Installation Guide Super-Cor Structural Plate Culverts

Super-Cor Assembly and Installation Guide Table of Contents

1.0 Introduction............................................................................................................ 2 1.1. Purpose ............................................................................................................. 2 1.2. Plans & Specifications....................................................................................... 2 1.3. Responsibility .................................................................................................... 2 2.0 Materials, Tools & Equipment ............................................................................... 3 2.1. Components, Material & tools Supplied by AIL ................................................. 3 2.2. Equipment Supplied by Contractor.................................................................... 3 2.3. Tools Supplied by Contractor ............................................................................ 3 2.4. Typical Crew Includes ....................................................................................... 4 2.5. Structural plates ................................................................................................ 4 2.5.1. Unassembled Plate Storage Recommendations....................................... 4 2.6. Bolts .................................................................................................................. 5 3.0 Installation ............................................................................................................. 5 3.1. Foundation/Bedding Preparation....................................................................... 5 3.2. Assembly Area .................................................................................................. 5 3.3. Drainage............................................................................................................ 5 3.4. Footings............................................................................................................. 5 3.4.1. Cast-in-place Concrete.............................................................................. 6 3.4.2. Pre-Cast Concrete..................................................................................... 6 3.4.3. Corrugated steel ........................................................................................ 6 3.5. Assembly........................................................................................................... 7 3.5.1. Bolting........................................................................................................ 7 3.5.2. Open Bottom Structure Assembly ............................................................. 8 3.5.3. Structure with Invert Assembly .................................................................. 9 3.6. Ribs ................................................................................................................. 11 3.7. Lifting............................................................................................................... 11 3.8. Encased Concrete RIBS ................................................................................. 12 4.0 Backfill ................................................................................................................. 13 4.1. Backfill requirements ....................................................................................... 13 4.2. Backfill Placement ........................................................................................... 13 4.3. Compaction ..................................................................................................... 14 5.0 Shape Monitoring ................................................................................................ 15 6.0 Summary ............................................................................................................. 17

*Page 12 may be omitted if the project does not have EC ribs.

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1.0 Introduction

1.1. PURPOSE The purpose of this manual is to provide the Owner, Engineer, Contractor & Inspection Staff the necessary information to properly assemble and install Super-Cor culverts. This manual shall be used in conjunction with the plans, specifications and contract documents. The procedures explained in this manual are based on past experience, and are not intended to limit the contractor to only these practices. 1.2. PLANS & SPECIFICATIONS The Contractor must ensure that on-site personnel have the most recent approved for construction plans and specifications relevant to the installation. These are typically packaged with the bolts, but may also be obtained from an AIL representative. 1.3. RESPONSIBILITY It is the responsibility of the Contractor to erect the structure according to the plans, specifications and contract documents. All quality control shall be the responsibility of the contractor unless otherwise directed in the contract documents. It is the responsibility of the Contractor to inspect all materials against the packing slip upon arrival at the site to ensure complete delivery in good order. Any damaged materials must be set aside and AIL shall be notified immediately. An Atlantic Industries Limited representative may be available to provide on-site assistance. The representative will not be responsible for inspection or quality control.

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2.0 Materials, Tools & Equipment
COMPONENTS, MATERIAL & TOOLS SUPPLIED BY AIL 1) Engineering & Shop drawings of the Super-Cor structure 2) Structural plates 3) Bolts 4) Nuts 5) Two (2) pry bars 6) One (1) drift pin 7) Base channel (if required) 8) Anchor bolts (if required) 9) Zinc rich paint 10) On-Site assistance (unpon request, per diem rates apply) 2.1.

