b-pipe construction manual

Pipe Construction Manual

Construction Related Performance Construction Related Performance ProblemsProblems

Pipe Manual OverviewPipe Manual Overview Trench WidthsTrench Widths Bedding and BackfillBedding and Backfill Documentation RequirementsDocumentation Requirements

Topics CoveredTopics Covered

Construction Inspection Related Construction Inspection Related Performance ProblemsPerformance Problems

In the 1980’s CMP’s were FailingIn the 1980’s CMP’s were Failing Reason: Construction Personnel were allowing Reason: Construction Personnel were allowing

Contractors to End Dump Backfill and Use Soil Contractors to End Dump Backfill and Use Soil Instead of Granular Material.Instead of Granular Material.

See Chapters 7 through 10 See Chapters 7 through 10 (pgs. 26-41)(pgs. 26-41)

Corrugated Metal Pipe ProblemsCorrugated Metal Pipe Problems


Bottom of Pipe Experiencing Early DeteriorationBottom of Pipe Experiencing Early Deterioration Reason: Construction Personnel Allowed the Reason: Construction Personnel Allowed the

Contractor to Place the Pipe on Rock.Contractor to Place the Pipe on Rock. See Chapter 5 See Chapter 5 Foundations (pg. 23)Foundations (pg. 23)

Concrete Pipe ProblemsConcrete Pipe Problems


Several of These Pipe Failed During Several of These Pipe Failed During ConstructionConstruction

Reason: Construction Personnel Allowed Heavy Reason: Construction Personnel Allowed Heavy Construction Equipment on the Pipe without Construction Equipment on the Pipe without Proper Cover.Proper Cover.

See Figure 900-8 See Figure 900-8 (pg. F-68) (pg. F-68)

Thermo Plastic Pipe ProblemsThermo Plastic Pipe Problems

Pipe Manual Overview

Chapter 1: Chapter 1: Type of Pipe and Uses (CMS Type of Pipe and Uses (CMS 603.02)603.02) Explains: All the different types of pipe…”A”, Explains: All the different types of pipe…”A”,

“B”, …“B”, …

Chapter 2: Chapter 2: Pipe Delivery and InspectionPipe Delivery and Inspection Explains: (1) The field material inspection Explains: (1) The field material inspection

requirements. (2) What defects to look for on requirements. (2) What defects to look for on the various types of pipe that are available. the various types of pipe that are available.


Chapter 3: Chapter 3: CConstruction Layoutonstruction Layout (CMS 603.05)(CMS 603.05) Explains: The use of a laser, alignment and box Explains: The use of a laser, alignment and box

culvert placement problems.culvert placement problems. Chapter 4: Chapter 4: Trench Width in a CutTrench Width in a Cut (CMS 603.03)(CMS 603.03)

Chapter 5: Chapter 5: FoundationsFoundations (CMS 603.03)(CMS 603.03)

Chapter 6: Chapter 6: DewateringDewatering (CMS 603.02)(CMS 603.02)

Chapter 7: Chapter 7: Bedding & Backfill Material Bedding & Backfill Material RequirementsRequirements (CMS 603.02)(CMS 603.02)


Chapter 8: Chapter 8: Bedding RequirementsBedding Requirements (CMS 603.04)(CMS 603.04) Different bedding classes are presented in Different bedding classes are presented in

Figures 800-1 thru 800-3 (pgs. 57-59)Figures 800-1 thru 800-3 (pgs. 57-59).. Chapter 9: Chapter 9: Backfill RequirementsBackfill Requirements (CMS 603.08)(CMS 603.08) Chapter 10: Chapter 10: Compaction RequirementsCompaction Requirements (CMS (CMS

603.081)603.081) Chapter 11: Chapter 11: Placing & Joining the PipePlacing & Joining the Pipe (CMS (CMS

603.06)603.06) Chapter 12: Chapter 12: DocumentationDocumentation (CMS 603.081)(CMS 603.081)

Check the Trench WidthCheck the Trench Width

Maximum Trench Width Minimizes the Maximum Trench Width Minimizes the Load on the PipeLoad on the Pipe

Minimum Trench Width Allows for Proper Minimum Trench Width Allows for Proper JointingJointing

Trench Width is Measured at the Top of the Trench Width is Measured at the Top of the PipePipe

Chapter 4 in Manual and in CMS 603.03Chapter 4 in Manual and in CMS 603.03

Trench Width in a CutTrench Width in a Cut

Minimum and Maximum for All Pipe in a Cut Minimum and Maximum for All Pipe in a Cut Except for Type “B” & “C” Thermo.Except for Type “B” & “C” Thermo.

