Insertion Lining of Culverts Art. 543.02 When cast-in-place reinforced concrete end sections are specified on the plans, the work will be paid for at the contract unit price per each for CAST-IN-PLACE REINFORCED CONCRETE END SECTIONS, of the diameter specified. When cast-in-place concrete collars are specified on the plans, the concrete will be paid for at the contract unit price per cubic yard (cubic meter) for CONCRETE COLLAR. Reinforcement will be paid for according to Section 508. Expansion bolts, when required, will be paid for according to Section 540. When specified on the plans, elbows and tees for polyethylene or metal pipe will be paid for at the contract unit price per each of PIPE ELBOW and PIPE TEE, of the diameter specified. Inlet boxes for median slopes and for side slopes will be paid for at the contract unit price per each for INLET BOX, STANDARD 542501; INLET BOX, STANDARD 542521; INLET BOX, STANDARD 542511; INLET BOX, STANDARD 542506; INLET BOX, STANDARD 542536; INLET BOX, STANDARD 542516; and INLET BOX, STANDARD 542541. Inlet boxes for median ditch checks will be paid for at the contract unit price per each for INLET BOX, STANDARD 542526 or INLET BOX, STANDARD 542531. Inlet boxes to be placed flush in medians will be paid for at the contract unit price per each for FLUSH INLET BOX FOR MEDIAN, STANDARD 542546. Reinforced concrete pipe elbows will be paid for at the contract unit price per each for REINFORCED CONCRETE PIPE ELBOW, of the diameter specified. Reinforced concrete pipe tees will be paid for at the contract unit price per each for REINFORCED CONCRETE PIPE TEE, of the pipe diameter and riser diameter specified. SECTION 543. INSERTION LINING OF CULVERTS
543.01 Description. This work shall consist of insertion lining of existing pipe
culverts and placing grout or cellular concrete in the annular space between the existing culvert and the liner.
543.02 Materials. Materials shall be according to the following.
Item Article/Section
a.Polyethylene (PE) Solid Wall Pipe with a Smooth Interior (Note 1) ... 1040.04
b.Polyethylene (PE) Profile Wall Pipe (Note 1) ...................................... 1040.04
c.Reinforced Plastic Mortar (RPM) Pipe (Note 1) .................................. 1040.05
d.Corrugated PVC with a Smooth Interior (Note 1) ............................... 1040.03
e.Corrugated Steel Pipe (Note 1)(Note 3) .............................................. 1006.01
f.Steel Casing (Note 1)(Note 4) ........................................................ 1006.05(d)
g.Grout Mixture (Note 2) ........................................................................ 1024.01
h.Portland Cement Concrete ...................................................................... 1020
i.Controlled Low-Strength Material ............................................................ 1019
j.Cellular Concrete .................................................................................... 1029 Art. 543.03 Insertion Lining of Culverts Note 1. Insertion linings are specified according to the existing pipe’s inside diameter to be lined. Unless the Contractor can demonstrate by calculation that a smaller cross sectional area is hydraulically equivalent or better, the insertion lining shall provide a minimum of 72 percent of the cross sectional opening of the existing culvert for diameters under 5 ft (1.5 m), 82 percent for culverts between 5 and 10 ft (1.5 and 3 m) in diameter, and 90 percent for culverts greater than 10 ft (3 m) in diameter. Any of the listed liner materials are permitted if the cross sectional area requirement is met and the liner is structurally adequate to handle the dead and live loads per AASHTO LRFD Bridge Design Specifications without the existing culvert taken into consideration. Note 2. The grout mixture shall be 6.50 hundredweight/cu yd (385 kg/cu m) of portland cement plus fine aggregate and water. Fly ash may replace a maximum of 5.25 hundredweight/cu yd (310 kg/cu m) of the portland cement. The water/cement ratio, according to Article 1020.06, shall not exceed 0.60. An air-entraining admixture shall be used to produce an air content, according to Article 1020.08, of not less than 6.0 percent nor more than 9.0 percent of the volume of the grout. The Contractor shall have the option to use a water-reducing or high range water-reducing admixture. Note 3. Corrugated metal pipe shall be spiral ribbed or double walled with a smooth interior and shall be polymer coated or Aluminized Steel Type 2. Note 4. For pipe diameter 24 in. (600 mm) and less, use 3/8 in. (9.5 mm) minimum wall thickness, and for pipe 36 in. (900 mm) and above use 1/2 in. (13 mm) minimum wall thickness. CONSTRUCTION REQUIREMENTS
543.03 General. The Contractor shall submit a work plan at least 15 days
