603METAL PLATE CULVERTS

603.1DESCRIPTION—This work is construction of metal plate pipes, metal plate pipe -arches, and metal

plate arch culverts.

603.2MATERIAL—

106.03(b)3. Comply with the requirements of AASHTO M 167/M 167M (Steel) and AASHTO M 219/M 219M

(Aluminum Alloy), except modify as follows:

1.a Section 11, Fabrication. Except:

• Space bolt holes 9.4 inches apart along plate edges that are to form circumferential seams .

• For bolt hole diameters, do not exceed the bolt diameter by more than 1/8 inch for longitudinal bolt holes or 1/4 inch for circumferential bolt holes.

• Form corrugations at right angles to the structure's longitudinal axis, having a depth of not less than 1 7/8 inches but not greater than 2 1/8 inches, unless otherwise accepted.

• Where necessary, to secure additional seam strength for pipe assembled with lap joints, increase the number of bolts per foot of longitudinal seam to six or eight.

In addition:

• Furnish plates in sizes that will allow length increments of 2 feet for square -ended structures.

• Provide a lap joint capable of transmitting the design thrust through the joint.

• Fabricate plates so not more than three plates come together at a point.

• In the two bottom segments of an arch, plates may be punched with one row of holes adjacent to the longitudinal plate edge that is to rest on the pier or abutment.

1.b Section 14, Dimensions and Tolerances. Determine the thickness of plates by weight of flat plates before corrugating. Comply with the following theoretical weights and tolerances :

THEORETICAL WEIGHTS AND TOLERANCES

Theoretical Weight Before Galvanizing (lbs. per sq. ft.) Theoretical Weight After Galvanizing (lbs. per sq. ft.) Permissible Variation of Average Weight of Lots* (percent) Gage Over Under 1 11.25 11.406 5.5 3 3 10.00 10.156 5.5 3 5 8.75 8.906 5.5 5 7 7.50 7.656 5.5 5 8 6.875 7.031 5 5 10 5.625 5.781 5 5 12 4.375 4.531 5 5

* The term “lot” means all the plates of one gage in the shipment, for thicknesses gage 7 and heavier and not less than 6,000 pounds, for thicknesses gage 8 and lighter, with all individual plates not below the theoretical weights by more than 10%.

1.c Section 17.1, Inspection. Inspect mill and factory base metal when required, according to AASHTO M 36. Test the weight of the spelter coating, according to AASHTO T 65.

an itemized statement showing the number, size, and certified chemical analysis of the plates in each shipment. A plate will be rejected if it:

• fails to meet specifications,

• shows defective workmanship, or

• has a bruised or broken spelter coat.

• Class A Cement Concrete. Section 704

• Cement Concrete for Miscellaneous Drainage. Section 704

• Reinforcement. Section 709.3

• Coarse Aggregate. Section 703.2

• Selected Borrow Excavation. Structure Backfill. As shown on the Standard Drawings

• Structural Steel. Section 1105.02(a)2

• Emulsified Asphalt Class RS-1 or CRS-1 (Mop Coat on Concrete Paving). Section 702

• Asphalt Coating. AASHTO M 243. Certify as specified in Section 106.03(b)3

• Asphalt Material. (For sealing the groove, metal bearing channel or angle or arches, as required.) Class BF-1 Asphalt Cement, Section 702

• Hook Bolts. Section 1105.02(d). Certify as specified in Section 106.03(b)3

• Metal Bearing Materials . AASHTO M 183/M 183M, galvanized as specified in Section 1105.02(s) (AASHTO M 232). Certify as specified in Section 106.03(b)3

• Curing and Protective Covers. Section 711.1

603.3CONSTRUCTION—

the proposed joint design on the drawings. Inspect metal plate culverts as specified in Section 601.3(n) and provide remediation as specified in Section 601.3(o).

unless an alternate method from the manufacturer is accepted:

Drawings. Place plates “shingle-wise” to allow water to flow over, not against, the edges of plates, except for haunch plates for pipe -arches. Haunch plates may require placement inside or outside of adjacent haunch plates. When indicated, place washers under nuts. Use sufficient bolts to hold plates of the pipe or pipe-arch in position until the structure is completed. Place the bottom two rows of bolts with t he threaded end inside the structure to facilitate tightening. Place bolts on other seams alternately, so nuts are always on the crests of corrugations, first inside, then outside, the culvert. Do not draw bolts and nuts tight until the structure is finished. Draw bolts and nuts tight before backfilling.

