603Culverts and Storm Drains

Culverts and Storm Drains

603.1DESCRIPTION

1 This section describes the requirements for constructing or relaying culverts and storm drains.

603.2MATERIALS

1 Provide materials in accordance with the following:

Material Subsection Admixtures 801.4 Aggregate for Concrete 803.2 Aggregate for Flowable Backfill 803.16 Aluminum-Coated Pipe 808.5 Aggregate for Bed Course Material 803.10 Bituminous-Coated Corrugated Steel pipe 808.5 Bolts, Nuts and Washers 815.6 Corrugated Aluminum Alloy Culvert Pipe 808.6 Corrugated Metal Units 808.7 Corrugated Steel Pipe and Pipe-Arches 808.5 Curing Materials 802.1 Fly Ash 801.2 Galvanized Coating 815.14 High Density Plyethylene Pipe 808.18 Pipe Joint Mortar 808.14 Polymeric Precoated Galvanized Steel Pipe 808.5 Polyvinyl Chloride Pipe – Smooth Wall 808.20 Polyvinyl Chloride Pipe – Profile Wall 808.21 Portland Cement 801.1 Reinforced Concrete Pipe 808.1 Reinforcing Steel 811.1 Rubber Ring Gaskets 808.15 Steel Mitered End Sections 808.16 Water 814.1

Culverts and Storm Drains SECTION 603

603.3EQUIPMENT

1 Ensure that equipment meets the following:

Equipment Subsection Batch Plant 513.3.1 Mixers 513.3.2 Placing Equipment 513.3.3

1 To mix flowable backfill, provide a rotary drum or other approved mixer capable of thoroughly dispersing all ingredients.

603.4CONSTRUCTION

603.4.1 General

1 The following abbreviations, when used in the contract, represent the full text shown.

RCP Reinforced Concrete Pipe

HERCP Horizontal Elliptical Reinforced Concrete Pipe

CSP Corrugated Steel Pipe

CAP Corrugated Aluminum Alloy Pipe

CMP Corrugated Metal Pipe

HDPE High Density Polyethylene Pipe (Smooth Interior)

PVCS Polyvinylchloride Smooth Wall Pipe (round pipe only)

PVCP Polyvinylchloride Profile Wall Pipe (round pipe only)

FE Flared End

SME Steel Mitered End

Culverts and Storm Drains SECTION 603

2 When the contract specifies CMP, the department allows the use of CSP or CAP meeting specifications. The department will designate pipe-arches of the above types of pipe by using the word “arch.”

3 Ensure that plants producing RCP and HERCP are certified in accordance with Subsection 502.4.1, Plant Certification. Submit a copy of the precast concrete manufacturer’s certification current at the time of manufacture to the engineer seven calendar days prior to delivery of RCP and HERCP to the project.

4 Use an end finish consisting of FE, bevel end, step bevel end, square-cut end, or SME sections. For HDPE and PVC, use metal flared ends meeting the specified CR number. Where the CR number exceeds 5 use metal flared ends meeting CR5. Provide SME sections with the specified slope and grate type and parallel drainage (PD) or cross drainage (CD) grate.

5 Maintain cover over pipes during construction to prevent damage. At pipe ends, construct embankment slopes to match flared end section slopes.

603.4.2 Pipe Selection

1 When extensions of existing pipes are required, provide and install the same type and size of pipe. For flexible (metal) pipe, use extensions made of the same base metal.

2 Select and provide rigid pipe with the strength class specified in the fill height tables for the installed fill heights.

3 Select and provide flexible pipe in accordance within the specified parameter in the specified fill height tables. For CMP, select metal type, corrugation pattern, thickness, equivalent seam type, etc. in accordance with the installed fill heights. A thicker gage metal pipe may be provided at no additional cost to the department. For plastic pipe, provide the minimum structural properties specified and confirm the actual properties provided meet the installed fill heights in accordance with the latest edition of AA SHTO Load and Factor Resistance Design (LRFD).

4 The department will allow substitution of equivalent sizes and classes of RCP arch and HERCP for each other when either is specified. For extensions, use the same size and class as existing pipe.

5 Select and provide pipe from among those allowed under the corrosion resistance number in Table 603.4.2-1, Corrosion Resistance Acceptability. Use the CR1 classification when no number is specified.

