Randy McDonald, Armtec Drainage’s Director of Engineering and Frank Klita, Senior Sales Representative, for the exciting second part of our 2-part Culvert series – Culvert Design 201! This presentation will build on the basics of culvert design covered in Culvert Design 101 and will focus in- depth on the structural design of culverts. Additionally, the presenters will review considerations and best practices for culvert installations. What You'll Learn Culvert types & applications Structural design of culverts and buried structures as per CHBDC (Canadian Highway Bridge Design Code) methods Installation best practices Review of applications across Canada

1. Randy McDonald,
P.Eng.
Director of Engineering
Armtec
Drainage Solutions
Frank Klita
Sales Representative
Armtec
Drainage Solutions
Randy McDonald, P.Eng.
Director of Engineering
Armtec
Drainage Solutions
Frank Klita
Senior Sales Representative
Armtec
Drainage Solutions
CULVERT DESIGN 201
STRUCTURAL DESIGN, DURABILITY & APPLICATIONS
TECHNICAL WEBINAR
THE BROADCAST WILL BEGIN SHORTLY
FRIDAY DECEMBER 11, 2015 / 9AM PST / 11AM CST / 12PM EST

2. Randy McDonald,
P.Eng.
Director of Engineering
Armtec
Drainage Solutions
Frank Klita
Sales Representative
Armtec
Drainage Solutions
Randy McDonald, P.Eng.
Director of Engineering
Armtec
Drainage Solutions
Frank Klita
Senior Sales Representative
Armtec
Drainage Solutions
FRIDAY DECEMBER 11, 2015 / 9AM PST / 11AM CST / 12PM EST
TECHNICAL WEBINAR
CULVERT DESIGN 201
STRUCTURAL DESIGN, DURABILITY & APPLICATIONS

3. YOUR HOST
Janine Yetke
Director of Marketing
Armtec, Drainage Solutions
LinkedIn: ca.linkedin.com/in/janineyetke/en
Email: Janine.Yetke@armtec.com

4. JOIN THE DISCUSSION
At any time during
the presentation,
please enter your
questions into the
Question Log

5. CPD CREDIT CERTIFICATES
• Qualifies in Most Jurisdictions in Canada & USA for 1 Hour Technical
Informal
• Formal completion certificates are emailed within one week of attending
• Check your local guidelines if unsure of your requirements
Email your complete attendee list should there be multiple individuals
viewing the same screen:
• Full Name
• Title
• Email
webinars@armtec.com
Armtec will send certificate to all participants

6. Armtec is one of Canada’s
largest infrastructure
company supplying precast,
corrugated steel and HDPE
products and solutions. Every
day, our proven products,
engineered solutions and
dedicated people are counted
on to support construction and
infrastructure projects in
communities everywhere. With
a national presence and a
local focus on exceptional
customer service, we are
dedicated to building
excellence.
Actual 2014
Locations 43
Drainage Locations
Precast Locations
ABOUT ARMTEC

7. SECTORS
Armtec specializes in all infrastructure markets and segments and can help with any project to ensure you
have the right products for the job. Our people have extensive experience and access to resources all across
the country, and can help with all facets of product selection, installation and support.
Stormwater Solutions
Mining & Energy
Commercial & Retail
Constructions
Transportation Underground & Utility
Infrastructure
Sports & Entertainment
Institutional Construction Industrial Construction Agriculture
Commercial & Residential
Landscaping
Forestry Residential & Hospitality
ABOUT ARMTEC

8. Armtec Drainage Solutions’ centralized engineering
department consists of design engineers, a drafting team,
and estimators.
Additionally, professionally licensed Region engineers are
located in all Market Areas across the country.
DRAINAGE ENGINEERING SUPPORT & ROLES
ABOUT ARMTEC

9. YOUR SPEAKERS
Randy McDonald P.Eng.
Director of Engineering
Armtec, Drainage Solutions
Randy.McDonald@armtec.com
Frank Klita
Senior Sales Representative
Armtec, Drainage Solutions
Frank.Klita@armtec.com

10. AGENDA
1. Overview - Segmental Plate Products for Buried Bridges
2. Buried Bridge Structural Design – Section 7 CSA S-6 CHBDC
3. Design Life - Designing for Durability
4. Projects and Applications

