606.01 Description. This item shall consist of the construction
of pipe culverts, flared end sections for pipe culv erts, and safety end sections for pipe culverts according to these speci fications; of the type, size, and dimensions shown on the plans; and in conformity with the locations, lines, and grades shown on the plans; or as directed. For side drains, when the type is not specified on the plans, the Contractor may furnish any of the types listed in S ubsection 606.02 provided that only one type and material shall be u sed for all side drains on the project. In addition, when circular pipe is specified for a side drain the Contractor may, at no additional c ost to the Department, substitute an arch pipe providing the e quivalent waterway.
606.02 Materials. Materials and design requirements for the
several types of pipe culverts and flared end secti ons shall comply with the following:
a.All Pipe and Flared End Sections. All pipe, flared end sections, precast curtain walls, preformed gaskets, and other accessories shall be furnished from those sources l isted on the QPL. 422 The Contractor shall furnish the Engineer an itemiz ed statement of the sizes and lengths of culvert pipe in each sh ipment. A field inspection will be made by the Engineer. This insp ection will include an examination of the culvert pipe for nomi nal specified diameter, net length of finished culvert pipe, cond ition of pipe, and any evidence of poor workmanship. The inspection m ay include an examination for deficiencies in lengths of sheets u sed and a check of the brand name and heat numbers.
b.Reinforced Concrete Pipe. The pipe may be of either bell and spigot or tongue and groove unless one type is specified on the plans or is required to extend an existing culvert. Tests shall be conducted according to AASHTO T 280.
1.The manufacture and furnishing of circular pipe sha ll be according to the provisions of AASHTO M 170 with a minimum B wall thickness.
2.The manufacture and furnishing of arch shaped pipe shall be according to the provisions of AASHTO M 206.
3.The manufacture and furnishing of horizontal ellipt ical pipe shall be according to the provisions of AASHTO M 207.
4.Joints shall be sealed with either preformed rubber gaskets or bitumen/butyl rubber plastic gaskets complying w ith AASHTO M 198 or with tubular cross-section closed c ellular rubber gaskets complying with the physical requirem ents of ASTM D 1056 (Type 2, Class C, Grade 1) and meeting the chemical requirements of AASHTO M 198. When a primer is recommended by the manufacturer to be used with the gasket, the material in the primer sh all comply with the requirements as specified by the manufacturer. When Reinforced Concrete Arch Pipe is specified, Re inforced Concrete Horizontal Elliptical Pipe of equivalent s ize may be substituted unless Arch Pipe is required to extend an existing culvert.
c.Corrugated Metal Pipe and Arch Pipe. Each end of individual metal pipe sections, 12" (300 mm) or equ ivalent diameter and larger, shall be reformed so as to have not les s than two annular 423 corrugations. Metal pipe shall comply with the fol lowing requirements:
1.Zinc Coated (Galvanized) Corrugated Steel Pipe. The manufacture and furnishing of zinc coated (galvaniz ed)corrugated steel pipe shall be according to AASHTO M 36 and M 218.
2.Aluminum Coated Corrugated Steel Pipe. The manufacture and furnishing of aluminum coated corru gated steel pipe shall be according to AASHTO M 36 and M 274.
3.Aluminum-Zinc Alloy Coated Corrugated Steel Pip e. The manufacture and furnishing of aluminum-zinc all oy coated corrugated steel pipe shall be according to AASHTO M 36 and AASHTO M 289.
4.Corrugated Aluminum Pipe. The manufacture and furnishing of corrugated aluminum pipe shall be acc ording to AASHTO M 196 or M 197.
5.Asphalt Coated Corrugated Metal Pipe. The manufacture and furnishing of asphalt coated corrug ated metal pipe shall be according to AASHTO M 190, Type A.
6.Polymer Precoated Metallic Coated Corrugated St eel Pipe Culverts. The manufacture and furnishing of polymer precoated metallic coated corrugated steel pipe cul verts shall comply with AASHTO M 245. The metallic coating sha ll comply with the applicable requirements of AASHTO M 218 or M 289 for zinc or aluminum-zinc alloy coating. The sheets shall have a polymeric coating of 0.010" (250 µm) minimum thickness on each side after corrugation.
