DESIGN MANUAL FOR ROADS AND BRIDGES

SUMMARY OF CORRECTION BD 12/01 Volume 2, Section 2, Part 6

DESIGN OF CORRUGATED STEEL BURIED STRUCTURES WITH SPANS GREATER THAN 0.9
METRES AND UP TO 8.0 METRES
In November 2001, page 7/1 7/2, was issued incorrectly. (The page number was incorrect as it
read 7/1 7/4). Please amend this page by crossing out page number 7/4, and writing 7/2.
November 2001
DESIGN MANUAL FOR ROADS AND BRIDGES
VOLUME 2 HIGHWAY STRUCTURES
DESIGN:
(SUBSTRUCTURES,
SPECIAL STRUCTURES
AND MATERIALS)
SECTION 2 SPECIAL STRUCTURES
PART 6
BD 12/01
DESIGN OF CORRUGATED STEEL
BURIED STRUCTURES WITH SPANS
GREATER THAN 0.9 METRES AND UP
TO 8.0 METRES
SUMMARY
This Standard covers the design and construction
requirements for corrugated steel buried structures with
spans greater than 0.9 metres and up to 8.0 metres.
INSTRUCTIONS FOR USE
This revised Standard is to be incorporated in the
Manual.
1. This document supersedes BD 12/95, which is
now withdrawn.
2. Remove existing contents page for Volume 2 and
insert new contents page for Volume 2 dated
November 2001.
3. Remove BD 12/95, which is superseded by
BD 12/01, and archive as appropriate.
4. Insert BD 12/01 in Volume 2, Section 2, Part 6.
5. Archive this sheet as appropriate.
Note: A quarterly index with a full set of Volume
Contents Pages is available separately from The
Stationery Office Ltd.
BD 12/01
Design of Corrugated Steel
Buried Structures with Spans
Greater Than 0.9 Metres and
up to 8.0 Metres
Summary: This Standard covers the design and construction requirements for corrugated
steel buried structures with spans greater than 0.9 metres and up to 8.0
metres.
DESIGN MANUAL FOR ROADS AND BRIDGES
THE HIGHWAYS AGENCY
SCOTTISH EXECUTIVE DEVELOPMENT DEPARTMENT
THE NATIONAL ASSEMBLY FOR WALES
CYNULLIAD CENEDLAETHOL CYMRU
THE DEPARTMENT FOR REGIONAL DEVELOPMENT
NORTHERN IRELAND
Volume 2 Section 2
Part 6 BD 12/01
November 2001
REGISTRATION OF AMENDMENTS
Amend Page No Signature & Date of Amend Page No Signature & Date of
No incorporation of No incorporation of
amendments amendments
Registration of Amendments
Volume 2 Section 2
Part 6 BD 12/01
November 2001
REGISTRATION OF AMENDMENTS
Amend Page No Signature & Date of Amend Page No Signature & Date of
No incorporation of No incorporation of
amendments amendments
Registration of Amendments
VOLUME 2 HIGHWAY STRUCTURES
DESIGN:
(SUBSTRUCTURES,
SPECIAL STRUCTURES
AND MATERIALS)
SECTION 2 SPECIAL STRUCTURES
PART 6
BD 12/01
DESIGN OF CORRUGATED STEEL
BURIED STRUCTURES WITH SPANS
GREATER THAN 0.9 METRES AND UP
TO 8.0 METRES
Contents
Chapter
1. Introduction
2. Design Principles
3. Design Loads
4. Design Load Effects
5. Strength Parameters
6. Ultimate Limit State Requirements
7. Serviceability Limit State Requirements
8. Durability
9. Excavation and Filling
10. Handling and Installation
11. End Treatment
12. Overlying Reinforced Concrete Slab
13. Concrete Invert Paving for Closed Invert
Structures
14. Carriageway Drainage
15. Multiple Installations
16. Technical Requirements and Design Checklist
17. References
18. Enquiries
Annex A Procedure and Conditions for Obtaining a
Type Approval Certificate for Corrugated
Steel Buried Structures
Annex B Longitudinal Seam Strength for Bolted
Segmental Structures
Annex C Specification for Tensile Strength of
Lockseams in Helically Wound Corrugated
Steel Structures
DESIGN MANUAL FOR ROADS AND BRIDGES
November 2001
Volume 2 Section 2
Part 6 BD 12/01
November 2001
1/1
Chapter 1
Introduction
1. INTRODUCTION
1.1 This Standard gives the design and construction
requirements for corrugated steel buried structures that
act compositely with the surrounding material to resist
loading. It describes the procedures to be followed that
permit the Contractor to choose a proprietary structure
that meets the Overseeing Organisations requirements.
It follows the principles of BD 12/95 and requires a
current Type Approval Certificate for all corrugated
steel buried structures, updates durability requirements
and clarifies the requirements in regard to excavation
and filling, handling and installation and end treatment.
Further clarification is made to the presentation of the
formulae given in this document.
Equivalence
1.2 The construction of corrugated steel buried
structures will normally be carried out under
contracts incorporating the Specification for
Highway Works (MCHW1). In such cases products
conforming to equivalent standards or technical
specifications of other states of the European
Economic Area and tests undertaken in other states
of the European Economic Area will be acceptable
in accordance with the terms of Clauses 104 and
105 in Series 100 of that Specification. Any
contract not containing these Clauses must contain
suitable clauses of mutual recognition having the
same effect regarding which advice should be
sought.
Scope
1.3 This Standard covers bolted segmental
corrugated steel buried structures, with spans
greater than 0.9 metres and up to 8 metres, which
are straight in plan, and which are of:
bolted segmental construction with cross sections
being:
(i) closed circular
(ii) closed multi-radii
(iii) circular arch; or
helically wound construction with cross sections
being:
(i) closed circular
subject to the following requirements:
a. The size and shape are within the limits
specified in Table 1.1.
b. The depth of cover measured from the
finished road surface or final ground level to
the crown of the structure is not less than
span/5 or 650mm whichever is greater.
However, where a reinforced concrete slab
is provided at finished road surface, a lesser
depth of cover will be acceptable (see
Clause 12.1 below).
c. The environment is non-aggressive or
aggressive as defined in Chapter 8. An
environment which is classed as very
aggressive is outside the scope of this
Standard and specialist advice should be
sought.
Volume 2 Section 2
Part 6 BD 12/01
November 2001 1/2
Chapter 1
Introduction
This Standard does not cover the use of corrugated
steel buried structures in the repair of other types
of structure, for example, as a liner for brick arch
structures. In these situations, specialist advice
should be sought from the manufacturers of
corrugated steel structures.
Environmental Considerations
1.4 The Overseeing Organisations requirements
for environmental design shall be taken into
account in designing corrugated steel buried
structures. Volume 10 of DMRB (Environmental
Design) gives advice on the use of underpasses by
multiple species of small mammals and fish. It
illustrates various forms of culvert design to
facilitate free passage of these species. Often these
considerations are fundamental to the
determination of the span, headroom, cross-section
invert and gradient of the structure.
Approval Procedure
1.5 Corrugated steel buried structures are
proprietary manufactured structures and the design
and contractual procedures required by Standard
SD4 (MCHW 0.2.4) shall be followed.
1.6 All bolted segmental and helically wound
corrugated steel buried structures and their
components require a current Type Approval
Certificate (MCHW1 Clause 104.9). Helically
wound corrugated steel buried structures and their
components shall also have a current British Board
of Agrment, Roads and Bridges, Certificate or
equivalent (MCHW1 Clauses 104.5 and 104.6) for
the end-use described in this Standard. The British
Board of Agrment (BBA) Certificate or
equivalent shall include guaranteed minimum
lockseam tensile strengths satisfying the
requirements of Annex C of this Standard.
1.7 Prior to being offered on a Contract, the
manufacturer of the corrugated steel buried
structure shall have obtained a Type Approval
Certificate from The Highways Agency. The
procedure for obtaining the Type Approval
Certificate for bolted segmental structures is
described at Annex A. The procedure for obtaining
the Type Approval Certificate for helically wound
structures is also as described at Annex A and
current certification by the British Board of
Agrment is mandatory.
1.8 Where the Contractor proposes a proprietary
system of invert protection, the proprietary invert
system shall have a current British Board of
Agrment Roads and Bridges Certificate or
equivalent for the end-use as indicated in the
Schedule of Employers Requirements included in
the Outline Approval in Principle.
1.9 Where the Contractor chooses a proprietary
protection coating with a designated life intended
to contribute towards the durability requirement of
the structure, a current British Board of Agrment
Roads and Bridges Certificate or equivalent shall
be provided confirming its life under service
conditions appropriate to the circumstances stated
in the Schedule of Employers Requirements.
1.10 The materials used for corrugated steel
buried structures, their manufacture and their
assembly and construction on site shall be in
accordance with the Specification for Highway
Works (MCHW1).
Contract/Design Procedure
1.11 A flow diagram for a typical contract/design
procedure is given in Figure 1.1 to assist users of this
Standard.
Implementation
1.12 This Standard shall be used forthwith on all
schemes for the construction and improvement of
trunk roads, including motorways, currently being
prepared, provided that, in the opinion of the
Overseeing Organisation this would not result in
significant additional expense or delay. Design
Organisations shall confirm its application to
particular schemes with the Overseeing
Organisation. In Northern Ireland the use of this
standard shall apply on those roads designated by
the Overseeing Organisation.
Mandatory Requirements
1.13 Sections of this document which form mandatory
requirements of the Overseeing Organisation are
highlighted by being contained within boxes. The
remainder of the document contains advice and
enlargement which is commended to designers for their
consideration.
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Symbols
1.14 The symbols used in this Standard are defined as
follows:
a (mm/mm) Cross-sectional area of corrugated
steel per unit length, the cross
section being parallel to the length
of the structure.
a
a
(mm/mm) Adjusted cross-sectional area of
corrugated steel per unit length
based on the remaining wall
thickness after deduction of
sacrificial metal thickness required
by Chapter 8.
B (mm) Diameter of plate used in plate load
test.
C (kN/m) Compressive hoop load in the wall
of the structure per unit length.
C
T
(kN/m) Total compressive hoop load in the
wall of the circular arch structure
per unit length acting upon the
foundation.
d
c
(mm) Depth of corrugation.
D (mm) Additional trench width required for
circular arch structures.
E (N/mm) Modulus of elasticity of the
structural steel.
E
s
(N/mm) Modulus of elasticity of the soil.
F(mm/N) Flexibility factor.
F
max
(mm/N) Limiting value of flexibility factor.
f
a
(N/mm) Compressive hoop stress.
f
b
(N/mm) Theoretical transverse elastic
buckling stress.
f
c
(N/mm) Nominal allowable buckling stress.
f
s
(N/mm) Stress derived from adjusted
nominal seam strength (kN/m) based
on the remaining wall thickness
after deduction of sacrificial metal
thickness required in Chapter 8.
f
y
(N/mm) Minimum yield strength of the steel.
h(m) Nominal height of fill above the
structure.
h
t
(m) Height of fill above the crown of the
structure including the thickness of
any road construction.
I(mm
4
/mm) Cross-sectional moment of inertia of
the corrugated steel per unit length,
the cross-section being parallel to
the length of the structure.
I
a
(mm
4
/mm) Adjusted cross-sectional second
moment of area of the corrugated
steel per unit length, the cross-
section being parallel to the length
of the structure.
I
d
Depth correction factor for plate
load test.
k(N/mm) Coefficient of soil reaction.
k
e
(N/mm) Modified coefficient of soil reaction.
K Constant.
K
a
Active earth pressure coefficient.
m Poissons ratio of the structural
steel.
M*(N/mm) Constrained soil modulus.
m
v
(mm/N) Coefficient of volume
compressibility.
N Uncorrected SPT value.
P(kN/m) Radial soil pressure on a circular
closed invert structure.
P
b
(kN/m) Radial soil pressure on the bottom of
a multi-radii structure.
P
c
(kN/m) Radial soil pressure on the corner of
a multi-radii structure.
P
t
(kN/m) Radial soil pressure on the top of a
multi-radii structure.
P
d
(kN/m) Design vertical superimposed dead
load pressure.
1/3
Chapter 1
Introduction
Volume 2 Section 2
Part 6 BD 12/01
November 2001
P
L
(kN/m) Design vertical live load pressure.
P
1
(kN/m) Overburden pressure on top of
footing of circular arch.
P
2
(kN/m) Lateral earth pressure on the outside
face of the footing of a circular arch.
P
3
(kN/m) Overburden pressure on top of
footing inside circular arch.
Q* Design Loads (Refer to BS 5400:
Part 1).
r(m) Radius of circular structure.
r
b
(m) Radius at the bottom of a multi-radii
structure.
r
c
(m) Radius at the corner of a multi-radii
structure.
r
t
(m) Radius at the top of a multi-radii
structure.
R* Design Resistance (Refer to
BS 5400: Part 1).
S (m) Span of the structure (diameter of
circular structure).
S* Design Load Effects (Refer to
BS 5400: Part 1).
t (years) Life of sacrificial thickness of steel.
T(m) Thickness of sacrificial metal for
each corroding face.
W
f
(kN/m) Self weight of foundation per unit
length.
y (m) Excavation width measured from the
walls of the structure.
Z
1
(m) Depth from road surface/ground
level to top of foundation.
Z
2
(m) Depth from road surface/ground
level to mid height of foundation.
(kN/m) Bulk unit weight of compacted fill.

