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A1 Motorway TORUŃ-STRYKÓW-TASK I Section I: Czerniewice interchange - Odolion interchange

(with Czerniewice interchange)

m Volume 3/15

/ DESIGNING STUDIO
OF TRANSPORT CIVIL
CONSTRUCTION
TRAKT
A1 Motorway, Toruń - Stryków - Task I
Section I: Czerniewice interchange - Odolion interchange (with Czerniewice interchange)
from km 151+900 to km 163+300
CONTENTS

Item Name Drawing No. Format

I DESCRIPTIVE SECTION - Specification 10 pages

II GRAPHIC SECTION

PZ-153b wildlife crossing at km 157+120


1. 01.01/3-15-PW-1 8A4
General drawing

PZ-153b wildlife crossing at km 157+120


2. 01.02/3-15-PW-1 8A4
Intermediate precast unit with a cantilever

PZ-153b wildlife crossing at km 157+120


3. 01.03/3-15-PW-1 8A4
Terminal precast unit with a cantilever

PZ-153b wildlife crossing at km 157+120


4. 01.04/3-15-PW-1 8A4
Inlet and outlet

PZ-153b wildlife crossing at km 157+120


5. 01.05/3-15-PW-1 8A4
Retaining wall - inlet

PZ-153b wildlife crossing at km 157+120


6. 01.06/3-15-PW-1 8A4
Retaining wall - outlet

PZ-153b wildlife crossing at km 157+120


7. 01.07/3-15-PW-1 8A4
Joining slab

PZ-153b wildlife crossing at km 157+120


8. 01.08/3-15-PW-1 8A4
Approach slab

PZ-153b wildlife crossing at km 157+120


9. 01.09/3-15-PW-1 8A4
Guard plate

P-01 culvert at km 158+020


10. 02.01/3-15-PW-1 8A4
General drawing
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P-01 culvert at km 158+020


11. 02.02/3-15-PW-1 8A4
Intermediate cast unit

P-01 culvert at km 158+020


12. 02.03/3-15-PW-1 8A4
Terminal cast unit

P-01 culvert at km 158+020


13. 02.04/3-15-PW-1 8A4
Inlet and outlet

P-01 culvert at km 158+020


14. 02.05/3-15-PW-1 2A4
Joining slab

PS-23b culvert at km 0+585, DW291 provincial


15. minor road (km159+792L) 03.01/3-15-PW-1 8A4
General drawing

PS-23b and PS-23c culverts


16. 03.02/3-15-PW-1 3A4
Intermediate cast unit

PS-23b and PS-23c culverts


17. 03.03/3-15-PW-1 3A4
Terminal cast unit

PS-23b and PS-23c culverts


18. 03.04/3-15-PW-1 3A4
Joining slab

PS-23b and PS-23c culverts


19. 03.05/3-15-PW-1 8A4
Inlet and outlet

PS-23c culvert at km 0+278, DW291 provincial


20. minor road (km159+816P) 04.01/3-15-PW-1 8A4
General drawing

Steel culvert under the road structure


21. 05.01/3-15-PW-1 8A4
General drawing

Steel culvert under the approach


22. 06.01/3-15-PW-1 4A4
General drawing

Precast and steel road culverts


23. 07.01/3-15-PW-1 3A4
Pre-camber

PZ-157b wildlife crossing at km 162+640


24. 08.01/3-15-PW-1 8A4
Longitudinal section, view, cross-section

Box culvert 3.0x2.0m - inlet/outlet


25. 08.02/3-15-PW-1 8A4
reinforcement

PZ-157c wildlife crossing at km 162+860


26. 09.01/3-15-PW-1 8A4
Longitudinal section, view, cross-section

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TABLE OF CONTENTS OF THE WORKING DESIGN