11. Segmental Plate Products1

12. Multi-Plate 152 x 51
Bridge-Plate 400 x 150
Tunnel Liner Plate 500 x 52
SPCSP AND DCSP

13. SHAPE OPTIONS

14. MULTI-PLATE SUPER-SPAN
14.4m span x 6.8m rise High Profile Arch

15. LARGEST SUPER-SPAN (1984)
18.0m span x 7.4m rise Low Profile Arch

16. DCSP
Deep Corrugated Structural Plate
• Bridge-Plate
• 400 x 150 corrugation
• Plates widths are 1200mm (3 corrugations)
• Wider plates allow faster assembly times
• 10 times greater stiffness than shallow corrugated
plate products

17. BRIDGE-PLATE BOX CULVERT

18. Structural Design2

19. STRUCTURAL DESIGN
Buried structures
• two distinctly different materials that interact to
create a complex composite geo-structural
system to support the overburden and surface
live loads
1. Soils encasing the buried shell
2. Corrugated Steel Shell

20. BURIED STRUCTURE COMPONENTS
20
• Soil Component:
– engineered granular
backfill envelope
– materials of known
geotechnical properties
• Steel Component:
– Corrugated steel shell
– Corrugated shell is highly
efficient member to support
axial compressive loads
• Net Result:
– economical buried structure
capable of supporting large
gravity loads

21. STRUCTURAL DESIGN
Load resistance of the composite system
• highly influenced upon the geotechnical
properties of the backfill materials encasing the
buried structure
Strength of the structure is dependent upon
• Geometry of the buried steel shell
• Stiffness /thickness of the selected plate
corrugation .

22. STRUCTURAL DESIGN
Force Analysis
• Determine thrusts, moments and deflections
during and post construction
Strength Analysis
• Determine resistance of the structure to
support the calculated load effects
Successful Design ensures:
Resistance > Demand

23. STRUCTURAL DESIGN
Load Definitions
Dead Loads
• Weight of the soil column directly above the
footprint of the structure
• Weight of the shell is included in FEA
• Accurate soil densities are critical
• Deep bury applications DL account for 100%
of applied loads

24. STRUCTURAL DESIGN
Live Loads (Surface Pressure)
• Position as many axles of the design
vehicle at the road surface above the
conduit span
• Distribute rectangular surface pressure
through the overburden @ 1:1 in
transverse direction, 2:1 in longitudinal
direction

25. STRUCTURAL DESIGN
1
1
1
1

26. STRUCTURAL DESIGN
Truck Loading
• Highway Trucks – CL625, CL800
• 5 axles – 225 kN maximum axle load
Extreme Live Loads
• Haul Trucks – 6120 kN GVW (CAT 797B)
• 2 axles – 4100 kN maximum axle load
• E90 Cooper Railway Loading

27. STRUCTURAL DESIGN
Railway Loading
80K AXLE LOAD = 355 kN
2526 kN Total

28. 250 TONNE HAUL TRUCK LIVE LOAD
12.4 m span x 5.6 m rise bridge-plate arch

29. STRUCTURAL DESIGN
Earthquake Loads
– Earthquake loads are limited to determining an
additional thrust component known as TE
– TE is equal to a percentage of the Dead Load Thrust
(TD)
– The percentage multiplier (AV) equals 2/3 of the
horizontal ground acceleration ratio AH
– Earthquake thrust is then summed with Dead Load
Thrust (TD) x load factor
– TE does not have to be considered with any other
load combinations

30. 10 Step Design Process
for Soil-Steel Structures
1 10

31. 5.0
6 





v
hh
D
DD
2
4.0 





v
h
D
D
Minimum Cover (Hmin) is the largest of:
a) 0.6 m
b)
c)
Determine Minimum Cover
For deep corrugated structures Hmin shall be
smaller of 1.0m and the minimum depth of
cover for structure with shallow
corrugations but the same conduit size
1

32. Determine Minimum Cover1

33. Calculate Dead Load Thrust
• TD = 0.5 (1.0 – 0.1 CS) Af W
• W = weight of column of material above
2
)(
1000
parameterstiffnessaxial
EA
DE
C vS
S 
TD/2TD/2

