604.1-DESCRIPTION: This work shall consist of the construction or reconstruction of pipe culverts, in accordance with these Specifications and in reasonably close conformity with the lines, grades, dimensions, and locations shown on the plans or established by the Engineer. 604.2-MATERIALS: Materials shall conform to the following requirements of Division 700, except as otherwise noted: MATERIAL SUBSECTION Aluminum Structural Plate Box Culvert 713.18 Aluminum Coated Corrugated Steel Pipe and Pipe Arch 713.24 Bitumen Sealant 708.9 Controlled Low Strength Material (CLSM) 219 Crushed Aggregate 704.6, Class 1 or Class 3 End Section for Corrugated Steel Pipe, Safety Slope, or Pipe Arch 713.20 Concrete Safety Slope End Section for Elliptical or Round Pipe 714.8 Fine Aggregate 702.1.2-702.1.5 and 702.2 or 702.6 Granular Material 716.1.1.2 High Density Polyethylene Pipe (HDPE), Profile Wall 714.19 High Density Polyethylene Pipe (HDPE), Steel-Reinforced 714.18 Polypropylene Pipe 714.17 Polyvinyl Chloride (PVC) Pipe 714.22 Precast Reinforced Concrete Box Culverts 714.7 Random Material 716.1.1 Reinforced Concrete Pipe 714.2 When the locations of manufacturing plants allow, the plants may be inspected periodically for compliance with specified manufacturing methods, and material samples may be obtained for laboratory testing for compliance with material quality requirements. This may be the basis for quality acceptance of manufactured lots. All materials will be subje ct to inspection for acceptance as to condition at the latest practicable time the Engineer has the opportunity to check for compliance prior to or during incorporation of materials in the work. All references to "corrugated steel pipe" are considered app licable to the paving classes (paved invert, full paved, etc.) for which the base metal conforms to AASHTO M 218 or AASHTO M 274. 604.2.1-Quality Control Testing: Quality control of the granular material and crushed aggregate is the responsibility of the Contractor as specified in subsection 106.1. The Contractor shall maintain necessary equipment and qualified personnel to perform all sampling and testing necessary to determine the magnitude of the various properties of the material governed by the Specifications and shall maintain these properties within the limits of the Specifications. The Contractor shall submit a quality control plan detailing the methods by which the quality control program will be conducted. This plan, prepared in accordance with the guidelines set forth in the appropriate portions of MP 307.00.50 and MP 717.04.21, shall be submitted to the Engineer at the preconstruction conference. The work shall not begin until the plan is reviewed for conformance with the contract documents. 604.2.2-Acceptance Testing: Quality control sampling and testing performed by the Contractor may be used by the Division for Acceptance. 604.2.3-Sampling and Testing: Frequency of sampling and testing shall be in accordance with the contractor’s quality control plan. The minimum sampling and testing frequencies for gradation shall be as indicated in Attachment 1 of MP 307.00.50. The material shall be sampled in accordance with MP 700.00.06. The minimum sampling and testing frequency for compaction will be in accordance with MP 717.04.21. 604.2.4-Acceptance Plan: 604.2.4.1-Compaction: Compaction of backfill material shall meet 604.8. 604.2.4.2-Gradation: The material shall be sampled and tested in accordance with Section 604.2.3. Acceptance for gradation shall be based on test results of consecutive random samples from a lot. A sublot is the quantity of material represented by a single gradation test as defined in MP 700.00.06. A lot shall be considered the quantity of material represented by an average test value, not to exceed five sublots. In the case where only one sample is needed for the total plan quantity, the sublot shall be considered the lot. The average shall start on the second sample result. The average is continued for the third through fifth sample result, averaging all previous sample results. Thereafter, only the last consecutive five sample results will be averaged, i.e., second test value through sixth te st value, third test value through seventh test value, and so forth as defined in MP 300.00.51. When the test value of a lot and the test value of the last sublot, or when the last three consecutive individual test values of a lot fall outside the gradati on limits of Table 704.6.2A the lot of material represented will be considered nonconforming to the extent that the last of its sublots are nonconforming. When this occurs, the last sublot shall have its price adjusted in accordance with Table 604.14.1. 