fL
Partial safety factor that takes
account of the possibility of
unfavourable deviation of the loads
from their nominal values and of the
reduced probability that various
loadings acting together will all
attain their nominal values
simultaneously.

f3
Partial safety factor that takes
account of inaccurate assessment of
the effects of loading, unforeseen
stress distribution in the structure,
and variations of dimensional
accuracy achieved in construction.

m
Partial safety factor that takes
account of variabilities in material
strength and uncertainties in the
assessment of component strength.

q
(N/mm) Change in pressure applied by the
plate (plate load test).

s
(mm) Change in average settlement of the
plate (plate load test).

x
(m) Increase in horizontal diameter or
span.
Re-entry angle of circular arch
measured between the vertical and
the tangent to the arch wall at the
top of the foundation.
Poissons ratio of the soil.
1/4
Chapter 1
Introduction
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Initial Feasibility Study and Assessment of
Employers Requirements in Chapter 16
by Design Organisation
Ensure Structure initially complies with the following Sections:
a) Introduction/Scope - Chapter 1
b) Handling Installation - Chapter 10
c) End Treatment - Chapter 11
d) Multiple Installations - Chapter 15
Determine Constrained
Soil Modulus M*
Stiffness of Soil Surrounding
the Structure Clauses 5.1 - 5.8
of Chapter 5
Determine Durability
Requirements in Chapter 8
Determine Sacrificial
Metal Thickness
For Corrugated Steel Product and
Gauge selected determine the
following:
I
a
Adjusted cross-sectional
moment of inertia
a
a
Adjusted cross-sectional area
f
s
Stress derived from adjusted
nominal seam strength
Taking into account sacrificial metal
loss Clauses 6.1 and 7.1
Determine Design Load Effects in Chapter 4
a) Compressive Hoop Stress - Clause 4.2
b) Radial Soil Pressure for
Closed Invert Structures - Clause 4.3
c) Foundation Loading for
Circular Arches - Clause 4.4
Ensure Compliance with Design Requirements and
Strength Parameters at Ultimate Limit State - Chapter 6
a) Buckling Capacity - Clause 6.2a
b) Yield - Clause 6.2b
c) Seam Strength - Clause 6.2c
d) Stress Limits for Helically Wound Structures - Clause 6.2d
Design Organisation to discuss proposals
with TAA, obtain outline approval and
produce an outline design as appropriate,
and incorporate into Contract Documents
Contractor/Manufacturer *
seeks Approval in Principle from TAA and
carries out Design for Structure Proposed
and obtains Relevant Approvals
Determine Nominal Buckling
Stress from Clause 5.9 - 5.10 of
Chapter 5
Determine Design Loads
in Chapter 3
Dead Loads
Superimposed Dead Loads
Live Loads
Continued
Overleaf
* Outline Approval in Principle Form and Approval in Principle Form shall both incorporate the
listings of Employers Requirement as set out in Chapter 16
FEASIBILITY STUDY
COMPLETE
OUTLINE AIP AND
OUTLINE DESIGN
COMPLETE
Figure 1.1 Flow Diagram for Contract/Design Procedure
1/5
Chapter 1
Introduction
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Ensure Compliance with Design Requirements and at Serviceability Limit State - Chapter 7
a) Deflection - Clause 7.2
b) Allowable Net Bearing Pressure - Closed Invert Structures - Clause 7.3 & 7.4
c) Foundation Design - Circular Arches - Clause 7.5
Determine Requirements for Excavation and Filling Chapter 9
Trench - Figure 9.1
Partial Trench - Figure 9.2
Embankments - Clause 9.14
(Check also Figure 8.1 of Chapter 8 for durability requirements)
a) Design End Treament - Chapter11
b) Design Overlying Reinforced Concrete Slab (if required) - Chapter 12
c) Design Invert Paving for Closed Invert Structures (if required) - Chapter 13
d) Check detail of carriageway drainage in vicinity of structure (if required) - Chapter 14
Check of Final Design
Formal Approval of Design and Design Information
for Construction
Contractor to Submit Final Design with Design
Certificate and Design Information required in
Chapter 16.
Determine, list and record information
required in Chapter 16
FEASIBILITY STUDY COMPLETE
- PROCEED TO OUTLI NE AIP
AND OUTLINE DESI GN
OUTLINE AIP & OUTLINE
DESIGN COMPLETE,
CONTRACTOR TO PROCEED
Submission of As Constructed Information for
Maintenance Manual as required in Chapter 16
Figure 1.1 Flow Diamgram for Contract/Design Procedure
Continued from Overleaf
1/6
Chapter 1
Introduction
Volume 2 Section 2
Part 6 BD 12/01
November 2001 2/1
Chapter 2
Design Principles
2. DESIGN PRINCIPLES
2.1 Limit state principles have been adopted for
design in this Standard. The limit states adopted
are:
a. Ultimate limit states represented by:
i. The strength of the structure as
determined by the yielding and
buckling behaviour of corrugated steel
buried structures, and
ii. The strength of a longitudinal bolted
seam as determined by tests on bolted
plate assemblies.
b. Serviceability limit states represented by:
i. A limiting deflection expressed as a
maximum percentage change in the
span dimension beyond which cause
for public concern may be expected
and remedial action to protective
coatings and finishings may be
required.
ii. The allowable net bearing pressure of
the foundation material for closed
invert structures.
iii The allowable net bearing pressure of
the foundation material beneath the
concrete foundations of circular arch
structures.
2.2 Design loads (Q*) are expressed as the
product of nominal loads and the partial safety
factor
fL
.
2.3 Design load effects (S*) are expressed as the
product of the effects of the design loads and the
partial safety factor
f3.
2.4 Design resistance (R*) is expressed as the
nominal strength of the component divided by the
partial safety factor
m
.
2.5 The design load effects (S*) at the ultimate
limit state must not be greater than the design
resistance (R*). In addition, at the serviceability
limit state the deflection must not be greater than
the limiting value given in this Standard and the
settlement of the foundation material must not
adversely affect the performance of the structure.
2.6 As the allowable net bearing pressure of soil
is not normally expressed in characteristic (or
nominal) strength terms, the checks involving
allowable net bearing pressure shall be undertaken
with unfactored nominal loads.
2.7 For the ultimate limit state the following
load combinations shall be considered:
a. Dead Loads together with Live Loads.
b. Dead Loads together with Temporary
Construction Loads.
2.8 For the serviceability limit state, Dead
Loads shall be considered together with Live
Loads.
2.9 The steel section chosen for the walls of the
structure must satisfy both the strength and
deflection requirements of Chapters 6 and 7 and
also the durability requirements of Chapter 8 in
terms of sacrificial steel. The steel thickness
required to satisfy these criteria may be different at
different points around the circumference of the
structure. Care shall be taken during assembly to
ensure the correct positioning of plates of different
thickness.
Volume 2 Section 2
Part 6 BD 12/01
November 2001
3/1
Chapter 3
Design Loads
3. DESIGN LOADS
Dead Load of Steel
3.1 a) The self-weight of corrugated steel
buried structures may be ignored for
the Ultimate Limit State requirements
and Serviceability Limit State
requirements as defined in Chapter 6
and Chapter 7 respectively.
b) During the construction, the self-
weight of corrugated steel buried
structures shall be considered if
temporary strutting or ties are
required to support the structure.
(Refer to Clause 10.5.)
c) In the case of end treatments, the self-
weight of corrugated steel buried
structures, including headwalls, ring
beams and collars etc, shall be taken
into account. (Refer to Chapter 11).
Values for
fL
are given in Table 3.1.
Superimposed Dead Load
3.2 The design vertical pressure on the structure
due to the superimposed dead load is given by:
P
d
=
fL
x nominal vertical pressure
=
fL
h

(kN/m)
where = Bulk unit weight of compacted fill
(kN/m)
and h = Nominal height of fill above the
structure (m), to be taken as
h
t
+ 0.25r for circular structures
and circular arches, and h
t
+ 0.25r
t
for multi-radii structures
where h
t
= Height of fill (m) above the crown
of the structure, including the
thickness of any road construction
r = Radius of closed circular structure
or circular arch structure, (m)
r
t
= Radius at the top of a multi-radii
structure, (m)
Values for
fL
are given in Table 3.1.
Live Loads
3.3 Nominal live loads shall be the HA or HB
loading whichever is the more onerous, applied in
accordance with BS 5400: Part 2, as implemented
by BD 37 (DMRB 1.3). HA loading shall consist
of a single nominal wheel load of 100kN. HA UDL
and KEL need not be considered. For Trunk Roads
including Motorways, HB loading shall consist of
a minimum of 45 units. For other classes of roads
refer to BD 37. There is no requirement for co-
existing HA and HB wheel loadings to be
considered either in the same or adjacent lanes.
3.4 On the carriageway each wheel load shall be
assumed to be uniformly distributed over a contact
area, circular or square in shape based on a
nominal tyre inflation pressure of 1.1N/mm.
3.5 To determine the nominal vertical live load
pressure, P
L
on the structure due to any wheel load,
dispersion in three dimensions may be assumed
from the limits of the contact area on the
carriageway to the level of the crown of the buried
structure at a slope of 2 vertically to 1 horizontally
as shown in Figure 3.1. This pressure shall be
taken to act over the whole span. A wheel load not
directly over the structure shall be included if its
dispersion zone falls over any part of the structure.
3.6 In the case of the HB vehicle only, the
dispersion zones of individual HB wheel loads
shall be combined and distributed jointly as
indicated in Figure 3.1. This applies to adjacent
wheels on the same axle and, where the span is
large enough, to wheels on succeeding axles.
Volume 2 Section 2
Part 6 BD 12/01
November 2001 3/2
Chapter 3
Design Loads
3.7 Where a reinforced concrete structural slab is
proposed in accordance with Clause 1.3(b) and Clauses
12.1 to 12.5 of this Standard, dispersion of any wheel
load as described in Clause 3.5 may be assumed to
occur throughout the depth of the structural slab at a
slope of 1 vertically to 1.5 horizontally. Below the level
of the bottom of the structural slab, dispersion of the
wheel loads may be assumed to occur at a slope of
2 vertically to 1 horizontally.
Alternatively, the nominal live load pressures acting on
the culvert may be assessed by a suitable multi-layer
elastic analysis, using one of the methods given in
Chapter 6 of Elastic Solutions for Soil and Rock
Mechanics by H G Poulos and E H Davis, (1) which
takes into account the relative stiffness of the structural
slab and the layers of material between the slab and the
crown of the culvert.
3.8 The nominal vertical live load pressure on
the structure due to tracked construction vehicles
or large rubber tyred earthmoving vehicles shall be
determined at a depth of cover of one fifth of the
span of the structure, or 1m, whichever is greater.
3.9 Braking loads and temperature effects shall
be ignored.
3.10 To obtain the design vertical live load
pressure, P
L
(kN/m), the nominal pressures shall
be multiplied by the appropriate values of
fL
given
in Table 3.1.
Volume 2 Section 2
Part 6 BD 12/01
November 2001
LOAD SLS ULS

