Deep Gulch: A challenging HDPE Culvert Rehabilitation project with KUSTOMFLO
- PRODUCTS : KUSTOMFLO
- REALIZATION : 01/08/2025
TECHNICAL DATA : A KUSTOMFLO PROJECT
DEEP GULCH AT CORNER BROOK
Location: Corner Brook, Newfoundland
Installation: June to July 2025
PROJECT DETAILS
Distributor: EMCO Waterworks
Contractor: JCL Investments Inc.
Engineer: ANDERSON ENGINEERING CONSULTANTS LTD.
SITE CONDITIONS
Trench Depth: 10ft in some areas up to 32ft in other areas
Trench width: Roughly 40ft and in the deeper areas almost 60ft
Type of existing soil: Previous construction backfill with local topsoil
Backfill material: Class 1 Crushed Stone
Surface Material: Topsoil and Pavement
Concerns regarding pH: None
CONTEXT
A High-Stakes Culvert Rehabilitation Under a Steep, High-Velocity Stormwater Corridor
A major roadway in Corner Brook, Newfoundland required urgent rehabilitation of its aging stormwater infrastructure. The project site presented serious challenges, including a steep slope, high-velocity water flow, and trench depths reaching 32ft.
These demanding conditions excluded traditional materials like concrete, leading engineers to seek an advanced, customized solution.
CHALLENGES
An Engineered HDPE System Designed for Durability, Performance, and Precision
The primary goal of the project was to design a system capable of withstanding abrasive, fast-moving stormwater, while meeting the project’s structural and access specifications. Soleno’s KUSTOMFLO HDPE solution quickly emerged as the only viable option.
Its high-performance thermoplastic construction ensured resistance to abrasion, lightweight handling, and a watertight system — all critical for both safety and long-term performance.
SOLUTION
A Complete HDPE Solution — Pipe and Manholes, Made to Measure
Soleno delivered a fully customized system tailored to the terrain and flow conditions:
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- Two 60in diameter KUSTOMFLO™ culverts crossing the road
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- 86in diameter KUSTOMFLO™ outlet pipes designed to handle steep-grade discharge
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- Energy dissipation rings at the outlet to reduce flow velocity and prevent erosion
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- Four vertical manholes (two 21ft, 18ft, 17ft) fabricated in HDPE
- All manholes were equipped with aluminum ladders and safety platforms, meeting Newfoundland’s stringent stormwater access standards
The project highlighted KUSTOMFLO’s ability to integrate pipe and structure into one seamless system, eliminating the need for mixed-material installations.
Benefits
“KUSTOMFLO was the only system that could meet all requirements. Other solutions required combining components from multiple suppliers — not ideal for this complex site.”
Beyond being one of the first major projects in Atlantic Canada to use aluminum access platforms in stormwater structures, the Corner Brook Deep Gulch project proves that custom HDPE solutions like KUSTOMFLO are ideal for complex installations with high performance demands.
- Resistance to high-velocity water flow
- Lighter and easier to install compared to concrete (10–20x lighter)
- 75+ year lifespan, ensuring durability
- Custom fabrication for both pipes and manholes
Soleno, only manufacturer capable of providing a full HDPE solution
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MORE ABOUT KUSTOMFLO
Made to measure. Made to last.
KUSTOMFLO large HDPE pipes are known for their robust and tailor-made piping systems designed to meet specific project requirements. The ADAPTIVE design allows optimization of the pipe profile to align with precise needs of the project or applicable standards.
These HDPE pipes are engineered to customer specifications to optimize the performance of a flexible pipe. They offer versatility with hundreds of profile types and configurations with variable wall thickness, including solid wall, closed profile, and open profile options.
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