Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020)

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NDEX

abandoned existing structures, 29-7
absorption, 29-17, 29-31, 29-45
access covers, 29-1, 29-42
Adhesive, 29-1, 29-2, 29-27, 29-30, 29-31, 29-

32, 29-33, 29-34

adhesives, 29-28, 29-31, 29-32, 29-33, 29-34,

29-35

alternative system, 29-35
anchors, 29-1, 29-30, 29-32, 29-33, 29-34, 29-

asphaltic concretes, 29-36
average weight, 29-31
backfilling, 29-5, 29-43, 29-44
blast cleaning, 29-38, 29-39
blasting, 29-6, 29-7, 29-8, 29-9, 29-16, 29-18,

29-38, 29-45

borrow materials, 29-44
bridge deck, 29-11, 29-36, 29-42
Bridge Deck, 29-1, 29-36
Bridge drainage systems, 29-1
casing, 29-10, 29-11
castings, 29-12, 29-13
Certificate of Compliance, 29-37
channel grates, 29-11
chipping, 29-6, 29-39
coal tar, 29-25, 29-29, 29-43
coarse brooming, 29-38
Cofferdams, 29-10
components, 29-11, 29-13, 29-15, 29-20, 29-

21, 29-27, 29-30, 29-38

Compression strength test, 29-42
concrete gutters, 29-11
contamination, 29-19, 29-33, 29-38, 29-39,

29-46

Continuous-type mixers, 29-39
cotton ball, 29-24
cotton strand, 29-24
cracks, 29-1, 29-9, 29-12, 29-15, 29-16, 29-

20, 29-22, 29-23, 29-33, 29-42, 29-45

culverts, 29-6
curing, 29-18, 29-24, 29-27, 29-32, 29-33, 29-

38, 29-40, 29-42

daily log, 29-20
demolition, 29-6, 29-8
density, 29-10, 29-31, 29-45
deteriorated concrete, 29-16
dewatering, 29-8, 29-9, 29-43
dimensions, 29-12, 29-47
dowels, 29-1, 29-30, 29-32, 29-33, 29-34
drainage blankets, 29-11
drilling, 29-6, 29-12, 29-16, 29-33, 29-35
Drip check angles, 29-1

ducts, 29-1, 29-42, 29-43, 29-44
edge distance, 29-35
End walls, 29-1, 29-42
end-bent piling, 29-10
Epoxy compounds, 29-1, 29-25
Epoxy injection, 29-1
equipment, 29-9, 29-10, 29-14, 29-15, 29-18,

29-20, 29-22, 29-23, 29-32, 29-33, 29-36,
29-38, 29-39, 29-40, 29-41, 29-46, 29-47

excavation, 29-5, 29-7, 29-8, 29-9, 29-10, 29-

Excavation, 29-9, 29-43
existing bridge structures, 29-1
Explosives, 29-6
falsework, 29-7
field test, 29-33, 29-34
Fillers, 29-30
finishing machine, 29-40, 29-41
fluid, 29-24, 29-25
frames, 29-11, 29-12, 29-13, 29-42
freshly placed concrete, 29-11, 29-44
geocomposite drainage systems, 29-11, 29-

grading, 29-10, 29-44, 29-45, 29-46
grinding, 29-6, 29-16, 29-24
ground elevation, 29-6
hazardous materials, 29-8
heat straightening, 29-6
high winds, 29-40
hot applied, 29-29
independent testing, 29-33
initiator, 29-21, 29-22
internal access walkways, 29-1
latex-modified concrete, 29-36, 29-37, 29-38,

29-40, 29-41

Lockable doors, 29-1, 29-42
low humidity conditions, 29-40
major structures, 29-5
mix designs, 29-28
mobile distribution, 29-23
monomer, 29-21, 29-22, 29-23
mortar, 29-14, 29-26, 29-28
navigation beacons, 29-48
navigation channel, 29-48
navigation direction signs, 29-48
Oscillating screed-type machines, 29-40
penetrant sealers, 29-17
perforated pipes, 29-13
personnel, 29-15, 29-16, 29-20, 29-23
Piezometers, 29-9
promoter, 29-21, 29-22
rain, 29-23, 29-40, 29-42

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Repairs, 29-6
retaining walls, 29-5, 29-10, 29-42
Right of Ways, 29-8
roadway surface, 29-36
rock armour, 29-45
rock cores, 29-8
Rotating roller-type machines, 29-40
rough texture, 29-38
sacrificial tests, 29-35
Safety considerations, 29-44
Salvaged, 29-7
sand, 29-12, 29-16, 29-17, 29-20, 29-22, 29-

23, 29-24, 29-26, 29-27, 29-28, 29-30, 29-
38, 29-39, 29-41, 29-42

Scour protection, 29-1
Sealing, 29-1, 29-16, 29-19, 29-20, 29-22, 29-

setting time, 29-31
shafts, 29-9, 29-10
sleeves, 29-12
slopes, 29-46, 29-47
slump, 29-37, 29-40
soil samples, 29-8
spacing, 29-16, 29-35

stress-strain, 29-25
structures foundations, 29-1
subgrade elevation, 29-6
subways, 29-11
Supervisor, 29-16
surface water, 29-11
surveying, 29-46
tanks, 29-24, 29-28
tolerances, 29-15, 29-33, 29-47
traffic, 29-5, 29-6, 29-22, 29-24, 29-28, 29-31,

29-32, 29-33, 29-39, 29-42, 29-48

underpasses, 29-11
unsuitable material, 29-8
unused material, 29-20
utilities, 29-6
variable pressures, 29-15
vibrations, 29-8, 29-9, 29-11
volatile solvent, 29-25
wearing surfaces, 29-1, 29-24, 29-36, 29-38,

29-42

weather conditions, 29-23
weep holes, 29-11, 29-14
welding, 29-6, 29-12
wrecking balls, 29-6

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MISCELLANEOUS METALS

30.1

Description

This work shall consist of furnishing and installing miscellaneous iron and steel, miscellaneous metal
(bridge), miscellaneous metal (restrainer), miscellaneous metal pipe, corrugated metal units,
aluminium for signs, and other items specifically identified as miscellaneous metal in the Contract
documents, all as shown on the Contract plans or as directed by the Engineer, and as specified in
these specifications and the Contract documents.

Miscellaneous iron and steel, miscellaneous metal (bridge), and miscellaneous metal (restrainer)
shall be inspected at the fabrication site. The Contractor shall notify the Engineer when materials
have been delivered to the fabrication site and shall give the Engineer at least two weeks

’ notice

after delivery before commencing the fabrication of the miscellaneous metal. Materials to be used
shall be made available to the Engineer so they can be examined. The Engineer shall have free
access at all times to any portion of the fabrication site where the material is stored or where work
on the material is being performed.

The Contractor shall submit to the Engineer four sets of working drawings two weeks prior to the
fabrication of the miscellaneous metal works. Working drawings shall show all information necessary
for the fabrication of the metal work and shall be in the same system of units as the Contract plans.

30.2

Reference Standards and Codes

Standards and codes for materials of miscellaneous metals and related construction works shall be
as specified in this section, in the Contract documents, if any, and the following, in their latest edition:

AASHTO LRFD

American Association of State Highway and Transportation Officials - Load
and Resistance Factor Design, Bridge Construction Specifications;

AASHTO LRFD

American Association of State Highway and Transportation Officials - Load
and Resistance Factor Design, Bridge Design Specifications;

AASHTO

Standard Specifications for Transportation Materials and Methods of Sampling
and Testing;

ADQCC (TR-516) Road Structures Design Manual;

ASTM

American Society for Testing and Materials;

AISI

American Iron and Steel Institute;

ANSI/AWS

Structural Welding Code

– Steel;

D1.1/D1.1M:2010

AASHTO/AWS

Bridge Welding Code;

D1.5M/D1.5:2010

FED RR-W-410F

Wire Rope and Strand, Federal Specifications and Standards, 06-Dec-2007.

Table 30-1 presents American Association of State Highway and Transportation Officials (AASHTO),
and American Society for Testing and Materials (ASTM) Standards that are related to materials for
miscellaneous metals. It also includes designations and titles.

