Wisconsin WisDOT Standard Specifications (within FDM) — Section 520

Effective with the December 2018 Letting 301 2019 Standard Spec ifications Section 520 Pipe Culverts

520.1Description

(1)This section describes providing culvert pipe, cattle pass, an d apron endwalls where the material used

is a contractor option; providi ng and removing temporary culvert pipe; and cleaning existing culvert pipes.

520.2Materials

520.2.1 Culvert Pipe

(1)Furnish culvert pipe consisten t with the diameter the bid item indicates. Furnish materials for the

various classes of pipe as follows: TABLE 520-1 ALLOWABLE MATERIALS FOR CULVERT PIPE

CLASS ALLOWABLE MATERIALS III Class III reinforced concrete , corrugated steel pipe of the thickness contract designates III-A Class II and Class III reinforced c oncrete, corrugated steel of the thickness the contract designates, corrugated polyethyle ne, corrugated polypropylene III-A Non-metal Class II and Class III reinforced c oncrete, corrugated polyethy lene, corrugated polypropylene III-B Class III reinforced concrete, co rrugated steel of the thickness the contract designates, corrugated polypropylene III-B Non-metal Class III reinforced concrete, corrugated polyp ropylene IV Class IV reinforced concrete, corrugated steel pipe of the t hickness contract designates V Class V reinforced concrete, co rrugated steel pipe of the thickness contract designates

(2)For the given materials, conform to the following:

Corrugated st eel pipe ......................................... ......................................................................................... 521.2 Reinforced conc rete pipe ...................................... ....................................................................................... 522.2 Corrugated polyeth ylene pipe .................................. .................................................................................... 530.2 Corrugated polypro pylene pipe ................................. ................................................................................... 530.2

(3)Under the Culvert Pipe Temporary bid items, use either new or used culvert pipe in a condition

suitable for the purpose intended. 520.2.2 Pipe Cattle Pass

(1)Under the Pipe Cattle Pass bid item, if the plans do not designate a specific material, the contractor

may use either corrugated steel o r reinforced concrete. For the given materials, conform to the following: Corrugated steel pipe cattl e pass ............................. ................................................................................... 521.2 Reinforced concrete pipe cattle pass .......................... ................................................................................. 522.2 520.2.3 Apron Endwalls for Culvert Pipe

(1)Under the Apron Endwalls for Cul vert Pipe bid items, use steel apron endwalls for corrugated steel,

corrugated polyethylene, and corr ugated polypropylene pipe culvert installations, and use concrete apron endwalls with concrete pipe culvert installations. For th e given materials, conform to the following: Steel apron endwalls .......................................... ......................................................................................... 521.2 Concrete apron endwalls ....................................... ...................................................................................... 522.2 520.2.4 Concrete Pipe Colla rs and Cattle Pass Walkways

(1)For concrete collars and cattle pass walkways, furnish grade A , A-FA, A-S, A-T, A-IS, A-IP, or A-IT

concrete conforming to 501 as modified in 716. Provide QMP for class III ancillary concrete as specified in 716. 520.2.5 Backfill 520.2.5.1 General

(1)Submit daily quantities for ma terial requiring department testing to the engineer as follows:

- For foundation backfill. - For trench backfill not obt ained from the excavation.

Effective with the December 2018 Letting 302 2019 Standard Spec ifications (2) Determine quantities at the poin t of placement by collecting t ruck tickets as the material is placed or by another engineer-approved method.

(3)Ensure there is adequate moistu re in backfill during placing, shaping, and compacting to prevent

segregation and achieve adequate compaction. 520.2.5.2 Foundation Backfill 520.2.5.2.1 General

(1)Furnish virgin materials consisting of either sand-sized particles or sand-sized particles mixed with

gravel, crushed gravel, or crushed stone. Do not use materials classified under 301.2.4.3 as crushed concrete, reclaimed asphalt, repr ocessed material, or blended m aterial. The contractor may use material from the work site.

