HELICALLY CORRUGATED STEEL PIPES. HelCor & HelCor PA

Transcription

1 HELICALLY CORRUGATED STEEL PIPES HelCor & HelCor PA

2 Table of Contents 1. Applications 2. Steel 3. Plate thickness and corrugation types 4. Production 5. Section lengths and coupling bands 6. Geometric and hydraulic parameters 7. Tolerances 8. Durability 9. Pipe end finishing 10. Fittings 11. Cover depth 12. Bedding and backfilling 13. Structural design 14. Installation and construction procedures 15. Other applications

3 1. Introduction The history of corrugated steel pipes dates back to 1896, when its production was started in the United States. The first helically corrugated steel pipes were also produced at that time in Russia, where 1300 m of this product was used as culverts under the railway lines. In Poland, the pipes appeared at the end of the 1970s, and since then they have been increasingly popular among designers and contractors. 3.

4 1. Applications Helically corrugated steel pipes HelCor and pipe-arches HelCor PA produced by ViaCon make up complete systems used in civil engineering as: - roads and railway culverts - underground passages - ecological passages - hydro technical structures - relining of existing old structures Complete system of helically corrugated pipes includes elbows or T-connections and also additional elements such as manholes, inspection chambers etc. According to the European Standard PN-EN :2007 HelCor and HelCor PA pipes can be used as engineering structures for every class of road and railway (up to V=200km/h) load. HelCor and HelCor PA pipes have Technical Approval issued by Polish Road and Bridge Research Institute (IBDiM). They have been approved for use in Scandinavia, The Baltic States, Switzerland, Hungary, Slovakia, The Czech Republic, Romania, Austria, The Ukraine, Belorus and other European countries. HelCor and HelCor PA are approved by Polish Central Mining Institute (GIG) to be used on subsidence areas. Installation time for HelCor and HelCor PA is much shorter then for concrete pipes. Easy and quick assembly helps in limiting time for construction of culverts or other structures and allows to construct culvert in stages without stopping the traffic as well as during winter time. Construction of culverts with the use of HelCor and HelCor PA is much cheaper than traditional concrete culverts. Pipes are produced in Rydzyna (PL) and are delivered to many European countries. 2.

5 2. Steel Steel used for the production of HelCor and HelCor PA pipes, as well as coupling bands conform to the European Standards: - EN 10327:2006 Continuously hot-dip coated strip and sheet of low carbon steels for cold forming Technical delivery conditions - EN 10326:2006 Continuously hot-dip coated strip and sheet of structural steels - Technical delivery conditions HelCor and HelCor PA pipes steel mechanical properties Steel grade Standard Yield point R e [MPa] Tensile strength R m [MPa] Elongation A 80min [%] DX51D EN S250GD EN Steel is delivered in coils, with a protection coating in accordance to a/m standards: g/m 2 zinc coating both sides, equivalent to 42μm on each side g/m 2 zinc coating both sides, equivalent to 70μm on each side g/m 2 zinc coating both sides, equivalent to 42μm on each side, with an additional 250μm polymer film (Trenchcoat TM or both sides or W-Protect ) on one 3.

6 3. Plate thickness and corrugation types HelCor and HelCor PA pipes are produced from steel strips with thickness ranging from 1,25mm to mm in two types of corrugation x 13 mm x 26 mm Plate thickness Area of section A Moment of Inertia I x Sectional properties of corrugated steel Corrugation 68 x 13 [mm] Section Modulus W x Area of section A Corrugation 125 x 26 [mm] Moment of Inertia I x Section Modulus W x [mm] [mm 2 /mm] [mm 4 /mm] [mm 3 /mm] [mm 2 /mm] [mm 4 /mm] [mm 3 /mm] 1,5 1,62 31,5 4,4 1,66 142,8 10,4 2,0 2,16 40,9 5,6 2,21 190,9 13,7 2,5 2,70 52,0 6,8 2,77 239,9 16,7 2,7 2,92 56,2 7,3 2,99 259,1 18,1 3,0 3,24 64,0 8,0 3,32 289,0 19,7 3,78 74,7 9,3 3,88 337,2 23,0 4.