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Table 30-1: Designations and titles for AASHTO and ASTM standards that apply to

miscellaneous metals

AASHTO

DESIGNATION

ASTM

DESIGNATION

TITLE

ASTM A36 /

A36M - 08

Standard Specification for Carbon Structural Steel

ASTM A575 -

96(2007)

Standard Specification for Steel Bars, Carbon, Merchant
Quality, M-Grades

ASTM A576 -

90b(2012)

Standard Specification for Steel Bars, Carbon, Hot-
Wrought, Special Quality

ASTM A307 - 10

Standard Specification for Carbon Steel Bolts and Studs,
60 000 PSI Tensile Strength

AASHTO M

314-90 (2008)

Standard Specification for Steel Anchor Bolts

ASTM A449 - 10

Standard Specification for Hex Cap Screws, Bolts and
Studs, Steel, Heat Treated, 120/105/90 ksi Minimum
Tensile Strength, General Use

ASTM A563 -

07a

Standard Specification for Carbons and Alloy Steel Nuts

ASTM F844 -

07a

Standard Specification for Washers, Steel, Plain (Flat),
Unhardened for General Use

AASHTO M

164-05

ASTM A325 - 10

Standard Specification for Structural Bolts, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength

ASTM F1852 -

Standard Specification for “Twist Off” Type Tension
Control Structural Bolt/Nut/Washer Assemblies, Steel,
Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM F436 - 11 Standard Specification for Hardened Steel Washers

ASTM F959 - 09

Standard Specification for Compressible-Washer-Type
Direct Tension Indicators for Use with Structural Fasteners

ASTM F593 -

02(2008)e1

Standard Specification for Stainless Steel Bolts, Hex Cap
Screws, and Studs

ASTM F738M -

02(2008)

Standard Specification for Stainless Steel Metric Bolts,
Screws, and Studs

ASTM F594 -

09e1

Standard Specification for Stainless Steel Nuts

ASTM F836M -

02(2010)

Standard Specification for Style 1 Stainless Steel Metric
Nuts

ASTM A536 -

84(2009)

Standard Specification for Ductile Iron Castings

AASHTO M

103M/M 103-12

ASTM A27 /

A27M - 10

Standard Specification for Steel Castings, Carbon, for
General Application

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AASHTO

DESIGNATION

ASTM

DESIGNATION

TITLE

ASTM A47 /

A47M -

99(2009)

Standard Specification for Ferritic Malleable Iron Castings

AASHTO M

105-09

ASTM A48 /

A48M -

03(2008)

Standard Specification for Gray Iron Castings

AASHTO M

306-10

Standard Specification for Drainage, Sewer, Utility, and
Related Castings

AASHTO M 36-

03 (R2011)

ASTM A760 /

A760M - 10

Standard Specification for Corrugated Steel Pipe, Metallic-
Coated, for Sewers and Drains

AASHTO M

218-03 (R2011)

Standard Specification for Steel Sheet, Zinc-Coated
(Galvanized), for Corrugated Steel Pipe

AASHTO M

274-87 (2012)

Standard Specification for Steel Sheet, Aluminum-Coated
(Type 2), for Corrugated Steel Pipe

AASHTO M

289-91 (2012)

Standard Specification for Aluminum-Zinc Alloy Coated
Sheet Steel for Corrugated Steel Pipe

AASHTO M

196-92 (2012)

ASTM B745 /

B745M -

97(2005)

Standard Specification for Corrugated Aluminum Pipe for
Sewers and Drains

AASHTO M

190-04 (2012)

Standard Specification for Bituminous-Coated Corrugated
Metal Culvert Pipe and Pipe Arches

AASHTO M

243-

1996(R2008)

Standard Specification for Field-Applied Coating

AASHTO M

167M/M 167-09

ASTM A761 /

A761M -

04(2009)

Standard Specification for Corrugated Steel Structural
Plate, Zinc-Coated, for Field-Bolted Pipe, Pipe-Arches,
and Arches

AASHTO M

219-92 (2012)

ASTM B746 /

B746M -

02(2012)

Standard Specification for Corrugated Aluminum Alloy
Structural Plate for Field-Bolted Pipe, Pipe-Arches, and
Arches

AASHTO M

245-00 (2012)

Standard Specification for Corrugated Steel Pipe,
Polymer-Precoated, for Sewers and Drains

AASHTO M

246-05 (R2011)

ASTM A742 /

A742M -

03(2008)

Standard Specification for Steel Sheet, Metallic-Coated
and Polymer-Precoated, for Corrugated Steel Pipe

AASHTO

M192M/M192-

1994

ASTM

A486/A486M -

Standard Specification for Steel Castings for Highway
Bridges

AASHTO M

169-09

ASTM A108 - 07

Standard Specification for Steel Bars, Carbon, and Alloy,
Cold-Finished

ASTM A240 /

A240M - 12

Standard Specification for Chromium and Chromium-
Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels and for General Applications

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AASHTO

DESIGNATION

ASTM

DESIGNATION

TITLE

ASTM B221 - 12

Standard Specification for Aluminum and Aluminum-Alloy
Extruded Bars, Rods, Wire, Profiles, and Tubes

ASTM B26 /

B26M - 12

Standard Specification for Aluminum-Alloy Sand Castings

ASTM A722 /

A722M - 12

Standard Specification for Uncoated High-Strength Steel
Bars for Prestressing Concrete

ASTM A653 /

A653M - 11

Standard Specification for Steel Sheet, Zinc-Coated
(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by
the Hot-Dip Process

ASTM A684 /

A684M - 12

Standard Specification for Steel, Strip, High-Carbon, Cold-
Rolled

ASTM D1056 -

Standard Specification for Flexible Cellular Materials

—

Sponge or Expanded Rubber

ASTM A716 - 08 Standard Specification for Ductile Iron Culvert Pipe

ASTM

A885/A885M-

96(2002)

Standard Specification for Steel Sheet, Zinc and Aramid
Fiber Composite Coated for Corrugated Steel Sewer,
Culvert, and Underdrain Pipe (Withdrawn 2006)

ASTM A1011 /

A1011M - 12a

Standard Specification for Steel, Sheet and Strip, Hot-
Rolled, Carbon, Structural, High-Strength Low-Alloy, High-
Strength Low-Alloy with Improved Formability, and Ultra-
High Strength

ASTM A849 - 10

Standard Specification for Post-Applied Coatings, Pavings,
and Linings for Corrugated Steel Sewer and Drainage Pipe

ASTM A74 - 09

Standard Specification for Cast Iron Soil Pipe and Fittings

ASTM B88 - 09

Standard Specification for Seamless Copper Water Tube

ASTM B209 - 10

Standard Specification for Aluminum and Aluminum-Alloy
Sheet and Plate

ASTM B211 -

12e1

Standard Specification for Aluminum and Aluminum-Alloy
Rolled or Cold Finished Bar, Rod, and Wire

ASTM B108 /

B108M - 12e1

Standard Specification for Aluminum-Alloy Permanent
Mold Castings

ASTM B22 -

09e2

Standard Specification for Bronze Castings for Bridges
and Turntables

ASTM A434 -

06(2012)

Standard Specification for Steel Bars, Alloy, Hot-Wrought
or Cold-Finished, Quenched and Tempered

ASTM B100 - 08

Standard Specification for Wrought Copper-Alloy Bearing
and Expansion Plates and Sheets for Bridge and Other
Structural Use

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AASHTO

DESIGNATION

ASTM

DESIGNATION

TITLE

ASTM A668 /

A668M -

04(2009)

Standard Specification for Steel Forgings, Carbon and
Alloy, for General Industrial Use

ASTM A53 /

A53M - 12

Standard Specification for Pipe, Steel, Black and Hot-
Dipped, Zinc-Coated, Welded and Seamless

ASTM A123 /

A123M - 12

Standard Specification for Zinc (Hot-Dip Galvanized)
Coatings on Iron and Steel Products

ASTM B29 -

03(2009)

Standard Specification for Refined Lead

ASTM B152 /

B152M - 09

Standard Specification for Copper Sheet, Strip, Plate, and
Rolled Bar

ASTM B6 - 12

Standard Specification for Zinc

The Contractor shall manufacture and test miscellaneous metals in accordance with these
specifications and in compliance with AASHTO/ASTM standards. Where miscellaneous metals are
manufactured and tested by standards other than AASHTO/ASTM, products conforming to
equivalent or higher standards will be acceptable if proven to be suitable.

