Design of Corrugated Steel Buried Structures
Design of Corrugated Steel Buried Structures
Design of Corrugated Steel Buried Structures
DN-STR-03003
December 2002
DN Design
Standards
TRANSPORT INFRASTRUCTURE IRELAND (TII) PUBLICATIONS
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collectively referred to as TII Publications (Technical). This system replaces the NRA Design
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Road Works (NRA MCDRW).
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TII Publication Title Design of Corrugated Steel Buried Structures with Spans Greater Than
0.9 Metres and up to 8 Metres [and Correction, February 2002]
TII Publication
DN-STR-03003
Number
For all documents that existed within the NRA DMRB or the NRA MCDRW prior to the launch of
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National Roads Authority Volume 2 Section 2
Design Manual for Roads and Bridges Part 6 BD 12/01
Addendum
NRA ADDENDUM TO
BD 12/01
This Addendum supersedes the NRA Addendum dated December 2000 to Standard BD 12/95. The revisions
have arisen due to the publication of Standard BD 12/01 dated November 2001, which supersedes BD 12/95,
and also of the Correction dated February 2002.
Standard BD 12/01 – Design of Corrugated Steel Buried Structures With Spans Greater Than 0.9 Metres and
up to 8.0 Metres [and Correction, February 2002] – is applicable in Ireland with the following amendments:
GENERAL
1. The Standard provides specification requirements for use in public purchasing contracts. It does not
lay down legislation requirements for products and materials used in road construction in Ireland.
2. At several locations:
December 2002 1
National Roads Authority Volume 2 Section 2
Design Manual for Roads and Bridges Part 6 BD 12/01
Addendum
SPECIFIC
1. Page 1/2, Clause 1.5, line 3:
For: “Standard SD4 (MCHW 0.2.4)”
Read: “the National Roads Authority”.
December 2002 2
National Roads Authority Volume 2 Section 2
Design Manual for Roads and Bridges Part 6 BD 12/01
Addendum
December 2002 3
National Roads Authority Volume 2 Section 2
Design Manual for Roads and Bridges Part 6 BD 12/01
Addendum
[Note: the following two amendments are required to the original Highways Agency November 2001 issue of
BD 12/01, but have been incorporated in the Correction issued by the Highways Agency in February 2002]
December 2002 4
National Roads Authority Volume 2 Section 2
Design Manual for Roads and Bridges Part 6 BD 12/01
Addendum
2 Non-Aggressive
> 2 but 4 Aggressive
>4 Very Aggressive
December 2002 5
National Roads Authority Volume 2 Section 2
Design Manual for Roads and Bridges Part 6 BD 12/01
Addendum
For: “BD 24: Design of Concrete Bridges. Use of BS 5400 Part 4 (DMRB 1.3.1).”
Read: “NRA BD 24: Design of Concrete Road Bridges and Structures: Use of BS 5400 Part 4: 1990
(NRA DMRB 1.3.1).
NRA BD 57: Design for Durability (NRA DMRB 1.3.7).”
“18.1 All technical enquiries or comments on this Standard should be sent in writing to:
…………………………………………
E O’CONNOR
Head of Project Management and
Engineering
December 2002 6
DESIGN MANUAL FOR ROADS AND BRIDGES
In November 2001, page 7/1 – 7/2, was issued incorrectly. (The page number was incorrect as it
read 7/1 – 7/4). Please amend this page by crossing out page number 7/4, and writing 7/2.
DESIGN MANUAL FOR ROADS AND BRIDGES
PART 6
BD 12/01
SUMMARY
November 2001
DESIGN MANUAL FOR ROADS AND BRIDGES BD 12/01
Summary: This Standard covers the design and construction requirements for corrugated
steel buried structures with spans greater than 0.9 metres and up to 8.0
metres.
Volume 2 Section 2
Part 6 BD 12/01 Registration of Amendments
REGISTRATION OF AMENDMENTS
Amend Page No Signature & Date of Amend Page No Signature & Date of
No incorporation of No incorporation of
amendments amendments
November 2001
Volume 2 Section 2
Registration of Amendments Part 6 BD 12/01
REGISTRATION OF AMENDMENTS
Amend Page No Signature & Date of Amend Page No Signature & Date of
No incorporation of No incorporation of
amendments amendments
November 2001
DESIGN MANUAL FOR ROADS AND BRIDGES
PART 6
BD 12/01
Contents
Chapter
1. Introduction
2. Design Principles
3. Design Loads
4. Design Load Effects
5. Strength Parameters
6. Ultimate Limit State Requirements
7. Serviceability Limit State Requirements
8. Durability
9. Excavation and Filling
10. Handling and Installation
11. End Treatment
12. Overlying Reinforced Concrete Slab
13. Concrete Invert Paving for Closed Invert
Structures
14. Carriageway Drainage
15. Multiple Installations
16. Technical Requirements and Design Checklist
17. References
18. Enquiries
November 2001
Volume 2 Section 2 Chapter 1
Part 6 BD 12/01 Introduction
1. INTRODUCTION
Equivalence
Scope
This Standard does not cover the use of corrugated 1.8 Where the Contractor proposes a proprietary
steel buried structures in the repair of other types system of invert protection, the proprietary invert
of structure, for example, as a liner for brick arch system shall have a current British Board of
structures. In these situations, specialist advice Agrément Roads and Bridges Certificate or
should be sought from the manufacturers of equivalent for the end-use as indicated in the
corrugated steel structures. Schedule of Employer’s Requirements included in
the Outline Approval in Principle.