Culverts and Storm Drains SECTION 603 Table 603.4.2-1 Corrosion Resistance Acceptability Type of Pipe Corrosion Resistance Number CR1 CR2 CR3 CR4 CR5 CR6 CR7 CR8 CR9 Galvanized Steel yes no no no no no no no no Aluminum Coated Steel (Type 2) yes no no no no no no no no Bituminous Coated Galvanized Steel yes yes no no no no no no no Aluminum Alloy yes yes yes yes no no no no no Polymeric Precoated Galvanized Steel yes yes yes yes yes no no no no RCP (Type II Cement) yes yes yes yes yes no no no no RCP (Type V Cement) yes yes yes yes yes yes yes no no RCP (Type V Cement/Fly Ash) yes yes yes yes yes yes yes yes no Epoxy Coated RCP (Type II or Type V Cement) yes yes yes yes yes yes yes yes yes High Density Polyethylene

Polyvinyl Chloride (PVC) yes yes yes yes yes yes yes yes yes 6 Do not use plastic pipes (PVC or HDPE): • U nder interstates and highways with a projected Average Daily Traffic (ADT) greater than 2000 vehicles per day (VPD); • Within the confines of bridge embankments; • Under building foundations; • Within the limits of backfill of mechanically stabilized earth (MSE) walls; and • For storm sewers. 7 Ensure that connecting bands and end sections have the same corrosion protection as the pipe. 603.

4.3Excavation

1 Excavate trenches or channels in accordance with Section 206, Excavation and Backfill for Culverts. Where required, camber the channel longitudinally. Vary the amount of camber for the fill height and supporting soil; do not reverse the pipe gradient.

Culverts and Storm Drains SECTION 603 603.4.4 Pipe Bed Preparation 1 Ensure that soil beneath the bedding layer is undisturbed, or otherwise a suitable, firm, compacted foundation. Provide a pipe bedding layer by loosely placing an 8 in [200 mm] lift of bed course material. Provide a shaping template for each size of pipe furnished. Match the curvature of the template to the pipe bottom for a width of the outside diameter divided by three. Use the shaping template to shape the loose bed course material in the central bedding zone without compacting the material in this zone. R emove sufficient material at each pipe protrusion such as joint bells to prevent stress concentrations on joints. Tamp material outside the central bedding zone within the bedding limits after the pipe is placed. Backfill additional lifts of bed course material in accordance with Subsection 206.4.5, Backfilling. Backfill over -excavations in trench locations with bed course material at no additional cost to the department. 603.

4.5Installing Pipe

1 Begin pipe installation at the downstream end. Ensure that the full length of each pipe segment bottom is in contact with the shaped bedding. Place bell or groove ends of rigid pipe and outside circumferential laps of flexible pipe facing upstream. Place flexible pipe with longitudinal laps or seams at the sides. Place reinforced-concrete elliptical pipe with the minor axis vertical and the major axis horizontal. 2 After placing the pipe, compact bed course material outside of the central bedding zone to 95.0 percent of maximum density and within plus 2 percent to minus 4 percent of optimum moisture content. Do not compact material in the central bedding zone. If foundation material is rock, increase minimum bedding thickness to 12 in [300 mm]. 603.

4.6Joining Pipe and End Sections

603. 4.6.1 General 1 Use galvanized tie bolts, washers, and nuts. 2 Rigid Pipe. Use bell-and-spigot or tongue- and-groove design. Join the sections with ends tight and inner surfaces flush and even. If difficulty is encountered in making joints tight and flush, use bolted joint ties. On slopes of 10 percent or steeper, use bolted joint ties or bell-and-spigot pipe. If water tight joints are specified, use rubber gaskets, mastic filler or an external joint wrap which meets a laboratory test pressure of 10.8 psi in accordance AASHTO M315. If a wrap is chosen for the sole method of sealing, the wrap must cover the entire circumference of the pipe and must be either an external sealing band that meets the requirements of ASTM C877 Type 1 or Type 2. 3 Flexible (Metal) Pipe. If helical pipe is furnished, re- roll pipe ends to provide annular corrugations for the entire area covered by the pipe bands. Place pipe ends

