Keep it Flowing! Culvert Design 20: Design, Durability & Applications
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This document outlines a technical webinar titled 'Culvert Design 201', presented by Randy McDonald and Frank Klita from Armtec Drainage Solutions, discussing structural design, durability, and applications of culvert and buried structures. It includes information about Armtec's capabilities in civil engineering, structural design techniques, and specific projects using their products, such as deep corrugated structural plates for various applications. The webinar is aimed at providing attendees with the knowledge to ensure proper product selection and support for infrastructure projects.
Keep it Flowing! Culvert Design 20: Design, Durability & Applications
- 1. Randy McDonald, P.Eng. Director of Engineering Armtec Drainage Solutions Frank Klita Sales Representative Armtec Drainage Solutions Randy McDonald, P.Eng. Director of Engineering Armtec Drainage Solutions Frank Klita Senior Sales Representative Armtec Drainage Solutions CULVERT DESIGN 201 STRUCTURAL DESIGN, DURABILITY & APPLICATIONS TECHNICAL WEBINAR THE BROADCAST WILL BEGIN SHORTLY FRIDAY DECEMBER 11, 2015 / 9AM PST / 11AM CST / 12PM EST
- 2. Randy McDonald, P.Eng. Director of Engineering Armtec Drainage Solutions Frank Klita Sales Representative Armtec Drainage Solutions Randy McDonald, P.Eng. Director of Engineering Armtec Drainage Solutions Frank Klita Senior Sales Representative Armtec Drainage Solutions FRIDAY DECEMBER 11, 2015 / 9AM PST / 11AM CST / 12PM EST TECHNICAL WEBINAR CULVERT DESIGN 201 STRUCTURAL DESIGN, DURABILITY & APPLICATIONS
- 3. YOUR HOST Janine Yetke Director of Marketing Armtec, Drainage Solutions LinkedIn: ca.linkedin.com/in/janineyetke/en Email: Janine.Yetke@armtec.com
- 4. JOIN THE DISCUSSION At any time during the presentation, please enter your questions into the Question Log
- 5. CPD CREDIT CERTIFICATES • Qualifies in Most Jurisdictions in Canada & USA for 1 Hour Technical Informal • Formal completion certificates are emailed within one week of attending • Check your local guidelines if unsure of your requirements Email your complete attendee list should there be multiple individuals viewing the same screen: • Full Name • Title • Email webinars@armtec.com Armtec will send certificate to all participants
- 6. Armtec is one of Canada’s largest infrastructure company supplying precast, corrugated steel and HDPE products and solutions. Every day, our proven products, engineered solutions and dedicated people are counted on to support construction and infrastructure projects in communities everywhere. With a national presence and a local focus on exceptional customer service, we are dedicated to building excellence. Actual 2014 Locations 43 Drainage Locations Precast Locations ABOUT ARMTEC
- 7. SECTORS Armtec specializes in all infrastructure markets and segments and can help with any project to ensure you have the right products for the job. Our people have extensive experience and access to resources all across the country, and can help with all facets of product selection, installation and support. Stormwater Solutions Mining & Energy Commercial & Retail Constructions Transportation Underground & Utility Infrastructure Sports & Entertainment Institutional Construction Industrial Construction Agriculture Commercial & Residential Landscaping Forestry Residential & Hospitality ABOUT ARMTEC
- 8. Armtec Drainage Solutions’ centralized engineering department consists of design engineers, a drafting team, and estimators. Additionally, professionally licensed Region engineers are located in all Market Areas across the country. DRAINAGE ENGINEERING SUPPORT & ROLES ABOUT ARMTEC
- 9. YOUR SPEAKERS Randy McDonald P.Eng. Director of Engineering Armtec, Drainage Solutions Randy.McDonald@armtec.com Frank Klita Senior Sales Representative Armtec, Drainage Solutions Frank.Klita@armtec.com