Environmental Considerations
1.9 Where the Contractor chooses a proprietary
protection coating with a designated life intended
1.4 The Overseeing Organisation’s requirements to contribute towards the durability requirement of
for environmental design shall be taken into the structure, a current British Board of Agrément
account in designing corrugated steel buried Roads and Bridges Certificate or equivalent shall
structures. Volume 10 of DMRB (Environmental be provided confirming its life under service
Design) gives advice on the use of underpasses by conditions appropriate to the circumstances stated
multiple species of small mammals and fish. It in the Schedule of Employer’s Requirements.
illustrates various forms of culvert design to
facilitate free passage of these species. Often these 1.10 The materials used for corrugated steel
considerations are fundamental to the buried structures, their manufacture and their
determination of the span, headroom, cross-section assembly and construction on site shall be in
invert and gradient of the structure. accordance with the Specification for Highway
Works (MCHW1).
Approval Procedure
Contract/Design Procedure
1.5 Corrugated steel buried structures are
proprietary manufactured structures and the design 1.11 A flow diagram for a typical contract/design
and contractual procedures required by Standard procedure is given in Figure 1.1 to assist users of this
SD4 (MCHW 0.2.4) shall be followed. Standard.
1.6 All bolted segmental and helically wound
corrugated steel buried structures and their Implementation
components require a current Type Approval
Certificate (MCHW1 Clause 104.9). Helically 1.12 This Standard shall be used forthwith on all
wound corrugated steel buried structures and their schemes for the construction and improvement of
components shall also have a current British Board trunk roads, including motorways, currently being
of Agrément, Roads and Bridges, Certificate or prepared, provided that, in the opinion of the
equivalent (MCHW1 Clauses 104.5 and 104.6) for Overseeing Organisation this would not result in
the end-use described in this Standard. The British significant additional expense or delay. Design
Board of Agrément (BBA) Certificate or Organisations shall confirm its application to
equivalent shall include guaranteed minimum particular schemes with the Overseeing
lockseam tensile strengths satisfying the Organisation. In Northern Ireland the use of this
requirements of Annex C of this Standard. standard shall apply on those roads designated by
the Overseeing Organisation.
1.7 Prior to being offered on a Contract, the
manufacturer of the corrugated steel buried Mandatory Requirements
structure shall have obtained a Type Approval
Certificate from The Highways Agency. The
1.13 Sections of this document which form mandatory
procedure for obtaining the Type Approval
requirements of the Overseeing Organisation are
Certificate for bolted segmental structures is
highlighted by being contained within boxes. The
described at Annex A. The procedure for obtaining
remainder of the document contains advice and
the Type Approval Certificate for helically wound
enlargement which is commended to designers for their
structures is also as described at Annex A and
consideration.
current certification by the British Board of
Agrément is mandatory.
1.14 The symbols used in this Standard are defined as h(m) Nominal height of fill above the
follows: structure.
a (mm²/mm) Cross-sectional area of corrugated ht(m) Height of fill above the crown of the
steel per unit length, the cross structure including the thickness of
section being parallel to the length any road construction.
of the structure.
I(mm4/mm) Cross-sectional moment of inertia of
aa (mm²/mm) Adjusted cross-sectional area of the corrugated steel per unit length,
corrugated steel per unit length the cross-section being parallel to
based on the remaining wall the length of the structure.
thickness after deduction of
sacrificial metal thickness required Ia (mm4/mm) Adjusted cross-sectional second
by Chapter 8. moment of area of the corrugated
steel per unit length, the cross-
B (mm) Diameter of plate used in plate load section being parallel to the length
test. of the structure.
C (kN/m) Compressive hoop load in the wall Id Depth correction factor for plate
of the structure per unit length. load test.
CT (kN/m) Total compressive hoop load in the k(N/mm³) Coefficient of soil reaction.
wall of the circular arch structure
per unit length acting upon the ke(N/mm³) Modified coefficient of soil reaction.
foundation.
K Constant.
dc (mm) Depth of corrugation.
Ka Active earth pressure coefficient.
D (mm) Additional trench width required for
m Poisson’s ratio of the structural
circular arch structures.
steel.
E (N/mm²) Modulus of elasticity of the
M*(N/mm²) Constrained soil modulus.
structural steel.
mv(mm²/N) Coefficient of volume
Es(N/mm²) Modulus of elasticity of the soil.
compressibility.
F(mm/N) Flexibility factor.
N Uncorrected SPT value.
Fmax (mm/N) Limiting value of flexibility factor.
P(kN/m²) Radial soil pressure on a circular
closed invert structure.
fa(N/mm²) Compressive hoop stress.
fb(N/mm²) Theoretical transverse elastic Pb(kN/m²) Radial soil pressure on the bottom of
buckling stress. a multi-radii structure.
PL(kN/m²) Design vertical live load pressure. γfL Partial safety factor that takes
account of the possibility of
P1 (kN/m²) Overburden pressure on top of unfavourable deviation of the loads
footing of circular arch. from their nominal values and of the
reduced probability that various
P2 (kN/m²) Lateral earth pressure on the outside loadings acting together will all
face of the footing of a circular arch. attain their nominal values
simultaneously.
