Culvert Dddesign

CULVERT DESIGN 201
STRUCTURAL DESIGN, DURABILITY & APPLICATIONS
TECHNICAL WEBINAR
FRIDAY DECEMBER 11, 2015 / 9AM PST / 11AM CST / 12PM EST
Randy McDonald,
Randy McDonald, P.Eng.
P.Eng.
Director
Engineering
Director
of of
Engineering
Frank Klita
Frank
Klita
Sales
Representative
Senior Sales Representative
Armtec
Armtec
Drainage
Solutions
Drainage
Solutions
Armtec
Armtec Solutions
Drainage
Drainage Solutions
ABOUT ARMTEC
Armtec is one of Canadas
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.
Drainage Locations
Precast Locations
Actual 2014
Locations
43
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
Transportation
Underground & Utility

Infrastructure
Sports & Entertainment
Mining & Energy
Institutional Construction
Industrial Construction
Agriculture
Commercial & Retail

Constructions
Commercial & Residential

Landscaping
Forestry
Residential & Hospitality
ABOUT ARMTEC
DRAINAGE ENGINEERING SUPPORT & ROLES
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.
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
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
1 Segmental Plate Products
SPCSP AND DCSP
Multi-Plate 152 x 51
Bridge-Plate 400 x 150
Tunnel Liner Plate
500 x 52
SHAPE OPTIONS
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
BRIDGE-PLATE BOX CULVERT
2 Structural Design
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

Steel Component:
Corrugated steel shell
Corrugated shell is highly
efficient member to
support axial
compressive loads
Soil Component:
engineered granular
backfill envelope
materials of known
geotechnical properties
Net Result:
economical buried
structure capable of
supporting large gravity
16
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
1
1
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
10
Determine Minimum Cover

Minimum Cover (Hmin) is the largest of:
a) 0.6 m
b)
c)
Dh
6
Dh
Dv
Dh
0.4
Dv
0.5
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
Determine Minimum Cover
Calculate Dead Load Thrust
TD = 0.5 (1.0 0.1 CS) Af W

W = weight of column of material above
TD/2
1000 ES Dv
CS
EA
TD/2
(axial stiffness parameter)
Calculate Dead Load Thrust
TD = 0.5 (1.0 0.1 CS) Af W

Af = arching factor
Span < Rise
Span = Rise (round)
Span > Rise
Calculate Live Load Thrust

TL 0.5 lesser of Dh and lt L m f
L Live Load pressure at crown kPa
m f mod ification factor for multi lane loading
Position as many axles of the CL-625 overtop

as would give maximum total load
Calculate Earthquake Thrust

Te TD Av
2
AV AH
3
where AH zonal acceleration ratio
AH varies from 0 to 0.40 in Canada
Calculate Total Thrust

Maximum of
T f D TD L TL 1 DLA
or
T f D TD TE
Calculate Compressive Stress

at ULS
Tf
Area
MPa
Area = area of selected plate thickness

(mm2/mm)
Calculate Wall Strength in

Compression fb (MPa)
Calculating the factored failure

compressive stress fb
Dependent upon the NA radius
R Re
R Re
f b t Fm Fy
F KR
12Er
2
fb
3 t Fm E
K R
r
Calculate Wall Strength in

Compression
To arrive at fb 7 equations, 18 variables

RC
Em E S 1
'
RC 1000 H H
2
EI
1.22 1.0 1.6

3
E
R
m c
r 6 E
Re
K Fy
1.22
EI
K
3
E
R
m
0.25
H H
1000
R
c
0.25
EI
0 1.6 0.2 log
3
Em R
'
0.5
1.0
0.5
0 .3 S
Fm 0.85
Dh
1 .0
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
Check Wall Strength

Requirements During
Construction
P
Ppf
1
M pf
P = unfactored axial thrust = TD +TC

Ppf = factored compressive strength = fhcAFy
M = unfactored bending moment = M1 + MB + MC
Mpf = factored plastic moment capacity = fhcMp
Check Wall Strength

Requirements During
Construction
M 1 k M 1 RB Dh3
M B k M 2 RB Dh2 H c
M C k M 3 RL Dh LC
Introduces 9 new variables;

kM1, kM2, kM3, RB, RL, NF, Ac, k4, Lc
Also requires previous known variables;
Dv, Dh, Es, E, I,
Check Wall Strength of