7.Smooth Lined Polymer Precoated Metallic Coated Corrugated Steel Pipe shall comply with AASHTO M 245, AASHTO M 246, and AASHTO Specifications for Highway Bridges, except as follows:
a.The minimum acceptable steel sheet thickness fo r the outer corrugated shell shall be 0.046 ″ (1.17 mm).
b.Both the outer corrugated shell and smooth inne r liner shall have a standard 2 oz./sq. foot (610 g/sq m) coating of zinc 424 (1 oz./sq foot [305 g/sq m] per side) and be precoa ted 10 mils (250 µm) on each side with a polymer precoated laminate.
c.The pipe ends shall be reformed in such manner as to seal the outer shell and liner together to protect the e nds from damage. The band coupler for connecting pipe ends shall have a minimum of 2 corrugations and be a minimum of 12 ″ (300 mm) wide.
d.Plastic Pipe.
1.Polyethylene Pipe. The manufacture and furnishing of polyethylene pipe shall be according to AASHTO M 29 4, Type S. Polyethylene pipe shall have a corrugated outer she ll with an essentially smooth wall waterway. Couplings and fi ttings supplied or recommended by the pipe manufacturer sh all be used.
2.PVC Pipe. The manufacture and furnishing of PVC pipe shall be according to AASHTO M 304. PVC pipe shall have annular or helical projections or ribs on the outer surface and an essentially smooth wall waterway. Couplings and fi ttings supplied or recommended by the pipe manufacturer sh all be used.
e.Flared End Sections for Pipe Culverts. The manufacture and furnishing of flared end sections for pipe culv erts shall comply with Subsection 606.02(b) for concrete pipe and Subsection 606.02(c) for metal pipe. The flared en d sections shall be of the same material as the culvert pipe for a g iven installation except that Zinc Coated, Aluminum Coated, or Alumin um-Zinc Alloy Coated Corrugated Steel Flared End sections m ay be used with any Corrugated Steel Pipe. Reinforced concrete flared end sections for circula r, arch, or elliptical pipe shall comply with the applicable re quirements for Class II or higher classes of pipe. The area of re inforcing for circular pipe flared end sections shall be accordin g to the requirements for elliptical reinforcing for Class I I pipe for the appropriate wall thickness. Concrete for curtain walls shall comply with Sectio n 802 for Class M concrete. Reinforcing steel for curtain walls shall comply wi th Section 804. 425 In lieu of constructing concrete curtain walls in p lace, the Contractor may elect to precast the units. Precast units shall comply with all applicable requirements of Subsection 606. 02(b) for concrete pipe. Flared end sections for corrugated steel circular o r arch pipe shall be fabricated from steel sheets having a thickness of 0.064" (1.63 mm) or more. Flared end sections for corrugated aluminum circula r or arch pipe shall be fabricated from aluminum sheets having a t hickness of 0.060" (1.5 mm) or more.
f.Coupling Bands. Except as otherwise required herein, coupling bands and other hardware for corrugated me tal pipe shall comply with the requirements of AASHTO M 36 for ste el pipe and M 196 for aluminum pipe. Coupling bands shall be m ade of the same base metal and coating (metallic or otherwise) as the pipe. Band widths shall be as specified in AASHTO M 36 an d M 196. Pipes shall be field jointed with corrugated lockin g bands. This includes pipe with helical corrugations that has re formed annular corrugations on the ends. Helical pipe without annular end corrugations will be permitted only when it is necessary to join a new pipe to an existing pipe that was installed with no annular end corrugations. In this event pipe furnished with helical corrugations at the ends sha ll be field jointed with either helically corrugated bands or with band s with projections (dimples). Bands with projections shall have circumferential r ows of projections with one projection for each corrugatio n. Unless otherwise shown on the plans, all bolts for coupling bands shall be 1/2" (12 mm) diameter. Bands 15" (380 mm) wide or less shall have a minimum of 2 bolts and bands greater t han 15" (380 mm) wide shall have a minimum of 3 bolts.