30.3

Materials

Miscellaneous metal items shall be constructed of materials conforming to the following AASHTO
(or ASTM) material specifications as shown in Table 30-2, unless otherwise specified in the Contract
documents or subsequent sections:

Table 30-2: Materials specifications

Materials

AASHTO and ASTM Designation

Steel bars, plates, and shapes

ASTM A36 / A36M - 08, Grade 36 or ASTM A575 -
96(2007), ASTM A576 - 90b(2012) (AISI or M
Grades 1016 through 1030 except Grade 1017)

Steel fastener components for general
applications:

•

Bolts and studs

•

Headed anchor bolts

•

Non-headed anchor bolts

•

High-strength

bolts

and

studs,

threaded rods, and non-headed
anchor bolts

•

Nuts

•

Washers

•

ASTM A307 - 10

•

ASTM A307 - 10, Grade B, including S1

supplementary requirements

•

ASTM A307 - 10, Grade C, including S1

supplementary requirements and S1.6 of AASHTO
M 314-90 (2008) supplementary requirements or
AASHTO M 314-90 (2008), Grade 250 or 380,
including S1 supplementary requirements

•

ASTM A449 - 10, Type 1

•

ASTM A563 - 07a, including Appendix X1*

•

ASTM F844 - 07a

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Materials

AASHTO and ASTM Designation

Components of high-strength steel
fastener assemblies for use in
structural steel joints:

•

Bolts

•

Tension control bolts

•

Nuts

•

Hardened washers

Direct tension indicators

•

AASHTO M 164-05 (ASTM A325 - 10, Type 1)

•

ASTM F1852 - 11, Type 1

•

ASTM A563 - 07a, including Appendix X1*

•

ASTM F436 - 11, Type 1, circular, including S1

supplementary requirements

•

ASTM F959 - 09, Type 325, zinc-coated

Stainless steel fasteners (Alloy 316) for
general applications:

•

Bolts, screws, studs, threaded rods,

and non-headed anchor bolts

•

Nuts

•

Washers

Stainless steel plates (Alloy 316) for
general applications

•

ASTM F593 - 02(2008)e1 or ASTM F738M -

02(2008)

•

ASTM F594 - 09e1 or ASTM F836M - 02(2010)

•

ASTM A240 / A240M - 12 and ANSI B 18.22M

•

ASTM A240 / A240M - 12

Carbon-steel castings

AASHTO M 103M/M 103-12 or ASTM A27 / A27M -
10, Grade 450-240, Class 1

Malleable iron castings

ASTM A47 / A47M - 99(2009), Grade 32510/ 22010

Gray iron castings

AASHTO M 105-09 or ASTM A48 / A48M - 03(2008),
Class 30B

Ductile iron castings

ASTM A536 - 84(2009), Grade 450-310-85

Aluminium alloy ladder rung material

ASTM B221 - 12, Alloy 6061-T6

Aluminium castings

ASTM B26 / B26M - 12, Alloy 356.0-T6

Cast iron pipe

Commercial quality

Steel pipe

Commercial quality, welded or extruded

Sheet metal

Commercial quality

Other parts for general applications

Commercial quality

* Zinc-coated nuts that will be tightened beyond snug or wrench tight shall be furnished with a dyed
dry lubricant conforming to Supplementary Requirement S2 in ASTM A563 - 07a.

30.4

Miscellaneous Iron and Steel

Miscellaneous iron and steel items shall conform to the dimensions and details shown on the
Contract plans and as specified in these specifications and the Contract documents.

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30.4.1

Frames, Grates, Rings, and Covers

Unless otherwise specified elsewhere in these standard specifications or in the Contract particular
specifications, the Contractor shall furnish and install frames, grates, rings, and covers for inlets,
manholes, and other structures in conformance with the following.

Fabrication shall be performed in a workmanlike manner in conformance with the practice in modern
commercial shops. Burrs, rough and sharp edges, and other flaws shall be removed. Warped pieces
shall be straightened after all fabrication and galvanizing.

Grates, manhole frames, and covers shall be fabricated from ductile iron castings. The Contractor
shall:

a. Provide clean castings conforming to the shape and dimensions shown on the plans.

b. Ensure that the castings are free from sand and blowholes or other defects, and that surfaces

of the castings are reasonably smooth.

c. Remove runners, risers, fins, and other cast-on pieces from the castings, and grind these

areas smooth.

d. Cast or machine the bearing surfaces between manhole rings and covers and between

grates and frames with such precision that uniform bearing is provided throughout the
perimeter area of contact.

e. Matchmark pairs of machined castings for proper identification at installation. Grates and

covers shall fit into their frames without rocking.

Frame, grate, ring, and cover castings shall meet the proof-load testing requirements of AASHTO M
306-10. The Contractor shall use commercial type frames, rings, risers, or appurtenances only with
prior approval of the Engineer.

30.4.1.1

Documentation

The Contractor shall furnish mill test reports or a

manufacturer’s certification to the Engineer for each

lot or shipment of iron materials. For castings, the Contractor shall

also furnish a manufacturer’s

certification stating that the castings meet the proof-load testing requirements of AASHTO M 306-
10.

30.4.1.2

Construction

The Contractor shall construct and install frames, grates, rings, and covers in accordance with the
details shown on the Contract plans. Welding shall be in accordance with the current AASHTO/AWS
D1.5M/D1.5:2010, Bridge Welding Code. The Contractor shall tack-weld grates and covers to the
frame or ring when directed by the Engineer.

The Contractor shall provide galvanized bolts and nuts in accordance with Section 30.12,
Galvanizing.

All other cast iron items shall be painted with or dipped in commercial quality asphaltum.

30.4.2

Stainless Steel Bolts

Unless otherwise specified in the Contract documents or other sections of these standard
specifications, stainless steel bolts shall conform to ASTM F593 - 02(2008)e1 Alloy Groups 1, 2, or
3. Stainless steel nuts shall conform to ASTM F594 - 09e1.

ASTM F593 - 02(2008)e1 Alloy Groups 1, 2, and 3 are 300 series stainless steel alloys. Fasteners
for stainless steel Alloys 304 and 316 shall be used uncoated in aluminium structures. Three-
hundred series stainless steel in contact with aluminium need not be painted.

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30.5

Miscellaneous Bridge Metal

Miscellaneous bridge metal shall conform to the provisions in Section 30.4, Miscellaneous Iron and
Steel, and the provisions in this section. Miscellaneous metal used in constructing bridges and other
structures described as bridge work in the Contract documents, excluding miscellaneous metal
identified under separate Contract items, shall conform to the details shown on the Contract plans
and as specified in these specifications and the Contract documents.

Miscellaneous bridge metal shall consist of the following:

1. Bearing assemblies and equalizing bolts

2. Expansion joint armor in steel and concrete bridge decks and sliding plate and finger-type

expansion joints

3. Manhole frames and covers, frames and grates, ladder rungs, guard posts, access opening

covers, and access door assemblies

4. Deck drains, area drains, retaining wall drains, and drainage piping

Bearing assemblies shall be fabricated from structural steel conforming to the requirements in ASTM
A36 / A36M - 08.

High-strength bolted connections shall conform to the provisions for high-strength steel fasteners
and bolted connections in Sections 23.4.2 and 23.6.9 of Chapter 23, Steel Structures, of these
standard specifications.

Equalizing bolts shall consist of bolts or threaded bars. Threaded bars identified as prestressing steel
on the Contract plans shall conform to the requirements for plain bars in ASTM A722 / A722M - 12,
including Supplementary Requirements. When noted on the Contract plans, nuts, bolts, threaded
bars, and plate washers shall be cleaned by blast cleaning or hand cleaning, at the option of the
Contractor. Unless otherwise specified, all surfaces, except the portion of threads engaged by nuts,
shall be painted with two applications of zinc-rich primer that has not been thinned (organic vehicle
type), and conforms to the provisions of Article 24.3.2.2 of Chapter 24, Painting. Aerosol cans shall
not be used. The second application shall be applied to nuts and threads after installation.

An approved thread locking system, consisting of a cleaner, primer, and anaerobic adhesive shall
be applied where shown on the Contract plans. Lubricants and foreign materials shall be removed
from the threaded areas of both parts using the cleaner and small wire brush. The primer shall be
applied to cover the threaded areas of both parts. The anaerobic adhesive shall be applied to fill the
male threads in the area of the final position of the nut. The nut shall be installed at the location or
to the torque shown on the Contract plans, and an additional fillet of anaerobic adhesive shall be
applied completely around the exposed junctions of the nut and male part.

Access opening covers shall be fabricated from commercial quality sheet steel. Sheet steel for
access doors shall be galvanized sheet conforming to the requirements in ASTM A653 / A653M -
11, Coating Designation G 210.

Springs for deck drain grating latches shall be made from commercial quality type 304 stainless steel
spring wire containing a nominal composition of 18% chromium and 8% nickel. Spring latches and
other mechanical devices shall be tested before delivery, and shall operate smoothly and properly.

Cast steel and cast iron shall conform to the applicable provisions in Chapter 23, Steel Structures,
of these standard specifications.

Pipe bends shall be commercial quality tube bends or fabricated bends of substantially equal
smoothness. Miter-joint bends will not be accepted.

Transition fittings between pipes of different diameters shall be smooth, uniform, without sags,
projections, or off-sets, and shall be at least 100 mm in length for each 25 mm reduction in pipe
diameter.

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Mechanical expansion anchors shall be the integral stud type or the shell type with internal threads
and an independent stud. Self-drilling mechanical expansion anchors shall not be used.

All metal parts of anchorage devices shall be fabricated from steel or stainless steel, except iron
castings for cast-in-place inserts, which shall be malleable iron or ductile iron.

When installed in accordance with the manufacturer's instructions and these specifications,
mechanical expansion and resin capsule anchors shall withstand the application of a sustained
tension test load of at least the values in Table 30-3 for a period of at least 48 hours with a movement
not greater than 0.9 mm.

