Published by department of transportation

66-1.01D(2)Quality Control

66-1.01D(2)a Field Testing of Corrugated Steel Pipe Siphons

Fill the pipe with water to a hydrostatic head of 10 feet above the highest point in the line after the pipe has been laid and backfill has been placed and compacted to a minimum of 2 feet above the pipe.

Conduct a hydrostatic test for a period of not less than 24 hours. Make accurate measurements of the water required to maintain the test pressure during the test period. Any leakage developed by the test must not exceed the allowable leakage as computed by the following formula:

E = 0.00002H^1/2LD

where:

E = allowable leakage in gpm

H = difference in elevation in feet between the water surface at 10 feet above the highest point in the line and the invert elevation of the pipe at its lowest point

L = length of the culvert or drainage pipe in feet

D = internal diameter of the pipe in inches
Furnish all water, materials, and labor for the hydrostatic test. Conduct all hydrostatic tests in the presence of the Engineer. The Department does not pay for hydrostatic testing.

Stop any leakage in excess of the allowable leakage as authorized. Repeat the hydrostatic test until the total leakage does not exceed the allowable leakage. Stop all obvious leaks whether or not the leakage from the line exceeds the allowable leakage.

66-1.02 MATERIALS

66-1.02A General

Ship, handle, and lay corrugated metal materials in a way that prevents bruising, scaling, or breaking of the galvanized surface, aluminized surface, or protective coating.

If concrete collars or tee connections are required, construct the collars or tee connections with minor concrete. Reinforcement must comply with section 52.

66-1.02B Dimensions and Thickness

The nominal sheet thickness for corrugated metal pipe must be equal to or greater than the nominal thickness described.

Lapped longitudinal seams of riveted pipe arches must be placed in the top arch and must be staggered so as to alternate on each side of the center of the top arch at least 3 inches.

66-1.02C Protective Coatings, Linings, and Paving

1. Bituminous coating

2. Polymeric sheet coating

3. Bituminous lining

4. Bituminous invert paving
Remove moisture, dirt, oil, unbonded or incompatible paint, grease, alkalies, or other foreign matter from the surface to be protected before application of the coating, lining, or paving material.

The bituminous coating for bituminous coated pipes must be applied to the inside and outside of pipes to a minimum thickness of 0.05 inch under AASHTO M 190, Type A.

An asphalt mastic coating may be used instead of the bituminous coating on corrugated steel pipe if linings and paving are not required. The asphalt mastic must be placed on the outside surface of the pipe. The inside of the pipe does not need to be coated.

Asphalt mastic coatings must comply with AASHTO M 243, except the asbestos fibers are not required. The asphalt mastic material must be applied uniformly to the surface with a thickness of at least 0.05 inch at any point. The asphalt mastic coating must be applied at the fabrication plant. Pinholes, blisters, cracks, or lack of bond are cause for rejection.

Polymeric sheet coatings must comply with AASHTO M 246. The polymeric sheet coating must be applied to both sides of the galvanized sheet before corrugating. The thickness of the coating must be at least 0.010 inch. Pinholes, blisters, cracks, or lack of bond are cause for rejection.

A bituminous lining must be applied to the inside of the pipe over the bituminous coating wherever bituminous lining is shown.

For bituminous lined corrugated metal pipe, the rivet heads inside the pipe must be located in the valley of the corrugation. Provisions must be made at the ends of the pipes to retain bituminous material during the fabrication process. Both the inside and outside surfaces must be bituminous coated under AASHTO M 190, Type A. In addition to this coating, the valleys on the inside periphery must be filled by the centrifugal process with the same type of bituminous material to the extent that the thickness on the crests of corrugations is at least 1/8 inch. The lining must be smooth and uniform, and its surface must be parallel to a line projected along the crests of the corrugations.

Bituminous paving must be applied to the inside bottom portion of the pipe over the bituminous coating under AASHTO M 190, Type C, where bituminous paving is shown.

If protective coatings are applied to pipes, clearly identify the thickness of the metal on each section of pipe and fittings on the inner surface with paint or by other authorized means.