604.2.4.3-Degree of Nonconformance: When a sublot of material is to have its price adjusted, the percentage point difference between the nonconforming test value and the specification limit shall be determined for each sieve size determined to be nonconforming, and this value shall be multiplied by its appropriate multiplication factor as set forth in Table 604.2.4.3. TABLE 604.2.4.3 Nonconforming Sieve Size Multiplication Factor 1 ½ in. (37.5 mm) 1.0 ¾ in. (19 mm) 1.0 No. 4 (4.75 mm) 1.0 No. 40 (425 µm) 1.0 No. 200 (75µm) 2.0 The total measure of nonconformance of an individual sublot is the sum of all nonconformance of an individual sieve sizes of that sublot. When the total degree of nonconformance has been established and it is 12.0 or less, the material will be for at an adjusted contract price as specified in Table 604.14.1. When the degree of nonconformance is greater than 12.0, the nonconforming sublot shall be resolved on an individual basis, requiring a special investigati on by the Engineer to determine the appropriate course of action to be followed. CONSTRUCTION METHODS 604.3-GENERAL: Subject to the provisions prescribed, the flow line of a pipe culvert may be altered from that shown on the plans. Galvanized steel pipe or bands shall not come in contact with aluminized steel pipe or bands. The diameter of pipe, as used in this Section, is the largest dimension, horizontal or vertical. 604.4-TRENCH EXCAVATION: 604.4.1-Pipe Culverts 18 Inches Through 96 Inches: In complete or partial fill sections, before trenching is begun, the fill shall be constructed for a minimum distance of six diameters on each side of the pipe and to a height of two (2) feet over the top of the pipe or to the surface of the completed embankment if less than two (2) feet above the top of the pipe. The minimum width of the trench, in either cut of fill sections, shall be calculated using the formulas below. The Contractor shall increase these minimums to a width that allows the jointing of the pipe, and adequate placement and compaction of the backfill. Pipe Culverts of thirty-six (36) inches diameter or less: = Outside Diameter + eighteen (18) Inches on each side of the pipe Pipe Culverts with diameter greater than thirty-six (36) inches: = Outside Diameter + twenty-four (24) Inches on each side of the pipe 604.4.1.1-Pipe Culverts Installed Using Controlled Low Strength Material (Type F Trench): When using a controlled low strength material (CLSM) the width of the trench shall not be less than the values in the table in Standard Detail DR-10; and for trenches in rock , a minimum trench width of Outside Diameter plus six (6) inches on each side of the pipe. 604.4.2-Pipes Greater than 96 Inches: In complete or partial fill sections, before trenching is begun, the fill shall be constructed for a di stance of six diameters on each side of the pipe and to a minimum height of 25 percent (25%) of the vertical dimension of the pipe. Installation of the pipe shall be as detailed in the plans, including the type and amount of backfill and bedding. The C ontractor shall submit shop drawings detailing all erection procedures including anticipated movements during backfilling operations. Backfill operations shall also be detailed to show lift thicknesses, sequence of lifts and shape of the culvert during these operations. The Contractor shall submit a plan of field control for the installation insuring the pipe is erected in accordance with the shop and erection drawings. 604.4.3-Structural Plate Box Culvert: Excavation for the foundations of structural plate box culvert shall be in accordance with 212.3. 604.4.4-Precast Concrete Box Culvert: The minimum width of the trench shall be eighteen (18) inches on each side of the box culvert. 604.5-BEDDING: Unless otherwise noted in the plans, bedding shall conform to the following requirements. Rigid pipe bedding shall be granular material or crushed aggregate with a three (3) inch minimum thickness. Flexible pipe bedding shall be crushed aggregate with a four ( 4) inch minimum thickness. The bedding material placed under the middle ⅓ of the pipe diameter shall be loosely placed and uncompacted to allow for cradling of the pipe bottom. Bedding outside of the middle ⅓ shall be compacted. When rock or unyielding material is present in the trench bottom, six (6) inches of granular material shall be installed below the bottom of the pipe or box culvert. Box culvert bedding shall be fine aggregate with a four (4) inch minimum thickness. 