(2)Ensure that material provided has a liquid limit less than or equal to 25 and a plasticity index less than

or equal to 6. 520.2.5.2.2 Gradation

(1)Furnish foundation backfill with a gradation conforming to the following:

- For the entire sample, conform to the following gradation lim its: SIEVE PERCENT PASSING BY WEIGHT 1 1/4-inch 100 No. 4 25 - 100 - For the portion of the sample passing the No. 4 sieve, confor m to the following gradation limits: SIEVE PERCENT PASSING BY WEIGHT No. 4 100 No. 40 ___ No. 100 0 - 30 No. 200 0 - 15.0

(2)The contractor may substitute ma terial with a gradation confor ming to the following:

3/4-inch dense-gra ded base course ............................. ......................................................................... 305.2.2.1 1 1/4-inch dense-gr aded base c ourse ........................... ........................................................................ 305.2.2.1 520.2.5.2.3 Sampling and Testing

(1)The department will sample and test material according to the following:

Sampling[1] ............................................................................................................................. ........... AASHTO T2 Percent passing t he 200 sieve ................................. ............................................................... ........ AASHTO T11 Gradation[1] ............................................................................................................................. ........ AASHTO T27 Liquid l imit .................................................. ............................................................... ...................... AASHT O T89 Plasticity index and plastic limit ............................ ............................................................... ........... AASHTO T90 [1] As modified in CMM 8-60.

(2)Submit contractor test results for gradation, liquid limit, an d plasticity index testing to the engineer for

approval before placing backfill . The engineer may waive contra ctor testing for known sources. 520.2.5.3 Trench Backfill

(1)Furnish trench backfill consisting of material from the typica l roadway section. Use material from the

excavation that is free of large lumps, clods, rocks and other perishable and deleterious matter. If the engineer determines that materia l from the excavation is not su itable, backfill the trench with an engineer-approved material. 520.2.6 Joint Connections

(1)Wrap or seal joints with material conforming to:

Geotextile Type DF, Schedul e A................................. ........................................................................... 645.2.2.4 Bituminous Masti c Joint Sealer ................................ .................................................................................... 608.2

520.3Construction

520.3.1 General

(1)Unless the engineer authorizes otherwise in writing, do not or der or deliver pipe cu lverts for the project

until the engineer furnishes a corrected list of sizes and leng ths.

(2)Provide temporary drainage fac ilities necessary to protect the work and adjacent property. Maintain

temporary drainage in effective operating condition, as the eng ineer approves, until the permanent

Effective with the December 2018 Letting 303 2019 Standard Spec ifications culvert pipe installations are operational. Remove and dispose of temporary culv erts after the permanent culvert pipe installations are operational.

(3)Place foundation and trench bac kfill in a way that does not da mage the pipe.

Revise 520.3.1 to clarify locations where pipe collars are needed.

(4)Construct concrete cattle pass wa lkways using concrete conforming to 520.2.4 where and as the plans

show.

(5)Construct concrete collars using concrete conforming to 520.2.4 where and as the plans show. Also

use collars for connections to existing pipe, existing endwalls , or dissimilar pipe materials where the engineer agrees a mortar joint, m anufactured joint, coupling, o r restraint can not be used. 520.3.2 Excavating and Constructing Foundations for Pipe Culverts 520.3.2.1 Public Highway Culvert

(1)If placing pipe culverts under any public highway in open tren ches, either place them in an excavation

in the existing ground, or in previously placed embankment compacted as specified for embankment in 207. Place and compact the embankm ent to at least one foot above t he top of the culvert before excavating the trench. Avoid pla cing embankment to an elevation exceeding 2 feet above the top of the culvert before placing the culvert.

(2)Perform trenching, shoring, and excavating according to 29 CFR part 1926, OSHA subpart P. If

utilities and other restraints make sloping or benching of the excavation impracticable, employ a shoring system. http://www.dol.gov/dol/cfr/title_29/

(3)Make trenches wide enough to provide free working space on eac h side of the pipe. This space shall

not exceed 1/2 the nominal diame ter of the pipe, and never be l ess than 6 inches. The required working space shall depend upon the size of the pipe and the ch aracter of the material in the excavation; however, always provide sufficient space between the pipe and the sides of the trench to allow for preparing the foundation, laying the pipe, and placing and compacting the backfill. If the height of the proposed embankment o r earth cover above the top of the pipe exceeds 6 feet, excavate the trench below the top of the pipe as vertical as possible.

(4)For steel or concrete pipe, mak e the trench wide enough to allow for preparing the foundation, laying

the pipe, and placing and comp acting backfill, except that the trench width shall not exceed the pipe's outside diameter by more than 36 inches. For polyethylene and polypropylene pipe, conform to ASTM D2321 and ensure that the trench is as wide or w ider than the pipe o utside diameter plus 16 inches or the pipe outside diameter times 1. 25 plus 12 inches whichever i s wider.

(5)Excavate the trench to at least 6 inches below the elevation established for the bottom of the pipe.

