850.01 Concrete Pipe.
d.Rubber Gaskets . Rubber gaskets shall be used on all round pipe joints. This material shall meet the latest requirements of ASTM C443 “Standard Specification for Joints for Concrete Pipe and Manholes Using Rubber Gaskets”. The material shall be installed per the manufacturer’s recommendations.
e.Other Types of Jo int Sealers . External wrap joint sealant meeting the Specifications noted in this Section may be used in addition to and combination with joint material as specified in Subarticle (a) above. This material if or when used shall meet the latest requirements of ASTM C877 “Standard Specification for External Sealing Bands for Concrete Pipe, Manholes, and Precast Box Sections”. The material shall be installed per the manufacturer’s recommendations. Other types of joint sealers or gaskets with proven satisfactor y performance records may be considered by the Department for use on individual contracts on a trial basis.
846.02 Flexible Pipe Sealers.
a.General . Connecting bands complying with the appropriate provisions of the type pipe being used may be considered as a satisfactory sealer provided the installation method provides a water tight joint for the full circumference of the joint, unless otherwise directed. Where a satisfactory joint seal cannot be obtained using only the connecting band, the joint shall be sealed by the use of gaskets designed for this purpose, mastic or other approved material. The producer of the sealant used in the joints shall furnish the Engineer with a certification showing the physical properties of the material and hydrostatic tests of joints sealed with his material.
b.Special Joints . If special joints or sealers are required, such will be designated by plan details. ROADWAY PIPE
850.01 Concrete Pipe.
a.General . Concrete pipe shall be reinforced circular or reinf orced arch concrete pipe. Circular concrete pipe shall comply with the requirements of AASHTO M 170, except that elliptical steel reinforcement will not be permitted unless such is permitted for special design pipe by details provided in the plans. Concret e arch pipe shall comply with the requirements of AASHTO M 206.
b.Special Design . When so permitted by the plans or in the proposal, pipe of designs other than those shown in the standard plans may be permitted; however, such pipe must meet performance a nd test requirements specified in AASHTO M 170 and shall be installed under the same specifications as circular pipe.
c.Classes of Pipe . Circular pipe and arch pipe shall be of the following classes, corresponding to AASHTO M 170 or AASHTO M 206 classes as tabulated herein. AASHTO CLASS ALDOT CLASS ABBREVIATION Class II Class 2 Reinf. Conc. Pipe Cl. 2 R.C. Pipe Class III Class 3 Reinf. Conc. Pipe Cl. 3 R.C. Pipe Class IV Class 4 Reinf. Conc. Pipe Cl. 4 R.C. Pipe Class V Class 5 Reinf. Conc. Pipe Cl. 5 R.C. Pipe Class II Class 2 Reinf. Conc. Arch Pipe Cl. 2 R.C. Arch Pipe Class III Class 3 Reinf. Conc. Arch Pipe Cl. 3 R.C. Arch Pipe Class IV Class 4 Reinf. Conc. Arch Pipe Cl. 4 R.C. Arch Pipe
850.02 Corrugated Steel Pipe.
d.Materials . Coarse aggregate, fine aggregate, cement, steel reinforcement, and water shall meet the requirements of AASHTO M 170 or M 206, whichever is applicable, except as modified in applicable Sections of Division 800, Materials.
e.Acceptance . All precast products furnished shall meet the requirements of Section 831.
f.Handling and Storage . Pipe shall be handled, transported, delivered, and stored in a manner that will not injure or damage the pipe. Pipe shall not be shipped before it has been inspected and approved. Pipe that is damaged during shipment or handling will be rejected even though satisfactory before shipment. Pipe dropped from platforms or vehicles or in the pipe trench will be rejected.
