Project Summary
Gregory County replaced a failing culvert near Burke, South Dakota, with three 120-inch corrugated steel pipes and prefabricated metal headwalls. The new system restored hydraulic functionality while reducing construction time and improving long-term roadway resilience.
When a Shipping Container Becomes a Culvert
Not every infrastructure problem begins with a conventional structure. Along County Road 27 near Burke, South Dakota, Gregory County faced an unusual challenge: a deteriorating culvert constructed from a repurposed shipping container.
Although the improvised structure had served its purpose for a time, it could no longer meet the roadway’s structural and hydraulic demands. The county needed a replacement capable of accommodating heavy vehicle loading while providing reliable drainage and meeting modern engineering standards.
However, performance was only part of the equation. Gregory County also needed a solution that could be installed efficiently without extending the construction schedule.
Working with engineering firm Ulteig, the county evaluated replacement options that would eliminate the need for traditional cast-in-place concrete headwalls. The team ultimately selected a triple-barrel corrugated steel culvert with prefabricated metal headwalls and wingwalls.
Manufactured by Contech Engineered Solutions, the system combined large-diameter corrugated steel pipe with an engineered headwall design. This approach addressed the county’s structural requirements while simplifying construction.
Engineering a Triple-Barrel Solution
Replacing the deteriorating shipping container required more than installing a new drainage pipe. The project team needed a structure that could provide sufficient hydraulic capacity while supporting modern highway loading.
The selected design incorporated three 120-inch-diameter corrugated steel pipes, each measuring 68 feet long. Together, the three barrels provided 204 linear feet of 10-gage corrugated steel pipe.
The triple-barrel configuration provided the hydraulic capacity required for the crossing while distributing loads efficiently beneath the roadway.
For rural transportation infrastructure, this combination of structural performance and drainage capacity is essential. County roads must accommodate heavy vehicles while maintaining reliable water conveyance beneath the roadway.
Large-diameter corrugated steel pipe systems provide engineers with flexible design options for crossings where hydraulic requirements call for multiple openings.
In Gregory County, the engineered steel system replaced an unconventional structure with infrastructure specifically designed for its intended application.
The project also demonstrates how corrugated steel can accommodate substantial roadway drainage requirements without sacrificing installation efficiency.
Prefabrication Makes the Difference
While the triple-barrel configuration addressed hydraulic and structural requirements, the headwall design played an equally important role in the project’s success.
Traditional cast-in-place concrete headwalls would have required several construction stages, including forming, reinforcing, pouring, and curing. Those activities would have added labor and time to the project.
Instead, the team selected a prefabricated steel headwall and wingwall system designed for multi-barrel culvert installations.
The structural components arrived ready for assembly, significantly reducing the amount of work required in the field. Installation crews needed only to join the pipe midsections to complete the culvert lengths.
This approach eliminated concrete curing delays while minimizing heavy forming operations and reducing on-site labor.
For contractors, these advantages can translate into more predictable construction schedules and fewer activities that must be completed before subsequent work can proceed.
The prefabricated system also provided the structural continuity and stability required for the completed culvert.
In this case, the steel headwall system offered the fastest installation among the alternatives considered by Gregory County.
The project highlights an important benefit of steel drainage infrastructure: prefabricated components can help simplify construction while maintaining the structural performance required for demanding roadway applications.
A Successful Installation Along County Road 27
With the design finalized, Sjolie Construction completed the installation in August 2025.
The finished crossing featured three large-diameter corrugated steel barrels integrated with prefabricated metal headwalls and wingwalls. Together, the components formed a fully engineered drainage structure beneath County Road 27.
The streamlined installation helped Gregory County maintain its project schedule while replacing the deteriorating culvert.
County officials were pleased with the construction process and the resulting infrastructure improvements.
Gregory County Highway Superintendent Bob Nelson commented:
“The construction for this project went well. If another project comes up requiring a headwall solution, I will be sure to consider a CHS™ solution again.”
The successful installation demonstrates how thoughtful design and prefabricated steel components can help municipalities address infrastructure challenges efficiently.
Rather than relying on extensive field construction, the project team used manufactured components to simplify assembly and reduce installation time.
For county highway departments responsible for maintaining rural transportation networks, these efficiencies can be particularly valuable when planning culvert replacement projects.
Built for Long-Term Roadway Performance
The County Road 27 project transformed an improvised drainage crossing into a modern, engineered culvert system.
By replacing the deteriorating shipping container with three 120-inch corrugated steel pipes, Gregory County restored hydraulic functionality and improved roadway safety and resilience.
The integrated metal headwalls and wingwalls provide structural stability, while the corrugated steel barrels are engineered to withstand modern highway loading.
Equally important, the prefabricated design allowed the county to achieve these improvements without the additional construction time associated with cast-in-place concrete headwalls.
The project illustrates how corrugated steel pipe can help communities balance infrastructure performance, installation efficiency, and long-term reliability.
For Gregory County, the result is a durable drainage crossing designed to support County Road 27 and the surrounding community for years to come.