fL

fL
Dead Load Concrete, End 1.0 1.2
Treatment Only (Chapter 11)
Dead Load, Corrugated Steel Only 1.0 1.2
(Chapters 6 & 7 and Clause 10.5)
Superimposed Dead Loading 1.1 1.3
HA wheel load 1.2 1.5
HB loading 1.1 1.3
Temporary Construction Loading - 1.3
All loads for Radial Soil Pressure 1.0 -
Calculation
All loads for determining thrust 1.0 -
acting on circular arch foundations
for bearing pressure calculation
SLS: Serviceability Limit State
ULS: Ultimate Limit State
Table 3.1 -
fL
- Partial Safety Factors for Loads
3/3
Chapter 3
Design Loads
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Chapter 4
Design Load Effects
4/1
4. DESIGN LOAD EFFECTS
4.1 The design load effects involved in the
design of the corrugated steel buried structures
covered by this Standard are the compressive hoop
stress f
a
(all structures) and the radial soil pressure
P (closed invert structures), which shall be
calculated from the design load pressures using the
formulae given below based on the ring
compression theory, where the compressive hoop
stress in the wall of the structure is assumed to be
uniform around its periphery and the radial soil
pressure at any point is assumed to be inversely
proportional to the radius of curvature at that point.
4.2 Compressive Hoop Stress
Compressive hoop stress f
a
= C
f3
(N/mm)
a
a
Where C = Compressive hoop load in the
wall of the structure per unit
length (see Figure 4.1)
= S (P
d
+ P
L
) (kN/m)
2
S = Span of the structure (m)
P
d
= Design vertical superimposed
dead load pressure at the
ultimate limit state (kN/m)
P
L
= Design vertical live load
pressure at the ultimate limit
state (kN/m)
a
a
= Adjusted cross-sectional area
of corrugated steel per unit
length, (mm/mm) the cross
section being parallel to the
length of the structure. (Refer
to adjustments required in
Clause 6.1 and 7.1). If the
cross-sectional area varies
along the length of the
structure, the minimum shall
be used, except that the
re-rolled ends of helically
wound culvert lengths shall not
be considered to affect the
cross-section unless they
extend for more than 250mm at
the end of each length.

f3
= is to be taken as the
appropriate value given in
Table 4.1 for the particular
type of structure and the limit
state involved. The values in
the table take account of the
influence of the relative
stiffness of the particular
structural form, the amount of
deformation occurring before
the various limit states are
reached, and the variation of
stress distribution in the
particular type of structure.
Volume 2 Section 2
Part 6 BD 12/01
November 2001
4/2
Chapter 4
Design Load Effects
4.3 Radial Soil Pressure for Closed Invert
Structures
This shall be calculated as follows:
a. Circular Structures
External radial soil pressure
P = C = P
d
+ P
L
(kN/m)
r
b. Multi-radii
Radial soil pressure on the top
P
t
= C (kN/m)
r
t
Radial soil pressure on the corner
P
c
= C (kN/m)
r
c
Radial soil pressure on the bottom
P
b
= C (kN/m)
r
b
where C is as defined in Clause 4.2 but calculated
using P
d
and P
L
from unfactored nominal loads (see
Clause 2.6)
r = Radius of circular structure (m)
r
t
= Radius of the top (m) ) of Multi-
) radii
r
c
= Radius of the corner (m) ) structures
) (see
r
b
= Radius of the bottom (m) ) Figure
) 4.2)
Reference should be made to Chapter 7, Clause 7.3
for the allowable net bearing pressure of the
foundation material.
4.4 Strip Foundation Loading - Circular
Arches (Serviceability Limit State only)
(a) Thrust
The total thrust C
T
, in the wall of the structure,
acting upon the foundation at an inclined angle of
to the vertical is given by:
C
T
= C
f3
(kN/m)
where C is given in Clause 4.2
except that P
D
and P
L
are at the
Serviceability Limit State and
f3
is given in
Table 4.1
Volume 2 Section 2
Part 6 BD 12/01
November 2001
(b) Earth Pressure from Fill
The overburden pressure P
1
, on the top of the
footing is given by:
P
1
=
f3
Z
1
(kN/m)
where Z
1
(m) is depth from road/ground level
to top of foundation, is unit weight of
overburden (kN/m), and
f3
= 1 for SLS
The lateral earth pressure, P
2
acting on the outside
face of the footing is given by:
P
2
=
f3
K
a
Z
2
(kN/m)
where Z
2
(m) is depth from road/ground level
to mid height of foundation, K
a
is active
earth pressure coefficient, and
f3
= 1 for
SLS
The lateral pressure acting on the inside face of the
footing may be ignored.
Vertical and horizontal pressures resulting from
live loading surcharge on the carriageway may be
ignored when assessing P
1
and P
2
.
Consideration shall be given to avoiding
differential settlement between the foundation and
the side fill such that the side fill settles to a
greater extent. This may cause the overburden
pressure on top of the footing to be larger than the
calculated P
1
value, and cause additional loading
on the foundation. Refer to Clause 7.5.
(c) Vertical Pressure on Inside Face
The vertical pressure on top of the footing, P
3
,
shall include any superimposed dead loadings. The
vertical pressure, P
3
, shall also include any
nominal live loads due to vehicular, rail or
pedestrian traffic and these nominal live loads
shall be in accordance with BS 5400: Part 2 as
implemented by BD 37 (DMRB 1.3).
(d) Self Weight
The self weight of the foundation is W
f
per unit
length (kN/m).
(e) Allowable Net Bearing Pressure for
Foundation Design
Reference shall be made to Chapter 7, Clause 7.5
for the allowable net bearing pressure of the
foundation material.
4.5 Other Types of Foundations for Circular
Arches
Circular arch structures can also be constructed on a
suitably designed base slab which supports both walls
of the structure simultaneously.
To reduce the effects of the lateral earth pressure P
2
,
and loads from the structure, struts may be adopted
between strip foundations.
Chapter 4
Design Load Effects
4/3
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Chapter 4
Design Load Effects
4/4
Values of
f3
Type
of ULS SLS
Structure
Buckling Yield Seam Thrust on
foundations
Multi-radii and bolted circular 1.15 1.15 1.15 -
closed invert
Circular Arch Profile, Type 1 1.15 1.53 1.53 1.33
20 to 30 re-entry
Circular Arch Profile, Type 2 1.75 2.3 2.3 2.0
10 to 20 re-entry
Helically Wound 1.10 1.10 - -
Table 4.1 -
f3
Partial Safety Factors
Volume 2 Section 2
Part 6 BD 12/01
November 2001
5. STRENGTH PARAMETERS
Constrained Soil Modulus
5.1 When the structure is to be installed
partially or wholly in trench the M* of existing
materials, within a distance equal to the span on
each side of the structure, shall be determined,
during the ground investigation for the scheme.
Normally the method given in Clause 642
MCHW1 shall be used for plate load testing, for
non-cohesive soils. Alternatively the methods
described in 5.4 and 5.5 may be used, as
appropriate, during the ground investigation.
5.2 The constrained soil modulus M* represents
the stiffness of the soil surrounding the structure,
whether backfill or existing material and is given
by:
M* = (1 - ) E
s
(N/mm)
(1 + ) (1 - 2 )
where = Poissons ratio of the soil (to be
taken as 0.3 when determining M*) and
E
s
= Modulus of elasticity of the soil
(N/mm)
5.3 When carrying out plate load testing using
the method given in Clause 642 MCHW1 for non-
cohesive soils the Modulus of elasticity E
s
of the
soil shall be determined used the formula:
E
s
=
whereB = diameter of plate used in the plate
load test (mm)

q
= change in pressure applied by the
plate (N/mm
2
)

s
= change in average settlement of the
plate (mm)
I
d
= depth correction factor (taken as
1.0 when test complies with
Clause 642 MCHW1)
= Poissons ratio of the soil (to be
taken as 0.3)
5.4 The M* for non-cohesive soils may be
determined using the results from standard
penetration resistance tests (SPT) carried out in
accordance with BS 1377: Part 9. In this case the
M* of the existing soil shall be determined from
the relationship:
M* = 0.39N
1.4

m
whereN = uncorrected SPT value and

m
= 1.3
5.5 For undrained cohesive soils, M* may be
determined by measuring the coefficient of volume
compressibility, m
v
, in accordance with BS 1377
Part 5 and using the formula:
M* = 1
m
v
The in-situ effective overburden pressure at the
level of the crown of the structure shall be used in
the test.
5.6 The M* value for design shall then be
obtained from Table 5.1 based on the in-situ test
result and also taking into consideration the
excavation width, and the compaction required in
MCHW1.
5.7 For structures constructed in embankments,
the M* value for design shall be obtained from
Table 5.1 taking into account the compaction
required.
5.8 When the Contractor proposes a value of
M* for design, in excess of 33N/mm, the
Contractor shall substantiate the proposed value by
testing the backfill during the back - filling
operation, using the method given in Clause 642
MCHW 1 for plate load testing.
Chapter 5
Strength Parameters
5/1
___ (1 -
2
) B ___ I
d
(N/mm
2
)

s
Volume 2 Section 2
Part 6 BD 12/01
November 2001
CLOSED INVERT STRUCTURES
Partial or Total Trench
Constrained Soil Required Required Compaction M* Value
Modulus (M*) of Excavation Width for Backfill for Design Use
Existing Soil on each side of Materials (N/mm)
(N/mm) structure
< 15 Span 85% max dry density 20
Span 90% max dry density 33 - 80++
15 but 33 Minimum + 90% max dry density As existing soil
Span 90% max dry density 33 - 80++
> 33 Minimum + 90% max dry density 33
Span 90% max dry density 33 - 80++
Embankment
- - 85% max dry density 20
- - 90% max dry density 33 - 80++
CIRCULAR ARCH STRUCTURES
Partial or Total Trench
Constrained Soil Required Required Compaction M* Value
Modulus (M*) of Excavation Width for Backfill for Design Use
Existing Soil on each side of Materials (N/mm)
(N/mm) structure
33 Span 90% max dry density 33 - 80++
> 33 Minimum 90% max dry density 33
Span 90% max dry density 33 - 80++
Embankment
- - 90% max dry density 33 - 80++
Obtained from in-situ test + See Clause 9.8
To be determined from BS 1377 Part 4, See Clause 9.9
using the vibrating hammer method. ++ See Clause 5.8
Table 5.1 - Design Values of Constrained Soil Modulus (M*)
Chapter 5
Strength Parameters
5/2
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Nominal Buckling Stress
5.9 The method for determining nominal
allowable buckling stress (f
c
) is based on the work
of G G Meyerhof (Meyerhof and Baikie, 1963). An
adjustment to the theoretical transverse elastic
buckling stress (f
b
) is made to allow for
imperfections of the pipe wall. (f
y
) is the minimum
yield strength of the steel.
5.10 The nominal allowable buckling stress f
c
shall be determined from the following formulae:
f
f
1
f
f
c
y
y
b

_
,

where f
b
= Theoretical transverse elastic buckling
stress (N/mm) to be taken as follows:
a. When the depth of cover above the crown of
the structure is greater than or equal to the
span of the structure
( )
f
2
a
kEI
1 m
provided
1000S
EI
1 m k
4
b
a
a
2
0.5
a
2
0.25

1
]
1

1
]
1
1
>
b. When the depth of cover above the crown of
the structure is less than the span of the
structure
( )
( )
f
2
a
k EI h
1 m S
provided
1000S
EI h
1 m k S
4
b
a
e a
2
0.5
a
2
e
0.25

1
]
1
1

1
]
1
1
>
wherek = Coefficient of soil reaction (N/mm)
= 0.333M*_ for circular structures
1000r
= 0.333M*_ for multi-radii structures
1000r
t
and k
e
= Modified coefficient of soil reaction
(N/mm)
=
=
E = Modulus of Elasticity of steel
= 205 x 10
3
N/mm
I
a
= Adjusted cross-sectional moment of
inertia per unit length (mm
4
/mm) of
the corrugated steel sheet about its
neutral axis, the section being parallel
to the length of structure. (Refer to
adjustments required in Clauses 6.1
and 7.1) If the cross-sectional moment
of inertia varies along the length of
the structure, the minimum shall be
used. The re-rolled ends of helically
wound culvert lengths shall not be
considered to affect the value of I to
be used unless they extend for more
than 250mm at the end of each length.
The effect of the helix angle of
helically wound culverts on I
a
may be
neglected.
h = Nominal height (m) of fill above the
structure (as defined in Clause 3.2)
a
a
= Adjusted cross-sectional area of
corrugated steel per unit length
(mm/mm) (as defined in Clause 4.2)
m = Poissons ratio of steel = 0.3.
M* = Constrained soil modulus design
value (N/mm) as determined from the
requirements of Clauses 5.1 to 5.8.
r = Radius of circular structure (m)
r
t
= Radius at the top of multi-radii
structure (m)
S = Span of the structure (diameter of
circular structure) (m)
Chapter 5
Strength Parameters
5/3
for closed circular
and circular arch
structures
1
r
r h
k,
2