Culverts and Storm Drains SECTION 603 approximately ¾ in [19 mm] from each other to allow the band corrugations or dimples to fully engage the corrugations of each pipe joined when tightened. P rovide pipe bands widths as follows:

equivalent round 4 If water tight joints are specified, do not provide flexible metal pipe unless specifically allowed in the contract. When metal pipe is allowed where water tight joints are specified, provide o- ring elastomeric gaskets or continuous sleeve gaskets the wi dth of the connecting bands under the bands on both sides of the culvert joint. 5 Flexible (Plastic) Pipe – HDPE and PVC. For PVC, u se bell and spigot joints with a positive connection that resists pulling apart and are soil tight. For HDPE, used either bell and spigot, or fused or extrusion-welded joints that resists pulling apart and are soil tight. Soil tight joints are to include an elastomeric gasket meeting the requirements of ASTM F477. Split or wrap around couplers incorporating plastic ties are only permitted if soil tight and approved in advance by the engineer. Connections are to have the same or better strength than the standard pipe section. If water tight joints are specified, ensure they meet a laboratory test pressure of 10.8 psi in accordance ASTM D3212. Band metal flared ends to HDPE and PVC pipe with an equivalent connection as required for metal flared ends to metal pipe. 603. 4.6.2 RCP FE Sections 1 Match the FE section joint configuration to the pipe joint. Use tie bolts on sections 60 in [1500 mm] or more in diameter. Use the bolts to hold ends together, not to pull sections tight. If the pipe is accessible to people and animals, ensure that tie bolt threads do not project inward. 603. 4.6.3 SME Sections 1 Provide and install required hardware and appurtenances (including the tapered sleeve required for RCP connections). Ensure a smooth, tight juncture consistent with flow characteristics of the pipe. Attach end sections using connectors in accordance with Table 603.4.6-1, SME Section Connectors. Table 603.4.6-1 SME Section Connectors Pipe Size Connector Type Round ≤ 24 in [600 mm] 1 (Straps) Round > 24 in [600 mm] and All Other Pipe 2 (Rods and Lugs)

Culverts and Storm Drains SECTION 603

603.4.7 Pipe Collars

1 When required, provide and place reinforcing steel as specified in accordance with 513.4.4, Mix Design.

2 Remove fill to expose the existing pipe end, and if required, remove the existing end section.

3 Form collars to the dimensions specified. Form, place, and cure concrete in accordance with applicable portions of Subsection 513.4, Construction. The engineer may waive forming of concrete for pipe collars if the final collar dimensions meet specified minimum dimensions.

603.4.8 Repair of Damaged Coating

1 Repair damage to metallic coatings in accordance with Subsection 501.4.2.9, Repair of Galvanizing. Repair damage to polymeric coating by applying a polymeric coating similar to and compatible with the original. Do not backfill around the pipe before inspection and approval by the engineer.

603.4.9 Backfilling

1 Do not backfill before the engineer inspects the pipe. Relay or replace misaligned, settled, or damaged pipe.

2 Place and compact backfill material in accordance with Section 206, Excavation and Backfill for Culverts. Bring up each lift equally on each side of pipe. Where necessary, secure pipe to prevent floatation. Fill over excavations in trench locations with select bed course. When specified, use flowable backfill in accordance with Subsection 206.4.5, Backfilling.

603.4.10 Relaying Pipe

1 Relay removed pipe, including end sections, using the existing hardware and appurtenances to join the pipe and connect the end sections in accordance with Subsection 603.4.6, Joining Pipe and End Sections.

603.4.11 Deflection Testing

1 Test Flexible (Plastic) Pipe installations for 5 % and 7.5 % def lection. Measure plastic pipe deflection using a deflection gauge (mandrel) meeting ASTM Specification F679 a minimum 30 calendar days following completion of installation in the presence of the engineer. Remove and replace all sections of pipe that do not meet a maximum pipe deflection of 7.5% at no additional cost to the department.

Culverts and Storm Drains SECTION 603

2 A pay factor will be determined in accordance with Table 603.4.11- 1, Pipe Deflection Pay Factors.

Table 603.4.11-1 Pipe Deflection Pay Factors Amount of Deflection (%) Pay Factor 0.0 – 5.0 1.00 5.1 – 7.5 0.75 ≥ 7.5 Remove and Replace

603.5MEASUREMENT and PAYMENT

603.5.1 General

1 The engineer will measure pipe with beveled, step- beveled, or square- cut ends along the invert from end to end, and, when FE or SME sections are used, will not include the length of the end section for new pipe but will include it for relaying pipe. The length for payment will not exceed the length staked.