Table 30-3: Values of sustained tension test loads for mechanical expansion and resin

capsule anchors

Stud Diameter (mm)

Sustained Tension Test Load (kN)

29.01 - 33.00

137.9

25.01 - 29.00

79.6

21.01 - 25.00

64.1

19.01 - 21.00*

22.2

15.01 - 19.00

18.2

12.01 - 15.00

14.2

9.01 - 12.00

9.34

6.00 - 9.00

4.23

* Maximum stud diameter permitted for mechanical expansion anchors.

When installed in conformance with the manufacturer's instructions and these specifications, cast-
in-place inserts shall withstand the minimum ultimate tensile loads indicated in Table 30-4.

Table 30-4: Ultimate tensile loads for studs of different diameters

Stud Diameter (mm)

Ultimate Tensile Load (kN)

30 - 33

112.1

27 - 30

88.1

24 - 27

71.2

20 - 24

51.6

16 - 20

32.0

14 - 16

29.4

12 - 14

18.7

Concrete anchorage devices shall be subject to the approval of the Engineer. Approval of anchorage
device types and sizes shall be contingent upon the Contractor submitting to the Engineer one
sample of each type of concrete anchorage device, the manufacturer's installation instructions and
certified results of tests, by an approved independent testing laboratory, indicating compliance with
the above requirements. Anchorage devices previously tested and found to be in compliance with
the above requirements and approved by the Engineer need not be re-tested.

Concrete anchorage devices shall be installed in the concrete as shown on the Contract plans, as
recommended by the manufacturer of the devices, and as specified herein, so that the attached
equipment or fixtures will bear firmly against the concrete. Shell type mechanical expansion anchors

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shall be installed so that the top surface of the anchor body remains 12 mm to 25 mm below the
surface of the concrete after expansion. After installation of shell type mechanical expansion
anchors, and prior to mounting any equipment or fixture, the Contractor shall demonstrate, in the
presence of the Engineer, that the expansion anchor is firmly seated within the above tolerances.

If the manufacturer's instructions do not include specific torque requirements, nuts used to attach
equipment or fixtures to anchorage devices shall be tightened to the following installation torque
values indicated in Table 30-5.

Table 30-5: Installation torque values, (Newton meters)

Stud Diameter

(mm)

Shell Type

Mechanical

Expansion

Anchors

Integral Stud Type

Mechanical

Expansion

Anchors

Resin Capsule

Anchors and

Cast-in-Place Inserts

29.01 - 33.00

—

650

25.01 - 29.00

—

400

21.01 - 25.00

—

290

19.01 - 21.00

110

235

180

15.01 - 19.00

120

12.01 - 15.00

9.01 - 12.00

6.00 - 9.00

Joints in drain pipe shall be watertight, and shall be smooth and free from projections or off-sets in
excess of 2 mm on the inside. Mechanical couplings in piping shall be gasketed, short sleeve type
couplings consisting of a mild steel middle ring with pipe stop, two rubber-compounded wedge-
section ring gaskets, two mild steel follower rings, and sufficient mild steel bolts to compress the
gaskets.

Galvanizing of miscellaneous bridge metal will not be required for portions of plates, shapes, or other
items embedded more than 50 mm in concrete; embedded steel pipe terminating at or below the
surface of encasing concrete; and items shown on the Contract plans to receive a different finish.

Where local conditions require that pipes under walkways and other improved areas be of smaller
diameter than the down-drain pipes, a transition section shall be provided.

During construction operations, deck drain grates and other grating openings shall be securely
covered to prevent intrusion of debris until after final cleanup of the deck and other drainage areas.

After the cleanup of the deck and other drainage areas, each drain pipe and facility, except short
free-fall pipes, shall be tested in the presence of the Engineer by discharging approximately 400
liters of water into the drain to demonstrate the proper operation of the drain pipe and facility. If
evidence of obstructions in the pipe is observed, the pipe shall be cleared and the test repeated until
the drain pipe and facility are unobstructed.

30.6

Bridge Joint Restrainer Units

Bridge joint restrainer units, of the type or types shown on the Contract plans, consisting of cables
or cable assemblies and associated materials or components, shall conform to the details shown on
the Contract plans and the requirements of these specifications and the Contract documents.

The associated materials or components required for each restrainer unit type shall be as shown on
the Contract plans or as specified in the Contract documents and include various combinations of
the following:

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•

Structural steel components

•

Bolts

•

Bearing plates

•

Cable drum units

•

Pipe sleeves

•

Polyvinyl chloride pipe

•

Elastomeric pads

•

Expansion joint filler

•

Expanded neoprene

•

Expanded polystyrene

•

Sheet neoprene

•

Hardboard

•

Incidentals

Cables shall be 19 mm pre-formed, 6 by 19, wire-strand core or independent wire rope core (IWRC),
galvanized, right regular lay, manufactured of improved plow steel with a minimum breaking strength
of 200 kN, and in conformance with the requirements in Specification FED RR-W-410F, Wire Rope
and Strand.

Cable assemblies shall consist of cables, swaged fittings, studs, nuts, cable yield indicators, disk
springs, and when shown on the Contract plans, turnbuckles, and shall conform to the following
requirements:

a. The swaged fitting shall be machined from hot, rolled bars of steel conforming to the

requirements in the AISI C1035, and shall be annealed, suitable for cold swaging. A lock pin
hole to accommodate a 6 mm plated spring steel pin shall be drilled through the head of the
swaged fitting to retain the stud in proper position. The manufacturer's identifying mark shall
be stamped on the body of the swaged fitting.

b. The 25 mm-diameter stud shall conform to the requirements in ASTM A449 - 10 after

galvanizing. Prior to galvanizing, a 10 mm slot for the locking pin shall be milled in the stud
end.

c. Nuts shall conform to the requirements in ASTM A563 - 07a including Appendix X1, except

that lubrication is not required.

d. The cable yield indicator shall be machined from hot rolled bars of steel conforming to the

requirements in AISI C 1035 and shall be annealed, suitable for cold swaging. The heat
number and manufacturer's identifying mark shall be stamped on the end surface of each
cable yield indicator. The wall thickness of the reduced section of the cable yield indicator
shall be machined by the Contractor so that the indicator yields at a load between 160.2 kN
and 169.1 kN when tested in compression along the major axis at a test speed not to exceed
12 mm per minute.

e. The disc springs shall be made from steel conforming to the requirements in ASTM A684 /

A684M - 12, Grade 1075. Galvanizing of the disc springs will not be required. The disc springs
shall be cleaned and painted with a paint recommended by the manufacturer and color-coded
as shown on the Contract plans.

f. Turnbuckles shall be the steel pipe type. Pulls for the turnbuckles shall consist of a swaged

fitting and stud assembly.

g. The swaged fittings, turnbuckles, stud, and nut assembly shall develop the specified breaking

strength of the cable.

h. The cable assemblies shall be shipped as a complete unit including cable yield indicator, disk

springs, stud and nut, and when required, turnbuckle.

i. The Contractor shall be responsible for determining the required lengths of the cable

assemblies.

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j. The Contractor shall notify the Engineer, in writing, at least two days prior to tightening and

setting of cable restrainer units.

The following materials shall be furnished to the Engineer at the manufacturer's plant:

•

One sample cable assembly, consisting of a cable properly fitted with a swaged fitting and

right hand thread stud at both ends, 1 meter in total length, for each 200 cable assemblies or
fraction thereof produced.

•

One turnbuckle fitted with a 200 mm stud at each end for each 200 turnbuckles or fraction

thereof produced.

•

One percent of the cable yield indicators, but not fewer than eight, produced from each mill

heat.

•

Two disc springs of each size produced from each mill heat.

Free ends of cable for restrainer units shall be securely wrapped at each end to prevent separation.

Bolts, thread locking systems, and concrete anchorage devices shall conform to the provisions in
Section 30.5, Miscellaneous Bridge Metal.

Unless otherwise specified, steel parts shall conform to the requirements in ASTM A36 / A36M - 08.
Steel for bearing bars or pins shall conform to the requirements in ASTM A36 / A36M - 08 or ASTM
A576 - 90b(2012) Grade 1030 (AISI 1030), and shall not be rimmed or capped steel.

Pipe sleeves shall be commercial quality welded steel pipe.

Steel parts shall be galvanized in conformance with the provisions in Section 30.12, Galvanizing.

Fabrication and welding shall conform to the provisions in Section 30.5, Miscellaneous Bridge Metal.
The minimum size of fillet welds shall conform to the requirements in ANSI/ AWS D1.1/D1.1M:2010,
except as indicated in Table 30-6.