34. Calculate Dead Load Thrust
• TD = 0.5 (1.0 – 0.1 CS) Af W
• Af = arching factor
2
Span < Rise
Span = Rise (round)
Span > Rise

35. Calculate Live Load Thrust
• Position as many axles of the CL-625 overtop
as would give maximum total load
3
  fLthL mlandDoflesserT 5.0
 kPacrownatpressureLoadLiveL 
loadinglanemultiforfactorificationmf mod

36. Calculate Earthquake Thrust
AH varies from 0 to 0.40 in Canada
4
vDe ATT 
ratioonacceleratizonalAwhereAA HHV 
3
2

37. or
5
 DLATTT LLDDf  1
EDDf TTT  
Maximum of
Calculate Total Thrust

38. 6
 MPa
Area
Tf

Calculate Compressive Stress
at ULS
Area = area of selected plate thickness
(mm2/mm)

39. 7 Calculate Wall Strength in
Compression – fb (MPa)
• Calculating the factored failure
compressive stress fb
• Dependent upon the NA radius
 










 2
2
12Er
KRF
FFf y
ymtb 2
3





r
RK
EF
f mt
b

eRR  eRR 

40. 7 Calculate Wall Strength in
Compression






 30 log2.06.1
RE
EI
m

  















2
'
1000
1
HHR
R
EE
C
C
Sm















25.0
3
6.10.122.1
cmRE
EI

25.0
3 






RE
EI
K
m

  0.11000
5.0
'





 

cR
HH

5.0
6









y
e
F
E
K
r
R

0.1
3.0
85.0 






h
m
D
S
F
22.1
• To arrive at fb – 7 equations, 18 variables

41. 8 Check Wall Strength
Requirements During
Construction
• Forces experienced during construction of
long span structures can sometimes be
greater than those values of the completed
structure
• Checks are made to ensure moments and
thrusts induced during construction do not
exceed the plastic moment capacity of the
structure

42. 8 Check Wall Strength
Requirements During
Construction
P = unfactored axial thrust = TD +TC
Ppf = factored compressive strength = fhcAFy
M = unfactored bending moment = M1 + MB + MC
Mpf = factored plastic moment capacity = fhcMp
1
2









pfpf M
M
P
P

43. 8 Check Wall Strength
Requirements During
Construction
3
11 hBM DRkM 
chBMB HDRkM 2
2 
ChLMC LDRkM 3
Introduces 9 new variables;
kM1, kM2, kM3, RB, RL, NF, Ac, k4, Lc
Also requires previous known variables;
Dv, Dh, Es, E, I,

44. 9 Check Wall Strength of
Completed Bridge-Plate
Tf = maximum thrust due to factored loads
Ppf = factored compressive strength = fhAFy
Mf = maximum moment due to factored loads
Mpf = factored plastic moment capacity = fhMp
1
2









pf
f
pf
f
M
M
P
T
 DLAMMMM LLDDDf  11 

45. 10 Check Seam Strength
Sjf ST 
• The calculated maximum thrust due to
factored loads shall be less than the
factored resistance of the longitudinal
seams;
SS = ultimate axial seam strength of bolted longitudinal seam

46. CHBDC FORMULA LIMITATIONS
• Box Culverts – maximum span
• All other shapes – single radius structures
• Standard Highway Loading
Analysis Options
• Rigorous Method – i.e. Finite Element Analyses
• Plaxis or CANDE are common software tools
• Each stage of construction is modelled
• Forces, moments & deflections captured for every stage

47. Vertical Stress Contours

48. Horizontal Stress Contours

49. Axial Force Diagram

50. Bending Moment Diagram

51. Crown
Deflection
4.5 mm Maximum
Time

52. STRUCTURAL DESIGN - SUMMARY
• Wall is predominately in compression for arch structures
• Bending moments developed in box-culvert structures
• Able to sustain high thrusts because it is laterally supported
against buckling by compacted engineered backfill
envelope
• Backfill provides a continuous and nearly elastic support to
the conduit wall
• Even after development of local buckling, soil-steel
structures can have substantial post buckling capacity by
dispersing load away from the member in distress to the
surrounding backfill envelope
• For segmental plate products, seam strength capacity of
bolted plate laps can be governing design condition

53. Design Life – Design for
Durability
3

54. DEFINITIONS
Design Life
• A period of time specified by the Owner during which a structure is
intended to remain in service
Durability
• the capability of a component, product, or structure to maintain its
function throughout a period of time with appropriate maintenance
Predicted Service Life
• an estimated period of time for the service life based on actual
construction data, condition surveys, environmental characterization, or
experience.
Service Life
• the actual period of time during which a structure performs its design
function without unforeseen costs for maintenance and repair.

