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September 2008

Process Industry Practices Civil

PIP CVE02350 Roadway Design Guide

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time.

Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes, overlays, addenda, or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP.

PRINTING HISTORY September 2008 Issued Not printed with State funds

September 2008

Process Industry Practices Civil

PIP CVE02350 Roadway Design Guide

Table of Contents 1. Introduction................................. 3
1.1 Purpose............................................ 3 1.2 Scope ............................................... 3 6.4 Vertical Alignment .......................... 13 6.5 Horizontal and Vertical Clearances..................................... 14 6.6 Guardrails and/or Guard Posts ...... 14 6.7 Pavement Marking/Signage........... 14

2. References .................................. 3
2.1 Process Industry Practices .............. 3 2.2 Industry Guides and Standards ....... 3

7. Paving/Roadway Design.......... 15
7.1 7.2 7.3 7.4 Paving System Selection ............... 15 Flexible Pavement ......................... 16 Rigid Paving................................... 24 Alternative Surface Treatment for Vehicle Traffic Area........................ 26 7.5 Paving Over Low-Strength Soils.... 28

3. Definitions ................................... 4 4. Roadway Classifications ........... 5

4.1 4.2 4.3 4.4 4.5 General ............................................ 5 Primary Roadways........................... 5 Secondary Roadways ...................... 6 Tertiary Roadways ........................... 6 Construction and Heavy Haul Roadways ........................................ 6 Right-of-Way .................................... 7 Access to Public Roadways............. 7 Materials........................................... 9 Climate ............................................. 9 Traffic Loading ............................... 10

8. Drainage Considerations......... 29
8.1 8.2 8.3 8.4 8.5 8.6 8.7 Roadway Drainage ........................ 29 Culverts .......................................... 29 Ditches ........................................... 31 Curbs, Gutters and Inlets ............... 32 Headwalls ...................................... 33 Pipe Crushing Strength.................. 33 Pipe Loading .................................. 35

5. General Design Considerations 7

5.1 5.2 5.3 5.4 5.5

9. Crossings.................................. 39
9.1 Railroad Crossings......................... 39 9.2 Pipeline Crossings ......................... 39

6. Layout and Traffic Control....... 10

6.1 General .......................................... 10 6.2 Traffic Flow..................................... 10 6.3 Plant Roadway Turning/Layout/Grades .................. 10

10. Typical Details .......................... 40

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CVE02350-01 Typical Roadway Sections at Cut and Fill CVE02350-02 Guard Rail Assembly CVE02350-03 Guard Rail Details CVE02350-04 Guard Posts CVE02350-05 Headwalls CVE02350-06 Headwalls with Wing Walls CVE02350-07 Typical Roadway Clearance Envelope CVE02350-08 Roadway Contraction Joint CVE02350-09 Roadway Doweled Expansion Joint CVE02350-10 Roadway Doweled Construction Joint CVE02350-11 Roadway Doweled/Keyed Joint

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1.1 Purpose This Practice provides guidance and recommended procedures for the layout and design of roadways inside plant boundaries and for access to a plant facility. 1.2 Scope This Practice describes roadway classifications and provides guidance for design of rightof-ways, access to public roads, use of local materials, climate effects, traffic loading, layout and traffic control, design of paving and roadways, providing drainage, and providing railroad and pipeline crossings for roadways within plant boundaries and for access to a plant facility.


Applicable requirements of the following Practices, and industry codes and standards, and references should be considered an integral part of this Practice. The edition in effect on the date of contract award should be used, except as otherwise noted. Short titles are used herein where appropriate. 2.1 Process Industry Practices (PIP) PIP CVS02350 Roadway and Area Paving Construction Specification PIP CVS02700 Underground Gravity Sewers Specification PIP PNE00003 Process Unit and Offsites Layout Guide PIP STS03001 Plain and Reinforced Concrete Specification PIP CVI02000 Civil General Notes and Typical Details 2.2 Industry Guides and Standards

AASHTO (American Association of State Highway and Traffic Officials) Guide for Design of Pavement Structures A Policy on Geometric Design of Highways and Streets

American Concrete Institute (ACI) ACI 302.1R Guide for Concrete Floor and Slab Construction ACI 504R Guide to Joint Sealants for Concrete Structures

ASTM International (ASTM) ASTM C76 Standard Specification for Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe ASTM D1195 Standard Test Method for Repetitive Static Plate Load Tests of Soils and Flexible Pavement Components, for Use in Evaluation and Design of Airport and Highway Pavements ASTM D1196 Standard Test Method for Nonrepetitive Static Plate Load Tests of Soils and Flexible Pavement Components, for Use in Evaluation and Design of Airport and Highway Pavements

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ASTM D1883 Standard Test Method for CBR (California Bearing Ratio) of Laboratory-Compacted Soils ASTM D2844 Standard Test Method for Resistance R-Value and Expansion Pressure of Compacted Soils

Federal Highway Administration (FHWA) Manual on Uniform Traffic Control Devices (MUTCD) Protocol P46 Long-Term Pavement Performance (LTPP)


asphalt concrete: High-quality, thoroughly-controlled hot mixture of asphalt cement and wellgraded, high-quality aggregate, thoroughly compacted into a uniform dense mass base course: A layer of well-graded granular material that supports the paving and distributes wheel loads over a greater area of the subgrade binder course: For a multi-layered paving system, a layer directly below the wearing course, and composed of intermediate-sized aggregate with a lesser amount of asphalt than the wearing course geogrid: High tensile strength polymer material designed with transverse and longitudinal grids. Laid directly on the subgrade, the grid geometry provides a mechanism for interlocking aggregate base or subbase material placed on the geogrid. The interlocking prevents lateral movement of the aggregate and improves load distribution to the subgrade. geotextile: Polyester fabric material laid over subgrade materials directly below an aggregate subbase. It maintains separation of subbase from subgrade. Geotextile is permeable, allowing pore water to pass vertically through the fabric. owner: The party who owns the facility wherein the roadway will be constructed paved surface: Reinforced or asphaltic concrete that distributes the load to base and subbase, seals against penetration of surface water or liquids, resists abrasion, and provides traction plant boundaries: The delineation between areas accessible to the general public and areas where access is controlled by the plant subbase: A compacted layer of well-graded fill that may be required under the base course. Typically provided over fine grained subgrade soils to improve drainage, resist frost heave, provide structural support by distributing loads, and to prevent pumping of finer grained soils into the base material at paving joints and edges. subgrade: Foundation soil placed and/or compacted during the rough grading work. Typically consists of natural soils found on site, unless soil strength is inadequate and imported soils are required. wearing course: A layer of fine aggregate or course sand held by an asphalt binder and designed to resist wear from traffic. The layer which directly supports traffic.

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Roadway Classifications
4.1 General 4.1.1 All major plant areas should be accessible by primary roads from two opposite sides minimum and preferably all around to provide adequate access for firefighting and other emergency equipment. As a minimum, a tertiary road around the plant should be considered. Plant areas containing process equipment should be accessible for plant maintenance activities. Roadways to these areas should be designed to permit access for the largest required maintenance equipment. Roadway design requirements within plant boundaries should be specified by owner and are typically unregulated by governmental agencies. Type of roadway pavement is defined based on traffic, load, weather, air and ground pollution controls, cost, etc. It includes paved roads such as asphalt and concrete and unpaved roads such as gravel. This guide focus is on paved roads.