_
,

1
]
1
for closed multi-
radii structures
1
r
r h
k,
t
t
2

_
,

1
]
1
Volume 2 Section 2
Part 6 BD 12/01
November 2001
6. ULTIMATE LIMIT STATE REQUIREMENTS
6.1 The design shall be based on adjusted
sectional properties and adjusted nominal seam
strengths based on the residual metal thickness
after deduction of the appropriate thickness of
sacrificial metal loss, as determined in Chapter 8.
6.2 At the ultimate limit state, the compressive
hoop stress, f
a
, shall not exceed any of the
following:
a. The nominal allowable buckling stress, f
c
,
divided by
m
= 1.3 where f
c
is given in
Clause 5.10.
b. The minimum yield strength, f
y
, of the steel
divided by
m
= 1.3. The value of f
y
will be
that nominated and guaranteed by the
manufacturer for inclusion in the Type
Approval Certificate for the products. (See
Annex A, Clause A.2.3.)
c. In the case of a bolted segmental structure,
the stress, f
s
, derived from the adjusted
nominal seam strength (as required in
Clause 6.1), of the longitudinal bolted joint,
divided by
m
of 2.0. The nominal seam
strength shall be as obtained from tests
carried out in accordance with Annex B,
normally provided by the proprietary
manufacturers for standard metal
thicknesses. Adjusted seam strength for
intermediate values of residual metal
thickness may normally be derived by linear
interpolation between values provided for
the greater and lesser values of metal
thickness (in increments no greater than
0.75mm), and for the appropriate number of
bolts.
d. In the case of a helically wound structure, a
stress of 370 N/mm divided by
m
of 2.0.
Chapter 6
Ultimate Limit State Requirements
6/1
Volume 2 Section 2
Part 6 BD 12/01
May 2002
7. SERVICEABILITY LIMIT STATE REQUIREMENTS
Deflection
7.1 The design shall be based on adjusted
sectional properties which allow for the loss of the
appropriate thickness of sacrificial metal loss as
determined in Chapter 8.
7.2 At the serviceability limit state, the increase
in the horizontal diameter or span(S) of the
structure,
x
, determined using the following
formula, shall not exceed 5%.