55. PLATE COATINGS OPTIONS
Hot Dip Galvanized
Variable zinc weights (thicknesses)
Provides cathodic protection of steel
Zinc weight is a function
• materials thickness & chemistry and dipping time
in the kettle.
Polymer Coating
Zinc Rich Base Coat + Ethylene Acrylic Acid
Copolymer Top Coat

56. Performance Guideline
56
www.cspi.ca

57. Structural Plate Coatings
Environmental
Parameter
Suggested Limits
Galvanized Steel
Suggested Limits for Polymer
Coated Steel
50 year
EMSL
75 year
EMSL
100 year
EMSL
pH
preferred range
5 – 9 3 – 12 4 – 9 5 – 9
Resistivity 2,000 – 8,000 ohm-cm
>100
ohm cm
>750
ohm cm
>1,500
ohm cm
Chlorides < 250 ppm NA NA NA
Sulfates < 600 ppm NA NA NA
Hardness > 80 ppm CaCO3 NA NA NA
Table 21
Environmental Limits For Galvanized Steel and Polymer Coated
Steel
1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012

58. Coatings – Hot Dip Galvanized
Nominal
Plate
Thickness
(mm)
Standard Zinc Coverage Non-Standard Zinc Coverage
Total Mass
Both Sides
(g/m2)
Thickness
per side
(µm)
Total Mass
Both Sides
(g/m2)
Thickness
per side
(µm)
< 4.0 915 64 NA NA
4.0 – 8.0 915 64 1220 87
1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012
Table 51
Zinc Coverage for Galvanized Structural Plate Products – CSA G401
Corrosion resistance is direct function of the coating
mass (thickness)

59. Zinc and Carbon Steel Corrosion
Material Period
AASHTO Standard
Loss Rate/year/side
(µm)1
UK Non-Aggressive
Loss Rate/year/side
(µm)2
Zinc Coating
First 2 years 15 4
Subsequently 4 4
Carbon Steel
After Zinc
Depletion
12 M=22.5ts
0.67
1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012
Table 111
Zinc and Carbon Steel Soil Side Loss Rates
1AASHTO LRFD Bridge Construction Specifications
2UK Design Manual for Roads and Bridges
ts is additional design service life in years after zinc depletion, M is the UK steel corrosion allowance after zinc depletion

60. POLYMER COATING
STRATA-CAT
• Bonded chemically to the steel preventing
delamination
• Provides a 10 mil barrier between the structure
and the environment
• Provides excellent corrosion resistance against
diluted acids, salts & alkalis
• Offers long term durability where extended
service life is required

61. GALVANIZED & POLYMER COATED

62. POLYMER COATING
www.armtec.com
CAT = Corrosion
Arresting Technology

63. Projects & Applications4

64. CULVERT DESIGN 201
Project Installations and Applications

65. Northeast Anthony Henday – Edmonton, AB
• Project Requirements:
Corrugated Arch protection
of 5 critical oil carrying
pipelines
• Design loads: Dead load
(embankment fill only)
• 100 year design service life
• Designed to CAN/CSA S6-
06 CHBDC
UTILIDOR PROTECTION
USING DEEP CORRUGATED STRUCTURAL PLATE

66. UTILIDOR PROTECTION
•
•
Project Drawing Snapshots:
• 47H SRA Bridge-Plate DCSP
(Deep Corrugated Structural Plate)
• 12750mm Span X 6370mm Rise
• Structure Length 24.120m (C/L)
• All plates 7.0mm thick
• 915 gm/m² Galvanized Coating
• 60 Degree Segmental Elbow
(constructed from 8 mini-elbows)