Completed Bridge-Plate
Tf
Ppf
Mf
M pf
Tf = maximum thrust due to factored loads

Ppf = factored compressive strength = fhAFy
Mf = maximum moment due to factored loads
M f D M 1 D M D L M L 1 DLA
Mpf = factored plastic moment capacity = fhMp
10
Check Seam Strength
The calculated maximum thrust due to

factored loads shall be less than the
factored resistance of the longitudinal
seams;
Tf j SS
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
Vertical Stress Contours
Horizontal Stress Contours
Axial Force Diagram
Bending Moment Diagram
Crown
Deflection
4.5 mm Maximum
Time
Design
Life
Design
for
3
Durability
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

Table 21
Environmental Limits For Galvanized Steel and Polymer Coated
Steel
Environmental
Parameter
Suggested Limits
Galvanized Steel
pH
preferred range
Suggested Limits for Polymer

Coated Steel
50 year
EMSL
75 year
EMSL
100 year
EMSL
59
3 12
49
59
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
Performance Guideline For Buried Steel Structures Tech. Bulletin 13, CSPI Feb 2012
Coatings Hot Dip Galvanized

Table 51
Zinc Coverage for Galvanized Structural Plate Products CSA G401
Standard Zinc Coverage
Nominal
Plate
Thickness
(mm)
Total Mass
Both Sides
(g/m2)
Thickness
per side
(m)
< 4.0
915
4.0 8.0
915
Non-Standard Zinc Coverage

Total Mass
Both Sides
(g/m2)
Thickness
per side
(m)
64
NA
NA
64
1220
87
Corrosion resistance is direct function of the coating

mass (thickness)
1
Zinc and Carbon Steel Corrosion

Table 111
Zinc and Carbon Steel Soil Side Loss Rates
Material
Zinc Coating
Carbon Steel
Period
AASHTO Standard
Loss Rate/year/side
(m)1
UK Non-Aggressive
Loss Rate/year/side
(m)2
First 2 years
15
Subsequently
After Zinc
Depletion
12
M=22.5ts0.67
AASHTO LRFD Bridge Construction Specifications

UK 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
1
2
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
GALVANIZED & POLYMER COATED
POLYMER COATING
CAT = Corrosion
Arresting Technology
www.armtec.com
4 Projects & Applications
CULVERT DESIGN 201

Project Installations and Applications
59
2015 Armtec LP Confidential & Proprietary
UTILIDOR PROTECTION
USING DEEP CORRUGATED STRUCTURAL PLATE
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 S606 CHBDC
60
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/m Galvanized Coating
60 Degree Segmental Elbow
(constructed from 8 mini-elbows)
61
DCSP UTILIDOR PROTECTION COVER

Northeast Anthony Henday Edmonton, AB
Foam blocking to reduce

settlement of the embankment
Embankment settlement /
adverse effect buried metal arc
(adds more load to the arch).
Max. height of cover = 6.0 m.
62
ARCH SHAPE - CONSIDERATIONS
Shape matters
Terminology
SRA Single Radius Arches
LPA Low Profile (2 radius Arches)
Box - Rectangular shapes
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
63
DCSP C/W REINFORCING RIBS

Albian Sands (2010) Ft. McMurray, AB
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)
64

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
65

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
66
DCSP RAILWAY LOADING

Railcar Loading Facility Hardisty, AB
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.
67

Loading Facility Hardisty, AB
Designed to handle 5 railway

lines
over (Cyclical loading)
Design Parameters:
Cooper E80 & CL-800 Live
Load
Unit weight of backfill = 22
kN/m
68

Critical Backfill zone design =
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
69

Designed for small vehicle

access
(Not a stream crossing)
70
MULTIPLE STRUCTURES
Quarry Park, Calgary, AB
DCSP Structure and Pedestrian Underpa

Designed to CL-800 loading
71
MULTIPLE STRUCTURES
Quarry Park, Calgary, AB
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
72
STRUCTURAL PLATE DURABILITY

Air Intake Application Potash Mine, Esterhazy SK
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
73
DURABILITY
Fabrication was handled

in house to provide a full
site solution
74
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 CL800 in event of detour from
Hwy 2 (Edm to Calgary).
75
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
76
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
77
was the Aluminum Box.
ALUMINUM BOX CULVERT

Pipestone Creek, Wetaskiwin, AB
Live load vehicle: CL 800 loading

Cover = min. 750mm max 1200mm
Aluminum Headwall and Wingwalls
78
ANIMAL OVERPASSES
Location: Banff / Lake Louise Hwy AB
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
79
BRIDGE-PLATE ANIMAL OVERPASSES