g.Selected pipe bedding shall consist of silty loam, loam, sand, or other similar material free from lumps, clods, a nd rocks.
h.Selected pipe backfill shall comply with the requir ements established by the Engineer. 426 (i) Structural Bedding for Reinforced Concrete Pipe Cu lverts shall be as shown in the plans for the specified in stallation type.
j.Structural Bedding and Structural Backfill for Cor rugated Metal Pipe Culverts shall meet the requirements for SM-3 material as shown in Subsection 302.02 of these specificatio ns or for Aggregate Base Course Classes 4, 5, 6, or 7, as sho wn in Subsection 303.02.
k.Structural Bedding and Structural Backfill for Pla stic Pipe Culverts shall meet the requirements for SM-3 mater ial as shown in Subsection 302.02 of these specifications except th at the maximum particle size shall be 1¼ ″ (31.5 mm) for Structural Bedding and 1½ ″ (37.5 mm) for Structural Backfill.
l.Safety End Sections for Pipe Culverts. The manufacture and furnishing of safety end sections for pipe culv erts shall comply with Subsection 606.02(c) (1) and the details shown in the plans.
606.03 Construction Requirements. (a) Depth of Exca vation.
Excavation shall be carried to a depth where founda tion materials are satisfactory to the Engineer regardless of the elevations shown on the plans, and foundations shall be inspected an d approved before placing any part of the structure. Unless otherwis e provided, soft or yielding material below the bottom of the specified pipe bedding shall be removed and replaced with a suitable mater ial. Pipe culverts under the roadbed shall be so placed that the minimum depth of cover at the subgrade shoulder for pipe of any diameter or type shall be not less than one foot (0 .3 m).
b.Forming Bed for Pipe. Where the pipe is to be laid below the ground line, a trench shall be excavated to the required depth and to the minimum width practicable for working condit ions. Structural bedding shall be placed and compacted as shown in the plans. For Reinforced Concrete Pipe Culverts using bell and spigot pipe, recesses shall be excavated to receive the be lls. Where unsuitable material exists at the bottom of the exc avated trench, the unsuitable material will be excavated and replaced with selected pipe bedding, which shall be compacted thoroughly i nto place with mechanical equipment. Where rock is encountered, t he trench shall be excavated to a minimum depth as shown on the pla ns and 427 backfilled with suitable material, which shall be t amped thoroughly with mechanical equipment. Where pipe is not laid in a trench, structural pipe bedding shall be placed as shown in the plans.
c.Laying Pipe. The pipe laying shall begin at the downstream end and bell or groove ends of concrete pipe and ou tside circumferential laps of corrugated metal pipe shall be placed facing upstream. Corrugated metal pipe shall be placed wi th longitudinal laps or seams at the sides. Pipe that is not in tr ue alignment or which shows settlement after laying shall be correc ted by the Contractor at no additional cost to the Department.
d.Joining Pipe. The method of joining pipe sections shall be such that the ends are fully entered and the inner surfaces are reasonably flush and even. Pipe protruding through structure walls shall be cu t off flush with the inside face of wall. All surfaces of the joint upon or against which joi nt seal gaskets may bear shall be smooth, free of spalls, cracks, f ractures, and imperfections that would adversely affect the perfo rmance of the joint. A primer shall be applied if recommended by the manufacturer.
1.When preformed rubber gasket is selected by the Contractor, the gasket shall be the sole element de pended upon to make the joint flexible and watertight. The gasket shall be a continuous ring that fits snugly into the annular s pace between the overlapping surfaces of the assembled pipe join t to form a flexible watertight seal. The circumference of the seated gasket shall not be more than 130% of its original circumf erence.
2.When bitumen/butyl plastic gasket is selected by th e Contractor, the following procedure shall be used. The protective wrapping shall be removed from one side of the gask et. The gasket shall be placed and pressed firmly to the su rface of the pipe joint around the entire circumference of the j oint. The remaining protective wrapping shall be removed and the pipe forced into connection until material fills the joi nt space.
