Deep Gulch: A challenging Culvert Rehabilitation project with KUSTOMFLO

Client : JCL
Sectors : Infrastructure, Commercial and Institutional
Products : KUSTOMFLO
Realization : 01/08/2025

CONTEXT

A High-Stakes 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 10 meters.

These demanding conditions excluded traditional materials like concrete, leading engineers to seek an advanced, customized solution.

CHALLENGES

An Engineered 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:

Two 1500 mm diameter KUSTOMFLO™ culverts crossing the road
2200 mm diameter KUSTOMFLO™ outlet pipes designed to handle steep-grade discharge
Energy dissipation rings at the outlet to reduce flow velocity and prevent erosion
Four vertical manholes (6.44 m, 6.47 m, 5.54 m, 5.18 m) 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.