4.1.3 4.1.4


Primary Roadways 4.2.1 Within Plant Boundaries Primary roadways provide access to product shipping and receiving points and sufficient space for major maintenance vehicles to pass. Primary roadways include all roads typically used by large trucks and cranes. Vehicle velocities are normally set by owner and are posted 30 mph or less. Roadways with high volume truck traffic (e.g., between main shipping and receiving docks) may require a greater than typical radius and should also be designed for loadings in accordance with AASHTO Guide for Design of Pavement Structures, and the local state highway design manuals for the applicable locale. Primary roadways typically have two 10 to 12 ft wide lanes with 3 ft shoulders. Primary roadways are typically paved. AASHTO, A Policy on Geometric Design of Highways and Streets, categorizes functional systems for travel movement. Although rural and urban areas differ in travel volumes and percentage of road length comprising each functional system, the broad categories share common traits. Public primary roadways generally are included in the arterial functional category either principal or minor. There can be some component of the lower hierarchy collector functional category included also. Typically, primary roadways in urban and rural areas include principal state highways, interstates, and routes providing higher levels of mobility between major population centers. 4.2.2

Urban and Rural Areas (Outside Plant Boundaries)

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The roadways are characterized by strict design and safety standards. Typically, states limit vehicle widths to 8 ft without permit. Height restrictions typically range from 12.5 to 14 ft. A nominal 12 ft wide lane is typical for general use. A 6 to 10 ft shoulder can be required depending upon surrounding terrain. Design of public primary roadways is seldom required for plant facilities. However, a project may include connecting a plant roadway to one of these roadways. Appropriate AASHTO documents should be consulted for further guidance.


Secondary Roadways 4.3.1 Within Plant Boundaries Secondary roadways provide access to equipment within plant areas by maintenance vehicles (except cranes) and personnel vehicles. Typically, vehicle velocities are set by owner and are posted 15 mph or less. Secondary roadways typically have one or two 10 ft wide lanes. Secondary roadways may or may not be paved depending on loading conditions and other considerations such as dust control and drainage. 4.3.2 Urban and Rural Areas (Outside Plant Boundaries) AASHTO functional categories included in the public secondary roadway classification are collector roads, local roads and streets, and roads that provide access between a primary roadway system and land use. Typically, secondary roadways have lower traffic volumes and vehicle velocities. Secondary roadways typically provide access to a facility. Pavement structures and geometric considerations are not as stringent as for primary roadways and can provide limited through-traffic accessibility. Design of public secondary roadways should be in accordance with local, state, and federal requirements. Appropriate AASHTO documents should be consulted for further guidance.


Tertiary Roadways 4.4.1 4.4.2 4.4.3 Typically, tertiary roadways provide occasional access to areas of a facility for maintenance, security, and firefighting vehicles. Tertiary roadways may have one or two lanes and be up to 20 ft wide, with or without shoulders. Tertiary roadways may or may not be paved.


Construction and Heavy Haul Roadways 4.5.1 4.5.2 Construction and heavy haul roadways provide greater than typical load capacity and have specialized service conditions. These roadways may be temporary or permanent.

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Composition of these roadways can range from a stabilized earth surface prepared by reshaping and compacting native soil to a high-quality subgrade with several layers of engineered base and subbase courses and pavement. Service life, maximum grade, clearances, turning points, load and unloading points, drainage, and environmental impact on the surrounding areas (e.g., surface drainage, noise, dust, etc.) should be considered in the initial layout of these roadways.



General Design Considerations

5.1 Right-of-Way 5.1.1 Within Plant Boundaries Right-of-way considerations are defined by owner. If the owner has sold or leased part of a plant facility to another entity, an easement condition can exist that includes sharing plant roads. 5.1.2 Outside Plant Boundaries Local, state, and federal right-of-way requirements apply to plant boundaries that border roadways outside plant boundaries and access points to the roadways. The right-of-way is acquired by the governmental authority through direct purchase or eminent domain with compensation. The right-of-way width is typically sufficient to accommodate the ultimate planned roadway including the traveled way, shoulders, medians and borders. 5.2 Access to Public Roadways 5.2.1 General Design of roadways within plant property boundaries is typically unencumbered by regulation and should be performed and executed with good engineering practices specific to a plants mobility needs and safety requirements. Movement of people, products and material across plant property boundaries requires interaction with adjacent property owners or authorities and entities vested with the power to regulate or control waterway usage, rail and pipeline systems, utilities, and roadways. Consideration of access to public roadways is important for the design of a new plant and can also be important for a major project at an existing plant. 5.2.2 Effects of Plant Activities Plant facilities can be heavy traffic generators and adequate access to a local roadway system during normal operating/production periods and for major onsite construction projects is important to a plants success.

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September 2008 Plant shift changes can place a heavy, short-term demand on a local roadway system two or more times a day. Outbound and inbound shipping of products, supplies and feed stocks by truck requires special consideration regarding access to local roadway systems. Because of additional transportation for craft workers and other project team members, increased truck traffic for delivery of equipment and materials, and traffic from permit loads for equipment and construction material, plant construction projects can affect local traffic conditions. Controlled and adequate access to local streets and highways during major construction projects requires early team planning and may require investment in new road access points. 5.2.3 Regulation of Access Control of access points is a method used by regulators to manage the quality of a roadways mobility, capacity, potential for collisions, and access for adjacent land use. Methods used by governmental authorities for controlling access points to public streets and roadways include the following: a. Regulations - Ordinances at the local level b. Eminent Domain - A way for the government to purchase property for public roads. Property owners are compensated for the property taken; however, property owners may donate land for right-of-way if they can benefit from a road project or from having new or additional access to a road. Long term planning is an essential aspect of access management and the principles and policies adopted by regulators are defined for an entire system that includes the roads and local land use that generates travel. Regulators are typically required to provide reasonable access, although not necessarily direct access, to roads from adjacent property. 5.2.4 Design of Access Points An owner typically employs a consultant with expertise in traffic impact studies to perform the necessary studies, prepare the reports required by the regulating authority, and assist the owner with the permitting process. A consultant may also be engaged to design the traffic controls and improvements at the access points. The roadway design from the access point interface to the plant boundary can then be performed. Connection from a public access point to a plant boundary can vary from a parking lot driveway to a multi-lane road with length measured in miles. The connection typically occurs on land owned by the plant. Depending on which public entity has jurisdiction at the access point, local, state, or federal regulations should be consulted for the design of the alignment, signage, road markings, etc.

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PIP CVE02350 Roadway Design Guide Expected plant traffic volume and generated loads should be determined to complete the pavement and drainage design to the plant boundary. 5.2.5 Plant Entry Permanent parking facilities for plant employees and visitors are typically located outside the plant fence. Permanent security facilities to enter a plant from the parking area are typically required and may consist of badge controlled turnstiles for pedestrians and checkpoint shelters occupied by security staff for vehicular access. Truck weigh stations are often required at plant vehicular entrances. Temporary parking and security facilities for construction projects may be required to be located on available plot space within the plant fence. 5.2.6 Easements Plant boundaries may be adjacent to or include dedicated easements or right-of-ways for drainage, utilities, pipelines and railroads. New plant roadways can be required to cross or run parallel to these easements. Design interfaces with one or more entities that own or regulate easements may be required in order to protect their facilities from new traffic loads. If more than one entity is involved, it can be challenging to resolve multiple requirements. Resolutions of easement concerns can involve the following items that are typically paid for by the plant owner: a. Raising or rerouting overhead lines b. Providing protective sleeves for pipelines c. Installing culverts or bridges for ditches d. Improving traffic crossings for railroads 5.3 Materials 5.3.1 The suitability of locally available materials for roadway construction should be investigated. A good source of information is a geotechnical consultant with knowledge of materials in the area. A geotechnical consultant can provide recommendations regarding the following: a. Stabilization of in situ soils b. Replacement of in situ soils with suitable borrow materials c. Economical specifications for base materials 5.4 Climate 5.4.1 5.4.2 Rainfall and temperature extremes should be considered for both the design and construction phases of roadway projects. Rainfall runoff totals affect drainage design and construction schedule.


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5.4.3 5.4.4 5.5

Cold weather affects the installation of concrete and asphalt surfaces. Asphalt may not be available in colder climates during part of the year. For hot weather, special provisions for placing concrete can be required.

Traffic Loading 5.5.1 5.5.2 Design loading criteria should be established for a roadway project. A standard highway loading frequently used in design is AASHTO HS-20. The HS-20 live load corresponds to a maximum truck wheel load of 16,000 lb per 200 sq in or 11,520 psf at the surface. Special loads from delivery of heavy equipment should be considered. For design of haul roads, type of transport equipment and frequency of travel should be considered.

