Drainage Structures on County Roads Mr. Walter Catlett Instructor - - PDF document

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Drainage Structures on County Roads Mr. Walter Catlett Instructor - - PDF document

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89 TH A NNUAL W EST T EXAS C OUNTY J UDGES AND C OMMISSIONERS A SSOCIATION C ONFERENCE Wednesday, April 25, 2018 1:50 2:40 p.m. Drainage Structures on County Roads Mr. Walter Catlett Instructor University of Texas Arlington, TxTAP

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89TH ANNUAL WEST TEXAS COUNTY JUDGES AND COMMISSIONERS ASSOCIATION CONFERENCE

Wednesday, April 25, 2018 1:50 – 2:40 p.m.

“Drainage Structures on County Roads”

  • Mr. Walter Catlett

Instructor University of Texas Arlington, TxTAP

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Drainage Structures for Roadways

Walt Catlett, P.E. TxLTAP

817‐272‐9678 txltap@uta.edu www.uta.edu/ded

AGENDA AGENDA

MODULE 1: PRECAST REINFORCED BOX CULVERT BASICS MODULE 2: MANUFACTURING PROCESS MODULE 3: PROPER INSTALLATION PROCEDURES MODULE 4: BOX CULVERT APPLICATIONS/FEATURES MODULE 5: THREE-SIDED RIGID STRUCTURES

AGENDA LEARNING OUTCOMES

  • 1. Explain the basics of precast box culverts
  • 2. Explain the proper procedures for proper box culvert

installation

  • 3. Explain the different applications of precast box culverts
  • 4. Explain how precast box culverts enable a pipe/bridge

crew.

  • 5. Explain the proper components for installation of a

three-sided rigid frame

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INSTALLATION METHODS

Trench Embankment Tunnel

Bedding - Leveling Course (6” Normal //8”to24” Rocky) Foundation Compacted Fill Material Final Backfill

Trench Terminology

3’ Minimum Cover for Construction Loading 0’ Minimum Cover for Design Loading

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Bedding - Leveling Course

A bedding thickness of 6 inches in non-rocky foundation.

If foundation is rock, bedding should be a minimum of 8” (24” max).

RCBs are designed for installed conditions not test conditions.

Bedding should have a uniform flat surface.

Coarse bedding materials are not beneficial due to irregular/sharp angles.

Bedding width should equal the width of the box and the length of the box.

This protects the box culvert during installation from impact damage.

Should be placed in uniform layers along sides/over top of box sections.

Should contain no debris, organic matter, frozen material or large stones.

Placed and compacted to prevent settlement at the surface.

Compaction and equipment loads should not exceed design strength.

Compacted Fill Material

Trench Terminology REINFORCEMENT

Reinforcement Two Layers of Steel Sheets of WWF Rebar Mats Spacers-Ensure Space Between Wheels – Keep Steel from Wall Spacers-Ensure Space Between Wheels – Keep Steel from Wall

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ASTM C1433 ASTM C1577

Welded wire fabric 65,000 psi Concrete 5,000 psi Dry Cast/Wet Cast/Steam Cured

MANUFACTURING

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INSTALLATION

EXCAVATION***DEWATERING***DIVERT DRAINAGE***BEDDING***DELIVERY***HOMING***GASKETS EXTERNAL WRAP***STRUCTURAL BACKFILL***DRIVING SURFACE

Installation

Scheduling/Unloading should be discussed to insure efficient delivery process.

Prepare site, excavate trenches to the minimum required for box culvert installation.

Divert drainage.

Establish a good level grade using fine to medium granular material.

Bedding – Leveling course should be a minimum of three (3) inches, except in rocky foundation it should be six (6) inches minimum.

Make sure the first few box sections are installed correctly,this will influence line and grade to follow.

Place joint material on the bottom half of the groove & top half of the tongue of box.

Make certain to check that boxes are aligned correctly prior to pushing home.

Keep the weight of the box section, being set, on the crane and use winches to pull the joint home/dozer to home.

Place backfill around structure to finished grade.

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Construction Load Structure not Designed for C-Loads 3’ Minimum of backfill

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Construction Loads Earth Loads Live Loads

DIVERT DRAINAGE

Divert Drainage Maintain dry conditions for installation Dewatering Control of Surface and subsurface water is required to maintain dry conditions for installation

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GRAVITY FLOW Retain water upstream Release through/around jobsite

EXCAVATION

Excavation Undercut when Necessary Excavate for backfill/bedding

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  • Explore Foundation to determine the type and

condition of the foundation

  • Explore to a depth in order to determine suitability
  • Stable Foundation must be provided to ensure proper

line and grade is maintained (select pipe bedding)

Pipe Foundation

Unsuitable Material Excavated and replaced with suitable select material

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Setting Grade/Site Prep BEDDING PLACEMENT