- 10. AGENDA 1. Overview - Segmental Plate Products for Buried Bridges 2. Buried Bridge Structural Design – Section 7 CSA S-6 CHBDC 3. Design Life - Designing for Durability 4. Projects and Applications
- 12. Multi-Plate 152 x 51 Bridge-Plate 400 x 150 Tunnel Liner Plate 500 x 52 SPCSP AND DCSP
- 13. SHAPE OPTIONS
- 14. MULTI-PLATE SUPER-SPAN 14.4m span x 6.8m rise High Profile Arch
- 15. LARGEST SUPER-SPAN (1984) 18.0m span x 7.4m rise Low Profile Arch
- 16. DCSP Deep Corrugated Structural Plate • Bridge-Plate • 400 x 150 corrugation • Plates widths are 1200mm (3 corrugations) • Wider plates allow faster assembly times • 10 times greater stiffness than shallow corrugated plate products
- 19. STRUCTURAL DESIGN Buried structures • two distinctly different materials that interact to create a complex composite geo-structural system to support the overburden and surface live loads 1. Soils encasing the buried shell 2. Corrugated Steel Shell
- 20. BURIED STRUCTURE COMPONENTS 20 • Soil Component: – engineered granular backfill envelope – materials of known geotechnical properties • Steel Component: – Corrugated steel shell – Corrugated shell is highly efficient member to support axial compressive loads • Net Result: – economical buried structure capable of supporting large gravity loads
- 21. STRUCTURAL DESIGN Load resistance of the composite system • highly influenced upon the geotechnical properties of the backfill materials encasing the buried structure Strength of the structure is dependent upon • Geometry of the buried steel shell • Stiffness /thickness of the selected plate corrugation .
- 22. STRUCTURAL DESIGN Force Analysis • Determine thrusts, moments and deflections during and post construction Strength Analysis • Determine resistance of the structure to support the calculated load effects Successful Design ensures: Resistance > Demand
- 23. STRUCTURAL DESIGN Load Definitions Dead Loads • Weight of the soil column directly above the footprint of the structure • Weight of the shell is included in FEA • Accurate soil densities are critical • Deep bury applications DL account for 100% of applied loads
- 24. STRUCTURAL DESIGN Live Loads (Surface Pressure) • Position as many axles of the design vehicle at the road surface above the conduit span • Distribute rectangular surface pressure through the overburden @ 1:1 in transverse direction, 2:1 in longitudinal direction
- 26. STRUCTURAL DESIGN Truck Loading • Highway Trucks – CL625, CL800 • 5 axles – 225 kN maximum axle load Extreme Live Loads • Haul Trucks – 6120 kN GVW (CAT 797B) • 2 axles – 4100 kN maximum axle load • E90 Cooper Railway Loading
- 27. STRUCTURAL DESIGN Railway Loading 80K AXLE LOAD = 355 kN 2526 kN Total
- 28. 250 TONNE HAUL TRUCK LIVE LOAD 12.4 m span x 5.6 m rise bridge-plate arch
- 29. STRUCTURAL DESIGN Earthquake Loads – Earthquake loads are limited to determining an additional thrust component known as TE – TE is equal to a percentage of the Dead Load Thrust (TD) – The percentage multiplier (AV) equals 2/3 of the horizontal ground acceleration ratio AH – Earthquake thrust is then summed with Dead Load Thrust (TD) x load factor – TE does not have to be considered with any other load combinations
- 30. 10 Step Design Process for Soil-Steel Structures 1 10
- 31. 5.0 6 v hh D DD 2 4.0 v h D D Minimum Cover (Hmin) is the largest of: a) 0.6 m b) c) Determine Minimum Cover For deep corrugated structures Hmin shall be smaller of 1.0m and the minimum depth of cover for structure with shallow corrugations but the same conduit size 1
- 33. Calculate Dead Load Thrust • TD = 0.5 (1.0 – 0.1 CS) Af W • W = weight of column of material above 2 )( 1000 parameterstiffnessaxial EA DE C vS S TD/2TD/2
- 34. Calculate Dead Load Thrust • TD = 0.5 (1.0 – 0.1 CS) Af W • Af = arching factor 2 Span < Rise Span = Rise (round) Span > Rise
