Contract Design, Estimating and Documentation (CDED) Manual REVISION PACKAGE #203

Transcription

1 Contract Design, Estimating and Documentation (CDED) Manual REVISION PACKAGE #203 Dated: December 17, 2015 Portable Document Format (PDF) copies of this revision package as well as the individual documents and the complete manual, can be accessed and printed free of charge from the Technical Publications website at Attached are copies of the CDED documents issued in digital format under this revision. Please update your manual as per the instructions detailed below. Chapter B - Detail Estimating Reference Code Existing Version Date New Version Date Implementation Date In CPS Remarks New (New), Revised (Rev), Cancelled (Can), Reissued (Rei) B331 March 2015 November 2015 December 17, 2015 Rev: Detail Estimating chapter for Full- Depth Reclamation With Expanded Asphalt Stabilization is reaffirmed. No changes to technical content. B333 July 2015 November 2015 December 17, 2015 Rev: Detail Estimating chapter for Cold In- Place Recycling is reaffirmed. No changes to technical content. B335 July 2015 November 2015 December 17, 2015 Rev: Detail Estimating chapter for Cold In- Place Recycling with Expanded Asphalt is reaffirmed. No changes to technical content. B410 April 2015 November 2015 December 17, 2015 Rev: Detail Estimating chapter for Pipe Sewers is reaffirmed. No changes to technical content. B421-2 June 2014 November 2015 December 17, 2015 Rev: Detail Estimating chapter for Pipe Culverts is reaffirmed. No changes to technical content. December 17, 2015 Page 1 of 3 CDED Revision #203

2 Chapter E - Standard Special Provisions (SSPs) Reference Code Existing Version Date E3-1 October F23 104S02 104S03 104S05 May 2015 April 2014 April 2014 May 2014 New Version Date December 2015 December S05 N/A October F58 331F01 May 2015 April F02 N/A November S03 April 2015 Implementation Date In CPS December 17, 2015 December 17, 2015 N/A December 17, 2015 N/A December 17, 2015 N/A December 17, 2015 December 17, 2015 N/A December 17, 2015 N/A December 17, 2015 December 17, 2015 N/A December 17, 2015 Remarks New (New), Revised (Rev), Cancelled (Can), Reissued (Rei) Rev: List of Active SSDs is revised. Rev: SP Amendment to OPSS 182 for Timing of In-Water Works, Oversight Requirements, and Measures to Avoid Harm to Fish is revised with changes throughout, including the addition of oversight requirements, and measures to avoid harm to fish. Can: SP Amendment to OPSS 421 for Post Installation Inspection for Pipe Culverts is cancelled. Applicable content incorporated into the updated specification. Can: SP Amendment to OPSS 410 for Post Installation Inspection for Pipe Sewers is cancelled. Applicable content incorporated into the updated specification. Can: SP Amendment to OPSS 401 is cancelled. Applicable content incorporated into the updated specification. New: SP Amendment to OPSS 1103 Material Specification for Emulsified Asphalt is implemented. Can: SP for Fisheries Act Authorization Compliance - Oversight, Monitoring, and Documentation - Requirements for Protection of Fish and Fish Habitat is cancelled. Applicable content incorporated into the updated specification and SSP 101F23. Can: SP Amendment to OPSS 331 is cancelled. Applicable content incorporated into the updated specification. New: SP Amendment to OPSS 331 for Design Rate of Expanded Asphalt is implemented. Can: SP Amendment to OPSS 333 is cancelled. Applicable content incorporated into the updated specification. December 17, 2015 Page 2 of 3 CDED Revision #203

3 Reference Code Existing Version Date New Version Date Implementation Date In CPS Remarks New (New), Revised (Rev), Cancelled (Can), Reissued (Rei) 335S03 April 2015 N/A December 17, 2015 Can: SP Amendment to OPSS 335 is cancelled. Applicable content incorporated into the updated specification. 410S02 April 2014 N/A December 17, 2015 Can: SP Amendment to OPSS 410 is cancelled. Applicable content incorporated into the updated specification. 421S05 December 2014 N/A December 17, 2015 Can: SP Amendment to OPSS 421 is cancelled. Applicable content incorporated into the updated specification. Chapter G - Ministry of Transportation Ontario (MTODs) Reference Code Existing Version Date New Version Date Implementation Date In CPS Remarks New (New), Revised (Rev), Cancelled (Can), Reissued (Rei) G2-0 October 2015 December 2015 December 17, 2015 Rev: List of Active MTODs is revised. Chapter H - OPSSs and OPSDs Reference Code Existing Version Date New Version Date Implementation Date In CPS Remarks New (New), Revised (Rev), Cancelled (Can), Reissued (Rei) H2-1 October 2015 December 2015 December 17, 2015 Rev: List of Active OPSSs - General and Construction Specifications is revised. H3-295 August 2015 December 2015 December 17, 2015 Rev: List of Active OPSDs - Division Electrical and ATMS is revised. H3-300 August 2015 December 2015 December 17, 2015 Rev: List of Active OPSDs - Division Structures is revised. Chapter I - Structural Standard Drawings (SSDs) Reference Code Existing Version Date New Version Date Implementation Date In CPS Remarks New (New), Revised (Rev), Cancelled (Can), Reissued (Rei) I2-0 October 2015 December 2015 December 17, 2015 Rev: List of Active SSDs is revised. December 17, 2015 Page 3 of 3 CDED Revision #203

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5 DETAIL ESTIMATING FULL-DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION B331 - FULL-DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION - OPSS.PROV GENERAL The work of Full-Depth Reclamation with Expanded Asphalt Stabilization consists of in-place full-depth reclamation of the existing hot mix asphalt (HMA) and underlying granular base. The reclaimed material is shaped, compacted and then stabilized inplace by the addition of expanded asphalt. The stabilized material is then graded to the required profile and compacted. Following a minimum three-day curing period, the stabilized base is overlaid with HMA. Full-Depth Reclamation with Expanded Asphalt Stabilization should be considered for roads that are severely cracked and structurally inadequate REFERENCES - None TENDER ITEM Full-Depth Reclamation with Expanded Asphalt Stabilization SPECIFICATIONS Details of the work are contained in OPSS SPECIAL PROVISIONS The designer should refer to Chapter "E" of the CDED Manual to review the applicable special provisions STANDARD DRAWINGS There are no Ontario Provincial Standard Drawings directly applicable to this type of work. November 2015 Page 1 of 5 B331

6 DETAIL ESTIMATING FULL-DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION DESIGN Geotechnical Design Considerations The processing depth should target approximately 50% by mass of asphalt coated particles. The extent that the existing granular material contains asphalt coated particles should be considered when determining the processing depth. Where project conditions will result in a blended material significantly greater than 50% by mass of asphalt coated particles, the designer should reduce adjust the minimum amount of expanded asphalt to be added. The amount of expanded asphalt to be added (design rate) is calculated using the following formula: Design rate of expanded asphalt = 0.04 x uncoated aggregate particles (% by mass) x asphalt coated particles (% by mass) For example, the design rate for a mix with 50% uncoated particles and 50% asphalt coated particles is 0.04 x 50% x 50% = 2.75%. Typical reclamation equipment has a total maximum processing depth of 300 mm. A maximum of 50% of the total maximum processing depth may be existing asphalt. This means that, in locations where the bituminous pavement depth is greater than 150 mm, milling of the existing asphalt pavement to a thickness of 150 mm or less is required prior to in-place full-depth reclamation. Alternatively, larger pavement thicknesses may be more suited to cold in-place recycling (CIR) or cold in-place recycling with expanded asphalt (CIREAM). Refer to CDED B510-5 for documentation requirements for milling (asphalt pavement removal, partial-depth). For projects with variation in existing asphalt pavement thicknesses, different pulverizing depths should be considered by clustering the pavement into segments of similar asphalt pavement thickness, and the design rate of expanded asphalt calculated for each segment accordingly. Full-Depth Reclamation with Expanded Asphalt Stabilization is meant to be a twostep process so that road profile and cross-fall can be corrected in the first pass, i.e. pulverizing and reshaping the road profile. In the second pass, expanded asphalt is added to stabilize the granular base and reclaimed material. A one step process using recycling train similar to CIR or CIREAM process is available and is commonly used, however it allows only minor cross-fall correction (<0.5%). The widths required for in-place processing are often wider than the widths required for stabilization with expanded asphalt. The Geotechnical section may recommend and designers should consider processing without stabilization existing tapers or November 2015 Page 2 of 5 B331

7 DETAIL ESTIMATING FULL-DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION paved shoulders, or where tapers or paved shoulders are being introduced. In some cases, granular shoulders are also processed without stabilization. Full width processing will ensure similar performance and drainage of the granular material. Following the in-place processing, expanded asphalt stabilization is typically only performed for full-lane pavement widths. Any required grading should be carried out as part of the in-place processing operation and not during the expanded asphalt stabilization process. Cold mix widening, full-depth curve widening, and asphalt curb and gutter may be processed with the underlying granular. The stabilized layer will gain strength over time and will perform similar to an asphalt binder layer, and one layer of hot mix overlying as wearing course may be sufficient, depending on traffic loading and design parameters To date, surface treatment and micro-surfacing have not been used as the wearing surface. Heavy traffic is not recommended on the processed surface before it has cured and been sealed with a wearing course. The wearing surface must be placed during the same construction season. The designer should be aware that the length of the recycling operation may affect traffic management. A typical recycling train may extend up to 80m long Pre-Engineering Investigation This section describes procedures and tests to be carried out during pre-engineering investigations on potential Full-Depth Reclamation with Expanded Asphalt Stabilization projects. Adequate pre-engineering must be carried out to establish existing pavement thicknesses and composition. Ground Penetrating Radar (GPR) is a useful method of providing more frequent measurement for the thicknesses of the asphalt and the underlying granular layers. This information is required for the designer to determine the processing depth, and the blend proportion of uncoated and asphalt coated particles, and to determine whether pre-milling is required. Field investigation is required to determine the pavement condition and distress manifestations. The borehole layout and drilling protocol should follow the applicable regional geotechnical investigation guideline. November 2015 Page 3 of 5 B331

8 DETAIL ESTIMATING FULL-DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION Other Design Considerations The work requires the use of a pilot vehicle as part of the process. The regional traffic section should be consulted regarding the deletion of the pilot vehicle requirement if the work is on a freeway. A pre-engineering mix design is recommended during the pre-engineering investigation stage to confirm the in-situ materials are suitable for stabilization, and to determine whether corrective aggregate or additive would be required for the mix to meet the minimum tensile strength requirement Information to be Provided to Bidders The existing pavement depth must be included in the documents in the form of soils borings, pavement cores, or ground penetrating radar graphs. In the absence of soils borings, pavement cores, or ground penetrating radar graphs, a table shall be included in the drawings denoting the existing pavement depths throughout the work area COMPUTATION Source of Information Requirements are as recommended in the Pavement Design Report or by the Regional Geotechnical Section Method of Calculation Full-Depth Reclamation with Expanded Asphalt Stabilization This is a plan quantity payment item. Areas in square metres may be measured or scaled from plans DOCUMENTATION Contract Drawings In complicated layout locations, the areas may be symbolized on the contract drawings. Drawing details may be required, for example where the limits of reclamation (in-place processing) and stabilization do not coincide. Typical sections are required indicating the road widths and depths to be in-place processed and the widths and depths of expanded asphalt stabilization. Staged typical sections may be required to fully detail the work, for example when the addition of granular is required to correct crossfall and/or superelevation. November 2015 Page 4 of 5 B331

9 DETAIL ESTIMATING FULL-DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION Q-Sheets The station to station limits and offsets for this work is to be shown on the Quantities Hot mix and Granular sheets together with the corresponding areas in square metres. A separate line entry should be initiated in any location where the stabilization depth changes Documentation Accuracy Station locations are required to the nearest metre accuracy, and offsets to the nearest 0.1 metre. Areas are calculated to the nearest whole square metre. November 2015 Page 5 of 5 B331

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11 DETAIL ESTIMATING COLD IN-PLACE RECYCLING B333 - COLD IN-PLACE RECYCLING - OPSS.PROV GENERAL The Cold In-place Recycling (CIR) process involves partial depth milling of the existing asphalt pavement, sizing, mixing with emulsified asphalt and water (if required), relaying and compacting the recycled cold bituminous mixture in-place in one single operation. CIR can rehabilitate pavement exhibiting age, thermal, fatigue and reflective cracking. CIR should be considered for roads that are severely cracked but structurally sound. It is not limited to pavements exhibiting surficial distresses. The existing pavement thickness should be at least 100 mm. CIR helps to retard reflection cracking and localized roughness. CIR is not suitable for pavements with extensive base or subbase problems, or structurally deficient pavements, i.e. lack of structural capacity, severe distortions and/or instability rutting. CIR processing should avoid reaching to pavement layers that contain asbestos, geogrid, glasgrid, or layers with rich asphalt content, high recovered penetration, or fine mixes such as HL-2. CIR process is more appropriate for roads with low to moderate traffic volumes (AADT < 15,000/2 lanes). CIR must be placed in warm, dry weather and therefore is limited to the summer months for construction, and all CIR treatment should be completed prior to September 1 st. CIR treatment cannot be carried out when the temperature is below 10 C or the overnight forecast is less than 2 C. Pavements that have the following maintenance treatments may be considered since they have no detrimental effects on the CIR mix design. - cold mix patching - spray patching - chip seal The benefits of CIR mix are: - The mix is flexible with high air voids, so reflection cracking is notably reduced % of the material is reclaimed - Traffic is allowed back on within one hour of its placement November 2015 Page 1 of 7 B333

12 DETAIL ESTIMATING COLD IN-PLACE RECYCLING REFERENCES CDED Section B206-3, Excavation for Pavement Widening CDED Section B308, Tack Coat CDED Section B313, Hot Mix Asphalt CDED Section B510, Removal TENDER ITEMS Cold In-Place Recycled Mix SPECIFICATIONS Details of the work are contained in OPSS SPECIAL PROVISIONS Refer to Chapter E of this manual to review the applicable standard special provisions STANDARD DRAWINGS - none DESIGN Geotechnical Design Considerations The CIR mix is susceptible to moisture intrusion and abrasion. It requires that a separate wearing surface such as hot mix overlay, surface treatment, or microsurfacing be placed to seal the CIR mix. The wearing surface must be placed during the same construction season. To date, surface treatment or micro-surfacing has not been used as the separate wearing surface. CIR treatment depths typically range from 75 mm to 125 mm. For projects with variation in existing asphalt pavement thicknesses, different treatment depths should be considered by clustering the pavement into segments of similar asphalt pavement thickness. The depth of CIR treatment shall be selected to avoid disturbance of the underlying granular base (so called breaking through ). The treatment depth shall be selected to avoid breaking through during CIR processing that could lead to potential claims and performance issues. In no case shall the remaining residual asphalt be less than 25 mm. When the residual asphalt requirement cannot be met, a different rehabilitation strategy should be considered. November 2015 Page 2 of 7 B333