x
= _____________________ (m)
where P
d
= Design vertical superimposed dead
load pressure at the serviceability
limit state (kN/m)
P
L
= Design vertical live load pressure
at the serviceability limit state
(kN/m)
K = 1.4, where P
L
is derived from
wheel loads which, at the level of
the crown of the structure, have a
total distributed width less than the
span (see Clause 3.5)
or K = 1.0, for all other cases
M* = Constrained soil modulus design
value (N/mm) as determined from
the requirements of Clauses 5.1 to
5.8
S = Span of the structure (diameter of
circular structure) (m).
and E and I
a
are as defined in Clause 5.10. S is
defined in Clause 4.2.
Allowable Net Bearing Pressure of the
Foundation Material for Closed Invert
Structures
7.3 The radial soil pressure, P, for closed
circular structures shall not exceed the allowable
net bearing pressure of the foundation material.
The radial corner pressure P
c
, for multi - radii
structures, shall not exceed the allowable net
bearing pressure of the foundation material or 300
kN/m, whichever is less. P and P
c
are derived
from C (compressive hoop load) calculated from
unfactored nominal loads (see Clause 4.3). The
allowable net bearing pressure of the foundation
material shall be taken to be one third of the
ultimate bearing capacity calculated in accordance
with BS 8004, as implemented by BD 74 (DMRB
2.1.8). Definitions of these terms are given in BS
8004, Clause 1.2, as implemented by BD 74
(DMRB 2.1.8).
7.4 Where the radial corner pressure P
c
exceeds
the lesser of 300kN/m or the allowable net bearing
pressure, consideration shall be given to deepening
and/or widening the trench in accordance with
Clause 9.2. Account may be taken of the reduction
in the value of maximum radial soil pressure with
distance from the face of the structure within the
bedding material. The reduced pressure may be
calculated as P
c
times the radius of the corner
plates, divided by minimum distance from the
centre of radius of the corner plates to the edge of
the fill. In any event the radial corner pressure P
c
in
contact with selected bedding or fill material shall
not exceed 400kN/m.
7.5 Circular Arches - Foundation Design
Foundations shall be in accordance with
BS 8004, as implemented by BD 74 (DMRB
2.1.8). The bearing pressures generated beneath
the foundation shall be calculated for the loadings
given in Clause 4.4. The allowable net bearing
pressure shall be taken to be one third of the
ultimate bearing capacity calculated in accordance
with BS 8004, as implemented by BD 74 (DMRB
2.1.8) (see Clause 7.3 above). The maximum
bearing pressure shall not exceed the allowable net
bearing pressure. Overturning and sliding shall be
in accordance with BS 8002 Earth Retaining
Structures. Guidance is also found in Bridge
Foundations and Sub-structures (Building
Research Establishment 1979).
Checks shall be carried out to ensure the above
criteria are met when the structure is not subjected
to live loading.
0.083 (P
d
+ KP
L
) S
4
x 10
6
8EI
a
+ (0.02M*S
3
x 10
9
)
Chapter 7
Serviceability Limit State Requirements
7/1
Volume 2 Section 2
Part 6 BD 12/01
May 2002
Footings should not be supported on piled
foundations or otherwise constructed in such a
manner that differential settlement would occur
between the structure and adjacent embankment,
thereby placing additional loading on the structure.
The design of the reinforced concrete foundation
shall be in accordance with BS 5400: Part 4 as
implemented by BD 24 (DMRB 1.3.1) The
detailed design shall be such as to ensure adequacy
of connection between the corrugated steel plates
and the foundation both during construction and in
service (see also Clause 10.6).
Reference shall also be made to Clause 8.17 and
8.18 for additional requirements
Chapter 7
Serviceability Limit State Requirements
7/2
Volume 2 Section 2
Part 6 BD 12/01
November 2001
8. DURABILITY
General and Definitions
8.1 The design life of corrugated steel buried
structures shall be 120 years.
8.2 All surfaces shall be protected by a hot-dip
galvanised coating to BS EN ISO 1461: 1999 using
a minimum average coating weight in accordance
with BS EN ISO 1461: 1999 Table 2. Prior to
galvanising, all the structural steel plates shall be
fully fabricated, ie cut to size, corrugated, curved,
and the bolt holes punched or drilled. The
exception to this is the raw edge incorporated into
the folded lockseam as part of the manufacturing
process of helically wound pipe (formed from pre-
galvanised strip to BS EN 10142: 2000). Where
site cutting is unavoidable, any exposed edge must
be protected with a cold applied zinc rich paint
prior to the application of a secondary protective
coating.
Helically wound pipe may be formed from
electrolytically galvanised steel strip precoated
with a suitable secondary protective coating prior
to corrugating, curving and crimping. This
secondary coating must survive the production
process intact and be fully incorporated into the
crimp seam. Such a manufacturing system shall
have a current British Board of Agrment (BBA),
Roads and Bridges Certificate, or equivalent.
8.3 Secondary protective coatings shall be
applied to all galvanised steel surfaces. The
minimum requirement for a secondary protective
coating applied to galvanised steel surfaces shall
be a bituminous coating as defined in BD 35
(DMRB 2.4.1) and applied in accordance with that
Standard. Protective coatings intended to provide
the minimum requirement shall have a current
Highways Agency registration in accordance with
the procedures described in BA 27 (DMRB 2.4.2).
It is not intended that the life of this minimum
secondary protective coating shall be taken into
account when calculating the required sacrificial
steel thickness in accordance with clauses 8.10 to
8.13. Where it is intended that the life of a
secondary protective coating shall be taken into
account to reduce the required sacrificial steel
thickness, that secondary protective coating shall
have a current British Board of Agrment (BBA),
Roads and Bridges Certificate, or equivalent,
certifying its life before it requires major
maintenance. The minimum life of a certified
secondary protective coating under service
conditions shall be 20 years before it requires
major maintenance.
Measures to achieve Design Life
8.4 Secondary protective coatings may be
applied to galvanised surfaces either in the factory,
or on site during construction. The method of
application of the secondary protective coating
shall be as described in BD 35 or in the current
British Board of Agrment (BBA), Roads and
Bridges certificate, or equivalent. To reduce
damage en route to site the manufacturer shall
recommend methods for transport and handling of
the coated components and structures. A suitable
method shall be identified for the repair and
patching of damage to coatings caused during
transport and construction, and also for making
good any deterioration in service.
8.5 In selecting the type of secondary protective
coatings to be applied to the basic galvanised steel
structure the designer shall take into account not
only the environment into which the structure is to
be placed but also the effect on the coating of (i)
the span of the structure (the greater the span the
greater the environmental exposure of the interior
coatings), (ii) its location, and (iii) its accessibility
for future maintenance.
8.6 Galvanised steel surfaces shall be deemed to
corrode at the rates of corrosion given in Clauses
8.11 and 8.13.
8.7 Each surface of the structure shall be
provided with a sacrificial thickness of steel to
achieve the required 120 year design life, taking
into account the corrosivity of the environment,
contributions from galvanising and contributions
from secondary protective coatings with a current
British Board of Agrment (BBA), Roads and
Bridges Certificate or equivalent.
Chapter 8
Durability
8/1
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Corrosivity Classification of Surfaces
8.8 Buried Surfaces
8.8.1 Buried surfaces shall be classified in the
Schedule of Employers Requirements, either
according to the properties of the surrounding soil
or of the effluent water carried, or of the ground
water where present, as determined from the
ground investigation where applicable. The
classification shall be the most severe of the three.
It should be appreciated that effluent water and/or
groundwater can penetrate through bolt holes and
seams to affect equally both internal and external
surfaces of the culvert. The selected fills, Classes
6K, 6L and 6M described in MCHW1 Clause 623,
shall provide a non aggressive environment when
dry and used to replace soils within the zone
indicated in Clause 8.8.3, but any water present
will determine the classification based on its
properties. Refer also to Clause 14.3.
8.8.2 The surrounding soil, invert fill, silt deposits
and select fill types in Clause 8.8.1 shall be
classified using the points system for each
property, shown in Table 8.1, and the ground water
shall be classified according to the highest
aggressivity indicated for any property in
Table 8.3. The properties shall be assessed using
the test methods listed in Table 8.2. Additionally,
where the culvert carries a continuous flow of
water or other fluid, classification of the water/
other fluid according to Table 8.3 shall be used to
classify both surfaces if it is more severe than the
classification of the surrounding soil or ground
water.
y = 0.4 + 0.23S
where S = span of the structure
and both S and y are in metres
Figure 8.1 - Corrosivity Classification Zone
for the External Buried Surface
Chapter 8
Durability
8/2
8.8.3 For structures constructed partly or totally in
trench, the existing soil within the zone shown in
Figure 8.1 shall be tested for corrosivity
classification purposes.
8.8.4 The inner surface of the structure shall be
regarded as a buried surface beneath any part that
is to be covered eg when a structure is used as a
vehicular underpass or has invert protection. Any
water or fill present shall be used to determine
corrosivity classification as in Clauses 8.8.1 and
8.8.2. Both inner and outer surfaces beneath this
covered part shall be classified for aggressive
conditions if it is likely that road salt or other
chemicals in solution will come into contact with
them from whatever source. Refer also to Clause
14.3.
8.9 Exposed Surfaces
8.9.1 Exposed surfaces shall be classified in the
Schedule of Employers Requirements according
to the aggressivity of any water or other fluid
carried by the structure or the aggressivity of the
ground water (to allow for water percolation
through joints or bolt holes) using the criteria in
Table 8.3, and also according to the corrosivity of
the atmosphere using the criteria in Table 8.4. The
overall classification shall be determined by the
most severe of the three.
8.9.2 Consideration shall be given to the effect on
exposed surfaces of the presence of chloride ions
from road salt. It has been found that chloride can
persist in the water carried throughout the year
including the summer months and may percolate
through joints or bolt holes.
8.9.3 The harshness of the atmospheric
environment shall be determined by the Design
Organisation from the map Relative Values of
Acid Deposition in the United Kingdom 1986 -
1991 published by ADAS, Reading (3). The
corrosivity (acid deposition) value shall be taken
as the average of the values indicated by the chart
grid square in which the proposed structure is sited
and the three nearest adjoining squares. The
atmospheric environment for the exposed surfaces
shall be determined from this corrosivity value
using Table 8.4. However, any other significant
environmental factors concerning the location shall
also be taken into account eg wind blown salt
spray near the coast or pollution from a nearby
industrial plant may override the general
Volume 2 Section 2
Part 6 BD 12/01
February 2002
classification, or constitute a very aggressive
environment.
Life of Protective Coatings and Sacrificial Steel
Thickness for All Surfaces
8.10 The design life of the structure shall be the
sum of the life of the sacrificial steel, the life of the
galvanised coating and the life of the secondary
protective coating.
8.11 The life of the galvanised coating shall be
calculated from the rate of corrosion which shall
be taken as 4m/year in non-aggressive
environments and 14m/year in aggressive
environments. Galvanising thickness may be
assumed to be 1m for each 7.15 g/m coating
weight.
8.12 The life of a secondary protective coating
applied to the galvanised steel components shall be
as determined in the current British Board of
Agrment (BBA), Roads and Bridges Certificate or
equivalent for the coating used.
8.13 The sacrificial thickness of steel required to
provide 120 years life less the life of the coatings,
shall be calculated from the formulae:
T = 22.5t
0.67
, for non-aggressive
environments; and
T = 40.0t
0.80
, for aggressive
environments,
where T = thickness of sacrificial steel on
each surface (m),
t = life of sacrificial thickness of steel
in years.
Invert Protection
8.14 In addition to the requirements of Clauses
8.10 to 8.13, the invert of all structures carrying
water or other fluid shall be protected from the
effects of abrasion or erosion by adopting one of
the following protection systems:
a. A reinforced concrete paving (See Clauses
13.1 to 13.7) with a minimum thickness of
100mm for structures of span less than or
equal to 2m, and with a minimum thickness
of 125mm for all other structures.
b. As an alternative to a reinforced concrete
pavement the following may be used for all
spans and gradients:
i. Paving blocks of 60mm minimum
thickness bedded on a compacted
Type 1 sand bed, with concrete
flaunchings used at the edges to
provide a transition between the
paviours and the sides of the CSBS.
ii. Precast slabs or natural stone set into
mass concrete having a minimum
thickness of 300mm. The pavement
may be profiled to suit local
requirements, for example the
inclusion of a channel to retain water
under low flow conditions; shaping to
simulate a natural channel; and the
provision of animal runs. Weirs or
eddy pools may be included within
the structure to provide resting places
for fish etc. passing through the
structure. Upstanding stone set into
the concrete may also be used for this
purpose.
iii. A liner plate manufactured from, for
example, galvanised steel sheet or
glass reinforced plastic (GRP) and
pre-shaped to the profile of the invert,
may be secured to the CSBS. The
void between the liner plate and the
invert shall be filled with a
cementitious grout or other water
resistant material.
c. A proprietary system giving an equivalent
level of invert protection and certified as
suitable for the end-use by the British Board
of Agrment or equivalent body, who will
also certify its design life.
d. For structures with little or no flow, and
which are therefore likely to hold standing
water, the following may be used as
alternatives to pavements:
i. A coating certified as suitable for the
end use by a current British Board of
Agrment, Roads and Bridges
Certificate, or equivalent, may be
used. The design life shall be stated
on the certificate.
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ii. The use of liner plates secured to the
structure to cover fluctuations of at
least 200mm above and below the
range of water depths. The liner plates
may be formed from, for example,
galvanized steel strip coated with a
bitumen-based product (or other
suitable protective coating) or from
GRP. The plates may be shaped to
follow the curvature of the walls of
the structure and if required may be of
sufficient size to completely cover the
invert. Any gap between the liner and
the structural shell should be filled
with, for example, concrete or
cementitious grout or other water
resistant filler, to seal the interior
surface of the structure. The liner
plates may be provided with grouting
points to facilitate the filling of the
void. If a secondary protective coating
is used to protect galvanised steel
liner plates, its design life given in a
current British Board of Agrment,
Roads and Bridges Certificate, or
equivalent, may be taken into account.
8.15 Invert protection shall be applied to the
wetted periphery of the structure for the winter
base flow plus 200mm on each side or 25% of the
total circumference for circular structures or 40%