1. GENERAL INFORMATION.............................................................................................5
1.1 Formal basis of the study.............................................................................5
1.2 Subject of the study............................................................................6
1.3 Scope of the elaboration................................................................................................6
2. DESCRIPTION OF CONSTRUCTION AND MATERIAL SOLUTIONS.....................7
2.1 Reinforced concrete precast culverts...........................................................................7
2.1.1 Construction materials............................................................................................7
2.1.2 Foundation of the structure.......................................................................................7
2.1.3 Calculation assumptions...........................................................................................8
2.1.4 Construction of culverts............................................................................................8
2.1.5 Inlets and outlets......................................................................................................9
2.1.6 Reinforcement.........................................................................................................9
2.1.7 Reinforcement cover, corrosion protection..............................................................9
2.1.8 Culvert foundation.....................................................................................................10
2.1.9 Approach slabs..................................................................................................10
2.1.10 Expansion joints........................................................................................................10
2.1.11 Backfill...................................................................................................................11
2.1.12 Insulation, drainage.................................................................................................11
2.1.13 Revetments.............................................................................................................11
2.1.14 Guard railings...........................................................................................................12
2.2 Steel culverts.................................................................................................................12
2.2.1 Construction materials............................................................................................12
2.2.2 Construction of culverts............................................................................................12
2.2.3 Inlets and outlets....................................................................................................12
2.2.4 Corrosion protection................................................................................................12
2.2.5 Culvert foundation.....................................................................................................12
2.2.6 Backfill...................................................................................................................13
2.2.7 Slope reinforcement................................................................................................13

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1. GENERAL INFORMATION
1.1 Formal basis of the study
The basis of the study are:
• Agreement of May 14th, 2007 between General Directorate of Domestic Roads and Motorways Warsaw
Division and the Consortium of BPBK TRAKT with registered office in Katowice and SENER INGENIERIA Y
SISTEMAS S.A. with registered office in Spain, for the preparation of materials for environmental decisions,
construction and detailed design, and tender documentation for A1 Motorway, Section Toruń-Stryków from km
151+900 to km 295+850 and realization of design supervision [1];
• Decision of the Toruń Provincial Governor no. 1/98 regarding the choice of location of a toll motorway in the
Toruń province dated 30.12.1998, mark GP.II.7331/1/98 [2];
• Basic technical documentation - Preliminary Design, A-1 Motorway sec. Czerniewice-Kowal km 151+900-
215+898, prepared by Transprojekt Gdański
in 1998. [4];
• The Ordinance of the Minister of Transport and Water Management, dated 30.05.2000, concerning the
technical conditions required for road engineering structures and their location (Journal of Laws no. 63, item 735)
[5];
• "Geological & engineering documentation" and "Hydrogeological documentation" prepared by "Geoprojekt" in
Warsaw in 2008 [6];
• Layout and height map with site reinforcement for design purpose, scale
1:1000, prepared in 2008 by GEOPROJEKT in Warsaw [7];
• Act of 07 July 1994 - Building 7.07.1994 (Journal of Laws no. 89, dated 25.08.1994) with subsequent
amendments. [8];
• Road culvert of precast units - Transprojekt - Warszawa Ltd.
2007 [9];
• PN-85/S-10030 Bridge structures. Loads [10];
• PN-81/B-03020 Building land. Direct foundation of the structure. Static calculations and designing [11];
• PN-91/S-10042 Bridge structures. Concrete, reinforced concrete and pre-stressed structures. Design [12].