13 DETAIL ESTIMATING COLD IN-PLACE RECYCLING A typical recycling train is installed with milling drum(s) of up to 3.8 m in width and paver with extending screed of up to 4.25 m in width. Typically, CIR process extends to the existing pavement edge (edge of lane) only. It is not recommended to process the pavement beyond the pavement edge as it will incorporate shoulder granular into the CIR mix. After processing, CIR mix will be fluffed up 10 to 15% of the original volume of pavement due to an increase in air voids. As a result, 10 to 15% raise in grade is expected if the width of CIR mat does not change. If grade raise restriction applies on the geometric design of pavement, the CIR mix can be spread out to avoid the grade raise, resulting in increase in mat s width. Pavement widening using CIR is not recommended. However when it is required, the Excavation for Pavement Widening standard item may be used to prepare the shoulder area. Refer to CDED B206-3 for documentation requirements. An asphalt base should be considered along the widening strip if the thickness difference between the existing asphalt pavement and the widening pavement is large. It is not recommended to incorporate shoulder granular into CIR mix for the purpose of pavement widening. A tack coat is required prior to Hot Mix Asphalt (HMA) paving over all areas of CIR. Use the tender item Tack Coat. The Tack Coat rate of application for cold in-place recycled surfaces is specified in OPSS 308. Reference is made to CDED Section B308, Tack Coat, for administration of this tender item. All crack sealants must be removed prior to CIR processing, as part of the item. Estimation of crack sealant quantity to be removed should be included in Pavement Design Report. In urban areas, the designer should be aware of appurtenance and adjustment requirements, curb heights, and accessibility concerns to accommodate the CIR equipment train and the requirement for traffic detours. At intersections, the main lanes and turn lanes of significant length (greater than 300 m) should be CIR. Different treatments (i.e., remove and replace with acceptable binder course HMA) may be applied to shorter turn tapers, irregularly shaped pavement areas, entrances, etc. CIR should be considered for daylight operations only due to traffic control and safety concerns. The designer should be aware that the length of the CIR paving operation may affect traffic management. A typical CIR train may extend up to 80m long. A one kilometer rolling closure is typical for the CIR operation. November 2015 Page 3 of 7 B333

14 DETAIL ESTIMATING COLD IN-PLACE RECYCLING Full depth repair zones such as frost treatment, distortion/distress and culvert replacement should be excavated and replaced in accordance with the designed subbase and base materials, then reinstated with HMA prior to CIR operation. The depth for the overlying HMA should be the processing depth of CIR plus 25mm. Alternatively, reclaimed asphalt pavement (RAP) can be considered instead of HMA. To avoid bumps and inconsistent transition of materials, CIR operation should continue through the full depth repair zone when its length is less than 50 m; otherwise, the zone will be skipped for CIR operation. Pre-milling on the existing pavement surface should only be specified at selective locations when crack sealants are closely spaced, the pavement surface is severely oxidized, or where the longitudinal and/or transverse profile must be corrected. Premilling should be kept to a minimum. A single pass of recycling train allows a minor cross-fall correction of up to 0.5% only. If a pavement section requires a cross-fall correction of larger than 0.5%, it should be adjusted using a patching or milling method prior to CIR operation instead of using the CIR recycling train. For design purposes CIR with an overlay should be compared to the following conventional technique to address non-structural surficial distresses: Pre-Engineering Investigation General: 40 mm Superpave 12.5 over 100 mm CIR Vs. Full depth reclamation, (FDR), 40 mm Superpave 12.5 over two 50 mm lifts of Superpave 19.0 This section describes procedures and tests to be carried out during pre-engineering investigations on potential CIR projects. Adequate pre-engineering must be carried out to establish existing pavement thicknesses and composition. Ground Penetrating Radar (GPR) is a useful method of providing more frequent measurement of the asphalt thickness. Additional investigation should be carried out where pavement composition changes, such as patched areas. This information is required for the designer to determine whether the existing pavement on potential projects meets the minimum thickness requirement in addition to assisting the designer in selecting a depth of CIR. Field investigation is required to determine the pavement condition, distress manifestations, and estimated sealant removal quantities. November 2015 Page 4 of 7 B333

15 DETAIL ESTIMATING COLD IN-PLACE RECYCLING Selection of Coring Locations: 1. A minimum of one core location per kilometre. 2. Cores shall be taken not less than 0.5 m from the edges of the pavement of the main lanes and in areas representative of the overall pavement condition. Core location should be random. 3. Cores should extend to the bottom of the lower hot mix lift. 4. Testing on cores should be conducted to determine extracted gradation, existing asphalt cement content and recovered penetration This information does not relieve the Contractor from obtaining cores to complete a CIR mix design. A mix design is recommended during the pre-engineering investigation stage to confirm the in-situ materials are suitable for CIR processing, and to determine whether active filler would be required for the mix. When Portland cement is used as active filler, the maximum addition rate is 1% Other Design Considerations The work requires the use of a pilot vehicle as part of the process. The regional traffic section should be consulted regarding the deletion of the pilot vehicle if work is on a freeway Information to be Provided to Bidders The existing pavement depth must be included in the documents in the form of soils borings, pavement cores, or ground penetrating radar graphs, along with the results of the pre-engineering core testing COMPUTATION Source of Information All requirements of a project with respect to hot mix, CIR depths, asphalt core analysis and test results including treatment of shoulders are stated in the Pavement Design Report. November 2015 Page 5 of 7 B333

16 DETAIL ESTIMATING COLD IN-PLACE RECYCLING Method of Calculation Cold In-Place Recycling Mix is a Plan Quantity Payment item. The unit of measurement for CIR is square metres. The Contractor is responsible for the CIR mix design and will supply emulsified asphalt on all contracts for the CIR mix. No quantity calculations are required by the designer for this material. The estimated bulk relative density of CIR is 2.20 t/m³ DOCUMENTATION It is necessary to ensure that this information is indicated for all CIR to be carried out on a project. It must include the depths of CIR and the hot mix overlays for the roadway, private and commercial entrances, side roads, tapers, interchange ramps, pavement widening, paved shoulders, partial paved shoulders, and any other miscellaneous areas to be paved. The designer is to specify the hot mix required to be used in areas inaccessible to the CIR equipment. The designer shall specify the following in the Contract Documents: 1. For the item Cold In-Place Recycled Mix, typical cross sections which show normal sectional requirements are to be included. Include on sections the required widths and depths of cold in-place recycling. 2. Each area quantity of CIR is shown on one row of the Miscellaneous Quantity Sheet. For each area, indicate both start and end chainage in the location and position column. 3. Sealant removal is included with the CIR tender item. 4. For areas considered by the designer to be inaccessible to the CIR equipment, hot mix is required, and is paid for under the applicable hot mix asphalt item(s). Refer to B313 for documentation requirements. Partial depth asphalt removal and overlying HMA thicknesses shall be noted on the drawings for all areas considered inaccessible or impractical for CIR, such as private and commercial entrances, side roads, tapers, ramps, channelization, shoulders, irregularly shaped pavement areas and miscellaneous areas to be paved. Refer to CDED B510 and B313 for the design and documentation requirements for partial depth asphalt removal and HMA, respectively. November 2015 Page 6 of 7 B333

17 DETAIL ESTIMATING COLD IN-PLACE RECYCLING Documentation Accuracy Calculated CIR quantity in square metres is recorded to the nearest whole number. Stations are recorded in whole number metres. November 2015 Page 7 of 7 B333

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19 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT B335 - COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT OPSS.PROV GENERAL The Cold In-placed Recycled Expanded Asphalt Mix (CIREAM) process involves partial depth milling of the existing asphalt pavement, sizing, mixing with expanded (foam) asphalt, re-laying and compacting the recycled cold bituminous mixture inplace in one single operation. CIREAM can rehabilitate pavement exhibiting age, thermal, fatigue and reflective cracking. CIREAM should be considered for roads that are severely cracked but structurally sound. It is not limited to pavements exhibiting surficial distresses. The existing pavement thickness should be at least 100 mm. CIREAM helps to retard reflection cracking and localized roughness. CIREAM is not suitable for pavements with extensive base or subbase problems, or structurally deficient pavements, i.e. lack of structural capacity, severe distortions and/or instability rutting. CIREAM processing should avoid reaching to pavement layers that contain asbestos, geogrid, glasgrid, or layers with rich asphalt content, high recovered penetration, or fine mixes such as HL-2. CIREAM is more appropriate for roads with low to moderate traffic volumes (AADT < 15,000 / 2 lanes). CIREAM must be placed in warm, dry weather and therefore is limited to the summer months for construction, and all CIREAM treatment should be completed prior to September 1 st. CIREAM treatment cannot be carried out when the temperature is below 15 C. Pavements that have the following maintenance treatments may be considered since they have no detrimental effects on the CIREAM mix design. - Cold mix patching - Spray patching - Chip seal The benefits of CIREAM are: - The mix is flexible with high air voids, so reflection cracking is notably reduced - The mix curing time is significantly shorter than CIR - 100% of the material is reclaimed - Traffic is allowed back on within one hour of its placement November 2015 Page 1 of 7 B335

20 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT REFERENCES CDED Section B206-3, Excavation for Pavement Widening CDED Section B308, Tack Coat CDED Section B313, Hot Mix Asphalt CDED Section B510, Removal TENDER ITEMS Cold In-Place Recycled Expanded Asphalt Mix SPECIFICATIONS Details of the work are contained in OPSS SPECIAL PROVISIONS Refer to Chapter E of this manual to review the applicable standard special provisions STANDARD DRAWINGS - none DESIGN Geotechnical Design Considerations The CIREAM is susceptible to moisture intrusion and abrasion. It requires that a separate wearing surface such as hot mix overlay, surface treatment, or microsurfacing be placed to seal the CIREAM. The wearing surface must be placed during the same construction season. To date, surface treatment or micro-surfacing has not been used as the separate wearing surface. CIREAM treatment depths typically range from 75 mm to 125 mm. For projects with variation in existing asphalt pavement thicknesses, different treatment depths should be considered by clustering the pavement into segments of similar asphalt pavement thickness. The depth of CIREAM treatment shall be selected to avoid disturbance of the underlying granular base (so called breaking through ). The treatment depth shall be selected to avoid breaking through during CIREAM processing that could lead to potential claims and performance issues. In no case shall the remaining residual asphalt be less than 25 mm. When the residual asphalt requirement cannot be met, a different rehabilitation strategy should be considered. November 2015 Page 2 of 7 B335

21 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT A typical recycling train is installed with milling drum(s) of up to 3.8 m in width and paver with extending screed of up to 4.25 m in width. Typically, CIREAM process extends to the existing pavement edge (edge of lane) only. It is not recommended to process the pavement beyond the pavement edge as it will incorporate shoulder granular into the CIREAM. After processing, CIREAM will be fluffed up 10 to 15% of the original volume of pavement due to an increase in air voids. As a result, 10 to 15% raise in grade is expected if the width of CIREAM mat does not change. If grade raise restriction applies on the geometric design of pavement, the CIREAM can be spread out to avoid the grade raise, resulting in increase in mat s width. Pavement widening using CIREAM is not recommended. However when it is required, the Excavation for Pavement Widening standard item may be used to prepare the shoulder area. Refer to CDED B206-3 for documentation requirements. An asphalt base should be considered along the widening strip if the thickness difference between the existing asphalt pavement and the widening pavement is large. It is not recommended to incorporate shoulder granular into CIREAM mix for the purpose of pavement widening. A tack coat is required prior to Hot Mix Asphalt (HMA) paving over all areas of CIREAM. The Tack Coat rate of application that corresponds to cold in-place recycled surfaces shall be used. Reference is made to CDED Section B308, Tack Coat, for administration of this tender item. All crack sealants must be removed prior to CIREAM processing, as part of the item. Estimation of crack sealant quantity to be removed should be included in Pavement Design Report. In urban areas, the designer should be aware of appurtenance adjustment requirements, curb heights, and accessibility concerns to accommodate the CIREAM equipment train and the requirement for traffic detours. At intersections, the main lanes and turn lanes of significant length (greater than 300 m) should be CIREAM. Different treatments (i.e., remove and replace with acceptable binder course HMA) may be applied to shorter turn tapers, irregularly shaped pavement areas, entrances, etc. CIREAM should be considered for daylight operations only due to traffic control requirements and safety concerns. The designer should be aware that the length of the CIREAM paving operation may affect traffic management. A typical CIREAM train may extend up to 80m long. A one kilometer rolling closure is typical for the CIREAM operation. November 2015 Page 3 of 7 B335

22 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT Full depth repair zones such as frost treatment, distortion/distress and culvert replacement should be excavated and replaced in accordance with the designed subbase and base materials, then reinstated with HMA prior to CIREAM operation. The depth for the overlying HMA should be the processing depth of CIREAM plus 25mm. Alternatively, reclaimed asphalt pavement (RAP) can be considered instead of HMA. To avoid bumps and inconsistent transition of materials, CIREAM operation should continue through the full depth repair zone when its length is less than 50 m; otherwise, the zone will be skipped for CIREAM operation. Pre-milling on the existing pavement surface should only be specified at selective locations when crack sealants are closely spaced, the pavement surface is severely oxidized, or where the longitudinal and/or transverse profile must be corrected. Premilling should be kept to a minimum. A single pass of recycling train allows a minor cross-fall correction of up to 0.5% only. If a pavement section requires a cross-fall correction of larger than 0.5%, it should be adjusted using a patching or milling method prior to CIREAM operation instead of using the CIREAM recycling train. For design purposes, CIREAM with an overlay should be compared to the following conventional technique to address nonstructural surficial distresses: Pre-Engineering Investigation 40 mm Superpave 12.5 over 100 mm CIREAM Vs. Full depth reclamation, (FDR), 40 mm Superpave 12.5 over two 50 mm lifts of Superpave 19.0 This section describes procedures and tests to be carried out during pre-engineering investigations on potential CIREAM projects. Adequate pre-engineering must be carried out to establish existing pavement thicknesses and composition. Ground Penetrating Radar (GPR) is a useful method of providing more frequent measurement of the asphalt thickness. Additional investigation should be carried out where pavement composition changes, such as patched areas. This information is required for the designer to determine whether the existing pavement on potential projects meets the minimum thickness requirement in addition to assisting the designer in selecting a depth of CIREAM. Field investigation is required to determine the pavement condition and distress manifestations, and estimated sealant removal quantities. November 2015 Page 4 of 7 B335