1.a Elongation. Elongate round pipes vertically 5%, using acceptable shop methods, or 3%, using timber strutting in the field, unless otherwise indicated. Submit a plan for review before placing timber strutting, showing strut sizes, spacing, and jacking methods. A tolerance of ±25% of the specified amount of elongation will be allowed. Complete the field strut before backfilling around the pipe. Place struts for pipe-arches when directed, to retain the size. Uniformly strut from end to end of pipes and pipe-arches without endwalls. If endwalls are used, do not elongate the ends of pipes or pipe -arches. Leave struts in place until the roadway embankment is complete and compacted, unless otherwise directed.

1.b Asphalt Coating. Clean and dry plates and field apply an asphalt coating, if indicated, at the proper temperature. Provide a coating with a minimum thickness of 0.05 inch, measured on the crest of corrugations, to the lower inside one-half of the pipe or pipe-arch.

1.c Concrete Paving. If indicated, pave inverts of pipes and pipe arches with Class A cement concrete, reinforced with 6 inches by 6 inches, 10 gage, steel wire fabric (WWR 152 x 152 - MW9 x MW9 and/or WWF 6 x 6 - W 1.4 x W 1.4). Anchor reinforcement to the structure. Cover 25 % of the periphery of pipes and 40% of the periphery of pipe-arches to a thickness of 2 inches above the crests of corrugations. If asphalt coating and concrete paving are both indicated, pave with concrete first. Do not apply asphalt coating on the paved portion. Tamp the concrete to the required thickness and contour. After initial set, cover concrete with a heavy spray or mop coat of emulsified asphalt, Class RS-1 or CRS-1.

parts of Section 1001.3. Place the metal channels or angles in the concrete foundation, as indicated. Erect metal plates one course at a time and hold in place temporarily, beginning at the sides, with lower plates fitted into their channels. Progress to the top or center of the arch. Portions of the arch may be assembled and lifted into place, if directed. Place downstream plates outside adjoining upstream plates, with each rise plate outside the adjoining lower plate and all placed “shingle-wise”, or as recommended by the manufacturer. When indicated, place washers under each nut. Use enough bolts to hold arch plates in position until the structure is formed. Then, place and tighten the remaining bolts. Place nuts on the crests of corrugations, alternately inside and outside of the arch. Draw all bolts tight before backfilling. After the arch has been completely placed, but before backfilling, fill the groove or channel used for the bearing area of the arch with asphalt material. If an angle is used for the bearing area, seal the intersection of the arch and angle with asphalt material.

around the pipe or pipe-arch, as specified in Section 601.3(f).

the Standard Drawings and as specified in Section 100 1.3(q)2.b when the substructure concrete has attained the required strength and plates have been erected, unless otherwise directed.

Place backfill in layers not exceeding 4 inches in depth, alternately on each side of the arch, or on each side of each arch in the case of a multiple installation. Compact with mechanical tampers until a power roller may be used, then place the remainder of the embankment, as specified in Section 206.3. When filling around and over arches, before endwalls are constructed, place the first fill material midway between the arch ends, forming as narrow a ramp as possible until the top is reached. Build the ramp evenly from both sides, compacting fill material while placing it. After the ramps have been built to the arch top, deposit the remainder of fill material from the top, in both directions, from the center to the ends, as evenly as possible on both sides. If endwalls are built before any fill material is placed around and over the arch, place fill material adjacent to one endwall until the arch top is reached, then dump fill material from the top toward the other endwall, using care to deposit material evenly on both sides of the arch. For a multiple installation, follow the procedure specified above, but bring material up evenly on each side of each arch, avoiding unequal pressure. Tamp the fill material thoroughly, but not excessively. Do not puddle the material with water. Remove fill material causing excessive distortion of plates. Brace plates into correct position, then replace fill material. Remove bracing, as directed. Conform to additional requirements from the manufacturers.

603.4MEASUREMENT AND PAYMENT—

Measured along the centerline of culverts with square or skewed vertical ends; the average length along the centerline of culvert with square or skewed beveled ends. Bedding, backfill, concrete paving, if indicated, and inspection of culverts, including personnel and equipment, is incidental.

Measured along the centerline of culverts with square or skewed vertical end; the average length along the centerline of culverts with square or skewed beveled ends.

For the class indicated.

The unit price does not include concrete paving, if indicated.