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• PN-B-03264 Concrete, reinforced concrete and prestressed structures. Static calculations and designing [13].
• PN-83/B-03010 Retaining walls. Static calculations and designing [14].
• Road structures of corrugated sheets. Design and realization. WKŁ 2007 [15]
• Design and technological recommendations for flexible road structures of corrugated sheets. IBDiM 2004 [16]
• IBDiM Technical Approval No. AT/2007-03-0248 Steel, spiral corrugated pipes together with HEL-COR and
HEL-COR Pipe-Arch connection fittings. [17]
• Building permit design Volume 3/15 Road structures Culverts and small animal crossings [18]
1.2 Subject of the study.
The subject of the elaboration is a detailed design in construction and
architecture branch for culverts and small animal crossings in A1 motorway at km 151+900 to 163+300.
1.3 Scope of the study
The elaboration involves the following structures:
A1 MOTORWAY CULVERTS
section Angle between road
Culvert Motorway Character Barrel Length Longitudinal slope
axis and culvert axis
number mileage (function) [m] [%]
[o]
REINFORCED CONCRETE CULVERTS
PZ-153b 157+120 ecological 250x250 41.29 2.00 90
P-01 158+020 irrigation and 0150cm 40.39 1.07 89
drainage
PZ-157b 162+640 ecological 300x200 38.80 0.85 90
PZ-157c 162+860 ecological 300x200 37.80 0.84 90
PS-23b 159+792 road 080cm 26.07 0.575 90
PS-23c 159+816 road 080cm 29.48 0.55 90
STEEL CULVERTS
PS-01 153+110L road 060cm 12.85 0,51 90
PS-03 153+705L road 060cm 9.85 0.67 90
PS-03a 153+800L road 060cm 7.80 1.92

PS-04b 154+296L road 080cm 15.35 0.54 88


PS-08 154+580L road 060cm 13.70 1.97 90
PS-09 154+618P road 060cm 11.80 0.68 91
PS-11 155+952P road 060cm 14.10 1.77

PS-12 155+960P road 060cm 16.00 1.62

PS-13 156+007P road 060cm 10.40 0.48

PS-14 156+017P road 060cm 10.40 0.48

PS-15 157+120L road 060cm 7.70 0.20

PS-16 157+120P road 060cm 10.00 0.20

PS-17 157+132P road 060cm 19.40 0.52 94

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PS-18 157+263P road 060cm 12.35 0.52 91


PS-19 157+276P road 060cm 11.20 0.89 88
PS-21 158+375P road 060cm 11.55 1.99

PS-21a 158+525P road 060cm 12.90 1.78

PS-23a 159+344P road 060cm 12.80 1.41 90


PS-24 160+000L road 080cm 14.40 0.85

PS-25 160+060P road 080cm 16.96 0.65

PS-27 160+795L road 080cm 10.90 0.58 81


PS-32 161+225P road 060cm 8.75 0.55 90
PS-33 162+230L road 060cm 9.65 0.31

PS-33a 162+640L road 060cm 18.32 0.20

PS-33b 162+640P road 060cm 19.40 0.21

PS-33c 162+860L road 060cm 18.40 0.60

PS-33d 162+860P road 060cm 18.23 0.20


The documentation shall be considered together with the necessary trade parts.
• VOLUME 1 COLLECTIVE SHEET AND GEODETIC DATA
• VOLUME 2 ROAD DESIGN
• VOLUME 5 DESIGN OF WATERWORKS AND SEWER-DRAINAGE SYSTEMS 2. DESCRIPTION OF
CONSTRUCTION-MATERIAL SOLUTIONS
2.1 Reinforced concrete precast culverts
2.1.1 Construction materials
Prefabricated elements of the culverts shall be made of B45 class concrete. Concrete and
materials used for its preparation must meet the requirements defined in "Technical conditions required from road
structures and their locations".
Structural concrete (approach slab) prepared on-site, B45 class. Reinforced with A-IIIN class steel.
Structural concrete (joining slab, inlets and outlets, retaining wall) prepared on-site, B30 class. Reinforcement
with A-IIIN steel.
Protection of insulation made of class B25 concrete, reinforced with a 0 8 bar grid, spacing 10x10 cm, class AIIIN
steel.
Concrete foundations under box elements, made of B10 concrete. Levelling concrete B10.
Soil stabilised with portland cement class 32.5 NA in the amount ensuring R=5 MPa strength constitutes the
foundation for piping elements. The approximate amount of cement for sandy soils amounts to 100kg/m3.
2.1.2 Structure foundation
Conditions for culverts foundation are considered good. The structures will be founded
directly in the ground. Organic soils occurring at the foundation level should be replaced up to the upper surface
of bases with cohesionless soils having compaction index IS =0.95