23 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT Selection of Coring Locations: 1. A minimum of one core location per kilometer. 2. Cores shall be taken not less than 0.5 m from the edges of the pavement of the main lanes and in areas representative of the overall pavement condition. Core location should be random. 3. Cores should extend to the bottom of the lower hot mix lift. 4. Testing on cores should be conducted to determine extracted gradation, existing asphalt cement content and recovered penetration. The information does not relieve the Contractor from obtaining cores to complete a CIREAM mix design. A mix design is recommended during the pre-engineering investigation stage to confirm the in-situ materials are suitable for CIREAM processing, and to determine whether active filler would be required for the mix to meet the minimum tensile strength requirement. When Portland cement is used as active filler, the maximum addition rate is 1% Other Design Considerations The work requires the use of a pilot vehicle as part of the process. The regional traffic section should be consulted regarding the deletion of the pilot vehicle requirement if the work is on a freeway Information to be Provided to Bidders The existing pavement depth must be included in the documents in the form of soils borings, pavement cores, or ground penetrating radar graphs, along with the results of the pre-engineering core testing COMPUTATION Source of Information All requirements of a project with respect to hot mix, CIREAM depths, asphalt core analysis and test results including treatment of shoulders are stated in the Pavement Design Report. November 2015 Page 5 of 7 B335

24 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT Method of Calculation Cold In-Place Recycled Expanded Asphalt Mix is a Plan Quantity Payment item. The unit of measurement for CIREAM is square meters. The Contractor is responsible for the CIREAM mix design and will supply asphalt cement, as required, on all contracts for the CIREAM. No quantity calculations are required by the designer for this material. The estimated bulk relative density of CIREAM is 2.20 t/m³ DOCUMENTATION It is necessary to ensure that this information is indicated for all CIREAM to be carried out on a project. It must include the depths of CIREAM and the hot mix overlays for the roadway, private and commercial entrances, side roads, tapers, interchange ramps, pavement widening, paved shoulders, partial paved shoulders, and any other miscellaneous areas to be paved. The designer shall specify the following in the Contract Documents: 1. For the item CIREAM, typical cross sections which show normal sectional requirements are to be included. Include on sections the required widths and depths of CIREAM. 2. Each area quantity of CIREAM is shown on one row of the Miscellaneous Quantity Sheet. For each area, indicate both start and end chainage in the location and position column. 3. Sealant removal is included with the CIREAM tender item. 4. For areas considered by the designer to be inaccessible to the CIREAM equipment, hot mix is required, and is paid for under the applicable hot mix asphalt item(s). Refer to B313 for documentation requirements. Partial depth asphalt removal and overlying HMA thicknesses shall be noted on the drawings for all areas considered inaccessible or impractical for CIREAM, such as private and commercial entrances, side roads, tapers, ramps, channelization, shoulders, irregularly shaped pavement areas and miscellaneous areas to be paved. Refer to CDED B510 and B313 for the design and documentation requirements for partial depth asphalt removal and HMA, respectively. November 2015 Page 6 of 7 B335

25 DETAIL ESTIMATING COLD IN-PLACE RECYCLING WITH EXPANDED ASPHALT Documentation Accuracy Calculated CIREAM quantity in square metres is recorded to the nearest whole number. Stations are recorded in whole number metres. November 2015 Page 7 of 7 B335

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27 DETAIL ESTIMATING PIPE SEWERS B410 - PIPE SEWERS OPSS.PROV GENERAL A sewer network is required in an urban setting or where open ditches in combination with pipe culverts cannot accomplish drainage of a roadway system, due to restricted property limits or susceptibility of a terrain to erosion. A sewer is an installation designed for the conveyance of storm water using preformed or pre-cast pipe sections, circular in cross section, laid end to end using suitable jointing material and connected by maintenance holes, catchbasins, ditch inlets or other appurtenances. All design assumptions and calculations required to design a sewer network shall be retained as part of the design documentation REFERENCES MTO Highway Drainage Design Standards MTO Drainage Management Manual MTO Gravity Pipe Design Guidelines Ontario Provincial Standards Specifications Ontario Provincial Standards Drawings Drainage Guidelines available on the MTO public web site All references noted are available through the Contract Preparation System (CPS) or through the ministry s public web site or through the MTO Online Catalogue library. The designer shall also reference other design manuals (i.e. MTO Roadside Safety Manual) as required for design assistance of other roadside features associated with the pipe sewer network design TENDER ITEMS Pipe Sewer Concrete Appurtenances Rock Excavation for Sewers Clay Seal November 2015 Page 1 of 24 B410

28 DETAIL ESTIMATING PIPE SEWERS SPECIFICATIONS The requirements for the pipe sewer tender items are specified in OPSS 410. The designer shall also reference or note other OPSS documents for construction and materials as identified or required when packaging a contract APPENDICES Appendix A - Pipe Sewer Tender Item This appendix describes the pipe sewer tender item and is to be followed by the designer to itemize the pipe sewer tender item entries, complete with size, type and class specifications, in the Quantities Sewer sheets for all ministry contracts with pipe sewer designs. Appendix B - CPS Master List of Pipe Sewer Tender Items This appendix provides a complete list of all pipe sewer tender items available SPECIAL PROVISIONS Refer to Chapter 'E' to review standard special provisions that may be required for inclusion in the contract STANDARD DRAWINGS Applicable standard drawings are contained in the 800 series of the Ontario Provincial Standard Drawings Manual; however, other OPSD or MTOD series may also apply DESIGN Pipe Sewer The general pipe layout, size, type and class of a pipe sewer network are established by the designer based on acceptable drainage theory. The designer shall use accepted drainage design methods by which to define the pipe sewer layout that satisfies required drainage standards and criteria for the highway project. Gravity pipe drainage design standards are applicable to sewers and are available in the MTO Highway Drainage Design Standards. Gravity pipe design requirements, November 2015 Page 2 of 24 B410

29 DETAIL ESTIMATING PIPE SEWERS analysis methods and other information are available in the MTO Gravity Pipe Design Guidelines and the MTO Drainage Management Manual. A. Size The design of a pipe sewer network involves determining the sizes of pipes, in conjunction with pipe type and class availability, which will permit the pipe sewer network to function within set design requirements and standards. The designer will also determine the maximum increase or tolerance range in the pipe size, in conjunction with pipe type and class availability, which will still permit the pipe sewer to function within the design parameters set. The designer shall also keep in mind the following basic guidelines in laying out the pipe sewer network: 1. Wherever possible, the invert elevation of a pipe sewer run entering a catch basin should be slightly higher (30 mm) than the invert elevation of the pipe leaving the structure. 2. Pipe culverts should never flow into a pipe sewer network but the reverse is permitted. 3. The spacing of the catch basins is detailed in Section B407-1, "Manholes, Catch Basins and Ditch Inlets", such that the length of the pipe sewer may be calculated. B. Type Pipe type refers to a pipe s inside wall design, which can be smooth or corrugated. A separate hydraulic analysis of each pipe type to determine hydraulic acceptability is required to determine if both pipe types are to be specified in a contract as alternative pipe type choices. The designer will use hydraulic flow parameters characteristic of each pipe type during the hydraulic analysis work. In some cases, only one pipe type may be achievable or conducive for the site conditions. The designer will analyze a sewer network for hydraulic acceptance based on one pipe type for the entire sewer network. Two separate hydraulic design analysis runs are required to determine if both pipe types are hydraulically acceptable. Where site circumstances are found that requires a sewer network that is pipe type sensitive, the designer need only perform the hydraulic analysis of the pipe sewer network for the one pipe type identified as suitable for the site conditions. November 2015 Page 3 of 24 B410

30 DETAIL ESTIMATING PIPE SEWERS C. Class Pipe class refers to the material specifications of the pipe products. These specifications include load and pressure ratings, pipe wall thickness, protective coatings, corrugations and reinforcement. Acceptable material specifications of a pipe sewer network are established based on structural loading and material durability requirements. The designer shall use accepted structural and durability assessment methods by which to establish the pipe class that satisfies both structural and material durability criteria. 1. Structural Assessment Pipe sewers, due to the fact that they are installed underground, are subject to dead and live loads. The loading requirements are addressed through placement of fill material on top of the pipe culvert. Bedding, cover, embedment in the case of flexible pipes, backfill, subgrade, and pavement are to be considered in the structural loading assessment. The height of fill available will define acceptable pipe sizes, types and classes. 2. Durability Assessment D. Joints Pipe sewer networks, for the different functional highway classifications, must be designed to specified Design Service Life (DSL) criteria. Every pipe material has an Estimated Material Service Life (EMSL) based on its material properties and the site environment. Acceptable pipe materials are those that have an EMSL greater than or equal to the DSL criteria. Pipe materials with an EMSL less than the DSL criteria may only be considered in a strategic pipe replacement context. A Life Cycle Cost Analysis (LCCA) must be performed to support a pipe replacement design. Highway Standards Branch approvals are required to use a pipe replacement design approach. The designer, through hydraulic analysis of surface flow or through subsurface information as provided in a foundations or geotechnical report, shall make an assessment of the type of pipe joints required for the pipe sewer. The designer shall refer to the MTO Gravity Pipe Design Guidelines for further information on pipe joint selection requirements. November 2015 Page 4 of 24 B410

31 DETAIL ESTIMATING PIPE SEWERS E. Outlet Pipe End Finish The end finishes on a pipe sewer outlet may be cut end finishes to the outlet pipe or attached prefabricated end sections. The end finish is to be decided by the designer through hydraulic analysis and final embankment slopes. Where traffic safety is an issue, the designer may select a prefabricated safety slope end treatment section specifically designed to address the safety concern at the pipe sewer outlet. Grating may be installed over the ends of pipe sewer outlets to prevent access by animals or children if deemed to be a concern. The designer shall refer to relevant design manuals and/or any associated OPSD s or MTOD s for further information on warrants and design of end finishes. F. Treatment In most cases, pipe sewers are constructed below the frost line and would not require any special treatments for frost. In rock fills, frost tapers are not required, but fill material must be provided. When the pipe sewer cannot be constructed below the frost line, special treatment will be required. Foundations or geotechnical reports shall contain information regarding recommended pipe fill materials and the configuration and extent of frost taper excavations. Where pipe fill material cannot protect the pipe sewer or frost tapers cannot be constructed, other frost protection options need to be considered. Designers may consider using extruded expanded polystyrene or other insulation materials to prevent the frost line from penetrating into the pipe sewers critical zone. Flow sources entering the pipe sewer carrying sediment loads under certain velocity conditions may require lining of the pipe sewer invert to prevent abrasion of the pipe material. Lining the pipe sewer invert can be done with concrete or shotcrete material. Bituminous products shall not be used to line the invert of the pipe sewer. In lieu of a lined invert, the designer may also consider pipe products with thicker walls and/or protective coatings to provide additional protection against abrasive forces. G. Concrete Appurtenances The flow out of a pipe sewer may need to be controlled to prevent erosion damage to the area around it or to the pipe structure itself. Concrete appurtenances such as November 2015 Page 5 of 24 B410

32 DETAIL ESTIMATING PIPE SEWERS Trench headwalls, wingwalls, energy dissipators, aprons, collars or other such types of structures are used to direct outflow, slow velocities to prevent erosion, offset buoyancy forces, etc. Concrete structures covered by OPSS 904 do not include the aforementioned concrete appurtenances. A. Excavation Excavated material may be used for embankment construction or used as native backfill to the excavated pipe sewer trench as determined by the designer based on foundation or geotechnical reports. Earth and rock excavation material not used as native backfill should be managed as outlined in Section B206 of this chapter. In view of the high unit cost for rock excavation, the designer shall endeavour to reduce the volume of excavation by relocating, pipe skewing, etc., wherever possible. B. Dewatering Dewatering refers to pumping, bailing, groundwater lowering, temporary ditching or vacuum removal of uncontaminated groundwater, rain water, melt water, surface runoff, water pipe leakage from excavations and trenches or within sheeted cofferdams to improve the soil stability or for other construction purposes. Where dewatering is required for the installation of a pipe sewer, the details of the operation shall comply with the requirements of OPSS 517. When recommended by the foundation engineer, a separate item for dewatering according to OPSS 902 is to be included. Although the Contractor is responsible for dewatering, the designer shall note any recommendations included in the foundation investigation and design report. The designer shall also refer to SP 100S59, Amendment to MTO General Conditions of Contract, Permits to Take Water, for additional requirements that may need to be specified in the contract. C. Fill Material Pipe fill material for rigid pipe installations is placed in distinct bedding, cover and backfill layers. Flexible pipe installations require pipe fill material to be placed as distinct embedment, which is from the bottom of the bedding layer to the bottom of the backfill layer, and backfill layers. November 2015 Page 6 of 24 B410

33 DETAIL ESTIMATING PIPE SEWERS Applicable minimum or maximum height of pipe fill material limits are placed in accordance with OPSD or MTOD Height of Fill tables for the pipe materials identified. A foundation or geotechnical report will include recommendations for the supply, placement, and specifications of pipe fill material or any special conditions for bedding, cover, embedment in the case of flexible pipes, and backfill layers. In addition, special consideration for scour protection at the pipe sewer outlet may be required. The designer shall, based on the recommendations of the foundation or geotechnical report, specify the pipe fill materials required for the installation. The designer should be familiar with the various installation methods available as referenced in the 800 series of the OPSD for the pipe sewer installation so that the pipe fill materials recommended are appropriately specified. The contractor, not the designer, is responsible for selecting the appropriate pipe sewer installation method, including excavation geometry, at the time of installation based on the soil types found on the construction site in accordance with the Occupational Health and Safety Act and Regulations for Construction Projects. D. Reinstatement Where existing driving lanes must be excavated to allow the construction of the pipe sewer network, the affected roadbed must be rebuilt to acceptable standards to maintain the continuity of the pavement. This is particularly important where there is to be no resurfacing of the highway. The designer shall determine and specify bedding, cover, embedment in the case of flexible pipe, and backfill depths and materials up to subgrade. Above subgrade, the designer shall determine the types and depths of granular and pavement courses necessary to achieve roadbed integrity. E. Protection Systems In general, the contractor determines the need for protection systems, except when the stability, safety or function of an existing roadway, railway, etc. may be threatened or impaired due to the construction of a pipe sewer or in cases where the pipe sewer will be installed at depth. In such cases the foundation engineer may recommend that the installation of protection systems be specified and paid by separate item. The design, installation, monitoring of protection systems is the Contractor s responsibility and the Contractor should base his plan on information as found in the soils data and/or foundation reports. Problematic soils, high groundwater November 2015 Page 7 of 24 B410

