When Idaho’s Ada County Highway District (ACHD) flagged a 42-inch corrugated metal culvert with severe flow-line corrosion, the risks were immediate and compounding. This wasn’t just another asset in need of attention. It was a pipe conveying a year-round creek beneath South Chipper Way, a blind-curved roadway lined with luxury homes and adjacent to Banbury Golf Course, one of Treasure Valley’s most high-profile recreational spaces.
Conventional open-cut replacement was off the table. ACHD faced three non-starters: potential turf and landscaping damage on golf course property, the risk of slope destabilization in the steep creek corridor, and unacceptable road closures on a curving collector with no bypass. They needed a trenchless rehabilitation method with zero margin for error and minimal surface disturbance.
Taking the jobs no one else wants
Enter Integrity Inspection Solutions, a Boise-area trenchless contractor known for making difficult jobs routine. Led by brothers Richard and Brian Mason, Integrity has built a reputation for saying yes to work others turn down, particularly access-constrained or environmentally sensitive rehab.
For the South Chipper Way culvert, they recommended an ultraviolet light-cured, glass-reinforced pipe (UV GRP) lining solution using Reline America’s Alphaliner, citing its minimal footprint, predictable cure behavior, and ability to bridge failing host pipe conditions without compromise.
“With UV, anything’s possible,” says Brian Mason. “It just takes the right materials vendor and technology in the right situation.”
Custom access, controlled curing
Site access required engineered creativity. The creek couldn’t be fully diverted, and staging equipment near the culvert was impossible with traditional methods. Integrity devised a control plan that included craning in concrete barrier blocks and tarps to form a temporary dam, stabilizing the flow without affecting the greens or upstream hydrology.
Once conditions were stable, the team craned the liner box directly into the corridor. To avoid damage to the liner or misalignment during insertion, they used a custom winch system fitted with centered sheaves and a ¾-inch cable to ensure consistent axial pull with no side loading. This setup eliminated unnecessary tension and preserved the liner’s structural performance envelope.
“If you take your time and get it set up right, from there it goes really well,” Mason explains. “The key is prep, not muscle.”
The liner was inserted in less than two hours. With the road’s layout preventing partial lane closures, ACHD authorized a full closure for active lining. Integrity maintained pedestrian pathways while ensuring crew safety and equipment security during the cure.
An engineering-led process with real-time adjustments
Reline America’s field engineers joined the Integrity team onsite, supporting real-time adjustments to curing parameters based on field conditions. They provided documented guidance for inflation pressure, light train pullback speeds, and curing temperature profiles.
“Reline didn’t just tell us what to do — they explained the why,” Mason notes. “Having a clear, science-based process gave us confidence and consistency.”
A few unexpected variables, such as late-day power adjustments and last-minute flow control tweaks, could have delayed less experienced teams. But Integrity pushed through and cured the liner that same day. That’s consistent with their project ethos: “Once we start, we don’t stop.”
Structural renewal, zero surface damage
By the end of a single extended shift, ACHD had a fully rehabilitated culvert with structural integrity restored. The UV GRP liner provided:
- Load-bearing capacity to meet traffic and slope demands
- Corrosion resistance suited for a creek environment
- A pipe-within-a-pipe installation with no disruption to golf course operations or road integrity
The trenchless installation neutralized the risk of sinkholes, roadway collapse, or hydrological intrusion without the cost, permitting challenges, and site disturbance of a full replacement.
Why it worked
This job succeeded because ACHD knew when to specify it and Integrity knew how to execute it. From barrier placement to cable alignment, cure controls to real-time adjustments onsite, each decision was grounded in an understanding of the site and the material.
When a jobsite can’t tolerate guesswork or disruption, UV GRP trenchless solutions like Alphaliner — paired with knowledgeable contractors and engineering-backed vendor support — can reduce risk and deliver long-term value without a visible trace.
Are you facing a complex trenchless rehabilitation project? Discover how Reline America can support your success with training, technology, and onsite expertise. Contact our team today at RelineAmerica.com to discuss your project.