prior to the start of work, detailing the methods for cleaning and preparing the existing culvert, the method(s) for joining the liner segments, the method for advancing the liner into the existing culvert, the process to fill the annular space and the proposed grout or cellular concrete mix design, and a list of potential corrective actions to address common installation issues that may arise. When applicable the method(s) for reconnecting or perpetuating existing lateral connections shall also be submitted. The Contractor shall verify that the specified liner can be installed and enough room remains to adequately fill the annular space remaining prior to ordering any materials. If a problem is discovered it shall be brought to the attention of the Engineer for resolution before ordering any materials. Individual liner section lengths shall be planned to have no more than three joints per 50 ft (15 m) of pipe length unless approved by the Engineer. Existing deformed culvert structures that require ovalled liners shall be lined with initial round solid wall PE pipe modified to an oval shape or elongated corrugated metal pipe. Insertion Lining of Culverts Art. 543.03 All obvious cavities outside the existing culvert shall be filled with controlled low- strength material prior to the liner installation or with material placed in conjunction with filling the annular space between the liner and existing culvert. Prior to commencing the liner installation, all jagged existing culvert edges or other deformities shall be repaired. All foreign material shall be removed from the existing culvert. Joints shall be watertight and meet a 10.8 psi (74 kPa) laboratory test per ASTM D 3212. A mechanical coupler or male and female joint design shall use a gasket meeting ASTM F 477. Joints shall have sufficient longitudinal or axial compression strength to withstand a maximum compressive force of 100 lbs/in. (17.5 N/mm) of outside diameter circumference in compression while maintaining joint integrity when tested. Joints shall have sufficient pull-apart strength to withstand maximum tensile force of 100 lbs/in. (17.5 N/mm) of outside diameter circumference in tension without joint disassembly when tested. Joints shall provide sufficient longitudinal or axial strength to preserve liner alignment, prevent separation at the joints, and maintain integrity while pushing or pulling pipe lengths into existing culverts. Joints shall be mechanical, fusion welded, or male and female joint connections. Mechanical or male and female joint connections shall be an integral part of the liner. Alternatively, the mechanical joint, male and female joints, or pipe ends may be heat fused provided that the fusion process meets the requirements of ASTM F 2620 and that the fused connection is watertight, and shall not reduce the inside diameter or enlarge the outside diameter of the liner being joined by 1/4 in. (6 mm). If a liner is fusion welded, it shall be welded with a continuous weld for the circumference of the liner both inside and outside. The ends of liners that are to be welded or fused shall be at the same ambient temperature ± 5 °F (2.8 °C) and alignment bands shall be utilized. Welding, fusing, or joining shall be performed at all times by an installer trained and certified by either the liner’s manufacturer or the welding, fusing, or joining equipment manufacturer. A copy of the welder’s, fuser’s, or joiner’s certificate shall be provided to the Engineer prior to the start of work. RPM liners or corrugated PVC liners with a smooth interior shall be joined according to the manufacturer's recommendations using joint lubricant. The joining may be accomplished in a jacking pit or other convenient location where the assembled liner can be brought into alignment with the existing culvert barrel without damage. The Engineer will approve each joint before each section of liner is inserted. The insertion may be made by pushing or pulling the assembled liner from either end of the culvert or if the size permits assembling inside the existing culvert. The Engineer may require the liner to have a temporary nose cone or plug to guide the liner past minor obstructions. The insertion operation shall not cause joints to separate nor damage the liner. Art. 543.03 Insertion Lining of Culverts After the liner has been completely inserted and has been inspected in place by the Engineer, it shall be cut off 8 in. (200 mm) past the ends of the existing culvert or as otherwise directed by the Engineer. The liner shall be allowed to cool to the temperature of the existing culvert before it is cut off. The entire length of the annular space between the existing culvert and the liner shall be filled with a grout or cellular concrete. Prior to filling the annular space, the upstream and downstream ends of the annular space shall have concrete bulkheads constructed to contain the grout mixture. The bulkheads shall be constructed with Class SI concrete. Alternative materials for the bulkhead as recommend by the pipe lining manufacturer may be used if approved by the Engineer. The bulkheads shall extend inward a minimum depth of 18 in. (450 mm) from the ends of the culvert. A method of venting through the bulkheads or grouting ports at the crown shall be utilized to allow air to escape when pumping material and to allow verification that the annular space has been filled. When the grout or cellular concrete is pumped into the annular space, the Contractor shall prevent the floating of the liner. This shall be accomplished by any of the following methods.
