Project 2.11: Culvert Rehabilitation using 3D Printed Diffusers

Project Summary:

Due to the increasing number of deteriorating and failing culverts under highways in Maine and across the nation, efforts have been underway to reduce costs by slip lining selected culverts rather than replacing them. While slip lining extends the useful life of culverts, it reduces the diameter of both the culvert and the inlet thus reducing culvert capacity. Utilizing diffuser technology can more than compensate from the reduction in capacity that results from the slip lining process. This trenchless technology of slip lining a culvert and adding a performance enhancing diffuser outlet can extend the useful life of the culvert by decades without compromising capacity. A partnership between MaineDOT and UMaine has provided a unique opportunity to utilize large-scale 3D printing technology to design and manufacture diffusers with the specific geometry required for each field installation. Whereas the use of fiberglass or reinforced concrete would require different forms for each different size diffuser, 3D printing can simply add a scaling factor to an existing diffuser design. Large-scale 3D printing technology using low-cost materials such as wood/PLA based composites shows great promise in designing and manufacturing inexpensive and site-specific diffusers. Because the addition of a diffuser would eliminate the reduced capacity resulting from slip lining, this cost-effective trenchless technology could be used much more broadly.

Sponsors:
University Transportation Centers Program, Department of Transportation
University of Maine

Implementation of Research Outcomes:
This project is in its initial research phase. Implementation of Research outcomes will be reported upon completion of initial research.

Impacts and Benefits of Implementation:

Improved asset performance: The 3D printed diffuser system can increase the capacity of the culvert by about 40%, eliminating the need for
replacement of the existing pipe.
Environmental benefit: The diffuser and outlet weir serve as an effective energy dissipator, addressing environmental concerns related to outlet
scour and downstream sedimentation.
Ease of installation: The 3D printed diffuser system can be installed by a maintenance staff without creating traffic disruption

Related Links:

Best Paper Award of the Additive Manufacturing sessions at ANTEC 2021 from The Society of Plastics Engineers (SPE)

Bhandari, S., Lopez-Anido, R.A., Anderson, J. and Mann, A. “Large-scale extrusion-based 3D printing for
highway culvert rehabilitation, ”ANTEC 2021, Classic, SPE Inspiring Plastics Professionals, Hybrid Edition.

Downloadable Documents