604.6-LAYING AND JOINING: 604.6.1-Rigid and Flexible Pipe and Concrete Box Culvert: The pipe/culvert placing, unless the Contractor is otherwise directed, shall begin at the downstream end of the pipe/culvert. The lower segment of the pipe/culvert shall be in contact with the bedding throughout its full length. Bell or groove ends of pipes and outside circumferential laps of corrugated steel pipe shall be placed facing upstream. Paved or partially lined culverts shall be laid so that the longitudinal centerline of the paved segment coincides with the flow line. Rigid pipes/culverts may be of either bell and spigot or tongue and groove design, unless one type is specified. The method of joining pipe sections shall be such that the ends are fully entered, and the inner surfaces are reasonably flush and even. Joints for rigid pipes/culverts shall be made with flexible gaskets that conform to ASTM C443 or bitumen sealant combined with an external sealing wrap which conforms to ASTM C877, Type III. All joints shall be installed to form a leak resistant seal. Flexible pipes shall be joined by bell and spigot joints, and the pipe shall be installed to preserve the alignment, provide a leak resistant joint that conforms to ASTM D 3212 performance requirements, and prevent the separation of sections. Pipe culverts shall be inspected before any backfill is placed. Any pipe found to be out of alignment, unduly settled, or damaged shall be removed and re-laid or replaced. 604.6.2-Structural Plate Box Culvert: Plate box culvert shall be set on footings as shown on the Plans. Beginning at the upstream end, the first side plates shall be set on the base angles. Then the remaining side plates and the top plates shall be bolted into place using only enough bolts to hold them without tightening securely. Drift pins may be used to assist in matching bolt holes. Temporary props may be used to hold plates in place until connections are made. After the plates comprising the first set h ave been assembled, the next set shall be placed in the same manner, finishing each set of side plates with a top plate before placing in the same manner, finishing each set of side plates with a top plate before placing the next set of side plates. New p lates shall be lapped one corrugation on the outside of the preceding plates. When all the plates are in position, the remaining bolts shall be inserted and all nuts firmly tightened. Steel bolts shall be torqued during installation to a minimum of 100 f t-lbs., and a maximum of 300 ft-lbs., Aluminum bolts shall be torqued during installation to a minimum of 100 ft-lbs., and a maximum of 150 ft-lbs. For power driven tools, the hold-on period may vary from 2 to 5 seconds. Bolts shall be of sufficient length to provide for a full nut. 604.7: Blank 604.8-BACKFILLING: The use of a bulldozer or other bladed equipment in placing backfill is expressly forbidden. Mechanical equipment with various type buckets may be used. All pipe, after being bedded and backfilled, shall be protected by a four (4) foot cover of fill, or more if necessary, before heavy equipment is permitted to cross during the construction of the roadway. The Contractor will be held responsible for any damage to the pipe resulting from movement of equipment over the structure. 604.8.1-Initial Backfill Zone: Rigid Pipe initial backfill material shall be suitable granular material free from particles larger than 1-½ inch, crushed aggregate, or controlled low strength material. For flexible pipe, the initial backfill material shall be crushed aggregate or controlled low strength material. The initial backfill material shall be placed along the pipe in layers not to exceed four (4) inches and compacted to 95% standard proctor; to a minimum of the spring line for rigid pipe and to a minimum height of six (6) inches over the top of flexible pipe. Controlled low strength material (CLSM) shall be placed according to Section 219; and any type of CLSM may be used unless otherwise indicated on the Plans or Standard Details. Unless otherwise specified in the plans, CLSM can be used as a substitute for granular material or crushed aggregate at the contractor’s option. At the contractor’s option, and if permitted by the Engineer, Class B concrete may be used as a substitute for CLSM at no additional cost to the Division. Care shall be taken to compact the material under the haunches of the pipe, to place the backfill evenly on each side of the pipe to retain its vertical axis, and to avoid displacement. The backfill and compaction efforts shall be advanced simultan eously on both sides of the pipe. Box culvert initial backfill material shall be suitable granular material free from particle sizes larger than 1-½ inch or crushed aggregate. Unless otherwise noted on the plans, it shall be placed to a minimum of twelve (12) inches over the top of box culvert. 604.8.2-Final Backfill Zone: Unless otherwise noted in the plans, the area above initial backfill zone shall be one of the following:
1.Suitable random material with material sized up to three (3) inches with no more than 20% retained on the 1-½ sieve (40mm),
2.Crushed aggregate, or