5.5.3 5.5.4


Layout and Traffic Control

6.1 General 6.1.1 Layout for a roadway within a plant should be in accordance with the plant grid system and the established plant coordinate system for horizontal and elevation control (e.g., Horizontal Control Plant Datum and Plant Elevation). Layout for a public roadway should be in accordance with the governing guidelines. Grading plans should minimize the quantity of earthwork. If only on-site materials are used for grading, cut and fill volumes should be calculated to try to achieve a reasonable balance after the initial clearing, grubbing and stripping.

6.1.2 6.1.3


Traffic Flow 6.2.1 6.2.2 6.2.3 Traffic flow within plant boundaries is typically limited to low volume, low speed vehicles, trucks, and construction and maintenance equipment. Emergency vehicle access and flow to the most critical sites of a plant should be considered. If truck loading/unloading is an essential part of the day-to-day plant operations, the daily delivery traffic flow should be considered in the roadway layout. Security, truck staging space, and loading/unloading operations should be considered.


Plant Roadway Turning/Layout/Grades 6.3.1 Minimum Turning Radius Minimum turning radii at road intersections and curves should be based on the turning requirements of vehicles that are expected to use the roadway regularly. Figure 1 shows the critical turning dimensions for common types of vehicles. For turning dimensions of other types of vehicles, see AASHTO A Policy on Geometric Design of Highways and Streets.

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Road Cross Section To prevent major process spills from flowing into adjacent areas, centerline elevations of roadways within plant boundaries should be 6 inches minimum above the high point of adjacent finished grades or high points of adjacent process units. Slope from the crown of a typical road section should be 2% for the lanes and 4% for the shoulders. For parking or wider areas, the minimum slope should be 1%. Typical lane and shoulder widths are shown in Table 1. Shoulder widths should be added to the lane(s) width to obtain total roadway width. See drawing CVE02350-01 for typical details of road sections at cut and fills.

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2-AXLE-TRUCK OR BUS (33' LONG ) 3' 4' 24' 12.5' 40.0' 19.3' 0.8'



" "C
" "B









4' 42.0' 28.3' 1.5'





3' 45.0' 17.0' 0.7'


Figure 1 Turning Radius for Passenger Car and Common Trucks Table 1 Typical Lane and Shoulder Widths Plant Road Type Primary Roads Secondary Roads Tertiary Roads Lane Width 10 - 12 ft 10 ft 8 ft Shoulder Width 3 ft 3 ft 2.5 ft

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Vertical Alignment 6.4.1 Gradients Maximum and minimum vertical gradients along a roadway alignment or across a paved area are shown in Table 2. If possible, vertical gradients should be kept near the minimum value shown in Table 2. For areas subject to ice and snow conditions, the vertical gradient should be 5% maximum.
Table 2 Vertical Gradients Type Primary Roads Secondary Roads Tertiary Roads Access ways (Ramps) Paved Parking / Paved Setback Areas Paved Areas Unpaved Areas Maximum 5.0% 7.5% 10.0% 10.0% 3.0% 6.0% 1.5% Minimum 1.0% 1.0% 1.0%


Curves Vertical curves provide a gradual transition between two intersecting tangent grade lines. The types of vertical curves are sag and crest. Each curve type has three subsets depending on the signs and relative magnitudes of the tangent gradient lines. The typical sign convention is positive for grades ascending forward and negative for grades descending forward. Algebraic change in gradient and stopping sight distance are the important parameters for vertical curve design at typical plant vehicle speeds. For example, at 20 mph, the AASHTO recommended stopping sight distance is 115 ft. The minimum recommended curve length for a 5% change in gradient is 35 ft for a crest curve and 85 ft for a sag curve. These lengths include factors for height of eye and the object sighted that would permit 115 ft stopping sight distance. Vertical curves should be provided for hard surfaced roads having a change in vertical alignment greater than 3% at typical low plant speeds. Vertical curves are designed parabolic with length measured as the horizontal projection of the curve, and are typically designed symmetrical with tangents of equal length. See AASHTO, A Policy on Geometric Design of Highways and Streets, or route design textbook for additional geometric design information.

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Horizontal and Vertical Clearances 6.5.1 A horizontal clearance of 5 ft minimum should be maintained between the extreme edge of roadway or face of curb and any structure projecting above adjacent grade including parallel fence lines and pipe rack columns. Owner should be consulted for special requirements that can dictate specific clearances. Minimum vertical clearances are shown in Table 3. See drawing CVE02350-07 for roadway design clearance envelope. See PIP PNE00003, Table 4, for additional minimum clearance requirements.
Table 3 Vertical Clearances Description Clearance over primary access roads where major maintenance vehicles are expected to pass Clearance over secondary and tertiary access roads Clearance to electrical transmission and distribution lines Minimum Clearance 18-0

6.5.2 6.5.3 6.5.4

10-0 22-0


Guardrails and/or Guard Posts 6.6.1 6.6.2 6.6.3 6.6.4 Guardrails and/or guard posts should be provided to protect equipment and/or structures that are not provided with the minimum horizontal clearance. Horizontal clearances for guardrails and guard posts should preferably be 2 ft minimum from outer edge of shoulder. Special hazards that have the minimum clearances can still require protection with guardrails or guard posts. See drawings CVE02350-02 to -04 for typical details for guardrail and guard posts.


Pavement Marking/Signage 6.7.1 Pavement marking and signage within plant boundaries are typically limited to road names, speed limits, stop signs, clearance signs, railroad crossings, and evacuation routes. For designating traffic control devices, pavement markings and signage within and outside plant boundaries, see FHWA Manual on Uniform Traffic Control Devices (MUTCD).


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Paving/Roadway Design
7.1 Paving System Selection 7.1.1 Types Typically, two types of paving systems are used for roadways: flexible and rigid. See example configurations in Figure 2. Flexible paving is composed of material such as asphaltic concrete, and relies on a relatively thin paving (e.g., 2 to 4 inches thick) in combination with layers of base and subbase material to distribute vehicle loads. Rigid paving is composed of material such as portland cement concrete which has low flexibility and is capable of distributing wheel loading over a wide area of subgrade. The relative costs of asphaltic concrete and portland cement concrete paving vary considerably between geographic locations. Typically, the initial cost of portland cement concrete is higher (30 to 50% in some cases) than asphaltic concrete paving. However, studies of state and federal highway records by the Portland Cement Association have shown that portland cement concrete paving has a lower total cost of ownership than asphaltic concrete paving.




Figure 2 Examples of Flexible and Rigid Paving


Advantages/Disadvantages Flexible Paving

1. Advantages of flexible paving may include the following: a. Surface can be more easily shaped to specified slopes. b. Greater flexibility permits adjustments to subgrade changes. c. Repairs can be made more easily. d. Subsurface lines can be accessed more easily.

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2. Disadvantages of flexible paving may include the following: a. Hydrocarbons can damage the paving. b. Heavy concentrated wheel loads can more easily damage the surface. c. During hot weather conditions, heavy wheel loads can cause surface distortion. d. Less durable, requiring more maintenance over time Rigid Paving

1. Advantages of rigid paving may include the following: a. Surface is hard wearing. b. Hydrocarbon leaks or spills cannot damage the paving. 2. Disadvantages of rigid paving may include the following: a. Unstable subgrades can cause poor performance of the paving. b. Differential settlement can cause cracking of the pavement. c. Repairs can be difficult and expensive. d. Special joints are required to control the location of cracks, provide relief from expansion, and provide for construction joints. 7.2 Flexible Pavement 7.2.1 Asphalt Terminology Following are definitions of terms used for various aspects of asphalt paving components and construction: a. Asphalt pavement structure: Combination of asphalt courses and asphaltaggregate or untreated aggregate courses, placed above the subgrade b. Full-depth asphalt pavement: Pavement in which asphalt mixtures are used for all courses above the subgrade c. Asphalt prime coat: Spray application of low-viscosity asphalt emulsion to an untreated base to bind the granular material to the asphalt layer d. Asphalt tack coat: Spray application of asphaltic material to existing pavement (e.g., portland cement or old asphalt) to insure bond between superimposed material and existing surface e. Asphalt seal coat: Thin asphalt surface treatment used to waterproof and improve the durability of an existing surface f. Emulsified asphalt: Fine droplets of asphalt suspended in water used for road construction, sealing and surface treatments, and patching mixes. Droplets are held in suspension for a long time because of emulsifying agents. The material can be handled with little or no heat. The following types are available: rapid setting, medium setting, and slow setting.