34 DETAIL ESTIMATING PIPE SEWERS tables or other installation issues, if identified, will give rise to recommendations regarding the design, installation and removal and would be provided in the foundation report. Recommendations for performance levels can also be found in foundation investigation and design reports. Requirements for field investigation, laboratory testing and engineering recommendations for protection systems are to be specified in the foundation engineering terms of reference for any specific project such that appropriate information for the Contractor is provided. F. Clay Seals Warrants for clay seals to be installed on pipe sewers can be found in the MTO Gravity Pipe Design Guidelines. Other physical flow control barrier options are in the GPDG April Recommendations may also be found in a foundation or geotechnical investigation and design report COMPUTATION Item Payment Basis Pipe Sewer items are Plan Quantity Payment items. Concrete Appurtenances are Plan Quantity Payment items. Rock Excavation for Pipe Sewers is a Plan Quantity Payment item Clay Seal is a Lump Sum item Sources of Information The main sources of information for pipe sewer items are: a) Photogrammetric or survey plans to provide drainage areas, existing natural watercourses and other features that may impact drainage. b) MTO Highway Drainage Design Standards provides the overall design criteria requirements of gravity pipe installations. c) MTO Gravity Pipe Design Guidelines provide DSL criteria, water chemistry testing and pipe material selection procedures and requirements. d) MTO Drainage Management Manual provides the overall guidance on the design of pipe sewers and other drainage systems. November 2015 Page 8 of 24 B410

35 DETAIL ESTIMATING PIPE SEWERS e) Foundation or geotechnical reports provide guidance and recommendations on subsurface and groundwater conditions, backfilling requirements, special foundation treatments, articulation and scour protection at the sewer outlets. The foundation or geotechnical reports should also provide recommendations regarding dewatering requirements Methods of Calculation Pipe Sewer The unit of measurement for pipe sewers is the metre. The price per metre for placing pipe sewers includes the following operations: a) Supplying, placing and joining pipe lengths; b) Supplying and installing access prevention grates, if required c) Finishing or supplying and installing sewer outlet pipe end sections, as required b) Earth excavations for trenches, frost tapers, etc. for pipes and concrete appurtenances; c) Supplying, placing and compacting all bedding, cover, embedment in the case of flexible pipes, and backfill materials for pipe sewers; d) Dewatering operations, unless otherwise specified; e) Design, installation and removal of protection systems, unless otherwise specified; f) Reinstating or constructing any highway ancillary features, not covered under other required works in the contract, as part of the pipe sewer installation; and g) Disposing of all surplus excavated materials. A. Length Measurement for the length of the pipe sewer will be made along the invert of the pipe sewer from centre to centre of the catch basins, and no deduction in length will be made for the catch basin. When designing a pipe sewer network, the catch basins should be placed such that the length of pipe sewer from centre to centre of the catch basins is in whole November 2015 Page 9 of 24 B410

36 DETAIL ESTIMATING PIPE SEWERS numbers. When the space is restricted or short lengths are required, the metric design length of pipe sewers may be determined as the next larger 0.1 metres. Where a pipe sewer pre-fabricated end section, other than safety slope end treatments, is to be installed on pipe sewer outlets, they are to be added to the pipe sewer length without rounding. Slope flattening should also be considered when calculating the length of pipe sewers. The length of a pipe sewer is measured horizontally, except when the pipe grade is 10% or steeper, in which case the length is measured along the slope. B. Joints Trench Pipe joints are inclusive with the work to be done when installing a pipe sewer. C. Concrete Appurtenances The unit of measurement for concrete appurtenances is the cubic metre. The volume of each structure is computed and the payment in cubic metre covers the cost of supplying and placing both concrete and reinforcing steel. Payment for excavation and backfilling, including the supply of granular material, is included with the associated pipe sewer tender item. D. Manholes, Catch Basins and Ditch Inlets The above are covered in Section B407-1 of this chapter. E. Connections to Existing Pipe Sewers, Drains and Service Connections The unit of measurement for service connections is "each". F. Pipe Culverts Pipe culverts are covered in Section B421-2 "Pipe Culverts" of this chapter. A. Excavation Earth excavation required to place pipe sewers is part of the cost of the pipe sewer item. Excavation in rock for placing pipe sewers is done according to OPS Drawings. November 2015 Page 10 of 24 B410

37 DETAIL ESTIMATING PIPE SEWERS Unlike excavation in earth, which is included in the bid price of the pipe, rock excavation is tendered as a separate item. Rock excavation uses information for the computation of rock excavation quantities from the foundations or geotechnical reports and soils profile and field survey notes. The unit of measurement for this tender item is the cubic metre. Rock excavation quantities are computed as outlined in Section B407-2 of this manual. Rock excavation operations shall be according to OPSS 403 when specified. B. Dewatering Dewatering operations are according to OPSS 517 or OPSS 902, when specified. The designer shall ensure the requirements of SP100S59 are accounted for. Should a rare situation occur where it would be unfair to the Contractor to include an expensive dewatering operation in his pipe sewer bid price, using a nonstandard tender item should be considered. Consultation with the Ministry s foundation or geotechnical staff is required prior to use of the non-standard dewatering item. C. Fill Material Granular volumes for frost tapers, bedding, cover, embedment in the case of flexible pipes, and backfill material for pipe sewers are computed as shown in Ontario Provincial Standard Drawings or from detail drawings when applicable. Granular materials for concrete appurtenances are included in the pipe sewer granular quantities. The total granular requirement for each pipe sewer run is computed in cubic metres, and may be converted to tonnes using the conversion factor determined according to Section B314 of this manual. This quantity is used for Geotechnical ASL purposes only DOCUMENTATION Drawings A. Pipe Sewer 1. Location All pipe sewers, either with or without end sections, are to be indicated on the construction plans of the contract drawings. Pipe sewer profiles, drainage structure number, rock line, sub grade and original ground must be indicated November 2015 Page 11 of 24 B410

38 DETAIL ESTIMATING PIPE SEWERS where applicable on the contract drawings. The pipe configuration, but not the size, type or class, and a direction of flow arrow are to be indicated. 2. Connections to Existing Pipe Sewers, Drains and Service Connections Locations of connections to existing pipe sewers, drains and other service connections are to be indicated on the construction plans of the contract drawings. 3. End Finish, Grates and End Sections The applicable drawings for sewer outlet pipe end finishes are shown in the Ontario Provincial Standard Drawings. In addition, any pipe sewers with end finishes or end sections are to be indicated on the new construction plans and profiles of the contract drawings. Access prevention grates at pipe sewer outlets are to be indicated on the construction plan sheets of the contract drawings. The types of safety slope end treatments are listed in the CPS Master Item list and will be listed as separate tender item in a column on the Quantities Sewers sheets. 4. Concrete Appurtenances B. Trench Concrete Appurtenances are identified on the contract plans by means of an arrowed note (e.g. - Concrete Apron), and specifying the OPSD number, or a special drawing, if required, showing the layout. 1. Fill Material Ontario Provincial Standard Drawings in the 800 series depict dimensions, classes or types of bedding requirements for circular pipes, of which the pipe can be either flexible or rigid. Typical cross-sections must be included in the contract drawings, giving dimensions of frost depth, slope of frost tapers and depth of fill material layers. Because of the variety of possible treatments, standard drawings are not considered appropriate. If special conditions for bedding, cover, embedment in the case of flexible pipes, or backfill materials are required, the appropriate dimensions must be November 2015 Page 12 of 24 B410

39 DETAIL ESTIMATING PIPE SEWERS Documents shown on applicable Ontario Provincial Standard Drawings or on detail drawings when applicable. 2. Reinstatement A typical section, traditionally known as "trench reinstatement," must be shown on the contract plans. The drawing should refer to the applicable OPSD numbers for bedding, cover, embedment in the case of flexible pipe, and backfill up to subgrade specifying the types and depths of pipe fill material necessary to achieve roadbed integrity. Above subgrade, the drawing should specify the types and depths of granular and pavement courses necessary to achieve roadbed integrity. These types and depths may be shown in table format adjacent to the trench reinstatement typical section. When the contract is for standalone pipe sewer replacements (i.e. no other pavement rehabilitation or resurfacing work), all of the work to reinstate the roadway, including granular and pavement layers above subgrade, may be included with the pipe sewer item, as per OPSS 492. In this case, the required attributes of the pavement and granular layers (e.g. Superpave traffic category, PGAC grade) shall be shown with the trench reinstatement typical section. 3. Special Foundation Treatment A detailed typical drawing and/or a modified OPSD will be necessary to show the depth of bedding and location if any special foundation treatment such as articulation, soil mixing, ground improvement, etc is required as noted in the foundation investigation and design report. 4. Protection Systems Where a separate item for protection systems is required, as recommended by the foundation engineer, the line of protection or a protection system shall be shown on the contract drawings depending on the magnitude of the protection required. Performance levels shall be included on the Contract Drawings. These are only approximate lengths or locations and it is up to the contractor to design, install and remove with actual lengths and locations defined. Quantities Sheet The "Quantities - Sewers" sheet shall show details such as: 1. Structure Number to Structure Number: identifies the starting structure to the connecting end structure/outlet for each pipe run in the pipe sewer network. November 2015 Page 13 of 24 B410

40 DETAIL ESTIMATING PIPE SEWERS 2. Location and position: the relevant alignment control line (e.g. highway centreline) with offset positions of start structure grate and end structure grate defined as the distance in metres left (LT) and/or right (RT) from the alignment control line (e.g. C/L 0.85 LT LT). 3. Upstream and downstream inverts: elevation entries of pipe sewer invert at the upstream and downstream structure locations. 4. Depth to Pipe: measured from highway or ground surface directly above the upstream pipe sewer invert down to top of base pipe opening. 5. Pipe Fill Material: Where there are no recommendations from a foundations or geotechnical report to specify any particular pipe fill material, the pipe fill materials will be specified, by default, as G for bedding and by extension embedment, and N for backfill and cover. The designer does not have to enter any material specifications in the columns to have the default material specifications apply. However, specific pipe fill material for bedding, cover or backfill, if recommended in a foundations or geotechnical report, shall be specified in the appropriate pipe fill material column. Pipe fill materials shall be specified as follows: N native material, which applies to cover and backfill layers only, and permits Granular B Type I, II or III, or Granular A to be used; G only Granular B Type I, II or III, or Granular A may be used; B only Granular B Type II or Granular A may be used; A only Granular A may be used; and C Unshrinkable Fill. A single letter code is used to indicate the same pipe fill material for a pipe fill layer if it is suitable for both rigid and flexible pipe options. If using the same pipe fill material is not suitable, two letter codes are used such that the first letter specifies the pipe fill material for rigid pipes while the second letter specifies the pipe fill material for flexible pipes for a pipe fill layer. The pipe fill material codes are structured in an ascending order of quality. All higher level codes above the code that is selected are deemed to be satisfactory for the installation. In cases where the higher level pipe fill materials are not suitable (i.e. different frost susceptibility characteristics), a designer shall insert a contract note to alert the contractor that only the specified pipe fill material is acceptable. November 2015 Page 14 of 24 B410

41 DETAIL ESTIMATING PIPE SEWERS Embedment for flexible pipes is from the bottom of bedding layer to bottom of backfill layer and is specified in the bedding material column. When only flexible pipes are specified, the pipe fill material cover column is not applicable. Clear stone may be used as bedding or embedment fill material, if groundwater conditions warrant the need. Refer to the MTO Gravity Pipe Design Guidelines for details. 6. Pipe Joints: Types of joints required are to be specified in the appropriately labeled column on the "Quantities Pipe Sewer" sheet. S denotes a joint that is soil tight while F denotes a joint that is silt or fines tight and L denotes a joint that is water tight. Pipe joints are specified by default as S regardless of whether or not the S code is entered into the Pipe Joints column. Joint classification is hierarchal in nature so that if an S joint is specified, the F and L joints are also acceptable, unless otherwise stated. 7. Pipe Sewer Tender Items: are shown using a separate column for each pipe sewer tender item. Each pipe sewer tender item is a composite tender item and is to be entered as shown below: Size mm Pipe Sewer Size + mm range S xxxxxx Size + mm range C xxxxxx Different pipe sewer sizes will necessitate entry of separate tender items. Same pipe sewer sizes with different size tolerance ranges and pipe material codes will necessitate entry as a separate composite tender item (e.g. more than one column is required to specify the pipe sewer tender item). Refer to Appendix A - Pipe Sewer Tender Item for information and guidance of how to define pipe sewer tender items for entry into the Quantities Sewers sheets. 8. Notes that may be required on the Quantities Sewers sheet A contract note can be a tender item note, which makes the note applicable to all sewer locations of that pipe size category, or can be a quantity item note if it is only applicable to certain sewer locations. i) Identified locations where the non-reinforced concrete pipe material is acceptable must be noted. ii) When corrugated steel pipes are specified and there are two different products permitted of the same size, the product with the greater material specifications November 2015 Page 15 of 24 B410

42 DETAIL ESTIMATING PIPE SEWERS must be noted at the locations where permitted since minimum material specifications have been identified in the pipe sewer tender item. iii) The locations of physical flow control barriers other than clay seals are to be indicated through a note. iv) When pipe sewer end finishes or end sections are required, a note shall be provided indicating the sewer end finish or section requirement. v) Wherever possible, tee and wye connections and the degree of elbows used for pipe sewer construction shall be indicated through the use of notes. vi) If frost treatment is different than standard 10 (k-d), a note shall be provided indicating the different treatment requirements. vii) When higher level pipe fill materials are not acceptable, a note shall be provided indicating that only the specified pipe material is acceptable. 9. Other Associated Pipe Sewers quantity items. To specify other pipe sewer quantity items as discussed below, the designer shall use CPS functional capabilities to enter the requirements into the contract package. Options may include creation of appropriate tender item columns on specific identified contract quantity sheets, attachment of standard or non-standard special provisions, or other suitable contract documentation methods. i) Where the installation of a pipe sewer is in a contract that includes other highway work (i.e. asphalt pavement removal, sidewalk removal, earth excavation, granular and pavement placement), the works above subgrade required in the pipe sewer installation area is included in the tender item for the other highway work. If the contract has no other highway work, that above subgrade work may be included in the pipe sewer item. ii) Rock excavation for pipe sewers is a separate tender item in accordance with OPSS 403. iii) On contracts where the excavated material is to be used for the construction of earth embankments, the quantity for pipe sewer excavation is to be calculated and the appropriate quantity indicated on the "Quantities - Grading & Granular" sheet under the "Material Available" column. iv) Granular and pavement to be supplied and placed for trench reinstatement would be included with the granular and pavement materials as part of the highway works. November 2015 Page 16 of 24 B410