3.Controlled low strength material. This method of backfilling and compacting shall be followed until the top of the trench is reached. 604.8.3-Backfill Testing: The quality control testing and acceptance of CLSM shall be in accordance with Section 219. Class B concrete shall be in accordance with Section 601, except that the job site and A-bar testing are waived. The quality control testing and acceptance for compaction of the random backfill material shall be in accordance with applicable sections of 207 and 716, granular material according to section 716, and crushed aggregate according to section 717, with the following exception: Testing will be conducted on both sides of the pipe and testing within a lot may include tests on both sides of the pipe. For pipe installations in an embankment where existing tests are on file for the adjacent emb ankment material, the target percentage of dry density for the pipe backfill will be equal to the average of the X values for the tests in the adjacent lots of embankment material or a minimum value of 95, whichever is greater. For embankments where no tests are on file, the target percentage of dry density will be 95. A lot shall have five
5.density tests performed for quality control. For pipes less than sixty (60) inches in diameter, a lot will normally consist of the quantity of backfill required for each 75 linear feet of pipe installed. For pipes sixty (60) inches in diameter and larger, a lot will normally consist of not more than 5 lifts of backfill. For pipe with lifts of backfill placed for the full length of the pipe, a sublot will normally consist of a lift of backfill placed on both sides for the full length of the pipe. For pipes that are backfilled in segments, a sublot will normally consist of a lift of backfill placed on both sides for the length of each segment of pipe backfilled. Backfill placed outside embankments and roadbed is to be compacted to or better than the average total dry density for the existing soil. An average total dry density will be determined from representative density tests conducted for each existing soil. Quality control testing will normally consist of one test per 100 linear feet of pipe installed, and lot evaluations are not required. The moisture tolerance is not applicable. 604.9-FIELD PAVING: The Contractor may pave with Portland cement concrete or use shotcrete. If practicable, such paving shall be delayed until completion of the fill over the structure. Before the placing of the paving, the surface of the plates shall be cleaned. The Portland cement co ncrete or shotcrete, mesh reinforcement, fastening of mesh, and paving dimensions shall be as specified and the minimum thickness over the crest of the corrugations shall be 1-½ inches. Concrete used shall have a design 28-day compressive strength of 3,000 psi (equivalent to Class B in 601.3); concrete may be hand mixed and shall be handled and placed as directed by the Engineer. After initial set has taken place, the paving shall be flooded or kept moist by sprinkling for three days. Liquid membrane -forming compound, conforming to subsection 707.9 may be used for curing at a minimum application rate of one gallon per 150 square feet of concrete surface. Other methods of curing may be used if approved by the Engineer. Field paving with shotcrete shall conform to Section 623. When paving with shotcrete, the exposed surface shall be brought to a uniform surface by screeding or troweling. After completion of the shotcrete paving, the reb ound material shall be cleaned from the culvert above the paved surface. Shotcrete shall be cured by (a) covering with burlap mats and keeping them wet for at least seven days after placing, (b) flooding for a period of at least seven days or, (c) applying liquid membrane curing compound, conforming to 707.9, at a minimum rate of one gallon per 150 per feet of shotcrete surface for each application. Shotcrete cured by membrane forming compound shall receive two applications; the second application shall b e made after the first application has set. Other methods of curing may be used if approved by the Engineer. After the completion of the fill over the pipe, any gaps which develop between the plates and the concrete or shotcrete paving shall be filled by pouring heated asphalt material complying with requirements of subsection 713.3. Prior to using Portland cement concrete or shotcrete for paving culverts with coatings containing aluminum, the aluminum -concrete contact area shall be coated with commercia lly- available paint.
604.10 Remove and Relay Pipe:
When specified, the Contractor shall remove, salvage, clean, safely store, and relay existing culverts. The construction requirements in this Section shall apply equally in the case of remove and relay pipe. The Contractor shall restore or replace, any pipe designated for reuse that incurs damage or destruction through faulty handling or storage. All pipes salvaged for relaying shall be cleaned of all foreign material prior to reinstallation.
