CONCRETE PIPE & BOX CULVERT INSTALLATION American Concrete Pipe Association • w
CONCRETE PIPE & BOX CULVERT INSTALLATION American Concrete Pipe Association • www.concrete-pipe.org American Concrete Pipe Association • www.concrete-pipe.org Table of Contents I. CONCRETE PIPE INSTALLATION MANUAL...5 Introduction...................................................5 PRE-CONSTRUCTION...................................... 6 Precautions................................................... 6 Ordering, Receiving And Handling...............6 Unloading...................................................... 7 Stockpiling..................................................10 INSTALLATION................................................ 12 Line And Grade........................................... 12 Excavation Limits........................................ 17 Excavated Material.....................................19 Dewatering.................................................. 19 Standard Installations................................. 20 Class A Bedding.........................................27 Class B Bedding.........................................27 Class C Bedding.........................................28 Class D Bedding.........................................29 Jointing.......................................................38 Rubber.................................................... 38 Mastic......................................................42 Mortar.....................................................42 Geotextile Filter Fabrics.......................... 43 External Bands.......................................43 Joint Procedures.........................................44 Service Connections................................... 46 Curved Alignment.......................................46 Final Backfilling........................................... 50 Acceptance Tests....................................... 50 Soil Density................................................. 51 Line And Grade........................................... 52 Visual Inspection......................................... 52 Infiltration....................................................53 Exfiltration...................................................56 Air Testing................................................... 58 Vacuum Testing.......................................... 61 American Concrete Pipe Association • www.concrete-pipe.org Joint Testing-Air.......................................... 62 Joint Testing-Water..................................... 62 II. BOX CULVERT INSTALLATION MANUAL.... 64 Introduction.................................................64 PRE-INSTALLATION......................................65 Precautions................................................. 65 Ordering, Receiving & Handling.................65 Scheduling / Unloading / Placing / Sequence.....................................66 Storing........................................................67 SITE PREPARATION...................................... 69 Excavation..................................................69 Trenchwater................................................ 70 Bedding/grade............................................. 70 INSTALLATION............................................... 73 Box Alignment............................................. 73 Box Placement............................................ 73 Jointing.......................................................73 Connecting the Boxes................................. 75 Completion.................................................. 76 Backfill........................................................76 Minimum Cover For Construction Loads....77 Visual Inspection......................................... 78 III. SPECIFICATIONS ........................................79 IV . APPENDIX...................................................... 87 Definitions...................................................87 Feet Head of Water into Pressure, Pounds Per Square Inch...............90 Feet Head of Water into Kilopascals (kN/m2)........................90 American Concrete Pipe Association • www.concrete-pipe.org I. CONCRETE PIPE INSTALLATION MANUAL INTRODUCTION This manual presents a guide for the proper in- stallation of concrete pipe. For many years, the American Concrete Pipe Association has conduct- ed comprehensive research and analysis of the factors which affect the field performance of con- crete pipe. The knowledge and beneficial practices gained through research and experience are pre- sented in this manual. While focusing on the construction of the pipe- soil system, this manual also addresses those fac- tors critical to the completion of the entire system, from delivery of the concrete pipe to the jobsite, to the acceptance of the installed pipeline. This manual is intended as a guide and is not to supersede the project specifications. American Concrete Pipe Association • www.concrete-pipe.org PRE-CONSTRUCTION PRECAUTIONS Federal regulations covering safety for all types of construction, including sewer and culvert instal- lations, are published in the Safety and Health Reg- ulations for Construction under the Department of Labor, Occupational Safety and Health Administra- tion (OSHA). These regulations are applicable to all prime contractors and subcontractors involved in any type of construction, including alterations and repair work. The installer should also review installation prac- tices with the engineer’s design assumptions, par- ticularly in relation to the use of trench boxes and compaction requirements of the backfill. ORDERING, RECEIVING AND HANDLING Although the ordering of materials is the contrac- tor’s responsibility, supplier and engineer familiarity with the contractor’s proposed schedule will en- able better coordination to avoid mistakes and pos- sible delays in pipe deliveries. Pipe manufactur- ers stock a wide range of pipe sizes and strengths, but production facilities must frequently be adapted to meet specific project requirements, particularly when large