43 DETAIL ESTIMATING PIPE SEWERS v) Service connection locations are to be listed under an appropriately labeled column. vi) When concrete appurtenances are to be placed on pipe sewers, they are treated as a separate item of work. Concrete appurtenances must be listed for each individual location on the "Quantities Miscellaneous sheet, or, if there are no other concrete items, they should be listed on the "Quantities - Sewers" sheet. vii) If dewatering is tendered as a separate non-standard item, it shall be entered as a lump sum in the contract. Ensure that any requirements as specified by SP100S59 are accounted for in the contract. viii) Where recommended by the foundation engineer, protection systems are entered as a separate tender item. ix) Safety slope end treatments, if required, shall be entered into a separate column. x) Access prevention grates, end finishes and/or end treatment sections shall be noted to the quantity affected. 10. Post Installation Inspections Pipe sewers on ministry contracts may be subject to post installation inspections. The following criteria shall be applied to determine if this work is necessary. 1. The total combined pipe sewer length of all pipe sewer tender items is greater than or equal to 500 m; or 2. If the total pipe sewer length of all pipe sewer tender items is less than 500 m, at least one sewer pipe run will be constructed with a pipe diameter greater than or equal to 450 mm and is greater than or equal to 100 m in length. Should post installation inspections for pipe sewers be required, SSP 104S03 shall be included. Payment for post installation inspection work is detailed in SSP 104S Documentation Accuracy Pipe sewers are to be measured by the metre. When the space is restricted, the metric design length of pipe sewers may be determined as the next larger 0.1 metres. Invert elevations are recorded in 0.01 m. November 2015 Page 17 of 24 B410

44 DETAIL ESTIMATING PIPE SEWERS Concrete Appurtenances should have concrete quantities and tender totals recorded to 0.1 m³. November 2015 Page 18 of 24 B410

45 DETAIL ESTIMATING PIPE SEWERS Appendix A Pipe Sewer Tender Item Pipe sewer is a variation tender item to be entered into a contract and has been structured to identify the acceptable circular pipe product based on size, type and class. The tender item follows the descriptive format as noted below: Size mm Pipe Sewer Size + mm range S xxxxxx base pipe diameter minimum smooth pipe diameter + tolerance range, type and material code Size + mm range C xxxxxx minimum corrugated pipe diameter + tolerance range, type and material code The pipe sewer material code element in the pipe sewer tender item is a 6 digit code that specifies the minimum material specifications for all acceptable pipe materials identified through design. Each digit represents a pipe material and has different values that specify pipe requirements. The Pipe Sewer Material Code is illustrated in Figure 1.0. Figure 1.0: Pipe Sewer Material Code November 2015 Page 19 of 24 B410

46 DETAIL ESTIMATING PIPE SEWERS The Pipe Sewer Material Code is interpreted in the following manner: 1. The 1 st digit represents concrete pipe. For concrete pipe, there are two product types for consideration. They are manufactured with reinforcing steel or without. To define the required reinforced concrete pipe, the designer will specify the appropriate values as: 1 for Class 50 D-Load; or 2 for Class 65 D-Load; or 3 for Class 100 D-Load; or 4 for Class 140 D-Load. The final concrete pipe class selection shall be dependent on the bedding class that is appropriate for the type of soils encountered at the site. When specifying any concrete pipe material, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size and load rating. Exception The designer shall note the acceptability of non-reinforced concrete pipe products on the Quantities Pipe Culvert sheet in the Contract. This will be done as a note to the tender item to indicate the suitability of this pipe product in all locations or as a note to a quantity if the suitability of non-reinforced concrete pipe only applies to one pipe location. 2. The 2 nd digit represents PVC and PP (polypropylene) pipes. There are two PVC product types for consideration. They are manufactured with a smooth inside and a ribbed outside (profile) wall or with a smooth inside and outside (solid) wall. To define the required PVC pipe, the designer will specify the appropriate value as 1 for all classes (Class 210 kpa (equivalent to SDR 41) or Class 320 kpa (equivalent to SDR 35)) which defines the strength requirement for either product type. When one of the PVC pipe products is not suitable for a given site, the designer, through a contract note, shall restrict the use of the unsuitable PVC pipe product. PP pipe product types are manufactured as dual (open profile) and triple wall (closed profile) pipes available in 320 kpa material specifications. To define the required PP pipe, the designer will specify the appropriate value as 2 for both product types which define the strength requirements for either product type. November 2015 Page 20 of 24 B410

47 DETAIL ESTIMATING PIPE SEWERS The designer should be aware that the 750 mm PP pipe is available in both an open and closed profile. If one of the PP pipe products is not suitable for a given site, the designer, through a contract note, shall restrict the use of the unsuitable PP pipe product. PP pipe products are automatically specified when the 2 nd digit pipe material code is 1. If this is not the case for a given site, then the designer, through a contract note, shall restrict the use of PP pipe at the site. When specifying any PVC or PP pipe material, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size and pipe stiffness rating. 3. The 3 rd digit represents HDPE pipes. There are two product types for consideration. They are manufactured with a smooth inside and a corrugated outside wall (open profile) or with a smooth inside and outside wall with a corrugated inner wall (closed profile). To define the required HDPE pipe, the designer will specify the appropriate value as 1 for open profile pipes and 2 for closed profile pipes. Closed profile HDPE pipe products are automatically specified when the 3 rd digit pipe material code is 1. If this is not the case for a given site, then the designer, through a contract note, shall restrict the use of the closed profile HDPE pipe at the site. When specifying any HDPE pipe material, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size and pipe stiffness. 4. The 4 th, 5 th and 6 th digits all represent steel and aluminum alloy pipe products. There are three pipe product lines for consideration. They are manufactured as spiral rib steel pipe (SRSP), corrugated steel pipe (CSP), and structural plate pipe (SPP). SRSP is a smooth pipe while CSP and SPP are corrugated pipes. SRSP and CSP pipe products come in three coatings; galvanized, aluminized type II and polymer laminated. Steel SPP is available with a galvanized coating and a polymer coating. SPP is also manufactured from aluminum alloy materials. The 4 th digit is used for specifying required galvanized SRSP, CSP and SPP products. To define the required SRSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; or 2 representing 2.0 mm thick walls; or 3 representing 2.8 mm thick walls. November 2015 Page 21 of 24 B410

48 DETAIL ESTIMATING PIPE SEWERS To define the required CSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; 2 representing 2.0mm thick walls; or 3 representing 2.8 mm thick walls; or 4 representing 3.5 mm thick walls; or 5 representing 4.2 mm thick walls. To define the required SSP products, the designer will specify the appropriate value as: 3 representing 3.0 mm thick walls; or 4 representing 4.0 mm thick walls; or 5 representing 5.0 mm thick walls; or 6 representing 6.0 mm thick walls; or 7 representing 7.0 mm thick walls. The 5 th digit is used for specifying aluminized type II SRSP and CSP pipe products and for specifying aluminum alloy SPP products. To define the required SRSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; or 2 representing 2.0 mm thick walls; or 3 representing 2.8 mm thick walls. To define the required CSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; 2 representing 2.0mm thick walls; or 3 representing 2.8 mm thick walls; or 4 representing 3.5 mm thick walls; or 5 representing 4.2 mm thick walls. To define the required aluminum alloy SSP products, the designer will specify the appropriate value as: 3 representing 3.18 mm thick walls; or 4 representing 3.81 mm thick walls; or 5 representing 4.45 mm thick walls; or 6 representing 5.08 mm thick walls; or 7 representing 5.72 mm thick walls; or 8 representing 6.35 mm thick walls. The 6 th digit is used for specifying polymer laminated or coated SRSP, CSP and SPP products. November 2015 Page 22 of 24 B410

49 DETAIL ESTIMATING PIPE SEWERS To define the required SRSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; or 2 representing 2.0 mm thick walls; or 3 representing 2.8 mm thick walls. To define the required CSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; 2 representing 2.0mm thick walls; or 3 representing 2.8 mm thick walls; or 4 representing 3.5 mm thick walls; or 5 representing 4.2 mm thick walls. To define the required SSP products, the designer will specify the appropriate value as: 3 representing 3.0 mm thick walls; or 4 representing 4.0 mm thick walls; or 5 representing 5.0 mm thick walls; or 6 representing 6.0 mm thick walls; or 7 representing 7.0 mm thick walls. When specifying any steel or aluminum alloy pipe materials, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size, protective coating and wall thickness. Exception For some diameters, CSP is available with two corrugation profiles. The pipe material durability analysis may determine a single wall thickness for both CSP product lines while the structural analysis of the pipe materials determines a different wall thickness for each CSP product lines. The designer shall identify the minimum wall thickness through the Pipe Material Code and note the greater wall thickness requirement of the other pipe product on the Quantities Pipe Culverts sheet in the Contract. This shall be done as a note to the tender item to indicate the greater wall thickness requirement of this pipe product in all locations on the contract or as a note to a quantity if the greater wall thickness requirement of this pipe product only applies to one pipe location. Note: Non-circular pipe sewer networks shall be specified through the use of a non-standard special provision. Pipe material codes will be similar to those used for non-circular pipe culvert installations. November 2015 Page 23 of 24 B410

50 DETAIL ESTIMATING PIPE SEWERS Appendix B CPS Master Items List of Pipe Sewer Tender Items The CPS Master Items List, lists all pipe sewer tender items and has been reproduced below. Contract Preparation System (CPS) Pipe Tender Item Sewer Pipe Size Range (mm) 100 mm Pipe Sewer 100 mm < 200 mm 200 mm Pipe Sewer 200 mm < 300 mm 300 mm Pipe Sewer 300 mm < 400 mm 400 mm Pipe Sewer 400 mm < 500 mm 500 mm Pipe Sewer 500 mm < 600 mm 600 mm Pipe Sewer 600 mm < 700 mm 700 mm Pipe Sewer 700 mm < 800 mm 800 mm Pipe Sewer 800 mm < 900 mm 900 mm Pipe Sewer 900 mm < 1000 mm 1000 mm Pipe Sewer 1000 mm < 1200 mm 1200 mm Pipe Sewer 1200 mm < 1300 mm 1300 mm Pipe Sewer 1300 mm < 1400 mm 1400 mm Pipe Sewer 1400 mm < 1500 mm 1500 mm Pipe Sewer 1500 mm < 1600 mm 1600 mm Pipe Sewer 1600 mm < 1800 mm 1800 mm Pipe Sewer 1800 mm < 1900 mm 1900 mm Pipe Sewer 1900 mm < 2000 mm 2000 mm Pipe Sewer 2000 mm < 2100 mm 2100 mm Pipe Sewer 2100 mm < 2200 mm 2200 mm Pipe Sewer 2200 mm < 2400 mm 2400 mm Pipe Sewer 2400 mm < 2500 mm 2500 mm Pipe Sewer 2500 mm < 2600 mm 2600 mm Pipe Sewer 2600 mm < 2700 mm 2700 mm Pipe Sewer 2700 mm < 3000 mm 3000 mm Pipe Sewer = 3000 mm November 2015 Page 24 of 24 B410

51 DETAIL ESTIMATING PIPE CULVERTS B421-2 PIPE CULVERTS OPSS.PROV GENERAL Pipe culverts are installations designed to provide for the conveyance of surface water, pedestrians or livestock using preformed or pre-cast pipe sections, circular or non-circular in cross-section, laid end to end using suitable joint materials. All design assumptions and calculations required to design a pipe culvert shall be retained as part of the design documentation REFERENCES MTO Highway Drainage Design Standards MTO Drainage Management Manual MTO Gravity Pipe Design Guidelines MTO Guide for Preparing Hydrology Reports for Water Crossings Ontario Provincial Standards Specifications Ontario Provincial Standards Drawings Drainage Guidelines available on the MTO public web site All references noted are available through the Contract Preparation System (CPS), through the ministry s public web site, or through the MTO Online Catalogue library. The designer shall also reference other design manuals (i.e. MTO Roadside Safety Manual) as required for design assistance of other roadside features associated with the pipe culvert design TENDER ITEMS Pipe Culvert Non-Circular Pipe Culvert Pipe Culvert Extension Non-Circular Pipe Culvert Extension Concrete Appurtenances Clay Seal SPECIFICATIONS The requirements for the pipe culvert, non-circular pipe culvert, pipe culvert extension, non-circular pipe culvert extension and concrete appurtenance tender items November 2015 Page 1 of 35 B421-2

52 DETAIL ESTIMATING PIPE CULVERTS are contained in OPSS 421. Trenching, backfilling and compaction requirements are specified in OPSS 401 while rock excavation requirements are specified in OPSS 403. The designer shall also reference or note other OPSS documents for construction and materials as identified or required when packaging a contract APPENDICES Appendix A - Pipe Culvert Tender Item This appendix describes the pipe culvert tender items and is to be followed by the designer to itemize the pipe culvert tender item entries, complete with all pipe material specifications, in the Quantity Pipe Culvert sheets for all ministry contracts. Appendix B - Additional Pipe Culvert Design Factors This appendix describes some additional components in pipe culvert designs and is to be used by the designer to accurately identify the pipe culvert installation work in the Quantity Pipe Culvert or other quantity sheets for all ministry contracts, as appropriate. Appendix C - CPS Master List of Pipe Culvert Tender Items This appendix provides a list of all available pipe culvert tender items for circular and non-circular pipes SPECIAL PROVISIONS Refer to Chapter 'E' to review standard special provisions that may be required for inclusion in the contract STANDARD DRAWINGS Applicable standard drawings are contained in the 800 series of the Ontario Provincial Standard Drawings Manual; however, other OPSD or MTOD series may also apply DESIGN Pipe Culvert The general alignment, size, type and class of a pipe culvert are established, based on November 2015 Page 2 of 35 B421-2

