St. Lawrence County Residency

Plate Arch, C750067, slip line

project, Town of Hammond, NY.

Liner ½ inch thick, smooth interior

Infrasteel liner, by Precision Pipe

and Products, Birmingham,

Alabama.

Presented by: Cullom Walker with Precision Pipe & Products, Inc.

with Permission by Ernest Olin, NYSDOT, Resident Engineer, St. Lawrence County

Problem: 11’-5” x 7’-3” corrugated Structural Pipe Arch

installed under Contract SH 65-28 in mid to late 1960’s invert

completely rusted through.

CIN C750067 under Route 12 in the

Town of Hammond

Preliminary Analysis

• Hydraulic Engineer deemed slip line not an option with current liners on NYSOGS Contract due to decreased hydraulic capacity of the Contract liners, which are predominately round or a smaller corrugated pipe arch.

• Structures ruled out paving the invert because of concerns of structural strength of such a repair, due to shallow cover and proximity to bedrock.

• The above lead this culvert to become a Job Order Contract (JOC) Candidate for replacement, which would take 2-4 years to come to fruition.

St. Lawrence County Highway Department had a slip lined pipe

and asked us to grout it knowing we had grout pump under a

formal shared service agreement.

In passing the Engineer at the County mentioned Precision Pipe’s

Infrasteel Technology, that could mimic the plate arch shape and

provide a smooth interior that would not decrease the Hydraulic

Capacity.

SLC Highway arranged a meeting with Precision Pipe at their

office and we discussed their product. Precision subsequently

provided a quote, which was under the $ 50,000 discretionary

limit.

I discussed my findings with my Regional Director of Operations

at our Annual Culvert Management Meeting, where all

Department Heads attend, and it was agreed to try this product.

Furthermore, Regional Planning funded the liner cost.

C750067 InfraSteel lining project

Existing culvert measurements for liner sizing

Total culvert length measurements:

Total length bottom middle of pipe from Inlet to Outlet = 82.5'

Total length top middle of pipe from Inlet to Outlet = 62'

Total length left side pipe from Inlet to Outlet = 82'

Total length right side pipe from Inlet to Outlet = 82'

RECORDED FIELD MEASUREMENTS TAKEN ON 7/18/13

Measurements to determine the Top, Corner and Bottom radii:

Begin measurements from Inlet side

Measurement #1 is 8' from begin Inlet Left

Distance between measurements is 12'

LOCATION 1 LEFT 2 LEFT 3 LEFT 4 LEFT 5 LEFT 6 LEFT 1 RIGHT 2 RIGHT 3 RIGHT 4 RIGHT 5 RIGHT 6 RIGHT

RISE 85 1/2" 83 7/8" 83 3/4" 82 7/8" 84 1/2" 85 1/4" ** ** ** ** ** **

SPAN 11.21' 11.28' 11.33' 11.35 11.24' 11.24 ** ** ** ** ** **

TOP CHORD 4' 4' 4' 4' 4' 4' 4' 4' 4' 4' 4' 4'

TOP DEPTH 4 1/2" 4 1/2" 4 1/2" 4 3/8" 4 1/2" 4 1/4" 4 7/16" 4 5/8" 4 3/8" 4 1/2" 4 3/8" 4 1/2"

CORNER CHORD 16" 16" 16" 16" 16" 16" 16" 16" 16" 16" 16" 16"

CORNER DEPTH 2 1/2" 2 3/8" 2 1/4" 2 3/8" 2 5/16" 2 1/4" 2 5/16" 2 1/2" 2 5/16" 2 5/16" 2 7/16" 2 7/16"

*BOTTOM CHORD 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2" 8' 2"

*BOTTOM DEPTH 6 1/2" 6" 6 1/8" 5 3/8" 5 15/16" 6 3/8" ** ** ** ** ** **

** Same as corresponding Left Side measurement

Measurements we took and provided to the Precision

Infrasteel shop drawing/delivery

Order placed July 31st, 2013

Delivered on site September 11th, 2013

Weld can be interior, exterior or a combination of both.

Shared Service Agreement

with St. Lawrence County Highway

Department for this project.Short agreement < $ 10,000 in value

NYSDOT to provide grout pump, materials (grout) and

labor to grout the County’s pipe on CR 47 in the Town

of Stockholm.

The County to provide 2 generator/welders, materials

(welding rod) and 2 welders to weld steel Infrasteel

liner on Route 12 in the Town of Hammond.

Services were recorded on MURK 11a Form, which

basically a Labor, Materials, Equipment Form used for

Force Account Work.

MURK 11a Form

St. Lawrence County Highways Project

County Route 47 in Town of Stockholm

BEFORE - Invert is gone

8' 7" X 5' 11" X 110’ pipe arch

Material Cost savings over replacement $162,500

Savings to the traveling public by

eliminating the Detour $ 399,800

AFTER - ½” Infrasteel Liner

NOTICE GROUT PORTS

General Site Safety Plan plan contained:

•Project Manager

•On-Site Contact Personnel

•Emergency Phone Numbers

•Maintenance and Protection of Traffic

•First Aid Procedures

•Fall Protection

•Lifting Plan

•Welding Safety

Condition of Shared Service Agreement:

“The County's employees shall remain under full supervision and

control of the County. The parties shall remain fully responsible for

their own employees for all matters, including but not limited to,

salary, insurance, benefits and Workers Compensation.”