Table 30-6: Minimum Size of Fillet Weld for Different Thicknesses

Base Metal Thickness of Thicker Part

Joined (mm)

Minimum Size of Fillet Weld

(mm)

19 - 38

30 - 57

58 - 150

Over 150

Concrete for filling cable drum units shall conform to the applicable provisions in Chapter 21,
Concrete Structures, or shall be a commercial-grade pea gravel mix with not less than 400 kg of
cement per cubic meter.

Existing structural steel paint areas damaged by the Contractor's operations and holes drilled
through existing steel members shall be repaired in conformance with the provisions for repair of
galvanized surfaces in Section 30.12, Galvanizing, at the Contractor's expense.

When shown on the Contract plans, bond breaker on PVC pipe shall consist of a mortar tight
wrapping of plastic sheet or rubber sheet, 0.25 mm minimum thick or equal.

Expansion joint filler shall conform to the provisions in Section 21.9.1 of Chapter 21, Concrete
Structures.

Closed-cell expanded neoprene material shall be of commercial quality conforming to the stiffness
requirements for Class SC Grade 43E material or firmer as set forth in ASTM D1056 - 07.

Each restrainer unit shall consist of the number of cable units shown on the Contract plans.

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Where  shown  on  the  Contract  plans,  the  cable  shall  be  covered  with  a  piece  of  19  mm  inside
diameter neoprene tubing having a wall thickness of no less than 3 mm. Neoprene tubing shall be
held  in  place  with  stainless  steel  hose  clamps.  Neoprene  tubing  and  hose  clamps  shall  be  of
commercial  quality.  Cadmium  plated  screws  furnished  with  stainless  steel  clamps  shall  be
acceptable.

30.7

Miscellaneous Metal Pipes

Unless otherwise specified in the particular specifications or elsewhere in these standard
specifications, the Contractor shall furnish metal pipes in accordance with this section and as
directed by the Engineer.

30.7.1

Ductile Iron Culvert Pipe

The Contractor shall conform to ASTM A716 - 08 for the sizes specified in the Contract documents.

30.7.2

Slotted Drain Pipe

The Contractor shall furnish pipe conforming to AASHTO M 36-03 (R2011) and either AASHTO M
218-03 (R2011), AASHTO M 274-87 (2012), or AASHTO M 289-91 (2012) for the dimensions and
thicknesses specified in the Contract documents. The Contractor shall fabricate the pipe with either
angle slots or grate slots, and as shown on the Contract plans.

The Contractor shall furnish grate assemblies for the grate slot drain conforming to ASTM A1011 /
A1011M - 12a, Grade 250, and shall galvanize slot angles and grate slot assemblies according to
Section 30.4.1, Frames, Grates, Rings, and Covers.

30.7.3

Metallic-coated Spiral Rib Pipe

The Contractor shall furnish pipe, special sections (such as elbows and branch connections), and
coupling bands conforming to AASHTO M 36-03 (R2011), type IR and IIR, AASHTO M 218-03
(R2011), AASHTO M 274-87 (2012), or AASHTO M 289-91 (2012) for the dimensions and
thicknesses specified in the Contract documents.

30.7.4

Aluminium-alloy Spiral Rib Pipe

The Contractor shall furnish pipe, special sections (such as elbows and branch connections), and
coupling bands conforming to AASHTO M 196-92 (2012) (ASTM B745 / B745M - 97(2005)), type IR
and IIR for the dimensions and thicknesses specified in the Contract documents.

30.7.5

Concrete-lined Corrugated Steel Pipe

The Contractor shall furnish pipe, special sections (such as elbows and branch connections), and
coupling bands conforming to Section 31.1.4 of Chapter 31, Metal Culverts, for the dimensions and
thicknesses specified in the Contract documents. The Contractor shall fully-line the pipe and special
sections with concrete according to ASTM A849 - 10, Class C.

30.7.6

Invert-paved Corrugated Steel Pipe

The Contractor shall furnish pipe, special sections (such as elbows and branch connections), and
coupling bands conforming to Section 31.1.4 of Chapter 31, Metal Culverts, for the dimensions and
thicknesses specified in the Contract documents. The Contractor shall pave the invert of the pipe
and special sections with concrete or asphalt material according to ASTM A849 - 10, Classes B or
C, as specified in the Contract documents.

30.7.7

Cast-iron Soil Pipe and Fittings

The Contractor shall furnish pipe and fittings conforming to ASTM A74 - 09, Class SV, for the
designated sizes.

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30.7.8

Seamless Copper Water Tube and Fittings

The Contractor shall furnish tube and fittings conforming to ASTM B88 - 09, Type L, for the
designated sizes.

30.8

Corrugated Metal Units

Unless otherwise specified in the particular specifications or elsewhere in these standard
specifications, the Contractor shall furnish steel corrugated units conforming to AASHTO M 36-03
(R2011) and aluminium corrugated units conforming to AASHTO M 196-92 (2012) (ASTM B745 /
B745M - 97(2005)). For coatings, the Contractor shall conform to the following:

•

Asphalt-coated corrugated units, AASHTO M 190-04 (2012), Type A

•

Polymer pre-coated corrugated units, AASHTO M 245-00 (2012), Grade 250/250

30.9

Aluminium for Signs

All aluminium shapes and materials shall be new. The Contractor shall comply with the following
requirements, unless otherwise indicated on the Contract plans:

a. Extruded aluminium shapes for panels and moldings shall comply with the requirements for

Aluminium Alloy ASTM B221 - 12, Alloy 6063-T6.

b. Aluminium alloy sheets and plates shall comply with the specifications for Aluminium Alloy

Sheet and Plate, ASTM B209 - 10, Alloy 6061-T6.

c. Panel bolts and post clip bolts shall be made from aluminium alloy, in compliance with ASTM

B211 - 12e1, Alloy 2024-T4. Thread fit for bolts shall comply with American National
Standards Institute Class 2A. All aluminium bolts shall have an anodic coating of 0.005 mm
minimum thickness with dichromate or boiling water seal.

d. Aluminium nuts (6.4 mm tap and under) and all bolts and machine screws shall be made from

Aluminium Alloy ASTM B211 - 12e1, Alloy 2024-T4. Nuts over 6.4 mm tap shall be Aluminium
Alloy ASTM B211 - 12e1, Alloy 6262-T9. The thread fit for bolts and machine screws shall
comply with American National Standards Institute Class 2A and the thread fit for the nuts
shall be Class 2B. All nuts (6.4 mm tap and under), bolts, and machine screws shall receive
an anodic coating of 0.005 mm minimum thickness with a dichromate or boiling water seal.

e. Flat washers for aluminium bolts and post clips shall be 9.9 mm I.D. by 19 mm 0.D. by

2.3 mm, and shall be made from Aluminium Alloy ASTM B209 - 10, Alloy 2024-T4.

f. Lock nuts shall be Aluminium Alloy ASTM B211 - 12e1, Alloy 2017-T4, and shall have an

anodic coating of 0.005 mm minimum thickness with dichromate or boiling water seal. Thread
fit for lock nuts shall be as recommended by the manufacturer. Aluminium spring-lock
washers shall be made from Aluminium Alloy ASTM B211 - 12e1, Alloy 7075-T6.

g. Extruded aluminium sign brackets for tubular posts shall be Aluminium Alloy ASTM B221 -

12, Alloy 6062- T6.

h. Sand-cast aluminium mounting brackets shall be Aluminium Alloy 356-T6, ASTM B26 / B26M

- 12, Alloy SG70A-T6.

i. Cast post clips shall be Aluminium Alloy 356-T6, ASTM B108 / B108M - 12e1, Alloy SG70G-

T6.

j. Side trim shall be Aluminium Alloy, ASTM B221 - 12, Alloy 6063-T6.

Corrosion protection measures should not be required for aluminium, except as specified herein.
Measures to provide protection from corrosion for the alloys listed above shall be specified where:

1. Aluminium is in contact with wood or other porous material that may absorb water; the

aluminium shall be painted.

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2. Aluminium is in contact with concrete or masonry where moisture is present; the aluminium

shall be painted.

3. Aluminium is in contact with steel and moisture is present; the steel shall be painted.

30.10

Other Miscellaneous Metals

30.10.1

Steel Castings

For other items specifically identified as miscellaneous metal in the Contract documents, the
Contractor shall use carbon steel castings conforming to Classes 70, 90, and 120 of AASHTO
M192M/M192-1994 (ASTM A486/A486M - 87) and the following:

a. The Contractor shall furnish the specific class of steel castings as shown in the Contract

plans or as specified in the Contract documents.

b. The Contract plans shall specify the non-destructive tests to perform and their extent.

c. The Contractor shall use steel castings that are true to pattern in form and dimensions and

free from defects affecting strength or service life.

d. The Contractor may weld defects using the Engineer

’s approved process and perform weld

repairs before annealing the casting. If the Engineer requires it, the Contractor shall re-anneal
the castings after welding.

e. If the Engineer requires it, the Contractor shall test castings by radiography or ultrasonic

testing to determine the presence of cracks, flaws, or other defects.

f. The Contractor shall ensure that the metal thickness remaining after completing the

machining is not less than the thickness the Contract plans show.

g. The Contractor shall thread the ends of the tensile test specimens for at least 19 mm with

19 mm American N.C. threads.