of the total circumference for multi-radii structures
whichever is greater. Where the invert protection is
in concrete and exceeds 25% of the total
circumference for circular structures or 40% of
multi-radii structures, or as appropriate for a
circular arch structure, formwork shall be used in
its installation. Any gap between the pavement and
the structural plates shall be sealed with an
appropriate sealant. The point at which the
pavement meets the structural plates shall be
shaped to prevent ponding of water against the
structural plates. To prevent accelerated
differential corrosion of the steel culvert,
particularly at the wet/dry line, paved inverts must
be inspected at regular intervals when
maintenance/replacement shall be carried out as
appropriate.
8.16 Subject to the agreement of the appropriate
river authority or Environment Agency, screens
shall be installed at the inlet of a culvert when it is
anticipated that water-borne stones or other debris
in excess of 100mm diameter would otherwise be
carried through it during normal or flood
conditions. For a culvert installed with a gradient
greater than 2 per cent, it is desirable to remove
water-borne stones or fragments of less than
100mm diameter through installation of drop inlets
or catchpits.
Invert Protection Below Circular Arch Structures
8.17 Reinforced concrete invert paving as
described in the relevant parts of Clause 8.14 shall
be provided, where necessary, to protect the arch
foundations and foundation material from scour,
abrasion or chemical attack from flowing water or
other fluid if present. The design of the paving
shall take account of hydraulic factors, the
foundation material and the nature of the stream/
river bed.
8.18 Where the level of winter flow is above the
foundation level, the invert paving shall also be
applied to the corrugated steel as described in
Clause 8.15. The most vulnerable area of an arch
structure to deterioration is at the springing and
great care shall be taken to avoid water entrapment
at this point. A typical detail is shown in Figure
8.2. The detail adopted should avoid entrapment of
water on the soil side of the structure and, where
concrete upstands are used, against the inside of
the arch structure: any gap between the structural
plates and the pavement must be thoroughly filled
and waterproofed. This seal shall be designed to be
maintainable. Care shall be taken to ensure that
any of the work done to protect the CSBS will not
adversely affect its structural performance.
8.19 Impact Protection
a. In the case of structures to be used by
vehicles consideration shall be given to
protecting the sides of the structure by
kerbing and/or by means of an appropriate
vehicle restraint system which should not be
connected to the sides of the structure.
Advice on a suitable system may be
obtained from the Overseeing Organisation.
Some measure of protection to the crown/
soffit should be provided by suitable design
of headwalls or ring beams and by alerting
drivers to the headroom restriction by means
of visual and/or audible warning systems.
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b. Where water carrying structures are to be
used by water craft, adequate protection
against impact and abrasion shall be
incorporated in the form of rubbing boards
etc. Suitable provision shall be made for
maintaining and replacing such items as
necessary.
8.20 Reinforced Concrete Foundations
The Overseeing Organisations requirements for
reinforced concrete are contained in Series 1700 of
MCHW1. The concrete mix shall be Grade 30 or
higher. Further guidance is given in Series NG1700
of Notes for Guidance on the Specification for
Highway Works MCHW2. Detailed guidance on
the assessment of ground aggressivity to concrete
is given in Part 1 of BRE Special Digest SD1
Concrete in aggressive ground (2001). The
ground to be assessed should include the
surrounding ground, the groundwater, the general
embankment fill and the backfill material, and any
contained water or effluent to be carried by the
structure. It should be noted that the ground
properties to be assessed and classification
procedure in respect of concrete are different to
those recommended for steel structures in Tables
8.1, 8.2 and 8.3 of this Standard. Detailed guidance
on the specification of concrete for foundations in
aggressive ground is given in parts 2 and 3 of BRE
Special Digest SD1. Provision is made in the
Digest for the use of various cement and cement
combinations in conjunction with aggregates of
differing carbonate content. The Digest also
recommends additional protective measures for
concrete where ground water is mobile and sulfate
concentrations are high.
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November 2001
PROPERTY MEASURED VALUE POINTS
Fraction passing 63m sieve 10%
Plasticity Index (PI) of fraction + 1
passing 425m sieve 6
Fraction passing 63m sieve > 10%
PI of fraction passing 425m sieve 6 0
Soil Type Any grading
PI of fraction passing 425m sieve > 6 but < 15 - 1
Any grading
PI of fraction passing 425m sieve 15 - 2
Organic matter > 1.0%
or material containing peat, cinder or coke - 3
10,000 + 2
< 10,000 but 3,000 + 1
Resistivity < 3,000 but 1,000 - 1
(ohm - cm) < 1,000 but 100 - 3
< 100 - 4
pH of soil 6 pH 9 0
5 pH < 6 - 2
Less than 5 or more than 9 - 4
Water-soluble 0.24 0
sulfates (WS) > 0.240 but 0.60 - 1
(g/l as SO
4
) > 0.60 but 1.20 - 2
> 1.20 - 4
Chloride ion 50 0
(ppm) > 50 but 250 - 1
> 250 but 500 - 2
> 500 - 4
Oxidisable 0.05 0
sulfides (OS) > 0.05 but 0.12 - 1
(% as SO
4
) > 0.12 but 0.24 - 2
> 0.24 - 4
POINTS TOTAL CORROSIVITY CLASSIFICATION
0 or more Non aggressive
- 1 to - 4 Aggressive
- 5 or less Very aggressive
Table 8.1 Corrosivity Classification of Surrounding Soil
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November 2001
PROPERTY TEST METHOD
Soil Type:
Grading BS 1377 : Part 2
Plasticity Index (PI) BS 1377 : Part 2
Organic Matter BS 1377 : Part 3
Resistivity Clause 637, MCHW1
pH BS 1377 : Part 3
Water-soluble sulfate and oxidisable sulfides TRL Report 447 Test Nos 1, 2 and 4
Chloride ion content BS 812 : Part 117
Table 8.2 - Test Methods for properties required in Table 8.1 and Table 8.3
NOTES (TABLES 8.1 AND 8.2)
1. When sampling for organic matter determination, great care must be taken to avoid contamination with top
soil, roots or overlying made ground. If contamination cannot be avoided, reduce the number of negative points
awarded in Table 8.1.
PROPERTIES OF WATER OR EFFLUENT
CORROSIVITY
CLASSIFICATION pH Chloride ion Water-soluble
(ppm) Sulfate (WS)
(g/l as SO
4
)
Non-Aggressive 6 pH 9 50 0.24
Aggressive 5 pH < 6 > 50 but 250 > 0.24 but 0.60
Very Aggressive Less than
5 or more > 250 > 0.60
than 9
Table 8.3 - Corrosivity classification of ground water, carried water and other contained fluids
Average Corrosivity Value Classification of the
(Acid Deposition Value from Atmospheric Environment
ADAS map)
2 Non-Aggressive
> 2 but 4 Aggressive
> 4 Very Aggressive
Table 8.4 - Classification of Surfaces Exposed to the Atmospheric Environment
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Chapter 8
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November 2001
9. EXCAVATION AND FILLING
Excavation for Bedding of Closed Invert Structures
9.1 Excavation for the bedding of closed invert
corrugated steel buried structures shall extend to a
depth below invert level of not less than one tenth
of the span and to a width not less than 800mm
(500mm for structures up to 3m span) beyond the
span on each side, provided that the allowable net
bearing pressure at this depth exceeds the
maximum radial soil pressure (P or P
c
). In any
event the excavation width should be not less than
the extent of side fill required in Table 5.1. The
excavation shall extend a length not less than
300mm beyond each end of the structure (see
Figures 9.1 and 9.2).
9.2 Where the allowable net bearing pressure of
the foundation material at the excavation level
given above is less than the maximum radial soil
pressure (P or P
c
), the excavation shall be
continued to such a depth that the allowable net
bearing pressure at the new excavation level is not
less than the maximum radial soil pressure.
Account may be taken of the reduction in the value
of maximum radial soil pressure with distance
from the face of the structure as described in
Clause 7.4. The allowable net bearing pressure of
the bedding material must not be exceeded. When
additional excavation is necessary it shall be wider
than the limits given in Clause 9.1 by an amount
on each side equal to the extra depth (see Figures
9.1 and 9.2).
9.3 Excavation in hard material shall extend to
an additional depth of not less than 300mm below
the level indicated in Clause 9.1 plus 40mm for
each metre of cover, in excess of 8m, above the
crown of the completed structure up to a maximum
additional depth of 600mm.
Excavation of the Foundation Level for Circular
Arches
9.4 The excavation for the foundation level shall
extend to a width not less than 800mm (500mm for
circular arches up to a 3m span) beyond the span
on each side and in any event to be not less than
the extent of side fill required in Table 5.1.
9.5 Additional excavation may be necessary to suit
the foundation size selected and the working space
required for construction of the foundation and
backfilling the structure.
9.6 In cases where the net allowable bearing pressure
of the foundation material at an excavation level results
in an impractical size of foundation, as calculated in
accordance with Clause 7.5, the excavation level may
be continued to such a depth to locate an improved net
allowable bearing pressure of the foundation material.
The additional excavation can be replaced with suitable
foundation material as indicated on Figures 9.1 and 9.2.
Alternatively, the depth of the foundation may be
increased. In both cases the foundations shall be
designed in accordance with Clause 7.5.
9.7 The depth of excavation to the foundation
level is measured from the top of the foundation
and is defined as (1000+D)mm (see Figures 9.1
and 9.2). In such a case, the width of excavation at
the foundation level shall be (500+D)mm for
circular arches up to 3m span and (800+D)mm for
circular arches of span 3m or greater, beyond the
span on each side (see Figures 9.1 and 9.2).
Trench Width for Closed Invert Structures
9.8 The trench width shall be not less than three
times the span (S) of the structure, unless the
constrained soil modulus (M*) of the existing soil
is greater than the values adopted for design (see
Table 5.1) when the trench width may be reduced
to the minimum required for the lower bedding
material, that is normally the span plus 500mm
each side for structures up to 3m span, or span plus
800mm each side for larger spans, or as otherwise
required in Clause 9.2 and shown in Figure 9.1. A
partial trench condition occurs when the level of
existing soil suitable for retention within a distance
of a span either side of the structure lies between
the crown of the structure and the underside of the
lower bedding. Refer to Figure 9.1. Partial trenches
can be treated similarly to trenches; alternatively
the excavation shall extend to a distance equal to
the span on each side of the structure. Reference to
Clause 8.8.3 is also necessary.
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Excavation and Filling
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Trench Width for Circular Arches
9.9 The trench width shall be not less than three
times the span (S) of the structure, unless the
constrained soil modulus (M*) of the existing soil,
within this extent, is greater than or equal to the
values adopted for design (see Table 5.1), when the
trench width may be reduced to the minimum
required for the width of excavation specified in
Clause 9.7 and shown in Figure 9.1. A partial
trench condition occurs when the level of existing
soil suitable for retention within a distance of a
span either side of the structure lies between the
crown of the structure and the underside of the
lower bedding. Refer to Figure 9.2. Partial trenches
can be treated similarly to trenches; alternatively
the excavation shall extend to a distance equal to
the span on each side of the structure. Reference to
Clauses 8.8.3, 9.4 and 9.7 is also necessary.
Filling - General
9.10 The earthworks requirements for the
selected fills and their compaction requirements
are given in Series 600 MCHW1.
Filling - Bedding for Closed Invert Structures
9.11 As far as possible, the lower bedding
material (Class 6K in Table 6/1 MCHW1) shall be
shaped to fit the invert such that it supports 20% of
the circumference of circular structures or the
whole of the portion of cross section of radius r
b
(see Table 1.1) for multi-radii structures. If this
cannot be met and the structure is erected on flat or
partially preshaped bedding, care must be taken to
ensure that the lower bedding material is properly
placed and compacted under the haunches.
9.12 The upper bedding material (Class 6L in
Table 6/1 MCHW1) is as described in Series 600
MCHW1.
Filling - Surround for All Structure Types
9.13 The surround material (Class 6M in Table
6/1 MCHW1) as described in Series 600 MCHW1
shall be used for filling all excavations, except
those in hard material for which lower bedding
material (Class 6K) shall be used, with minimum
excavation. In all cases (for embankments and
trenches and partial trenches) surround fill shall
extend to a height of not less than a fifth of the
span or 650mm whichever is the greater, above the
crown of the structure, or to the formation level of
the road if this is lower. See Clause 9.16 for
requirement for placing of fill.
9.14 In embankments the surround material shall
be used for a minimum distance equal to the span
on each side of the structure. In trenches the
surround material shall be used for a minimum
distance as defined in Clause 9.8 or 9.9 on each
side of the structure. For partial trenches (where
the level of the existing ground suitable for
retention is lower than the crown of the structure)
the surround material in the trench may be used for
a minimum distance as defined in Clause 9.8 or
9.9. Alternatively, the fill shall extend to a distance
equal to the span of each side of the structure. The
surround material above the level of the existing
soil suitable for retention in partial trench
conditions shall be used for a minimum distance
equal to the span on each side of the structure. (See
Figures 9.1 and 9.2.)
Filling - Overlying Fill above All Structural Types
9.15 The overlying fill material as described in
MCHW1 Series 600 shall be used for embankment
construction in the zone over the structure shown
in Figures 9.1 and 9.2. Argillaceous rocks such as
shales and mudstones, slag and PFA shall not be
used as fill or road sub-base materials in this zone.
Filling - Deposition, Spreading and Compaction
9.16 Surround fill and fill placed above the level
of the crown of the structure, as described in
Clause 9.13 to 9.15, shall be deposited, spread and
compacted in such a manner that any out of
balance forces transmitted to the culvert are kept to
a minimum. This will require that trafficking by
construction plant is not all in one direction and
that the compacted surface of the fill is kept as
near horizontal as practicable.
9.17 Compaction of the surround material shall
comply with the requirements given in Series 600
MCHW1 except that in some circumstances it may
be more economical to relax the requirement to
85% of the maximum dry density. (See Table 5.1.)
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Excavation and Filling
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10. HANDLING AND INSTALLATION
10.1 Structures must have enough rigidity to
permit practical handling and installation. For this
purpose a flexibility factor, F shall be calculated
from the formula:
F = S x 10
6
EI
where S = Span of the structure (m)
E = Modulus of Elasticity of steel
= 205 x 10 N/mm
I = Cross-sectional Moment of inertia
per unit length, (mm
4
/mm) of the
corrugated steel sheet about its
neutral axis, the section being
parallel to the length of the
structure. If the cross sectional
moment of inertia varies along the
length of the structure, the
minimum shall be used. The
re-rolled ends of helically wound
culvert lengths shall not be
considered to affect the value of I
to be used unless they extend for
