ASTM B789/B789M-99

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Designation: B 789/B 789M – 99
Standard Practice for
Installing Corrugated Aluminum Structural Plate Pipe for
Culverts and Sewers
This standard is issued under the fixed designation B 789/B 789M; 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 (e) indicates an editorial change since the last revision or reapproval.
1. Scope *
1.1 This practice describes 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 B 790/B 790M.
1.2 This practice is applicable to either inch-pound units as
B 789 or to SI units as B 789M. Inch-pound units are not
necessarily equivalent to SI units. SI units are shown in the text
in brackets, and they are the applicable values for metric
installation.
FIG. 1 Typical Trench Installation
1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
D 1557 Test Method for Laboratory Compaction Character-
responsibility of the user of this standard to establish appro-
isticsofSoilUsingModifiedEffort(56,000ft-lbf/ft [2,700
priate safety and health practices and determine the applica-
kN-m/m ])
bility of regulatory limitations prior to use.
D 2167 Test Method for Density and Unit Weight of Soil in
2. Referenced Documents
Place by the Rubber-Balloon Method
D 2487 Classification of Soils for Engineering Purposes
2.1 ASTM Standards:
(Unified Soil Classification System)
B 746/B 746M Specification for Corrugated Aluminum Al-
D 2922 Test Methods for Density of Soil and Soil-
loy Structural Plate for Field-Bolted Pipe, Pipe-Arches,
Aggregate in Place by Nuclear Methods (Shallow Depth)
and Arches
D 2937 Test Method for Density of Soil in Place by the
B 790/B 790M Practice for Structural Design of Corrugated
Drive-Cylinder Method
Aluminum Pipe, Pipe–Arches, and Arches for Culverts,
Storm Sewers, and Other Buried Conduits
D 698 Test Method for Laboratory Compaction Character-
istics of Soil Using Standard Effort (12,400 ft-lbf/ft
[600kN-m/m])
D 1556 Test Method for Density and Unit Weight of Soil in
Place by the Sand-Cone Method
ThispracticeisunderthejurisdictionofASTMCommitteeB-7onLightMetals
and Alloys and is the direct responsibility of Subcommittee B07.08on Aluminum
Culvert.
Current edition approved May 10, 1999. Published August 1999. Originally
published as B 789 – 88. Last previous edition B 789/B 789M–97.
Annual Book of ASTM Standards, Vol 02.02.
Annual Book of ASTM Standards, Vol 04.08. FIG. 2 Typical Embankment (Projection) Installation
*A Summary of Changes section appears at the end of this standard.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
B 789/B 789M
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 arch, n—segmentofacircularshapespanninganopen
invert between the footings on which it rests.
3.1.2 bedding, n—earth or other material on which a pipe is
supported.
3.1.3 haunch, n—portion of the pipe cross section between
the maximum horizontal dimension and the top of the bedding.
3.1.4 invert, n—lowest point on the pipe cross section; also,
the bottom portion of a pipe.
3.1.5 pipe, n—conduit having a full circular shape; also, in
a general context, all structure shapes covered by this specifi-
cation.
3.1.6 pipe-arch, n—pipe with an approximate semicircular
crown, small-radius corners, and large-radius invert.
3.1.7 underpass, n—pipe with an approximate semicircular
crown, large-radius sides, small-radius corners between sides
and invert, and large-radius invert.
4. Significance and Use
d 5 ⁄2 in./ft. [40 mm/m] of fill over pipe, with a 24-in. [600 mm] maximum.