30.10.2

Bronze Castings

If using bronze castings for bearings, trunnions, journals of bridges, and expansion plates, the
Contractor shall conform to ASTM B22 - 09e2, Alloy C91100.

30.10.3

Cold-finished, Carbon Steel Shafting

The Contractor shall use cold-finished, carbon steel shafting conforming to AASHTO M 169-09
(ASTM A108 - 07), Grades 1016 through 1030. If used for structural pins, then the Contractor shall
conform the shafting to ASTM A434 - 06(2012), Grade BC, quenched and tempered.

30.10.4

Lubricated Bronze Plates

Lubricated bronze plates shall be fabricated as the Contract plans show and with materials
conforming to ASTM B100 - 08, Copper Alloy C51000, or to ASTM B22 - 09e2, Alloy C91100.

The Contractor shall provide the Engineer with a certified report of tests or analyses indicating the
manufacturer’s test results for the lubricated bronze plates on their chemical and physical properties,
including the coefficient of friction of the material used.

The Fabricator shall bore or cast the surface of the lubricated bronze plates in a geometric pattern
of recesses. The Fabricator shall:

a. Fill the recesses with a lubricating compound consisting of graphite and metallic substances

with a lubricating binder capable of withstanding the atmospheric elements

b. Hydraulically press the compound into the recesses to form dense, non-plastic lubricating

inserts

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c. Ensure the lubricated area is within a range of 25 to 33%, inclusive of the bearing face, with

a coefficient of friction not greater than 0.1.

d. Unless the plans show or the Contract directs otherwise, only lubricate the top face of the

bronze plate.

30.10.5

Steel Forgings

The Contractor shall use steel forgings for pins, rollers, trunnions, and other forged parts conforming
to the requirements for class M quenched and tempered forgings of ASTM A668 / A668M - 04(2009).
The Contractor shall thread the ends of the tensile test specimens for at least 19 mm with 19 mm
American N.C. threads.

30.10.6

Welded and Seamless Steel Pipe

The Contractor shall furnish welded and seamless steel pipe for railings and general use conforming
to ASTM A53 / A53M - 12, Types F or E, Grade B, or Type S, Grade B. Unless provided otherwise,
the Contractor shall use black, standard weight pipe.

30.10.7

Pipe Fittings

The Contractor shall use malleable cast iron or pressed steel pipe fittings for railings and other
required uses. If zinc-coated fittings are required, the coating shall conform to ASTM A123 / A123M
- 12.

30.10.8

Sheet Lead

The Contractor shall furnish lead in sheet form conforming to ASTM B29 - 03(2009), using lead
sheets of uniform thickness throughout, free from cracks, seams, slivers, scale, and other surface
defects.

Unless the Contract plans show otherwise, the Contractor shall use sheet lead 3.2 mm thick with a
tolerance of ± 0.8 mm. The Contractor shall ensure that the length and width are within 3.2 mm of
the Contract plan dimensions.

30.10.9

Sheet Copper

The Contractor shall furnish strip or sheet copper conforming to ASTM B152 / B152M - 09 and
suitable for the purpose intended. Unless specified otherwise, the Contractor shall use sheet copper
with a minimum thickness of 0.5 mm.

30.10.10 Sheet Zinc

For sheet or plate zinc, the Contractor shall conform to Prime Western Grade ASTM B6 - 12, using
sheet and plate zinc of uniform thickness, free from cracks, seams, slivers, scale, surface corrosion,
adhering matter, and other surface defects.

The Contractor shall use sheet and plate zinc conforming to the zinc gauge shown on the Contract
plans, with a thickness tolerance of ± 6%. The Contractor shall use sheets within 3.2 mm of the
length and width the Contract plans show.

30.11

Fabrication

Fabrication of miscellaneous metal items shall be performed in a manner conforming to the practice
in modern commercial shops. Burrs, rough and sharp edges, and other flaws shall be removed.
Warped pieces shall be straightened after fabrication and galvanizing.

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30.12

Galvanizing

Unless otherwise specified in the Contract documents, all steel items that are not embedded at least
50 mm in concrete and all cast iron sidewalk frames and covers shall be galvanized in accordance
with Section 23.4.10 of Chapter 23, Steel Structures. Assemblies shall be galvanized after
fabrication.

30.13

Transporting Materials

All miscellaneous metal works as specified herein and as indicated on the Contract plans shall be
transported and protected during all handling to prevent distortion, deformation, or damage of any
kind. Any metal materials damaged during transportation, handling, or otherwise shall be rejected
and the Contractor shall provide new material as required at no additional expense to the Owner.

30.14

Storage of Materials

All miscellaneous metal works as specified herein and as indicated on the Contract plans shall be
stored above the ground on platforms, skids, or other supports. All metal materials shall be kept free
from dirt, grease, and other foreign matter, and shall be protected from corrosion.

30.15

Clean-up

At the completion of the Contract, all miscellaneous metal works shall be cleaned of concrete spatter,
mud, oil, shop markings if visible to the public, and other foreign materials

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NDEX

access door assemblies, 10
access opening covers, 10
aluminium, 3, 9, 16, 17
area drains, 10
Bearing assemblies, 10
bearing surfaces, 9
bolts, 7, 8, 9, 10, 12, 16
bridge, 3, 10, 12
cable assemblies, 12, 13, 14
Cable drum units, 13
castings, 8, 9, 11, 17
certification, 9
corrugated metal, 3
covers, 9, 10, 19
Culverts, 15
Deck drains, 10
Department of Transport, ii
drainage piping, 10
Expansion joint armor, 10
Fabrication, 9, 14, 18
fabrication site, 3
finger-type expansion joints, 10
frames, 9, 10, 19
Galvanizing, 9, 12, 13, 14, 19

grates, 9, 10, 12
guard posts, 10
Hardboard, 13
Incidentals, 13
inlets, 9
journals of bridges, 17
ladder rungs, 10
manholes, 9
metal pipe, 3
mill test reports, 9
non-destructive tests, 17
restrainer, 3, 12, 14
retaining wall drains, 10
rings, 9, 12
seamless, 18
signs, 3
sliding plate, 10
stainless steel, 9, 10, 11, 15
steel forgings, 18
tensile test specimens, 17, 18
transportation, 19
trunnions, 17, 18
Turnbuckles, 13

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Chapter 31: Metal Culverts

ABLE OF

ONTENTS

Table of Contents............................................................................................................................. i

List of Figures ................................................................................................................................. ii

List of Tables .................................................................................................................................. ii

Metal Culverts ................................................................................................................. 31-1

31.1

General ........................................................................................................................ 31-1

31.2

Reference Standards and Codes ................................................................................. 31-1

31.3

Working Drawings ........................................................................................................ 31-2

31.4

Materials ...................................................................................................................... 31-3

31.4.1

Corrugated Metal Pipe .......................................................................................... 31-3

31.4.2

Structural Plate ..................................................................................................... 31-3

31.4.3

Nuts and Bolts ...................................................................................................... 31-4

31.4.4

Mixing of Materials ................................................................................................ 31-4

31.4.5

Fabrication ............................................................................................................ 31-4

31.4.6

Welding ................................................................................................................ 31-4

31.4.7

Protective Coatings ............................................................................................... 31-4

31.4.8

Bedding and Backfill Materials .............................................................................. 31-4

31.4.8.1

General Specifications for Bedding and Backfill Materials .............................. 31-4

31.4.8.2

Long-span Structural Plate Structures ........................................................... 31-5

31.4.8.3

Box Culverts .................................................................................................. 31-5

31.4.8.4

Deep Corrugated Structures .......................................................................... 31-5

31.4.8.5

Concrete Backfill ............................................................................................ 31-5

31.5

Assembly ..................................................................................................................... 31-5

31.5.1

General ................................................................................................................. 31-5

31.5.2

Joints .................................................................................................................... 31-6

31.5.2.1

Field Joints .................................................................................................... 31-6

31.5.2.2

Joint Types .................................................................................................... 31-6

31.5.2.3

Soil Conditions ............................................................................................... 31-6

31.5.2.4

Joint Properties .............................................................................................. 31-6

31.5.3

Assembly of Long-span Structures ....................................................................... 31-7

31.6

Installation ................................................................................................................... 31-8

31.6.1

General ................................................................................................................. 31-8

31.6.2

Foundation ............................................................................................................ 31-8

31.6.3

Bedding .............................................................................................................. 31-10

