ASTM B789/B789M-99(2005)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: B789/B789M – 99 (Reapproved 2005)
Standard Practice for
Installing Corrugated Aluminum Structural Plate Pipe for
Culverts and Sewers
This standard is issued under the fixed designation B789/B789M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This practice covers procedures, soils, and soil place-
ment for the proper installation of corrugated aluminum
structural plate culverts and sewers in either trench or embank-
ment installations.Atypical trench installation is shown in Fig.
1, and a typical embankment (projection) installation is shown
in Fig. 2. Structural plate structures as described herein are
those structures factory fabricated in plate form and bolted
together on site to provide the required shape, size, and length
of structure. This practice applies to structures designed in
accordance with Practice B790/B790M.
1.2 The values stated in either inch-pound units or SI units
are to be regarded separately as standard. Within the text, the
SI units are shown in brackets. The values stated in each
system are not exact equivalents; therefore, each system shall
be used independently of the other. Combining values from the
FIG. 1 Typical Trench Installation
two systems may result in nonconformance with the standard.
1.3 This standard does not purport to address all of the
D698 Test Methods for Laboratory Compaction Character-
safety concerns, if any, associated with its use. It is the
istics of Soil Using Standard Effort (12 400 ft-lbf/ft (600
responsibility of the user of this standard to establish appro-
kN-m/m ))
priate safety and health practices and determine the applica-
D1556 Test Method for Density and Unit Weight of Soil in
bility of regulatory limitations prior to use.
Place by Sand-Cone Method
D1557 Test Methods for Laboratory Compaction Charac-
2. Referenced Documents
teristics of Soil Using Modified Effort (56,000 ft-lbf/
3 3
2.1 ASTM Standards:
ft (2,700 kN-m/m ))
B746/B746M Specification for Corrugated Aluminum Al-
D2167 Test Method for Density and Unit Weight of Soil in
loy Structural Plate for Field-Bolted Pipe, Pipe-Arches,
Place by the Rubber Balloon Method
and Arches
B790/B790M Practice for Structural Design of Corrugated
Aluminum Pipe, Pipe-Arches, and Arches for Culverts,
Storm Sewers, and Other Buried Conduits
This practice is under the jurisdiction of ASTM Committee B07 on Light
Metals and Alloys and is the direct responsibility of Subcommittee B07.08 on
Aluminum Culvert.
Current edition approved Apr. 1, 2005. Published April 2005. Originally
approved in 1988. Last previous edition approved in 1999 as B789/B 789M – 99.
DOI: 10.1520/B0789_B0789M-99R05.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. FIG. 2 Typical Embankment (Projection) Installation
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
B789/B789M – 99 (2005)
D2487 Practice for Classification of Soils for Engineering 6. Foundation
Purposes (Unified Soil Classification System)
6.1 The supporting soil beneath the structure must provide a
D2922 TestMethodsforDensityofSoilandSoil-Aggregate
reasonably uniform resistance to the imposed load, both
in Place by Nuclear Methods (Shallow Depth)
longitudinally and laterally. Sharp variations in the foundation
D2937 Test Method for Density of Soil in Place by the
must be avoided. When rock is encountered, it must be
Drive-Cylinder Method
excavatedandreplacedwithsoil.Ifthestructureistobeplaced
onacontinuousrockfoundation,itwillbenecessarytoprovide
3. Terminology
a bedding of soil between the rock and the structure. See Fig.
3.
3.1 Definitions of Terms Specific to This Standard:
6.2 Lateral changes in foundation should never be such that
3.1.1 arch, n—segmentofacircularshapespanninganopen
the structure is firmly supported while the backfill on either
invert between the footings on which it rests.
side is not.When soft material is encountered in the foundation
3.1.2 bedding, n—earth or other material on which a pipe is
and must be removed to maintain the grade on the structure,
supported.
then it must be removed, usually for a minimum of three
3.1.3 haunch, n—portion of the pipe cross section between
structure widths. See Fig. 4. A smaller width of removal can
the maximum horizontal dimension and the top of the bedding.
sometimes be used if established by the engineer.
