PIPE CONSTRUCTION Ohio Department of Transportation Corrugated Metal Pipe Installation Brian Flint Regional Engineer CONTECH CONSTRUCTION PRODUCTS, INC.

What is There to Talk About ? Materials Corrugations & Gauges Coatings Structural Design Foundation Considerations Backfill Procedures Proper Cover Requirements CSP Joint Options

CONTECH Construction Products, Inc. 80 years of Metal Product Innovation

Corrugated Metal Pipe Design Criteria Hydraulics Can You Achieve the Flow Requirements Structural Capacity Can You Handle the Loading Condition Durability Can You Last 75 Years Prove It ! Economy

Structural Design 1. Determine the loads on the pipe. 2. Calculate ring compression. 3. Perform basic strength and stiffness checks. a) wall strength b) seam strength c) handling stiffness 4. Ensure minimum cover. 5. Check and account for corner pressures on multiple radius pipes. (i.e. pipe arches)

Physical Strength Structural Design Installation Stiffness Importance of a Quality Backfill Deflection: Modified Iowa Formula Deflection = Load Pipe Stiffness + Soil Stiffness Soil Stiffness Accounts for 90% of Total Stiffness

Approved ODOT Sizes CONTECH size range from 6 “ to 144 “. ODOT Sizes: 707.01 1/4” or 1/2” deep 6” - 84” 707.02 1” deep 36” - 120” 707.12 Spiral Rib 18” - 78” ALUMINIZED Steel Type 2 Only 707.08 and 707.09 Fiber Bonded CSP No Longer Available !

Durability How Long Should it Last ? 50 years or 75 years What is the Design Service Life Required ? ODOT has Durability Charts for Metal Pipe L & D Manual: 1002-5 and 1002-6 ALT2 provides a minimum of 75 years for 16ga when 5<pH<9 and R>1500. As the gage is increased, the service life increases.

MANUFACTURER TYPE OF COATING GAUGE HEAT NUMBER DATE OF MANUFACTURE SPECIFICATIONS

Installation Overview Unloading and Handling Basic Installation Bedding Backfill ULTRA FLO (Spiral Rib) Connections/Bands/Accessories

Unloading and Handling Easily shipped in “nested” bundles (fewer trucks) Easy to handle and unload: Light weight ( light equipment ) Lifting Lugs for Large Diameter used with slings and hooks Slings or fork lift for smaller Diameter DO NOT Roll off truck Long Joints ( 20 ft - 40 ft ) Small outside Diameter

Proper Bedding Uniform Support Lateral Longitudinal Well graded granular material Free of frozen soil, sod, and large rocks Upper few inches should be relatively loose to allow corrugations to seat in bedding

Proper Foundation Uneven Foundation Uniform Foundation Pipe Pipe Soft Firm Soft Pipe Uneven Foundation Pipe Uniform Foundation

Soft Foundations Soft Excavate Soft Soil and Replace with Highly compacted granular material Soft In-Situ Soil W D Soft Shape Bottom For Pipe Arch For pipe-arch, excavate under pipe and replace with granular material only as deep as is necessary to obtain stable bed to install pipe

Minimum Permissible Spacing For Multiple Installations Arches Pipe Arches Span Pipe Diameter Up to 36”……..12” 36” to 108”……1/3 span 108” to 189”…..36” Diam. Up to 24”…..12” 24” to 72”….1/2 diam. 72” and over..36”

Backfill Satisfactory material: Well graded granular, w/ little to no plasticity Clean/dense/stable/drainable soil Proper placement (6”- 8” lifts on each side) Proper Compaction (90% Std. Density)AASHTO T99 Maintain minimum Height of Cover Installation conditions: Embankment or Trench

Proper Backfill - Embankment Diameter 8” Lifts Thoroughly compact fill in 8” max loose lifts. Keep fill at same level on both sides of pipe. Lifts Should extend at least 1 pipe diameter on each side

Proper Backfill - Trench 8” Lifts Diameter Outside diameter plus sufficient room for compaction equipment

Tamping Under the Haunches Span Diameter Tampered Fill Care must be taken to assure that voids and soft spots are not left under the haunches of pipe

Proper Backfill: Pipe Arches Span Compacted Layers in 8” Lifts Compacted to max density below and beside the haunches Stable

Heavy Construction Loads Finished Grade Height of Cover Temporary Cover for Construction Loads Pipe

Compaction Techniques Walk Behind Compactor Sheep Foot or Rubber Tire Roller Vibrating Rollers Flooding with Water approved ODOT methodology

Bands and Accessories HUGGER® Band Bolt Bar and Strap Connector O Ring Gaskets Flat Band Flat Gasket STAB Joint Fluted Gasket Dimple Band

Your Greatest Strength Can be Your Greatest Weakness Easy to assemble Positive Joint, w/ pull apart resistance Soil tight Can be done with 1 or 2 people Small amount of tools Felton Band Puller Mallet Open end or Deep socket wrench Impact Equipment

Band Fasteners Scafco Angle Bar, Bolt and Strap Used for smaller Diameter Pipe Bar, Bolt and Strap Single Double Rod and Lug (Levee Band Applications)

HUGGER Band 12-1/8” 12-1/8” Connection Detail Single 10-1/4” H-12 HUGGER BAND H-12 HUGGER BAND 12-1/8” 10-1/4” O-Ring Gasket Gasketed Section Connection Detail Single Bolt, Bar, & Strap

HUGGER Bands Bands are normally furnished as follows: 12” thru 48” 1 piece 54” thru 96” 2 piece 102” thru 144” 3 piece Band fasteners are attached w/ spot welds Rerolled ends are 2-2/3” x 1/2” corrugation

Longer Lengths = Fewer Joints

In Line Fittings: Improved Hydraulics

O RING Gaskets: Soil Tight Joints

HUGGER Band

Band Puller: Helps You Get Started

Fabricated Fittings Full line of fittings including elbows, tees, wyes, risers, bulkheads, reducers, etc.

Conclusions Handle it Properly The Right Foundation: The Key to a Quality Life Quality Backfill and Placement: Important for all Systems Roadway Embankment is Final Objective HUGGER Bands Applied Properly Stab Joints are Coming