2.2. EQUIPMENT SUPPLIED BY CONTRACTOR Forklift or properly equipped front-end loader to unload bundles of structural plates. Lifting equipment such as a small crane, excavator or boom truck. Backfill equipment including dump trucks, dozers, loaders and water trucks to haul, spread and place fill. Water may be needed to obtain optimum moisture content. Small plate tampers or walk behind rollers are needed to compact the material within 1m (3ft) of the structure. Single drum vibratory rollers are needed to compact the remaining portion of the fill. 2.3. TOOLS SUPPLIED BY CONTRACTOR 1) Additional pry bars 2) Minimum four 19mm ( ) clevises 3) Acceptable chains, cables or straps for lifting plates 4) Impact gun (air driven, 19mm () minimum drive recommended, 85 CFM @ 100 psi) 5) Ratchet with 32mm (1 ) socket 6) Ladders, Scaffolding, Safety harnesses 7) 32mm (1 ) spud wrench 8) 2-4kg (5-8 lbs.) sledgehammer 9) Torque wrench (350 N-m / 250 ft-lbs minimum capacity) 10) Flat screwdriver. 11) Snips 12) Tape measure 13) Wooden blocks

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2.4. TYPICAL CREW INCLUDES 1) One working foreman 2) One crane operator 3) Laborer to connect plates to crane 4) Two labourers to align and bolt plates 5) Two labourers to torque bolts

2.5. STRUCTURAL PLATES Structural plates shall be handled with care to prevent damage to the zinc coating. Plates are typically shipped in bundles of 10, with individual weighs ranging from 15-330 kgs (30-725 lbs).. Plates are supplied in 762mm (2-6) widths, (plate width runs longitudinally along the structures length), and lengths ranging from 634-5104mm (25-169) normally from 1S to 14S long. These can be identified by the number of circumferential bolt holes. (S is the space between circumferential bolt holes, which is 406.4mm (16"). Avoid abrasions from forks or chains when unloading and moving plates, and avoid collisions with the structure when moving plates into place. When lifting and placing plates NEVER put yourself or any part of your body between the structure and a plate. Never stick a finger through an empty bolt hole, as the plates may shift and cause injury. 2.5.1. Unassembled Plate Storage Recommendations With certain adverse storage methods, a condition generally referred to as wet storage stain or white rust, may develop. This is a condition familiar to users of galvanized materials. When wet storage staining is found on galvanized materials, it is rarely detrimental to the coating protection, and normally disappears with weathering. The contractor should use reasonable handling and storage procedures for the materials at the construction site to ensure that a stain-free product is installed. When relatively long outdoor storage is necessary, plates should be raised from the ground and separated with strip spacers to provide free access of air to all parts of the surface. Plates should be inclined in a manner that will give maximum drainage. The material should also be stored under cover whenever possible. Bolts and nuts must be stored inside, and checked to ensure that the containers are free from moisture or condensation.

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2.6. BOLTS Bolts are typically supplied in two lengths for Super-Cor structures, 50mm (2) and 75mm (3). If other bolts sizes are required, their size and use will be noted on the installation drawings.

3.0

Installation
The following is a guideline. Other procedures and field experience may yield better results. Prior to assembly, refer to the assembly drawings. The drawings provide the proper plate layout for each structure and must be used to guide assembly.

3.1. FOUNDATION/BEDDING PREPARATION Foundation preparation is the responsibility of the Contractor. Excavate the site to the proper depth and length as per the contract drawings. Any unsuitable foundation material below the structure, footings, engineered backfill, as determined by the Owners Geotechnical Engineer, should be excavated to a depth as directed by the Engineer. Unsuitable material must be excavated and replaced with acceptable granular material compacted as directed by the Owners Geotechnical Engineer. 3.2. ASSEMBLY AREA The assembly area must be fairly flat, free of large brush, stumps, or trees and as close to the installation site as possible. Utilize the roadway for an assembly area when practical. In those cases where there are no level places to assemble the structure, make arrangements to level an area for assembly. The assembly area required is generally a width of [2x(Span) + 5 m (15)] by the length of the structure. 3.3. DRAINAGE Drainage (when required) shall be installed as per the Contractors Engineer. 3.4. FOOTINGS To improve assembly time, ensure all footings are installed square (check by survey, measuring diagonals) and at the proper grade. Base channel and anchor bolts shall be installed at the same time to prevent misalignment of bolts and bolt holes. Ensure that base channels form a straight line and are spaced at 381mm (15) c/c. This is easily accomplished using a jig as shown below:

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Before casting, check the total length of the channel to ensure there is no cumulative error. String lines, careful measurements and proper surveying can verify proper footing alignment and save time and money. 3.4.1. Cast-in-place Concrete Base channel and anchor bolts must be assembled and set at the proper angle before casting the concrete. The proper angle can be achieved by tying the anchor bolts to the rebar, or by adding wooden supports to the formwork. To set to a specified angle, cut wooden blocks to the required angle using a mitre saw, and then attach these to the channels. Avoid spilling concrete into the base channel where it will interfere with the structure. Any concrete in the channel should be chipped out before placing the structure. 3.4.2. Pre-Cast Concrete Pre-cast concrete footings require one of the following: 1) A keyway to restrain the structure. Keyways must be grouted after assembly is completed and before backfill begins. 2) Base channel anchored using epoxied or mechanically restrained anchors (i.e. Hilti). The footing designer must determine the minimum embedment depth. 3) Base channel CIP as indicated in section 3.3.1. 3.4.3. Corrugated steel Corrugated steel footings are laid out prior to assembly, and may be loosely bolted to the base channel to provide flexibility during construction. All bolts must be fully torqued before beginning backfill operations.

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Super-Cor Assembly and Installation Guide

3.5. ASSEMBLY Ideally, plates should be installed to produce a shingling effect on the inside surface in the direction of flow, to reduce water exfiltration into the structural fill. If the structure has an invert, construction should be started at the downstream end and progress upstream. The construction of the top plates, or and arch, should proceed from upstream to downstream. Plates should initially be fastened with as few bolts as possible. Once a plate is held in position by partial bolting, the remaining bolts can be inserted and hand tightened. After bolts are in place, tighten longitudinal seams prior to the circumferential seams. Always tighten two (2) or three (3) rings behind assembly of plates to permit assembly flexibility and alignment of bolt holes. Install rib plates (if applicable) as the barrel is built to help maintain the shape. This also eliminates the need to remove certain bolts if the ribs are added later in construction. Install bevel plates after the main barrel of a structure has been completed. The completed rings support the bevel and prevent it from distorting the design shape of the structure. 3.5.1. Bolting 50mm (2) bolts are used for attaching plates to the base channel and for most seams in the barrel of the structure. In locations where there are three overlapping plates, 75mm (3) bolts may be required to pull plates together. These bolts will subsequently be replaced with 50mm (2) bolts unless otherwise specified on the drawings. On structures with ribs, 75mm (3) bolts are used to connect the ribs to the main barrel. Countersunk bolts are also provided on structures with ribs, for use as shown below:

Nuts shall be placed with the tapered face towards the hole on corrugated plates, and with the tapered face away from the hole on flat steel (base channel, rolled angles). Typically, nuts placed outside of the structure make torquing easier, but may be on the inside if the structure has an invert (bottom).

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Super-Cor Assembly and Installation Guide