3.1.4 invert, n—lowest point on the pipe cross section; also,
6.3 Performance of buried structures is enhanced by allow-
the bottom portion of a pipe.
ing the structure to settle slightly relative to the columns of
3.1.5 pipe, n—conduit having a full circular shape; also, in
earth alongside. Therefore, when significant settlement of the
a general context, all structure shapes covered by this specifi-
overall foundation is expected, it is beneficial to provide a
cation.
yieldingfoundationunderstructuralplatestructures.Ayielding
3.1.6 pipe-arch, n—pipe with an approximate semicircular
foundationisonethatallowsthestructuretosettleverticallyby
crown, small-radius corners, and large-radius invert.
a greater amount than the vertical settlement of the columns of
3.1.7 underpass, n—pipe with an approximate semicircular
earth alongside. It can usually be obtained by placing beneath
crown, large-radius sides, small-radius corners between sides
the structure a layer of suitable thickness of compressible soil,
and invert, and large-radius invert.
less densely compacted than the soil alongside. This is particu-
larly important on structures with relatively large-radius invert
4. Significance and Use
plates.
4.1 Corrugated aluminum structural plate pipe functions
6.4 For all structures with relatively small-radius corner
structurally as a flexible ring that is supported by and interacts
plates adjacent to large-radius invert plates (such as pipe-
with the compacted surrounding soil. The soil placed around
arches or underpass structures), excellent soil support must be
the structure is thus an integral part of the structural system. It
provided adjacent to the small-radius corner plates by both the
is therefore important to ensure that the soil structure is made
in-situ foundation and the structural backfill. See Fig. 4 and
up of the acceptable material and well-constructed. Field
Fig. 5. A yielding foundation must be provided beneath the
verification of soil structure acceptability using Test Methods
D1556, D2167, D2922,or D2937, as applicable, and compar-
ing the results with Test Methods D698 or D1557, in accor-
dance with the specifications for each project, is the most
reliable basis for installation of an acceptable structure. The
required density and method of measurement are not specified
by this practice but must be established in the specifications for
each project.
5. Trench Excavation
5.1 To obtain the anticipated structural performance of
structural plate structures, it is not necessary to control trench
width beyond the minimum necessary for proper assembly of
the structure and placement of the structural backfill. However,
the soil on each side beyond the excavated trench must be able
to support anticipated loads. When a construction situation
calls for a relatively wide trench, it may be made as wide as
required for its full depth, if so desired. However, trench
excavation must be in compliance with any local, state, and
federal codes and safety regulations.
d = ⁄2 in./ft. [40 mm/m] of fill over pipe, with a 24-in. [600 mm] maximum.
NOTE—Section B-B is applicable to all continuous rock foundations
Withdrawn. The last approved version of this historical standard is referenced
on www.astm.org. FIG. 3 Foundation Transition Zones and Rock Foundations
B789/B789M – 99 (2005)
be shaped to facilitate the required compaction of the structural
backfill under the haunches. A shaped bedding on a yielding
foundation is always required under structures with small-
radius corner plates adjacent to large-radius invert plates.
7.3 Material in contact with the pipe must not contain rock
retained on a 3-in. [75-mm] diameter ring, frozen lumps,
chunks of highly plastic clay, organic matter, corrosive mate-
rial, or other deleterious material.
8. Assembly
8.1 Structural plate structures are furnished in components
of plates and fasteners for field assembly. These components
are furnished in accordance with Specification B746/B746M.
Plates are furnished in a 4 ft, 6 in. [1372 mm] width and
multiple lengths, preformed and punched for assembling into
FIG. 4 Soft Foundation Treatment
the required structure shape, size, and length.The plate lengths
form the periphery of the structure. Arrange the single width
and the multiple lengths to allow for staggered, transverse
seams to avoid four-plate laps. The fabricator of the structural
plate shall furnish an assembly drawing showing the location
of each plate by width, length, thickness, and curvature. The
plates must be assembled in accordance with the fabricator’s
drawing.
8.2 For structures with inverts, assembly shall begin with
the invert plates at the downstream end. As the assembly
proceeds upstream, plates that fall fully or partly below the
maximum width of the structure are lapped over the preceding
plates to construct the transverse seams.