Backfill to this depth with foundation backfill. Mechanically c ompact foundation backfill before laying the pipe. After laying the pipe, place and mechanically compact foundation backfill to an elevation of 12 inches above the pipe to provide full and continuous support. Do not place lifts m ore than 6 inches thick as measured after compaction. Compact the entire layer before placing the next layer. Do not compact by flooding if using foundation backfill with a dense-g raded base gradation.

(6)Excavate and backfill pipe arches as specified above, except backfill and trim to a height that fully and

continuously supports the pipe arch.

(7)If the engineer determines that e xisting foundation material f or at least 6 inches below the bottom of

the pipe conforms to 520.2.5.1 ; the contractor need not excavate, backfill, or shape the bed under the pipe.

(8)If rock, hardpan, or fragmented material exists, excavate the trench below the pipe to a depth equal to

1/2 inch per foot of proposed em bankment above the top of the p ipe, but not less than 6 inches. Construct the foundati on and backfill to 12 inches above the pi pe with foundation backfill as specified above.

(9)Excavate recesses to rec eive bells if necessary.

(10)Notify the engineer if the proper bearing c annot be obtained 6 inches below the bottom of the pipe.

Excavate unsuitable material a s the engineer directs and backfi ll with foundation backfill. 520.3.2.2 Private Entrance and Temporary Culverts

(1)Shape the earth foundation for the pipe culverts for private entrances, and temporary installations to fit

the pipe exterior with reasonable closeness for a height of at least 10 percent of the pipe's overall diameter.

(2)If rock, hard pan, boulders, or fragmented material exist, bed the pipe on an earth, or granular

bedding, compacted and shaped similarly to the above, for no le ss than 6 inches below the pipe.

Effective with the December 2018 Letting 304 2019 Standard Spec ifications 520.3.3 Laying Pipe

(1)Do not place any pipe culvert until the engineer approves the foundation. Additionally, do not place

pipe culverts in cuts until completing the rough grading.

(2)Unless the plans show otherwis e, if laying 2 or more pipes nex t to each other, separate them by a

distance equal to at least 1/2 the pipe diameter, with a minimu m distance of 18 inches. For pipes with attached apron endwalls, separate them by a distance that provi des a minimum of 6 inches between the apron endwalls. For cast-in -place concrete or other alterna te endwall installations, space pipes as the plans show.

(3)Lay concrete pipe with bells or grooves up grade and with spig ot or tongue ends fully inserted in the

bells or grooves. Protect each joint against backfill infiltration by providing a full circumferential wrap of geotextile extending one foot or more on each side of each join t and securing the wrap in place.

(4)The contractor may use sealers instead of the geotextile joint wrap. Seal conforming to 608.3.4 .

(5)Provide joint ties on the upstr eam and downstream ends of circ ular and horizontal elliptical concrete

culvert and concrete cattle pass installations. Tie the last 3 sections or, if using apron endwalls, the endwall and the last 2 sections. T ies are not required on culve rts with masonry endwalls unless the plans show otherwise.

(6)For polyethylene or polypropylene pipe, use full pipe sections except as needed to meet the plan

specified length. Place full pipe sections at infall or outfall ends unless the engineer allows otherwise. If a partial pipe section must be used at an infall or outfall end, restrain as the manufacturer recommends, or absent a recommendation, use one or more of the following: - A manufacturer supplied ex ternal mechanical coupling. - A manufactured coupling with a mastic impregnated geotextile wrap and mechanical fastening bands. - A concrete collar meeting 520.2.4 .

(7)Lay riveted or spot-welded corr ugated steel pipe so that flow is over the lap of t he sheets, except for

beveled end sections where the c ontractor may reverse the lap a t the outlet end. Make field joints by joining the metal pipe sections together with a band bolted fir mly in place. If elongation of the vertical diameter is specified, provide an appropriately modified prefab ricated section.

(8)Ensure that culvert pipe join ts are soil-tight as follows:

- For polyethylene according to AASHTO M294. - For polypropylene according to AASHTO M330.

(9)Lay pipes true to the designated line, grade, and required cam ber. Fit and match them to form a

smooth and uniform invert.

(10)Carefully fit the sections of p ipe together to keep the size o f joint openings to a minimum.