7 4. Production HelCor pipes are produced by cold forming of the steel strip into a round corrugated shape with diameters ranging from 300mm to 3600mm. During forming of the pipe a lock-seam is performed to keep the pipe integrity. HelCor Pipe Arches are produced through controlled mechanical deformation of HelCor pipes with the use of hydraulic jacks. 5.

8 5. Section lengths and coupling bands The standard lengths of HelCor pipes are 6m, 7m and 8m, however the production process allows the manufacturing of any length of pipe. The pipe-arches are produced in 6m long segments from HCPA-01 to HCPA-20 and 7m and 8m long segments from HCPA- 21 to HCPA-50. Typically the pipes are bevel cut in factory in accordance with the design to conform the slope and the skew angle. Cut ends are protected against corrosion. In order to obtain the designed length of the pipe, several segments are joined with coupling bands. The coupling bands are made out of flat or corrugated steel. Depending on the diameter and purpose of the pipe, different types and widths of coupling bands are used. TYPE 1: flat connected by bolts for diameters mm TYPE 2: helically corrugated connected by bolts for diameters mm TYPE 3: helically corrugated connected by bolts in tubes (for relining) TYPE 4: annular corrugated for connection of pipes with re-corrugated ends 6.

9 For HelCor PA pipes only helically corrugated coupling bands (TYPE 2 or TYPE 3) are used. Coupling bands dimensions and tolerances Coupling band type TYPE 1 TYPE 2 TYPE 3 TYPE 4 Width [mm] 345 to to to Tolerance [%] Acc to EN 10143:1997 ±2% ±2% ±2% Coupling band diameter for HelCor pipes and dimensions for HelCor PA depend on pipe diameter or span/rise of pipe arch cross section. TYPE 1 TYPE 2 TYPE 3 TYPE 4 7.

10 6. Geometric and hydraulic parameters Thickness parameters for respective diameters/dimensions of HelCor and HelCor PA pipes are given in the table below. Standard plate thickness is shown with bold, but it is possible to manufacture a pipe of a different plate thickness. Standard plate thickness is calculated for A Class of live load acc to Polish Bridge Standard PN-85/S (4 x 200kN x 1,5 factor = 1200KN, four axis vehicle), with minimum cover calculated as shown in chapter 11 of this catalogue. If other live load is expected, plate thickness should be checked assuming respective standard requirements. For more details or other solutions please contact the ViaCon technical department or your local dealer / representative. HelCor Pipes Diameter [mm] Cross section area [m 2 ] Corrugation Plate thickness* [mm] Zinc coating Weight [kg/m] Zinc coating + Trenchcoat TM layer Plate thickness* [mm] Weight [kg/m] 300 0,07 1,5 13,0 1,6 14, ,12 1,5 17,3 1,6 19, ,19 1,5 21,7 1,6 24, ,28 1,5 / 2,0 34,7 1,6 / 2,0 35, ,38 1,5 / 2,0 40,5 1,6 / 2,0 41, ,50 1,5 / 2,0 46,2 1,6 / 2,0 47, ,63 1,5 / 2,0 52,0 1,6 / 2,0 53, ,79 / 1,5 / 2,0 / 2,5 57,8 1,6 / 2,0 / 2,5 / 2,7 59, ,95 / 2,0 / 2,5 63,6 2,0 / 2,5 / 2,7 65, ,13 / 2,0 / 2,5 69,4 2,0 / 2,5 / 2,7 71, ,32 / 2,0 / 2,5 75,1 2,0 / 2,5 / 2,7 77, ,54 / 2,0 / 2,5 / 3,0 106,5 2,0 / 2,5 / 2,7 109, ,76 / 2,0 / 2,5 / 3,0 114,1 2,0 / 2,5 / 2,7 116, ,01 / 2,0 / 2,5 / 3,0 121,7 2,0 / 2,5 / 2,7 124, ,27 / 2,0 / 2,5 / 3,0 129,3 2,0 / 2,5 / 2,7 132, ,54 / 2,5 / 3,0 / 164,3 2,5 / 2,7 / 3,0 / 167, ,83 2,5 / 3,0 / 17 2,5 / 2,7 / 3,0 / 177, ,14 2,5 / 3,0 / 182,6 2,7 / 3,0 / 186, ,46 2,5 / 3,0 / 191,7 2,7 / 3,0 / 195, ,80 2,5 / 3,0 / 200,8 2,7 / 3,0 / 205, ,15 2,5 / 3,0 / 210,0 2,7 / 3,0 / 214, ,52 2,5 / 3,0 / 219,1 2,7 / 3,0 / 223, ,91 3,0 / 266,3 3,0 / 271, ,30 3,0 / 276,9 3,0 / 281, ,72 3,0 / 287,6 3,0 / 292, ,15 3,0 / 298,2 3,0 / ,60 3,0 / 308,9 3,0 / 314, ,06 3,0 / 319,5 3,0 / 325, ,55 330,2 336, ,04 340,8 346, ,55 351,5 357, ,08 362,1 368, ,62 372,8 379, ,18 383,4 390,2 8.