Location: Banff / Lake Louise Hwy AB
17 m span and 7.0 mm plate barely more than a -inch

of steel.
Up to 3 m of soil cover.
80
ANIMAL OVERPASSES
Location: Banff / Lake Louise TCH AB
End treatments are MSE

precast face wall panel
(RECo).
Studies have shown that
these overpasses are
successfully diversifying
the bear population.
81
UNBALANCED LOADING
Whistler BC, 2010 Winter Olympics
Unbalanced loading
conditions
Designed using Finite
Element Analysis (FEA)
1500 mm min. cover.
1:4 slope across the top
of the structure
82
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)
83
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
84
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
85
UNBALANCED LOADING
The Best Solution Horizontal Ellipse Structure
86
UNBALANCED LOADING
The Test Fit
87
UNBALANCED LOADING
Assembly
88
UNBALANCED LOADING
Backfill
89
UNBALANCED LOADING
Worlds 1st ever Bridge-Plate Horizontal Ellipse!
90
AVALANCHE PROTECTION ROGERS PASS
1960 CONSTRUCTION 2012 PHOTO

91
UNIQUE STRUCTURE DESIGNS
ridge-Plate Box c/w Full Invert Scour Plates

Bridge-Plate c/w full invert and
footing plates eliminates cast-inplace footings
Provides a quick economical
installation.
Mini-Span Bridges
Ideally suited for remote

locations
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
92
L-75, L-100, L-150, and L-165
FLEXIBLE SOIL STEEL STRUCTURES
93
Contact Your Local Sales Rep:

www.armtec.com/sales-offices/
Todays Speakers:
Randy McDonald
Frank Klita
94
UPCOMING WEBINARS
NEW PRODUCT LINE
FROM ARMTEC!
Introducing Hauraton Surface

Drainage - February and March, 2016
For more info please visit

www.armtec.com/events
Remember For CPD
certificates, send names & emails
to webinars@armtec.com!
95
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Keep it Flowing! Culvert Design 201 Structural

Design, Durability & Installation
QUESTIONS?
97
Contact Your Local Sales Rep:

www.armtec.com/sales-offices/
Todays Speakers:
Randy McDonald
Frank Klita
98

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CULVERT DESIGN 201

STRUCTURAL DESIGN, DURABILITY & APPLICATIONS

Underground & Utility

Sports & Entertainment

Mining & Energy

Commercial & Retail

Commercial & Residential

Residential & Hospitality

Armtec Drainage Solutions centralized engineering

1 Segmental Plate Products

SPCSP AND DCSP

14.4m span x 6.8m rise High Profile Arch.

LARGEST SUPER-SPAN (1984)

18.0m span x 7.4m rise Low Profile Arch

BRIDGE-PLATE BOX CULVERT

BURIED STRUCTURE COMPONENTS

Live Loads (Surface Pressure)

Extreme Live Loads

250 TONNE HAUL TRUCK LIVE LOAD

12.4 M SPAN X 5.6 M RISE BRIDGE-PLATE ARCH

10 Step Design Process

Determine Minimum Cover

For deep corrugated structures Hmin shall be

Determine Minimum Cover

Calculate Dead Load Thrust

TD = 0.5 (1.0 0.1 CS) Af W

(axial stiffness parameter)

Calculate Dead Load Thrust

TD = 0.5 (1.0 0.1 CS) Af W

Calculate Live Load Thrust

m f mod ification factor for multi lane loading

Position as many axles of the CL-625 overtop

Calculate Earthquake Thrust

where AH zonal acceleration ratio

AH varies from 0 to 0.40 in Canada

Calculate Total Thrust

Calculate Compressive Stress

Area = area of selected plate thickness

Calculate Wall Strength in

Calculating the factored failure

Calculate Wall Strength in

To arrive at fb 7 equations, 18 variables

1.22 1.0 1.6

Check Wall Strength

Forces experienced during construction of

Check Wall Strength

P = unfactored axial thrust = TD +TC

Check Wall Strength

Introduces 9 new variables;

Check Wall Strength of

Tf = maximum thrust due to factored loads

Mpf = factored plastic moment capacity = fhMp

Check Seam Strength

The calculated maximum thrust due to

SS = ultimate axial seam strength of bolted longitudinal seam

CHBDC FORMULA LIMITATIONS

Vertical Stress Contours

Horizontal Stress Contours

Axial Force Diagram

Bending Moment Diagram

A period of time specified by the Owner during which a structure is

the capability of a component, product, or structure to maintain its

Predicted Service Life

an estimated period of time for the service life based on actual