Repair damaged protective coatings, linings, and invert paving. Use bituminous material under AASHTO M 190 or other authorized materials to repair damaged bituminous coatings. Use asphalt mastic material under AASHTO M 243 to repair damaged asphalt mastic coatings. Use tar base material under AASHTO M 243 to repair damaged polymeric sheet coatings.

Coupling bands and connecting hardware for coated pipes must have a protective coating. Coupling bands to be protected by coatings under AASHTO M 190 may be single-dipped with the coating thickness requirement waived.

66-1.02D Coupling Bands

Choose one of the types of corrugated metal pipe coupling bands shown. The metal bands must be corrugated, dimpled, or otherwise formed in a way that will effectively engage the corrugations of the pipe ends.

Coupling bands for corrugated steel pipe must comply with AASHTO M 36. Coupling bands for corrugated aluminum pipe must comply with AASHTO M 196.

If channel or wing channel coupling bands are used, the interior bend radii of the pipe flange and the channel must be at least the thickness of the metal of which they are formed.

Joints for siphons must consist of connections made with coupling bands shown for positive joints. Do not use universal coupling bands.

Joints for siphons and joints for pipes shown as watertight must be watertight under pressure and all conditions of expansion, contraction, and settlement, and must comply with section 61-2.01D(1)(a) for watertightness.

66-1.02E Corrugated Steel Pipe

66-1.02E(1) General

Corrugated steel materials must comply with AASHTO M 36 and be fabricated from either zinc-coated steel sheet or aluminum-coated steel sheet as shown.

Zinc-coated steel sheet must comply with AASHTO M 218, except the coating weight is determined under ASTM A123/A123M and A153/A153M.

Aluminum-coated steel sheet must comply with AASHTO M 274.

66-1.02E(2) Fabrication

66-1.02E(2)(a) General

Corrugated steel pipe must be fabricated by one of the following methods:

1. Riveting

2. Helically corrugated steel pipe with a continuous helical lock seam

3. Continuous helical welded seam paralleling the corrugation

Pipes fabricated from 0.050-inch-thick sheets must be helically corrugated steel pipe with a continuous helical lock seam or a continuous helical welded seam.

Annular corrugated steel pipe must be fabricated from sheets having either 2-2/3-by-1/2-inch or 3-by-1-inch corrugations.

66-1.02E(2)(b) Fabrication by Riveting

Pipes fabricated by riveting must comply with AASHTO M 36.

66-1.02E(2)(c) Fabrication by Continuous Helical Seam

66-1.02E(2)(c)(i) General

Helically corrugated steel pipe must comply with AASHTO M 36.

Helically corrugated pipe must be fabricated using corrugation profiles and continuous helical seam pitches as shown in the following table:

Corrugation Profile
Diameter (Inches)	Nominal pitcha (inches)	Max. pitcha (inches)	Nominal depth (inches)	Seam pitcha (inches)
6–18	1-1/2	1-7/8	1/4	12
12–84	2-2/3	2-3/4	1/2	24
48–120	3	3-1/4	1	21
48–120	5	5-3/16	1	29-1/2
aPitch must be measured at right angles to the direction of corrugations. A tolerance of ±1/2 inch on seam pitch is allowable.

66-1.02E(2)(c)(ii) Fabrication by Continuous Lock Seam

You may use pipes fabricated with a continuous helical lock seam extending from end to end of each length for full circle and equivalent pipe arch sizes. Fabrication must comply with AASHTO M 36.

66-1.02E(2)(c)(iii) Fabrication by Continuous Welded Seam

You may use pipes fabricated with a continuous helical welded seam parallel to the corrugations for full circle and equivalent pipe arch sizes. Control the welding process so that the combined width of the weld and adjacent spelter or aluminum coating burned by the welding does not exceed 3 times the metal thickness.

If the spelter is damaged by the welding outside the specified area, repair the weld and damaged spelter adjacent to the weld under section 75-1.02B

If the metalizing is applied immediately in a continuous operation following the resistance welding, apply a coating of aluminum to the welded area of aluminum-coated pipe using the metalizing process under AWS C2.2, except surface cleaning will not be required.

