PART NO: 14

CIVIL ENGINEERING
STANDARD SPECIFICATION

ISSUE: Initial
DATE:
PAGE:

21.07.93
1 of 6

CORRUGATED METAL PIPE CULVERTS

ISSUE
Initial

DATE

DESCRIPTION/REASON

21.07.93

AUTHORISED BY:

DATE:
CIVIL CONTRACTS MANAGER

QR
This document is copyright and may not be copied or reproduced in any way without the approval
of the Manager Civil Engineering.
The information contained in this document is the property of QR and may not be used by any
party without the express approval of the Manager Civil Engineering.

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294544068.doc

ISSUE:
DATE:

Initial
21.07.1993

Corrugated Metal Pipe Culverts

Page 2 of 6

TABLE OF CONTENTS
Page
14.1

SCOPE.............................................................................................................................................. 3

14.2

PREPARATION OF FOUNDATIONS................................................................................................ 3

14.3

SELECTED GRANULAR FILL......................................................................................................... 3

14.4

CORRUGATED METAL PIPES......................................................................................................... 3

14.5

COATING OF PIPE DRAINS............................................................................................................ 4

14.6

CONCRETING OF INVERT.............................................................................................................. 4
14.6.1
14.6.2
14.6.3
14.6.4
14.6.5
14.6.6

Extent of Concreting..................................................................................................... 4
Surface Preparation...................................................................................................... 4
Reinforcement............................................................................................................... 4
Concrete........................................................................................................................ 4
Concrete Pipe Joint.................................................................................................... 4
Protection of Finished Concrete....................................................................................4

14.7

HEADWALLS AND APRONS........................................................................................................... 4

14.8

SCHEDULE OF QUANTITIES AND PRICES...................................................................................5

APPENDIX 14A QUALITY REQUIREMENTS.............................................................................................. 6

QR - Civil Engineering

Standard Specification Part 14

ISSUE:
DATE:

14.1

Initial
21.07.1993

SCOPE

This part of the Specification includes the supply

and erection of corrugated steel pipe and
associated works required to construct such
culverts in accordance with the Drawings and,
unless otherwise specified, in accordance with
AS2041 and AS2042 (Corrugated metal pipes) or
AS1761 and AS1762 (helical lock-seam corrugated
steel pipes), as applicable.
14.2

PREPARATION OF FOUNDATIONS

The ground surface shall be trimmed to provide a

foundation of the grading, width and depth
indicated on the Drawings or as directed by the
Superintending Officer. Any low spots shall be
filled with select backfill in accordance with Part 5
of this Specification to conform with this profile.
Selected bedding material shall be of a fine
granular nature, free of sod, boulders or rocks, and
shall be provided to form an earth cushion having
a minimum thickness of 75mm under the
corrugated multi plate steel pipe. Where rock is
exposed in the excavation, the thickness of this
cushion shall be increased to 250mm or 0.25 times
the nominal diameter, whichever is less. The
bedding surface shall be true to line and grade as
established by the Superintending Officer and shall
provide a firm foundation of uniform density
throughout the entire length of the pipe. The
bedding shall be accurately shaped and rounded to
conform to the outside circular shape of the pipe
for its entire length and be of sufficient width to
permit efficient compaction of the fill under the
haunches of the pipe. The bedding shall be
tamped to provide uniform, firm support for the
pipe. A uniform blanket of loose granular material
of 12mm maximum aggregate size shall cover the
shaped bedding to a depth sufficient to allow the
corrugations to become filled with the material.
14.3

SELECTED GRANULAR FILL

In the embankment adjacent to the corrugated

metal pipe culverts and within the limits shown on
the Drawings, selected granular fill shall be
provided. Such material may be from excavation
or borrow and shall be free from large lumps,
clods, vegetable matter, stone larger than 75mm in
size, or other objectionable materials.
The
selected material shall have a pH 6 - 10 and a
minimum resistivity of 3000 ohm. - cms., except
that for pH 6.5 - 7.5, no minimum resistivity is
specified.
The Contractor shall forward to the nearest
Queensland Department of Transport, Roads
Division, District Soils Laboratory, samples of
material proposed for selected granular fill, not
QR - Civil Engineering

Corrugated Metal Pipe Culverts

Page 3 of 6

less than 50kg in each sample, for examination

and testing. No material shall be placed as
selected granular fill until the Contractor has
received written approval from the Manager Civil
Engineering that the material is acceptable.
The material shall be uniformly spread in layers
longitudinally,
(not
exceeding
150mm
in
compacted depth), simultaneously on both sides of
the pipe for the full length of the pipe, and shall be
compacted by rolling parallel with the pipe or by
tamping or ramming. Compaction shall continue
until a density of 90% of the maximum dry density
of the material as determined by the Modified
Compaction Test, according to AS1289.E2.1, is
obtained. Special care shall be taken to ensure
thorough compaction of the fill under the haunches
of the pipe. Compaction to this standard shall
extend to the limits indicated on the Drawings,
beyond which the embankment construction shall
proceed as specified in Part 6 of this Specification.
Care shall be exercised during the filling and
compacting operations to avoid disturbance to the
line and joints of the pipes. Any damage to the
pipe shall be repaired by the Contractor to the
satisfaction of the Superintending Officer.
14.4