a.Intermittent Pumping Method. Small amounts of material shall be pumped into the annular space and allowed to harden. This shall continue until the bond between the liner and material is sufficient to resist floating. The remainder of the annular space shall then be filled.
b.Bracing Method. Braces shall be installed in the annular space to prevent floating of the liner. Only braces which do not damage the liner shall be used. Bracing shall run parallel to the culvert.
c.Water Fill Method. The liner shall be temporarily filled with water before filling the annular space with grout. The pumping operation shall completely fill the annular space along the entire length, but shall be performed in a manner that does not distort the liner. The pressure developed in the annular space shall not exceed the liner manufacturer’s recommended value. The air temperature at time of placement and for 24 hours thereafter shall be a minimum of 35 °F (2 °C). The temperature of the cellular concrete at point of discharge shall be a minimum of 45 °F (7 °C) and a maximum of 95 °F (35 °C). The grout or cellular concrete mixture shall have a minimum 28 day compressive strength of 150 psi (1035 kPa). The Engineer will sample the grout or cellular concrete a minimum of once each day for compression strength during production. Mold the grout specimens according to ASTM C 1107, and the cellular concrete according to ASTM C 495. For each test, three 2 in. x 2 in. (50 mm x 50 mm) specimens will be molded for the grout and four 3 in. x 6 in. (75 mm x 150 mm) specimens will be molded for the cellular concrete. The specimens shall be stored in a temperature range of 60 to 80 °F (16 to 27 °C) for the first 24-72 hours, and the Contractor shall provide a field curing box. After this time, the Engineer will transport the specimens to the laboratory for curing and testing. The grout will be tested for Storm Sewers Art. 550.02 compressive strength according to ASTM C 109, and the cellular concrete will be tested for compressive strength according to ASTM C 495. Upon completion of the pumping operation, all remaining unfilled vent holes including those at both the upstream and downstream ends shall be filled with a nonshrink grout. Only enough water to make a stiff but workable nonshrink grout shall be used. The air temperature at time of placement and for 24 hours thereafter shall be a minimum of 35 °F (2 °C).
543.04 Method of Measurement. This work will be measured for payment in
place in feet (meters). Excavation in rock will be measured for payment according to Article 502.12.
543.05 Basis of Payment. This work will be paid for at the contract unit price
per foot (meter) for INSERTION CULVERT LINER for the existing size specified. Excavation in rock will be paid for according to Article 502.13. SEWERS SECTION 550. STORM SEWERS
550.01 Description. This work shall consist of constructing storm sewers.
550.02 Materials. Materials shall be according to the following.
Item Article Section
a.Clay Sewer Pipe ................................................................................ 1040.02
b.Extra Strength Clay Pipe ................................................................... 1040.02
c.Concrete Sewer, Storm Drain, and Culvert Pipe ..................................... 1042
d.Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe .................. 1042
e.Reinforced Concrete Elliptical Culvert, Storm Drain, and Sewer Pipe (Note 1) ........................................................................ 1042
f.Reinforced Concrete Arch Culvert, Storm Drain, and Sewer Pipe (Note 1) ........................................................................ 1042
g.Polyvinyl Chloride (PVC) Pipe ........................................................... 1040.03
h.Corrugated Polyvinyl Chloride (PVC) Pipe with a Smooth Interior ..... 1040.03
i.Corrugated Polypropylene (CPP) Pipe with Smooth Interior ............. 1040.08
j.Rubber Gaskets and Preformed Flexible Joint Sealants for Concrete Pipe .................................................................................... 1056
k.Mastic Joint Sealer for Pipe .................................................................... 1055
l.External Sealing Band ............................................................................ 1057
m.Fine Aggregate (Note 2) .................................................................... 1003.04
n.Coarse Aggregate (Note 3) ................................................................ 1004.05
o.Reinforcement Bars and Welded Wire Reinforcement ...................... 1006.10
p.Handling Hole Plugs .......................................................................... 1042.16
q.Polyethylene (PE) Pipe with a Smooth Interior .................................. 1040.04
r.Corrugated Polyethylene (PE) Pipe with a Smooth Interior ............... 1040.04
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 496–500 of 1,217. View official source ↗