- 35. Calculate Live Load Thrust • Position as many axles of the CL-625 overtop as would give maximum total load 3 fLthL mlandDoflesserT 5.0 kPacrownatpressureLoadLiveL loadinglanemultiforfactorificationmf mod
- 36. Calculate Earthquake Thrust AH varies from 0 to 0.40 in Canada 4 vDe ATT ratioonacceleratizonalAwhereAA HHV 3 2
- 37. or 5 DLATTT LLDDf 1 EDDf TTT Maximum of Calculate Total Thrust
- 38. 6 MPa Area Tf Calculate Compressive Stress at ULS Area = area of selected plate thickness (mm2/mm)
- 39. 7 Calculate Wall Strength in Compression – fb (MPa) • Calculating the factored failure compressive stress fb • Dependent upon the NA radius 2 2 12Er KRF FFf y ymtb 2 3 r RK EF f mt b eRR eRR
- 40. 7 Calculate Wall Strength in Compression 30 log2.06.1 RE EI m 2 ' 1000 1 HHR R EE C C Sm 25.0 3 6.10.122.1 cmRE EI 25.0 3 RE EI K m 0.11000 5.0 ' cR HH 5.0 6 y e F E K r R 0.1 3.0 85.0 h m D S F 22.1 • To arrive at fb – 7 equations, 18 variables
- 41. 8 Check Wall Strength Requirements During Construction • Forces experienced during construction of long span structures can sometimes be greater than those values of the completed structure • Checks are made to ensure moments and thrusts induced during construction do not exceed the plastic moment capacity of the structure
- 42. 8 Check Wall Strength Requirements During Construction P = unfactored axial thrust = TD +TC Ppf = factored compressive strength = fhcAFy M = unfactored bending moment = M1 + MB + MC Mpf = factored plastic moment capacity = fhcMp 1 2 pfpf M M P P
- 43. 8 Check Wall Strength Requirements During Construction 3 11 hBM DRkM chBMB HDRkM 2 2 ChLMC LDRkM 3 Introduces 9 new variables; kM1, kM2, kM3, RB, RL, NF, Ac, k4, Lc Also requires previous known variables; Dv, Dh, Es, E, I,
- 44. 9 Check Wall Strength of Completed Bridge-Plate Tf = maximum thrust due to factored loads Ppf = factored compressive strength = fhAFy Mf = maximum moment due to factored loads Mpf = factored plastic moment capacity = fhMp 1 2 pf f pf f M M P T DLAMMMM LLDDDf 11
- 45. 10 Check Seam Strength Sjf ST • The calculated maximum thrust due to factored loads shall be less than the factored resistance of the longitudinal seams; SS = ultimate axial seam strength of bolted longitudinal seam
- 46. CHBDC FORMULA LIMITATIONS • Box Culverts – maximum span • All other shapes – single radius structures • Standard Highway Loading Analysis Options • Rigorous Method – i.e. Finite Element Analyses • Plaxis or CANDE are common software tools • Each stage of construction is modelled • Forces, moments & deflections captured for every stage
- 52. STRUCTURAL DESIGN - SUMMARY • Wall is predominately in compression for arch structures • Bending moments developed in box-culvert structures • Able to sustain high thrusts because it is laterally supported against buckling by compacted engineered backfill envelope • Backfill provides a continuous and nearly elastic support to the conduit wall • Even after development of local buckling, soil-steel structures can have substantial post buckling capacity by dispersing load away from the member in distress to the surrounding backfill envelope • For segmental plate products, seam strength capacity of bolted plate laps can be governing design condition
- 53. Design Life – Design for Durability 3
- 54. DEFINITIONS Design Life • A period of time specified by the Owner during which a structure is intended to remain in service Durability • the capability of a component, product, or structure to maintain its function throughout a period of time with appropriate maintenance Predicted Service Life • an estimated period of time for the service life based on actual construction data, condition surveys, environmental characterization, or experience. Service Life • the actual period of time during which a structure performs its design function without unforeseen costs for maintenance and repair.