3.When tubular cross-section closed cellular rubb er gaskets are selected by the Contractor, the gaskets shall b e a single, 428 continuous part conforming to the joint shape. The outer surface of the gasket shall be completely covered with a na tural skin. The cross-sectional diameters and installation prac tices shall be in accordance with the manufactures’ recommendations f or the size of pipe or culvert being placed. To ensure an even and well-filled joint, the final joining of the pipe shall be accomplished by either pushing or pul ling, by approved mechanical means, each joint of the pipe as it is l aid. In cold weather, when directed, the joint material shall be warmed in a hot water bath, or by other approved methods, to the ex tent required to keep the material pliable for placement without bre aking or cracking. (e) Field cutting of polymer precoated pipe shall be by mechanical means as approved by the Engineer. Torc h cutting or other applied heat methods shall not be used. Ends of pipe that have been field cut shall be treated and/or repaired acc ording to the manufacturer's recommendations. Coatings damaged during manufacturing, shipping, or installation shall be repaired according to the applicable AASHT O specifications. Treatment and/or repair of damaged or cut ends shall be at no cost to the Department.
f.Backfilling. (1) General. Special care shall be taken to compact the fill under the haunches of the pipe. I n trench excavation, the backfill above the area specified a s structural backfill (or structural bedding for reinforced concrete pipe culverts) shall be placed in 6 ″ (150 mm) lifts and compacted with mechanical equipment to 95% of the maximum density, as determi ned by AASHTO T 99. In a fill section, the backfill shal l be brought up evenly on each side for the full length of the pipe to avoid displacement. The berm of thoroughly compacted mat erial on each side of the pipe shall be at least as wide as the o utside diameter of the pipe. The Department will perform acceptance s ampling and testing of the compacted backfill material in accor dance with Subsection 210.10 at the frequencies established in the Department’s Manual of Field Sampling and Testing Procedures . Pipe damaged during construction operations shall be replaced at no cost to the Department. When the existing material excavated for the pipe t rench is determined by the Engineer to be unsuitable for pip e backfill, this 429 material shall be placed at other locations on the project such as backfill behind curbs, placed on the fill slopes, e tc. If the Engineer determines that no suitable location exists on the project to utilize this material, the Engineer may approve the materia l to be wasted at an appropriate location outside the project limits according to Subsection 210.08. Material declared unsuitable fo r backfill shall be replaced with suitable material from roadway excava tion and/or borrow. If suitable material from roadway excavati on and/or borrow is not available, the Engineer may authorize the us e of the Selected Pipe Backfill.
2.Reinforced Concrete Pipe Culverts. Backfilling around the pipe shall be with material as shown on the plans. The material shall be placed along side the pipe in layers not to exce ed 6 ″ (150 mm) at near optimum moisture content and compacted with me chanical equipment to 95% of the maximum density, as determi ned by AASHTO T 99.
3.Corrugated Metal Pipe Culverts and Plastic Pip e Culverts. Structural backfill material shall be placed alon g side the pipe in layers not to exceed 6 ″ (150 mm) at near optimum moisture content and compacted with mechanical equipment to 95% of the maximum density, as determined by AASHTO T 99, up t o an elevation of not less than 12 ″ (300 mm) above the top of the pipe. Backfilling of the pipe trench above the structural backfill will be accomplished as described in (1) above.
g.Curtain Walls for Flared End Sections. The foundation for curtain walls shall be prepared to the required depth. For cast in place curtain walls, the forming, placement of rein forcing steel, and placement, finishing, and curing of concrete shall be according to the applicable requirements of Sections 802 and 804. P recast curtain walls shall be installed according to the applicabl e requirements for laying concrete pipe. The Department will perform all acceptance sampling and testing at the frequencies shown for C ontractor acceptance testing in Subsection 802.06.
