B-Pipe Construction Manual

Pipe Construction Manual
Topics Covered
 Construction Related Performance

Problems
 Pipe Manual Overview
 Trench Widths
 Bedding and Backfill
 Documentation Requirements
Construction Inspection Related
Performance Problems
Corrugated Metal Pipe Problems
 In the 1980’s CMP’s were Failing

 Reason: Construction Personnel were allowing
Contractors to End Dump Backfill and Use Soil
Instead of Granular Material.
 See Chapters 7 through 10 (pgs. 26-41)
Concrete Pipe Problems
 Bottom of Pipe Experiencing Early Deterioration

 Reason: Construction Personnel Allowed the
Contractor to Place the Pipe on Rock.
 See Chapter 5 Foundations (pg. 23)
Thermo Plastic Pipe Problems
 Several of These Pipe Failed During

Construction
 Reason: Construction Personnel Allowed Heavy
Construction Equipment on the Pipe without
Proper Cover.
 See Figure 900-8 (pg. F-68)
Pipe Manual Overview
 Chapter 1: Type of Pipe and Uses (CMS
603.02)
 Explains: All the different types of pipe…”A”,
“B”, …
 Chapter 2: Pipe Delivery and Inspection

 Explains: (1) The field material inspection
requirements. (2) What defects to look for on
the various types of pipe that are available.
 Chapter 3: Construction Layout (CMS 603.05)
 Explains: The use of a laser, alignment and box
culvert placement problems.
 Chapter 4: Trench Width in a Cut (CMS 603.03)
 Chapter 5: Foundations (CMS 603.03)
 Chapter 6: Dewatering (CMS 603.02)
 Chapter 7: Bedding & Backfill Material
Requirements (CMS 603.02)
 Chapter 8: Bedding Requirements (CMS 603.04)
 Different bedding classes are presented in
Figures 800-1 thru 800-3 (pgs. 57-59).
 Chapter 9: Backfill Requirements (CMS 603.08)
 Chapter 10: Compaction Requirements (CMS
603.081)
 Chapter 11: Placing & Joining the Pipe (CMS
603.06)
 Chapter 12: Documentation (CMS 603.081)
Check the Trench Width
Chapter 4 in Manual and in CMS 603.03
 Maximum Trench Width Minimizes the

Load on the Pipe
 Minimum Trench Width Allows for Proper
Jointing
 Trench Width is Measured at the Top of the
Pipe
Trench Width in a Cut
Chapter 4 in the Manual and in 603.03
 Minimum and Maximum for All Pipe in a Cut

Except for Type “B” & “C” Thermo.
 6” to 15” for Pipe less than 60”
 6” to 24” for Pipe 60” and more
 Thermo Plastic Pipe Minimums in Figure 400-2
(pg. 54)
 Minimum Trench Width for Large Structures
(Boxes & Three-Sided).
W = OD + 2(2’)….2 foot each side
Trench Width Changes
 Changes With:
 Kind of Pipe, (conc., thermo, etc.,)
 Type of Pipe, (“A”,”B”….)
 Cut or Fill Situation
 All Iterations are Detailed in Figures 400-3

and 900-1 thru 900-7
 Typical Changes on Figures 900-6 & 900-7
 Record Figure Numbers on Inspection
Form C-170
Check the Foundation
Manual in Chapters 5& 6, CMS 603.03
 Soft Foundation
 Rock Foundation
 Wet Conditions
Soft Conditions
Manual in 502.0 (pg. 22), and in CMS 603.03
 Most Common Foundation Problem

 If Workers Can Work, Then the Foundation
is Adequate
 Under Cut and Replacement of approx. 12”
is Usually Satisfactory
 Presently, Contractor Responsible for the
Top 12”
 Will Be Changed in Specification Revision
Rock Foundation
Manual in 503.0 (pg. 23), and in CMS 603.03
 All Rock Must Be Under Cut 6” Below the