CORRUGATED METAL PIPES

All pipes shall be of corrugated steel and shall

comply in all respects with AS 2041 or AS 1761 as
applicable. Steel plates shall be of the thicknesses
shown in the Drawings for the individual culverts.
All steel plates, bolts, nuts and washers shall be
galvanised.
The reinforcement fabric incorporated in the
concrete invert protection shall be welded to the
assembly bolt nuts at the spacings shown on the
Drawings. When assembly bolts do not meet the
required spacing, "dummy" bolts of 20mm
diameter shall be installed to provide the required
minimum spacing.
The pipes shall be erected in accordance with
AS2042 or AS1762, as applicable, and to the
manufacturer's
specifications
and
recommendations and shall be located and graded
in accordance with the Drawings or as directed by
the Superintending Officer. No pipe shall be laid
except in the presence of the Superintending
Officer who shall inspect each section before it is
laid. Defective sections shall be replaced.
Care shall be exercised in handling structural plate
to avoid damage to the galvanic protective
coatings and any damage to such coatings shall be
immediately and adequately corrected by painting
with two coats of approved cold galvanic paint.

Standard Specification Part 14

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14.5

Initial
21.07.1993

COATING OF PIPE DRAINS

The corrugated multi-plate steel in the case of

bolted pipes, or the pipes in the case of riveted
pipes, shall be supplied in a galvanised condition.
After erection, the pipes shall be covered
externally with three coats of "DENSO DIMET
Alumastic" protective mastic coating, applied
strictly in accordance with the manufacturer's
specifications. All surfaces shall be thoroughly
cleaned and well dried before application of
coatings.
Exterior surfaces of bottom plates
inaccessible after placement shall be coated prior
to placement. The total thickness of the coatings
shall be 0.75mm.
14.6

CONCRETING OF INVERT

14.6.1

Extent of Concreting

Concrete shall be placed in the inverts of the pipes

in accordance with the Drawings. Concreting shall
not be carried out until all filling material has been
placed and consolidated above the pipes.
14.6.2

Surface Preparation

All foreign material shall be removed from the

surface to be paved and, where corrosion has
occurred, all loose scale shall be removed with
wire brushes to the satisfaction of the
Superintending Officer.
Immediately before
placement of the concrete, all free water shall be
removed and the surface flushed with a mortar
made of the standard concrete mix by elimination
of the coarse aggregate fraction.
14.6.3

Reinforcement

The invert shall be reinforced with a single layer of

fabric F42.
Cover to fabric shall be 25mm
minimum. The reinforcing fabric shall be securely
fastened to the bolts as indicated on the Drawings.
Such fastening shall be spaced as shown on the
Drawings. All laps in fabric shall be in accordance
with Part 7 of the Specification. The fabric shall be
folded under upstream and downstream lips of the
structure at least 300mm and embedded in
concrete. Fabric shall extend to within 125mm of
edges of concrete on each side.
14.6.4

Concrete

Concrete shall be Grade N20 in accordance with

Part 7 of the Specification. The concrete shall not
be vibrated but shall be sufficiently compacted and
tamped to eliminate large voids and shall be
finished in a workmanlike manner.
14.6.5

Concrete Pipe Joint

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Corrugated Metal Pipe Culverts

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A groove of the dimensions shown on the Drawings

shall be cast along the entire length of invert
protection and be filled with "Tremco Polyroof TM"
one-part roof elastomer or an approved equivalent.
14.6.6

Protection of Finished Concrete

No water should be allowed to flow over the

surface of the inverts for twelve hours after
placement of the concrete and heavy flow shall be
diverted to the satisfaction of the Superintending
Officer for at least 48 hours.
14.7

HEADWALLS AND APRONS

Headwalls and aprons shall be provided to the

extent shown on the Drawings or as ordered by the
Superintending Officer.
Headwalls of culverts with skew numbers between
70 and 110 shall be 100mm thick concrete,
reinforced with a single layer of F62 fabric centrally
placed, or alternatively stone pitching may be used
in accordance with Part 6 of the Specification.
Headwalls of culverts with skew numbers less than
70 or greater than 110 shall be 225mm thick
concrete, reinforced with a single layer of F102
fabric centrally placed.
Hook bolts shall be
installed at 300mm centres around the ends of
such pipes and shall be bent before fitting so that
they align with the headwall.
Concrete and reinforcing steel shall be
accordance with Part 7 of this Specification.