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Bedding Key to smooth installation Establish bedding at 3”-6” Minimum Bedding and Foundation Key to smooth installation Establish bedding at 3”-6” Minimum Unloading RCBs Caution must be exercised Handled per Manufacturer’s recomm. Crane with stabilizers

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Unloading RCBs Contact manufacturer to determine weight

Scheduling/Unloading Section Placement

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Placement of RCBs 1st RCB sets the stage Take your time and get it right More time on #1 smoother it goes Section Placement Install first few boxes with care Influence line and grade of rest

SKEWED END/PENETRATION

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Placement of RCBs 2nd section can shift first section. Skewed Sections/Shorter End Pieces Placement of Gasket Do not overlap gasket material

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Placement of Gasket Can Arrive Already in Place Homing of box culverts Several techniques driven by crew capabilities, EQPT/Conditions Continual Check Grade/Bedding Bedding Adjustments Keep Bedding Level Continuously check Grade

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Homing of box culverts Ensure bedding is smooth at face

  • f joint. Smooth out in order to

improve homing of RCBs

Joining Box Sections

Homing of box culverts Protect the Joint Maintain Lift Pressure on Box Utilize Buffer

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Homing of box culverts Come-along Hook Homing Alignment Compress Gasket

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Homing Alignment Compress Gasket Placement of Membrane All box joints Top external joint Extend 1’ down sides

  • Min. width/12”-6” each side of c/l

Placement of Membrane All box joints Top external joint Extend 1’ down sides

  • Min. width/12”-6” each side of c/l
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Multi-Barrel Create distributed load condition Lean Grout (6” min.) Lifts (8” max.) 1.5 Sacks pc/Ton material mixture Or 3 to 6 inches Aggregate Size No. 78 or No. 8 (min. Grade B)

Box Culvert Bedding/Backfill

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Multi-Barrel Create distributed load condition Lean Grout (6” min.) Lifts (8” max.) 1.5 Sacks pc/Ton material mixture Or 3 to 6 inches Size No. 78 or No. 8 (min. Grade B) Multi-Barrel Create distributed load condition Lean Grout (6” min.) Lifts (8” max.) 1.5 Sacks pc/Ton material mixture Multi-Barrel Create distributed load condition Lean Grout (6” min.) Lifts (8” max.) 1.5 Sacks pc/Ton material mixture Or 3 to 6 inches Size No. 78 or No. 8 (min. Grade B)

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Box Culvert Bedding/Backfill

Structural Backfill Backfill material placed in lifts (6” loose/4” compacted) Backfill free of lumps/stumps/Rocks Bedding/Leveling Course (4”-8”) Structural Backfill Compact 6” loose / 4” tight Avoid Damage to Box Culvert Compact to Receive Driving Surface

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Structural Backfill Compact 6” loose/4” tight Avoid Damage to Box Culvert Compact to Receive Driving Surface End Treatments Footings Toewalls/Wingwalls Aprons

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Headwalls/Apron/Wingwalls WWF exposed along top/walls/bottom Headwalls #4 Rebar @ 10” o.c. top of headwall #4 J Bar (2 per box) for headwall

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Headwalls/Apron/Wingwalls Match Embankment Slope Headwalls/Apron/Wingwall Flared to Maximize Flow Reduce Maintenance

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ACCELERATED PRECAST CONSTRUCTION CHARACTERISTICS

MULTI-BARREL**SKEWS**PENETRATIONS**LOW WATER CROSSING **ELBOWS**MINIMAL COVER**OPEN CHANNEL**BOTTOMLESS BOX LARGE BOX CULVERTS**MULTI-CELL**JACKING BOX CULVERTS

Obrien County, Iowa Hancock Concrete Products Single 12’ x 10’ Curved Alignment End Section 2-1or3-1 Slope 0-15-30-45 degree skews 1” U-Tie 1’ above Centerline

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Multi-Cell Reduces Installation Time Requires Greater Lift Capability Precast Headwall Attached Multi-Cell Reduces Installation Time Requires Greater Lift Capability Precast Headwall Attached Innovative Low Flow Culvert Corbels for Approach Slabs

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Large Box Culverts Allowed per Special Design Up to 24’ Span (Wet Cast) Requires Greater Lift Capability

23’ x 8’ Reducer

Determine the weight of 8’x8’ RCB: – Cast in place (9.5”x8”x9.5”) = 0.992 CY/FT

  • 2.01 tons/ft

– Precast

  • (8”x8”x8”) = 1.8 tons/ft
  • (8”x7”x7”) = 1.63 tons/ft

– Concrete = 150#/CF or 4050#/CY 

Which does a contractor prefer:

– 5’x2’ Cast In Place – 5’x2’ Precast

Low Water Crossing Triple Barrel CMP Vertical Curve with Highpoint Roadway Washes Away Each Event

