System and method for rehabilitating a host pipe

A method for in situ rehabilitation of a host pipe in the form of a corrugated culvert or other conduit, comprising:

• applying a preparation treatment to an inner surface of the host pipe to at least partially fill in at least some corrugated indentations in the inner surface of the host pipe;
• disposing a support frame within the interior of the host pipe and adjacent to the host pipe inner surface, and coupling said support frame to the host pipe;
• assembling a plurality of longitudinal planks within the interior of the host pipe to form a liner, comprising attaching the longitudinal planks to the support frame and further comprising coupling together adjacent longitudinal planks via coupling structures that are arranged along each of the opposite longitudinal edges of each of the longitudinal planks, wherein each longitudinal plank has an inwardly facing surface that forms a portion of an inner surface of the liner and an opposite outwardly facing surface having at least one longitudinal protrusion extending away therefrom;
• and,
• at least partially filling a space that is defined between the preparation treatment applied to the inner surface of the host pipe and the assembled plurality of longitudinal planks with a cementitious grout material, to form a grout layer upon curing of the cementitious grout material,
• wherein the cementitious grout material flows around and surrounds the at least one longitudinal protrusion during the step of filling the space, such that the at least one longitudinal protrusion is embedded within the grout material upon curing of the cementitious grout material.

A system for in situ rehabilitation of a host pipe in the form of a corrugated culvert or other conduit, comprising:

• a support frame, which is sized for being received within and coupled to an inner surface of the host pipe, the support frame configured to provide a plurality of attachment points spaced away from the inner surface of the host pipe;
• a plurality of interconnected longitudinal planks forming a liner within the host pipe, each longitudinal plank of the plurality of longitudinal planks having an inwardly facing surface that forms a portion of an inner surface of the liner, and each longitudinal plank of the plurality of longitudinal planks having an outwardly facing surface opposite the inwardly facing surface with at least one longitudinal protrusion extending away therefrom;
• and
• a layer of a cured cementitious grout material filling or substantially filling a space between the inner surface of the host pipe and the plurality of interconnected planks,
• wherein the at least one longitudinal protrusion of each longitudinal plank is embedded within the cured cementitious grout material.

A rehabilitated culvert, comprising:

• a corrugated steel pipe (CSP) having an outer corrugated surface and an inner corrugated surface;
• a preparation treatment applied to the inner corrugated surface;
• a layer of cured cementitious grout material bonded to the preparation treatment;
• a support frame embedded within the layer of the cementitious grout material;
• and
• a plurality of interconnected longitudinal planks arranged side-by-side and end-to-end, each longitudinal plank having at least one longitudinal protrusion on a surface thereof facing the inner corrugated surface, the at least one longitudinal protrusion of each longitudinal plank being imbedded within the layer of cured cementitious grout material, the interconnected longitudinal planks cooperating to form an inside liner of the CSP that is spaced away from the inner corrugated surface of the CSP.