g. Liquid asphalt or cutback asphalt: Uses solvents to thin the asphalt to enable handling at lower temperatures. Naphtha-type, kerosene-type, and light oil

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solvents are used to produce rapid, medium, and slow curing asphalt materials, respectively. Because of environmental concerns, federal and state regulations either severely restrict or prohibit the use of liquid asphalt. Liquid asphalts have typically been replaced by emulsified asphalts. h. Asphalt cold mix: Mixture of unheated mineral aggregate and emulsified asphalt. May be produced in stationary plants with close control of the production process or mixed in place. Spreading and compaction is performed with conventional equipment. 7.2.2 Basic Design Concepts for Asphalt Paving General

1. Industry-wide standard design criteria cannot be applied to asphalt paving because of the following reasons: a. Major environmental characteristics can impact the strength and performance of subgrade materials. AASHTO has subdivided the continental U.S.A. into six climatic regions for various combinations of environmental characteristics (e.g., freeze/thaw cycling, wet, dry, hard freeze, and no freezing). b. Materials of construction vary widely. In some locations the highest quality aggregate is readily available, whereas it may be prohibitively expensive in others. c. Asphaltic concrete mixes should be based on local and state highway department specifications. Locally specified mixes are what local asphalt mixing plants are prepared to provide, and the local mixes are expected to be designed in accordance with local requirements. 2. Knowledge of local paving practices can be developed from the following sources: a. District office for the state department of highways b. County or city offices responsible for public roadways c. Local geotechnical engineers d. Asphalt plant operators and paving contractors e. Personal observation of local roads under equivalent service These sources should provide a sound basis for making decisions about materials, design criteria, and installation procedures for achieving quality paving at reasonable cost. Subgrade Strength Evaluation

1. General a. Thickness requirements for asphalt pavements depend mainly on the strength requirements of the finished subgrade. b. For a project with significant paving requirements, with heavy vehicle loading, and no directly relatable paving experience for the site, subgrade evaluation should be included as part of other

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geotechnical studies. Because stability of the subgrade is closely related to its density and moisture content, subgrade soil testing should be performed as near as possible to anticipated in-service conditions. c. Frequently, because of the typical nature and intended use of a specified paving and available knowledge and experience with the local subgrade materials, paving design can be performed with confidence without a site specific subgrade evaluation. d. If testing is required to evaluate the strength of the subgrade, the following tests can be used for determining in-place base and subbase strengths: (1) Plate Bearing Test (2) California Bearing Ratio Method (3) Resistance Value Method (4) Resilient Modulus Method Results from any of the four testing methods cannot be converted to equivalent values of another method. 2. Plate Bearing Test a. The Plate Bearing Test, in accordance with ASTM D1195, can be used for subgrade evaluations, and for strength measurements for subbase, base, or finished pavement. b. The test procedure involves loading a 6- to 30-inch diameter test plate on top of the surface of the materials. The deflection and rebound are measured at the plate and at distances up to 1.5 times the diameter from the edge of the plate. 3. California Bearing Ratio (CBR) a. The CBR test, in accordance with ASTM D1883, consists of measuring the load required to cause a plunger of standard size to penetrate a soil specimen at a specified rate. b. The CBR rating is the resultant of the CBR test expressed as a percentage of the load for the same test performed on a standard sample of crushed rock. 4. Resistance Value (R-Value) Method a. The R-Value Method, in accordance with ASTM D2844, is a two-test procedure as follows: (1) A resistance value test determines the thickness of a pavement structure required to prevent plastic deformation of the soil under imposed wheel loads. (2) An expansion pressure test determines the thickness or weight of cover required to maintain the compaction of the soil. b. The design R-Value is determined from the moisture content and density where the thicknesses from the two tests are equal.

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5. Resilient Modulus (Mr) Method a. The Mr Method, in accordance with FHWA Protocol P46, determines the resilient modulus of untreated fine-grained subgrade soils for conditions that are representative of stresses in pavements subjected to moving wheel loads. b. The Mr Method involves testing of soils in a triaxial chamber, subjected to repeated loads of fixed magnitude, frequency, and load duration. 7.2.3 Paving, Base, and Subbase Thicknesses See Table 4 for guidelines for estimating paving and base and subbase thicknesses for three types of subgrade materials, and five types of service and traffic requirements for roadways. The guidelines in Table 4 are based on untreated aggregate bases. An alternative design, using asphalt mixtures for base or subbase courses, can resist pavement stresses better than un-bonded aggregate layers which have no tensile strength. Consequently, wheel loads are spread over broader areas using the alternative design and less pavement thickness is required. The guideline thicknesses shown in Table 4 are based on a relatively dry and non-freezing location. See Table 5 for a relative comparison of roadbed soils that shows the impact of various climates on design requirements. Relatively poor subgrade soils can be treated in about the same manner regardless of the climatic conditions at a particular site. For fair subgrade soils, additional base and/or subbase thicknesses are probably required for more severe climates. For good subgrade soils, climate becomes a more important consideration. Good subgrade soils in locations subject to hard freezes can be expected to perform no better than fair subgrade soils in areas without freezing. For example, good subgrade soils in Wyoming should be downgraded to fair if using Table 4. Subbase and base thicknesses should be adjusted accordingly. If the depth of frost penetration is greater than the total thickness of a subbase, base, and pavement system, the subbase thickness should be increased until the total system thickness equals the frost depth or 18 inches whichever is less. Considering the total pavement structure, it should be understood that there is not a single unique design solution. Instead, there are many combinations of paving, base, and subbase that can provide satisfactory results. The combination selected should be based on cost, construction, and maintenance considerations.

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Table 4 Thicknesses for Untreated Aggregate Bases

Subgrade Soils Typical Evaluation Values Relative Quality GOOD Coarse-grained soils (well-graded) Gravel, sand w/limited clay binder FAIR Coarse-grained soils (poorly-graded) Sands, and sand/clay mixtures POOR Fine-grained soils Plastic, high shrinkage and expansion, low-permeability CBR

Approximate Thickness (in) Traffic Volume Trucks Cars

Pavement (Note 1)

Resist. Mod. (Mr)

12,000 psi

>500 Unlimited

<500 Unlimited

<50 <2000

<20 <300

<5 <50

Base & Subbase (Note 2) 20-40 5,500 psi Pavement (Note 1)

Base & Subbase (Note 2) 4-20 3,000 psi Pavement (Note 1)

Base & Subbase (Note 2)




Notes: (1) Paving thicknesses are based on asphaltic concrete (hot-mix). Alternative paving materials (cold-mix) may require additional thickness or additional base/subbase. (2) A minimum of 6-inches of higher quality base materials should be placed over lower quality subbase materials.

Table 5 Impact of Climate on Various Roadbed Soils

Relative Subgrade Quality Soil Resilient Modulus (psi) Climate Description Dry, no freeze Wet, no freeze Wet, freeze/thaw cycling Wet, hard freeze, spring thaw Dry, freeze/thaw cycling Dry, hard freeze, spring thaw Examples S California, S Texas W Oregon, N California, Gulf States Midwest and East Central States Great Lakes to New England E Washington, N Texas Wyoming, Montana Good 12,000 9,500 7,300 5,700 8,200 5,700 Fair 5,500 5,000 4,500 4,000 5,000 4,100 Poor 3,000 2,800 2,700 2,700 3,000 2,800

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Base, Subbase, and Subgrade Compaction Base courses should be compacted in layers not greater than 4 inches. Subbase should be compacted in layers not greater than 6 inches. Base course should be compacted to a dry density not less than 95% of the maximum dry density (Modified Proctor). Subbase, and top 6 inches of subgrade should be compacted to a dry density not less than 90% of the maximum dry density (Modified Proctor).