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according to the technical specification for the realization and final acceptance of works. Swelling soils occurring
in the foundation level should be replaced at the depth of 120 cm below ground level (trench bottom, base slab)
with cohesionless soils having compaction index IS =0.95. The replacement should be done under terminal
elements of the structure (inlet or outlet), together with the terminal segment. Cohesive soils with soft consistency
occurring in the foundation level should be replaced to the lower surface with cohesionless soils having
compaction index IS=0.95. Conditions of earthworks realization, considering the occurring soil types -
advantageous. In the case of groundwater level higher than the planned foundation level of the culvert, first of all
a proper drainage of the terrain where the culvert is located should be ensured.
2.1.3 Calculation assumptions
All culvert components were designed for moving load of "A" class
according to PN-85/S-10030 standard, and special-purpose vehicle load of 150 STANAG 2021 class. Catalogue
solutions of precast units according to section 5.1 [9] are designed for the aforementioned load, and the initial
backfill thickness does not exceed the maximum values.
A section working in a plane state of strain was accepted as a structural arrangement for calculation of load
capacity of the foundation. As the load scheme of the foundation, a load with "A" class motor vehicles or 150
class special-purpose vehicle in the most unfavourable location, and pavement courses' (passageway,
foundation) and nonstructural layers' (pavement, road foundation, joining slab) weights was assumed.
Full static-strength calculations may be found in the archive of the agency preparing the Catalogue of Road
Culverts made of Precast Units [9].
Static-strength calculations for nontypical elements (retaining walls) may be found in the archive of the agency
preparing this project.
2.1.4 Culvert structure
The culverts were designed using circular and boxed
precast units. Pipes with internal diameters of 150 and 80 cm, and box sections with internal dimensions of
250x250 cm and 300x200 cm were used. Thickness of the precast units was chosen according to the guidelines
included in [9].
Length of a typical single element is 1990 mm - clearance between precast units is 1 cm. Connections between
precast units have form of concrete

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locks transmitting transverse forces. The precast units will be joined using a reinforced concrete slab prepared
on-site. Considering the shrinkage in the joining slab, in the place of contact of old and fresh concrete, it is
necessary to properly prepare of the concrete surface (eg. by wet-sandblasting). In the place of the approach
slab rest - boxed precast units with shaped cantilever having 150 mm outreach. Inlets and outlets designed as
jointless.
2.1.5 Inlets and outlets
Inlets and outlets of the culverts are shaped in the form of trapezoidal base slab
made of reinforced concrete and triangular wingwalls supporting fill batters, deviated in the plan from the culvert's
axis by an angle of 30-45deg. Inlets and outlets terminated with an endplate 30 cm thick and a groin 30 cm wide
and at least 90 cm high. Wingwalls 25 cm thick attached to the base and endplate slabs.
For PZ-153b culvert, outlet and inlet were designed as retaining walls 35 cm thick, with variable height of 68-417
cm, and lengths of 350 and 582 cm. Elements of the culvert's inlet (outlet) are joined using a boxed unit with 90
cm total length, prepared on-site, with the terminal precast unit of the culvert.
2.1.6 Concrete reinforcement
Reinforcement has been designed for ribbed steel of A-IIIN class. Reinforcement was located in two near-surface
meshes, excluding piping prefabricated elements <D80 cm, Two-way reinforced joining slab. Joining
prefabricated elements with the joining slab is ensured by couplers glued onto the prefabricated element by
means of an epoxy glue. Bolts fitting the approach slab 2022/mb of L=400 mm. Diameters and length of bars in
accordance with [9].
Reinforcement of inlets and outlets with 08- 016 bars.
2.1.7 Reinforcement cover, corrosion protection
The surfaces of the prefabricated elements that are not covered: E class, 4 cm cover. Surfaces covered with
haunching or concrete prepared on-site, 4 cm cover.
When the culvert is located in an averagely or highly aggressive environment, all exposed concrete surfaces
should be protected with protective paints for concrete, according to "Catalogue of surface protective treatments
for road structures", IBDiM 2002.