2 The engineer will measure new or relaid pipes installed in a storm sewer system along the centerline of the pipe from invert to invert of manholes or invert of inlet to invert of manhole.

3 The engineer will measure branch connections along their inverts from the intersection of their flow line with the flow line of the trunk line to the center of the manhole or inlet.

4 The engineer will measure:

Arch _____ × _____ in [mm], RCP Elliptical _____ × _____ in [mm], CMP _____ in [mm], CMP Arch _____ × _____ in [mm], HDPE _____ in [mm], PVCS _____ in [mm], PVCP _____ in [mm], and Relaying Pipe _____ in [mm] by the foot [meter].

Sect _____ in [mm], RCP Arch FE Sect _____ × _____ in [mm], RCP Elliptical FE Sect _____ × _____in [mm], CMP FE Sect _____ in [mm], CMP Arch FE Sect _____ × _____ in [mm], SME Sect _____ in [mm], SME Sect _____ in [mm] w/Grate, SME Arch Sect _____ × _____ in [mm], and SME Arch Sect _____ × _____ in [mm] w/Grate by the installed number of units of each size.

derived from the minimum collar dimensions specified.

Culverts and Storm Drains SECTION 603 5 The department will pay for approved alternate types of pipe as follows: Pay Item Pay Unit Measure to the Nearest Pay to the Nearest Pipe _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] Pipe Arch _____ × _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] Pipe FE Sect _____ in [mm] EA [Ea] EA [Ea] EA [Ea] Pipe Arch FE Sect _____ × _____ in [mm] EA [Ea] EA [Ea] EA [Ea] 6 The department will pay for specific types of pipe as follows: Pay Item Pay Unit Measure to the Nearest Pay to the Nearest CMP _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] CMP Arch _____ × _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] CMP FE Sect _____ in [mm] EA [Ea] EA [Ea] EA [Ea] CMP Arch FE Sect _____ × _____ in [mm] EA [Ea] EA [Ea] EA [Ea] HDPE _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] PVCS _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] PVCP _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] Pipe Collars CY [m3] 0.1 ft [0.05 m] 0.1 CY [0.1 m3] RCP _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] RCP Arch _____ × _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] RCP Elliptical _____ × _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] RCP FE Sect _____ in [mm] EA [Ea] EA [Ea] EA [Ea] RCP Arch FE Sect _____ × _____ in [mm] EA [Ea] EA [Ea] EA [Ea] RCP Elliptical FE Sect _____ × _____ in [mm] EA [Ea] EA [Ea] EA [Ea] Relaying Pipe _____ in [mm] FT [m] 0.1 ft [0.05 m] FT [0.5 m] SME Sect _____ in [mm] EA [Ea] EA [Ea] EA [Ea]

Culverts and Storm Drains SECTION 603 Pay Item Pay Unit Measure to the Nearest Pay to the Nearest SME Sect _____ in [mm] w/ Grate EA [Ea] EA [Ea] EA [Ea] SME Arch Sect _____ × _____ in [mm] EA [Ea] EA [Ea] EA [Ea] SME Arch Sect _____ × _____ in [mm] w/Grate EA [Ea] EA [Ea] EA [Ea] 603.

5.2Referenced Sections for Direct Payment

1 When specified, the engineer will measure and pay for:

Culverts.

relaying is specified, the removal is incidental to relaying.

Culverts. 603.

Pay Adjustments

T he engineer will calculate pay adjustments for plastic pipe deflection as follows: P ipe Deflection: PD = (PIPE - USC) x (DEF-1) x LP W here: PD = Pay Adjustment for Pipe Deflection PI PE = Unit Contract Price for the respective Culvert or Pipe pay item US C = Unit Supplier Cost to the contractor excluding delivery costs for the respective Culvert or Pipe pay item DEF = Pipe Deflection Pay Factor L P = Length of pipe measured for payment S ubmit paid invoices substantiating the supplier cost to the contractor excluding delivery costs to the engineer.