11 HelCor PA Pipes Type Span / rise [m] Cross section area [m 2 ] Corrugation Plate thickness* [mm] Zinc coating Weight [kg/m] Zinc coating + Trenchcoat TM layer Plate thickness* [mm] Weight [kg/m] HCPA-01 1,34/1,05 1,13 2,0 / 2,5 86,7 2,0 / 2,5 / 2,7 88,8 HCPA-02 1,44/0,97 1,10 2,0 / 2,5 87,4 2,0 / 2,5 / 2,7 89,6 HCPA-03 1,49/1,24 1,46 2,0 / 2,5 98,3 2,0 / 2,5 / 2,7 100,7 HCPA-04 1,62/1,10 1,42 2,0 / 2,5 97,5 2,0 / 2,5 / 2,7 99,9 HCPA-05 1,65/1,38 1,82 2,0 / 2,5 109,1 2,0 / 2,5 / 2,7 111,8 HCPA-06 1,80/1,20 1,70 2,5 / 3,0 130,9 2,5 / 2,7 / 3,0 133,6 HCPA-07 1,80/1,50 2,15 2,5 / 3,0 143,0 2,5 / 2,7 / 3,0 146,0 HCPA-08 1,84/1,39 2,04 2,5 / 3,0 140,4 2,5 / 2,7 / 3,0 143,3 HCPA-09 1,84/1,48 2,16 2,5 / 3,0 143,9 2,5 / 2,7 / 3,0 146,9 HCPA-10 1,89/1,55 2,32 2,5 / 3,0 149,1 2,5 / 2,7 / 3,0 152,2 HCPA-11 1,91/1,46 2,23 2,5 / 3,0 147,4 2,5 / 2,7 / 3,0 150,4 HCPA-12 1,95/1,32 2,04 2,5 / 3,0 142,2 2,5 / 2,7 / 3,0 145,1 HCPA-13 2,01/1,59 2,55 2,5 / 3,0 156,9 2,5 / 2,7 / 3,0 160,1 HCPA-14 2,04/1,49 2,41 2,5 / 3,0 15 2,5 / 2,7 / 3,0 156,6 HCPA-15 2,10/1,45 2,42 2,5 / 3,0 156,9 2,5 / 2,7 / 3,0 160,1 HCPA-16 2,10/1,55 2,59 3,0 158,7 2,7 / 3,0 161,9 HCPA-17 2,14/1,64 2,74 3,0 166,5 2,7 / 3,0 169,9 HCPA-18 2,16/1,62 2,80 3,0 166,5 2,7 / 3,0 169,9 HCPA-19 2,20/1,71 2,99 3,0 169,9 2,7 / 3,0 173,4 HCPA-20 2,23/1,68 2,93 3,0 169,9 2,7 / 3,0 173,4 HCPA-21 2,28/1,70 3,03 214,1 217,8 HCPA-22 2,35/1,77 3,28 219,4 223,3 HCPA-23 2,35/1,73 3,16 217,3 221,1 HCPA-24 2,37/1,83 3,45 219,4 223,3 HCPA-25 2,48/1,79 3,47 227,9 231,9 HCPA-26 2,49/1,83 3,61 230,1 234,1 HCPA-27 2,55/1,86 3,73 234,3 238,4 HCPA-28 2,58/1,94 3,97 240,7 244,9 HCPA-29 2,60/1,93 3,97 240,7 244,9 HCPA-30 2,75/1,95 4,20 250,8 255,2 HCPA-31 2,76/2,05 4,48 255,6 260,1 HCPA-32 2,80/2,01 4,43 255,6 260,1 HCPA-33 2,84/2,02 4,58 258,8 263,4 HCPA-34 2,95/2,04 4,69 267,3 272,0 HCPA-35 2,96/2,16 5,06 271,6 276,4 HCPA-36 2,97/2,00 4,57 265,2 269,9 HCPA-37 3,08/2,08 4,94 274,8 279,6 9.