31.6.4

Structure Backfill ................................................................................................. 31-10

31.6.4.1

General ........................................................................................................ 31-10

31.6.4.2

Arches ......................................................................................................... 31-11

31.6.4.3

Long-span Structural Plate Structures ......................................................... 31-11

31.6.4.4

Box Culverts ................................................................................................ 31-12

31.6.4.5

Concrete Backfill .......................................................................................... 31-12

31.6.5

Bracing ............................................................................................................... 31-12

31.6.6

Arch Substructures and Headwalls ..................................................................... 31-13

31.6.7

Inspection Requirements for CMP ...................................................................... 31-13

31.6.7.1

Visual Inspection.......................................................................................... 31-13

31.6.7.2

Installation Deflection ................................................................................... 31-14

31.6.7.3

Internal Inspection of Culverts...................................................................... 31-15

31.7

Construction Precautions ........................................................................................... 31-16

31.8

Salvaged Metal Culverts ............................................................................................ 31-17

31.8.1

Description .......................................................................................................... 31-17

31.8.2

Construction ....................................................................................................... 31-17

Index ...................................................................................................................................... 31-18

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METAL CULVERTS

31.1

General

This work shall furnish, fabricate, install, and inspect metal pipes, structural plate metal pipes,
arches, pipe arches, box structures, and deep corrugated structures

— as well as the associated

substructures and headwalls in conformance with these specifications and the details shown in the
Contract documents. As used in this specification, long-span structures shall consist of metal plate
horizontal elliptic, inverted pear, and multiple radius arch shapes

— as well as special shape culverts,

as defined in Section 12 of the

American Association of State Highway and Transportation Officials

(AASHTO)

Load and Resistance Factor Design

(LRFD)

Bridge Design Specifications

Terms referring to “metal pipes” and “metal structural plate pipes” include circular and pipe arches
and underpass and elliptical shapes. Metal structural plate arches consist of a metal plate arch
supported on reinforced concrete footings with or without a paved invert slab. Pipe arches are
constructed to form a pipe having an arch-shaped crown and a relatively flat invert. Structural plate
metal box structures are conduits, rectangular in cross section, and constructed of metal plates.

The metal culvert descriptions refer to Section 12, Buried Structures and Tunnel Liners, of the
AASHTO LRFD

Bridge Design Specifications

31.2

Reference Standards and Codes

Standards and codes for metal culverts shall be as specified in these specifications, in the Contract
documents, if any, and the following, in their latest edition:

AASHTO LRFD American Association of State Highway and Transportation Officials - Load and

Resistance Factor Design, Bridge Construction Specifications;

AASHTO

Standard Specifications for Transportation Materials and Methods of Sampling
and Testing;

AASHTO/AWS

Bridge Welding Code;

D1.5M/D1.5:2010

ADQCC (TR-516) Road Structures Design Manual;

ANSI

American National Standards Institute;

ANSI/AWS D1.2/ Structural Welding Code

—Aluminum;

D1.2M:2003

ASTM

American Society for Testing and Materials;

AWS

American Welding Society;

OSHA

Occupational Safety and Health Administration;

Standards -29 CFR OSHA Regulations;

Table 31-1 presents American Association of State Highway and Transportation Officials (AASHTO)
and American Society for Testing and Materials (ASTM) standards that are related to materials for
metal culverts. It also includes designations and titles.

Table 31-1: Designations and titles for AASHTO and ASTM standards that apply to metal

culverts construction works

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AASHTO

Designation

ASTM

Designation

Title

AASHTO M 36-

03 (R2011)

ASTM A760 /

A760M - 10

Standard Specification for Corrugated Steel Pipe,
Metallic-Coated for Sewers and Drains

AASHTO M

218-03 (R2011)

Standard Specification for Steel Sheet, Zinc-Coated
(Galvanised), for Corrugated Steel Pipe

AASHTO M

196-92 (2012)

ASTM B745 /

B745M -

97(2005)

Standard Specification for Corrugated Aluminium Pipe for
Sewers and Drains

AASHTO M

219-92 (2012)

ASTM B746 /

B746M -

02(2012)

Standard Specification for Corrugated Aluminium Alloy
Structural Plate for Field-Bolted Pipe, Pipe-Arches, and
Arches

AASHTO M

167M/M 167-09

ASTM A761 /

A761M -

04(2009)

Standard Specification for Corrugated Steel Structural
Plate, Zinc-Coated, for Field-Bolted Pipe, Pipe-Arches,
and Arches

ASTM A307 -

Standard Specification for Carbon Steel Bolts and Studs,
60,000 PSI Tensile Strength

AASHTO M

190-04 (2012)

Standard Specification for Bituminous-Coated Corrugated
Metal Culvert Pipe and Pipe Arches

AASHTO M

246-05 (R2011)

ASTM A742 /

A742M -

03(2008)

Standard Specification for Steel Sheet, Metallic Coated
and Polymer Precoated for Corrugated Steel Pipe

ASTM D2487 -

Standard Practice for Classification of Soils for
Engineering Purposes (Unified Soil Classification
System)

AASHTO M

145-91 (2008)

Standard Specifications for Classification of Soils and
Soil-Aggregate Mixtures for Highway Construction
Purposes

ASTM A449 -

Standard Specification for Hex Cap Screws, Bolts and
Studs, Steel, Heat Treated, 120/105/90 ksi Minimum
Tensile Strength, General Use

ASTM F468 - 10

Standard Specification for Nonferrous Bolts, Hex Cap
Screws, and Studs for General Use

AASHTO T 99-

Standard Method of Test for Moisture-Density Relations
of Soils Using a 2.5-kg (5.5-lb) Rammer and a 305-mm
(12-in.) Drop

AASHTO T 180-

Standard Method of Test for Moisture-Density Relations
of Soils Using a 4.54-kg (10-lb) Rammer and a 457-mm
(18-in.) Drop

31.3

Working Drawings

Whenever specified in the Contract documents, or requested by the Engineer, the Contractor shall
provide the Manufacturer's assembly instructions or working drawings and substantiating
calculations in sufficient detail to permit a structural review of the structural design. To allow for their
review, revision, and approval without delaying the work, the Contractor shall submit the working
drawings in advance of construction.

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Construction of any metal culvert, for which working drawings are required, shall not begin until the
Engineer has approved the drawings. Such approval will not relieve the Contractor of responsibility
for results obtained by use of these drawings or any other contractual responsibilities.

31.4

Materials

Materials for metal culverts shall comply with the requirements outlined in this section.

31.4.1

Corrugated Metal Pipe

Steel pipes, steel apron end walls, and other components conforming to the requirements of
AASHTO M 36-03 (R2011) (ASTM A760 / A760M - 10) shall be furnished by the Contractor. These
components shall be fabricated from either zinc-coated steel sheet or aluminium-coated steel sheet
except when fabrication from zinc-coated steel sheet is required by the Contract documents.

Zinc-coated steel sheets shall conform to the requirements in AASHTO M 218-03 (R2011).

If specified, aluminium pipes and aluminium apron end walls shall conform to the requirements of
AASHTO M 196-92 (2012) (ASTM B745 / B745M - 97(2005)). If steel apron end walls are delivered
attached to the corrugated aluminium pipe, the Contractor shall install a suitable insulating material
approximately 1.6 mm thick between the pipe and the end wall, at the joint. One, or more, of the
following materials may be used by the Contractor:

•

Asphalt impregnated fabric;

•

A sheet plastic;

•

A rubber gasket; or,

•

Other non-degradable material of substantial strength.

Pipe types and corresponding AASHTO designations are shown in Table 31-2.

Table 31-2: Corrugated Metal Pipe Types

Pipe Type

AASHTO Classification

Circular

Type I

Circular, smooth-lined

Type IA

Circular, spiral rib

Type IR

Arch

Type II

Arch, smooth-lined

Type IIA

Arch, spiral rib

Type IIR

Corrugated metal pipe, of all types, shall be provided with annular, helical, or spiral rib corrugations
that project outward.

Pipes with helical end corrugations shall be provided only when joining new pipe to existing pipe with
helical end corrugations is necessary.

For precoated galvanised

steel pipe, a minimum polymer coating thickness of 300 μm shall be

provided on each side.

31.4.2

Structural Plate

Steel structural plates shall conform to the requirements of AASHTO M 167M/M 167-09 (ASTM A761
/ A761M - 04(2009)). Aluminium alloy structural plates shall conform to the requirements of AASHTO
M 219-92 (2012) (ASTM B746 / B746M - 02(2012)).

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31.4.3

Nuts and Bolts

Nuts and bolts for steel structural plate pipes, arches, pipe arches, and box structures shall conform
to the requirements of AASHTO M 167M/M 167-09 (ASTM A761 / A761M - 04(2009)). Nuts and
bolts for aluminium structural plates shall consist of aluminium conforming to the requirements of
ASTM F468 - 10 or standard-strength steel conforming to ASTM A307 - 10.