P3 (kN/m²) Overburden pressure on top of
footing inside circular arch. γf3 Partial safety factor that takes
account of inaccurate assessment of
Q* Design Loads (Refer to BS 5400: the effects of loading, unforeseen
Part 1). stress distribution in the structure,
and variations of dimensional
r(m) Radius of circular structure. accuracy achieved in construction.
rb(m) Radius at the bottom of a multi-radii γm Partial safety factor that takes
structure. account of variabilities in material
strength and uncertainties in the
rc(m) Radius at the corner of a multi-radii
assessment of component strength.
structure.
∆q (N/mm²) Change in pressure applied by the
rt(m) Radius at the top of a multi-radii
plate (plate load test).
structure.
∆s (mm) Change in average settlement of the
R* Design Resistance (Refer to
plate (plate load test).
BS 5400: Part 1).
∆x (m) Increase in horizontal diameter or
S (m) Span of the structure (diameter of
span.
circular structure).
θ Re-entry angle of circular arch
S* Design Load Effects (Refer to
measured between the vertical and
BS 5400: Part 1).
the tangent to the arch wall at the
t (years) Life of sacrificial thickness of steel. top of the foundation.
Contractor/Manufacturer *
seeks Approval in Principle from TAA and
carries out Design for Structure Proposed OUTLINE AIP AND
and obtains Relevant Approvals OUTLINE DESIGN
COMPLETE
* Outline Approval in Principle Form and Approval in Principle Form shall both incorporate the
listings of Employer’s Requirement as set out in Chapter 16
Continued
Overleaf
Ensure Compliance with Design Requirements and at Serviceability Limit State - Chapter 7
a) Deflection - Clause 7.2
b) Allowable Net Bearing Pressure - Closed Invert Structures - Clause 7.3 & 7.4
c) Foundation Design - Circular Arches - Clause 7.5
2. DESIGN PRINCIPLES
2.1 Limit state principles have been adopted for the limiting value given in this Standard and the
design in this Standard. The limit states adopted settlement of the foundation material must not
are: adversely affect the performance of the structure.
a. Ultimate limit states represented by: 2.6 As the allowable net bearing pressure of soil
is not normally expressed in characteristic (or
i. The strength of the structure as nominal) strength terms, the checks involving
determined by the yielding and allowable net bearing pressure shall be undertaken
buckling behaviour of corrugated steel with unfactored nominal loads.
buried structures, and
2.7 For the ultimate limit state the following
ii. The strength of a longitudinal bolted load combinations shall be considered:
seam as determined by tests on bolted
plate assemblies. a. Dead Loads together with Live Loads.
b. Serviceability limit states represented by: b. Dead Loads together with Temporary
Construction Loads.
i. A limiting deflection expressed as a
maximum percentage change in the 2.8 For the serviceability limit state, Dead
span dimension beyond which cause Loads shall be considered together with Live
for public concern may be expected Loads.
and remedial action to protective
coatings and finishings may be 2.9 The steel section chosen for the walls of the
required. structure must satisfy both the strength and
deflection requirements of Chapters 6 and 7 and
ii. The allowable net bearing pressure of also the durability requirements of Chapter 8 in
the foundation material for closed terms of sacrificial steel. The steel thickness
invert structures. required to satisfy these criteria may be different at
different points around the circumference of the
iii The allowable net bearing pressure of structure. Care shall be taken during assembly to
the foundation material beneath the ensure the correct positioning of plates of different
concrete foundations of circular arch thickness.
structures.
3. DESIGN LOADS
and h = Nominal height of fill above the 3.6 In the case of the HB vehicle only, the
structure (m), to be taken as dispersion zones of individual HB wheel loads
ht + 0.25r for circular structures shall be combined and distributed jointly as
and circular arches, and ht + 0.25rt indicated in Figure 3.1. This applies to adjacent
for multi-radii structures wheels on the same axle and, where the span is
large enough, to wheels on succeeding axles.
where ht = Height of fill (m) above the crown
of the structure, including the
thickness of any road construction
4.1 The design load effects involved in the cross-section unless they
design of the corrugated steel buried structures extend for more than 250mm at
covered by this Standard are the compressive hoop the end of each length.
stress fa (all structures) and the radial soil pressure
P (closed invert structures), which shall be γf3 = is to be taken as the
calculated from the design load pressures using the appropriate value given in
formulae given below based on the ring Table 4.1 for the particular
compression theory, where the compressive hoop type of structure and the limit
stress in the wall of the structure is assumed to be state involved. The values in
uniform around its periphery and the radial soil the table take account of the
pressure at any point is assumed to be inversely influence of the relative
proportional to the radius of curvature at that point. stiffness of the particular
structural form, the amount of
4.2 Compressive Hoop Stress deformation occurring before
the various limit states are
Compressive hoop stress fa = C γf3 (N/mm²) reached, and the variation of
aa stress distribution in the
particular type of structure.