- 55. PLATE COATINGS OPTIONS Hot Dip Galvanized Variable zinc weights (thicknesses) Provides cathodic protection of steel Zinc weight is a function • materials thickness & chemistry and dipping time in the kettle. Polymer Coating Zinc Rich Base Coat + Ethylene Acrylic Acid Copolymer Top Coat
- 57. Structural Plate Coatings Environmental Parameter Suggested Limits Galvanized Steel Suggested Limits for Polymer Coated Steel 50 year EMSL 75 year EMSL 100 year EMSL pH preferred range 5 – 9 3 – 12 4 – 9 5 – 9 Resistivity 2,000 – 8,000 ohm-cm >100 ohm cm >750 ohm cm >1,500 ohm cm Chlorides < 250 ppm NA NA NA Sulfates < 600 ppm NA NA NA Hardness > 80 ppm CaCO3 NA NA NA Table 21 Environmental Limits For Galvanized Steel and Polymer Coated Steel 1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012
- 58. Coatings – Hot Dip Galvanized Nominal Plate Thickness (mm) Standard Zinc Coverage Non-Standard Zinc Coverage Total Mass Both Sides (g/m2) Thickness per side (µm) Total Mass Both Sides (g/m2) Thickness per side (µm) < 4.0 915 64 NA NA 4.0 – 8.0 915 64 1220 87 1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012 Table 51 Zinc Coverage for Galvanized Structural Plate Products – CSA G401 Corrosion resistance is direct function of the coating mass (thickness)
- 59. Zinc and Carbon Steel Corrosion Material Period AASHTO Standard Loss Rate/year/side (µm)1 UK Non-Aggressive Loss Rate/year/side (µm)2 Zinc Coating First 2 years 15 4 Subsequently 4 4 Carbon Steel After Zinc Depletion 12 M=22.5ts 0.67 1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012 Table 111 Zinc and Carbon Steel Soil Side Loss Rates 1AASHTO LRFD Bridge Construction Specifications 2UK Design Manual for Roads and Bridges ts is additional design service life in years after zinc depletion, M is the UK steel corrosion allowance after zinc depletion
- 60. POLYMER COATING STRATA-CAT • Bonded chemically to the steel preventing delamination • Provides a 10 mil barrier between the structure and the environment • Provides excellent corrosion resistance against diluted acids, salts & alkalis • Offers long term durability where extended service life is required
- 61. GALVANIZED & POLYMER COATED
- 62. POLYMER COATING www.armtec.com CAT = Corrosion Arresting Technology
- 64. CULVERT DESIGN 201 Project Installations and Applications
- 65. Northeast Anthony Henday – Edmonton, AB • Project Requirements: Corrugated Arch protection of 5 critical oil carrying pipelines • Design loads: Dead load (embankment fill only) • 100 year design service life • Designed to CAN/CSA S6- 06 CHBDC UTILIDOR PROTECTION USING DEEP CORRUGATED STRUCTURAL PLATE
- 66. UTILIDOR PROTECTION • • Project Drawing Snapshots: • 47H SRA Bridge-Plate DCSP (Deep Corrugated Structural Plate) • 12750mm Span X 6370mm Rise • Structure Length 24.120m (C/L) • All plates 7.0mm thick • 915 gm/m² Galvanized Coating • 60 Degree Segmental Elbow (constructed from 8 mini-elbows)
- 67. DCSP UTILIDOR PROTECTION COVER • Foam blocking to reduce settlement of the embankment. • Embankment settlement / adverse effect buried metal arch (adds more load to the arch). • Max. height of cover = 6.0 m. Northeast Anthony Henday – Edmonton, AB
- 68. DCSP C/W REINFORCING RIBS • • • Heavy Haul Road Crossing • Design - 8mm thk corrugated shell c/w 8mm reinforcing ribs spaced at 2400 mm • Designed for two loaded CAT 797B Mine Trucks crossing at the same time. • One loaded CAT 797B = 1.4 million lbs. ! (635,000kg) Albian Sands (2010) Ft. McMurray, AB