8.3 Arches on Footings:
8.3.1 Footings—Arches have no integral invert and usually
rest in key ways cast into footings. Key ways must be
accurately set to span, line, and grade, as shown in the plans
and specifications. When the arch is not a half circle, the key
way must be angled (rotated) or sized to allow proper entrance
of the plate. All pertinent dimensions must be shown on the
drawings.
8.3.2 Assembly—For arch structures, assembly typically
begins at the upstream end and proceeds downstream, with
FIG. 5 Bedding and Corner Zone Treatment for Large-Radius
each succeeding plate lapping on the outside of the previous
Invert Plate Structures
plate. There may be cases where it is more advantageous to
start assembly at some other point along the length of the
invert plates for such structures when soft foundation condi-
structure, such as is in the case where an elbow is involved.
tions are encountered.
During the erection of the ring, plates are not self-supporting
and must be temporarily supported. If the size of the key ways
7. Bedding
is such that the plates may move during backfilling, the plates
7.1 In most cases, structural plate structures may be as- must be temporarily blocked in the key ways to maintain span.
sembled directly on in-situ material fine-graded to proper Assemble as few plates as practical. Start with a row of several
alignment and grade. Take care to compact the material plates along both of the footings. Before finishing the bottom
beneath the haunches prior to placing structural backfill. For row of plates, start at the end of the structure with the next row
structures with relatively small-radius corner plates adjacent to ofplates.Beforereachingtheendofthefirstrowofplates,start
large-radiusinvertplates,itisrecommendedtoeithershapethe again at the end of the structure with the next row of plates.
bedding to the invert plate radius or fine-grade the foundation Continue this process until the first ring is closed at its top, and
to a slight v-shape. The soil adjacent to the corners must be of then continue assembling all rows in this same manner. The
an excellent quality and highly compacted to accommodate the structure will have a “stair step” appearance as a result of this
high reaction pressures that can develop at that location. See procedure. This practice helps to hold the structure’s shape.
Fig. 5. 8.4 Generally, structural plate should be assembled with as
7.2 Structures having a span greater than 15 ft [4.5 m] or a few bolts as practical. These bolts should be placed loose and
depth of cover greater than 20 ft [6 m] should be provided with remainlooseuntiltheperipheryhasbeencompletedforseveral
ashapedbeddingonayieldingfoundation.Thebeddingshould plate lengths. However, on large structures, it is practical to
B789/B789M – 99 (2005)
A,B
TABLE 1 Structural Backfill Width Requirements
align bolt holes during assembly and tighten the bolts to
maintain structure shape.After the periphery of the structure is Adjacent Material Required Structural Backfill Width
Normal highway embankment As needed to establish pipe bedding and
completedforseveralplatelengths,allboltsmaybeplacedand
compacted to minimum of to place and compact the backfill in the
tightened. Correct any significant deviation in the structure
90 % Test Methods D698 haunch area and beside the pipe. Where
shape before tightening bolts (see Section 10). It is advisable density, or equivalent trench backfill materials that do not require
wall. compaction are used, such as cement
not to tighten bolts on the loosely assembled structure within a
slurry or controlled low strength material
distance of 30 ft [9 m] of where plate assembly is ongoing.All
(CLSM), a minimum of 3 in. [75 mm] on
each side of the pipe is required.
bolts shall be tightened using an applied torque of between 100
Embankment or trench wall of Increase backfill width as necessary to
and 150 ft·lbf [135 and 205 N·m]. It is important not to
lesser quality. reduce horizontal pressure from pipe to a
over-torque the bolts.
level compatible with bearing capacity of
adjacent materials.
8.5 Standard structural plate structures, because of the
A
For pipe arches and other multiple radius structures, as well as for all
bolted construction, are not intended to be watertight. On
structures carrying off-road construction equipment, the structural backfill width,
occasions where a degree of watertightness is required, it is
including any necessary foundation improvement materials, must be sufficient to
practical to introduce a seam sealant tape within the bolted
reduce the horizontal pressure from the structure so that it does not exceed the
bearing capacity of the adjacent material.
seams. The tape shall be wide enough to effectively cover all
B
In embankment construction, the structural backfill width must be adequate to
rows of holes in plate laps, and of the proper thickness and
resist forces caused by the embankment construction equipment. Generally, the
consistency to
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