6” to 15” for Pipe less than 60”6” to 15” for Pipe less than 60” 6” to 24” for Pipe 60” and more6” to 24” for Pipe 60” and more Thermo Plastic Pipe Minimums in Thermo Plastic Pipe Minimums in Figure 400-2 Figure 400-2

(pg. 54)(pg. 54) Minimum Trench Width for Large Structures Minimum Trench Width for Large Structures

(Boxes & Three-Sided).(Boxes & Three-Sided).W = OD + 2(2’)….2 foot each sideW = OD + 2(2’)….2 foot each side

Chapter 4 in the Manual and in 603.03Chapter 4 in the Manual and in 603.03

Trench Width Changes

Changes With:Changes With: Kind of Pipe, Kind of Pipe, (conc., thermo, etc.,)(conc., thermo, etc.,) Type of Pipe, Type of Pipe, (“A”,”B”….)(“A”,”B”….) Cut or Fill SituationCut or Fill Situation All Iterations are Detailed in All Iterations are Detailed in Figures 400-3 Figures 400-3

and 900-1 thru 900-7and 900-1 thru 900-7 Typical Changes on Typical Changes on Figures 900-6 & 900-7Figures 900-6 & 900-7 Record Figure Numbers on Inspection Record Figure Numbers on Inspection

Form Form C-170C-170

Check the FoundationCheck the Foundation

Soft FoundationSoft Foundation Rock FoundationRock Foundation Wet ConditionsWet Conditions

Manual in Chapters 5& 6, CMS 603.03Manual in Chapters 5& 6, CMS 603.03

Soft Conditions

Most Common Foundation ProblemMost Common Foundation Problem If Workers Can Work, Then the Foundation If Workers Can Work, Then the Foundation

is Adequateis Adequate Under Cut and Replacement of approx. 12” Under Cut and Replacement of approx. 12”

is Usually Satisfactoryis Usually Satisfactory Presently, Contractor Responsible for the Presently, Contractor Responsible for the

Top 12”Top 12” Will Be Changed in Specification RevisionWill Be Changed in Specification Revision

Manual in 502.0 Manual in 502.0 (pg. 22)(pg. 22), and in CMS 603.03, and in CMS 603.03

Rock Foundation

All Rock Must Be Under Cut 6” Below the All Rock Must Be Under Cut 6” Below the Bedding or 12” Below the Bottom of the Bedding or 12” Below the Bottom of the PipePipe

If not, the Rock will Cause a Point LoadIf not, the Rock will Cause a Point Load The Bottom will Fail as Illustrated Earlier The Bottom will Fail as Illustrated Earlier

Manual in 503.0 Manual in 503.0 (pg. 23)(pg. 23), and in CMS 603.03, and in CMS 603.03

Wet Conditions

Contractor is Responsible to Provide Contractor is Responsible to Provide DrainageDrainage Such as Rerouting Water, Pumping…Such as Rerouting Water, Pumping…

When all Reasonable Methods are not When all Reasonable Methods are not WorkingWorking Then, and Only Then, an Open Graded Then, and Only Then, an Open Graded

#67 or #57 #67 or #57 (Type 3 Granular Backfill)(Type 3 Granular Backfill) May May be used Below the Pipe be used Below the Pipe

This will Alleviate Most ProblemsThis will Alleviate Most Problems

Manual in Chapter 6, and in CMS 603.02Manual in Chapter 6, and in CMS 603.02

Dip in the RoadDip in the Road

If you Use Open Graded Material and Put Sand or If you Use Open Graded Material and Put Sand or Soil on Top as BackfillSoil on Top as Backfill

The Fine Sand or Soil will Migrate into the #57’s or The Fine Sand or Soil will Migrate into the #57’s or #67’s and Cause Dips#67’s and Cause Dips

See Piping in Manual 601.0 See Piping in Manual 601.0 (pg. 24)(pg. 24)

Preventable Construction Related ProblemsPreventable Construction Related Problems

Bedding & Backfill Materials

Type 1 Granular Material……304Type 1 Granular Material……304 Type 2 Granular Material……SandType 2 Granular Material……Sand Type 3 Granular Material……#57 or #67Type 3 Granular Material……#57 or #67 Type 1 and 2 Allowed AnywhereType 1 and 2 Allowed Anywhere Restrictions on Type 3 were Covered Restrictions on Type 3 were Covered

