Culvert Design 201 Structural Design, Durability & Applications

Randy McDonald,
P.Eng.
Director of Engineering
Armtec
Drainage Solutions
Frank Klita
Sales Representative
Armtec
Drainage Solutions
Randy McDonald, P.Eng.
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

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

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

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

YOUR SPEAKERS
Randy McDonald P.Eng.
Armtec, Drainage Solutions
Randy.McDonald@armtec.com
Frank Klita
Senior Sales Representative
Armtec, Drainage Solutions
Frank.Klita@armtec.com

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

Multi-Plate 152 x 51
Bridge-Plate 400 x 150
Tunnel Liner Plate
500 x 52
SPCSP AND DCSP

MULTI-PLATE SUPER-SPAN
14.4m span x 6.8m rise High Profile Arch.

LARGEST SUPER-SPAN (1984)
18.0m span x 7.4m rise Low Profile Arch

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

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

BURIED STRUCTURE COMPONENTS
16
• 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

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 .

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

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

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

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

STRUCTURAL DESIGN
Railway Loading
80K AXLE LOAD = 355 kN
2526 kN Total

250 TONNE HAUL TRUCK LIVE LOAD
12.4 M SPAN X 5.6 M RISE BRIDGE-PLATE ARCH

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

10 Step Design Process
for Soil-Steel Structures
1 10

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

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

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

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

Calculate Earthquake Thrust
AH varies from 0 to 0.40 in Canada
4
vDe ATT 
ratioonacceleratizonalAwhereAA HHV 
3
2

or
5
 DLATTT LLDDf  1
EDDf TTT  
Maximum of
Calculate Total Thrust

6
 MPa
Area
Tf

Calculate Compressive Stress
at ULS
Area = area of selected plate thickness
(mm2/mm)

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 

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

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

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

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,

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 

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

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

Crown
Deflection
4.5 mm Maximum
Time

Design Life – Design for
Durability
3

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.

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

Performance Guideline
51
www.cspi.ca

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

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
Table 51
Zinc Coverage for Galvanized Structural Plate Products – CSA G401
Corrosion resistance is direct function of the coating
mass (thickness)

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
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

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

POLYMER COATING
www.armtec.com
CAT = Corrosion
Arresting Technology

59
© 2015 Armtec LP • Confidential & Proprietary
CULVERT DESIGN 201
Project Installations and Applications

60
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

61
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)

62
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

63
ARCH SHAPE - CONSIDERATIONS
Shape matters
• SRA is more efficient than a LPA
• SRA tends to pure ring compression
• Plays to the strength of thin gauge corrugated steel shell
• LPA is more efficient than a Box Culvert
• LPA resists loads through both bending and compression
• Box Culvert is least efficient (requires the most material)
• This shape is essentially a moment resisting structure
• Design is dominated by bending forces
Terminology
SRA – Single Radius Arches
LPA – Low Profile (2 radius Arches)
Box - Rectangular shapes

64
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

65
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

66
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

67
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

68
• 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

69
• 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

70
• Designed for small vehicle access
(Not a stream crossing)

71
MULTIPLE STRUCTURES
• DCSP Structure and Pedestrian Underpass
• Designed to CL-800 loading
Quarry Park, Calgary, AB

72
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

73
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

74
DURABILITY
• Fabrication was handled in
house to provide a full site
solution

75
LOW HEADROOM DESIGN
Pipestone Creek, County of Wetaskiwin, AB
Objective
• Replacement for existing timber
bridge in rural Alberta.
• Consultant / Owner looking 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).

76
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

77
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.

78
ALUMINUM BOX CULVERT
• Live load vehicle: CL 800 loading
• Cover = min. 750mm max 1200mm
• Aluminum Headwall and Wingwalls
Pipestone Creek, Wetaskiwin, AB

79
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

80
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.

81
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

82
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

83
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)

84
UNBALANCED LOADING
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

85
UNBALANCED LOADING
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

86
UNBALANCED LOADING
The Best Solution … Horizontal Ellipse Structure

87
UNBALANCED LOADING
The Test Fit

88
UNBALANCED LOADING
Assembly

89
UNBALANCED LOADING
Backfill

90
UNBALANCED LOADING
World’s 1st ever Bridge-Plate Horizontal Ellipse!

91
AVALANCHE PROTECTION – ROGERS PASS
1960 CONSTRUCTION – 2012 PHOTO

92
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

93
FLEXIBLE SOIL STEEL STRUCTURES

94
Contact Your Local Sales Rep:
www.armtec.com/sales-offices/
Todays Speakers:
Randy McDonald
Frank Klita

95
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

96
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97
Keep it Flowing! – Culvert Design 201 – Structural
Design, Durability & Installation
QUESTIONS?

98
Contact Your Local Sales Rep:
www.armtec.com/sales-offices/
Todays Speakers:
Randy McDonald
Frank Klita

Culvert Design 201 Structural Design, Durability & Applications

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