more than 250mm at the end of
each length. The effect of the helix
angle of helically wound culverts
on I may be neglected.
10.2 For acceptable performance during
installation, the flexibility factor, (F) must be less
than a limiting value (F
max
), which depends on the
depth of corrugation (d
c
). For the purposes of this
Clause the depth of corrugation (d
c
) is defined as
the depth in millimetres from any peak to the
adjacent trough in the corrugation.
10.3 For circular structures, circular arches and
multi-radii structures with 1.3 >
r
r
c
t
> 0.7 where
r
c
is the corner radius and r
t
is the top radius, the
value of F
max
shall be calculated from the formula:
F
max
= 0.29 0.0034 d
c
but with a minimum of 0.115mm/N and a
maximum of 0.25mm/N. d
c
is defined in Clause
10.2.
10.4 For multi-radii structures with 0.7 >
r
r
c
t
> 0.2,
as defined in Clause 10.3 the value of F
max
shall be
calculated from the formula:
F
max
= 0.435 0.0051 d
c
but with a minimum of 0.173mm/N and a
maximum of 0.375mm/N. d
c
is defined in Clause
10.2.
10.5 If F F
max
the structure is acceptable. In the
case where F
max
< F the structure is not acceptable
and either the span S must be reduced, the flexural
rigidity EI must be increased or temporary
supports must be used. If temporary supports are
used (Clause 3.1b) then a temporary works design
is required to ensure local overstressing and
distortion of the corrugated steel is avoided. Partial
safety factors in Clause 3.10 (Table 3.1) shall be
used in conjunction with appropriate values of
f3
(Table 4.1).
Foundations for Circular Arches
10.6 The connection between the corrugated steel
plates and the reinforced concrete foundation is
normally achieved using a seating channel supplied
by the manufacturer. The seating channel shall be
capable of transmitting loads from the corrugated
steel plates into the foundation both during
construction of the structures and in service.
Reference shall be made to the requirements of
Clause 7.5.
Chapter 10
Handling and Installation
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November 2001
11. END TREATMENT
11.1 End treatments shall be included within the
designated outline as defined in SD4 (MCHW
0.2.4). All end treatments shall be designed in
accordance with Clauses 11.2 to 11.6 and regard
shall be paid to the aesthetic appearance of the
structure.
11.2 Reinforced concrete collars, headwalls, or
retaining walls shall be designed to support the
face edges of the corrugated steel where the skew
angle of the corrugated steel structure exceeds 15,
the bevel of square ends exceeds 2:1 (eg
embankment flatter than 1 in 2), or the cut end
supports highway loading. In these instances the
reinforced concrete elements shall be designed to
offer adequate support to the corrugated steel shell
where it is discontinuous and unable to act in ring
compression normal to the centre line of the
corrugated steel structure. The structural adequacy
of the corrugated steel plates is to be considered.
Structural steel ring beams, collars, and spreader
beams may be utilised, together with ties anchored
into the fill, and shall be designed to the
appropriate Standards. Reinforced concrete
elements shall be designed according to BS 5400:
Part 4 as implemented by BD 24 (DMRB 1.3.1).
Account shall be taken of the effects of the
construction sequence, loads from the corrugated
steel plates being directly supported, other loads
from the corrugated steel structure, the self weight
of the reinforced concrete, earth pressures, the
effects of ground creep and settlement, and
hydraulic loadings. Partial safety factors in Tables
3.1 and 4.1 shall be adopted as appropriate. If
temporary works are necessary the requirements of
Clause 10.5 shall be adopted.
11.3 In other instances the backfill and free edges
of other corrugated structures shall normally be
protected by end treatments such as headwalls or
collars. The loading considerations for the design
of the end treatment shall be the same as those
required in Clause 11.2.
11.4 Consideration should be given to the weight
of the wet concrete when forming the headwall,
ring beam or collar during construction. In some
circumstances, it may be necessary to install
temporary supports.
11.5 For hydraulic structures, measures shall be
taken to secure the metal edges at inlet and outlet
against hydraulic forces.
11.6 In the case of hydraulic structures, the
headwall, ring beam or collar shall be designed to
take into account the possible effects of scour of
the material beneath the invert of the structure.
11.7 The designer shall identify on the Contract
drawings any construction sequence assumed in
the design.
Chapter 11
End Treatment
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12. OVERLYING REINFORCED CONCRETE SLAB
12.1 Where the depth of cover measured from the
finished road surface to the crown of the structure
is less than the greater of span/5 or 650mm (Clause
1.3b), a reinforced concrete slab may be used
within the thickness of the carriageway pavement
above the corrugated steel culvert or underpass
with a reduced thickness of cover above the crown
of the structure. A minimum thickness of 150mm
of surround material (Clause 9.13, Class 6M in
Table 6/1 MCHW1) shall be placed and compacted
between the crown of the structure and the
underside of the slab.
12.2 The length of the reinforced concrete slab
shall be sufficient to extend beyond each side of
the structure for a distance of 3 metres or half the
span of the structure which ever is greater.
12.3 Where the carriageway pavement is
reinforced concrete, the slab may constitute the
concrete pavement continued over the crown of the
structure. In this case, the thickness of the slab
(minimum 200mm) and reinforcement shall be in
accordance with HD 26: Pavement Design (DMRB
7.2.3.)
12.4 Alternatively the concrete may form the
lower half of a composite pavement, normally
overlain by 100mm of flexible surfacing. Again
thickness and reinforcement shall be in accordance
with HD 26 or with BS 5400: Part 4 as
implemented by BD 24 (DMRB 1.3.1).
12.5 It is important to ensure adequate compaction of
the fill material under the ends of the slab to prevent the
formation of voids leading to the production of dynamic
load effects under trafficking.
Chapter 12
Overlying Reinforced Concrete Slab
12/1
Volume 2 Section 2
Part 6 BD 12/01
November 2001
13. CONCRETE INVERT PAVING FOR CLOSED
INVERT STRUCTURES
13.1 When a concrete invert paving in
accordance with Clause 8.14 is to be used, it shall
be as described in the following Clauses.
13.2 The concrete shall be Class 30/20 as
described in MCHW1 Series 1700.
13.3 The concrete invert paving shall be
reinforced with a steel fabric complying with
MCHW1 Series 1700 having mesh dimensions not
greater than 150mm x 300mm and a nominal wire
size not less than 5mm. All laps in the mesh shall
be at least 150mm. The steel fabric shall be
securely fixed to the structure by means of fixings
at the bolt positions. It shall extend to within a
distance not greater than 100mm, nor less than
40mm inside the edges of the concrete on each
side. A nominal cover of 45mm shall be provided
to all other faces, including that to the crest of the
corrugations in the structural steel.
13.4 The invert shall be cast in lengths not
exceeding 10 metres with the provision of a water
bar between adjacent panels and the joints sealed
with a joint sealant to Clause 2303 MCHW 1.
13.5 Prior to commissioning, a flaunch (mortar
slope) shall be applied at the plate/pavement
interface to seal gaps and avoid the problem of
standing water on ledges adjacent to the shell of
the CSBS.
13.6 At each end of the structure the concrete
invert paving shall be either:
a. Terminated with a toe that returns at least
200mm under the structural steel forming
the structure. The steel fabric shall be folded
under the lips of the structure to suit. The
toe shall be detailed with a thickness of not
less than that required for the paving, as
determined from Clause 8.14, or
b. Detailed to suit any headwall arrangement
eg paving reinforcement lapped with
headwall reinforcement.
13.7 All foreign matter, (but not any secondary
proprietary protective coating unless indicated
otherwise in the Type Approval Certificate or
British Board of Agrment (BBA), Roads and
Bridges Certificate referred to in Clause 1.6) and
free standing water shall be removed from the
surfaces to be paved, before commencing work.
Chapter 13
Concrete Invert Paving for Closed Invert Structures
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14. CARRIAGEWAY DRAINAGE
14.1 All measures shall be taken to avoid
contaminated carriageway water (impregnated with
road salts) collecting on the buried face of the
structure. In the vicinity of the structure,
carriageway drainage shall be constructed with
watertight joints and tested as described in the 500
Series MCHW1, and the trenches lined with a
heavy-duty impervious membrane prior to
backfilling. Carriageway drainage filter drains
(including fin drains), soakaways, and where
possible, gullies and chambers, shall not be sited
near the structure. A zone bounded by planes
projected at a slope of 1 horizontally to 1 vertically
from the extremities in plan of the structure will
normally be sufficient for these requirements.
14.2 Carriageway drainage outfalls shall be sited
downstream of the structure.
14.3 If, exceptionally, the requirements of
Clauses 14.1 and 14.2 are not achieved it shall be
assumed that contaminated water will affect both
the inner and outer faces of the corrugated steel
structure, giving rise to the surfaces being
classified for aggressive conditions in accordance
with Clauses 8.8 and 8.9.
Chapter 14
Carriageway Drainage
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Volume 2 Section 2
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15. MULTIPLE INSTALLATIONS
15.1 Adjacent structures shall be separated
sufficiently for mechanical equipment to operate
between them for adequate compaction. In the
absence of special measures, the spacing shall not
be less than:
circular structures i) up to 2m span - one
half of the span of the
larger structure or
600mm whichever is
greater.
ii) 2m to 8m span - 1m.
multi radii structures i) up to 3m span - one
third of the span of
the larger structure or
600mm whichever is
greater.
ii) 3m to 8m span - 1m.
Chapter 15
Multiple Installations
15/1
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16. TECHNICAL REQUIREMENTS AND DESIGN
CHECKLIST
16.1 The procedures to be followed when specifying a
proprietary manufactured structure are given in
Standard SD4 (MCHW 0.2.4). The particular
requirements for corrugated steel buried structures are
described here.
16.2 The Design Organisation, prior to inviting
tenders, normally submits an Outline Approval in
Principle containing a Schedule of Employers
Requirements which should include the following
information:
i. Location plan and name of structure.
ii. Environmental considerations (see clause 1.4).
iii. Long Section along centre-line of structure.
iv. Finished levels of carriageways and side slopes
within designated outline.
v. Skew of structure.
vi. Minimum width of structure.
vii. Minimum headroom of structure.
viii. Hydraulic requirements or clearance envelope, if
any, and requirement for invert protection.
ix. Gradient of invert.
x. End detail requirements, including any
requirement for reinforced concrete headwalls.
xi. Highway loading requirements.
xii. The value of constrained soil modulus M* to be
assumed for existing soil.
xiii. Allowable net bearing pressure for foundation
material.
xiv. The corrosivity (aggressivity) classification of
existing soil, ground water, contained water/
effluent, the atmosphere and of any fill material
(or silt) to be placed inside the structure in
contact with the corrugated steel. A drawing is
also required showing the corrosivity
classification for each surface type on the
structure on a suitably marked up cross section.
The extent of each surface type (including
maintained surfaces) shall be clearly indicated.
xv. Protection of structures against vehicle impact.
xvi. Public safety requirements including lighting and
protection for pedestrians round headwalls.
xvii. Aesthetic requirements including colour of
coatings.
xviii. Identification of any elements in addition to the
corrugated steel plating requiring design.
xix. Any other essential requirements.
Special requirements should be avoided. However
where the circumstances are such that they are justified
then care must be taken to avoid requirements
implicitly favouring the system of a particular
manufacturer.
16.3 Subsequent to the award of contract and prior to
the commencement of construction, the Contractor
normally completes the AIP form (containing the
Schedule of Employers Requirements), the design and
the design certificate, and submits these for approval/
appraisal. The full design normally contains the
following additional information relating to the
particular proprietary product which forms the basis of
the design. For bolted segmental structures the list
includes:
a. Structure Geometry:
- Structure type/shape
- Internal span
- Internal height
- Radii.
Chapter 16
Technical Requirements and Design Checklist
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b. Materials:
- Steel specification
- Corrugation dimensions
- Nominal thicknesses of steel and
galvanising
- Additional protective coatings (if any)
- Proprietary secondary protective coatings
(if proposed) - thickness and other relevant
details
- Invert protection system details - concrete
or proprietary system.
c. Bolts and Nuts:
- Specification
- Arrangement at joints
- Torque.
d. Footings of Circular Arches (if relevant):
- Geometry
- Concrete type
- Reinforcement
- Allowable net bearing pressure of
foundation material
- Means of connecting structure to footing.
e. End Treatment:
- Geometry
- Concrete type and reinforcement
(if required)
- Means of connection to structure.
f. Construction sequence.
g. Confirmation of foundation depth and material.
h. Internal fill in contact with wall of structure:
- Soil properties, bulk density, grading and
corrosion classification in accordance with
Chapter 8.
i. The current Type Approval Certificate and
current British Board of Agrment Roads and
Bridges or equivalent Certificate or Certificates -
as required in Clauses 1.6 to 1.9.
And for helically wound pipes:
a. Structural Geometry:
- Internal diameter.
b. Materials:
- Corrugation dimensions
- End corrugation dimensions
- Nominal thicknesses of steel and
galvanising
- Coupling band details
- Proprietary protective coatings (if
proposed) - thickness and other relevant
details
- Invert protection system details.
c. End Treatment:
- Geometry
- Concrete type and reinforcement (if
required)
- Means of connection to structure.
d. Construction sequence.
e. Confirmation of foundation depth and material.
f. Internal fill in contact with wall of structure:
- Soil properties, bulk density, grading and
corrosion classification in accordance with
Chapter 8.
g. The current Type Approval Certificate and
current British Board of Agrment Roads and
Bridges or equivalent Certificate, as required by
Clauses 1.6 to 1.9.
16.4 The Contractor shall additionally supply with his
design the following information relating to the design
requirements of the earthworks:
Lower Bedding Material:
- Constrained soil modulus (M*).
- Compaction (% of maximum dry density).
- Durability classification to Clause 8.8.2.
Surround Material:
- Constrained soil modulus (M*).
- Compaction (% of maximum dry density).
- Durability classification to Clause 8.8.2.
Chapter 16
Technical Requirements and Design Checklist
16/2
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November 2001
16.5 The further stages in the post award contract
procedures are given in Chapter 4 of Standard SD 4
(MCHW 0.2.4).
16.6 Following construction copies of the following
will be required for inclusion in the maintenance
manual and health and safety file:
1. The completed AIP used for design.
2. A set of as constructed drawings, including a
record of the final structure profiles achieved.
3. A design summary for information listed in
Clauses 16.3 and 16.4.
4. Other relevant information.
Chapter 16
Technical Requirements and Design Checklist
16/3
Volume 2 Section 2
Part 6 BD 12/01
November 2001
Chapter 17
References
17/1
17. REFERENCES
17.1 Design Manual for Roads and Bridges