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Features Multi-Cell Precast Box Culvert Level Grade to Minimize Velocity Toe-Walls & Apron Tied into Boxes Features Multi-Cell Precast Box Culvert Level Grade to Minimize Velocity Toe-Walls & Apron Tied into Boxes Peak Flow

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SKEWED END

RCBs are skewed Left Forward Skew Right Forward Skew Limited: size/degree of skew

Features Penetration Addressed in Plant Top and Bottom Penetrations Features Penetration Addressed in Field Contract Manufacturer

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Features Manufacture Any Bend Angle Bends on Multi-Barrels Saves Money/Eliminates Junction Box Features Manufacture Any Bend Angle Bends on Multi-Barrels Saves Money/Eliminates Junction Box Innovations Precast Fitting Saves Money + Time Versus Cast in Place

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Minimum Cover Maximize Hydraulic Capacity Place Road Surface directly on top Minimum Cover Maximize Hydraulic Capacity Place Road Surface directly on top

Jacking – Precast Box Culverts

Factors

1. Nature of soil, water table & effects of dewatering 2. Jacking/Receiving Pit 3. Length, alignment and outside dimension of pipeline 4. Jacking Forces 5. Pipe Joints 6. Loads on shield and pipe 7. Size of overbore 8. Lubrication 9. Grouting

  • 10. Spoils Removal
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THREE-SIDED RIGID FRAME

Footer/Keyway (Per Manufacturer’s Design)

Foundation Compacted Fill Material Final Backfill

Terminology

3’ Minimum Cover for Construction Loading 0’ Minimum Cover for Design Loading Piles (if required) Shim(s)

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Installation

Planning/Scheduling insures efficient process.

Lift plan/handling discussion addresses adequate lift capacity and procedures

Prepare site, including any diversion of drainage.

Construct footing per design/Inspect for compliance.

Place sections, shim for support.

Keep the weight of the section, being set, on the crane and pull section home to final position.

Grout keyway in rigid frame, grout at footing.

Place external joint wrap material across the top and one foot down the wall of the 3 sided rigid frame.

Place backfill in specified lifts (alternating sides) on each side of structure to finished grade.

Prepare Site – Key Steps

  • Divert Drainage
  • Reroute Utilities
  • Excavation/Demolition/Removal

Footing

  • Inspected before delivery of sections
  • Cast-in-place footing
  • Keyway sized per leg dimension
  • Soil bearing capacity data provided by engineer/owner
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Styles

  • Spread Footing
  • Stem wall
  • Pile Supported

Precast Footing Precast Rigid Frame Precast Wingwalls Precast Footers

40’x12’x8’ (12” legs/18” slab =105,600#)

Planning/Scheduling

  • Completed Before Delivery
  • Lift plan determined
  • Insures efficiency
  • Critical Path Created
  • Route – Traffic Considerations
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Pick Hole

Plan = Success

  • Identifying Proper Crane
  • i. Reach
  • ii. Lift capacity
  • Rigging

Installation

Lift Plan/Handling

Installation

Placement

Warren County

  • Shipping Restrictions
  • Double Drum Crane

Shims

  • Addresses irregularities
  • Creates uniform bearing
  • Shims may vary in thickness
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Installation

Placement

Proper Equipment is Critical Take your time and get it right Ensure sections sealed properly

Placing 1st Section Placing additional sections All Sections placed Almost Completed

Installation

Placement

Completed Bridge Replaced

Multi-cell options Guard rail capable External sealing band

  • Across top & 1’ down wall
  • Prevent migration of soils
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End Treatments

  • Headwall/parapet
  • Wingwalls
  • Toewalls
  • Apron
  • Gabions/Rip rap

Embeds

Rails Wing walls Head walls Parapets Curbs

Minimum Cover

  • Designed for 0’ cover (minimum)
  • Wearing surface required
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EASY AS ONE TWO THREE

Installation

Guard rail

Plan View

Skew

Skews

Standard Skews Special Skews Multi-cell Skew

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Penetrations

Side walls Top Straddling joint

Special Features

Brick Treatments Rock Treatments Separated Traffic

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181

Why Consider Accelerated Precast Construction? The traveling public deserves it. FHWA is promoting it. ACPA wants to team with FHWA. Our Industry Provides it.

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PROVIDE LOCAL AGENCIES WITH FREE:

817‐272‐9678 txltap@uta.edu www.uta.edu/ded

Classroom Training Hands on Technical Assistance Website with Videos, Newsletters, Lending Library, and Equipment Checkout

AGENDA LEARNING OUTCOMES

  • 1. Explain the basics of precast box culverts
  • 2. Explain the proper procedures for proper box culvert

installation

  • 3. Explain the different applications of precast box culverts
  • 4. Explain how precast box culverts enable a pipe/bridge

crew.

  • 5. Explain the proper components for installation of a

three-sided rigid frame