Required torque on bolts is 203-338 N-m (150-250 ft-lb). Bolts can be over torqued and a visual inspection of the plate fit is good practice. The minimum torque must be met to maintain structural strength. Bolt torque should be rechecked prior to backfill as some plate movement may occur during the torquing process. When inspecting and testing for bolt torque it is good practice to randomly test approximately 5% of the bolts in the structure. If a low torque value is recorded, the bolts in the immediate vicinity should be tested to assure a seam has not been missed. If an unacceptable number of low values are recorded the contractor must recheck the torque on all bolts. Note: If a plate seam remains untorqued, the structure may develop a localized failure during backfilling or once the structure has gone into service. Localized failures can extend and cause complete failure of structures. 3.5.2. Open Bottom Structure Assembly The first step of assembly is assembling and fully tightening two complete rings lying on the ground. Extra care should be taken to ensure alignment of holes and edges of plates, as these rings establish the shape for the remainder of the structure. These completed rings should then be lifted into place on the upstream end of the structure. Each successive ring should be lapped outside of the previous ring for support. Plates should be lifted into position using two clevises attached with two separate cables or chains. Clevises should be attached such that the plate is suspended in the position it attaches to the structure, i.e. crown plates shall be hooked at the center to suspend them horizontally. When constructing a ring, begin with a base plate, bolting to the base channel first then working up the seam. Bolt holes shall be aligned as best as possible; if they are aligned just enough to push a bolt through then there may be difficulty as construction proceeds. Using two pry bars in opposite directions will draw plates together and help to align holes. In locations where there are 3 overlapping plates, it may be necessary to draw the plates into alignment using a drift pin. Drift pins shall be driven using a sledgehammer until the adjacent holes are aligned. Place bolts in the adjacent holes and tighten them enough to hold the plates, then remove the drift pin by hammering it back out. 13/02/2007 Atlantic Industries Limited 8

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Plates are added in a shingling pattern as shown on the construction drawings. For water crossings and sites where proper staging or man lifts cannot be used, it is best to construct a proper platform to work from, which will increase productivity and safety. 3.5.3. Structure with Invert Assembly Bedding is the material located between the native or engineered foundation and the structure. Bedding is a very important part of the installation because it provides the interface between the rigid or unyielding foundation and the flexible soil - steel structure. Structures with inverts require bedding preparation. The base shall be a stable area free of organic matter and large rocks. The base shall be laid over with a 300 mm (12) layer of structural fill. This layer (bedding) shall be compacted to 100% Standard Proctor Density except for a 200mm (8) layer in direct contact with the pipe wall. This portion shall be left uncompacted. In general, the area uncompacted shall be the middle 1/3 of the diameter for round and vertical ellipse pipes and the middle 1/2 for pipe arches and horizontal ellipses.

The loose bedding allows uniform settlement of the structure, which in turn allows the voids in the corrugations, of the invert, to become filled during backfilling. If this bedding layer is not loose the structure will be subject to non-uniform support, which may cause the corrugations to flatten or the entire invert may be deformed. Bedding final grade shall be uniform and without humps and/or hollows. Pre-shaping of the bedding is recommended for horizontal ellipse shapes where it is difficult to place backfill material under the structure. However, pre-shaping may cause the following difficulties: 13/02/2007 Atlantic Industries Limited 9

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1) It is more difficult to uniformly grade a shaped bed, even with the most experienced equipment operators. Therefore, undulations and voids may occur. 2) The shaped bedding will not permit access to the invert from the outside of the pipe. This causes difficulty in placing some of the bolts. These problems are offset by a reduction of manual placement and compaction of the fill under the culvert. If the site conditions permit, start at the downstream end. Assemble bottom center plates, for the entire length of structure, as indicated on the drawing. Blocks of wood may be used to support the curvature of the structure and add stability during assembly, if pre-shaped bed has not been provided. Assemble and fully tightening two part rings lying on the ground. Extra care should be taken to ensure alignment of holes and edges of plates, as these rings establish the shape for the remainder of the structure. These completed rings should then be lifted into place on the upstream end of the structure and attached to the invert. Each successive ring should be lapped outside of the previous ring for support. Plates should be lifted into position using two clevises attached with two separate cables or chains. Clevises should be attached such that the plate is suspended in the position it attaches to the structure, i.e. crown plates shall be hooked at the center to suspend them horizontally. When constructing a ring, begin with a base plate, bolting to the base channel first then working up the seam. Best practice is to skip as few bolt holes as possible. Bolt holes shall be aligned as best as possible; if they are aligned just enough to push a bolt through then there may be difficulty as construction proceeds. Using two pry bars in opposite directions will draw plates together and help to align holes. In locations where there are 3 overlapping plates, it may be necessary to draw the plates into alignment using a drift pin. Drift pins shall be driven using a sledgehammer until the adjacent holes are aligned. Place bolts in the adjacent holes and tighten them enough to hold the plates, then remove the drift pin by hammering it back out. Plates are added in a shingling pattern as shown on the construction drawings.