4.1 Corrugated aluminum structural plate pipe functions
NOTE 1—Section B-B is applicable to all continuous rock foundations
structurally as a flexible ring that is supported by and interacts
FIG. 3 Foundation Transition Zones and Rock Foundations
with the compacted surrounding soil. The soil placed around
the structure is thus an integral part of the structural system. It
side is not.When soft material is encountered in the foundation
is therefore important to ensure that the soil structure is made
up of the acceptable material and well-constructed. Field and must be removed to maintain the grade on the structure,
then it must be removed, usually for a minimum of three
verification of soil structure acceptability using Test Methods
D 1556, D 2167, D 2922, or D 2937, as applicable, and structure widths. See Fig. 4. A smaller width of removal can
sometimes be used if established by the engineer.
comparing the results with Test Methods D 698 or D 1557, in
accordance with the specifications for each project, is the most 6.3 Performance of buried structures is enhanced by allow-
ing the structure to settle slightly relative to the columns of
reliable basis for installation of an acceptable structure. The
required density and method of measurement are not specified earth alongside. Therefore, when significant settlement of the
overall foundation is expected, it is beneficial to provide a
by this practice but must be established in the specifications for
each project. yieldingfoundationunderstructuralplatestructures.Ayielding
foundationisonethatallowsthestructuretosettleverticallyby
5. Trench Excavation
a greater amount than the vertical settlement of the columns of
earth alongside. It can usually be obtained by placing beneath
5.1 To obtain the anticipated structural performance of
the structure a layer of suitable thickness of compressible soil,
structural plate structures, it is not necessary to control trench
less densely compacted than the soil alongside. This is particu-
width beyond the minimum necessary for proper assembly of
larly important on structures with relatively large-radius invert
the structure and placement of the structural backfill. However,
plates.
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.
6. Foundation
6.1 The supporting soil beneath the structure must provide a
reasonably uniform resistance to the imposed load, both
longitudinally and laterally. Sharp variations in the foundation
must be avoided. When rock is encountered, it must be
excavatedandreplacedwithsoil.Ifthestructureistobeplaced
onacontinuousrockfoundation,itwillbenecessarytoprovide
a bedding of soil between the rock and the structure. See Fig.
3.
6.2 Lateral changes in foundation should never be such that
the structure is firmly supported while the backfill on either FIG. 4 Soft Foundation Treatment
B 789/B 789M
6.4 For all structures with relatively small-radius corner are furnished in accordance with Specification B 746/B 746M.
plates adjacent to large-radius invert plates (such as pipe- Plates are furnished in a 4 ft, 6 in. [1372 mm] width and
arches or underpass structures), excellent soil support must be
multiple lengths, preformed and punched for assembling into
provided adjacent to the small-radius corner plates by both the the required structure shape, size, and length. The plate lengths
in-situ foundation and the structural backfill. See Fig. 4 and
form the periphery of the structure. Arrange the single width
Fig. 5. A yielding foundation must be provided beneath the
and the multiple lengths to allow for staggered, transverse
invert plates for such structures when soft foundation condi-
seams to avoid four-plate laps. The fabricator of the structural
tions are encountered.
plate shall furnish an assembly drawing showing the location
of each plate by width, length, thickness, and curvature. The
7. Bedding
plates must be assembled in accordance with the fabricator’s
7.1 In most cases, structural plate structures may be as-
drawing.
sembled directly on in–situ material fine-graded to proper
8.2 For structures with inverts, assembly shall begin with
alignment and grade. Take care to compact the material
the invert plates at the downstream end. As the assembly
beneath the haunches prior to placing structural backfill. For
proceeds upstream, plates that fall fully or partly below the
structures with relatively small-radius corner plates adjacent to
maximum width of the structure are lapped over the preceding
large-radiusinvertplates,itisrecommendedtoeithershapethe
plates to construct the transverse seams.
bedding to the invert plate radius or fine-grade the foundation
8.3 Arches on Footings:
to a slight v-shape. The soil adjacent to the corners must be of
an excellent quality and highly compacted to accommodate the 8.3.1 Footings—Arches have no integral invert and usually
high reaction pressures that can develop at that location. See
rest in key ways cast into footings. Key ways must be
Fig. 5. accurately set to span, line, and grade, as shown in the plans
7.2 Structures having a span greater than 15 ft [4.5 m] or a
and specifications. When the arch is not a half circle, the key
depth of cover greater than 20 ft [6 m] should be provided with
way must be angled (rotated) or sized to allow proper entrance
ashapedbeddingonayieldingfoundation.Thebeddingshould
of the plate. All pertinent dimensions must be shown on the
be shaped to facilitate the required compaction of the structural
drawings.
