Part 14 Corrugated Metal Pipe Culverts

CIVIL ENGINEERING

STANDARD SPECIFICATION

PART NO: 14ISSUE: Initial

DATE: 21.07.93PAGE: 1 of 6

CORRUGATED METAL PIPE CULVERTS

ISSUE DATE DESCRIPTION/REASON

Initial 21.07.93

AUTHORISED BY: DATE:

CIVIL CONTRACTS MANAGER

© QR

This document is copyright and may not be copied or reproduced in any way without the approval of the Manager Civil Engineering.

The information contained in this document is the property of QR and may not be used by any party without the express approval of the Manager Civil Engineering.

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ISSUE: Initial Corrugated Metal Pipe CulvertsDATE: 21.07.1993 of 6

TABLE OF CONTENTSPage

14.1 SCOPE......................................................................................................................................... 3

14.2 PREPARATION OF FOUNDATIONS............................................................................................3

14.3 SELECTED GRANULAR FILL.....................................................................................................3

14.4 CORRUGATED METAL PIPES....................................................................................................3

14.5 COATING OF PIPE DRAINS........................................................................................................4

14.6 CONCRETING OF INVERT..........................................................................................................4

14.6.1 Extent of Concreting..................................................................................................414.6.2 Surface Preparation...................................................................................................414.6.3 Reinforcement...........................................................................................................414.6.4 Concrete....................................................................................................................414.6.5 Concrete – Pipe Joint.................................................................................................414.6.6 Protection of Finished Concrete.................................................................................4

14.7 HEADWALLS AND APRONS.......................................................................................................4

14.8 SCHEDULE OF QUANTITIES AND PRICES................................................................................5

APPENDIX 14A – QUALITY REQUIREMENTS...........................................................................................6

QR - Civil Engineering Standard Specification Part 14


14.1 SCOPE

This part of the Specification includes the supply and erection of corrugated steel pipe and associated works required to construct such culverts in accordance with the Drawings and, unless otherwise specified, in accordance with AS2041 and AS2042 (Corrugated metal pipes) or AS1761 and AS1762 (helical lock-seam corrugated steel pipes), as applicable.

14.2 PREPARATION OF FOUNDATIONS

The ground surface shall be trimmed to provide a foundation of the grading, width and depth indicated on the Drawings or as directed by the Superintending Officer. Any low spots shall be filled with select backfill in accordance with Part 5 of this Specification to conform with this profile.

Selected bedding material shall be of a fine granular nature, free of sod, boulders or rocks, and shall be provided to form an earth cushion having a minimum thickness of 75mm under the corrugated multi plate steel pipe. Where rock is exposed in the excavation, the thickness of this cushion shall be increased to 250mm or 0.25 times the nominal diameter, whichever is less. The bedding surface shall be true to line and grade as established by the Superintending Officer and shall provide a firm foundation of uniform density throughout the entire length of the pipe. The bedding shall be accurately shaped and rounded to conform to the outside circular shape of the pipe for its entire length and be of sufficient width to permit efficient compaction of the fill under the haunches of the pipe. The bedding shall be tamped to provide uniform, firm support for the pipe. A uniform blanket of loose granular material of 12mm maximum aggregate size shall cover the shaped bedding to a depth sufficient to allow the corrugations to become filled with the material.

14.3 SELECTED GRANULAR FILL

In the embankment adjacent to the corrugated metal pipe culverts and within the limits shown on the Drawings, selected granular fill shall be provided. Such material may be from excavation or borrow and shall be free from large lumps, clods, vegetable matter, stone larger than 75mm in size, or other objectionable materials. The selected material shall have a pH 6 - 10 and a minimum resistivity of 3000 ohm. - cms., except that for pH 6.5 - 7.5, no minimum resistivity is specified.

The Contractor shall forward to the nearest Queensland Department of Transport, Roads Division, District Soils Laboratory, samples of material proposed for selected granular fill, not less than 50kg in each sample, for examination and testing. No material shall be placed as selected granular fill until the Contractor has received written approval from the Manager Civil Engineering that the material is acceptable.

The material shall be uniformly spread in layers longitudinally, (not exceeding 150mm in compacted depth), simultaneously on both sides of the pipe for the full length of the pipe, and shall be compacted by rolling parallel with the pipe or by tamping or ramming. Compaction shall continue until a density of 90% of the maximum dry density of the material as determined by the Modified Compaction Test, according to AS1289.E2.1, is obtained. Special care shall be taken to ensure thorough compaction of the fill under the haunches of the pipe. Compaction to this standard shall extend to the limits indicated on the Drawings, beyond which the embankment construction shall proceed as specified in Part 6 of this Specification.