31.4.4

Mixing of Materials

Unless  the  materials  are  adequately  separated  or  protected  to  avoid  galvanic  reactions,  the
Contractor  shall  not  mix  aluminium  and  steel  materials  in  any  installation.  Hot-dipped  galvanised
steel  and  stainless  steel  bolts  and  nuts  are  acceptable  materials  to  connect  aluminium  structural
plates.

31.4.5

Fabrication

Bolts with the seams staggered so that no more than three places come together at any one point
shall connect the plates at longitudinal and circumferential seams.

31.4.6

Welding

If required, welding of the steel shall conform to the current AASHTO,

American Welding Society

AASHTO/AWS D1.5M/D1.5:2010

Bridge Welding Code

. All welding of steel plates, other than

fittings, shall be performed prior to galvanizing.

If required, welding of aluminium shall conform to the

American Welding Society

ANSI/AWS

D1.2/D1.2M:2003,

Structural Welding Code

—Aluminum

31.4.7

Protective Coatings

When required in the Contract documents, the Contractor shall protect metal pipes and structural
metal  plate  culverts  with  a  bituminous  coating  or  shall  pave  the  invert  with  bituminous  materials.
Unless  otherwise  specified  in  the  Contract  documents,  the  Contractor  shall  apply  bituminous
coatings as instructed in AASHTO M 190-04 (2012), Type A. If required, the Contractor shall apply
bituminous  pavings  over  the  bituminous  coatings  to  the  inside  bottom  portion  of  the  pipe

— as

provided in AASHTO M 190-04 (2012), Type C

— unless otherwise specified in the Contract

documents. After installation, the Contractor shall coat the portions of all nuts and bolts used for the
assembly of coating structural plate pipes, arches, pipe arches, and box culverts that project outside
the pipe. Portions of the nuts and bolts projecting inside the pipe need not be coated.

When required in the Contract documents, polymeric coatings shall conform to the requirements of
AASHTO M 246-05 (R2011) (ASTM A742 / A742M - 03(2008)). Prior to corrugating, the Contractor
shall apply polymeric coatings to the galvanised sheet. Unless otherwise specified in the Contract
documents, the coating thickness shall not measure less than 0.25 mm. Any pinholes, blisters,
cracks, or lack of bond shall be a cause for rejection. Polymeric coatings are not permitted on
structural plates.

31.4.8

Bedding and Backfill Materials

31.4.8.1

General Specifications for Bedding and Backfill Materials

Bedding shall consist of loose native or granular material with a maximum particle size measuring
less  than  one-half  the  corrugation  depth.  Backfill  for  metal  culverts  shall  consist  of  a  granular
material,  as  specified  in  the  Contract  documents  and  specifications,  and  shall  be  free  of  organic
material  and  rock  fragments  larger  than  75  mm  in  the  greatest  dimension.  These  materials  shall
have  moisture content  within  the  limits  required for  compaction.  As  a  minimum,  backfill materials
shall meet the requirements of AASHTO M 145-91 (2008) for A-1, A-2, or A-3.

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31.4.8.2

Long-span Structural Plate Structures

Bedding and backfill materials shall meet the general requirements of Article 31.4.8.1, General
Specifications for Bedding and Backfill Materials. As a minimum, backfill materials for structures with
less than 3.6 m of cover shall meet the requirements of AASHTO M 145-91 (2008) for A-1, A-2-4, A-
2-5, or A-3. Minimum backfill requirements for structures with 3.6 m or more cover shall meet
AASHTO M 145-91 (2008) requirements for A-1 or A-3.

31.4.8.3

Box Culverts

Bedding and backfill materials shall meet the general requirements of Section 31.4.8, Bedding and
Backfill Materials. As a minimum, backfill shall meet the requirements of AASHTO M 145-91 (2008)
for A-1, A-2-4, A-2-5, or A-3.

31.4.8.4

Deep Corrugated Structures

For deep corrugated structures, the selected backfill within the structural backfill zone shall meet the
requirements of AASHTO M 145-91 (2008) A-1, A-2-4, A-2-5, or A-3 (ASTM D2487

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lassifications GW, GP, SW, SP, GM, SM, SC, GC) and the Manufacturer’s requirements.

31.4.8.5

Concrete Backfill

At locations where the Contractor will backfill the pipe with concrete, as shown in the Contract
documents, the concrete backfill shall consist of minor concrete conforming to the provisions in
Section 21.27 of Chapter 21, Concrete Structures

— except that minor concrete shall contain not

less than 200 kg of cement per 1 cubic metre of concrete. Types of concrete to be used will be
designated in the Contract documents.

31.5

Assembly

31.5.1

General

Corrugated metal pipes and structural plate pipes shall be assembled in accordance with the
Manufacturer's instructions. All pipes shall be unloaded and handled with reasonable care. Pipes or
plates shall not be rolled or dragged over gravel or rock, and the Contractor shall prevent them from
striking rock or other hard objects during placement in the trench or on the bedding.

Starting at the downstream end, the Contractor shall place the corrugated metal pipes (CMPs) in the
bed. Pipes with circumferential seams shall be installed with their inside circumferential sheet laps
pointing downstream.

Bituminous-coated, polymer-coated, and paved-invert pipes shall be installed in a similar manner to
CMPs with special care in handling to avoid damage to coatings. Paved-invert pipes shall be installed
with the invert pavement placed and centred on the bottom.

Structural  metal  plate  culverts  and  pipes  shall  be  assembled  and  installed  as  specified  in  the
Contract  documents  and  detailed  erection  instructions.  Copies  of  the  Manufacturer's  assembly
instructions shall be furnished as specified in Section 31.3, Working Drawings. Bolted longitudinal
seams shall be well-fitted with the lapping plates parallel to each other. Applied bolt torques for 19-
mm-diameter (M20), high-strength steel bolts (ASTM A449 - 10) for the assembly of steel structural
plates shall be a minimum of 0.135 kN.m, and a maximum of 0.407 kN.m. Aluminium structural plates
shall  be  assembled using  19-mm-diameter (M20)  aluminium  bolts (ASTM  F468  -  10)  or  standard
strength  steel  bolts  (ASTM  A307  -  10)  that  shall  be  torqued  to  a  minimum  of  0.135  kN.m,  and  a
maximum of 0.203 kN.m. When the Contractor uses a seam sealant tape or a shop-applied asphalt
coating,  bolts  shall  be  retightened  no  more  than  once    and  generally  within  24  hours  after  initial
tightening.

Longitudinal seams in deep corrugated structures shall be staggered.

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31.5.2

Joints

Joints for corrugated metal culverts and drainage pipes shall meet the requirements described
herein.

31.5.2.1

Field Joints

Designs for transverse field joints shall permit the successive connection of pipe sections and form
a continuous line free from appreciable irregularities in the flow line. Additionally, the joints shall meet
the general performance requirements described in Articles 31.5.2.2 through 31.5.2.4.

Suitable transverse field joints that satisfy the requirements for one or more of the subsequently
defined joint performance categories can be obtained with the following types of connecting bands
when furnished with the suitable band-end fastening devices:

a. Corrugated bands;

b. Bands with projections;

c. Flat bands;

d. Bands of special design that engage factory reformed ends of corrugated pipe; or,

e. Other equally effective types of field joints may be used with the approval of the Engineer.

31.5.2.2

Joint Types

Standard or special joints shall be specified within the Contract documents, as appropriate for the
requirements at hand.

Standard joints are for pipes not subject to large soil movements or disjointing forces. These joints
are satisfactory for ordinary installations where simple slip-type joints are typically used. Special
joints are for more severe requirements, including the following:

a. A need to withstand soil movements or resist disjointing forces;

b. Poor foundation conditions; and,

c. Conditions producing longitudinal hydraulic forces requiring down drain joints, such as pipes

on steep slopes or sharp curves.

31.5.2.3

Soil Conditions

When poor soil conditions are encountered, the Contract documents should specify which special
joints the Contractor shall use.

31.5.2.4

Joint Properties

Joint property requirements shall be taken as specified in Table 31-3. A rational analysis or suitable
test may determine the values for various types of pipes.

When considering the design of, or selection of, pipe joints, the Contractor shall consider the
following design issues:

a. Joint Overlap: Standard joints that do not meet the moment strength alternatively shall have

a minimum sleeve width overlapping the abutting pipes. Minimum total sleeve widths shall
be as given in Table 31-3. Any joint meeting the requirements for a special joint may be used
in lieu of a standard joint.

b. Soil Tightness: Soil tightness refers to openings in the joint through which soil may infiltrate.

No opening may exceed 25 mm. Additionally, for all categories, if the size of the opening
exceeds 3 mm, the length of the channel shall be at least four times the size of the opening.

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