Before installation, a General Site Safety Plan was developed and

tailgate meeting held on site with all team members. Shared

Service Agreement was secured with SLC County.

Installation begins

We had 2 of our own Highway Maintenance welders, 2 Bridge

Maintenance welders and two SLC County Welders.

5 working days the liner is fully welded and slide into it’s final

resting place.

Specialty Equipment

Hyundai 140 track hoe 11,900 pound lifting capacity

Hyundai 290 track hoe 29,000 pound lifting capacity

Chains/slings 6,600 pound capacity

MAYCO C-30HDZ Diesel Concrete/grout pump, 25 cy/hr

Large barn fans, compressor with venturi tubes for positive air flow away from

the welding operation

St. Lawrence County provided two Miller Big 40 D arc welders/generators and

2 Bridge welders.

NYSDOT Residency Crews will provided 2 Miller BobCat 225 welders with wire

feeder attachment 12RC. Bridge Maintenance provided 2 arc

welder/generators and BR welders.

Misc. – grinders, cutting torches, ladders, clamps and porta-powers.

Respirators /PAPRs

C-Channel was used in the host pipe to reduce

friction and clear old bolt heads when pushing

the liner.

The liner pipe was “paired up and welded” in an

adjacent staging area on box beam cradles, and then

joined and welded at the outlet of the host pipe

Box Beam Cradle at outlet to

aide in positioning and

welding the pipe

Kobelco 295 used to lift and push

liner, fan for proper positive

ventilation during inner welding

Liner ready for grouting, inlet and

outlet slopes to be flattened with

stone.

Redi mix truck discharging flowable fill into grout pump

purchased by the Residency off OGS Contract (McQuade

and Bannigan).

State Forces grouting the

void between the host pipe

and liner. Threaded bung

holes field installed inside

the pipe, at different

elevations to ensure

complete filling of voids.

Theoretical volume of

flowable fill was calculated

and quantities were

monitored as crews filled the

void slowly, to ensure the

void was filled completely

and we didn’t lose any to

leaks.

NYSDOT Route 12 – Estimate of Cost Savings

Cost Estimated if Project was put out to JOC Contract – Cutting

the Road and Replacing the Existing Structure = $360,000

Total Cost of Slip Lining Installation including Equipment,

Material, and Labor = $85,000

Provided a Savings of $275,000

Ernest Olin – NYSDOT Region 7

St. Lawrence County Road 47 – Estimate of Cost Savings

Savings of Road Cut – Excavation

Cross Section Estimating

(1/2)(30+80)*(25’) = 1,375 ft2

Length of Full Depth Cut Due to Skew of Pipe = 110’

1,375 ft2 x 110’ long = 5,600 yd3

Estimate of Taper Cuts into/out of main excavation [(2/3)(1,375ft2)x(3)(25’ cuts)]/27= 2,550yd3

Total Excavation 5,600 + 2,550 = 8,150 yd3

Estimate In-House Cost to Remove, Stock Pile, Replace, and Compact @ $15/yd = $122,250

Estimate for Crushed Stone Under Replacement Pipe – 110’ Long, 10’ Wide, 2’ Deep = 160 Tons

160 Tons @ $15/Ton = $2,400

Estimate for New Crusher Run Base for Roadway – 600 Tons @ $15 Ton = $9,000

Estimate for Asphalt - 260’ Pavement, 24’ Wide, 4 ½’ Deep = 170 Tons @ $75/Ton = $12,750

2013 State Bid on New CMPA of Same Size – 110’ x $211.25ft = $23,251.50

Estimate on Forming/Pouring New 2 Toewalls $3,000

30’

80’

25’

St. Lawrence County Road 47 – Estimate of Cost Savings

Estimate of 5 Weeks Extra Labor $5000/wk = $25,000

+10% Contingency

= $217,500

Materials Used for Lining $55,000

$217,500

<$55,000>

Material Savings = $162,500

Cost to public if detour was put in place:

Detour would be 24 Miles 702 AADT for 6 weeks @ $.565/Mile = $399,800

Andy Willard – St. Lawrence County NY

Material Savings $162,500

Cost of Detour $399,800

Total Savings $562,300

Cost to

Traveling

Public

Coordinated Effort – NYSDOT & St. Lawrence County

NYSDOT – Estimated Cost to Cut Road & Replace Structure = $360,000

Estimated Cost of Slip Lining Structure = $85,000

Total Savings = $275,000

St. Lawrence County – Estimated Cost to Cut Road & Replace Structure = $617,300

Estimated Cost of Slip Lining Structure = $55,000

Total Savings = $562,300

Installation Completed in 2 Weeks

Life Span of Liner 50 -100 Years Based on Environmental Site Factors

Coordinated Effort Total Savings = $837,300