Bedding or 12” Below the Bottom of the
Pipe
 If not, the Rock will Cause a Point Load
 The Bottom will Fail as Illustrated Earlier
Wet Conditions
Manual in Chapter 6, and in CMS 603.02
 Contractor is Responsible to Provide

Drainage
 Such as Rerouting Water, Pumping…
 When all Reasonable Methods are not

Working
 Then, and Only Then, an Open Graded
#67 or #57 (Type 3 Granular Backfill) May

be used Below the Pipe
 This will Alleviate Most Problems
Dip in the Road
Preventable Construction Related Problems
 If you Use Open Graded Material and Put Sand or

Soil on Top as Backfill
 The Fine Sand or Soil will Migrate into the #57’s or
#67’s and Cause Dips
 See Piping in Manual 601.0 (pg. 24)
Bedding & Backfill Materials
 Type 1 Granular Material……304

 Type 2 Granular Material……Sand
 Type 3 Granular Material……#57 or #67
 Type 1 and 2 Allowed Anywhere
 Restrictions on Type 3 were Covered
Earlier
Placing the Bedding & Backfill
Manual in Chapter 8 & 9, and in CMS 603.08 & 603.081
 This is Obviously Incorrect!

 Material is Placed in 8” lifts
Placing & Spreading the Bedding
 Trackhoe or Loader are Often Used

 Truck End Dumping Can Not Place Material in
8” Lifts
 Place the Material in 8” Lifts!!
Compact the Bedding Material
 Leave the Middle 1/3 of the Pipe Bedding

Uncompacted
 See Figure 1000-1 (pg. 69)
 Avoids Causing Point Loading on the Pipe
 Check the Grade and Rake if needed
Place the Next Section of Pipe
Manual in Chapter 11, and in CMS 603.05, 603.06 & 603.082
Each Manufacturer will Cover the Details of

the Placement and Jointing of the Different
Types of Pipe.
Check the Joint Gap
 One Inch Tolerance is Acceptable for Most Pipe

 Should Get Closer than 1”
 Look for Non-uniform Gaps
Look for Leaking Joints
Make Corrections as Necessary

Backfill Placement
Manual in Chapter 9, and in CMS 603.08 & 603.081
 Place and Spread the Backfill in 8” Lifts

 Manipulate in and around the Pipe Prior to
Compaction
 Use Shovels if Necessary
Compact the Backfill
 Compact Thoroughly
 Particularly From the Bottom of the Pipe to the
Middle of the Pipe (a.k.a. haunch area)
A Hoe-Ram Usually can get close enough to

the Pipe for Full Coverage of the Backfill.
Use Spud Bars, Shovel Slicing or Automated

Spud Bar in Tight Areas.
 Use Combinations of Compaction Equipment

 Notice the Automated Spud Bar (above to the left)
Check Compaction
 Type 1 (304) Compaction Testing

 Use Test Section and Moisture from M-D Curve
to Establish Maximum Density
 Average a Minimum Compaction of 96% of
Maximum.
 Minimum Individual Reading 92% of Maximum
 Make a New Test Section When Conditions
Change
Check for Compaction
 Add Water to Stockpile if Needed

 Type 1 (304) Optimum Moisture +/- 5 to 10%
Check Compaction
 Add Water in Trench if Needed

 This is not Flooding!!
Flooding the Backfill Properly
 Type 2 (sand) Requires Flooding

 Place Material in 8” Lifts. Then,
construct an 8” wall.
Proper Flooding Technique
Fill the Trench up with Water

Proper Flooding
 Allow the Water to Dissipate.

