Project Background

A highway culvert in Bolu had been in operation for nearly 50 years and had developed structural damage over time. Reinforcement of the structure was required to ensure continued safe operation.

The site presented a significant logistical challenge. The highway is a major transport corridor with more than 37 million vehicles per year, corresponding to approximately 102,000 vehicles per day. Because of the high traffic volume, the rehabilitation works needed to be completed quickly while minimizing disruption to road users.

Engineering Solution

The original rehabilitation concept involved replacing the culvert using reinforced concrete, which would have required approximately four months of construction.

To accelerate the project, the stakeholders selected a corrugated steel culvert relining solution supplied by ViaCon Türkiye.

The new corrugated steel structure was installed inside the existing concrete culvert, forming a new structural liner. Once the steel structure was assembled, concrete grout was injected into the space between the existing culvert and the new steel lining, creating a composite system that restored the structural integrity of the crossing.

The installation of the steel structure was completed in three days, significantly reducing construction time compared to the original plan.

Construction

The modular steel plates were transported to the site and assembled directly inside the existing culvert. The lightweight components allowed installation without the need for heavy construction equipment.

After assembly, concrete was injected between the existing culvert and the new steel structure to complete the reinforcement system.

Project Outcome

The rehabilitation solution delivered several key benefits:

• Construction completed in 3 days instead of 4 months
• Minimal disruption to a high-traffic highway corridor
• Lower overall project cost compared to the original concrete solution
• Extended service life of more than 75 years
• Reduced transport and installation requirements due to lightweight modular components

The project demonstrates how corrugated steel relining systems can provide a rapid and efficient solution for upgrading aging culvert infrastructure while maintaining continuous traffic operations.