604.11 Jacking Pipe:
Jacking or tunneling may be designated on the Plans or may be permitted if written approval is obtained. Culverts to be jacked shall be reinforced concrete pipe. The strength of pipe designated in the Contract will be designated as required for vertical load only. Additional reinforcement or strength of pipe required to withstand jacking pressure shall be determined and furnished by the Con tractor without additional cost to the Division. Variation from theoretical alignment and grade at the time of completion of jacking placement shall not exceed 0.2 feet for each twenty (20) feet of pipe so placed. An approach trench shall be constructed on the side from which jacking operations shall take place. The end of the approach trench away from the jacking face shall be cut perpendicular to the axis of the jacking operation to provide bearing surface for the back stop and the jack blocking. The length of the approach trench shall be such that the distance between the jack blocking and the face of the bore shall be equal to five (5) feet plus the length of the individual pipe sections. The jacking face shall be a minimum of three (3) feet above the top of the pipe; the face shall be cut vertically and shall be shored to prevent raveling and slipping. A sump shall be constructed in one corner of the trench to provide drainage. The back stop shall be constructed of heavy timbers or steel rails capable of withstanding the jacking force. In the event the site of jacking operations is such that an approach trench cannot be constructed, the jack blocking shall be constructed to carry the reaction of the jack to the ground. This may be accomplished by means of timber, steel, or concrete vertical back stops set into the ground with the tops supported by diagonal members bearing against an embedded anchorage. Directly opposite the approach trench, an exit trench shall be constructed to line and grade. The exit trench shall be constructed in the same manner as the approach trench except that no back wall is necessary. Jacks shall be of sufficient capacity to overcome soil resistance to the jacking operation and shall be operated in pairs. As a guide, c apacity of jacks for concrete pipe shall be a minimum of 50 tons each. For large pipe, more than one pair of jacks may be required. Small track jacks may be used to start the pipe. Pipe guides shall be constructed in the approach trench and may be eithe r timber or steel rail or concrete guides on a cradle. Since the pipe guides will support the pipe as it enters the jacking face, the pipe guides shall be accurately set to line and grade, and excavation for the guides shall be made to grade to avoid occurrence of settlement. Guides shall be spaced, as required. Reaction of the jack to the pipe shall be transmitted by either a jacking frame or jacking beams constructed of timber or steel. Jacking frames and beams shall be so placed as to exert equal pressure on each side of the pipe. For pipes thirty-six (36) inches in diameter or smaller, a steel jacking ring may be used in lieu of the jacking frame. The pressure from the jacking frame or beams may be transmitted to a jacking collar or head on the pipe itself. Jacking collars or heads for concrete pipe shall be constructed to prevent damage to the pipe ends. Jacking collars and jacking frames shall be constructed to allow passage of men and material. Joints of concrete pipe shall be cushioned and protected from infiltration of fine materials occurring during the jacking operation by insertion of a plywood or OSB of ½” -¾” thickness cushioning material into each pipe joint. After the pipe is in position, the joints shall be pointed from the inside with mortar joint compound. The use of a jacking shield is permitted. To prevent the pipe from "freezing" and becoming incapable of movement, jacking operations should, if possible, be carried out on a 24-hour basis. Alignment and grade of the pipe guides shall be checked at least once each shift. To aid in the prevention of "freezing," the pipe shall be lubricated in a manner and with a material meeting the approval of the Engineer. Excavation for the bore shall be to grade at the bottom and approximately one (1) inch greater than the diameter of the pipe at the top and sides. As excavation proceeds, the jacking shall proceed until the effective limit of the jacking is reached, at which time additional blocking shall be added. This process shall be conti nued until there is room for an additional pipe section. For long runs of pipe, the use of intermediate jacking stations will be allowed as approved by the Engineer. Pipe cover shall be a minimum of one diameter or three (3) feet from top of pipe to bottom of the subgrade of ballast when jacking under a highway. After the pipe has been jacked into place, the annular area between the pipe wall and the remaining soil shall be pressure grouted to remove any chance of settling. The backfill shall be tightly compacted around both ends of the culvert to prevent erosion. Any departure from the above specifications necessitated due to site conditions shall be approved in wri ting by the Engineer. Areas resulting from caving or excavation outside the above limits shall be backfilled with grout, or by a method which will fill the voids. Joints shall be completed as specified for the type of pipe being installed.