Care shall be exercised during the filling and compacting operations to avoid disturbance to the line and joints of the pipes. Any damage to the pipe shall be repaired by the Contractor to the satisfaction of the Superintending Officer.

14.4 CORRUGATED METAL PIPES

All pipes shall be of corrugated steel and shall comply in all respects with AS 2041 or AS 1761 as applicable. Steel plates shall be of the thicknesses shown in the Drawings for the individual culverts. All steel plates, bolts, nuts and washers shall be galvanised.

The reinforcement fabric incorporated in the concrete invert protection shall be welded to the assembly bolt nuts at the spacings shown on the Drawings. When assembly bolts do not meet the required spacing, "dummy" bolts of 20mm diameter shall be installed to provide the required minimum spacing.

The pipes shall be erected in accordance with AS2042 or AS1762, as applicable, and to the manufacturer's specifications and recommendations and shall be located and graded in accordance with the Drawings or as directed by the Superintending Officer. No pipe shall be laid except in the presence of the Superintending Officer who shall inspect each section before it is laid. Defective sections shall be replaced.



Care shall be exercised in handling structural plate to avoid damage to the galvanic protective coatings and any damage to such coatings shall be immediately and adequately corrected by painting with two coats of approved cold galvanic paint.

14.5 COATING OF PIPE DRAINS

The corrugated multi-plate steel in the case of bolted pipes, or the pipes in the case of riveted pipes, shall be supplied in a galvanised condition. After erection, the pipes shall be covered externally with three coats of "DENSO DIMET Alumastic" protective mastic coating, applied strictly in accordance with the manufacturer's specifications. All surfaces shall be thoroughly cleaned and well dried before application of coatings. Exterior surfaces of bottom plates inaccessible after placement shall be coated prior to placement. The total thickness of the coatings shall be 0.75mm.

14.6 CONCRETING OF INVERT

14.6.1 Extent of Concreting

Concrete shall be placed in the inverts of the pipes in accordance with the Drawings. Concreting shall not be carried out until all filling material has been placed and consolidated above the pipes.

14.6.2 Surface Preparation

All foreign material shall be removed from the surface to be paved and, where corrosion has occurred, all loose scale shall be removed with wire brushes to the satisfaction of the Superintending Officer. Immediately before placement of the concrete, all free water shall be removed and the surface flushed with a mortar made of the standard concrete mix by elimination of the coarse aggregate fraction.

14.6.3 Reinforcement

The invert shall be reinforced with a single layer of fabric F42. Cover to fabric shall be 25mm minimum. The reinforcing fabric shall be securely fastened to the bolts as indicated on the Drawings. Such fastening shall be spaced as shown on the Drawings. All laps in fabric shall be in accordance with Part 7 of the Specification. The fabric shall be folded under upstream and downstream lips of the structure at least 300mm and embedded in concrete. Fabric shall extend to within 125mm of edges of concrete on each side.

14.6.4 Concrete

Concrete shall be Grade N20 in accordance with Part 7 of the Specification. The concrete shall not be vibrated but shall be sufficiently compacted and tamped to eliminate large voids and shall be finished in a workmanlike manner.

14.6.5 Concrete – Pipe Joint

A groove of the dimensions shown on the Drawings shall be cast along the entire length of invert protection and be filled with "Tremco Polyroof TM" one-part roof elastomer or an approved equivalent.

14.6.6 Protection of Finished Concrete

No water should be allowed to flow over the surface of the inverts for twelve hours after placement of the concrete and heavy flow shall be diverted to the satisfaction of the Superintending Officer for at least 48 hours.

14.7 HEADWALLS AND APRONS

Headwalls and aprons shall be provided to the extent shown on the Drawings or as ordered by the Superintending Officer.

Headwalls of culverts with skew numbers between 70 and 110 shall be 100mm thick concrete, reinforced with a single layer of F62 fabric centrally placed, or alternatively stone pitching may be used in accordance with Part 6 of the Specification.

Headwalls of culverts with skew numbers less than 70 or greater than 110 shall be 225mm thick concrete, reinforced with a single layer of F102 fabric centrally placed. Hook bolts shall be installed at 300mm centres around the ends of such pipes and shall be bent before fitting so that they align with the headwall.

Concrete and reinforcing steel shall be in accordance with Part 7 of this Specification.

Weepholes shall be provided in headwalls at spacings of 1,500mm both horizontally and vertically with the bottom row of weepholes 600mm above natural ground level. Weepholes shall be 50mm in diameter and a reverse filter of granular material approximately 300mm cube shall be placed behind each weephole. The pocket of granular material shall extend a distance of 75mm below the lower edge of each weephole.

