Memphis, Tennessee: Sears Crosstown Box Culvert

Memphis, Tennessee 2017


In 2015, the City of Memphis’ Sears crosstown box culvert system was under inspection. The inspection included the evaluation of twin 8’ x 10’ concrete box culverts, each a length of 500 linear ft, that are part of the Madison Heights drainage basin. The assigned engineering firm concluded that rehabilitation was needed for the system and suggested slip lining in the culvert as well as spray-on lining system. After the full inspection, the system had severe corrosion, spalling and cracking. Inland Pipe Rehabilitation, LLC (IPR) was awarded the project in early 2017, due to the company’s expertise in box culvert repairs. 


IPR recommended their EcoCast geopolymer lining solution for the job and applied a minimum of 1.5” of geopolymer mortar to recover and protect the steel structure as well as fill in voids, cracks and other defects that were allowing water infiltration into the culvert from the surrounding soil.

Materials & Services


EcoCast combines installation and application equipment with a custom formulated geopolymer called GeoSpray®.  It is an extremely versatile system specifically developed for very large structures.  It has a high compressive strength, extremely high modulus of elasticity and high bond strength. It works in a wide range of temperatures and cures in a matter of hours. 


Once the city and the engineer approved the design, work began on the culvert in earnest in early November 2017, after delays in the summer of 2017 due to excessive flooding in the area that made dewatering the culvert impossible. However, the project was completed in early January 2018. The City of Memphis was please for the fast turnaround time box culvert system was reopen.  The City of Memphis continues to assign IPR with new projects, including the rehabilitation of the AW Willis project.