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3.6. RIBS Ribs should be added to the structure as it is built to reduce the flexibility and help to hold the proper shape. Adding ribs after the entire structure is built is typically more difficult and requires the removal of some bolts. 3.7. LIFTING

The lifting of pre-assembled sections of structures or entire structures is a proven and fairly common method of installation. However, attention must be given to proper techniques and safety measures. Structures must be lifted carefully in a controlled and balanced fashion. The use of slings and/or full perimeter cables is recommended. However, many structures have been lifted into place using eyebolts, lifting plate assemblies or lifting lugs. The type, number and location of lifting devices will be dependent upon the size, length and weight of structure. Lifting devices are normally located at a seam, or at a rib if applicable, with appropriate backup plates, washers, etc. used to distribute the load. Rigging a structure to be lifted into place is done by proportioning the weight between the lifting points to achieve balanced loading and control. If two sets of lift assemblies are used, these are generally located at the and points along the length. When three sets of lifting assemblies are used, they are typically located at the 1/6, and 5/6 points of the structure length. When four or more lifting points are used, they should be positioned in a similar fashion to insure balanced loading and control. The use of a spreader beam with multiple lifting points is desirable since this serves to stiffen the structure and better distribute lift loads. Additionally, the lift loads are transmitted vertically to the structure, minimizing eccentric forces on lift assemblies and excessive bending.

WARNING
DO NOT ATTEMPT ANY LOADING OF A STRUCTURE (INCLUDING LIFTING A PRE-ASSEMBLED STRUCTURE INTO PLACE) PRIOR TO THE TORQUING OF ALL NUTS. COME-A-LONGS AND/OR STRUTS MAY BE REQUIRED TO MAINTAIN STRUCTURE SPAN DIMENSION FOR OUT OF TRENCH ASSEMBLY AND INSTALLATON.

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Super-Cor Assembly and Installation Guide

3.8. ENCASED CONCRETE RIBS Structures having Encased Concrete (EC) ribs require additional work during construction. Spray foam insulation is used to fill gaps between plates and around boltholes. Ensure foam does not expand into the rib cavity. The structure must be backfilled approximately 300mm (12) above the open end of the rib in order to contain the concrete. Concrete properties are detailed on the construction drawings. Typically, a self consolidating concrete mix with a flow circle of 600mm (24) will flow well. The addition of super-plasticizers is common. The recommended aggregate size is 10mm (3/8). Using smaller aggregates may cause excessive flow of concrete out of the ribs through bolt holes, seams and small gaps. When pumping concrete, it is best to use a smaller diameter hose so that the flow can be directed to either side of the structure. Vibration may be required to improve flow of the concrete. Common methods include using frequent light taps with a hammer along the length of the rib as it is filled, electric concrete vibrators or the use of light compaction equipment on the soil at the base of the rib. Inspection holes are typically required at the haunch to ensure the rib is filled to the end. These holes also double as a secondary vent hole. It is good practice to determine the volume of concrete required for each rib, and the number of ribs that each truckload should fill. This helps ensure ribs are being completely filled, and gives early indication if extra concrete will be needed. To reduce unsymmetrical loading of the structure, start at one end of the structure and fill every other rib. When the opposite end is reached, work back and fill ribs that were skipped. Ribs shall be sounded for voids both during the pour and after the concrete has set. Wherever hollow tones are found, inspection holes shall be drilled, and any voids filled with high strength grout.

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4.0
4.1.