Where C = Compressive hoop load in the
wall of the structure per unit
length (see Figure 4.1)
a. Circular Structures
P = C = Pd + PL (kN/m²)
r
b. Multi-radii
(b) Earth Pressure from Fill (e) Allowable Net Bearing Pressure for
Foundation Design
The overburden pressure P1, on the top of the
footing is given by: Reference shall be made to Chapter 7, Clause 7.5
for the allowable net bearing pressure of the
P1 = γf3 γZ1 (kN/m²) foundation material.
The lateral earth pressure, P2 acting on the outside Circular arch structures can also be constructed on a
face of the footing is given by: suitably designed base slab which supports both walls
of the structure simultaneously.
P2 = γf3 Ka γZ2 (kN/m²)
To reduce the effects of the lateral earth pressure P2,
where Z2(m) is depth from road/ground level and loads from the structure, struts may be adopted
to mid height of foundation, Ka is active between strip foundations.
earth pressure coefficient, and γf3 = 1 for
SLS
Values of γf3
Type
of ULS SLS
Structure
Buckling Yield Seam Thrust on
foundations
5. STRENGTH PARAMETERS
5.3 When carrying out plate load testing using 5.6 The M* value for design shall then be
the method given in Clause 642 MCHW1 for non- obtained from Table 5.1 based on the in-situ test
cohesive soils the Modulus of elasticity Es of the result and also taking into consideration the
soil shall be determined used the formula: excavation width, and the compaction required in
MCHW1.
___ ∆q I (N/mm2)
π (1 - ν2) B ___ 5.7 For structures constructed in embankments,
Es = d
4 ∆s the M* value for design shall be obtained from
Table 5.1 taking into account the compaction
where B = diameter of plate used in the plate required.
load test (mm)
5.8 When the Contractor proposes a value of
∆q = change in pressure applied by the M* for design, in excess of 33N/mm², the
plate (N/mm2) Contractor shall substantiate the proposed value by
testing the backfill during the back - filling
∆s = change in average settlement of the operation, using the method given in Clause 642
plate (mm) MCHW 1 for plate load testing.
Embankment
Embankment
8. DURABILITY
8.11 The life of the galvanised coating shall be ii. Precast slabs or natural stone set into
calculated from the rate of corrosion which shall mass concrete having a minimum
be taken as 4µm/year in non-aggressive thickness of 300mm. The pavement
environments and 14µm/year in aggressive may be profiled to suit local
environments. Galvanising thickness may be requirements, for example the
assumed to be 1µm for each 7.15 g/m² coating inclusion of a channel to retain water
weight. under low flow conditions; shaping to
simulate a natural channel; and the
8.12 The life of a secondary protective coating provision of animal runs. Weirs or
applied to the galvanised steel components shall be eddy pools may be included within
as determined in the current British Board of the structure to provide resting places
Agrément (BBA), Roads and Bridges Certificate or for fish etc. passing through the
equivalent for the coating used. structure. Upstanding stone set into
the concrete may also be used for this
8.13 The sacrificial thickness of steel required to purpose.
provide 120 years life less the life of the coatings,
shall be calculated from the formulae: iii. A liner plate manufactured from, for
example, galvanised steel sheet or
T = 22.5t 0.67, for non-aggressive glass reinforced plastic (GRP) and
environments; and pre-shaped to the profile of the invert,
T = 40.0t 0.80, for aggressive may be secured to the CSBS. The
environments, void between the liner plate and the
where T = thickness of sacrificial steel on invert shall be filled with a
each surface (µm), cementitious grout or other water
t = life of sacrificial thickness of steel resistant material.
in years.
c. A proprietary system giving an equivalent
Invert Protection level of invert protection and certified as
suitable for the end-use by the British Board
8.14 In addition to the requirements of Clauses of Agrément or equivalent body, who will
8.10 to 8.13, the invert of all structures carrying also certify its design life.
water or other fluid shall be protected from the
effects of abrasion or erosion by adopting one of d. For structures with little or no flow, and
the following protection systems: which are therefore likely to hold standing
water, the following may be used as
a. A reinforced concrete paving (See Clauses alternatives to pavements:
13.1 to 13.7) with a minimum thickness of
100mm for structures of span less than or i. A coating certified as suitable for the
equal to 2m, and with a minimum thickness end use by a current British Board of
of 125mm for all other structures. Agrément, Roads and Bridges
Certificate, or equivalent, may be
used. The design life shall be stated
on the certificate.
ii. The use of liner plates secured to the anticipated that water-borne stones or other debris
structure to cover fluctuations of at in excess of 100mm diameter would otherwise be
least 200mm above and below the carried through it during normal or flood
range of water depths. The liner plates conditions. For a culvert installed with a gradient
may be formed from, for example, greater than 2 per cent, it is desirable to remove
galvanized steel strip coated with a water-borne stones or fragments of less than
bitumen-based product (or other 100mm diameter through installation of drop inlets
suitable protective coating) or from or catchpits.