 Then Compact the Material
 Note: Notice Flooding Finds the Bad Joint
Compact the Sand after Flooding
 Check Compaction after Flooding, then after

Compaction
 If Density goes Down……Use Flooding Only
 If Density goes Up…….Use Flooding and
Compaction
Compaction of Sand
 May Non-Perform Flooding if:

 Water Doesn’t Dissipate
 If there is no way to Drain the Water
(Median Pipe)
Granular Material Requirements
 Granular Material is Required for a Minimum

Height above the Pipe
 See Figures 900-1 thru 900-8
 Changes with:
 Kind and Type of Pipe as well as Fill vs. Cut
Situations
Compaction in Confined Spaces
 Trench Boxes Complicate the Process

 Place and Compact in the Trench Box
Raise the Front of the Trench Box
Trench May Collapse
 Place Material in the Trench as the Box

is Removed
 Notice that the Center of the Backfill is
Not Displaced when the Box is Removed
 Not the Best Situation, but Acceptable
Compact Material to Road Surface
 Remember to Protect the Pipe

 See Figure 900-8
 Remember the Example
Documentation Requirements
Pipe Manual Chapter 12 (pgs. 49-51)
 All Pipe Operations Should Have an

Inspector Present
 Record Inspection on C-170 and CMS-1
Forms
 Chapter 12 Outlines 11 Areas of Inspection
 Details the Type of Operation and
Required Documentation
Example of Documentation
Pipe Manual Chapter 12 (pg. 50)
 Check the Pipe Trench Width

 Record the Pipe Outside Diameter
 Record the Trench Width Used
 See Chapter 400, Trench Widths in a Cut
C-170 Daily Pipe Construction
Inspection Form
Pipe Manual (pgs. 70-71)
 Top Portion……General Information

 Location, Bubble Number, Plan Page…
 Sketch Area… Specification… Width, Depth
 Trench & Bedding Checks… Field Measurements
 Manual Figure Numbers…(pgs. 53-69)
 Figures Show the Dimensions for the Type of Pipe
 Pipe Marking and Joint Checks… Bottom
Back of Form C-170
Pipe Manual Chapter 12 (pg. 50)
 Top Portion…Pay Adjustments, Creep,

Structures, Measurements for Pay
 Lower Portion
 Remarks Area…Soft Foundation,
Undercuts
 Sketch Area
 Inspectors and Engineers/Supervisors
Signature

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Pipe Construction Manual

 Construction Related Performance

 In the 1980’s CMP’s were Failing

 Bottom of Pipe Experiencing Early Deterioration

 Several of These Pipe Failed During

 Chapter 2: Pipe Delivery and Inspection

 Maximum Trench Width Minimizes the

 Minimum and Maximum for All Pipe in a Cut

 Type of Pipe, (“A”,”B”….)

 Cut or Fill Situation

 All Iterations are Detailed in Figures 400-3

 Most Common Foundation Problem

 All Rock Must Be Under Cut 6” Below the

 Contractor is Responsible to Provide

 When all Reasonable Methods are not

#67 or #57 (Type 3 Granular Backfill) May

 If you Use Open Graded Material and Put Sand or

 Type 1 Granular Material……304

 This is Obviously Incorrect!

 Trackhoe or Loader are Often Used

 Leave the Middle 1/3 of the Pipe Bedding

Each Manufacturer will Cover the Details of

 One Inch Tolerance is Acceptable for Most Pipe

Make Corrections as Necessary

 Place and Spread the Backfill in 8” Lifts

A Hoe-Ram Usually can get close enough to

Use Spud Bars, Shovel Slicing or Automated

 Use Combinations of Compaction Equipment

 Type 1 (304) Compaction Testing

 Add Water to Stockpile if Needed

 Add Water in Trench if Needed

 Type 2 (sand) Requires Flooding

Fill the Trench up with Water

 Allow the Water to Dissipate.

 Check Compaction after Flooding, then after

 May Non-Perform Flooding if:

 Granular Material is Required for a Minimum

 Trench Boxes Complicate the Process

 Place Material in the Trench as the Box

 Remember to Protect the Pipe

 All Pipe Operations Should Have an

 Check the Pipe Trench Width

 Top Portion……General Information

 Top Portion…Pay Adjustments, Creep,

 Inspectors and Engineers/Supervisors

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