12 HelCor PA Pipes Type Span / rise [m] Cross section area [m 2 ] Corrugation Plate thickness* [mm] Zinc coating Weight [kg/m] Zinc coating + Trenchcoat TM layer Plate thickness* [mm] Weight [kg/m] HCPA-38 3,14/2,27 5,63 288,6 293,7 HCPA-39 3,17/2,06 5,12 279,1 284,0 HCPA-40 3,23/2,12 5,41 285,4 290,5 HCPA-41 3,23/2,15 5,39 288,6 293,7 HCPA-42 3,28/2,17 5,67 289,7 294,8 HCPA-43 3,33/2,23 5,97 298,2 30 HCPA-44 3,33/2,39 6,29 305,7 311,1 HCPA-45 3,35/2,19 5,65 297,2 302,4 HCPA-46 3,38/2,25 5,60 300,9 306,2 HCPA-47 3,49/2,27 6,28 306,8 312,1 HCPA-48 2/2,49 6,91 319,5 325,1 HCPA-49 3,65/2,39 6,85 323,8 329,5 HCPA-50 3,67/2,61 7,52 336,6 342,5 * Plate thickness tolerances acc. to EN 10143:1997. For the same water level the pipe-arch shape has 65% - 100% better water flow capacity than a round pipe with the same rise. 10.

13 Hydraulic parameters The above table shows the reference water flow Q m for HelCor pipes with water level at 75% height but at least 25 cm from the crown, according to Polish national regulations. Water-flow regulations may differ slightly depending on national standards. For more details or other solutions please contact the ViaCon technical department or your local dealer / representative. 11.

14 Hydraulic parameters The above table shows the reference water flow Q m for HelCor PA pipes with water level at 75% height but at least 25 cm from the crown, according to Polish national regulations. Water-flow regulations may differ slightly depending on national standards. For more details or other solutions please contact the ViaCon technical department or your local dealer / representative. 12.

15 7. Tolerances Manufacturing tolerances of HelCor pipes Parameter Diameter deviation Diameter deformation after backfilling Unit % of nominal diameter % of pipe diameter Acceptable tolerance ± 1,5 ± 2,0 Manufacturing tolerances of HelCor PA pipes Manufacturing tolerance of HelCor and HelCor PA length is ±0,5% of the designed length. A gap between two pipes connected with a coupling band should not exceed 30 mm. Parameter Unit Acceptable tolerance Dimensions deviation for pipe corrugation 68x13mm % of nominal equivalent diameter ± 2,0 Dimensions deviation for pipe corrugation 125x26mm % of nominal equivalent diameter ± 5,0 Dimensions deformation after backfilling % of pipe span ± 2,0 13.

16 8. Durability Type of corrosion protection of HelCor and HelCor PA pipes determines the durability of the culvert. ViaCon offers three types of corrosion protection, which allows the long term operation of the culvert in any given environmental condition in the most economical way. Atmosphere aggressiveness category according to EN ISO Water parameters Soil parameters - C1 - C2 Non-aggressive environment - ph from 6,5 to 8,0 - hardness of water 20 mg Ca/I - speed of water 1,5 m/s - ph from 6,0 to 8,0 - soil permeability k 8,0 m/24h - no organic parts - non-uniformity C u 5 - humidity 17% Aggressive environment - C3 - C4 - C5-I, C5-M - ph from 3,0 to 6,5 & from 8,0 to 12,0 - hardness of water < 20 mg Ca/I - speed of water > 1,5 m/s - ph from 3,0 to 6,0 & from 8,0 to 12,0 - soil permeability k < 6,0 m/h - contains organic parts - non-uniformity C u < 5 - humidity > 17% Corrosion protection endurance Zinc coating 42 μm (600g/m 2 ) Zinc coating 70 μm (1000g/m 2 ) Zinc coating 42 μm (600g/m 2 ) + polymer coating 250 μm min. 40 years years over 100 years Not recommended years 80 to 100 years TRENCHCOAT TM and W-Protect coating Coating steel with a polymer film, called trenchcoating, is a technique invented, patented and used in USA since 1974 and in Europe since the beginning of The zinc coated steel strip is covered with a polymer foil in a fully controlled in-house process. As a result a very smooth and highly adhesive layer of polymer film protects galvanized coating. Production process conforms to EN (W-Protect ) and ASTM 742 (Trenchcoat TM ). Trenchcoat TM film can be applied on either one or both sides of the pipe. Protection obtained in such a process is the best way to prevent natural corrosion in zinc and steel, it also protects against mechanical damage and chemical corrosion. Research findings indicate that Trenchcoat TM film resists aggressive chemicals in excellent way. This is the best corrosion protection that is available on the culvert market today. It guarantees over 100 years life-time in most environmental conditions. 14.