850.02 Corrugated Steel Pipe.
a.General . Corrugated steel pipe used in the constru ction of roadway culverts shall be either circular or arch pipe meeting the requirements of AASHTO M 36, for Type I, IR, or II culverts, the requirements noted in this Section, and the details shown in the plans. The pitch and depth of corrugations allowed by the AASHTO Specifications but not covered by plan details must be approved by the Department before use. Acceptance of pipe will be based on job site inspection for workmanship and compliance with fabrication requirements. A certificate of compliance f or each shipment as per AASHTO M 36 will not be required; however, a copy of the manufacturer's analysis of the sheets used in the manufacture of the pipe will be furnished. Corrugated steel roadway pipe shall have a protective coating and in most cases requires a paved invert. Certain secondary roads may use plain galvanized steel pipe. A paved invert will not be required in a Type IR pipe unless needed for abrasion resistance. When such is the case, the requirement for a paved invert in a Type IR pipe wil l be shown on the plans.
b.Fabrication . All pipes furnished under this Section shall be fabricated with circumferential corrugations and a riveted lap joint, or with helical corrugations and a continuous lock seam or welded seam, or helical ribs projecti ng outwardly with a continuous lock seam extending from end to end of each length of pipe. In addition, helical corrugated or helical ribbed pipe shall comply with the following:
1.Lock joints or seams shall produce a continuous water -tight seam parallel to the corrugations or ribs and as near as practical to the neutral axis of the corrugations or mid -point between ribs, for all sizes without perforations. The seam shall be so designed and fabricated as to develop strength and serviceability equal to that of riveted pipe of the same wall thickness.
2.Welded seams shall produce a continuous water -tight seam parallel to the corrugations and as near as practical to the neutral axis of the corrugations. The welding process shall be so controlled that the comb ined width of the weld and the adjacent spelter coat burned by the welding operation shall not exceed three times the thickness of the metal being joined. If the spelter is damaged outside the above specified width, the weld and the damaged area adjacent t o the weld shall be cleaned and treated as required by the appropriate Article of AASHTO M 36. A coating of rust on the base metal portions of the weld is not considered a defect. The welding process shall be such that the welded seam strength shall not be less than 70 percent of the base metal. The manufacturer of welded seam pipe shall submit a certified test report of his production testing that shows the production will meet the above noted weld strength requirements. One test will be reported for each day's production run with the test performed on the final joint produced for that day.
3.All ends of helical corrugated or helical ribbed pipe which are to be joined to other pipe with coupling bands shall be reformed to provide a minimum of two standard size circumferential corrugations.
850.02 Corrugated Steel Pipe.
c.Protective Coatings, Linings, and Paved Inverts .
1.General . Protective coating for corrugated metal round and arch pipe shall meet one of the requirements noted in this Article. Concrete linings for corrugated steel round pipe shall meet the requirements specified in Subarticle (d) of this Article. Paved inverts shall be formed by the addition of a smooth pavement in the invert of the pipe filling the corrugations for at least 25% of the circumference for a round pip e and 40% for an arch pipe. The pavement shall have a minimum thickness of 1/8 of an inch {3 mm} above the crest of the corrugations, except where the upper edges intersect the corrugations. In addition the following will be required for the manufacturer o f each length of coated pipe shipped to a project:
a.Each length of protective coated corrugated metal pipe shall have one section covered with duct tape for identification. This covered section shall include the heat number and metal thickness.
b.The section of pipe covered with duct tape shall be marked for easy location by project personnel.
c.Pipe that is not properly taped shall not be placed on a project until it has been sampled and tested by the Central Laboratory.
2.Coating. Bituminous coating shall meet the requirements of AASHTO M 190 for Type "A" Pipe. Polymeric coatings on precoated metal sheets meeting the requirements of AASHTO M 246 for Type "B" sheets may be used provided the pipe is fabricated so that the heavier coating is located on the inside of the pipe.
3.Paved Inverts . Paved inverts for bituminous coated pipe shall conform to the requirements of AASHTO M 190 for Type "C" Pipe. Paved inverts for pipe formed from precoated metal sheets shall be compatible with the coating material , capable of providing an acceptable bond with coating material and otherwise meeting the same basic test requirements of Section 5 of AASHTO M 190.