in

Weepholes shall be provided in headwalls at

spacings of 1,500mm both horizontally and
vertically with the bottom row of weepholes
600mm above natural ground level. Weepholes
shall be 50mm in diameter and a reverse filter of
granular material approximately 300mm cube shall
be placed behind each weephole. The pocket of
granular material shall extend a distance of 75mm
below the lower edge of each weephole.
All inlet and outlet aprons shall be 100mm thick
concrete reinforced with one single layer of F62
fabric centrally placed and shall extend a distance
equal to the diameter of the largest pipe in the
culvert, from the toe of the embankment. Cut off
walls 600mm deep reinforced as for the aprons
shall be provided around the edges of the aprons.
Where approved by the Manager Civil
Engineering, grouted stone pitching in accordance
with Part 6 of the Specification, revetment
mattresses, 230mm thick, may be used in lieu of
concrete aprons.
Where shown on the Drawings or where directed
by the Superintending Officer, the stream bed shall
Standard Specification Part 14

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Corrugated Metal Pipe Culverts

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be excavated beyond the downstream apron for a

distance equal to the diameter of the largest pipe
in the culvert, to a depth of 600mm, and the
excavation filled with dumped rock or "floodstone".
This rock shall consist of sound igneous or
metamorphic rock of maximum size 600mm cube
and average size of not less than 300mm cube.
The rock shall be dumped into place and worked
into position by machines so that the spaces
between the larger rocks are filled with smaller
spalls and the top surface shall be shaped to the
line and level of the surrounding ground and apron.
14.8

SCHEDULE OF QUANTITIES AND

PRICES

Excavation for foundations (including inlets and

outlets) and select backfill shall be measured and
paid for at the relevant Schedule Unit Prices per
cubic metre.
Headwalls and aprons will be measured and paid
for at the Schedule Unit Prices per square metre,
which shall include all costs associated with
excavating below the level of the final top surface
of the concrete and the supply, placing and
finishing of all concrete and reinforcing steel. No
separate payment will be made for apron cut-off
walls which shall be included in the Schedule Item
for aprons.
The Schedule item for construction of the
corrugated metal pipes shall include the costs of
erection, coating of the pipes, supply, placing and
compaction of selected bedding material and
selected granular fill and all other incidental costs
associated with the construction of the culvert in
accordance with the Drawings and this
Specification.
The Schedule item for the concreting of the inverts
of the pipes shall include the costs of all materials
and work necessary to complete the work specified
in accordance with the Drawings and this
Specification.
Dumped rock or "floodstone" will be measured and
paid for at the Schedule Unit Price per cubic
metre, which shall include all costs associated with
excavating as specified and supplying, delivering,
dumping and working the rock into place in
accordance with the Drawings and this
Specification.

QR - Civil Engineering

Standard Specification Part 14

ISSUE:
DATE:

Initial
21.07.1993

Corrugated Metal Pipe Culverts

Page 6 of 6

APPENDIX 14A QUALITY REQUIREMENTS

Table 1 : Process requirements for documented construction procedures, lot identification and traceability
PROCESS

CONSTRUCTION PROCEDURE

LOT IDENTIFICATION

TRACEABILITY

Supply & Deliver

Required 7 days prior to manufacture

As per Supplier Quality Plan

As per Supplier Quality Plan

Installation

Required 7 days prior to use

One Culvert = 1 lot

Material source to
bedding/backfill

End Structures

Required 7 days prior to use

Once concrete pour = 1 lot

Batch plant to concrete pour

lot

Table 2 : Authority and responsibility for specified inspection/approval points

PROCESS

ACTIVITY

INSPECTION POINT

REFERENCE

LEVEL OF

RESPONSIBILITY FOR

CLAUSE

INSPECTION

INSPECTION

Supply &
Deliver
Installation

End Structures

Bedding

Prior to laying metal pipe culverts

14.2

Hold Point

Superintending Officer

Backfill Material

Prior to use of backfill material in

Works

14.3

Hold Point

Manager Civil Engineering

Laying

During laying of each pipe section

14.4

Witness

Superintending Officer

Repairs

After repair of damage to pipes

14.3

Hold Point

Superintending Officer

Concrete Invert

After surface preparations and prior

to concreting

14.6 (ii)

Hold Point

Superintending Officer

Prior to protecting invert against

water flow after placement of
concrete

14.6 (vi)

Witness

Superintending Officer

Concrete

As per PART 7 CONCRETE

Slope
Protection

As per PART 6 - EARTHWORKS

Table 3 : Minimum inspection and test requirements

PROCESS

ACTIVITY

QUALITY VERIFICATION REQUIREMENT

REFERENCE
CLAUSE

MINIMUM TEST
FREQUENCY

MINIMUM
REQUIREMENT

DESCRIPTION

TEST REQUIRED

Source Assessment

One 50 kg sample

14.3

1 per M.S.

1 per M.S.

Grading

AS 1289.C6.1

14.3

1 per 200 m

1 per M.S.

Acidity (pH)

QDOT Q121

Resistivity

QDOT122A

Compaction

AS 1289.E2.1

14.3

As required

1 per M.T.

1 per 100 m

1 per lot

Supply & Deliver

Installation

Backfill
Material

Backfilling

AS 1289.E3.1
End Structures

Concrete
Slope
Protection

As per PART 7 CONCRETE

As per PART 6 - EARTHWORKS

M.D.R. = Moisture/Density Relation, F.D.D. = Field Dry Density, M.T. = Material Type, M.S. = Material Source

QR - Civil Engineering

Standard Specification Part 14