Earlier Earlier


Placing the Bedding & BackfillPlacing the Bedding & Backfill

This is Obviously This is Obviously Incorrect!Incorrect! Material is Placed in 8” liftsMaterial is Placed in 8” lifts

Manual in Chapter 8 & 9, and in CMS 603.08 & 603.081Manual in Chapter 8 & 9, and in CMS 603.08 & 603.081

Placing & Placing & SpreadingSpreading the Bedding the Bedding

Trackhoe or Loader are Often UsedTrackhoe or Loader are Often Used Truck End Dumping Can Not Place Material in Truck End Dumping Can Not Place Material in

8” Lifts8” Lifts Place the Material in 8” Lifts!!Place the Material in 8” Lifts!!

Compact the Bedding MaterialCompact the Bedding Material

Leave the Middle 1/3 of the Pipe Bedding Leave the Middle 1/3 of the Pipe Bedding UncompactedUncompacted

See See Figure 1000-1 Figure 1000-1 (pg. 69)(pg. 69)

Avoids Causing Point Loading on the PipeAvoids Causing Point Loading on the Pipe Check the Grade and Rake if neededCheck the Grade and Rake if needed


Place the Next Section of PipePlace the Next Section of Pipe

Each Manufacturer will Cover the Details of Each Manufacturer will Cover the Details of the Placement and Jointing of the Different the Placement and Jointing of the Different Types of Pipe.Types of Pipe.

Manual in Chapter 11, and in CMS 603.05, 603.06 & 603.082Manual in Chapter 11, and in CMS 603.05, 603.06 & 603.082

Check the Joint Gap

One Inch Tolerance is Acceptable for Most PipeOne Inch Tolerance is Acceptable for Most Pipe Should Get Closer than 1”Should Get Closer than 1” Look for Non-uniform Gaps Look for Non-uniform Gaps


Look for Leaking JointsLook for Leaking Joints

Make Corrections as NecessaryMake Corrections as Necessary

Backfill PlacementBackfill Placement

Place and Spread the Backfill in 8” LiftsPlace and Spread the Backfill in 8” Lifts Manipulate in and around the Pipe Prior to Manipulate in and around the Pipe Prior to

CompactionCompaction Use Shovels if NecessaryUse Shovels if Necessary

Manual in Chapter 9, and in CMS 603.08 & 603.081Manual in Chapter 9, and in CMS 603.08 & 603.081

Compact the BackfillCompact the Backfill

Compact ThoroughlyCompact Thoroughly Particularly From the Bottom of the Pipe to the Particularly From the Bottom of the Pipe to the

Middle of the Pipe Middle of the Pipe (a.k.a. haunch area)(a.k.a. haunch area)



A Hoe-Ram Usually can get close enough to A Hoe-Ram Usually can get close enough to the Pipe for Full Coverage of the Backfill.the Pipe for Full Coverage of the Backfill.


Use Spud Bars, Shovel Slicing or Automated Use Spud Bars, Shovel Slicing or Automated Spud Bar in Tight Areas.Spud Bar in Tight Areas.


Use Combinations of Compaction EquipmentUse Combinations of Compaction Equipment Notice the Automated Spud BarNotice the Automated Spud Bar (above to the left)(above to the left)

Check CompactionCheck Compaction

Type 1 Type 1 (304) (304) Compaction TestingCompaction Testing Use Test Section and Moisture from M-D Curve Use Test Section and Moisture from M-D Curve

to Establish Maximum Densityto Establish Maximum Density Average a Minimum Compaction of 96% of Average a Minimum Compaction of 96% of

Maximum.Maximum. Minimum Individual Reading 92% of MaximumMinimum Individual Reading 92% of Maximum Make a New Test Section When Conditions Make a New Test Section When Conditions

Change Change


Check for CompactionCheck for Compaction

Add Water to Stockpile if NeededAdd Water to Stockpile if Needed Type 1 Type 1 (304)(304) Optimum Moisture +/- 5 to 10% Optimum Moisture +/- 5 to 10%

Check CompactionCheck Compaction

Add Water in Trench if NeededAdd Water in Trench if Needed This is not Flooding!!This is not Flooding!!

Flooding the Backfill ProperlyFlooding the Backfill Properly

Type 2 Type 2 (sand)(sand) Requires Flooding Requires Flooding Place Material in 8” Lifts. Then, Place Material in 8” Lifts. Then,

construct an 8” wall.construct an 8” wall.