(11)Clean sockets carefully before lowering pipes into trenches. L ower the pipes in a way that avoids

unnecessary handling in the trench. 520.3.4 Backfilling Trenches 520.3.4.1 Public Highway Culverts

(1)Place trench backfill from 1 foot above the top of the pipe to the top of the subgr ade in layers no more

than 8 inches thick after com paction. Mechanically compact the entire length of each layer to the same degree as the material next to t he trench before placing the ne xt layer.

(2)Immediately after backfilling, c ushion pipe for at least the t rench width with compacted earth. Provide 2

feet or more cover, including backfill depth, above the pipe to prevent damage under construction loads. Maintain this cushion during subsequent operations. Do n ot walk, travel across, or work near completed pipe until minimu m cover is established.

(3)Place the remaining portion of the embankment, if any, above t he top of the trench as specified for the

adjacent embankment. 520.3.4.2 Private Entrance and Temporary Culverts

(1)Carefully backfill private entrance and temporary culverts in layers no more than 8 inches deep after

compaction, then ram and tamp material to completely fill spaces under and next to the pipe. 520.3.5 Placing Apron Endwalls

(1)Excavate the foundation for t he apron endwall to the required width and grade. For metal aprons with

toe plates, excavate a trench to allow placing the toe plate ag ainst the inner face of the trench if the apron is in its final position. After securing the apron to the pipe, backfill and firmly compact the trench.

(2)Place the concrete apron endwall with its tongue or groove fully entered in the groove or tongue of the

pipe.

Effective with the December 2018 Letting 305 2019 Standard Spec ifications (3) Use the same backfill for the apron as required for the culver t pipe unless the engineer directs otherwise. 520.3.6 Cleaning Culvert Pipes

(1)Clean the existing culvert pipes of dirt and vegetation. Use a ll suitable materials removed from the

culvert pipes in other areas requiring fill material within the project limits as the engineer directs. Dispose of surplus and unsuitable material as specified in 205.3.12 . 520.3.7 Deflection Testing

(1)The department accepts polyethylene and polypropylene pipe based on testing with a department-

approved mandrel. Test pipe as the engineer directs after installation but before paving or finish grading.

(2)Provide a mandrel with a diameter equal to 92.5 percent of the pipe's nominal diameter and having

cable attachment points on eac h end of the core. Ensure that th e mandrel has nine fins or legs permanently marked to designate the pipe size and the allowable percent deflection.

(3)The engineer will designate at l east 10 percent of the installed length of pipe for testing The mandrel

must pass through the entire section in one pass when pulled by hand without using excessive force. If the designated length of pipe fails, engineer may require addit ional testing.

(4)Relay or replace pipe with def lection greater than 5 percent. Retest all relayed or replaced pipe.

520.4Measurement

(1)The department will measure the Culvert Pipe bid items and Pip e Cattle Pass by the linear foot

acceptably completed, measured along the invert. Revise 520.4(2) to specify measurement of Concrete Collars for Pipe only where the plans show or contract requires.

(2)The department will measure the Apron Endwalls, Cleaning Culvert Pipes, and Concrete Collars bid

items as each individual unit acceptably completed. The department will only measure Concrete Collars for Pipe if required under 520.3.1(5) or 608.3.3(10) .

(3)The department will measure Cleaning Culvert Pipes as each ind ividual culvert acceptably completed.

520.5Payment

520.5.1 General

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

520.1000 - 1199 Apron Endwalls for Culvert Pipe (size) EACH

520.2000 - 2099 Culvert Pipe Temporary (size) LF

520.3100 - 3199 Culvert P ipe Class III (size) LF

520.3300 - 3399 Culvert Pi pe Class III-A (size) LF

520.3400 - 3499 Culvert Pipe Cl ass III-A Non-metal (size) LF

520-3500 - 3599 Culv ert Pipe Class III- B (size) LF

520.3600 - 3699 Culvert Pipe Cl ass III-B Non-metal (size) LF

520.4100 - 4199 Culvert Pipe Class IV (size) LF 520.5100 - 5199 Culvert P ipe Class V (size) LF

520.8000 Concrete Collars for Pipe EACH 520.8500 Pipe Cattle Pass LF

520.8700 Cleaning Culvert Pipes EACH

(2)Payment for the Apron Endwalls for Culvert Pipe bid items is full compensation for providing apron

endwalls; and for excavating, c onstructing the foundation, and backfilling. The department will pay separately for cast-in-place concrete and alternate endwall ins tallations under the Concrete Masonry Endwalls bid item as specified in 504.5 and other associated bid items. Revise 520.5.1(3) to clarify payment for concrete collars.

