existing conditions of 24 culverts renewed with SAPL in the states of Delaware, Florida, Minnesota, New York, North Carolina, Ohio, and Pennsylvania by considering various physical and operational factors. The inspections were focused on large-diameter corrugated metal pipes (CMPs) and reinforced concrete pipes (RCPs) renewed with cementitious and geopolymer SAPLs. This study is part of a broader research project to develop a standard design methodology for this renewal method. Identifying potential problems after installation can be considered during planning and design of SAPL. Therefore, the first objective of this paper is to conduct field data collections and in situ inspections of recent SAPL projects to identify renewal defects and installation issues. The second objective of this paper is to make suggestions for development of proper performance construction specifications to prevent SAPL potential problems. The data collected through the field inspection are used to assess the structural conditions of these projects. The results present a strong need for SAPL performance construction specifications, a standard design methodology, a robust quality control protocol, postinspection requirements, and recommendations for SAPL installation improvements.

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