604.12 Inspection and Acceptance:
In addition to the inspection performed by the Division during the initial installation of pipe culverts, a post installation inspection will be conducted before final acceptance. No sooner than 30 days following installation, the Engineer will visually i nspect all culverts. Pipes larger than forty-two (42) inches in diameter will be manually inspected by inspectors on the project for excessive deflection of flexible pipe, excessive cracking in rigid pipe, and joint issues for all pipes. Inspectors will note and document any defects with locations in their daily work reports. Any excessive cracks, differential movement, spalls, exposed reinforcement, delamination, slabbing, dents, buckling, holes, damaged coating, obstructions, improperly engaged joints, improper gasket placement, excessive joint gaps, misaligned joints, excessive deflection, or undue horizontal or vertical misalignment will be cause for repair or replacement at no cost to the Division. Efflorescence and rust stains should be evaluated t o determine if detrimental or just a cosmetic defect.
604.12.1 Rigid Pipe Criteria: Concrete pipe cracks equal to or less than one hundredth
of an inch (0.01) are considered hairline and minor. Cracks greater than one hundredth of an inch (0.01) but less than five hundredths of an inch (0.05), shall be sealed by the method proposed by the manufacturer and approved by the Engineer. Concrete pipe with cracks with width equal to or greater than five hundredths of an inch (0.05) and less than one tenth (0.1) shall be evaluated by the Engineer for repair or replacement. Concrete pipe with cracks one tenth (0.1) inch or greater in width shall be replaced by the Contractor to the satisfaction of the Engineer. Cracking, whether longitudinal or transverse, shall be evaluated as described above. Spalling is defined as a localized pop-out of concrete along the wall of the pipe/culvert, or at the edges of longitudinal or circumferential cracks. If spall/chips are detected, there are 3 classifications:
a.Spalled areas with no exposed reinforcement, are considered nonstructural and shall be patched with material from approved list and meeting Section 715.4 with R-3 requirements and approved by the Engineer.
b.Spalled area with exposed reinforcement, with a single spall area less than or equal to 150 square inches, the Contractor shall submit repair plan for remediation to the Engineer.
c.Spalled area with exposed reinforcement with a single spall area greater than 150 square inches, the Contractor shall submit a pipe analysis and remediation plan for repair or replacement. Delamination and Slabbing appears as a separation of the concr ete from the reinforcing steel and can be detected by a hollow sound when tapped with a device such as a hammer. If identified, the Contractor shall submit remediation methods for delamination/slabbing in accordance with recommendations of the pipe manufa cturer, to the Engineer for approval before proceeding. Where delamination/slabbing is of such magnitude that, in the opinion of the Engineer, the integrity or service life of the pipe or culvert is severely compromised, the section(s) of pipe shall be re placed at the Contractor’s expense to the satisfaction of the Engineer. Maximum allowable joint gaps are dependent on each pipe manufacturer’s joint design and equipment. Pipe manufacturers will provide maximum joint gaps based on minimum gasket compression required. If any soil infiltration is identified at a pipe joint during inspection, a pipe analysis and a remediation plan for repair or replacement shall be submitted to the Engineer for approval.
604.12.2 Flexible Pipe Criteria: Flexible pipe deflection equal to or less than
5 percent (5%) of the original diameter will not require remediation. Deflections of 5 percent (5%) up to 7.4 percent (7.4%) of the original diameter will be evaluated by the Engineer for repair or replacement; if repaired the final pipe deflection must be equal to or less than 5 percent (5%) of the original diameter for acceptance. If flexible pipe is deflected 7.5 percent (7.5%) or more than the original diameter, the pipe shall be replaced by the Contractor to the satisfaction of the Engineer. Flexible pipe with any crack (interior, exterior, or both) shall be replaced to the satisfaction of the Engineer. Pipes showing evidence of crushing at the joints will need a repair plan submitted to the Engineer for approval. Replacement at no cost to the Division as an option if necessary. I f any soil infiltration is identified at the pipe joint during inspection, a pipe analysis and a remediation plan for repair or replacement shall be submitted to the Engineer for approval.