17 Trenchcoat TM layer chemical aggression resistance test results Test Resistance to 10% concentration of HCl Resistance to HNO 3 Resistance to NH 4 OH Resistance to NaOH Resistance to 30% concentration of H 2 SO 4 Resistance to NaOH Resistance to 10% concentration of NaCl Resistance to SO 2 steam Research method ASTM 308 ASTM 308 ASTM 308 ASTM 308 ASTM D543, A742 ASTM D543, A742 ASTM D543, A742 DIN 50018, 2.0L Outcome Resistance to chloroform (trichlorometan CHCI 3 ) ISO 175, 28 days, 23 0 C Resistance to DMSO (dimetylosulfoxyde) ISO 175, 28 days, 23 0 (CH C 3 ) 2 SO Resistance to MeCI 2 (chloro- metylene) ISO 175, 28 days, 23 0 C Resistance to THF (tetrahydrofuran) C 4 H 8 O Resistance to 20% concentration of NaOH in water Resistance to 10% concentration of ammonia CO(NH 2 ) 2 in water Resistance to 25% concentration of NH 4 OH Resistance to 25% concentration of H 2 SO 4 Resistance to 20% concentration of HNO 3 Resistance to i-propanol (CH 3 ) 2 CHOH (izopropyl alkohol) Resistance to aceton CO(CH 3 ) 2 (propanon) Resistance to CH 3 CO-O-C 2 H 5 Resistance to C 6 H 5 (CH 3 ) (metylobenzen) Resistance to poliethylen glicol C 2n H 4n+2 O n+1 ISO 175, 28 days, 23 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C 23 0 C ISO 175, 90 days 80 0 C ISO 175, 90 days 23 0 C 80 0 C 8% decrease in coating thickness 3% decrease in coating thickness * * * 4% decrease in coating thickness ** ** 3% decrease in coating thickness ** 4% decrease in coating thickness Destruction of the coating 4% decrease in coating thickness Dielectric strength of Trenchcoat TM is 86,6 kv/mm which gives 21,6 kv for the thickness of 250 μm. This considerably outnumbers the value of the stray currents arising within the electrified railway lines sub grade. Using Trenchcoat TM guarantees 100% protection against the corrosion that may be caused by stray currents. * - NH4OH, H2SO4, HNO3 test at 80 O C stopped due to formation of gases ** - (CH 3 ) 2 CHOH, CO(CH 3 ) 2, CH 3 CO-O-C 2 H 5 test at 80 O C stopped due to achieve the boiling point Additional corrosion protection by painting In special cases it is possible to protect the galvanized pipes with the paint of the thickness up to 400μm. Please contact the ViaCon technical department or your local dealer / representative. 15.

18 9. Pipe end finishing Using HelCor and HelCor PA pipes enables an accurate adjustment of both ends to fit the slope and in the required angle. Bevel cut can be done on one or both sides with full bevel or step bevel. It is recommended to use a vertical step of 1/3 the height of the pipe. The embankment slopes in the in- and outlet areas can be reinforced in several ways: Vertical end pipe: - vertical reinforced concrete head wall - vertical wall made of gabions Bevel end pipe: - reinforcement of the slope with concrete or stone blocks placed on sand-cement mix - reinforcement with perforated concrete panels - reinforcement with stone rip rap - reinforcement with reinforced concrete collar 16.

19 It is possible for both skewed inlet/outlet of the culvert (at the culvert and road axis intersection angle 90 ) to be square beveled. Minimum allowable skew angle is 55. In special cases it is necessary to make additional reinforcements in the skewed area. 17.