GRP. The plates may be shaped to
follow the curvature of the walls of Invert Protection Below Circular Arch Structures
the structure and if required may be of
sufficient size to completely cover the
8.17 Reinforced concrete invert paving as
invert. Any gap between the liner and
described in the relevant parts of Clause 8.14 shall
the structural shell should be filled
be provided, where necessary, to protect the arch
with, for example, concrete or
foundations and foundation material from scour,
cementitious grout or other water
abrasion or chemical attack from flowing water or
resistant filler, to seal the interior
other fluid if present. The design of the paving
surface of the structure. The liner
shall take account of hydraulic factors, the
plates may be provided with grouting
foundation material and the nature of the stream/
points to facilitate the filling of the
river bed.
void. If a secondary protective coating
is used to protect galvanised steel 8.18 Where the level of winter flow is above the
liner plates, its design life given in a foundation level, the invert paving shall also be
current British Board of Agrément, applied to the corrugated steel as described in
Roads and Bridges Certificate, or Clause 8.15. The most vulnerable area of an arch
equivalent, may be taken into account. structure to deterioration is at the springing and
great care shall be taken to avoid water entrapment
8.15 Invert protection shall be applied to the
at this point. A typical detail is shown in Figure
wetted periphery of the structure for the winter
8.2. The detail adopted should avoid entrapment of
base flow plus 200mm on each side or 25% of the
water on the soil side of the structure and, where
total circumference for circular structures or 40%
concrete upstands are used, against the inside of
of the total circumference for multi-radii structures
the arch structure: any gap between the structural
whichever is greater. Where the invert protection is
plates and the pavement must be thoroughly filled
in concrete and exceeds 25% of the total
and waterproofed. This seal shall be designed to be
circumference for circular structures or 40% of
maintainable. Care shall be taken to ensure that
multi-radii structures, or as appropriate for a
any of the work done to protect the CSBS will not
circular arch structure, formwork shall be used in
adversely affect its structural performance.
its installation. Any gap between the pavement and
the structural plates shall be sealed with an 8.19 Impact Protection
appropriate sealant. The point at which the
pavement meets the structural plates shall be a. In the case of structures to be used by
shaped to prevent ponding of water against the vehicles consideration shall be given to
structural plates. To prevent accelerated protecting the sides of the structure by
differential corrosion of the steel culvert, kerbing and/or by means of an appropriate
particularly at the wet/dry line, paved inverts must vehicle restraint system which should not be
be inspected at regular intervals when connected to the sides of the structure.
maintenance/replacement shall be carried out as Advice on a suitable system may be
appropriate. obtained from the Overseeing Organisation.
Some measure of protection to the crown/
8.16 Subject to the agreement of the appropriate soffit should be provided by suitable design
river authority or Environment Agency, screens of headwalls or ring beams and by alerting
shall be installed at the inlet of a culvert when it is drivers to the headroom restriction by means
of visual and/or audible warning systems.
Any grading
PI of fraction passing 425µm sieve ≥ 15 - 2
≥ 10,000 + 2
< 10,000 but ≥ 3,000 + 1
Resistivity < 3,000 but ≥ 1,000 - 1
(ohm - cm) < 1,000 but ≥ 100 - 3
< 100 - 4
pH of soil 6 ≤ pH ≤ 9 0
5 ≤ pH < 6 - 2
Less than 5 or more than 9 - 4
Water-soluble ≤ 0.24 0
sulfates (WS) > 0.240 but ≤ 0.60 - 1
(g/l as SO4) > 0.60 but ≤ 1.20 - 2
> 1.20 - 4
Chloride ion ≤ 50 0
(ppm) > 50 but ≤ 250 - 1
> 250 but ≤ 500 - 2
> 500 - 4
Oxidisable ≤ 0.05 0
sulfides (OS) > 0.05 but ≤ 0.12 - 1
(% as SO4) > 0.12 but ≤ 0.24 - 2
> 0.24 - 4
Soil Type:
Table 8.2 - Test Methods for properties required in Table 8.1 and Table 8.3
1. When sampling for organic matter determination, great care must be taken to avoid contamination with top
soil, roots or overlying made ground. If contamination cannot be avoided, reduce the number of negative points
awarded in Table 8.1.
CORROSIVITY
CLASSIFICATION pH Chloride ion Water-soluble
(ppm) Sulfate (WS)
(g/l as SO4)
Non-Aggressive 6 ≤ pH ≤ 9 ≤ 50 ≤ 0.24
Aggressive 5 ≤ pH < 6 > 50 but ≤ 250 > 0.24 but ≤ 0.60
Very Aggressive Less than
5 or more > 250 > 0.60
than 9
Table 8.3 - Corrosivity classification of ground water, carried water and other contained fluids
≤2 Non-Aggressive
> 2 but ≤ 4 Aggressive
>4 Very Aggressive
Excavation for Bedding of Closed Invert Structures 9.5 Additional excavation may be necessary to suit
the foundation size selected and the working space
9.1 Excavation for the bedding of closed invert required for construction of the foundation and
corrugated steel buried structures shall extend to a backfilling the structure.
depth below invert level of not less than one tenth
of the span and to a width not less than 800mm 9.6 In cases where the net allowable bearing pressure
(500mm for structures up to 3m span) beyond the of the foundation material at an excavation level results
span on each side, provided that the allowable net in an impractical size of foundation, as calculated in
bearing pressure at this depth exceeds the accordance with Clause 7.5, the excavation level may
maximum radial soil pressure (P or Pc). In any be continued to such a depth to locate an improved net
event the excavation width should be not less than allowable bearing pressure of the foundation material.
the extent of side fill required in Table 5.1. The The additional excavation can be replaced with suitable
excavation shall extend a length not less than foundation material as indicated on Figures 9.1 and 9.2.