604.12.3 Testing of Pipe: A post installation camera/video inspection of pipe culverts and
laser/mandrel deflection inspection of flexible pipe shall be conducted by the Contractor on all pipe culverts that meet the following requirements:
1.Cumulative total of 200 linear feet or more of pipe culverts on project; and
2.Project located on National Highway Systems (NHS) routes The Contractor may visually inspect, in the presence of the Engineer, in lieu of camera/video inspection where pipe culverts size, orientation, and location allow for easy visual examination. When camera/video inspection is required, it shall be conducted by the Contractor in the presence of the Engineer. The Contractor will note and document any defects or flaws with locations in their reports. Equipment used in these inspections must have the following features: Camera/Video inspection equipment shall be:
1.Configured properly in the pipe both vertically and horizontally, and having the ability to pan and tilt to a 90 degree angle with the axis of the pipe and rotate 360 degrees.
2.Low barrel distortion camera capable to measure cracks as small as 0.01”.
3.Color image with a minimum standard resolution of 720x480 pixels.
4.Equipped with sufficient lighting to provide a clear image of the full circumference of the pipe.
5.Capable of recording the station, milepost, distance along the invert of the pipe, or other indicators of location superimposed on the video.
6.Capable of moving through the entire length of the pipe.
7.Software capable of generating a report that shows each fault along with its location from the inspection entrance and a still frame image of the fault. Laser deflection measure device on flexible pipe up to forty-eight (48) inches in diameter shall be capable of measuring deflection to an accuracy of 0.5% or better with a repeatability of 0.12% or better. Mandrel device must have an odd number of legs (9 minimum) having a length not less than the outside diameter of the mandrel. The mandrel shall b e pulled by hand with no mechanical assistance. The diameter of the mandrel, whether it is fixed or variable size, must be verified with a proving ring or other method as per the manufacturer’s guidelines. The minimum diameter of the installed pipe at a ny point shall not be less than the diameter, as calculated per equation below: Minimum Diameter of Installed Pipe = (Actual Pipe Diameter) x (Deflection Percentage) Where: Actual Pipe Diameter = Inside pipe diameter of pipe being installed prior to installation Deflection Percentage = 0.95 for 5% deflection and 0.925 for 7.5% deflection The Contractor shall provide a digital copy of the camera/video inspection and issue a report in digital format, detailing all issues or deficiencies noted d uring the inspection, including a remediation plan for each deficiency, no later than 7 calendar days after completion of the inspection.
604.13 Method of Measurement:
Pipe of the different types and sizes, both new and re -laid, will be measured by the linear foot in place, the measurement being made along the centerline of each pipe installed. Branch connections, tees, wyes, and elbows will be measured along their centerlines and these lengths included in the total lengths of the pipe. Wyes, tees, and other branch connections will be measured along the centerlines to points of intersection. Pipe with sloped or skewed ends will be measured along the invert. The portion of pipe extending through to the inside face of headwalls of all types, manholes, inlets, boxes, or other structures shall be included in the measurement. Pipe designated on the Plans to be installed by the jacking method will be measured separately by the linear foot in place and shall be the actual portion jacked, completed in place, and accepted. End sections will be measured by the number of units installed.
604.14 Basis of Payment:
The quantities, determined as provided above, will be paid for at the contract unit prices bid for the items listed in 604.15, which prices and payments shall be full compensation for excavation and bedding, except as oth erwise provided, backfilling, jacking when called for, furnishing all materials and doing all the work prescribed in a workmanlike and acceptable manner, including all labor, tools, equipment, supplies, and incidentals necessary to complete the work. The unit price bid for end sections shall include excavation and backfill. When, by the authority of the Engineer, the flow line of a pipe is lowered from that shown on Plans, or due to a lack of a firm foundation, or due to a solid rock foundation, unsatisfa ctory material is removed and replaced with suitable material, the work of excavation, replacement, and compaction of material will be paid for in accordance with 109.4.
1.For pipe culverts less than forty-eight ( 48) inches diameter, the work of excavation, measured in excess of one (1) foot below the original planned pipe elevation, will be paid for under the provisions of 109.4. When suitable material is not available from the project excavation, payment for replace ment material below final grade line will be made in accordance with subsection 109.4.