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2.1.8 Culverts foundations


Foundation of pipe culverts is the ground stabilised with cement, on which
the precast units should be placed. Footing dimensions, in accordance with [9]. For the ground stabilisation,
Portland cement 32.5 NA class should be used in a quantity ensuring strength of R=5MPa. The approximate
amount of cement for sandy soils is 100 kg/m3. Maximum contents of cement in the mix, calculated in relation to
dry soil weight, is 8%. The soil to be stabilised should not contain grains larger than 50 mm, and it should contain
no more than 20% of clay fraction (0.002 mm max.). Soils with sand equivalent value 20<WP<50 and contents of
<0.075mm fraction of 15% maximum, and >2mm grain content of at least 30% are preferred.
Strip footing made of B10 concrete constitutes box culverts foundation. Footing dimensions, in accordance with
[9]. Prefabricated elements shall be placed on a layer of green cement mortar, 1-2 cm thick. Foundation directly
on load bearing soil.
2.1.9 Approach slabs
For the initial backfill H<1.5 m and H<0.5Ht , where Ht - height of the prefabricated element
together with the joining slab - Ht >2.0m, execution of the approach slabs under the roadway was assumed.
Approach slabs with length of 4.0 are anticipated to rest on cantilevers shaped in the joining slab or in the
precast units. Approach slabs' thickness 30 cm, longitudinal gradient 10%.
Connection with the joining slab of the culvert by means of pipes: 031.8x2.9 L=210 mm welded to 025 bars
protruding from the reinforced concrete elements. Foundation by means of B10 concrete bedding,10 cm thick.
Behind the slabs, a longitudinal drain made of PCV 0150 is planned, surrounded with aggregate wrapped in
filtrating geotextile fabric. Subbase under drain made of a layer of cohesionless soil, 20 cm thick and 60 cm wide.
The drainage outlet should be lined and directed towards the batter.
2.1.10 Expansion joints
Joint gaps 25 mm wide in the joining slab shall be secured by means of external joint filler
tapes with a flexible duct based on PVC-B/BV (plasticized PVC resistant to bitum) of total tape width equal to 240
mm and external joint filler tapes based on PVC-B/BV. Void shall be filled with a cork board 25 mm thick,
saturated with bitum.

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10 mm wide gaps between prefabricated elements shall be filled with swelling seal made of hydrophilic rubber.
2.1.11 Backfill
Culvert backfill shall be made of non-cohesive soil that was not contaminated with organic or heave soils, or
waste (gravel, gravel-sand mixes, sands, sandy gravel, broken aggregate, arch stone) with water permeability of
k>8m/day, aggregate of granulation between 0 and 75 mm and diversity index not less than 5. Compaction index
IS = 1.0.
2.1.12 Insulation, drainage
The following shall be covered with torch-on membrane waterproofing system:
- top surface of the reinforced concrete joining slab whose width exceeds 1.5 m, formed in a two-way crossfall.
- joints between prefabricated elements by means of strips approx. 30cm.
Sheet-membrane waterproofing system covering the upper surface of the joining slab should be wrapped onto
horizontal surfaces at a height of 25 cm or laid out onto the approach slab at 50 cm stretch. On the sheet-
membrane waterproofing system, a protective layer will be made of B25 (C20/25) concrete reinforced with a <D8
mm mesh having 10 x 10 cm spacing.
Thin insulation shall be used for covering, by means of double bituminous covers, all concrete surfaces directly
contacting the soil, that are available prior to the production of backfill.
Road embankment within the area of connection with culvert in the form of filter layer , at least 50 cm thick,
horizontal (on the upper surface) and vertical (behind faces) made of non-cohesive soils (sand and gravel mix,
road stone, gravel, coarse and medium grained sand). Filter layers shall be made and compacted simultaneously
with the backfilling of culvert.
2.1.13 Stabilisation
An embankment strip 50 cm wide within the area of inlets and outlets on the joining with concrete shall be
reinforced with a HDPE geogrid 100 mm high.
Bottoms and slopes of watercourse beds and land drainage channels will be stabilised on inlets and outlets using
riprap protection. The stabilisation shall be made according to documentation in volume 10/1 "Makeover of land
drainage channels".