300mm beyond each end of the structure (see Alternatively, the depth of the foundation may be
Figures 9.1 and 9.2). increased. In both cases the foundations shall be
designed in accordance with Clause 7.5.
9.2 Where the allowable net bearing pressure of
the foundation material at the excavation level
given above is less than the maximum radial soil 9.7 The depth of excavation to the foundation
pressure (P or Pc), the excavation shall be level is measured from the top of the foundation
continued to such a depth that the allowable net and is defined as (1000+D)mm (see Figures 9.1
bearing pressure at the new excavation level is not and 9.2). In such a case, the width of excavation at
less than the maximum radial soil pressure. the foundation level shall be (500+D)mm for
Account may be taken of the reduction in the value circular arches up to 3m span and (800+D)mm for
of maximum radial soil pressure with distance circular arches of span 3m or greater, beyond the
from the face of the structure as described in span on each side (see Figures 9.1 and 9.2).
Clause 7.4. The allowable net bearing pressure of
the bedding material must not be exceeded. When
additional excavation is necessary it shall be wider Trench Width for Closed Invert Structures
than the limits given in Clause 9.1 by an amount
on each side equal to the extra depth (see Figures 9.8 The trench width shall be not less than three
9.1 and 9.2). times the span (S) of the structure, unless the
constrained soil modulus (M*) of the existing soil
9.3 Excavation in hard material shall extend to is greater than the values adopted for design (see
an additional depth of not less than 300mm below Table 5.1) when the trench width may be reduced
the level indicated in Clause 9.1 plus 40mm for to the minimum required for the lower bedding
each metre of cover, in excess of 8m, above the material, that is normally the span plus 500mm
crown of the completed structure up to a maximum each side for structures up to 3m span, or span plus
additional depth of 600mm. 800mm each side for larger spans, or as otherwise
required in Clause 9.2 and shown in Figure 9.1. A
Excavation of the Foundation Level for Circular partial trench condition occurs when the level of
Arches existing soil suitable for retention within a distance
of a span either side of the structure lies between
9.4 The excavation for the foundation level shall the crown of the structure and the underside of the
extend to a width not less than 800mm (500mm for lower bedding. Refer to Figure 9.1. Partial trenches
circular arches up to a 3m span) beyond the span can be treated similarly to trenches; alternatively
on each side and in any event to be not less than the excavation shall extend to a distance equal to
the extent of side fill required in Table 5.1. the span on each side of the structure. Reference to
Clause 8.8.3 is also necessary.
Filling - Bedding for Closed Invert Structures 9.15 The overlying fill material as described in
MCHW1 Series 600 shall be used for embankment
9.11 As far as possible, the lower bedding construction in the zone over the structure shown
material (Class 6K in Table 6/1 MCHW1) shall be in Figures 9.1 and 9.2. Argillaceous rocks such as
shaped to fit the invert such that it supports 20% of shales and mudstones, slag and PFA shall not be
the circumference of circular structures or the used as fill or road sub-base materials in this zone.
whole of the portion of cross section of radius rb
(see Table 1.1) for multi-radii structures. If this Filling - Deposition, Spreading and Compaction
cannot be met and the structure is erected on flat or
partially preshaped bedding, care must be taken to 9.16 Surround fill and fill placed above the level
ensure that the lower bedding material is properly of the crown of the structure, as described in
placed and compacted under the haunches. Clause 9.13 to 9.15, shall be deposited, spread and
compacted in such a manner that any out of
9.12 The upper bedding material (Class 6L in balance forces transmitted to the culvert are kept to
Table 6/1 MCHW1) is as described in Series 600
a minimum. This will require that trafficking by
MCHW1.
construction plant is not all in one direction and
that the compacted surface of the fill is kept as
Filling - Surround for All Structure Types near horizontal as practicable.
9.13 The surround material (Class 6M in Table 9.17 Compaction of the surround material shall
6/1 MCHW1) as described in Series 600 MCHW1 comply with the requirements given in Series 600
shall be used for filling all excavations, except MCHW1 except that in some circumstances it may
those in hard material for which lower bedding be more economical to relax the requirement to
material (Class 6K) shall be used, with minimum 85% of the maximum dry density. (See Table 5.1.)
excavation. In all cases (for embankments and
trenches and partial trenches) surround fill shall
level
level
where S = Span of the structure (m) but with a minimum of 0.173mm/N and a
E = Modulus of Elasticity of steel maximum of 0.375mm/N. dc is defined in Clause
= 205 x 10³ N/mm² 10.2.