2.For pipe culverts 48-inches diameter or larger, all additional excavation below the original planned pipe elevation and for a width not in excess of the outside pipe diameter plus eighteen (18) inches on each side of the pipe, will be paid for at the unit bid price for Item 207001-* "Unclassified Excavation". When no Item 207001 -* is included in the Proposal, payment for excavation, backfill compaction and replacement material will be made in accordance with 109.4. When suitable material is not available from the project excavation, replacement material will be paid for in accordance with 109.4.
604.14.1 Price Adjustment: Crushed aggregate not conforming with the gradation
requirements as described in subsection 604.2.4.2 will be paid for at the adjusted contract price base on the degree of nonconformance as specified in Table 604.14.1. A revised unit price for calculation purposes in subsection 307.9.1 will be established based on the unit bid cost minus the cost of the pipe. TABLE 604.14.1 Adjustment of Contract Price for Gradation not Within Specifications Degree of Nonconformance Percent of Contract Price to be Reduced 1.0 to 3.0 2 3.1 to 5.0 4 5.1 to 8.0 7 8.1 to 12.0 11 Greater than 12 * * The Division will make a special evaluation of the material and determine the appropriate action.
604.15 Pay Items:
ITEM DESCRIPTION UNIT 604037-* “size” Reinforced Concrete Pipe, Class ** Linear Foot 604039-* “size” Reinforced Concrete Pipe Arch, Class ** Linear Foot 604041-* “size” Reinforced Concrete Elliptical Pipe, X Linear Foot 604045-* “size” Polypropylene Pipe Linear Foot 604050-* “size” High Density Polyethylene Pipe, profile wall Linear Foot 604051-* “size” High Density Polyethylene Pipe, steel reinforced Linear Foot 604052-* “size” Polyvinyl Chloride Pipe Linear Foot 604053-* “size” Relaid Existing Pipe Linear Foot 604054-* “size” Jacked Pipe, Reinforced Concrete Pipe, Class ** Linear Foot 604070-* “size” Precast Concrete Box Culvert Linear Foot 604071-* “size” Concrete Safety Slope End Section for Round Pipe Each 604073-* “size” Concrete Safety Slope End Section for Elliptical Pipe Each 604074-* “size” Aluminum Structural Plate Box Culvert, YZ Linear Foot 604076-* “size” Aluminum Coated Corrugated Steel Pipe, YZ Linear Foot 604077-* “size” Aluminum Coated Corrugated Steel Pipe Arch, YZ Linear Foot 604080-* "size" Aluminum Coated Corrugated Steel Pipe and Paved Invert Linear Foot 604090-* “size” Corrugated Steel Pipe End Section Each 604091-* “size” Corrugated Steel Pipe Arch End Section Each 604092-* “size” Corrugated Steel Pipe Safety Slope End Section Each * Sequence number ** Class designated by Roman numerals. “special design” may be used for unique circumstance X = Type of elliptical pipe in accordance with the following table Y = Base metal thickness in accordance with the following table. Z = A one digit number designating metal pipe corrugatio ns in accordance with the following table. For Aluminum Box Culverts, haunch and crown plate thicknesses as specified on the Plans Y Mil Thickness Steel Aluminum A 64 60 B 79 75 C 109 105 D 138 135 E 168 164 F 188 --- G 218 --- H 249 --- J 4 Bolts/Ft 280 -- K 6 Bolts/Ft 280 100 L 8 Bolts/Ft 280 125 M 313 150 N 375 185 P --- 200 Q --- 225 R --- 250 Z Metal Corrugations Pipe Class 1 1½”x ¼” --- 2 ⅔” x ½” --- 3 3” x 1” --- 5 5” x 1” --- 6 6” x 2” --- 7 7½” x ¾” x ¾” --- I or 1 --- I II or 2 --- II III or 3 --- III IV or 4 --- IV V or 5 --- V X Concrete Pipe H Horizontal Elliptical V Vertical Elliptical
Referenced in this section
Pipe Culverts in other states
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Source: Standard Specifications for Roads and Bridges, 2023 Edition. Pages 402–415 of 1,006. View official source ↗