Located in Cleveland, Ohio, the Emerald Parkway Culvert Repair Project (EPCR) consisted of replacing a 250 linear foot section of collapsed 11-foot diameter corrugated metal pipe culvert. EPCR is adjacent to heavily utilized Interstate 480, under which the existing culverted creek flows. Upstream flooding, created by the collapse, threatened local infrastructure and public safety as water approached the ground surface, about 60 feet above the culvert. This Design-Build Contract allowed for a collaborative project approach under critical conditions.

Following Inspection it was determined an 11' corrugated metal pipe (CMP) culvert collapsed causing extensive flooding of a tributary on the Rocky River. Northeast Ohio Regional Sewer District (NEORSD) entered into a Design-Build contract with Turn-key Tunneling, Inc. to replace 250 lf of 11' diameter CMP with a depth of cover of 70' ft.

Special conditions included installing a 24' diameter shaft to access the deep storm sewer. Workers found significant obstructions while installing the liner plate and rib shaft near the bottom elevation at approximately 70' ft of cover. Construction and demolition debris in the form of asphalt, concrete slabs, and duct bank were encountered. Two auger bores were completed for a dewatering stem. In total the project used 370--lf of 104" diameter HOBAS flush reline pipe. To line the existing culvert downstream and the new tunnel upstream.

Due to the ground cover, the repair required multiple trenchless technologies through fill soils containing substantial obstructions. To mitigate risks associated with excavation towards retained water, two auger bored steel casings (24-inch and 36-inch diameter) were installed for dewatering of the impounded water along the length of collapsed pipe. This was followed by hand mined 11-foot rib and lagging primary tunnel liner around the collapsed culvert, which required change in excavation plans due to unanticipated culvert cross sections within the tunnel heading.

Additional trenchless operations included culvert relining beyond the collapse and secondary tunnel liner installation within the rib and board, both consisting of 104-inch diameter Hobas pipe. The operations were performed from a strategically placed 24-foot diameter construction shaft.

Additional challenges included void stabilization and temporary bypass pumping in order to maintain safety. This paper discusses the unique project challenges, innovations, and selection of trenchless technologies by the Design-Build Team of Turn-Key Tunneling Inc. and NTH Consultants Ltd., under direction of the Northeast Ohio Regional Sewer District, to re-establish safe conditions.