backfill under the haunches. A shaped bedding on a yielding
8.3.2 Assembly—For arch structures, assembly typically
foundation is always required under structures with small-
begins at the upstream end and proceeds downstream, with
radius corner plates adjacent to large-radius invert plates.
each succeeding plate lapping on the outside of the previous
7.3 Material in contact with the pipe must not contain rock
plate. There may be cases where it is more advantageous to
retained on a 3-in. [75-mm] diameter ring, frozen lumps,
start assembly at some other point along the length of the
chunks of highly plastic clay, organic matter, corrosive mate-
structure, such as is in the case where an elbow is involved.
rial, or other deleterious material.
During the erection of the ring, plates are not self-supporting
and must be temporarily supported. If the size of the key ways
8. Assembly
is such that the plates may move during backfilling, the plates
8.1 Structural plate structures are furnished in components
must be temporarily blocked in the key ways to maintain span.
of plates and fasteners for field assembly. These components
Assemble as few plates as practical. Start with a row of several
plates along both of the footings. Before finishing the bottom
row of plates, start at the end of the structure with the next row
ofplates.Beforereachingtheendofthefirstrowofplates,start
again at the end of the structure with the next row of plates.
Continue this process until the first ring is closed at its top, and
then continue assembling all rows in this same manner. The
structure will have a “stair step” appearance as a result of this
procedure. This practice helps to hold the structure’s shape.
8.4 Generally, structural plate should be assembled with as
few bolts as practical. These bolts should be placed loose and
remainlooseuntiltheperipheryhasbeencompletedforseveral
plate lengths. However, on large structures, it is practical to
align bolt holes during assembly and tighten the bolts to
maintain structure shape.After the periphery of the structure is
completedforseveralplatelengths,allboltsmaybeplacedand
tightened. Correct any significant deviation in the structure
shape before tightening bolts (see Section 10). It is advisable
not to tighten bolts on the loosely assembled structure within a
distance of 30 ft [9 m] of where plate assembly is ongoing.All
bolts shall be tightened using an applied torque of between 100
and 150 ft·lbf [135 and 205 N·m]. It is important not to
FIG. 5 Bedding and Corner Zone Treatment for Large-Radius
Invert Plate Structures over-torque the bolts.
B 789/B 789M
8.5 Standard structural plate structures, because of the depths, and compaction equipment. Soil used as structural
bolted construction, are not intended to be watertight. On backfill must not contain rock retained on a 3-in. [75-mm]
occasions where a degree of watertightness is required, it is diameter ring, frozen lumps, highly plastic clays, organic
practical to introduce a seam sealant tape within the bolted matter, corrosive material, or other deleterious foreign matter.
seams. The tape shall be wide enough to effectively cover all Soil classifications are defined in Classification D 2487. Ac-
rows of holes in plate laps, and of the proper thickness and ceptable soils include Groups GW, GP, GM, GC, SW, and SP,
consistency to effectively fill all voids in plate laps. General when compacted to the specified percent of maximum density,
procedures for installing sealant tape are as follows: On as determined by Test Methods D 698 or D 1557, using Test
longitudinal seams, prior to placing the lapping plate, roll the Methods D 1556, D 2167, D 2922, or D 2937. Soil types SM
tape over the seam and work into the corrugations. Do not and SC are acceptable but may require closer control to obtain
stretch the tape. Remove any paper backing prior to making up the specified density. Soil groups ML and CL are not preferred
the joint. Seal transverse seams in a like manner with tape. At materials, while soil groups OL, MH, CH, OH, and PT are not
all points where three plates intersect, place an additional acceptable.
thickness of tape for a short distance to fill the void caused by
10. Shape Control
the transverse seam overlap. It is most practical to punch the
tapeforboltswithahotspudwrenchorsharptool.Atleasttwo 10.1 Excessive compaction, unbalanced loadings, loads
from construction equipment, as well as inadequate compac-
tightenings of the bolts will usually be necessary to accomplish
the required torque. tion or poor structural backfill materials, can cause excessiv
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