I = Cross-sectional Moment of inertia
per unit length, (mm4/mm) of the 10.5 If F ≤ Fmax the structure is acceptable. In the
corrugated steel sheet about its case where Fmax < F the structure is not acceptable
neutral axis, the section being and either the span S must be reduced, the flexural
parallel to the length of the rigidity EI must be increased or temporary
structure. If the cross sectional supports must be used. If temporary supports are
moment of inertia varies along the used (Clause 3.1b) then a temporary works design
length of the structure, the is required to ensure local overstressing and
minimum shall be used. The distortion of the corrugated steel is avoided. Partial
re-rolled ends of helically wound safety factors in Clause 3.10 (Table 3.1) shall be
culvert lengths shall not be used in conjunction with appropriate values of γf3
considered to affect the value of I (Table 4.1).
to be used unless they extend for
more than 250mm at the end of
each length. The effect of the helix Foundations for Circular Arches
angle of helically wound culverts
on I may be neglected. 10.6 The connection between the corrugated steel
plates and the reinforced concrete foundation is
10.2 For acceptable performance during normally achieved using a seating channel supplied
installation, the flexibility factor, (F) must be less by the manufacturer. The seating channel shall be
than a limiting value (Fmax), which depends on the capable of transmitting loads from the corrugated
depth of corrugation (dc). For the purposes of this steel plates into the foundation both during
Clause the depth of corrugation (dc) is defined as construction of the structures and in service.
the depth in millimetres from any peak to the Reference shall be made to the requirements of
adjacent trough in the corrugation. Clause 7.5.
10.3 For circular structures, circular arches and
rc
multi-radii structures with 1.3 > r > 0.7 where
t
11.1 End treatments shall be included within the 11.5 For hydraulic structures, measures shall be
designated outline as defined in SD4 (MCHW taken to secure the metal edges at inlet and outlet
0.2.4). All end treatments shall be designed in against hydraulic forces.
accordance with Clauses 11.2 to 11.6 and regard
shall be paid to the aesthetic appearance of the 11.6 In the case of hydraulic structures, the
structure. headwall, ring beam or collar shall be designed to
take into account the possible effects of scour of
11.2 Reinforced concrete collars, headwalls, or the material beneath the invert of the structure.
retaining walls shall be designed to support the
face edges of the corrugated steel where the skew 11.7 The designer shall identify on the Contract
angle of the corrugated steel structure exceeds 15°, drawings any construction sequence assumed in
the bevel of square ends exceeds 2:1 (eg the design.
embankment flatter than 1 in 2), or the cut end
supports highway loading. In these instances the
reinforced concrete elements shall be designed to
offer adequate support to the corrugated steel shell
where it is discontinuous and unable to act in ring
compression normal to the centre line of the
corrugated steel structure. The structural adequacy
of the corrugated steel plates is to be considered.
Structural steel ring beams, collars, and spreader
beams may be utilised, together with ties anchored
into the fill, and shall be designed to the
appropriate Standards. Reinforced concrete
elements shall be designed according to BS 5400:
Part 4 as implemented by BD 24 (DMRB 1.3.1).
Account shall be taken of the effects of the
construction sequence, loads from the corrugated
steel plates being directly supported, other loads
from the corrugated steel structure, the self weight
of the reinforced concrete, earth pressures, the
effects of ground creep and settlement, and
hydraulic loadings. Partial safety factors in Tables
3.1 and 4.1 shall be adopted as appropriate. If
temporary works are necessary the requirements of
Clause 10.5 shall be adopted.
13.1 When a concrete invert paving in 13.7 All foreign matter, (but not any secondary
accordance with Clause 8.14 is to be used, it shall proprietary protective coating unless indicated
be as described in the following Clauses. otherwise in the Type Approval Certificate or
British Board of Agrément (BBA), Roads and
13.2 The concrete shall be Class 30/20 as Bridges Certificate referred to in Clause 1.6) and
described in MCHW1 Series 1700. free standing water shall be removed from the
surfaces to be paved, before commencing work.
13.3 The concrete invert paving shall be
reinforced with a steel fabric complying with
MCHW1 Series 1700 having mesh dimensions not
greater than 150mm x 300mm and a nominal wire
size not less than 5mm. All laps in the mesh shall
be at least 150mm. The steel fabric shall be
securely fixed to the structure by means of fixings
at the bolt positions. It shall extend to within a
distance not greater than 100mm, nor less than
40mm inside the edges of the concrete on each
side. A nominal cover of 45mm shall be provided
to all other faces, including that to the crest of the
corrugations in the structural steel.
iii. Long Section along centre-line of structure. xix. Any other essential requirements.
iv. Finished levels of carriageways and side slopes Special requirements should be avoided. However
within designated outline. where the circumstances are such that they are justified
then care must be taken to avoid requirements
v. Skew of structure. implicitly favouring the system of a particular
manufacturer.
vi. Minimum width of structure.
16.3 Subsequent to the award of contract and prior to
vii. Minimum headroom of structure. the commencement of construction, the Contractor
normally completes the AIP form (containing the
viii. Hydraulic requirements or clearance envelope, if Schedule of Employer’s Requirements), the design and
any, and requirement for invert protection. the design certificate, and submits these for approval/
appraisal. The full design normally contains the
ix. Gradient of invert. following additional information relating to the
particular proprietary product which forms the basis of
x. End detail requirements, including any the design. For bolted segmental structures the list
requirement for reinforced concrete headwalls. includes:
xi. Highway loading requirements. a. Structure Geometry:
xii. The value of constrained soil modulus M* to be - Structure type/shape
assumed for existing soil.
- Internal span
xiii. Allowable net bearing pressure for foundation - Internal height
material.
- Radii.
xiv. The corrosivity (aggressivity) classification of
existing soil, ground water, contained water/
effluent, the atmosphere and of any fill material
(or silt) to be placed inside the structure in
contact with the corrugated steel. A drawing is
also required showing the corrosivity
h. Internal fill in contact with wall of structure: - Constrained soil modulus (M*).