606.04 Method of Measurement. (a) Pipe Culverts and Side
Drains will be measured by the linear foot (meter) measured parallel to the flow line of the pipe. Where inlets, catch basins, junction boxes, or other structures are included in lines of pipe, that length of pipe extending to and flush with the inside of the structure wall will 430 be included for measurement but no other portion of the structure length or width will be so included. No allowance will be made for any pipe cut-off. Whenever possible, the lengths s hown on the plans may be adjusted by the Engineer to accommodate the pipe lengths available from the supplier that most nearly match the plan lengths. For multiple pipes, the measured length will be the sum of the lengths of the individual barrels measured as presc ribed above.
b.Flared End Sections for pipe culverts will be measu red by the unit and will include the curtain wall, complete in place.
c.Selected Pipe Bedding material will be measured eit her by the cubic yard (cubic meter) or ton (metric ton). When measured by the cubic yard (cubic meter), no adjustment will be mad e for swell.
d.Selected Pipe Backfill material will be measured ei ther by the cubic yard (cubic meter) or ton (metric ton). When measured by the cubic yard (cubic meter), no adjustment will be mad e for swell.
e.When pipe culvert is used for extensions of existin g culverts, the removal of any headwall, end section, or pipe j oints shall be accomplished according to Section 202.
f.Structural Bedding for Reinforced Concrete Pipe Cu lverts, Structural Bedding and Structural Backfill for Corr ugated Metal Pipe Culverts, and Structural Bedding and Structura l Backfill for Plastic Pipe Culverts will not be measured or paid for separately but full compensation therefor will be considered inclu ded in the contract unit prices bid per linear foot (meter) fo r the respective type of pipe culvert.
g.Safety End Sections for Pipe Culverts will be measu red by the unit.
606.05 Basis of Payment. (a) Work completed and accepted and
measured as provided above will be paid for at the contract unit price bid per linear foot (meter) for the respectiv e type of Pipe Culverts of the several sizes, which price shall be full compensation for furnishing, hauling, and installing the pipe; f or materials including joint filler for concrete pipe and connec ting bands for metal pipe; for excavation and backfilling, includi ng compacting backfill; for furnishing, placing, and compacting s tructural bedding and structural backfill; for removing and disposing of the existing headwall and attached end joint of concrete pipe or the flared end 431 section on all types of pipe, in order to accomplis h culvert extensions; and for all labor, equipment, tools, an d incidentals necessary to complete the work.
b.Work completed and accepted and measured as provide d above will be paid for at the contract unit price b id each for the respective type of Flared End Sections of the sever al sizes, which price shall be full compensation for furnishing, ha uling, and installing the end sections; for materials, includi ng joint filler for concrete end sections and connecting bands for meta l end sections; for excavation and backfilling, including compactin g backfill; and for all labor, equipment, tools, and incidentals ne cessary to complete the work.
c.Work completed and accepted and measured as provide d above will be paid for at the contract unit price b id per cubic yard (cubic meter) or ton (metric ton) for Selected Pipe Bedding, which price shall be full compensation for excavating and disposing of soft and yielding material; for furnishing, placing, and compacting bedding material; and for all labor, equipment, too ls, and incidentals necessary to complete the work.
d.Work completed and accepted and measured as provide d above will be paid for at the contract unit price b id per cubic yard (cubic meter) or ton (metric ton) for Selected Pipe Backfill, which price shall be full compensation for furnishing bac kfill material; and for all labor, equipment, tools, and incidentals ne cessary to complete the work. Placing and compacting backfill will not be paid for separately, but full compensation therefor will be considered included in the contract unit price bid for Pipe Cu lverts and Flared End Sections.