Backfill
BACKFILL REQUIREMENTS The backfill material structural characteristics are an integral part of soil-steel structure design. It is the responsibility of the Contractor to ensure that the backfill material meets the required parameters set out in the contract documents and AILs shop drawings. The Contractor is required to submit a list of the construction vehicles that will be crossing the structure in order to determine the minimum heights of cover. If this list is not provided, the required cover shall be taken as the minimum height for the design, as stated on the construction drawings. No vehicles greater than the intended design load may cross the structure.

4.2.

BACKFILL PLACEMENT Material is not to be dumped or pushed perpendicular to structure but shall be placed in layers starting no closer than 1500mm (5) from the side. Heavy construction vehicles shall not approach within 1000mm (34) of the structure (see backfill clearance diagram). The depth of each un-compacted lift must not exceed 200mm (8 inches) unless otherwise specified in the contract documents. Reduce lift height if there is difficulty reaching required compaction. Fill depth shall be maintained approximately equal on each side of the structure at all times. The maximum difference in elevation at any transverse section shall not exceed 200mm (8). When the backfill reaches 3/4 of the rise, all struts and bracing (if any) inside the structure must be removed. When the backfill reaches 3/4 of the rise, spreading and compaction over the top of the structure must be in the direction perpendicular to the length of the structure, i.e. parallel to the corrugations, until the finished height of critical backfill zone is reached as per design. This can be achieved by gradually pushing fill material towards the crown of the structure with a light dozer, always maintaining 610 mm (2) minimum vertical cover between the dozer and the structure. 610 mm (2) minimum cover can also be achieved be placing the fill material over the structure with an excavator. This is the preferred method because it maintains maximum distance between the equipment and the structure. At this stage it is critical to monitor the structure for defection to assure the equipment is not altering the design shape. Light compaction equipment shall be used at this stage of backfill.

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4.3.

COMPACTION When compacting the backfill material it is important not to allow any large vibratory equipment within 1 m (3.3 ft) of the structure. A small plate tamper is usually used within this area to ensure proper compaction without damaging the structure. At least three passes with a lightweight tamper are required. Heavy equipment shall also veer away from the ends of a structure, particularly structures with bevels and/or skews. Select granular backfill material shall be compacted to a minimum of 95% Standard Proctor Maximum Dry Density unless otherwise specified in the contract documents or manufacturers drawings.

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Construction loads
No equipment shall be allowed over the structure that would exceed the design live load. Construction equipment may require additional cover, please consult with an Atlantic Industries Limited representative. When compacting fill material over the structure on the first several lifts, all vibratory action should be stopped, or else the backfill material does not compact well due to the vibration of the structure.

5.0

Shape Monitoring
The design dimensions should be verified during the assembly to assure proper dimensions are being achieved. If not, bracing may be required to maintain desired shape. The tolerance is plus or minus 1% of the span. Horizontal cables or vertical struts are used to stabilize and maintain design shape during assembly. These cables or struts may be required to remain in place until structure is completely assembled and partially backfilled. Struts must be removed before backfilling and compacting over the top. This is typical for large structures to support the weight of the top plate, preventing distortion of the design shape. Monitoring deflection is required during backfilling. Typically this is done by hanging plumb-bobs inside the structure or using a total station to monitor changes in shape during backfilling procedures. Any change in dimension or plumb of the structure warns that heavy equipment must work further away from structure. To correct any upward movement of the top of the structure, place backfill material on top of the structure acting as a surcharge load to reduce the peaking effect. To correct rolling of the structure, remove backfill material on the opposite side until the structure corrects itself. In either case the monitoring is critical to assure the structure has not moved too far out of shape to be corrected by the noted methods. Bevels require close monitoring during the backfilling process as they may have a tendency to move out of the desired shape if larger compaction equipment is used at too close a proximity to the bevel.

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Corrective action must be taken immediately when tolerances have been exceeded. Peaking can be countered by top loading a structure with fill using an excavator. Rolling can be corrected by removing fill from the unbalanced side until the structure corrects itself. Should deflections greater than 1% of any dimension occur, work should be stopped and an AIL representative consulted before any corrective action is taken.

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6.0 Summary

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