- 69. DCSP C/W REINFORCING RIBS Albian Sands (2010) Ft. McMurray, AB • Reinforcing ribs were continuous around the arch from footing to footing for added compressive strength. • Designed with Finite Element Analysis (FEA) • Strongest Bridge-Plate section (8mm shell w/ full 8mm ribs) • During backfill the composite design of the ribs and shell allowed the structure to behave within the design parameters
- 70. DCSP C/W REINFORCING RIBS Albian Sands – Ft. McMurray, AB • 13 m span x 10 m rise • Max. height of cover = 4.5 m • Tallest Bridge-Plate arch (high profile shape) ever supplied by Armtec
- 71. DCSP – RAILWAY LOADING • Full periphery structure • 6615mm Diameter (50H) Bridge- Plate Round Pipe • 72.08 m Long • All plates 5.0mm thickness • 1220 gm/m2 Galvanized Coating • CHBDC was used for main design using AREMA loading and impact factors. Railcar Loading Facility Hardisty, AB
- 72. DCSP – RAILWAY LOADING • • • Designed to handle 5 railway lines over (Cyclical loading) • Design Parameters: Cooper E80 & CL-800 Live Load • Unit weight of backfill = 22 kN/m³ Loading Facility Hardisty, AB
- 73. DCSP – RAILWAY LOADING • • • Critical Backfill zone design = ½ Dia. min. each side of the structure to finished cover • Critical zone material - engineered well graded granular compacted to minimum 95% SP density • 2.0m Height of Cover Loading Facility Hardisty, AB
- 74. DCSP – RAILWAY LOADING • Designed for small vehicle access (Not a stream crossing) Loading Facility Hardisty, AB
- 75. MULTIPLE STRUCTURES • • • DCSP Structure and Pedestrian Underpass • Designed to CL-800 loading Quarry Park, Calgary, AB
- 76. MULTIPLE STRUCTURES • 1500mm Spacing between structures • Spacing required to provide adequate room for placement and compaction of granular material • Small sized compaction equipment • 200mm layered lifts to 95% SPD Quarry Park, Calgary, AB
- 77. STRUCTURAL PLATE – DURABILITY • Armtec Multi Plate Ventilation Plenums c/w Polymer Coating (StrataCAT) and Fabricated Elbows. • 4450mm Dia. • StrataCAT chosen due to the corrosive potash environment • Interesting Fact - both ends were supplied with pre- attached mounting flanges Air Intake Application – Potash Mine, Esterhazy SK
- 78. DURABILITY • • • Fabrication was handled in house to provide a full site solution
- 79. LOW HEADROOM DESIGN Pipestone Creek, County of Wetaskiwin, AB Objective • Replacement for existing timber bridge in rural Alberta. • Consultant / Owner looking for a single opening & cost effective structure versus a multiple culvert pipe installation. Challenges • Low headroom at site • Potentially corrosive water. • Live load Design Vehicle CL-800 in event of detour from Hwy 2 (Edm to Calgary).
- 80. LOW HEADROOM DESIGN Pipestone Creek, County of Wetaskiwin, AB • Aluminum Box Culvert was selected • 10.6m Span X 3.4m Rise X 17.8m long • All plates: 6mm thick Aluminum • Full Corrugated Invert and Footing Plates: Aluminum • Reinforcing Ribs required for both Haunch & Crown • Foundation required a full width granular bed densely compacted was to 98% SPD. • Minimum required bearing capacity of foundation = 290 kPa
- 81. ALUMINUM BOX CULVERT Other site challenges: Roadway Superelevation – this required attention by the consultant in order to achieve the minimum specified covers and to not exceed the maximum cover. Solution was the Aluminum Box.