20 10. Fittings Depending on the function of the structure, HelCor and HelCor PA pipes can be equipped with additional elements, e.g. fittings steel shelves for animals connection pipes elbows, three-way adapters, flanges grids manholes, pumping stations equipment latches, walls throttles, etc. 18.

21 11. Cover depth Culvert cover under road can be described as a vertical distance between the top of the culvert and the road grade-line, including the road pavement construction. Culvert cover under railway can be described as a vertical distance between the top of the culvert and the bottom of the railway sleeper, including the construction layers of the railroad. Below formulas can be used for calculation of the depth of cover for the A-class road live load or the k+2 class railway live load (UIC-71), respectively to the Polish Bridge Standard PN-85/S-10030, providing that the standard thickness of the pipe wall is applied (as described in chapter 6). If other live load is expected, plate thickness should be matched with respective standard requirements. For road applications, the minimum allowable depth of cover is the largest of: H=B/6 [m], H=B/8+0,2 [m], H 0,6 m For the railway applications, the minimum allowable depth of cover is the largest of: H=B/4 [m], where: H depth of cover [m] B diameter or span of a pipe [m] H 0,6 m When the thickness of road surface structure is greater then minimum cover, the aggregate thickness over the structure should be at least 0,10 0,15 m, measured from the top of the pipe. For the road culverts in special conditions, e.g. exits from main roads, the minimum depth of cover can be 0,3m. In a case when it is necessary to build a culvert with a lower cover or with a non-standard thickness of the steel, a static calculations should be performed. When technological traffic should run over the culvert on a job site, special features should apply. The minimum cover must be adjusted to extreme construction. It can be performed as placing concrete slabs over the culvert or adding another layer of compacted soil. Stopping of the construction equipment directly over or directly next to a culvert is not allowed. For more details or other solutions please contact the ViaCon technical department or your local dealer / representative. 19.

22 12. Bedding and backfilling HelCor and HelCor PA pipes tolerates uneven settlements of the subsoil very well. They can be successfully used on soft soils and subsidence areas. It is related to distribution of pressure around the pipes which in contrary to concrete pipes, limits the downward pressure directly under pipe. In order to ensure correct work of flexible pipe several conditions must be fulfilled, i.e. concerning bedding preparation, making of aggregate foundation as well as proper backfilling of the structure. Appropriate performance of structure and its durability depends on quality of these steps. The designer should specify the load bearing capacity of the subsoil on which HelCor pipe should be placed. Subsoil which does not meet the demands should be reinforced with use of geotextile or other common geotechnical means. Graining of the bedding and backfilling material (gravel, coarse, gravel-sand mixture) depends on the corrugation type. Maximum size of grain in the vicinity ( 0,3m - 0,5m) of HelCor and HelCor PA is 31,5mm. For remaining zone bigger grains can be used. Material for bedding and backfill should meet the following demands: non-uniformity index curvature index permeability C u >5,0 1<C c <3 U>6 m/24 hours Requirements for bedding preparation: - bedding should extend transversely to at least half of pipe s diameter or span, and not less than 0,60m on each side of the culvert - thickness of bedding should not be smaller than 20cm (30cm recommended) - aggregate degree of compaction should not be smaller than I s =0,98 according to standard Proctor density - extra layer with 5cm of loose sand material should be made on the bedding so that the pipe corrugation can be seated on the bedding. 20.

23 Requirements for backfill preparation: - backfill adjacent to pipe should exceed its perimeter by half its diameter or span and not less than 0,60m on each side of the pipe (for installation in trench minimum is 0,30m). - backfill should be evenly laid in not compacted layers at maximum 30cm thick, on each side of the pipe, no more than one layer difference in elevation on each side of the pipe should be allowed - degree compaction of each layer should not be less than I s =0,98 standard Proctor density, however, directly near the pipe, I s =0,95 is allowed Backfill compaction should be carried out using light backfilling equipment (vibrating plates or jumping jacks). Heavy backfilling equipment is not allowed until the full backfill height has been laid. Appropriate compaction in haunch area of the pipe is very important due to load bearing capacity of a culvert. 21.