Subbase and Base Materials Subbase

1. For a subbase with a CBR of 20 (R-Value 55) minimum, the following materials may be used: a. Coarse sand b. Poorly graded gravel c. Sandy loam d. Decomposed granite with fines e. Gravel containing fines f. Sand/shell mixtures 2. Subbase material should contain not greater than 20% by weight of particles finer than 200 mesh. 3. Very fine sand or silty sand should not be permitted as a base or subbase material. 4. Maximum size of stone should not be greater than one-third the lesser thickness of the base course or the subbase course. Base

1. For a base with a CBR of 70 (R-Value 80) minimum, the following materials may be used: a. Crushed rock b. Pit run gravel (well-graded) c. Well-graded sand (asphalt stabilized) d. Coarse decomposed granite (well-graded) 2. Base material should contain not greater than 7% by weight of particles finer than 200 mesh. 3. Maximum size of stone should not be greater than one-third the thickness of the base course.

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September 2008 Frost Considerations

1. For areas subject to frost damage, base and subbase materials should contain not greater than 8% by weight of particles finer than 200 mesh. This helps to maintain good drainage through the materials and reduce frost heave potential. 2. If low-quality subgrade soils are present, consideration should be given to the use of geotextiles (see Section 7.4). The cost of using geotextile fabric over the weak subgrade may be offset by reduction in base and subbase costs. 7.2.6 Types of Asphalt Paving Plant Mix Asphalt Concrete (Hot-Mix)

1. Asphalt paving mixtures prepared in a central mixing plant are known as plant mixes. Asphalt concrete is considered to be the highest-quality plant mix. 2. Asphalt concrete consists of well-graded, high-quality aggregate and asphalt cement. The asphalt and aggregate are heated separately from 250 to 325F, carefully measured and proportioned, then mixed until the aggregate particles are coated with asphalt. 3. The hot mixture, kept hot during transit, is hauled to the construction site, where it is spread on the roadway by an asphalt paving machine at temperatures greater than 240F. The uniform layer of asphalt mix is spread by a paver, motor grader, or by hand followed by compaction with rollers to specified density before the asphalt cools. 4. Asphalt concrete may be placed in lifts from 2 to 4 inches compacted thickness. 5. Advantages of asphalt concrete include the following: a. Produces a high-quality paving surface suitable for heavy traffic b. Good quality control can be achieved at the mix plant c. Can be installed in a wide range of ambient temperatures provided quality control is maintained d. Because the aggregate is heated the moisture can be controlled 6. Limitations of asphalt concrete include the following: a. Paving placement requires careful monitoring to assure that the compaction procedures and equipment are providing the specified compaction before the mixture cools. b. If hot-mix plants are too far from the work site, mix temperature considerations and economics can preclude use of hot-mix. c. Hot-mix plants in cold regions typically shut down during winter months.

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PIP CVE02350 Roadway Design Guide Plant Mix Cold-Mix

1. Cold-mix paving is a mixture of unheated mineral aggregate and emulsified asphalt that may also be produced at a central mixing plant. 2. Cold mix may be placed in lifts of 2 to 3 inches compacted thickness. 3. Advantages of cold-mix include the following: a. Similar to a hot-mix, production can be closely controlled b. Does not require stringent control of mix temperature during placement and compaction c. Can be used for patching during cold temperatures when hot mix is not available d. Can be pre-mixed and stockpiled for subsequent small quantity repair jobs 4. Cold-mix cannot provide the high-quality, long-wearing paving that is attainable with hot-mix. Road Mix (Mixed-in-Place)

1. Road mix paving is emulsified asphalt sprayed onto and mixed into aggregate at moderate-to-warm ambient temperatures. Mixed-inplace construction may be used for surface, base, or subbase courses. 2. If used as a surface or wearing course, road mix is typically satisfactory for light and medium traffic. However, mixed-in-place layers covered by a high-quality plant mix surface course can provide a pavement suitable for heavy traffic. 3. Advantages of road mix include the following: a. Can use aggregate already on the roadbed or available from nearby sources, and without extensive processing b. Eliminates the need for a central mixing plant c. Placement can be performed with a variety of machinery often readily available (e.g., motor graders, rotary mixer with revolving tines, and traveling mixing plants). 4. Limitations of road mix include the following: a. Should not be installed if ambient temperatures is less than 50F because proper mixing of asphalt and aggregate is difficult b. If surface moisture on the aggregate is not properly controlled, excessive moisture causes problems in mixing, curing and compacting. Typically surface moisture should not be greater than 3%. c. Quality of mixed-in-place paving is more difficult to control than plant mixes.

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Asphalt Coatings Prime Coat

1. Typically for untreated granular bases, when the base course has been properly compacted and loose material removed, an asphalt prime coat should be applied. 2. A pressure distributor should be used to spray approximately 0.2 to 0.5 gal/sq yd of low-viscosity asphalt on the prepared surface of the base. 3. The asphalt prime coat should be fully absorbed by the base and permitted to set and cure before placing the surfacing. Tack Coat

1. If asphalt surfacing is to be applied over a surface of existing asphalt (e.g., a surface (wearing) course over a binder course), an asphalt tack coat should be applied to achieve proper bonding. 2. A tack coat should be very thin and uniformly cover the area to be paved. 3. Asphalt should be sprayed on at a rate of approximately 0.05 to 0.15 gal/sq yd. 7.3 Rigid Paving 7.3.1 Subgrade General

1. The most important consideration for a subgrade for rigid pavement is its ability to provide uniform support. 2. Concentrated wheel loads are distributed over a large supporting area of the subgrade because of the rigidity of the concrete slab. The effectiveness of slabs on grade to distribute loads has been demonstrated by tests conducted by the Portland Cement Association and others. Wheel loads up to 15,000 pounds applied to 6-inch and 8-inch thick slabs resulted in subgrade pressures of 5 psi or less. 3. If the subgrade is non-uniform, with abrupt changes from hard to soft, cracking can occur where the slab bridges over soft spots or rides on hard spots. Modulus of Subgrade Reaction

1. Typically design references for thickness of portland cement concrete paving evaluate subgrade support on the basis of modulus of subgrade reaction (i.e., Westergaards k). 2 The modulus is intended to measure the temporary (elastic) properties of the subgrade, rather than long-term soil bearing properties.

3. The modulus is calculated in accordance with ASTM D1196 using the loading pressure to make a rigid 30-inch diameter bearing plate deflect 0.05 inch into the subgrade material.

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4. The value of the modulus of subgrade reaction, k in pounds/cubic inch, is calculated in accordance with the following equation: k = load (psi) / deflection (inch) where: deflection = actual measured deflection (approx. 0.05 inch) 5. Typical values for subgrade materials are shown in Table 6.
Table 6 Typical k Values for Subgrade Material Relative Quality Very Good Good Fair Poor Very Poor k Value (pci) >550 400-550 250-350 150-250 <150 Examples of Subgrade Soils Crushed Rock Well-graded gravel Sand/Clay Mixture, Well-graded Gravel/Clay, Poorly Graded Silts and Clays


Subbase General

A subbase is not mandatory for rigid paving, but should be considered for the following conditions: a. The subgrade lacks uniformity because of minor soil variations. However, a subbase layer cannot correct major subgrade defects. Major defects should be corrected by excavating poor material. b. A significant number of vehicles with axle loads exceeding H-20 are expected routinely. c. To provide a stable working surface during paving construction d. The subgrade materials are known to be problem soils (e.g., differential shrinkage and expansion or excessive frost heave). Thickness

1. If a subbase is provided, the thickness should be limited to 4 inches. Tests performed by the Portland Cement Association show minor increases in subgrade support with thicker subbase. 2. A thicker subbase should only be used for large wheel loads on poor material. Material Characteristics

1. Dense-graded material 2. Maximum aggregate size, 1/3 subbase thickness 3. Particles finer than 200 mesh, 15% maximum 4. Plasticity Index, 6% maximum

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Paving Thickness For light traffic areas, walkways, and areas designed for automobiles or pick-up trucks, paving should be 4 inches thick. For areas designed for heavier vehicles (e.g., equivalent H-20 loading maximum), paving should be 6 inches minimum. For areas designed for heavier loads (e.g., large mobile cranes), a more detailed paving analysis should be considered. See Table 7 for recommended thicknesses for various subgrade strengths and expected loadings. See drawings CVE02350-08 to -11 for typical details of rigid roadway joints. See ACI 504R for joint sealants information.
Table 7 Concrete Paving Thicknesses Subgrade Description and k Value Silt & Clay Sandy Silt & Clay Sand/Clay Mixture (Highly Poorly-graded Well-graded Compressible) Sand or Gravel Sand & Gravel < 100 pci 100-250 pci >250 pci 4-1/2 4 4 4 4 with or without 6 5-1/2 5 4 4 4 7 6-1/2 6 6 4 4