67. DCSP UTILIDOR PROTECTION COVER
• Foam blocking to reduce
settlement of the embankment.
• Embankment settlement /
adverse effect buried metal arch
(adds more load to the arch).
• Max. height of cover = 6.0 m.
Northeast Anthony Henday – Edmonton, AB

68. DCSP C/W REINFORCING RIBS
•
•
• Heavy Haul Road Crossing
• Design - 8mm thk corrugated
shell c/w 8mm reinforcing ribs
spaced at 2400 mm
• Designed for two loaded CAT
797B Mine Trucks crossing at
the same time.
• One loaded CAT 797B = 1.4
million lbs. ! (635,000kg)
Albian Sands (2010) Ft. McMurray, AB

69. DCSP C/W REINFORCING RIBS
Albian Sands (2010) Ft. McMurray, AB
• Reinforcing ribs were continuous around
the arch from footing to footing for
added compressive strength.
• Designed with Finite Element Analysis
(FEA)
• Strongest Bridge-Plate section (8mm
shell w/ full 8mm ribs)
• During backfill the composite design of
the ribs and shell allowed the structure
to behave within the design parameters

70. DCSP C/W REINFORCING RIBS
Albian Sands – Ft. McMurray, AB
• 13 m span x 10 m rise
• Max. height of cover = 4.5 m
• Tallest Bridge-Plate arch (high profile shape)
ever supplied by Armtec

71. DCSP – RAILWAY LOADING
• Full periphery structure
• 6615mm Diameter (50H) Bridge-
Plate Round Pipe
• 72.08 m Long
• All plates 5.0mm thickness
• 1220 gm/m2 Galvanized Coating
• CHBDC was used for main design
using AREMA loading and impact
factors.
Railcar Loading Facility Hardisty, AB

72. DCSP – RAILWAY LOADING
•
•
• Designed to handle 5
railway lines over (Cyclical
loading)
• Design Parameters: Cooper
E80 & CL-800 Live Load
• Unit weight of backfill = 22
kN/m³
Loading Facility Hardisty, AB

73. DCSP – RAILWAY LOADING
•
•
• Critical Backfill zone design
= ½ Dia. min. each side of
the structure to finished
cover
• Critical zone material -
engineered well graded
granular compacted to
minimum 95% SP density
• 2.0m Height of Cover
Loading Facility Hardisty, AB

74. DCSP – RAILWAY LOADING
• Designed for small
vehicle access (Not a
stream crossing)
Loading Facility Hardisty, AB

75. MULTIPLE STRUCTURES
•
• • DCSP Structure and
Pedestrian Underpass
• Designed to CL-800
loading
Quarry Park, Calgary, AB

76. MULTIPLE STRUCTURES
• 1500mm Spacing between
structures
• Spacing required to provide
adequate room for placement and
compaction of granular material
• Small sized compaction equipment
• 200mm layered lifts to 95% SPD
Quarry Park, Calgary, AB

77. STRUCTURAL PLATE – DURABILITY
• Armtec Multi Plate Ventilation
Plenums c/w Polymer Coating
(StrataCAT) and Fabricated
Elbows.
• 4450mm Dia.
• StrataCAT chosen due to the
corrosive potash environment
• Interesting Fact - both ends
were supplied with pre-
attached mounting flanges
Air Intake Application – Potash Mine, Esterhazy SK

78. DURABILITY
•
•
• Fabrication was handled
in house to provide a full
site solution

79. LOW HEADROOM DESIGN
Pipestone Creek, County of Wetaskiwin, AB
Objective
• Replacement for existing timber
bridge in rural Alberta.
• Consultant / Owner looking for a
single opening & cost effective
structure versus a multiple culvert
pipe installation.
Challenges
• Low headroom at site
• Potentially corrosive water.
• Live load Design Vehicle CL-800 in
event of detour from Hwy 2 (Edm
to Calgary).

80. LOW HEADROOM DESIGN
Pipestone Creek, County of Wetaskiwin, AB
• Aluminum Box Culvert was
selected
• 10.6m Span X 3.4m Rise X 17.8m
long
• All plates: 6mm thick Aluminum
• Full Corrugated Invert and Footing
Plates: Aluminum
• Reinforcing Ribs required for both
Haunch & Crown
• Foundation required a full width
granular bed densely compacted
was to 98% SPD.
• Minimum required bearing
capacity of foundation = 290 kPa

81. ALUMINUM BOX CULVERT
Other site challenges:
Roadway Superelevation – this required attention by the
consultant in order to achieve the minimum specified covers
and to not exceed the maximum cover. Solution was the
Aluminum Box.

