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Kenway Corporation’s Hybrid Composite Culvert Repair System

Posted by Composite Advantage on Feb 11, 2021

Composite Panels Installed in Failing Steel Culverts Prove Cost Effective Method to Restore Structural Integrity and Improve Fish Passage.

Three additional Hybrid Composite Culvert Repair Systems have been successfully installed in Ebeemee and Indian Townships in central Maine. Developed by Kenway Corporation of Augusta Maine and the University of Maine’s Advanced Structures and Composites Center (AEWC) the Hybrid Composite Culvert Repair System utilizes pre-engineered light-weight composite panels that conform to the existing culvert pipe with minimal invert change.

The Hybrid Composite Culvert Repair System has many advantages compared to total culvert replacement or traditional repair methods. Composite panels install quickly and easily with little need for heavy equipment, there is minimal culvert invert change, the process is less disruptive to the environment, there is reduced “in stream” time, traffic disruption is minimal, project duration is reduced and overall costs are less.

Composite panels are built, inspected and fully cured before leaving the factory. Properly formulated, composite panels comply with FDA regulation 21 CFR 177.2420 associated with materials intended for repeated use in contact with food. Unlike other composite culvert repair methods, such as Cured-In-Place (CIPP) rehabilitation, there is no styrene or chemical leaching from the composite panels and components. Utilizing pre-manufactured composite panels eliminates the risk of elevated PH levels in the water, a common issue associated with curing concrete used in traditional culvert repair methods.

The lifespan of the highly corrosion, abrasion and impact resistant composite panels exceeds 75 years, providing a maintenance free timeframe that exceeds those of galvanized steel or concrete culverts. Composite panels also allow the easy attachment of pre-manufactured fish weirs and ladders that are now required in many locations and can be customized to meet each sites particular need.

A review of Kenway’s first Hybrid Composite Culvert Repair Rehabilitation project installed in 2009 in Amherst Maine is performing well and has demonstrated the system’s ability to withstand Maine’s extreme fluctuating weather conditions. With a proven track record, Kenway’s Hybrid Composite Culvert Repair System represents a significant opportunity for transportation agencies looking to maintain road safety and meet environmental regulations with increasingly tight budgets.

Ebeemee Township Maine – Stinking Brook Culvert Rehabilitation Project

Kenway Corporation was the lead contractor for the installation of a76’ long 11’7” wide plate arch style culvert rehabilitation where the Stinking Brook passes under Route 11 in Ebeemee Township, Maine. The bottom of the existing galvanized steel culvert had significant corrosion and rot compromising its structural integrity. All eight of the necessary 10’ x 11’7” composite panels were installed and fastened inside the culvert by a 5 person crew in one day. An additional 2 days were spent sealing the joints and pumping grout into the annular space behind the panels to add stiffness and strength. With good weather and proper preparation a typical 70-80’ steel culvert can be completely rehabilitated with composite panels in one week. To promote salmon migration through the culvert a total of 6 internal fish weirs and an external fish ladder with three pools was incorporated into the final culvert rehabilitation design.

Indian Township Maine – Partridge Brook & Grant Brook Culvert Rehabilitation Projects

Nelson Construction of Houlton Maine was the lead contractor for both the Partridge Brook and Grant Brook culvert rehabilitation projects both located in Indian Township, Maine. Kenway Corporation manufactured and installed all the necessary composite panels and fish weirs in both culverts. The Partridge Brook culvert is a plate arch styled galvanized steel culvert 77’ in length and 14’ 2” in diameter. A total of 8 panels were installed and fastened by a crew of 5 in 10 hours, setting the stage for subsequent joint sealing, grouting and fish weir installation. The Grant Brook culvert is a circular style galvanized steel culvert 77’ in length and 10’ in diameter that also had a total of 8 custom shaped panels installed along with 6 internal fish weirs.

All projects were competitively bid with the Hybrid Composite Culvert Repair system winning as low bidder against traditional concrete and shotcrete repair methods. All three culvert repairs were completed on time and on budget with minimal environmental impact.

Kenway Corporation specializes in custom composite manufacturing and field service. The company offers complete composite engineering and design capabilities and manufactures a variety of items for industries ranging from marine, pulp and paper, infrastructure, transportation and renewable energy.

Kenway History—

In 1947 Kenneth G. Priest, Sr. founded Kenway Boats, building wooden runabouts of his own design. The next two decades witnessed the transition to fiberglass boats and other composite fabrications as the company diversified its product offerings. Gradually, Kenway Boats’ reputation for excellence spread to industrial customers and the corrosion resistant, custom fabricated pipes, tanks, hoods, and the myriad other special molded products they required. Finally, in 1966, the decision was made to focus exclusively on these industrial clients and Kenway Corporation replaced Kenway Boats.

As Kenway Corporation continued to evolve over the following decades what remained constant was the focus on providing the highest quality composite products and the determination to innovate. Currently, the company and its (70) employees are strategically positioned to serve customers by offering complete engineering and design capabilities so that they may bring both standard items as well as “one-off” special molded fabrications from the design phase, through the manufacturing phase, to the final on-site installation. Custom work and custom service are what distinguish Kenway as it manufactures product for industries ranging from marine, to coal-fired power, to infrastructure, to pulp and paper, to transportation, to renewable energy, incorporating a variety of manufacturing techniques, including open-molding, vacuum infusion, prepreg lamination, dry film infusion, high temperature epoxy, and temperature controlled molding. What links the company’s various business lines is: technologically advanced manufacturing techniques; products manufactured for exacting service applications; and the highest quality assurance procedures and processes.