Design Vehicle Loading Pickup H-15 H-20

Paving (inch) Subbase (inch) Paving (inch) Subbase (inch) Paving (inch) Subbase (inch)


Alternative Surface Treatment for Vehicle Traffic Area 7.4.1 General Paving with asphalt or portland cement concrete is typically limited to areas where, because of traffic loads or other considerations, the cost of paving is justified. Other surface treatments that have application for limited vehicle traffic include the following: a. Crushed rock b. Gravel c. Stabilized soil Walking on these alternate surfaces can be difficult unless suitable material gradations are used and compacted to 90 to 95% of their maximum density. 7.4.2 Compacted Crushed Rock Depending on the quality of the subgrade, adequate support for occasional vehicle loads can be provided using crushed rock approximately 4 inches thick.

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PIP CVE02350 Roadway Design Guide Crushed rock surfacing is typically used for the following conditions: a. An all-weather, well-drained surface is specified. b. Neat appearance is important. c. Heavy vehicle traffic is not expected. For the best wearing, well-compacted surface, a well-graded crushed rock material with the gradation (e.g., grain-size distribution) shown in Table 8 should be provided.
Table 8 Crushed Rock Gradation Sieve Size 1 inch 3/4 inch 1/2 inch 3/8 inch No. 4 Amount Passing Sieve, % 100 90-100 25-60 10-15 0-3 To limit the growth of vegetation through the rock surface, a weed killer approved by owner should be applied to the area before spreading the crushed rock. 7.4.3 Gravel Gravel is defined to be the wide variety of soil mixtures that have a significant portion of gravel (e.g., grain size .08 inch to about 3 inches) and/or coarse sand. Gravel can be found naturally at the site, or imported from a borrow pit. Gravel can be well-graded (e.g., relatively uniform distribution of grainsize particles) to poorly graded (e.g., excessive percentages of certain grain sizes and absence of others). Some gravels have some plasticity, whereas others are non-plastic. Well-graded gravels provide better and longer-lasting surfaces, and tend to perform better if they have a small percentage of clay which acts as a binder. Poorly-graded gravels can become soft during wet weather and loose and dusty in dry weather. The wearing properties of gravel surfaces can be improved by applying emulsified asphalt to cement the gravel. For well-graded gravel, the gradation shown in Table 9 should be provided.
Table 9 Gravel Gradation Designated Sieve No. 10 No. 40 No. 200 Amount Passing Sieve, % 20-100 10-70 3-25

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Stabilized Soil In addition to typical compaction techniques for strengthening soils, chemical additives including the following can enhance soil properties: a. Portland cement b. Asphalt c. Lime d. Calcium chloride Chemical additive treatments can accomplish the following: a. Upgrade the strength of very poor subgrade materials under roadways b. Decrease the permeability of soils c. Act as a palliative to control dust problems d. Provide a surface for areas not subject to heavy vehicle loads The quantity of additive required and the expected stabilization gain depends on the properties of the natural soil and the depth of soil to be stabilized. Laboratory testing may be performed to assess the value of using chemical additives. Following is a typical procedure for stabilizing soils: a. Scarify the existing surface b. Spread chemical additives c. Mix with motor grader using windrow mixing or alternative procedure d. Spread the mixture e. Compact the surface as required


Paving Over Low-Strength Soils 7.5.1 General Historically, if low-strength soils were encountered, the undesirable soils were either excavated and replaced with better material, or over-laid with thicker subbase materials to reduce unit loading to the subgrade. However, with the development of a line of geogrid and geotextile products, other alternatives are available for working with problem soils. 7.5.2 Geogrids Geogrids are manufactured from high tensile strength polymer, and designed with transverse and longitudinal ribs. Laid directly on subgrade, the geogrid geometry provides a mechanism for interlocking aggregate base or subbase material placed on the geogrid. The interlocking prevents lateral movement of the aggregate and improves load distribution to the subgrade.

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PIP CVE02350 Roadway Design Guide Geogrid materials are inert to typical chemical and biological conditions in soils and are not expected to degrade. 7.5.3 Geotextile Geotextile is manufactured from polyester in rolls up to 16 ft wide and 300 to 1000 ft long. Laid over subgrade materials directly below an aggregate subbase, geotextile is designed to perform any or all of the following functions: a. Maintains separation between subbase and subgrade. Coarse aggregate cannot move downward, and fine soil particles in the subgrade cannot rise into the subbase. b. Is permeable and permits pore water to pass vertically through the fabric c. Tensile strength of the geotextile material provides tensile reinforcement for subbase d. Permits lateral water flow within the plane of the geotextile material and dissipates excess pore water pressure Geotextiles are resistant to freeze-thaw and soil chemicals.


Drainage Considerations
8.1 Roadway Drainage 8.1.1 Roadway drainage systems consist of collection, conveyance, removal, and disposal of surface water runoff from the traveled way, shoulders, and adjoining roadside areas. Culverts, headwalls, ditches, swales, curbs and gutters are typically integral parts of roadway drainage systems. Subsurface water should also be drained away from the roadbed for a sufficient depth below the road surface to prevent frost troubles, and maintain a layer of stable material thick enough to distribute the pavement pressure successfully to less stable layers beneath.



Culverts 8.2.1 General Culverts are used to channel water under roadways and driveways or to remove drainage from ditches. A wide variety of standard shapes and sizes are available for most culvert materials. Because equivalent openings can be provided by a number of standard shapes, the selection of shape may not be critical in terms of hydraulic performance. Factors governing culvert shape selection may include some of the following: a. Depth of cover b. Limited headwater elevation where a low profile shape may be required

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c. Potential for clogging by debris d. Requirement for a natural stream bottom e. Structural and hydraulic requirements 8.2.2 Culvert Materials General

1. The selection of a culvert material may depend upon structural strength, hydraulic roughness, durability, and corrosion and abrasion resistance. 2. The most common culvert materials are concrete (e.g., reinforced and non-reinforced), corrugated aluminum, corrugated steel, solidwall, profile wall, and reinforced plastic. 3. Culverts may be lined to inhibit corrosion and abrasion, or reduce hydraulic resistance (e.g., corrugated metal culverts may be lined with asphaltic concrete). Concrete

1. Concrete culverts may be made from either precast or cast-in-place reinforced concrete depending on the size and complexity of the culvert design. 2. Precast culvert sections are uniform in size and shape and are made in sections that can easily be transported, lifted, and installed. 3. Cast-in-place culvert construction is typically used if ready-mix concrete is available and a culvert is specified to be constructed without joints. 4. Precast concrete culverts may be made with high strength concrete. 5. Cast-in-place concrete culverts may have special reinforcement at critical locations to resist high loads and stresses. Corrugated Steel

1. Corrugated steel culverts are made from factory-produced corrugated sheet steel. 2. Corrugated pipe culverts are made with factory-produced corrugated pipe sections. 3. Large corrugated culverts are typically field-assembled using structural plate products. Corrugated Aluminum

Corrugated aluminum culverts may be made from factory assembled corrugated aluminum pipe or field assembled from structural plates. Plastic

1. Many types of materials may be used to produce plastic pipe. 2. The strength and other properties of a plastic pipe typically depend on the type of base resin and the blend or formulation of chemicals in the final resin material.