Proper Flooding TechniqueProper Flooding Technique

Fill the Trench up with WaterFill the Trench up with Water

Proper FloodingProper Flooding

Allow the Water to Dissipate. Allow the Water to Dissipate. Then Compact the MaterialThen Compact the Material Note: Notice Flooding Finds the Bad JointNote: Notice Flooding Finds the Bad Joint

Compact the Sand after FloodingCompact the Sand after Flooding

Check Compaction after Flooding, then after Check Compaction after Flooding, then after CompactionCompaction

If Density goes Down……Use Flooding OnlyIf Density goes Down……Use Flooding Only If Density goes Up…….Use Flooding and If Density goes Up…….Use Flooding and

CompactionCompaction


Compaction of Sand

May Non-Perform Flooding if:May Non-Perform Flooding if: Water Doesn’t DissipateWater Doesn’t Dissipate If there is no way to Drain the Water If there is no way to Drain the Water

(Median Pipe)(Median Pipe)

Granular Material RequirementsGranular Material Requirements

Granular Material is Required for a Minimum Granular Material is Required for a Minimum Height above the PipeHeight above the Pipe

See See Figures 900-1 thru 900-8Figures 900-1 thru 900-8 Changes with:Changes with:

Kind and Type of Pipe as well as Fill vs. Cut Kind and Type of Pipe as well as Fill vs. Cut SituationsSituations


Compaction in Confined SpacesCompaction in Confined Spaces

Trench Boxes Complicate the ProcessTrench Boxes Complicate the Process Place and Compact in the Trench BoxPlace and Compact in the Trench Box

Raise the Front of the Trench BoxRaise the Front of the Trench Box

Place Material in the Trench as the Box Place Material in the Trench as the Box is Removedis Removed

Notice that the Center of the Backfill is Notice that the Center of the Backfill is Not Displaced when the Box is RemovedNot Displaced when the Box is Removed

Not the Best Situation, but AcceptableNot the Best Situation, but Acceptable

Trench May CollapseTrench May Collapse

Compact Material to Road SurfaceCompact Material to Road Surface

Remember to Protect the PipeRemember to Protect the Pipe See See Figure 900-8Figure 900-8 Remember the ExampleRemember the Example

Documentation Requirements

All Pipe Operations Should Have an All Pipe Operations Should Have an Inspector PresentInspector Present

Record Inspection on C-170 and CMS-1 Record Inspection on C-170 and CMS-1 FormsForms

Chapter 12 Outlines 11 Areas of InspectionChapter 12 Outlines 11 Areas of Inspection Details the Type of Operation and Details the Type of Operation and

Required DocumentationRequired Documentation

Pipe Manual Chapter 12 Pipe Manual Chapter 12 (pgs. 49-51)(pgs. 49-51)

Example of Documentation

Check the Pipe Trench WidthCheck the Pipe Trench Width Record the Pipe Outside DiameterRecord the Pipe Outside Diameter Record the Trench Width UsedRecord the Trench Width Used See Chapter 400, Trench Widths in a CutSee Chapter 400, Trench Widths in a Cut

Pipe Manual Chapter 12 Pipe Manual Chapter 12 (pg. 50)(pg. 50)

C-170 Daily Pipe Construction Inspection Form

Top Portion……General InformationTop Portion……General Information Location, Bubble Number, Plan Page…Location, Bubble Number, Plan Page… Sketch Area… Specification… Width, DepthSketch Area… Specification… Width, Depth Trench & Bedding Checks… Field MeasurementsTrench & Bedding Checks… Field Measurements Manual Figure Numbers…Manual Figure Numbers…(pgs. 53-69)(pgs. 53-69)

Figures Show the Dimensions for the Type of PipeFigures Show the Dimensions for the Type of Pipe Pipe Marking and Joint Checks… BottomPipe Marking and Joint Checks… Bottom

Pipe Manual Pipe Manual (pgs. 70-71)(pgs. 70-71)

Back of Form C-170

Top Portion…Pay Adjustments, Creep, Top Portion…Pay Adjustments, Creep, Structures, Measurements for PayStructures, Measurements for Pay

Lower PortionLower Portion Remarks Area…Soft Foundation, Remarks Area…Soft Foundation,

UndercutsUndercuts Sketch AreaSketch Area Inspectors and Engineers/Supervisors Inspectors and Engineers/Supervisors

SignatureSignature

Pipe Manual Chapter 12 Pipe Manual Chapter 12 (pg. 50)(pg. 50)

b-pipe construction manual

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