Restoring Strength Below the Surface: SprayWall Reinforces Texas Highway Culverts 

Beneath a critical Texas highway, three concrete box culverts—each 8 feet wide, 3 feet tall, and 80 feet long—were found to have severe spalling, large voids, and exposed rebar during a routine transportation district inspection. As bridge-class structures spanning over 20 feet collectively, their rehabilitation required compliance with AASHTO LRFD Bridge Design standards. 

Due to the significant road closures and inconveniences that it would cause for commuters, a traditional dig-and-replace approach was not an option. Instead, Fuquay, a Sprayroq Certified Partner and expert in structural rehabilitation, proposed SprayWall®—Sprayroq’s ultra-high build polyurethane lining system—as the ideal trenchless solution. 

Situated only two feet below the roadway and crucial to stormwater management, these culverts posed a risk of collapse if left unaddressed. SprayWall was applied at a 550-mil thickness to restore structural integrity, meeting stringent bridge-class design parameters for load and stress. This approach reinforced the culverts’ load-bearing capacity while eliminating the need for excavation. 

Fuquay’s technical precision ensured the concrete profile was properly restored before applying SprayWall, enabling strong adhesion and long-term performance. The district’s approval of this application highlights the success of a minimally disruptive and proven structural solution that strengthens aging infrastructure. 

This project showcases Sprayroq’s ability to meet the evolving needs of transportation agencies nationwide. The combination of Fuquay’s field expertise and SprayWall’s performance sets a new standard in culvert rehabilitation—prioritizing public safety, structural integrity, and uninterrupted service.

Click here to see the full case study on our website and for more information on how SprayWall can benefit you with your next rehabilitation project.