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Culvert Coatings General

1. A variety of coatings may be used either singularly or in a combination of layers to protect culverts from chemical and/or abrasion attack. 2. The type of coating to use depends upon the type of culvert material and the types of deterioration or distress to be resisted. 3. The need for protective coatings depends upon of the following factors: a. Chemistry and acidity of the adjacent soil b. Chemistry and acidity of the water passing through the culvert c. Particle size and velocity of the solid material being transported through the culvert d. Environmental effects including freezing and thawing Metal Culverts

1. Corrugated steel culverts may be protected with metallic coatings of zinc (e.g., galvanized) or aluminum. 2. Protective coatings for metal culverts may also include bituminous coatings, bituminous paving, fiber-bonded bituminous coatings, polymer, concrete paving, and concrete coatings. These protective coatings may be applied in addition to a metallic coating for serious corrosion or abrasion conditions. 3. Inverts of corrugated metal culverts are typically paved to extend the life of the culvert by protecting the invert against corrosion and abrasion. The paving smoothes the inside of the culvert and improves hydraulic capacity. Concrete Culverts

1. Typically, concrete culverts are not coated when constructed. 2. If installed in aggressive chemical environments, concrete culverts may be coated with epoxy resins or special high density, low porosity concrete materials that have a high resistance to chemicals and chemical attack. 8.3 Ditches 8.3.1 General Roadside ditches should prevent water from pooling on the roadway surface, and prevent overland runoff from reaching the roadway. Design considerations for roadside drainage ditches include ditch shape, slope, lining considerations, and capacity requirements.

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Shape Typically, ditch shape is either V-shaped or trapezoidal. For mild side slopes, the ditch shape tends to approach a parabolic shape, which is the most hydraulically efficient shape. Because V-shaped ditches are more susceptible to erosion, trapezoidal ditches may be preferred for certain soil conditions. The size and depth of ditch should be set by volume of water that needs to be channeled. The roadbed may need to be elevated to permit depth of ditch to be sufficient for good drainage. Special design features (e.g., drop structures, check dams, etc.) should be considered to minimize shear stresses exerted on the ditch boundary or lining, and avoid occurrence of supercritical flow.


Slope The side slopes of a ditch should not exceed the angle of repose of the soil comprising the ditch line, and should typically be 3:1 (e.g., horizontal:vertical) or less. For typical surface drainage over pavement to a ditch, the road side slope of the ditch should be 4:1 to minimize erosion. The other side of ditch can be 4:1 or 3:1 depending on elevation change. If a rigid lining is specified, the use of steeper ditch slopes greater than 2:1 may be more economical.


Lining Linings can be either rigid or flexible. Lined ditches generally allow for steeper slopes and can provide protection against erosion caused by high velocities at ditch outlets. Rigid linings include concrete, paved, or other low permeability linings. Rigid linings may be specified where ditches are designed to carry runoff from process areas adjacent to roadway. Flexible linings include asphalt, vegetation, riprap, or geotechnical material.


Curbs, Gutters and Inlets 8.4.1 8.4.2 8.4.3 Sidewalks and curbs may be specified along a roadway. The change in elevation from curbs along a roadway edge channels surface water runoff, forming gutters. Gutter grades should be 0.3% to 0.4% minimum. Inlets and/or catch basins should be placed along curb and gutters to remove the surface runoff.

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Catch basin spacing should be determined based on the following conditions: a. Flatness of the grade b. Volume of rainfall typical for the location c. If applicable, firewater flow

8.4.5 8.4.6 8.4.7 8.5

Inlets should be ample to receive the full flow of water. Maximum spacing of catch basins is typically 250 ft. Water should not be permitted to cross the surface of an intersecting street.

Headwalls Headwalls control and direct the transitional flows in and out from a pipeline to an open ditch or creek. Headwalls may be cast in place or pre-cast units. See drawings CVE02350-05 to -06 for typical details for headwalls.


Pipe Crushing Strength 8.6.1 General For designing underground culverts, pipe crushing strength should be known so the supporting capability of the pipe is not exceeded by the earth and live loads. Crushing strengths are typically obtained from pipe manufacturers catalogs, and can also be calculated from formulas derived using specific tests. ASTM testing standards typically require pipe crushing strengths to resist expected live and dead loads. However, unusual conditions (e.g., extraordinary loads or very deep or shallow depths of bury) require special consideration. Pipe used for culverts is typically classified either rigid or flexible. Rigid pipe (e.g., cast iron, concrete, or clay) either cracks or ruptures if the combined load (e.g., internal pressure and external load) imposed becomes greater than the inherent circumferential strength of the pipe.

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September 2008 Crushing strengths for various categories and sizes of rigid pipe, calculated in accordance with ASTM testing methods, are shown in Table 10.
Table 10 Crushing Strength of Pipe
3-Edge Bearing Test, Pounds per Linear Foot Pipe Size (Inches) Vitrified Clay Extra Strength ASTM C-700 Nonreinforced Concrete Class 2 ASTM C-14 2,000 2,000 2,000 2,000 2,250 2,600 3,000 3,300 3,600 C.I. Soil Pipe Extra Heavy ASTM A-74 6,500 4,400 4,275 4,275 4,425 5,310 1,000 1,250 1,500 1,750 2,000 2,250 2,500 2,750 3,000 1,350 1,688 2,025 2,363 2,700 3,038 3,375 3,713 4,050 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 3,000 3,750 4,500 5,250 6,000 6,750 7,500 8,250 9,000 Reinforced Concrete, ASTM C-76 Load to Produce a 0.01 Inch Crack Class II Class III Class IV Class V

4 6 8 10 12 15 18 21 24 27 30 33 36

2,000 2,000 2,200 2,400 2,600 2,900 3,300 3,850 4,400 4,700 5,000 5,500 6,000


Concrete Pipe For reinforced concrete pipe only, laboratory load strength may be expressed as either of the following: a. Load per foot of pipe that causes the pipe to develop a 0.01 inch crack b. Ultimate load the pipe can withstand The load strength of the pipe, either the 0.01 inch crack or ultimate, divided by the nominal internal diameter of the pipe in feet, is called the D load strength. For example, if a 48-inch diameter reinforced concrete pipe has a 3-edge bearing test load at 0.01-inch crack of 8,000 lb/ft, and an ultimate strength of 12,000 lb/ft, the 0.01-inch crack strength is 2,000D and the ultimate strength is 3,000D.

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Flexible Pipe Flexible pipe (e.g., steel and plastic) resists deflection using the pipe load strength combined with the lateral support of the compacted soil at the side fills. The maximum external load that can be applied to a flexible pipe is the load that gives a deflection greater than the following: a. For flexible coating, 5% of nominal pipe diameter b. For rigid coating, 2% of nominal pipe diameter Internal pressure assists flexible pipe in resisting external loads but cannot be used in load calculations because the pipe may be empty.


Pipe Loading 8.7.1 General Formulas and charts for determining loads on an underground pipe have

been determined from theories developed by Anson Marston, Iowa State University. For designing underground culverts, earth loads and live or transmitted loads should be considered. Data on live and dead loads can be obtained from many different handbooks available and from pipe manufacturers guidelines. Every condition of bury or loading does not have to be considered for design. Typically, pipe loading should not need to be checked. Underground pipe design regulations typically require that pipe be designed for typical depths of bury with typically expected live loads. The following conditions should be checked for pipe loading: a. Depths of bury greater than 10 feet b. Abnormal soil conditions c. Unusually high live or transmitted loads d. Live loads for depths of bury less than 3 feet 8.7.2 Types of Bury Types of bury are classified as that in cut (e.g., trench condition) or that in fill (e.g., embankment condition). Combinations of both trench and embankment conditions can exist. To simplify and provide conservatism, this guideline is limited to trench conditions and embankment conditions. Combination conditions are considered embankment conditions. 8.7.3 Earth (Dead) Loads The amount of earth load that is transmitted to an underground pipe is dependent on many factors including the following: a. Depth of cover b. Width of trench at top of pipe