53 DETAIL ESTIMATING PIPE CULVERTS acceptable drainage theory, by the designer. The designer shall use accepted drainage design methods by which to establish the pipe culvert design that satisfies required drainage standards or criteria for the highway project. As a general rule, pipe culverts, if embedment depths have not been defined through the design process, other than entrance pipe culverts should be embedded to a depth equal to one tenth of the height or diameter of the pipe culvert below the bottom of ditch, unless there are reasons for deviating from this rule. Gravity pipe drainage standards are available in the MTO Highway Drainage Design Standards. Gravity pipe design requirements, analysis methods and other information are available in the MTO Gravity Pipe Design Guidelines, the MTO Drainage Management Manual and the MTO Guide for Preparing Hydrology Reports for Water Crossings A. Size The design of a pipe culvert involves determining the size of a pipe, in conjunction with pipe type and class availability that will permit the pipe culvert to function within set design requirements and standards. The designer will also determine the maximum increase or tolerance range in pipe culvert size, of like pipe type and class availability that will still permit the pipe culvert to function within the design parameters set. For crossings where multiple pipe culverts are required, refer to Appendix B Additional Pipe Culvert Design Factors for additional information on how to determine spacing and other requirements. B. Type Pipe type refers to a pipe s inside wall design, which can be smooth or corrugated. A separate hydraulic analysis of each pipe type to determine hydraulic acceptability is required to determine if both pipe types should be specified in a contract as alternative pipe type choices. The designer will use hydraulic flow parameters, characteristic of each pipe type, during the hydraulic analysis work. For some sites, only one pipe type may be appropriate for the site conditions. The designer will analyze a pipe culvert for hydraulic acceptance based on one pipe type for the entire pipe culvert length. Two separate hydraulic design analysis runs are required to determine if both pipe types are hydraulically acceptable. Only where site circumstances are found to be pipe type sensitive, will it not be necessary for a designer to perform the hydraulic analysis separately for both pipe types. November 2015 Page 3 of 35 B421-2

54 DETAIL ESTIMATING PIPE CULVERTS Circular or non-circular pipe culverts greater than 3000 mm in diameter or span are classified as structures and are designed from first principles in conjunction with structural engineers following the requirements of the Canadian Highway Bridge Design Code and the MTO Structural manual. C. Class Pipe class refers to the material specifications of the pipe products. These specifications include load and pressure ratings, pipe wall thickness, protective coatings, corrugations and reinforcement. Acceptable material specifications of a pipe culvert are established, based on structural loading and material durability requirements, by the designer. The designer shall use accepted structural and durability assessment methods to establish the pipe class that satisfies both structural and material durability criteria. 1. Structural Assessment Pipe culverts, due to the fact that they are installed underground, are subject to dead and live loads. The loading requirements are addressed through placement of fill material below, around and on top of the pipe culvert. Bedding, cover, embedment in the case of flexible pipes, backfill, subgrade, and pavement are to be considered in the structural loading assessment. The height of fill available will define acceptable pipe sizes, types and classes in terms of structural strength. 2. Durability Assessment D. Joints Pipe culverts, for the different functional highway classifications, must be designed to the specified Design Service Life (DSL) criteria. Every pipe material has an Estimated Material Service Life (EMSL) based on its material properties and the site environment. Acceptable pipe materials are those that have an EMSL greater than or equal to the DSL criteria, unless otherwise determined during the design criteria setting for the project. Pipe materials with an EMSL less than the DSL criteria may only be considered in a strategic pipe replacement context. A Life Cycle Cost Analysis (LCCA) must be performed to support any pipe replacement design. Highway Standards Branch approvals are required to use a pipe replacement design approach. The designer, through hydraulic analysis of surface flow or through subsurface information as provided in a foundations or geotechnical report, shall make an assessment of the type of pipe joints required for the pipe culvert. November 2015 Page 4 of 35 B421-2

55 DETAIL ESTIMATING PIPE CULVERTS The designer shall refer to the MTO Gravity Pipe Design Guidelines for further information on pipe joint selection requirements. E. End Finish and Safety The use of bevels, end finishes or safety grates on a pipe culvert is determined by the designer based on hydraulic analysis and the final embankment slopes. When corrugated steel pipe is used for a pipe culvert, the protruding end may be cut to more aesthetically blend with the surrounding slopes. Where traffic safety is an issue, the designer may also consider a safety end treatment on the pipe culvert ends. The designer shall refer to relevant design manuals and any associated OPSD s for information on warrants and design of safety end treatments. F. Treatment Frost treatment is required if the frostline falls below the top of the pipe culvert, within the bedding layer or below the bedding layer. Foundations or geotechnical reports shall contain information regarding recommended pipe fill materials and the configuration and extent of frost taper excavations. Frost tapers are not required when the frostline falls above the pipe culvert. In rock or granular fills, frost tapers are not required. Pipe culverts being placed on sideroads and entrances that are paved or will be paved, either under the current project or in the foreseeable future, must be provided with frost tapers, where required, regardless of the length of paving (pipe culvert within the limits of paving or future paving). Information on future sideroad requirements should be obtained from municipalities. On gravel roads, pipe culverts should not be provided with frost tapers unless specifically identified in a foundations or geotechnical report or requested by the municipality. Flow sources carrying sediment loads under certain velocity conditions may require lining the pipe culvert invert to prevent abrasion of the pipe material. Lining the pipe culvert invert can be done with concrete or shotcrete material. Bituminous products shall not be used to line the invert of the pipe culvert. In lieu of a lined invert, the designer may also consider pipe products with thicker walls and/or protective coatings to provide the required protection against November 2015 Page 5 of 35 B421-2

56 DETAIL ESTIMATING PIPE CULVERTS Trench abrasive forces. Fish bearing streams may require channel substrate or baffles to provide suitable conditions for fish to travel through the pipe culvert. The pipe culvert size may need to be larger to properly embed the pipe culvert and provide suitable substrate depth in which to form the low flow channel for fish passage or to accommodate baffle block heights and provide suitable resting zone water depths and lengths. Baffle configurations and heights may also dictate a larger pipe size to maintain the flow capacity requirements for larger storm events. The designer shall also refer to the MTO Drainage Management Manual for further information on design of low flow channels and baffles. G. Concrete Appurtenances The flow through a pipe culvert may need to be controlled to prevent erosion damage to the area around it or to the pipe structure itself. Concrete appurtenances such as headwalls, wingwalls, energy dissipators, aprons, collars or other such types of structures are used to direct flow, slow velocities to prevent erosion, offset buoyancy forces, etc. Concrete structures covered by OPSS 904 do not include the aforementioned concrete appurtenances. A. Excavation Excavated earth material may be used for embankment construction or used as native backfill to the excavated pipe culvert trench as determined by the designer based on foundation or geotechnical reports. Surplus or unsuitable excavation material should be managed as outlined in B206 of this manual. In view of the high unit cost of rock excavation, the designer shall endeavour to reduce the volume of excavation by relocating, pipe skewing, etc., wherever possible. Excavation in rock for placing pipe culverts is also done according to OPS Drawings. B. Tunnelling, Jacking and Boring Pipe Culverts In addition to the open-cut method of installing pipes, there are three other methods employed where trenching is not cost-effective: a) Tunnelling; b) Jacking and boring; and c) Pipe lining (non-standard special provisions are required) November 2015 Page 6 of 35 B421-2

57 DETAIL ESTIMATING PIPE CULVERTS Details of the first two methods of installation are discussed in Sections B415 and B416 of this manual. C. Dewatering Dewatering refers to pumping, bailing, groundwater lowering, temporary ditching or vacuum removal of uncontaminated groundwater, rain water, melt water, surface runoff, water pipe leakage from excavations and trenches or within sheeted coffer dams to improve the soil stability or for other construction purposes. Where dewatering is required for the installation of a pipe culvert, the details shall comply with the requirements of OPSS 517 or OPSS 902 when specified. Although the Contractor is responsible for a dewatering plan, the designer shall note any recommendations included in the foundation investigation and design report. The designer shall also refer to SP100S59, Amendment to MTO General Conditions of Contract, Permits to Take Water, for additional requirements that may need to be specified in the contract. D. Fill Material Pipe fill material for rigid pipe installations is placed in distinct bedding, cover and backfill layers. Flexible pipe installations require pipe fill material to be placed as distinct embedment, which is from the bottom of the bedding layer to the bottom of the backfill layer, and backfill layers. Applicable minimum or maximum height of pipe fill material limits are placed in accordance with OPSD or MTOD Height of Fill tables for the pipe materials identified. The minimum depth of cover for entrance pipe culverts is 300 mm. In rock cuts, this may require lowering of the ditch grade, using pipe arches or excavating the shatter below the ditch bottom. A foundation or geotechnical report will include recommendations for the supply, placement, and specifications of pipe fill material or any special conditions for bedding, cover, embedment in the case of flexible pipes, and backfill layers. In addition, special consideration for scour protection at the pipe culvert inlet or outlet may be required. The designer shall, based on the recommendations of the foundation or geotechnical report, specify the pipe fill materials required for the installation. The designer should be familiar with the various installation methods available as referenced in the 800 series of the OPSD for the pipe culvert installation so that November 2015 Page 7 of 35 B421-2

58 DETAIL ESTIMATING PIPE CULVERTS the pipe fill materials recommended are appropriately specified. The contractor, not the designer, is responsible for selecting the appropriate pipe culvert installation method, including excavation geometry, at the time of installation based on the soil types found on the construction site in accordance with the Occupational Health and Safety Act and Regulations for Construction Projects. E. Reinstatement Where existing driving lanes must be excavated to allow the construction of the pipe culvert crossing, the affected roadbed must be rebuilt to acceptable standards to maintain the continuity of the pavement. This is particularly important where there is to be no resurfacing of the highway. The designer shall determine and specify bedding, cover, embedment in the case of flexible pipe, and backfill depths and materials up to subgrade. Above subgrade, the designer shall determine the types and depths of granular and pavement courses necessary to achieve roadbed integrity. F. Protection Systems These systems will be applicable where the stability, safety or function of an existing roadway, railway, etc. may be threatened or impaired due to the construction of a pipe culvert or in cases where the pipe culvert will be installed at a depth where protection schemes are required. The design, installation, monitoring of protection systems is the Contractor s responsibility and the Contractor should base his plan on information as found in foundation reports. Problematic soils, high groundwater tables or other installation issues, if identified, will give rise to recommendations regarding the design, installation and removal and would also be provided in this report. Recommendations for performance levels can also be found in foundation investigation and design reports. Requirements for field investigation, laboratory testing and engineering recommendations for protection systems are to be specified in the foundation engineering terms of reference for any specific project such that appropriate information for the Contractor is provided. G. Clay Seals Warrants for clay seals to be installed on pipe culverts can be found in the MTO Gravity Pipe Design Guidelines. November 2015 Page 8 of 35 B421-2

59 DETAIL ESTIMATING PIPE CULVERTS Other physical flow control barrier options are in the GPDG April Recommendations may also be found in a foundation or geotechnical investigation and design report. H. Camber COMPUTATION Item Payment Basis A foundations or geotechnical report will contain information and design requirements for the camber depths needed for flexible pipe installations. Also refer to Appendix B Additional Pipe Culvert Design Factors for additional information on how to determine the amount of camber depth is required. Pipe Culvert items are Plan Quantity Payment items. Non-Circular Pipe Culvert items are Plan Quantity Payment items. Pipe Culvert Extension items are Plan Quantity Payment items. Non-Circular Pipe Culvert Extension items are Plan Quantity Payment items. Concrete Appurtenances are Plan Quantity Payment items. Rock Excavation for Trenches and Associated Structures is a Plan Quantity Payment item. Clay Seal is a Lump Sum item Sources of Information The main sources of information for pipe culvert items are: a) Survey notes and plans that provide profiles along the drainage course at both existing and new pipe culvert locations and drainage courses in addition to drainage areas, mosaic studies, soil types, etc, that provide information to assist in the calculation of pipe culvert sizes. b) MTO Highway Drainage Design Standards provides the overall design criteria requirements of pipe culvert installations. c) MTO Gravity Pipe Design Guidelines provides DSL criteria, water chemistry testing and pipe material selection procedures and requirements. d) MTO Guide for Preparing Hydrology Reports for Water Crossings provides an overview to the design issues associated with culverts on water crossings. e) MTO Drainage Management Manual provides the overall guidance on the design of pipe culverts and other storm drainage systems. November 2015 Page 9 of 35 B421-2

60 DETAIL ESTIMATING PIPE CULVERTS f) Foundation or geotechnical reports provide guidance and recommendations on subsurface and groundwater conditions, backfilling requirements, special foundation treatments, camber, articulation, scour protection at the culvert inlets/outlets and the need for placing clay seals. The foundation or geotechnical reports should also provide recommendations regarding dewatering requirements Methods of Calculation Pipe Culvert The unit of measurement for circular and non-circular pipe culverts is the metre. The price per metre for placing pipe culverts includes the following operations: a) Supplying, placing and joining pipe lengths; b) Earth excavations for trenches, frost tapers, etc. for pipes, culvert treatments, end finishes and concrete appurtenances; c) Supplying, placing and compacting all bedding, cover, embedment in the case of flexible pipes, and backfill materials for pipe culverts; d) Dewatering operations, unless otherwise specified; e) Design, installation and removal of protection systems, unless otherwise specified; f) Reinstating or constructing any highway ancillary elements, not covered under other required works in the contract, as part of the pipe culvert installation; and g) Disposing of all surplus excavated materials. A. Length The design length (L) of pipe culverts is the distance between the toes of embankment slopes where they meet the streambed profile measured to the nearest full metre. When the space is restricted or short lengths are required, the metric design length of pipe culverts may be determined as the next larger 0.1 metre. Where pipe culvert end treatment sections are used the length of the end treatment sections added. While the standard rock slope is 1¼:1, the length of pipe culvert should be based on a rock slope of 1½:1. November 2015 Page 10 of 35 B421-2

61 DETAIL ESTIMATING PIPE CULVERTS Slope flattening should also be considered when calculating the length of pipe culverts. The length of a pipe culvert is measured horizontally, except when the pipe grade is 10% or steeper, in which case the length is measured along the slope. B. Joints Trench Pipe joints are inclusive with the work to be done when installing a pipe culvert. C. Concrete Appurtenances The unit of measurement for concrete appurtenances is the cubic metre. The volume of each appurtenance is computed and the payment in cubic metre covers the cost of supplying and placing both concrete and reinforcing steel. Payment for excavation and backfilling, including the supply of granular material, is included with the associated pipe culvert tender item. A. Excavation Earth excavation required to place pipe culverts is part of the cost for placing the pipe culvert. Excavation in earth for placing pipe culverts is done according to OPS Drawings. Unlike earth excavation, which is included in the bid price of the pipe, rock excavation is tendered as a separate item. Rock excavation uses information for the computation of rock excavation quantities from the foundations or geotechnical reports and soils profiles and field survey notes. The unit of measurement for this tender item is the cubic metre. Rock excavation is computed as outlined in Section B407-2 of this manual. Rock excavation operations shall be according to OPSS 403 when specified. Usually, the field survey drainage information contains a profile along the centreline of the pipe culvert, which is used to compute both pipe culvert length and volume of excavation. When the only information available is a profile along the centreline of the pipe culvert, the excavation is computed as shown in Figure B421-4, which can be found in Appendix B. However, when cross-sections are taken normal to the axis of the projected pipe culvert location, a more accurate computation of the quantity of excavation is obtained. November 2015 Page 11 of 35 B421-2