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2.1.14 Barriers
In the culverts with inlets (outlets) higher than 1.5 m or with the embankment limited
by a retaining wall higher than 1.5 m, traffic barriers with rails driven or cast into a foundation attached to the
joining slab should be used. Barrier foundations made of B25 concrete, with dimensions of 500x300xB, where B -
length of strip footing corresponding with the width of the joining slab. For 060cm pipe culverts joining slab width
is B=420mm, for 080cm ones - B=500mm, for 0100cm ones - B=600mm, for 0120cm
ones - B=700mm, for 0150cm ones - B=850mm
2.2 Steel culverts
2.2.1 Construction materials
Culverts are designed of diamond pattern construction plate 2 mm thick of
steel conforming with PN-EN 10327:2006-DX51D+Z or PN-EN 10326:2006-S250 GD. The plate is pre-protected
with a layer of zinc 42 |im thick in accordance with PN-EN 10327 and a layer of polymer 250 |im thick in
accordance with PN-EN 10169-1:2004.
2.2.2 Culvert structure
Culverts are designed of spiral, corrugated, cold-formed pipes of
circular cross-section and diameters of 0500, 0600 i 0800. Typical elements with 6 m length are connected on-
site using connecting bands 300 mm wide for 0500-0800 pipes.
Depending of the height of newly built embankment and on the foundation soil type, a construction height should
be provided for - according to fig. 58.02/3-19-PW-0.
2.2.3 Inlets and outlets
Edges of pipes near the inlets and outlets are cut and chamfered (adjusted to
the slopes) in a manufacturing plant. For pipes 0500 and 0600 in diameter, located under the road prism and the
access road, vertical cut amounts to 20 cm and for 0800 - 25 cm. Typical slope amounts to 1:1.5.
2.2.4 Anti-corrosive protection
Plate surface pre-protected by means of a layer of zinc 42 |m thick in accordance with
PN-EN 10327 and a layer of polymer 250 |im thick in accordance with PN-EN 10169-1:2004
2.2.5 Culverts foundations
Gravel and sand mix base of maximum aggregate particles size

amounting to32 mm. Foundation thickness 30 cm and compacted to compaction ratio min.

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0.98 standard Proctor density. Top 5 cm laid loosely in order for the ribs of the steel structure to be inserted
freely. Foundation width for 0500 pipe amounts to 170 cm, for 0600 amounts to 180 cm, for 0800 amounts to 200
cm. It is not permitted to place the foundation of the structure directly on a rocky base.
2.2.6 Backfill
Culvert backfill shall be made of non-cohesive soil that was not contaminated with organic or heave soils, or
waste (gravel, gravel-sand mixes, sands, sandy gravel, broken aggregate, arch stone) with water permeability of
k>8m/day, aggregate of granulation between 0 and 32 mm. The backfill around a 0500-0800 pipe should exceed
its circumference for min. 60cm. Lay down in layers evenly from each side, with the thickness of loose layers not
exceeding 30 cm. The compaction ratio of each layer shall not be lower than 0.95 acc. to the standard Proctor
test, at a distance of 20 cm from the wall of the structure and 0.98 in other areas.
Minimum thickness of backfill under the culvert amounts to 15 cm. The minimum soil surcharge over the culvert
together with the structural layers of the pavement shall be 60 cm for roads and 30 cm for entries. The maximum
soil surcharge for 0500 culverts from corrugated sheets with thickness of 2.0 mm shall be 42 metres, for 0600
culverts with thickness of 2.0 mm - 35 metres, for 0800 culverts with thickness of 2.0 mm 26 metres.
2.2.7 Slope revetment
Embankment strip 150 cm wide within the area of inlets and outlets on the connection with a steel pipe
to be reinforced with concrete pitchers 10 cm thick, on 1:3 cement and sand bed.

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