e.Side Drains completed and accepted and measured as provided above will be paid for at the unit price b id per linear foot (meter) for Side Drains of the size specified, whic h price shall be full compensation for furnishing, hauling, and inst alling the pipe; for materials including joint filler for concrete pipe and connecting bands for metal pipe; for excavating and backfillin g; and for all labor, equipment, tools, and incidentals necessary to complete the work. Backfill for PVC pipe will not be paid for s eparately, but full compensation therefor will be considered included i n the contract unit price bid for Side Drains. 432 (f) Work completed and accepted and measured as provide d above will be paid at the contract unit price bid e ach for Safety End Sections of the several sizes, which shall be full compensation for furnishing, hauling and installing the end section; for all materials; for excavating and backfilling; and for all labor, equipment, tools, and incidentals necessary to complete the work. Payment will be made under: Pay Item Pay Unit __" (__mm) Reinforced Concrete Pipe Culverts (Class__) Linear Foot (Meter) __" (__mm) Zinc Coated (Galvanized) Corrugated Steel Pipe Culverts (___Gauge) Linear Foot (Met er) __" (__mm) Aluminum Coated Corrugated Steel Pipe Culverts (___Gauge) Linear Foot (Meter) __" (__mm) Aluminum-Zinc Alloy Coated Corrugated Steel Pipe Culverts (___Gauge) Linear Foot (Met er) __" (__mm) Corrugated Aluminum Pipe Culverts (___Gauge) Linear Foot (Meter) __" (__mm) Asphalt Coated Corrugated Steel Pipe Culverts (___Gauge) Linear Foot (Meter) __" (__mm) Polymer Precoated Metallic Coated Corrugated Steel Pipe Culverts (___Gauge) Linear Foot (Meter) __" (__mm) Asphalt Coated Corrugated Aluminum Pipe Culverts (___Gauge) Linear Foot (Meter) __"x__" (__x__mm) Reinforced Concrete Arch Pipe Culverts (Class___) Linear Foot (Meter) __"x__" (__x__mm) Reinforced Concrete Horizontal Elliptical Pipe Culverts (Class___) Linear Foot (Meter) __"x__" (__x__mm) Zinc Coated (Galvanized) Corrugat ed Steel Arch Pipe Culverts (___Gauge) Linear Foot (Meter) __"x__" (__x__mm) Aluminum Coated Corrugated Steel Arch Pipe Culverts (___Gauge) Linear Foot (Mete r) 433 Pay Item Pay Unit __"x__" (__x__mm) Aluminum-Zinc Alloy Coated Corrugated Steel Arch Pipe Culverts (___Gauge) Linear Foot (Meter) __"x__" (__x__mm) Corrugated Aluminum Arch Pipe Culverts (___Gauge) Linear Foot (Meter) __"x__" (__x__mm) Asphalt Coated Corrugated Steel Arch Pipe Culverts (___Gauge) Linear Foot (Meter) __"x__" (__x__mm) Polymer Precoated Metallic Coated Corrugated Steel Arch Pipe Culverts (___Gauge) Linear Foot (Meter) __"x__" (__x__mm) Asphalt Coated Corrugated Aluminu m Arch Pipe Culverts (___Gauge) Linear Foot (Mete r) __" (__ mm) Flared End Sections for Pipe Culverts Each __"x__" (__x__mm) Flared End Sections for Arch Pipe Culverts Each __" (__ mm) Smooth Lined Polymer Precoated Metallic Coated Corrugated Steel Pipe Linear Fo ot (Meter) __"x__" (__x__mm) Smooth Lined Polymer Precoated Metallic Coated Corrugated Steel Arch Pipe Linear Foot (Meter) __" (__ mm) Side Drain Linear Foot (Meter) __"x__" (__x__mm) Side Drain Linear Foot (Meter) Selected Pipe Bedding Cubic Yard (Cubic Meter),or Ton (Metric Ton) Selected Pipe Backfill Cubic Yard (Cubic Meter), or Ton (Metric Ton) __" (__ mm) Safety End Sections for Cross Drain Pipe Culverts (Class ___) Each 434 Pay Item Pay Unit __"x__" (__x__mm) Safety End Sections for Cross Drain Arch Pipe Culverts (Class ___) Each __" (__ mm) Safety End Sections for Side Drain Pipe Culverts (Class ___) Each __"x__" (__x__mm) Safety End Sections for Side Drain Arch Pipe Culverts (Class ___) Each
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