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c. Rigid or flexible pipe d. Trench or embankment construction condition e. Soil density and cohesion characteristics Formulas and charts developed by Anson Marston provide a means to closely calculate the earth loading for the variable factors listed in Section This data can be found in many available handbooks. Full descriptions of the various construction conditions are also given in the handbooks. To simplify the determination of earth loading, Table 11 may be used for approximate values. For the following reasons, values from the table should be satisfactory for design: a. Depths of cover are typically less than 8 feet. b. Earth load values for a depth of 8 feet should be well below the 3-edge bearing strength of vitrified clay pipe or reinforced concrete pipe for any properly installed system. c. Unless the width of the trench is specified and controlled during construction, calculating earth loads from Anson Marstons formulas is impractical. d. The unit weight of soil used in Table 11 is 120 pcf. e. Pipes 12 inches in diameter and less are assumed to have a trench width 1 foot greater than the outside diameter of the pipe. Pipes greater than 12 inches to 36 inches are assumed to have a trench width 2 feet greater than the outside diameter of the pipe.
Table 11 Dead Load from Earth Cover on Underground Pipe
Loads in Pounds per Linear Foot of Pipe Depth of Cover, Feet
4 2 3 4 5 6 7 8 180 270 370 470 570 670 780 6 240 370 520 660 800 950 1,080 8 290 460 650 830 1,000 1,130 1,370 10 340 550 780 1,000 1,200 1,420 1,620

Nominal Pipe Diameter, Inches

12 390 630 920 1,160 1,430 1,700 1,960

15 450 750 1,080 1,420 1,710 2,050 2,400

18 500 860 1,230 1,610 2,000 2,400 2,780

21 560 950 1,400 1,810 2,230 2,700 3,200

24 610 1,040 1,520 2,010 2,500 3,050 3,550

27 700 1,120 1,630 2,200 2,700 3,300 3,900

30 750 1,200 1,750 2,340 2,950 3,570 4,200

33 820 1,300 1,850 2,500 3,180 3,900 4,500

36 875 1,400 2,000 2,630 3,350 4,100 4,800 Table 11 is intended to be used as a guide in determining earth loads for underground conduits with typical bury conditions. For unusual bury conditions (e.g., large diameter pipes or deep pipes), the pipe manufacturers catalog should be consulted for design criteria.

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PIP CVE02350 Roadway Design Guide


Live Loads Typically live loads do not need to be considered unless the loads are very large or occur on culverts with very little cover. A few calculations under various conditions should establish the relative importance of live loads. Based on depth of cover and size of pipe, trucks or construction equipment moving over the ground surface above underground piping can transmit a percentage of the total load to the pipe. If the area above the piping is paved with flexible pavement, more load can be transmitted to the pipe; whereas, with rigid pavement (e.g., concrete) the load can bridge the pipe transmitting more load to the surrounding soil. Table 12 shows the percent of live load that can be transmitted to the pipe for various depths of cover. For determining transmitted loads, Table 12 should be used with the following guidelines: a. For piping under a roadway, depth of cover should be based on rough grade elevations for the roadway because underground piping can be subject to truck traffic before any paving is applied. b. The minimum wheel load for design purposes is 16,000 pounds which is normal H-20 loading. If greater loads are expected, the calculations should be based on actual loads. The heaviest wheel load that would be expected from a large unladen truck crane is 32,000 pounds (1/2 axle load of 64,000 pounds). The wheel load may be on dual tires but is still considered one wheel. Heavier loads could be possible during equipment handling or lifting activities and this point should be reviewed with construction management. Generally, the pipe is protected with timber mats or omitted entirely during these operations.

Table 12 Percentage of Wheel Loads Transmitted to Underground Pipe

Note: Each value is a percentage of wheel loads to apply to one linear foot of pipe. Depth of Cover, Feet
4 1 2 3 4 5 6 7 8 9.3 4.3 2 1.2 0.7 0.5 0.2 0.1 6 12.8 5.7 2.9 1.7 1.2 0.8 0.5 0.4 8 15 7 3.6 2.1 1.4 1 0.7 0.5 10 17.3 8.3 4.3 2.5 1.7 1.1 0.8 0.6

Nominal Pipe Diameter, Inches

12 20 9.6 5.2 3.1 2.1 1.4 1 0.8

15 22.6 11.5 6.4 3.9 2.6 1.8 1.3 1

18 24.8 13.2 7.5 4.6 3.1 2.1 1.6 1.2

21 26.4 15 8.6 5.3 3.6 2.5 1.3 1.4

24 27.2 15.6 9.3 5.8 3.9 2.8 2.1 1.6

27 28 16.8 10.2 6.5 4.4 3.1 2.3 1.8

30 28.6 17.8 11.1 7.2 4.9 3.5 2.6 2

33 29 18.7 11.8 7.9 5.3 3.8 2.9 2.2

36 29.4 19.5 12.5 8.5 5.8 4.2 3.2 2.3 For flexible pavement, the live load transferred to below grade varies in function of the depth as shown in Figure 3. Cranes are designed so that the live load applied to the soil is 2,000 psf maximum. Live load from locomotives is transferred in accordance with the Coopers E-80 curve

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PIP CVE02350 Roadway Design Guide

September 2008

shown in Figure 3. The load is based on a locomotive axial load of 80,000 lbs with 4 axles spaced at 5 feet.
Live Load Transferred to Buried Structures at Different Depths


AASHTO H-20 Cooper's E-80


Load on the Structure, psf





0 0.0 2.0 4.0 6.0 8.0 10.0 12.0

Depth, ft

Figure 3 Live Load Transfer Below Flexible Pavements For rigid pavement, the live load transferred to below grade is negligible at any depth. 8.7.5 Pipe Bedding Pipe bedding is the contact area between a pipe and the foundation on which the pipe rests. The soil on the sides of and above a pipe is the backfill. The 3-edge bearing strength for a pipe is multiplied by the load factor or number determined from the pipe bedding to calculate the field supporting strength. The field supporting strength of a rigid pipe and, therefore, the load factor for a particular culvert, depend on the following installation characteristics: a. Width of pipe bedding and quality of the contact between the pipe and bedding as the contact affects the distribution of the vertical forces b. Magnitude of lateral pressure acting against the sides of a pipe and the area of the pipe over which the lateral pressure acts

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PIP CVE02350 Roadway Design Guide Cohesion between backfill material and the sides of a trench for pipe bedding in trenches should be assumed to be negligible because of the following: a. Considerable time is required for effective cohesion. b. Assuming that cohesion is negligible provides the maximum probable load on the pipe. 8.7.6 Factor of Safety A factor of safety should be applied to the pipe loading designs to account for unforeseen stresses which can be imposed on an underground pipe. A factor of safety cannot be computed by laws and equations, but depends entirely upon engineering judgment and experience. Typically, the factor of safety should range from 1.0 to 1.5 depending on a variety of conditions or situations. The following factors should be considered when choosing a factor of safety for underground pipe designs: a. Culvert (e.g., non-pressure pipe) typically fails gradually. Pipe under pressure typically fails quickly once a crack develops. b. Pipe bedding and backfill variable factors c. Typically, rigid pipes should be designed with a higher factor of safety than flexible pipes because flexible pipes can deflect more before failure.


9.1 Railroad Crossings 9.1.1 9.1.2 Railroad facilities within a process plant are typically owned by the plant but subject to one or more local railroad operating company specifications. To cross railroad tracks with a new plant road, an acceptable crossing detail should be developed in coordination with the railroad operating company. Typical details can range from asphalt infill between rails to proprietary concrete panels. Typically, a process plant has a preferred railroad contractor that performs the plants rail construction and maintenance. Specialty vendors may be consulted for rail crossing materials and traffic control signage and devices.



Pipeline Crossings 9.2.1 Pipelines under roadways should be enclosed in an encasing pipe or embedded in solid reinforced concrete to protect carrier pipe from external loads or shock, either during or after construction of the roadway. The encasing pipe or enclosure should be capable of supporting the expected overhead traffic. Unless otherwise specified by owner, the top of the encasing pipe or enclosure should be 3 feet minimum below the surface of the roadway. Pipeline crossings should be identified by permanent markers.


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PIP CVE02350 Roadway Design Guide

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9.2.3 9.2.4 9.2.5

Pipelines crossing ditches should be placed 24 inches minimum below the ditch flow line. Pipe, conduit, sewer, or other similar facility should not be placed inside a drainage pipe. Pipelines exposed to damage by vehicular traffic should be protected by guard rails or curbs of concrete or metal.


Typical Details
See drawings CVE02350-01 to -10 for typical details for road sections, guard rails and posts, culverts, headwalls, roadway clearances, and concrete pavement joints.

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Process Industry Practices