4.Concrete Lining . Concrete lined pipe shall be bituminous coated on the outside as outlined in Item 2 abo ve. Although not required, bituminous coating of the inside of the pipe will be permitted. Concrete for the lining shall be composed of cement, fine aggregate, and water that are well mixed and of such consistency as to produce a dense, homogeneous, non -segregated lining. The cement shall be Portland cement, Type II, conforming to AASHTO M 85. Aggregate shall conform to the requirements of AASHTO M 6 except the sections on gradation and uniformity of gradation. 100% of the aggregate shall pass the No. 4 {4. 75 mm} sieve with not more than 10% passing the No. 200 {75 µm} sieve. The concrete used as lining shall have a minimum 28 day compressive strength of 5000 psi {35 MPa} when tested in accordance with AASHTO T 22. The concrete lining shall be applied in one or more courses by a machine traveling through the pipe and discharging the concrete over stationary pipe sections. The rate of travel of the machine and the rate of concrete discharge shall be regulated so as to produce a homogeneous, non -segregated lining throughout. The lining machine shall be equipped with attachments for mechanically troweling the concrete lining. The trowel attachment shall be such that the pressure applied to the lining will be uniform and shall produce a lining that has a uniform t hickness and a smooth surface. The concrete lining thickness shall be 3/8 inch + 1/8 inch {10 mm + 3 mm} over the inside crests of the corrugations. The manufacturer shall submit certifications stating the gage of the pipe and that the cement, aggregate, a nd the lining itself all comply with the above specifications. Random samples of the cement, aggregate, and cylinders made from the lining mixture shall be submitted on request of the Department. If cylinders are required, they shall be made from the last batch mix of the day's operation. Either standard rodded cylinders or cylinders compacted and cured in the same manner as the pipe lining will be acceptable. The minimum average 28 day compressive strength of cylinders tested from any one batch shall be 50 00 psi {35 MPa}.
850.03 Corrugated Aluminum Pipe.
d.Connecting Bands . Connecting bands shall be made of material conforming to AASHTO M 218 or to AASHTO M 274 depending on the type of metallic coat on the pipe. All bands shall have a minimum of two circumferential corrugations which sha ll effectively engage the second, as a minimum, circumferential corrugated valley from the end of each pipe. Connecting bands shall be no more than three nominal sheet thicknesses lighter than the thickness of the pipe to be connected but in no case lighter than 17 gage. Bolts and nuts for connecting bands, furnished in sufficient sizes and numbers to adequately perform the intended function, shall conform to the requirements of ASTM A 307. Band connection hardware consisting of bolts, nuts, bars, and rivet s shall be galvanized in accordance with the requirements of AASHTO M 232 or be coated by the electroplating process as provided in ASTM B 633 Class Fe/Zn 8. Protective coatings for connecting bands shall be the same as used on the pipes which are being connected and shall meet the appropriate requirements for such noted in Subarticle (c) above.
e.Blank .
f.Handling and Storage . Pipe shall be handled, transported, delivered, and stored by methods that will not damage the pipe or bituminous coating, and with the paved invert at the bottom of the pipe. Any pipe damaged or bent will be rejected even though previously inspected and found satisfactory, and shall be replaced or repaired at the Engineer's option, without additional compensation. Damaged coating or paving shall be repaired in a manner satisfactory to the Engineer using approved materials.
850.03 Corrugated Aluminum Pipe.
a.General . Corrugated aluminum pipes used in the construction of roadway culverts shall be either circular or arch pipe meet ing the requirements of AASHTO M 196 except as provided in this Article or shown on the plans. The pitch and depth of corrugation allowed by the AASHTO Specifications but not covered by plan details must be approved by the Department before use. Acceptance of pipe will be based on job site inspection for workmanship and compliance with fabrication requirements. A certificate of compliance for each shipment as per AASHTO M 196 will not be required; however, a copy of the manufacturer's analysis of the sheets used in the manufacture of the pipe shall be furnished. For correlation of the specified plate thickness of corrugated metal pipe, and aluminum sheet thickness shown in the detailed plans, the following shall apply: Aluminum Sheet Thickness (Nom inal) Table 3 AASHTO M 197 Specified Culvert Sheet Thickness (Nominal) Table 4 AASHTO M 218 0.060 inches {1.5 mm} 0.064 inches {1.6 mm} 0.075 inches {1.9 mm} 0.079 inches {2.0 mm} 0.105 inches {2.7 mm} 0.109 inches {2.8 mm} 0.135 inches {3.4 mm} 0.138 inches {3.5 mm} 0.164 inches {4.2 mm} 0.168 inches {4.3 mm} NOTE: Minimum acceptable aluminum sheet thickness 0.060 inches {1.5 mm}. Tolerances for aluminum sheet thickness noted in Table 1 AASHTO M 197 shall apply.