- 82. ALUMINUM BOX CULVERT • Live load vehicle: CL 800 loading • Cover = min. 750mm max 1200mm • Aluminum Headwall and Wingwalls Pipestone Creek, Wetaskiwin, AB
- 83. ANIMAL OVERPASSES • • • Twin Structures 16.7m span arches for the Trans Canada designed as use for animal overpasses. • Keeping the driving lanes and wildlife safe is the main purpose of these bridges Location: Banff / Lake Louise Hwy AB
- 84. BRIDGE-PLATE ANIMAL OVERPASSES Location: Banff / Lake Louise Hwy AB • 17 m span and 7.0 mm plate – barely more than a ¼-inch of steel. • Up to 3 m of soil cover.
- 85. ANIMAL OVERPASSES • End treatments are MSE precast face wall panel (RECo). • Studies have shown that these overpasses are successfully diversifying the bear population. Location: Banff / Lake Louise TCH, AB
- 86. UNBALANCED LOADING • Unbalanced loading conditions • Designed using Finite Element Analysis (FEA) • 1500 mm min. cover. • 1:4 slope across the top of the structure Whistler BC, 2010 Winter Olympics
- 87. UNBALANCED LOADING 58H Bridge-Plate Horizontal Ellipse 1st Challenge: Determine a suitable grade slope • Steep grade slopes are a “no-no” over flexible soil-steel structures • Structure wants to “roll” due to unbalanced dead load weight, inducing bending in shell wall • Hand calculations were able to predict a suitable grade slope; FE analysis confirmed it Displacement diagram (from Plaxis)
- 88. UNBALANCED LOADING • • 58H Bridge-Plate Horizontal Ellipse 2nd Challenge: Manufacturing • Curving 8mm Bridge-Plate to a tight (2400mm) radius can be a challenge • Several combinations of plate layouts were created before arriving at final layout Plate layout of 58H Horizontal Ellipse
- 89. UNBALANCED LOADING • • 58H Bridge-Plate Horizontal Ellipse 3rd challenge: Assembly and Fit • Test rings were assembled at an off-site yard • After some challenges, an assembly method was developed to prevent “creeping” of the BP dimensions Assembly instructions
- 90. UNBALANCED LOADING The Best Solution … Horizontal Ellipse Structure
- 91. UNBALANCED LOADING The Test Fit
- 94. UNBALANCED LOADING World’s 1st ever Bridge-Plate Horizontal Ellipse!
- 95. AVALANCHE PROTECTION – ROGERS PASS 1960 construction – 2012 photo
- 96. UNIQUE STRUCTURE DESIGNS • Bridge-Plate c/w full invert and footing plates eliminates cast-in-place footings • Provides a quick economical installation. • Ideally suited for remote locations Bridge-Plate Box c/w Full Invert Scour Plates Mini-Span Bridges • Mini-Spans are pre-engineered and pre- assembled structures • Available Up to 3660 mm Span • Ideally suited for Resource road crossings ‘Designed for L-Series logging truck loading’ L-75, L-100, L-150, and L-165
- 97. FLEXIBLE SOIL STEEL STRUCTURES
- 98. Contact Your Local Sales Rep: www.armtec.com/sales-offices/ Todays Speakers: Randy McDonald Randy.McDonald@armtec.com Frank Klita Frank.Klita@armtec.com
- 99. UPCOMING WEBINARS For more info please visit www.armtec.com/events Remember – For CPD certificates, send names & emails to webinars@armtec.com! NEW PRODUCT LINE FROM ARMTEC! Introducing Hauraton Surface Drainage - February and March, 2016
- 100. STAY CONNECTED! Armtec respects your privacy. All communications comply with CASL and general best practices. For more information, you can find links to privacy policy and options to unsubscribe in footer of any emails. On Social Media On armtec.com Webinars Follow us! After the webinar fill out our survey and click yes! Fill out the form at armtec.com and stay up to date on the latest /armtecltd /ArmtecLtd /company/armtec See our presentation on SlideShare and YouTube!
- 101. Keep it Flowing! – Culvert Design 201 – Structural Design, Durability & Installation QUESTIONS?
- 102. Contact Your Local Sales Rep: www.armtec.com/sales-offices/ Todays Speakers: Randy McDonald Randy.McDonald@armtec.com Frank Klita Frank.Klita@armtec.com