(3)Payment for Concrete Collars for Pipe is full compensation for providing concrete pipe collars required

under 520.3.1(5) or 608.3.3(10) .

(4)Payment for Cleaning Culvert Pipes is full compensation for cl eaning the culvert pipe and for disposing

of excess material.

(5)Payment for the 520 bid items also includes water for compacti on and dust control, except if the

contract contains the Water bid item, the department will pays eparately for water under 624.5 .

Effective with the December 2018 Letting 306 2019 Standard Spec ifications 520.5.2 Culvert Pipe and Cattle Pass Revise 520.5.2(1) to clarify payment for concrete collars.

(1)Payment for the Culvert Pipe bid items and Pipe Cattle Pass is full compensation for providing pipe;

for concrete collars not required under 520.3.1(5) or 608.3.3(10) ; for excavating, constructing the foundation, and backfilling; for as sociated dewatering and maintaining drainage; and for concrete cattle pass walkways.

(2)If material from the typical road way section is not suitable for trench backfill, the department will pay

separately for trench backfill under other contract bid items.

(3)The department will pay separately for excavating unsuitable m aterial and backfilli ng as specified in

520.3.2.1(10) as extra work.

Effective with the December 2018 Letting 307 2019 Standard Spec ifications Section 521 Corrugated Steel Culverts

521.1Description

(1)This section describes providing corrugated steel culvert incl uding pipe, pipe arch, cattle pass, and

steel apron endwalls.

521.2Materials

(1)Furnish corrugated steel pipe and steel apron end walls as follows:

- Corrugated steel culvert pipe, steel apron endwalls, aluminum coated corrugated steel culvert pipe, and other components conforming to AASHTO M36. - Polymer coated corrugated steel culvert pipe and pipe arch fabricated from zinc coated sheet steel conforming to AASHTO M218. Befor e fabrication, coat the sheets on both sides with polymer protective coating grade 250/250 according to AASHTO M246. Fabricate the p ipe according to AASHTO M245.

521.3Construction

521.3.1 General

(1)Construct as specified in 520.3 .

521.3.2 Coating Repair

(1)Repair damaged zinc c oating on cuts according to AASHTO M36.

(2)Repair damaged aluminum coating by blast cleaning, power sanding, or wire brushing the damaged

and surrounding areas. Apply zinc-rich paint to the cleaned are a within 24 hours and before rusting or soiling occurs, to a minimum thickness of 5 mils.

(3)Repair damaged polymer coating with a polymer coating similar to, and compatible with the original

coating, or with a tar base material or asphaltic mastic confor ming to AASHTO M243. 521.3.3 Handling Polymer Coated Pipe and Pipe Arch

(1)Minimize damage to polymer coatings during transportation, han dling, and installation. Store on

padded supports and pad objects placed against polymer coated m aterials.

521.4Measurement

(1)The department will measure the LF bid items under this section acceptably completed as specified for

pipe in 520.4 and the Apron Endwalls bid ite ms acceptably completed as speci fied for apron endwalls in 520.4 .

521.5Payment

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

521.0300 - 0699 Apron Endwalls for (type) Cross Drains Steel (s ize) (slope) EACH

521.1000 - 1399 Apron Endwalls for (type) Steel (size) EACH

521.1500 - 1899 Apron Endwalls for (type) Side Drains Steel (si ze) (slope) EACH

521.1900 Pipe Cattle Pass Corrugated Steel LF 521.3100 - 3299 Culvert Pipe Corrugated Steel (size) LF

521.3700 - 3899 Pipe Arch Corrugated Steel (size) LF

521.5100 - 5299 Culvert Pipe Corru gated Steel Polymer Coated (s ize) LF

521.5700 - 5899 Pipe Arch Polymer Coated Corrugated Steel (size ) LF

521.6100 - 6299 Culvert Pipe Corrugated Steel Alum inum Coated ( size) LF

521.6700 - 6899 Pipe Arch Corrugated Steel Aluminum Coated (siz e) LF

(2)The department will pay for the wo rk under this section as spe cified in 520.5 as follows:

- Pipe, pipe arch, cattle pass, and apron endwalls bid items. - Cast-in-place concrete and alternate endwall installations. - Water for compacti on and dust control. - Excavation and foundation ba ckfill at depths greater than 6 i nches below the culvert.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 310–315 of 601.

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519 Brick Masonry and Concrete Brick or Block Masonry

521 Corrugated Steel Culverts