82. ALUMINUM BOX CULVERT
• Live load vehicle: CL 800
loading
• Cover = min. 750mm max
1200mm
• Aluminum Headwall and
Wingwalls
Pipestone Creek, Wetaskiwin, AB

83. ANIMAL OVERPASSES
•
•
• Twin Structures 16.7m
span arches for the
Trans Canada designed
as use for animal
overpasses.
• Keeping the driving
lanes and wildlife safe is
the main purpose of
these bridges
Location: Banff / Lake Louise Hwy AB

84. BRIDGE-PLATE ANIMAL OVERPASSES
Location: Banff / Lake Louise Hwy AB
• 17 m span and 7.0 mm plate – barely more than a
¼-inch of steel.
• Up to 3 m of soil cover.

85. ANIMAL OVERPASSES
• End treatments are MSE
precast face wall panel
(RECo).
• Studies have shown that these
overpasses are successfully
diversifying the bear
population.
Location: Banff / Lake Louise TCH, AB

86. UNBALANCED LOADING
• Unbalanced loading
conditions
• Designed using Finite
Element Analysis (FEA)
• 1500 mm min. cover.
• 1:4 slope across the top of
the structure
Whistler BC, 2010 Winter Olympics

87. UNBALANCED LOADING
58H Bridge-Plate Horizontal Ellipse
1st Challenge: Determine a suitable
grade slope
• Steep grade slopes are a “no-no” over
flexible soil-steel structures
• Structure wants to “roll” due to
unbalanced dead load weight, inducing
bending in shell wall
• Hand calculations were able to predict a
suitable grade slope; FE analysis
confirmed it
Displacement diagram (from Plaxis)

88. UNBALANCED LOADING
•
•
58H Bridge-Plate Horizontal Ellipse
2nd Challenge: Manufacturing
• Curving 8mm Bridge-Plate to a tight
(2400mm) radius can be a challenge
• Several combinations of plate
layouts were created before arriving
at final layout
Plate layout of 58H Horizontal Ellipse

89. UNBALANCED LOADING
•
•
58H Bridge-Plate Horizontal Ellipse
3rd challenge: Assembly and Fit
• Test rings were assembled at an
off-site yard
• After some challenges, an
assembly method was developed
to prevent “creeping” of the BP
dimensions
Assembly instructions

90. UNBALANCED LOADING
The Best Solution … Horizontal Ellipse Structure

91. UNBALANCED LOADING
The Test Fit

92. UNBALANCED LOADING
Assembly

93. UNBALANCED LOADING
Backfill

94. UNBALANCED LOADING
World’s 1st ever Bridge-Plate Horizontal Ellipse!

95. AVALANCHE PROTECTION – ROGERS PASS
1960 construction – 2012 photo

96. UNIQUE STRUCTURE DESIGNS
• Bridge-Plate c/w full invert and footing
plates eliminates cast-in-place footings
• Provides a quick economical installation.
• Ideally suited for remote locations
Bridge-Plate Box c/w Full Invert Scour Plates
Mini-Span Bridges
• Mini-Spans are pre-engineered and pre-
assembled structures
• Available Up to 3660 mm Span
• Ideally suited for Resource road crossings
‘Designed for L-Series logging truck
loading’ L-75, L-100, L-150, and L-165

97. FLEXIBLE SOIL STEEL STRUCTURES

98. Contact Your Local Sales Rep:
www.armtec.com/sales-offices/
Todays Speakers:
Randy McDonald
Randy.McDonald@armtec.com
Frank Klita
Frank.Klita@armtec.com

99. UPCOMING WEBINARS
For more info please visit
www.armtec.com/events
Remember – For CPD
certificates, send names & emails
to webinars@armtec.com!
NEW PRODUCT LINE
FROM ARMTEC!
Introducing Hauraton Surface
Drainage - February and March, 2016

100. STAY CONNECTED!
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101. Keep it Flowing! – Culvert Design 201 – Structural
Design, Durability & Installation
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