66-1.02E(3) End Finish

Helically corrugated steel pipe ends may be rerolled to form annular corrugations extending at least 2 corrugations from the pipe end or to form an upturned flange with or without reformed annular corrugations. The diameter of the reformed ends must not exceed that of the pipe barrel by more than the depth of the corrugation. All types of pipe ends, whether rerolled or not, must be matched in a joint so that the maximum difference in diameter of the abutting pipe ends is 1/2 inch.

If the ends of helically corrugated steel lock seam pipes have been rerolled, the lock seam in the rerolled end must not contain visible cracks in the base metal and the tensile strength of the lock seam must be at least 60 percent of the tensile strength required for the remainder of the pipe. This requirement does not apply to the lock seam located within a flange formed in rerolling. The rerolled ends of the pipe and flanges must exhibit good workmanship and must not have open lock seams.

If corrugated steel pipe is rerolled for coupling with a wing channel coupling or a channel coupling band, the maximum distance from any point on the end of the pipe to the plane, normal to pipe axis and passing through the outermost portion of the pipe end, must not exceed 1/2 the width of the channel minus the thickness of the pipe metal. The difference between the minimum and maximum flange diameter must not exceed 1/2 inch.

Fabricate pipes so that they can be joined effectively with the described standard coupling bands.

66-1.02E(4) Damaged Galvanizing

Repair damaged galvanized surfaces under section 75-1.02B.

If you burn the galvanized surfaces by welding, thoroughly clean all the surfaces of the welded connections by wire brushing and remove all traces of the welding flux and loose or cracked galvanizing before repair.

66-1.02E(5) Damaged Aluminum Coatings

Repair damaged aluminum coatings under section 75-1.02B.

66-1.02E(6) Corrugated Steel Pipe Siphons

The thickness of siphons must be the described thickness. If coating is required, coated pipes must comply with section 66-1.02C.

Order pipes for siphons in lengths that will keep the number of field connections to a minimum.

If soldering is required, the outside seams of pipe fabricated by riveting, or continuous helical lock seam must be soldered, the solder being sweated into the joints. If the pipe is fabricated by riveting, rivets on the circumferential seams must be spaced at approximately 2-1/2-inch centers with a maximum spacing of 3 inches. If the pipe is fabricated by a continuous helical welded seam, soldering is not required.

66-1.02F Corrugated Aluminum Pipe

66-1.02F(1) General

Corrugated aluminum materials must comply with AASHTO M 196 and AASHTO M 197.

66-1.02F(2) Fabrication

66-1.02F(2)(a) General

Corrugated aluminum pipe must be fabricated by riveting or with a continuous helical lock seam paralleling the corrugations. Annular or helically corrugated pipe must be fabricated from sheets having 2-2/3-by-1/2-inch or 3-by-1-inch corrugations.

66-1.02F(2)(b) Fabrication by Riveting

Pipes fabricated by riveting must be lap joint construction with annular corrugations. Fabrication must comply with AASHTO M 196.

66-1.02F(2)(c) Fabrication by Continuous Helical Lock Seam

For full circle and equivalent pipe arch sizes, you may install pipes fabricated with a continuous helical lock seam extending from end-to-end of each length. Fabrication must comply with AASHTO M 196.

66-1.02F(3) End Finish

Helically corrugated aluminum pipe ends may be rerolled to form annular corrugations extending at least 2 corrugations from the pipe end. The diameter of the reformed ends must not exceed the diameter of the pipe barrel by more than the corrugation depth. All types of pipe ends, whether rerolled or not, must be matched in a joint so that the maximum difference in diameter of the abutting pipe ends is 1/2 inch.

If the ends of helically corrugated aluminum lock seam pipes have been rerolled, the lock seam in the rerolled end must not contain visible cracks in the base metal and the tensile strength of the lock seam must be at least 60 percent of the tensile strength required for the remainder of the pipe. The rerolled pipe ends must exhibit good workmanship and must not have open lock seams.

Pipes must be fabricated so that they can be joined effectively with the described standard coupling bands.

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