62 DETAIL ESTIMATING PIPE CULVERTS Where a pipe culvert is installed in a rock cut, the volume of excavation is measured from the top of the shatter. B. Swamp Excavations In swamp areas where existing embankments are being widened, excavate existing embankment and swamp as per the appropriate Ontario Provincial Standard drawings, and apply swamp excavation quantities to Earth Excavation (Grading) or Rental of Swamp Excavation Equipment. C. Dewatering Dewatering operations are according to OPSS 517 or OPSS 902 when specified. The designer shall ensure the requirements of SSP 100S59 are accounted for. Should a rare situation occur where it would be unfair to the Contractor to include an expensive dewatering or unwatering operation in his pipe bid price, consideration shall be given to using a separate non-standard tender item for the dewatering. Consultation with the Ministry s foundation or geotechnical staff is required prior to use of the non-standard dewatering item. D. Fill Material Granular volumes for frost tapers, bedding, cover, embedment in the case of flexible pipes, and backfill material for pipe culverts are computed as shown in Ontario Provincial Standard Drawings or from detail drawings when applicable. Granular materials for concrete appurtenances are included in the pipe culvert granular quantities. The total granular requirement for each pipe culvert location is computed in cubic metres, and may be converted to tonnes using the conversion factor determined according to B314 of this manual. This quantity is used for Geotechnical ASL purposes only. E. Clay Seal The unit of measurement for this tender item is lump sum, which covers excavation and the supply and placement of all materials to provide an effective seal. No volume calculations for clay seals are needed. November 2015 Page 12 of 35 B421-2

63 DETAIL ESTIMATING PIPE CULVERTS DOCUMENTATION Drawings A. Pipe Culvert 1. Location New pipe culverts, and existing pipe culverts requiring extensions or endsections, are shown on the contract drawings, numbered sequentially in the direction of chainage. Pipe culverts to be removed are not numbered, however details regarding elevation and length of existing pipe culverts are shown crossed out on the drawings. 2. End Finishes and Safety End Treatments The applicable drawing for such end finishes are shown in the Ontario Provincial Standard Drawings. The types of safety slope end treatments are listed in the CPS Master Item list and will be listed as separate tender item in a column on the Quantities Pipe Culverts sheets. 3. Concrete Appurtenances Concrete Appurtenances are identified on the contract plans by means of an arrowed note (e.g. - Concrete Collar), and specifying the OPSD number, or a special drawing, if required, showing the layout. 4. Treatment B. Trench Typical cross section drawings must be included in the contract drawings giving dimensions and shape of channel substrate materials or fish baffles. Locations of baffles must be shown on a typical profile drawing. 1. Fill Material Ontario Provincial Standard Drawings in the 800 series depict dimensions, classes or types of bedding requirements for circular and non-circular pipes, of which the pipe can be either flexible or rigid. November 2015 Page 13 of 35 B421-2

64 DETAIL ESTIMATING PIPE CULVERTS Typical cross-sections must be included in the contract drawings, giving dimensions of frost depth, slope of frost tapers and depth of fill material layers. Because of the variety of possible treatments, standard drawings are not considered appropriate. If special conditions for bedding, cover, embedment in the case of flexible pipes, or backfill materials are required, the appropriate dimensions must be shown on applicable Ontario Provincial Standard Drawings or on detail drawings when applicable. 2. Reinstatement A typical section, traditionally known as "trench reinstatement," must be shown on the contract plans. The drawing should refer to the applicable OPSD numbers for bedding, cover, embedment in the case of flexible pipe, and backfill up to subgrade specifying the types and depths of pipe fill material necessary to achieve roadbed integrity. Above subgrade, the drawing should specify the types and depths of granular and pavement courses necessary to achieve roadbed integrity. These types and depths may be shown in table format adjacent to the trench reinstatement typical section. When the contract is for standalone pipe culvert replacements (i.e. no other pavement rehabilitation or resurfacing work), all of the work to reinstate the roadway, including granular and pavement layers above subgrade, may be included with the pipe culvert item, as per OPSS 492. In this case, the required attributes of the pavement and granular layers (e.g. Superpave traffic category, PGAC grade) shall be shown with the trench reinstatement typical section. 3. Special Foundation Treatment A detailed typical drawing and/or a modified OPSD will be necessary to show the depth of bedding and location if any special foundation treatment such as cambering, articulation, soil mixing, ground improvement, etc is included in the foundation investigation and design report. 4. Protection Systems When protection systems are required, the line of protection or a protection system shall be shown on the contract drawings. Performance levels shall be included on the Contract Drawings. These are only approximate lengths or locations and it is up to the contractor to design, install and remove with actual lengths and locations defined. November 2015 Page 14 of 35 B421-2

65 DETAIL ESTIMATING PIPE CULVERTS 5. Clay Seal Documents Quantities Sheet A detailed dimensioned sketch must be shown on the contract drawings for each location, based on information from foundations or geotechnical report. The "Quantities - Pipe Culverts" sheet shall show details such as: 1. Culvert Number: numerical identifier of pipe culverts in the contract. 2. Station: chainage measurement on the contract. 3. Location: For cross culverts, the relevant alignment control line (e.g. highway centreline) at the identified station with offset positions of pipe culvert upstream and downstream ends designated as the distance in metres left (LT) and right (RT) from the alignment control line (e.g. C/L 31.5 LT RT). For non-cross culverts, the relevant alignment control line at the identified station coincident with the culvert midpoint by length with offset position of pipe culvert upstream and downstream ends designated as the distance in metres left (LT) and/or right (RT) as applicable from the alignment control line (e.g. EB Alignment 25.8 LT LT).. 4. Extension: identifies placement of pipe culvert extensions by entering the length of the extension into the appropriate right or left extension column of the Quantities Pipe Culverts sheet. The total length of the extension must also be entered into the appropriate Pipe Culvert Extension tender item column of the Quantities Pipe Culverts sheet. If an existing culvert is to have both a left and right extension added, each extension is to be entered as a separate record entry with reference to the same culvert number. 5. Skew number: Refer to Appendix B Pipe Culvert Design Factors for information on how to determine skew number. 6. End Finish: type of end finish to be applied to the pipe culvert which can be Square or protruding ends which are applicable to any accepted pipe material. When corrugated steel structural plate pipe is used the protruding end may be cut or bevelled to more aesthetically blend with the surrounding slopes. Steel toe sections may be attached to the end of a smooth or corrugated steel pipe, if required. Refer to relevant OPSD for available end finish options for pipe culverts. November 2015 Page 15 of 35 B421-2

66 DETAIL ESTIMATING PIPE CULVERTS 7. Depth to Pipe: from the surface downward to top of base pipe opening at the midpoint by length of the culvert. 8. Pipe Fill Material: Where there are no recommendations from a foundations or geotechnical report to specify any particular pipe fill material, the pipe fill materials will be specified, by default, as G for bedding and by extension embedment, and N for backfill and cover. The designer does not have to enter any material specifications in the columns to have the default material specifications apply. However, specific pipe fill material for bedding, cover, embedment in the case of flexible pipes, or backfill, if recommended in a foundations or geotechnical report, shall be specified in the appropriate pipe fill material column. Pipe fill materials shall be specified as follows: N native material, which applies to cover and backfill layers only, and permits Granular B Type I, II or III, or Granular A to be used; G only Granular B Type I, II or III, or Granular A may be used; B only Granular B Type II or Granular A may be used; A only Granular A may be used; and C Unshrinkable Fill (Concrete). A single letter code is used to indicate the same pipe fill material for a pipe fill layer is suitable for both rigid and flexible pipe options. If using the same pipe fill material is not suitable, two letter codes are used such that the first letter specifies the pipe fill material for rigid pipes while the second letter specifies the pipe fill material for flexible pipes for a pipe fill layer. The pipe fill material codes are structured in an ascending order of quality. All higher level codes above the code that is selected are deemed to be satisfactory for the installation. In cases where the higher level pipe fill materials are not suitable (i.e. different frost susceptibility characteristics), a designer shall insert a contract note to alert the contractor that only the specified pipe fill material is acceptable. Embedment for flexible pipes is from the bottom of bedding layer to bottom of backfill layer and is specified in the bedding material column. When only flexible pipes are specified, the pipe fill material cover column is not applicable. Clear stone may be used as bedding or embedment fill material, if groundwater conditions warrant the need. Refer to the MTO Gravity Pipe Design Guidelines for details. 9. Pipe Joints: Types of joints required are to be specified in the appropriately labeled column on the "Quantities Pipe Culvert" sheet. S denotes a joint that November 2015 Page 16 of 35 B421-2

67 DETAIL ESTIMATING PIPE CULVERTS is soil tight while F denotes a joint that is silt or fines tight and L denotes a joint that is water tight. Pipe joints are specified by default as S regardless of whether or not the S code is entered into the Pipe Joints column. Joint classification is hierarchal in nature so that if an S joint is specified, the F and L joints are also acceptable, unless otherwise stated. 10. Treatment: Type or types of treatment that a pipe culvert will require are to be specified in the appropriately labelled column on the "Quantities Pipe Culvert" sheet where F specifies frost treatment, P specifies paved invert, S specifies channel substrate placement and B specifies baffle placements. All appropriate treatment letters shall be entered in the column. Up to 2 letters may be specified in the column of the "Quantities Pipe Culvert" sheet. Should a 3 rd treatment letter be required, a contract note is to be used. 11. Upstream and downstream inverts: elevation entries of pipe culvert invert at the upstream and downstream locations. Refer to Appendix B Pipe Culvert Design Factors for information on how to determine grades and elevations. 12. Pipe Culvert Tender Items: Pipe culverts are shown on the "Quantities Pipe Culverts" sheet using a separate column for each pipe culvert tender item. Each pipe culvert tender item is formatted as shown below: Circular Pipe Culverts Size mm Pipe Culverts Size + mm range S xxxxxx Size + mm range C xxxxxx Non-circular Pipe Culverts Size mm Non-Circular Pipe Culverts Size + mm S xxxxxx Size + mm C xxxxxx Pipe Culvert Extensions Size mm Pipe Culvert Extensions Size S xxxxxx Size C xxxxxx Non-Circular Pipe Culvert Extensions Size mm Non-Circular Pipe Culvert Extensions Size S xxxxxx Size C xxxxxx November 2015 Page 17 of 35 B421-2

68 DETAIL ESTIMATING PIPE CULVERTS Different pipe culvert, non-circular pipe culvert, pipe culvert extension and noncircular pipe culvert extension sizes will necessitate entry of separate tender items. Same pipe culvert, non-circular pipe culvert, pipe culvert extension and noncircular pipe culvert extension sizes but with different size tolerance ranges and pipe material codes for different locations will necessitate entry as a composite pipe culvert tender item (e.g. more than one column is required to specify the pipe culvert tender item). Refer to Appendix A - Pipe Culvert Tender Item for information and guidance of how to define pipe culvert, non-circular pipe culvert, pipe culvert extension and non-circular pipe culvert extension tender items for entry into the Quantities Pipe Culverts sheets. Refer to Appendix C - CPS Master List of Pipe Culvert Tender Items for a complete list of all pipe culvert, non-circular pipe culvert, pipe culvert extension and non-circular pipe culvert extension tender items to be used in MTO contracts. 13. Pipe Culvert length: The pipe length for each pipe culvert tender item must be entered in the appropriate columns at each pipe culvert location. 14. Frost penetration depth must be entered on the Quantities Pipe Culverts sheet. 15. Notes that may be required on the Quantities Pipe Culverts sheet A contract note can be a tender item note, which makes the note applicable to all culvert locations of that pipe size category, or can be a quantity item note if it is only applicable to certain culvert locations. i) Identified locations where the non-reinforced concrete pipe material is acceptable must be noted. ii) iii) iv) When corrugated steel pipes are specified and there are two different products permitted, the product with the greater material specifications must be noted at the locations where permitted since minimum material specifications have been identified in the pipe culvert tender item. All culverts, other than entrance culverts, shall have the non-designed embedment depth equal to one tenth of the height or diameter of the pipe culvert specified through an attached tender item note. Any culvert embedment depths, as determined through design, require a note specifying the embedment depth requirement. When special culvert end treatments are required, a note shall be provided indicating the culvert end treatment requirement. November 2015 Page 18 of 35 B421-2

69 DETAIL ESTIMATING PIPE CULVERTS v) The locations of clay seals or other types of physical flow control barriers are to be indicated through a note. vi) vii) If frost treatment is different than standard 10 (k-d), a note shall be provided indicating the different treatment requirements. Where camber is required, the pipe culvert number and camber distances must be noted. viii) When more than two culvert treatments are required, the additional treatments require a note indicating the treatment requirement. ix) When higher level pipe fill materials are not acceptable, a note shall be provided indicating that only the specified pipe material is acceptable. 16. Other Associated Pipe Culvert quantity items. To specify other pipe culvert quantity items as discussed below, the designer shall use CPS functional capabilities to enter the requirements into the contract package. Options may include creation of appropriate tender item columns on specific identified contract quantity sheets, attachment of standard or non-standard special provisions, or other suitable contract documentation methods. i) Where the installation of a pipe culvert is in a contract that includes other highway work (i.e. asphalt pavement removal, sidewalk removal, earth excavation, granular and pavement placement), the works above subgrade required in the pipe culvert installation area is included in the tender item for the other highway work. If the contract has no other highway work, that above subgrade work may be included in the pipe culvert item. ii) iii) iv) Swamp excavation is included in either "Earth Excavation (Grading)" or "Rental of Swamp Excavation Equipment". Rock excavation for trenches and associated structures requires a separate entry for each pipe culvert in rock to be shown in the Rock Excavation column of the "Quantities - Pipe Culverts" sheet, and the total quantity transferred to the Tender document. Rock material from trenches and associated structures excavations is shown as "Material Available for Fill" on the "Quantities - Grading" sheet. Rock shatter that must be excavated to place pipe culvert bedding is quantified for payment under this item. Granular and pavement to be supplied and placed for trench reinstatement would be included with the granular and pavement materials as part of the highway works. November 2015 Page 19 of 35 B421-2