b.Fabrication . All pipe furnished under this Article shall be fabricated with circumferential co rrugations and a riveted lap joint or with helical corrugations and a continuous lock seam or welded seam extending from end to end of each length of pipe provided the seams and ends of the pipe comply with the additional requirements of paragraph 2 of Subarticle 850.02(b).
c.Bituminous Coating and Paved Invert. Bituminous coatings and paved inverts shall comply with the requirements of Subarticle 850.02(c).
d.Connecting Bands . The width and design of connection bands shall be as noted in AASHTO M 196 with the pitch and depth of corrugations, etc. consistent with the type corrugations of the pipe being used. Bituminous
850.03 Corrugated Aluminum Pipe.
coating for use with bituminous coated pipe and pipe arches shall conform to the appropriate requirements of AASHTO M 190.
e.Handling and Storage . Handling and storage shall meet the requirements of Subarticle 850.02(f). SECTION 851 SIDE DRAIN PIPE
851.01 Concrete Pipe.
a.General. Concrete pipe shall be reinforced circular or reinforced arch concrete pipe except that pipe 24 inches {600 mm} or less in diameter, and equivalent size arch pipe, may be plain concrete provided the pipe meets all other requirements of this Article.
b.Special Design. When so permitted by the plans or in the proposal, pipe of designs other than thos e shown in the standard plans may be permitted; however, such pipe must meet the performance and test requirements specified, for AASHTO M 170 and shall be installed under the same specifications as circular pipe.
c.Classes of Pipe.
1.Plain Concrete Pip e (PC). Only plain concrete pipe 24 inches {600 mm} or less in diameter (or equivalent area in arch pipe) will be permitted. Circular pipe shall meet the requirements for Class 2 pipe of AASHTO M 86 or for Class II of AASHTO M 170 without steel reinforcement, provided the same strength requirements for the same size pipe provided in AASHTO M 86 for Class II pipe are met. Arch pipe equivalent to a 24 inches {600 mm} diameter round pipe or less shall meet the requirements for Class A -II of AASHTO M206 withou t steel reinforcement provided the same strength requirements of the equivalent size circular pipe provided in AASHTO M86 for Class 2 pipe are met.
2.Reinforced Concrete Pipe (RC). Circular pipe shall meet the requirements of AASHTO M 170 for the class of pipe designated by the plans. Arch pipe shall meet the requirements of AASHTO M 206 for the class of pipe designated by the plans.
d.Materials. Coarse aggregate, fine aggregate, cement, steel reinforcement, and water shall meet the requirements of AASHT O M 170 or M 206, whichever is applicable except as modified in applicable Sections of Division 800, Materials.
e.Tests. All precast products furnished must meet the requirements of Section 831, Precast Concrete Products.
f.Handling and Storage. Handli ng and storage shall meet the requirements of Subarticle 850.01(f).
851.02 Corrugated Steel Pipe (CS).
CS used in the construction of side drain culverts shall be either circular or arch pipe meeting the requirements of Article 850.02, except that most side drain pipe may use plain galvanized steel pipe.
851.03 Corrugated Aluminum Pipe (CA).
CA used in the construction of side drain culverts shall be either circular or arch pipe meeting the requirements of Article 850.03.
Source: Alabama Standard Specifications for Highway Construction, 2022 Edition. Pages 768–771 of 934.