Volume 1: Section 1 Approval Procedures
BD 2: Part 1 - Technical Approval of Highway
Structures (DMRB 1.1)
Volume 1: Section 3 General Design
BD 24: Design of Concrete Bridges. Use of
BS 5400 Part 4(DMRB 1.3.1).
BD 37: Loads for Highway Bridges
(DMRB 1.3)
Volume 2: Section 2 Substructures
BD 74 Part 8 Foundations (DMRB 2.1.8)
Volume 2: Section 4 Paints and other Protective
Coatings
BD 35 Quality Assurance Scheme for Paints
and Similar Protective Coatings
Volume 2: Section 4 Paints and other Protective
Coatings
BA 27 Quality Assurance Scheme for Paints
and Similar Protective Coatings
Volume 7: Section 2 Pavement Design and
Construction
HD 26: Pavement Design (DMRB 7.2.3)
Volume 10: Environmental Design.
17.2 Manual of Contract Documents for Highway
Works
Volume 0: Section 2 Implementing Standards
SD4 Procedures for Adoption of
Proprietary Manufactured Structures
(MCHW 0.2.4).
Section 3 Advice Notes
SA1 Lists of Approved/Registered
Products (MCHW 0.3.1)
Volume 1: Specification for Highway Works
HMSO 1998 (MCHW1) with revisions
to 2001
17.3 British Standards
BS 812: Part 117: 1988 - Method for
Determination of Water Soluble
Chloride Salts. Replaced by
BS EN 1744-1:1998 but remains
current
BS 1377: 1990 - Methods of Test for Soils for
Civil Engineering Purposes.
Part 2: Classification tests.
Part 3: Chemical and electro-chemical tests.
Part 4: Compaction-related tests.
Part 5: Compressibility, permeability and
durability tests.
Part 9: In-situ tests.
BS EN ISO 1461 1999. Hot dip galvanised coatings
on fabricated iron and steel articles
- Specifications and test methods.
BS EN 1744 Tests for chemical properties of
aggregate.
BS EN 1744-1 1998 - Chemical analyses
BS 7371: Coatings on metal fasteners
Part 1: 1991: Specification for general
requirements and selection
guidelines
Part 6: 1998: Specification for hot dipped
galvanised coatings
BS 5400: Steel, Concrete and Composite
Bridges.
Part 1 1988: General Statement.
Part 2: 1978: Specification for Loads.
Part 4: 1990: Code of Practice for Design
of Concrete Bridges.
BS 5930: 1981 - Code of Practice for Site
Investigations
BS 8002: 1994 - Earth Retaining Structures
BS 8004: 1986 - Foundations
BS EN ISO 9002: 1994. Quality Systems. Model for
quality assurance in production,
installation and servicing. (Formerly
BS 5750:Part 2).
BS EN 10142 2000. Specification for continuously
hot-dip zinc coated low carbon steel
strip and sheet for cold forming:
technical delivery conditions.
(Replaces BS 2989: 1982).
BS EN 10143 1993. Continuously hot-dip metal
coated sheet steel and strip.
Tolerances on dimensions and
shape. (Replaces BS 2989:1992)
17.4 Other Documents (reference number)
1. Poulos, H. G. and Davis E. B. - Elastic
Solutions for Soil and Rock Mechanics - John
Wiley and Sons, 1974, Chapter 6.
2. Vogel, A. I. - Vogels Qualitative Inorganic
Analysis - Sixth Edition (revised by G. Svehla) -
Longman, 1987 (pp 159 - 161).
Volume 2 Section 2
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November 2001 17/2
Chapter 17
References
3. Relative Values of Acid Deposition in the
United Kingdom 1986 - 1991 - available from
ADAS Consultancy Ltd, ADAS Bridgets,
Martyrs Worthy, Winchester, Hants SO21 1AP.
4. TRL Report 447 Sulfate specification for
structural backfills Reid J.M., M.A. Czerwko,
J.C. Cripps and D. M. Hiller, Transport Research
Laboratory, Crowthorne. (2001)
17.5 Bibliography
1. Meyerhof G. G. and Baikie L. D. - Strength of
Steel Culvert Sheets Bearing against Compacted
Sand Backfill Highway Research Board,
Research Record No. 30, 1963. HRB, 2101
Constitution Avenue, Washington DC 240418.
2. Bridge Foundations and Sub-structures,
Department of the Environment, Building
Research Establishment, London 1979: Her
Majestys Stationery Office.
3. BRE Special Digest SD1. Concrete in aggressive
ground. (2001).
Volume 2 Section 2
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November 2001 18/1
18. ENQUIRIES
All technical enquiries or comments on this Standard should be sent in writing as appropriate to:
Chief Highway Engineer
The Highways Agency
St Christopher House
Southwark Street G CLARKE
London SE1 0TE Chief Highway Engineer
Chief Road Engineer
Scottish Executive Development Department
Victoria Quay
Edinburgh J HOWISON
EH6 6QQ Chief Road Engineer
Chief Highway Engineer
The National Assembly for Wales
Cynulliad Cenedlaethol Cymru
Crown Buildings
Cathays Park J R REES
Cardiff CF10 3NQ Chief Highway Engineer
Director of Engineering
Department for Regional Development
Roads Service
Clarence Court
10-18 Adelaide Street G W ALLISTER
Belfast BT2 8GB Director of Engineering
Chapter 18
Enquiries
A1. The manufacturer or supplier will be required to
obtain from The Highways Agency of the Department
of Transport, Local Government and the Regions, a
Type Approval Certificate for any bolted segmental or
helically wound structure before it may be offered in a
tender. Separate Certificates must be obtained for
bolted segmental and helically wound structures.
A2. The following evidence and information is
required by Safety, Standards and Research, Civil
Engineering Division, The Highways Agency:
A.2.1. A full technical specification of the
product supported by two copies of the
Manufacturers Design Manual and any
relevant current British Board of
Agrment Roads and Bridges
Certificates or equivalent. In the case of
arch profile structures, the
arrangements to connect the corrugated
steel plates to the reinforced concrete
shall be fully described. In the case of
helically wound structures, a current
British Board of Agrment Roads and
Bridges Certificate is mandatory.
A.2.2. Confirmation that all the requirements
of this Standard are satisfied.
A.2.3. The minimum yield strength f
y
(N/mm
2
)
of the steel forming the structure.
A.2.4 The results of tests carried out to
determine the nominal seam strengths
(kN/m) to be used in the design of the
structure. These tests shall be carried
out and reported on as described in
Annex B.
A.2.5. A specification for the bolts and nuts
employed and the European or national
Standard(s) which they meet. The
recommended range of torque values
(kN.m) applied to the bolts shall be
stated.
A.2.6. The results of tests carried out to
determine the tensile strengths (kN/m)
of the lockseams in helically wound
corrugated steel. The lockseams tests
shall be able to withstand the forces as
described in Annex C.
A.2.7. Evidence that the manufacturer
operates a Quality Control System
conforming to BS EN ISO 9002:1994.
A.3. The continuing validity of the Certificate is
conditional upon an acceptable quality of workmanship
and materials being maintained and upon satisfactory
findings from checks and tests which The Highways
Agency or its authorised representatives will make from
time to time either on site or at the manufacturers
premises.
A.4. Any variation in the specification of a product
that has been submitted to The Highways Agency
should be notified immediately. Failure to do so may
result in the withdrawal of the Type Approval
Certificate.
A.5. Applications for Type Approval of bolted
segmental products from suppliers and manufacturers
should be made to The Highways Agency, Safety,
Standards and Research, Civil Engineering Division.
The basis for the granting of type approval of
corrugated steel buried structures by the Highways
Agency is:
A.5.1. Verification that the applicant has
submitted all the evidence required by
Clause A2.
A.5.2. Verification that the technical
specification of the product meets the
requirements of the Standard.
A.5.3. Verification that the requirements of the
Standard are met.
A.5.4. Verification that the stated minimum
yield strength is achievable for the steel
grade specified in the technical
specification of the product.
ANNEX A: PROCEDURE AND CONDITIONS FOR
OBTAINING A TYPE APPROVAL CERTIFICATE FOR
CORRUGATED STEEL BURIED STRUCTURES
Annex A
Procedure and Conditions for Obtaining A Type Approval Certificate for
Corrugated Steel Buried Structures
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A.5.5. Verification that the nominal seam
strength/bolt configuration has been
correctly derived in accordance with
Annex B following evaluation by The
Highways Agency, Safety, Standards
and Research, Civil Engineering
Division of the acceptability of the
seam strength test results in terms of
their technical reliability.
A.5.6. Verification that the nuts and bolts meet
the applicants stated national standard
and have been used in the tests in A.5.5.
above.
A.5.7 Verification that the manufacturer
operates a Quality Control System
conforming to BS EN IOS 9002: 1994.
A.6. Applications for Type Approval of helically
wound products from suppliers and manufacturers
should be made to The Highways Agency, Safety,
Standards and Research, Civil Engineering Division.
The basis for the granting of type approval of
corrugated steel buried structures by the Highways
Agency is:
A.6.1. Verification that the applicant has
submitted all the evidence required by
Clause A2.
A.6.2. Verification that the technical
specification of the product meets the
requirements of the Standard.
A.6.3. Verification that the requirements of the
Standard are met.
A.6.4. Verification that the stated minimum
yield strength is achievable for the steel
grade specified in the technical
specification of the product.
A.6.5. Verification that the lockseam strength
meets the requirements of Annex C. A
current British Board of Agrment
(BBA) Certificate or equivalent shall be
submitted to The Highways Agency,
Safety, Standards and Research, Civil
Engineering Division in accordance
with Clause 1.6.
A.6.6. Verification that the manufacturer
operates a Quality Control System
conforming to BS EN IOS 9002: 1994.
A.7. When all the above information has been
verified, a Type Approval Certificate is issued. All
corrugated steel buried structures which have been
given Type Approval are listed in Advice Note SA1
(MCHW 0.3.1 Annex B). Type Approval previously
granted is liable to be withdrawn at any time following
non-compliance with any of the requirements set out in
this Annex.
Annex A
Procedure and Conditions for Obtaining A Type Approval Certificate for
Corrugated Steel Buried Structures
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B.1. For bolted segmental structures, the manufacturer
shall submit to The Highways Agency of The
Department of Transport, Local Government and the
Regions the results of tests on longitudinal bolted joints
to determine the nominal seam strengths to be used in
the design of the structures. These will be required for
each combination of plate thickness and bolt
arrangement to be certified. The tests shall be
performed at a laboratory accredited by NAMAS or
equivalent, for the appropriate compression testing and
carried out in accordance with the procedures set out
below. Tests in accordance with national standards of
European Economic Area states which are equivalent to
the tests stated in this document will be deemed to be
acceptable.
B.2. Test Samples
B.2.1. For each plate thickness and bolt arrangement to
be tested, at least three samples, each with a
longitudinal seam across it, shall be prepared from
materials which are fully representative of the
manufactured product, except that the samples need not
have any protective coating. The samples shall be
formed from corrugated but uncurved steel plates and
each will include an even number of corrugations with a
minimum of two.
B.2.2. Two parallel flat end-plates are to be welded to
the two edges normal to the plane of the corrugated
plate, to act as compression bearing surfaces. The flat
end-plates shall be rectangular and shall extend at least
30mm in each direction beyond the welded ends of the
corrugated sample. The welded length shall not exceed
a distance of half the longitudinal bolt spacing beyond
the last bolt in each direction.
B.2.3. The sample shall be of sufficient length to allow
the permitted joint displacement without the corrugated
plates touching the opposite end plate and the weld.
B.2.4. The bolt arrangement shall be representative of
the joints proposed. The bolts shall be torqued to a
value agreed with The Highways Agency.
B.3. Test Procedure
B.3.1. The seam strength tests shall be undertaken by a
laboratory accredited by the National Measurement and
Accreditation Services, NAMAS, or equivalent to
undertake compression tests in the load range required
for the tests.
B.3.2. A compression testing machine of suitable
capacity and capable of applying the load at a uniform
rate and maintaining it during slipping of the joint shall
be used. It shall be equipped with bearing platens which
are to be at least as large as the sample. Any horizontal
movement of the sample shall be prevented. Unless the
machine can record both load and deflection, two dial
gauges reading accurately to 0.1mm shall be mounted
between the platens on either side of the sample and on
its longitudinal centre line.
B.3.3. The sample shall be placed in the machine so that
the applied load will not be eccentric to the sample. It
shall then be loaded in approximately 20 equally spaced
load increments which are to be determined on the basis
of previous experience. In the absence of such
experience, a trial test should be carried out.
Alternatively, when the load can be applied
automatically it shall be applied continuously with the
rate of deformation not exceeding 5mm per minute and
the load displacement recorded automatically.
B.3.4. Unless the load has been applied automatically as
described in B.3.3. above, a record of load and
deflection shall be taken and plotted, the deflection
being the average recorded by the two dial gauges.
B.4. Nominal Seam Strength
B.4.1. The seam strength for each sample tested shall be
determined from the least of the following:
i. The load (kN) recorded at failure,
ii. The load (kN) corresponding to a joint
displacement in the direction of loading equal to
the lesser of the amplitude of the corrugation or
40mm,
iii. Three times the load corresponding to one third
of the displacement at failure.
B.4.2. The nominal longitudinal seam strength (kN/m)
of a particular combination of plate thickness and bolt
arrangement shall be taken as the average of three seam
strength test results, provided the lowest value is within
ANNEX B: LONGITUDINAL SEAM STRENGTH FOR
BOLTED SEGMENTAL STRUCTURES
Annex B
Longitudinal Seam Strength for Bolted Segmental Structures
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10% of the highest. Results from samples that fail by
shearing of the bolts shall not be allowed.
B.5. Reporting of Test Results
The manufacturer shall submit to The Highways
Agency a report prepared by the testing establishment
giving the following details:
NAMAS Accreditation Certificate or equivalent for
compression testing in the range required.
Sample identification marks and numbers.
Statement of test procedure.
Plate thickness and corrugation details.
Bolt type, size and arrangement and strength
designation.
Method of forming the bolt holes and hole size.
Plot of load against displacement for each test.
Description of the mode of failure for each test.
Ultimate load and corresponding displacement for each
test.
Load at displacement equal to the amplitude of the
corrugation or 40mm (as appropriate).
Proposed nominal seam strength (kN/m) for each
corrugation/bolt arrangement.
Photographs of each test sample after failure.
B.6. Retention of Samples
After testing the samples shall be retained by the
manufacturer for a period of at least three months
following receipt by The Highways Agency of the
report required by Clause B.5. The samples shall be
stored in such a way that they can be readily inspected
if required.
Annex B
Longitudinal Seam Strength for Bolted Segmental Structures
B/2
C1 Lockseams shall be able to withstand tensile forces across the seam, according to steel sheet thickness, as
tabulated below:
Nominal Sheet Thickness Minimum Tensile
(mm) Force across Seam
(kN/m)
1.00 36
1.30 51
1.60 65
2.00 88
2.80 136
3.50 182
4.20 234
For intermediate sheet thicknesses, the minimum tensile force required may be determined by linear interpolation.
ANNEX C: SPECIFICATION FOR TENSILE
STRENGTH OF LOCKSEAMS IN HELICALLY
WOUND CORRUGATED STEEL STRUCTURES
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November 2001
Annex C
Specification for Tensile Strength of Lockseams in Helically Wound
Corrugated Steel Structures