24 13. Structural design Each application of HelCor and HelCor PA pipes requires a technical design, including estimated loads, hydrological conditions or clearance to choose the appropriate diameter or dimensions of the pipe. Life-time analysis should specify corrosion protection to be applied. The design should follow the guidelines issued by ViaCon and local requirements. HelCor and HelCor PA culverts are produced according to the technical design in its final form, i.e. length, bevel, skew. All cutting, welding, corrosion protection and coupling bands are performed by the producer in the factory. Designing guideline - selection of pipe diameter or dimensions depending on the function of a structure (hydraulics, clearance, etc.) - setting bottom-line of the culvert (proper grade should be designed to prevent erosion under the pipe) - checking minimum cover condition for expected live load - specifying corrosion protection required durability - specifying thickness of steel wall and corrugation type - bedding (foundation) and backfill designing - calculation of culvert length - selection of pipe end finish type (inlet and outlet) - other features design 22.

25 Relining HelCor and HelCor PA can be used for relining purposes. Prior to relining a good check of internal dimensions of existing culverts or bridges that will be relined is required. Also, the bedding conditions need to be investigated. Space in between existing structures and HelCor or HelCor PA should be filled with concrete semi-liquid or liquid mixture pressurised in order to fill in the space completely. A minimum of 10 cm space is recommended (15cm strongly recommended). Load bearing capacity of the concrete filling the gap is neglected in the static calculations. The culvert should be secured from any movement when filling the gap with concrete. Ballasting with sandbags and staged pouring with concrete is recommended. For HelCor arches determination of placing them on foundations should be done. 23.

26 14. Installation and construction procedures Soil-structure interaction is a main concept when building flexible culverts. Appropriate assembly in accordance with the producers guidelines, as well as appropriate backfilling procedures are the key factors in successful installations. Pipes are delivered to the job site by trucks. Unloading and placing of the pipes should be performed with a use of light mechanical devices (crane or pay-loaders) with the help of textile belts. Pipes should not be dumped from the truck. 24.

27 Pipes are connected with coupling-bands. Separate elements (pipes and coupling-bands) are marked by the producer in a way allowing for fast and correct assembly. The process of assembling HelCor and HelCor PA pipes is not complicated and can be performed by a group of unskilled workers under the supervision of an engineer. It allows for a quick work, without the use of heavy or specialized mechanical equipment, even in bad weather conditions. Short construction time reduces the inconvenience in traffic related to blocking of a road, and the relining allows for carrying out the construction work without stopping the traffic and dismantling the old structure. 25.

28 15. Other applications HelCor and HelCor PA can be used when building or re-building of the following underground retention tanks manholes, pump stations, lightening of concrete decks in bridges 26.

29 under- and on-ground ventilation systems technological tunnels, escape routes, conveyor protection For further questions, please contact ViaCon technical department or local dealer or representative. 27.

30 ViaCon Sp. z o.o. ViaCon Sp. z o.o. is a member of ViaCon Group established in Sweden and Norway in At present ViaCon Group operates in a dozen or so European countries and belongs to SAFEROAD Group. Thanks to the support from the entire group and the possibility of using the shared experience, each member company can offer professional technical consulting and top quality products. Business profile of the company: manufacture, design, sale and installation of plastic and steel pipes and flexible structures used for construction and repair of culverts, bridges, overpasses, tunnels, farm accommodation underpasses, wildlife crossings, other engineering structures, and used also as belt conveyor housings, manufacture, design and sale of storm water drainage systems and holding tanks, design, sale and installation of geosynthetics, such as non-woven geotextile fabrics, woven geotextile fabrics, geogrids, geomembranes, and bentonite mats, sale and lease of temporary bridges, sale of gabions, design, manufacture and sale of three retaining structure systems from reinforced soil.

31 MP200 pl ok_folder-srodek2.qxd :00 Strona 13 PECOR OPTIMA HelCor HelCor PA MultiPlate MP200 SuperCor Acrow 700XS - temporary bridges Woven and non-woven geotextiles Geogrids Gabions HelCor TC holding tanks HelCor wells PECOR OPTIMA M wells ViaWall A retaining walls ViaWall B retaining walls Pecor Quattro sewage system ViaBlock retaining walls Our goal is to improve products and to cooperate closely with customers, scientific and research centres, public administration and suppliers. ViaCon Sp. z o.o. ul. Przemysłowa Rydzyna, Poland phone: fax: office@viacon.pl That s why our motto is: Let s Create a Better Future Together