- Compaction (% of maximum dry density).
- Soil properties, bulk density, grading and
corrosion classification in accordance with - Durability classification to Clause 8.8.2.
Chapter 8. Surround Material:
i. The current Type Approval Certificate and - Constrained soil modulus (M*).
current British Board of Agrément Roads and
- Compaction (% of maximum dry density).
Bridges or equivalent Certificate or Certificates -
as required in Clauses 1.6 to 1.9. - Durability classification to Clause 8.8.2.
17. REFERENCES
17.1 Design Manual for Roads and Bridges Part 4: Compaction-related tests.
Part 5: Compressibility, permeability and
Volume 1: Section 1 Approval Procedures durability tests.
BD 2: Part 1 - Technical Approval of Highway Part 9: In-situ tests.
Structures (DMRB 1.1) BS EN ISO 1461 1999. Hot dip galvanised coatings
Volume 1: Section 3 General Design on fabricated iron and steel articles
BD 24: Design of Concrete Bridges. Use of - Specifications and test methods.
BS 5400 Part 4(DMRB 1.3.1). BS EN 1744 Tests for chemical properties of
BD 37: Loads for Highway Bridges aggregate.
(DMRB 1.3) BS EN 1744-1 1998 - Chemical analyses
Volume 2: Section 2 Substructures BS 7371: Coatings on metal fasteners
BD 74 Part 8 – Foundations (DMRB 2.1.8) Part 1: 1991: Specification for general
Volume 2: Section 4 Paints and other Protective requirements and selection
Coatings guidelines
BD 35 Quality Assurance Scheme for Paints Part 6: 1998: Specification for hot dipped
and Similar Protective Coatings galvanised coatings
Volume 2: Section 4 Paints and other Protective BS 5400: Steel, Concrete and Composite
Coatings Bridges.
BA 27 Quality Assurance Scheme for Paints Part 1 1988: General Statement.
and Similar Protective Coatings Part 2: 1978: Specification for Loads.
Volume 7: Section 2 Pavement Design and Part 4: 1990: Code of Practice for Design
Construction of Concrete Bridges.
HD 26: Pavement Design (DMRB 7.2.3) BS 5930: 1981 - Code of Practice for Site
Volume 10: Environmental Design. Investigations
BS 8002: 1994 - Earth Retaining Structures
17.2 Manual of Contract Documents for Highway BS 8004: 1986 - Foundations
Works BS EN ISO 9002: 1994. Quality Systems. Model for
quality assurance in production,
Volume 0: Section 2 Implementing Standards installation and servicing. (Formerly
SD4 Procedures for Adoption of BS 5750:Part 2).
Proprietary Manufactured Structures BS EN 10142 2000. Specification for continuously
(MCHW 0.2.4). hot-dip zinc coated low carbon steel
Section 3 Advice Notes strip and sheet for cold forming:
SA1 Lists of Approved/Registered technical delivery conditions.
Products (MCHW 0.3.1) (Replaces BS 2989: 1982).
Volume 1: Specification for Highway Works BS EN 10143 1993. Continuously hot-dip metal
HMSO 1998 (MCHW1) with revisions coated sheet steel and strip.
to 2001 Tolerances on dimensions and
shape. (Replaces BS 2989:1992)
17.3 British Standards
17.4 Other Documents (reference number)
BS 812: Part 117: 1988 - Method for
Determination of Water Soluble 1. Poulos, H. G. and Davis E. B. - “Elastic
Chloride Salts. Replaced by Solutions for Soil and Rock Mechanics” - John
BS EN 1744-1:1998 but remains Wiley and Sons, 1974, Chapter 6.
current
BS 1377: 1990 - Methods of Test for Soils for 2. Vogel, A. I. - “Vogel’s Qualitative Inorganic
Civil Engineering Purposes. Analysis - Sixth Edition (revised by G. Svehla)” -
Part 2: Classification tests. Longman, 1987 (pp 159 - 161).
Part 3: Chemical and electro-chemical tests.
17.5 Bibliography
18. ENQUIRIES
All technical enquiries or comments on this Standard should be sent in writing as appropriate to:
Director of Engineering
Department for Regional Development
Roads Service
Clarence Court
10-18 Adelaide Street G W ALLISTER
Belfast BT2 8GB Director of Engineering
A.5.5. Verification that the nominal seam A.7. When all the above information has been
strength/bolt configuration has been verified, a Type Approval Certificate is issued. All
correctly derived in accordance with corrugated steel buried structures which have been
Annex B following evaluation by The given Type Approval are listed in Advice Note SA1
Highways Agency, Safety, Standards (MCHW 0.3.1 Annex B). Type Approval previously
and Research, Civil Engineering granted is liable to be withdrawn at any time following
Division of the acceptability of the non-compliance with any of the requirements set out in
seam strength test results in terms of this Annex.
their technical reliability.
C1 Lockseams shall be able to withstand tensile forces across the seam, according to steel sheet thickness, as
tabulated below:
1.00 36
1.30 51
1.60 65
2.00 88
2.80 136
3.50 182
4.20 234
For intermediate sheet thicknesses, the minimum tensile force required may be determined by linear interpolation.
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