All inlet and outlet aprons shall be 100mm thick concrete reinforced with one single layer of F62 fabric centrally placed and shall extend a distance



equal to the diameter of the largest pipe in the culvert, from the toe of the embankment. Cut off walls 600mm deep reinforced as for the aprons shall be provided around the edges of the aprons. Where approved by the Manager Civil Engineering, grouted stone pitching in accordance with Part 6 of the Specification, revetment mattresses, 230mm thick, may be used in lieu of concrete aprons.

Where shown on the Drawings or where directed by the Superintending Officer, the stream bed shall be excavated beyond the downstream apron for a distance equal to the diameter of the largest pipe in the culvert, to a depth of 600mm, and the excavation filled with dumped rock or "floodstone". This rock shall consist of sound igneous or metamorphic rock of maximum size 600mm cube and average size of not less than 300mm cube. The rock shall be dumped into place and worked into position by machines so that the spaces between the larger rocks are filled with smaller spalls and the top surface shall be shaped to the line and level of the surrounding ground and apron.

14.8 SCHEDULE OF QUANTITIES AND PRICES

Excavation for foundations (including inlets and outlets) and select backfill shall be measured and paid for at the relevant Schedule Unit Prices per cubic metre.

Headwalls and aprons will be measured and paid for at the Schedule Unit Prices per square metre, which shall include all costs associated with excavating below the level of the final top surface of the concrete and the supply, placing and finishing of all concrete and reinforcing steel. No separate payment will be made for apron cut-off walls which shall be included in the Schedule Item for aprons.

The Schedule item for construction of the corrugated metal pipes shall include the costs of erection, coating of the pipes, supply, placing and compaction of selected bedding material and selected granular fill and all other incidental costs associated with the construction of the culvert in accordance with the Drawings and this Specification.

The Schedule item for the concreting of the inverts of the pipes shall include the costs of all materials and work necessary to complete the work specified in accordance with the Drawings and this Specification.

Dumped rock or "floodstone" will be measured and paid for at the Schedule Unit Price per cubic metre, which shall include all costs associated with excavating as specified and supplying, delivering, dumping and working the rock into place in accordance with the Drawings and this Specification.



APPENDIX 14A – QUALITY REQUIREMENTS

Table 1 : Process requirements for documented construction procedures, lot identification and traceability

PROCESS CONSTRUCTION PROCEDURE LOT IDENTIFICATION TRACEABILITY

Supply & Deliver Required 7 days prior to manufacture As per Supplier Quality Plan As per Supplier Quality Plan

Installation Required 7 days prior to use One Culvert = 1 lot Material source to bedding/backfill

End Structures Required 7 days prior to use Once concrete pour = 1 lot Batch plant to concrete pour lot

Table 2 : Authority and responsibility for specified inspection/approval points

PROCESS ACTIVITY INSPECTION POINT REFERENCE

CLAUSE

LEVEL OF

INSPECTION

RESPONSIBILITY FOR

INSPECTION

Supply & Deliver

Installation Bedding Prior to laying metal pipe culverts 14.2 Hold Point Superintending Officer

Backfill Material Prior to use of backfill material in Works

14.3 Hold Point Manager Civil Engineering

Laying During laying of each pipe section 14.4 Witness Superintending Officer

Repairs After repair of damage to pipes 14.3 Hold Point Superintending Officer

Concrete Invert After surface preparations and prior to concreting

14.6 (ii) Hold Point Superintending Officer

Prior to protecting invert against water flow after placement of concrete

14.6 (vi) Witness Superintending Officer

End Structures ConcreteAs per PART 7 – CONCRETE

Slope Protection

As per PART 6 - EARTHWORKS

Table 3 : Minimum inspection and test requirements

PROCESS ACTIVITY QUALITY VERIFICATION REQUIREMENT REFERENCE CLAUSE

MINIMUM TEST FREQUENCY

MINIMUM REQUIREMENT

DESCRIPTION TEST REQUIRED

Supply & Deliver

Installation Backfill Material

Source Assessment One 50 kg sample 14.3 1 per M.S. 1 per M.S.

Grading AS 1289.C6.1 14.3 1 per 200 m³ 1 per M.S.

Acidity (pH) QDOT Q121

Resistivity QDOT122A

Backfilling Compaction AS 1289.E2.1 14.3 As required 1 per M.T.

AS 1289.E3.1 1 per 100 m³ 1 per lot

End Structures ConcreteAs per PART 7 – CONCRETE

Slope Protection

As per PART 6 - EARTHWORKS

M.D.R. = Moisture/Density Relation, F.D.D. = Field Dry Density, M.T. = Material Type, M.S. = Material Source


Part 14 Corrugated Metal Pipe Culverts

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