quantities and/or special types of pipe are involved. Information required to initiate a pipe order should be in writing and include: name and location of project pipe size, laying length and strength total footage of each type and size of pipe type of joint size and quantity of manhole base sections, riser sections, cone sections and grade rings list of fittings and specials including radius pipe • • • • • • American Concrete Pipe Association • www.concrete-pipe.org laying sequence required specifications material test requirements joint material and quantity invoicing instructions The pipe should be checked for the following in- formation, clearly marked on each pipe section: specification designation pipe class or strength designation span, rise, table number, top of box and de- sign earth cover for ASTM C 1433(M) or C 1577(M), or AASHTO M259(M) or M273(M) box sections date of manufacture name or trademark of the manufacturer for reinforced pipe with elliptical or quadrant reinforcement orientation, the letters E or Q, respectively and “top”. UNLOADING Unloading of pipe should be coordinated with the construction schedule and installation sequence to avoid re-handling and unnecessary equipment movement. Access to the jobsite shall be provided by the contractor to ensure that the pipe manufac- turer’s trucks can deliver pipe to the unloading area under their own power. Each shipment of pipe is loaded, blocked and tied down at the plant to avoid damage during tran- sit. However, it is up to the receiver to make cer- tain, damage has not occurred in delivery from the plant to the construction site. An overall inspection of each pipe shipment should be made on arrival, before the pipe is unloaded. Total quantities of each item should be checked against the delivery slip and any damaged or missing items recorded on • • • • • • • • • • • American Concrete Pipe Association • www.concrete-pipe.org AUTOMATIC UNLOADER the delivery document. If a pipe is damaged during delivery or unload- ing, the pipe should be set aside. Damaged ends, chips or cracks, which do not pass through the wall, can usually be repaired. Many carriers are equipped with automatic un- loaders, which further expedite the unloading of cir- cular pipe. These automatic unloaders consist of a forklift type of apparatus mounted at the rear of a flat bed truck. The forks rotate vertically rather than move up and down, such that, when the forks are in a vertical position they extend above the truck bed. This provides a backstop and cushion for the pipe sections as they are rolled to the rear of the truck for unloading. A cradle formed by the forks and unloader frame securely retains the pipe section being unloaded as the forks are rotated downward and lowered to the ground. Unloading of the pipe should be controlled so as not to collide with the other pipe sections or fittings, and care should be taken to avoid chipping or spall- ing, especially to the spigots and bells. Caution should be exercised to be sure personnel are out of American Concrete Pipe Association • www.concrete-pipe.org the path of the pipe as it is lowered. If the pipe has to be moved after unloading, the sections should be rolled or lifted and should never be dragged. Pipe sections should not be rolled over rough or rocky ground. The use of mechanical equipment is necessary for unloading arch, elliptical and box sections and larger size circular pipe, and can usually simplify and speed up the unloading of smaller pipe. When using mechanical equipment for unloading, the lifting device, which connects to the pipe, should enable proper and safe handling without damage to the pipe. Lifting devices such as slings, chain, steel wire, cable and rope should be placed around the pipe and arranged so that the pipe is lifted in a horizontal position. If the lifting device could chip or damage the pipe, padding should be provided between the pipe and lifting device. These types of lifting devices should not be passed through the pipe. Other devices, which are designed to pass into or through the pipe, should not touch the spig- ot or bell jointing surfaces, and should extend far enough beyond the end of the pipe for adequate clearance of lifting lines. When pipe is provided with lifting holes, the lift- ing device should pass through the wall and distrib- ute the weight along the inside barrel of pipe. The most common lifting device for use with lift- ing holes consists of a steel threaded eye bar with a wing type nut and bearing plate. If a specially de- signed lifting device is not readily available, a single looped sling can be passed through the lift hole into the bore of the pipe and then around a piece of tim- ber of adequate length and cross-section to assure structural stability. For manhole sections, cone sections, bases, fittings and other precast appur- American Concrete Pipe Association • www.concrete-pipe.org 10 LIFT HOLD DEVICES tenances, the lifting holes or lifting eyes provided should be used. Regardless of the method used to unload pipe, precautions should be taken to avoid damage to the pipe and assure the pipe is unloaded in a safe manner. STOCKPILING Any stockpiling of pipe should be as near as possible to where the pipe will be installed. Small diameter pipe should be layered in the same man- ner as they were loaded on the truck. The bottom layer should be placed on a flat base, adequately blocked to prevent shifting as more layers are add- ed. Each layer of bell and spigot pipe should be arranged so that all the bells are at the same end. The bells in the next layer should be at the opposite end, and projecting beyond the spigots of the pipe sections in the lower layer. Where only one layer is being stockpiled, the bell and spigot ends should alternate between the adjacent pipe sections. All pipes should be supported by the pipe barrel so that the joint ends are free uploads/s3/ culverts-installation-guide 1 .pdf
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- Publié le Aoû 27, 2022
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