70 DETAIL ESTIMATING PIPE CULVERTS v) When concrete appurtenances are to be placed on pipe culverts, they are treated as a separate item of work. Concrete appurtenances must be listed for each individual location on the "Quantities Miscellaneous sheet, or, if there are no other concrete items, they should be listed on the "Quantities - Pipe Culverts" sheet. vi) Clay Seal is a lump sum item and is identified as a separate tender item without quantity on the "Quantities - Pipe Culverts" Sheet. The designation of 100% is recorded for each location and is entered in the tender totals column while the designation LS is entered into the unit column of the quantity sheet. vii) If dewatering is tendered as a separate item, it shall be entered as a lump sum in the contract. Ensure that any requirements as specified by SP100S59 are accounted for in the contract. viii) Elaborate protection systems require separate tender items. ix) Safety slope end treatments shall be entered into a separate column, if required, on the "Quantities - Pipe Culverts" Sheet. 17. Post Installation Inspections Pipe culverts on ministry contracts may be subject to post installation inspections. The following criteria shall be applied to determine if this work is necessary. 1. The total combined pipe culvert length of all pipe culvert tender items, excluding entrance culverts and culvert extensions, is greater than or equal to 200 m; or 2. The total combined pipe culvert length of all pipe culvert tender items, excluding entrance culverts and culvert extensions, is less than 200 m, however, at least one pipe culvert is greater than or equal to 450 mm in diameter and is greater than or equal to 40 m in length. Should post installation inspections for pipe culverts be required, SSP104S02 shall be included. Payment for post installation inspection work is detailed in SSP104S Documentation Accuracy Stations are recorded to the nearest metre except for unusual circumstances, when 0.1 m may be required. Offsets are usually recorded to the nearest metre, or 0.1 m where required. November 2015 Page 20 of 35 B421-2

71 DETAIL ESTIMATING PIPE CULVERTS Individual pipe design lengths are recorded in whole metres (except 0.1 m where space is restricted and when steel end-sections are used), and placed on the "Quantities - Pipe Culverts" sheet in suitably headed columns. Pipe culvert extension size, type, and class, for both circular and non-circular, require separate columns based on individual pipe extension sizes, types and pipe material codes. Individual pipe extension design lengths are recorded in whole metres (except 0.1 m where space is restricted). Invert elevations are recorded in 0.01 m. Concrete Appurtenances should have concrete quantities and tender totals recorded to 0.1 m 3. Clay Seal is a lump sum tender unit of measurement. November 2015 Page 21 of 35 B421-2

72 DETAIL ESTIMATING PIPE CULVERTS Appendix A Pipe Culvert Tender Item The pipe culvert item is a variation tender item to be entered into a contract and for circular pipe has been structured to identify: a base pipe diameter; the minimum smooth inner wall diameter plus the upper size range tolerance in mm with associated pipe material code; and, if appropriate, the minimum corrugated inner wall diameter plus the upper size range tolerance in mm with associated pipe material code. This tender item format can fully specify the acceptable pipe products based on size, type and class. The tender item follows the descriptive format as noted below: Size mm Pipe Culvert Size+mm range S xxxxxx Size+mm range C xxxxxx base pipe diameter minimum smooth pipe diameter + tolerance range, type and material code minimum corrugated pipe diameter + tolerance range, type and material code The need to insert the pipe diameter for the circular pipe in the item description necessitates a separate tender item for each size of circular pipe culvert. Non-circular pipe culvert tender items have been structured to identify: the equivalent circular base pipe diameter to the span and rise dimensions required; the minimum circular equivalent smooth inner wall diameter plus the upper size range tolerance in mm with associated pipe material code; and, if appropriate, the minimum circular equivalent corrugated inner wall diameter plus the upper size range tolerance in mm with associated pipe material code. The designer uses the equivalent circular diameter to identify the appropriate non-circular pipe span and rise dimensions that the noncircular pipe culvert design requires. This tender item format can fully specify the acceptable pipe products based on size, type and class. The tender item follows the descriptive format as noted below: Size mm Non-Circular Pipe Culvert Size+mm range S xxxxxx Size+mm range C xxxxxx base pipe span x rise minimum smooth pipe diameter + tolerance range, type and material code minimum corrugated pipe diameter + tolerance range, type and material code The need to insert the equivalent pipe diameter for the non-circular pipe in the item description necessitates a separate tender item for each size of non-circular pipe culvert. A pipe culvert extension is essentially a pipe, circular or non-circular, that is fitted onto the end of an existing culvert in order to lengthen the existing culvert to the desired length. Circular pipe culvert extension tender items have been structured to identify diameter, type and the required material specifications. The tender item follows the descriptive format as noted below: November 2015 Page 22 of 35 B421-2

73 DETAIL ESTIMATING PIPE CULVERTS Size mm Pipe Culvert Extension Size S xxxxxx Size C xxxxxx base pipe diameter diameter, smooth pipe type and material code diameter, corrugated pipe type and material code The need to insert the pipe diameter for pipe culvert extensions in the item description necessitates a separate tender item for each size of pipe culvert extension. Non-circular pipe culvert extension tender items have been structured to identify the equivalent diameter, type and the required material specifications. The tender item follows the descriptive format as noted below: Size mm Non-Circular Pipe Culvert Extension base pipe diameter Size S xxxxxx equivalent diameter, smooth pipe type and material code Size C xxxxxx equivalent diameter, corrugated pipe type and material code The need to insert the equivalent pipe diameter for non-circular pipe culvert extensions in the item description necessitates a separate tender item for each size of non-circular pipe culvert extension. The pipe culvert material code is a 6 digit code that specifies the minimum material specifications for all acceptable pipe materials identified through design. Each digit represents a pipe material and in turn each digit has different values that specify the material specifications of that pipe material. November 2015 Page 23 of 35 B421-2

74 DETAIL ESTIMATING PIPE CULVERTS The Pipe Culvert Material Code is illustrated in Figure 1.0. Figure 1.0: Pipe Culvert Material Code The Pipe Culvert Material Code is interpreted in the following manner: 1. The 1 st digit represents concrete pipe, both circular and non-circular. For circular concrete pipe, there are two product types for consideration. They are manufactured with reinforcing steel or without. To define the required reinforced circular concrete pipe, the designer will specify the appropriate values as: 1 for Class 50 D-Load; or 2 for Class 65 D-Load; or 3 for Class 100 D-Load; or 4 for Class 140 D-Load. November 2015 Page 24 of 35 B421-2

75 DETAIL ESTIMATING PIPE CULVERTS To define the required reinforced non-circular concrete pipe, the designer will specify the appropriate values as: 1 for HE-A; or 2 for HE-I; or 3 for HE-II; or 4 for HE-III; or 5 for HE-IV. The final concrete pipe class selection shall be dependent on the bedding class that is appropriate for the type of soils encountered at the site. When specifying any concrete pipe material, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size and load rating. Exception The designer shall note the acceptability of non-reinforced concrete pipe products on the Quantities Pipe Culvert sheet in the Contract. This will be done as a note to the tender item to indicate the suitability of this pipe product in all locations or as a note to a quantity if the suitability of non-reinforced concrete pipe only applies to one pipe location. 2. The 2 nd digit represents PVC and PP (polypropylene) pipes. There are two PVC product types for consideration. They are manufactured with a smooth inside and a ribbed outside (profile) wall or with a smooth inside and outside (solid) wall. To define the required PVC pipe, the designer will specify the appropriate value as 1 for all classes (Class 210 kpa (equivalent to SDR 41) or Class 320 kpa (equivalent to SDR 35)) which defines the strength requirement for either product type. When one of the PVC pipe products is not suitable for a given site, the designer, through a contract note, shall restrict the use of the unsuitable PVC pipe product. PP pipe product types are manufactured as dual (open profile) and triple wall (closed profile) pipes available in 320 kpa material specifications. To define the required PP pipe, the designer will specify the appropriate value as 2 for both product types which define the strength requirements for either product type. The designer should be aware that the 750 mm PP pipe is available in both an open and closed profile. If one of the PP pipe products is not suitable for a given site, the designer, through a contract note, shall restrict the use of the unsuitable PP pipe product. November 2015 Page 25 of 35 B421-2

76 DETAIL ESTIMATING PIPE CULVERTS PP pipe products are automatically specified when the 2 nd digit pipe material code is 1. If this is not the case for a given site, then the designer, through a contract note, shall restrict the use of PP pipe at the site. When specifying any PVC or PP pipe material, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size and pipe stiffness rating. 3. The 3 rd digit represents HDPE pipes. There are two product types for consideration. They are manufactured with a smooth inside and a corrugated outside wall (open profile) or with a smooth inside and outside wall with a corrugated inner wall (closed profile). To define the required HDPE pipe, the designer will specify the appropriate value as 1 for open profile pipes and 2 for closed profile. Closed profile HDPE pipe products are automatically specified when the 3 rd digit pipe material code is 1. If this is not the case for a given site, then the designer, through a contract note, shall restrict the use of the closed profile HDPE pipe at the site. When specifying any HDPE pipe material, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size and pipe stiffness. 4. The 4 th, 5 th and 6 th digits all represent steel and aluminum alloy pipe products. There are three pipe product lines for consideration. They are manufactured as spiral rib steel pipe (SRSP), corrugated steel pipe (CSP), and structural plate pipe (SPP). SRSP is a smooth pipe while CSP and SPP are corrugated pipes. SRSP and CSP pipe products come in three coatings; galvanized, aluminized type II and polymer laminated. Steel SPP is available with a galvanized coating and a polymer coating. SPP is also manufactured from aluminum alloy materials. The 4 th digit is used for specifying required galvanized SRSP, CSP and SPP products. To define the required SRSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; or 2 representing 2.0 mm thick walls; or 3 representing 2.8 mm thick walls. November 2015 Page 26 of 35 B421-2

77 DETAIL ESTIMATING PIPE CULVERTS To define the required CSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; 2 representing 2.0mm thick walls; or 3 representing 2.8 mm thick walls; or 4 representing 3.5 mm thick walls; or 5 representing 4.2 mm thick walls. To define the required SSP products, the designer will specify the appropriate value as: 3 representing 3.0 mm thick walls; or 4 representing 4.0 mm thick walls; or 5 representing 5.0 mm thick walls; or 6 representing 6.0 mm thick walls; or 7 representing 7.0 mm thick walls. The 5 th digit is used for specifying aluminized type II SRSP and CSP pipe products and for specifying aluminum alloy SPP products. To define the required SRSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; or 2 representing 2.0 mm thick walls; or 3 representing 2.8 mm thick walls. To define the required CSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; 2 representing 2.0mm thick walls; or 3 representing 2.8 mm thick walls; or 4 representing 3.5 mm thick walls; or 5 representing 4.2 mm thick walls. To define the required aluminum alloy SSP products, the designer will specify the appropriate value as: 3 representing 3.18 mm thick walls; or 4 representing 3.81 mm thick walls; or 5 representing 4.45 mm thick walls; or 6 representing 5.08 mm thick walls; or 7 representing 5.72 mm thick walls; or 8 representing 6.35 mm thick walls. The 6 th digit is used for specifying polymer laminated or coated SRSP, CSP and SPP products. November 2015 Page 27 of 35 B421-2

78 DETAIL ESTIMATING PIPE CULVERTS To define the required SRSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; or 2 representing 2.0 mm thick walls; or 3 representing 2.8 mm thick walls. To define the required CSP products, the designer will specify the appropriate value as: 1 representing 1.6 mm thick walls; 2 representing 2.0mm thick walls; or 3 representing 2.8 mm thick walls; or 4 representing 3.5 mm thick walls; or 5 representing 4.2 mm thick walls. To define the required SSP products, the designer will specify the appropriate value as: 3 representing 3.0 mm thick walls; or 4 representing 4.0 mm thick walls; or 5 representing 5.0 mm thick walls; or 6 representing 6.0 mm thick walls; or 7 representing 7.0 mm thick walls. When specifying any steel or aluminum alloy pipe materials, the designer should reference the pipe availability tables in Appendix C of the MTO Gravity Pipe Design Guidelines to ensure that the pipe products specified are indeed commercially available in size, protective coating and wall thickness. Non-circular steel pipe products shall have the material requirements specified in the same fashion as for circular steel pipe products. Exception For some diameters, CSP is available with two corrugation profiles. The pipe material durability analysis may determine a single wall thickness for both CSP product lines while the structural analysis of the pipe materials determines a different wall thickness for each CSP product lines. The designer shall identify the minimum wall thickness through the Pipe Material Code and note the greater wall thickness requirement of the other pipe product on the Quantities Pipe Culverts sheet in the Contract. This shall be done as a note to the tender item to indicate the greater wall thickness requirement of this pipe product in all locations on the contract or as a note to a quantity if the greater wall thickness requirement of this pipe product only applies to one pipe location. November 2015 Page 28 of 35 B421-2

79 DETAIL ESTIMATING PIPE CULVERTS Appendix B Additional Pipe Culvert Design Factors Pipe Culvert Alignment Pipe culvert location and alignment is discussed in detail in the MTO Drainage Management Manual. The crossing often is oblique to the highway centreline, and is referred to as being skewed. Referring to Figure B421-1 "Skew Diagram for Pipe culverts", the designer will determine the angle of crossing and, from it, assign a "Skew Number". The SKEW NUMBER is obtained by measuring CLOCKWISE, to the nearest degree, the angle between the centreline of the highway and the centreline of the pipe culvert. Figure B421-1 November 2015 Page 29 of 35 B421-2

80 DETAIL ESTIMATING PIPE CULVERTS Multiple Pipe Culvert Installations Figure B421-2 "Spacing for Multiple Pipe Culvert Installations" gives the minimum spacing allowed between pipe culverts when placing two or more circular or non-circular pipes in a multiple installation. November 2015 Page 30 of 35 B421-2

81 DETAIL ESTIMATING PIPE CULVERTS Pipe Culvert Camber Flexible pipes on compressible soils, especially under high embankments, should be longitudinally cambered (Fig. B421-3). This will counteract the effects of differential settlement, to avoid ponding inside the pipe culvert. A geotechnical report shall contain information and recommendations as to the amount of camber required. Steel / PVC / HDPE Pipe Camber Streambed Camber Final Grade after Settlement Cambered Grade Figure B421-3 November 2015 Page 31 of 35 B421-2

82 DETAIL ESTIMATING PIPE CULVERTS Rock Excavation for Trenches and Associated Structures Calculations of rock removal are quantified based on the dimensional parameters shown below in Figure B Placing of Culvert in Existing Roadbed Under a Reconstruction Project Bottom of Subgrade New Cross Section Bottom of Backfill Layer Existing Cross Section Original Ground Excavation for Culvert For actual dimensions refer to the Ontario Provincial Standard Drawings Figure B421-4 November 2015 Page 32 of 35 B421-2