The Magazine of the American Concrete Pipe Association · Gary Wilder Wilder Studios Production Published by: American Concrete Pipe Association 222 W. Las Colinas Blvd., Suite 641

www.concrete-pipe.orgVolume 57 No. 3 Summer 2005

The Magazine of theAmerican Concrete Pipe Association

American Concrete Pipe Association

Precast concretebox storm water

vault systemcovering 1.4

acres installed inlieu of traditional

storm waterpond.

Cover Photos: Rinker Materials –Hydro Conduit Division

This issue:Volume 57, Number 3Summer 2005Concrete Pipe News is published four timeseach year by the American Concrete PipeAssociation. It is designed to provideinformation on the use and installation ofprecast concrete pipe products for a widevariety of applications, including drainageand pollution control systems. Industrytechnology, research and trends are alsoimportant subjects of the publication.Readers include engineers, specifiers, publicworks officials, contractors, suppliers,vendors and members of the AmericanConcrete Pipe Association.

American Concrete Pipe Association StaffJohn J. DuffyPresidentMichael W. Beacham, P.E.Director of State and Federal ProgramsJosh Beakley, P.E.Director of Technical ServicesMatt Childs, P.E.Director of Engineering ServicesKaren HunterMarketing ManagerWanda CochranAdministrative AssistantLaHonda HolleAdministrative AssistantWendy LambertControllerMedia Task GroupBill GardnerMadison Concrete Pipe, Inc.Madison, WisconsinRobert PowersInland Pipe LimitedEdmonton, AlbertaBill HobsonN C ProductsRaleigh, North CarolinaRobert RyanMaster Builders, Inc.Cleveland, OHSteve BerloScituate Concrete Pipe Co.Scituate, MAMerle HeadingtonCretex Concrete Products Midwest, Inc.Cedar Rapids, IARick PhillipsRinker Materials - Hydro ConduitValley, NEContract Editorial StaffA. Grant LeeAGL Marketing LimitedExecutive EditorGary WilderWilder StudiosProduction

Published by:American Concrete Pipe Association222 W. Las Colinas Blvd., Suite 641Irving, Texas 75039-5423Phone: (972) 506-7216Fax: (972) 506-7682E-mail: [email protected]

Opinions expressed by authors other than staff of the AmericanConcrete Pipe Association do not necessarily reflect the officialpositions or policies of the Association. No part of this publicationmay be reproduced or transmitted by any means without writtenpermission from the publisher.© Copyright 2005 ACPA

Regular DepartmentsFarewell To Friends and Colleagues ............................................................................................ 3From Association President John J. Duffy

And Now You Know...Concrete Pipe Is The Only Pipe That Gets Stronger With Age ......................................................... 4In most environments, concrete pipe continues to cure at a slower rate than the rate set duringproduction of the pipe. Tests on old pipe discovered during reconstruction projects, or tested undercircumstances decades later, repeatedly confirm that the strength of concrete pipe increases as timepasses.

Feature StoryPrecast Box Storm Water Vault Meets Environmental and Structural Design Challenges ............. 6Engineers sometimes face a regulatory challenge when designing systems to treat storm water before itis released into water bodies. When this challenge is coupled with the system capacity requirements ofa densely populated development, the use of storm water ponds for treatment is not always desirable,or feasible. The Westshore Yacht Club, located in historic South Tampa, presented such a challenge. Onthis project, the engineer recommended a precast concrete system over other vault systems includingcast-in-place due largely to final grade limitations, water table concerns, and overall reducedconstruction costs.

StoriesCatastrophic Pipe Failures Continue to Mark the End of Short Service Lives of CMP ................... 9Collapse of a twin line of 84-inch diameter corrugated metal storm sewer in Knoxville, Tennesseeclearly demonstrates how major cities in the Southeast United States have underground infrastructureon the verge of failure, and the impact that failed infrastructure has on local businesses. The CMPsewer was replaced with a concrete pipe system with a depth of cover to top of pipe that ranged from20 to 25 feet.

2005 Fall Short Course School ................................................................................................. 12ACPA’s annual training program is conducted by industry experts from November 7 to 9 in Las Vegas.The program covers a variety of topics related to the design, specifications and installation of concretepipe. Each year the program attracts engineers, consultants, designers and specifiers of concrete pipeproducts. CEUs and professional development hours are offered. Space is limited and registrationcloses October 12, 2005. Visit www.concrete-pipe.org for details.

Deep Tunnel Built With Reinforced Concrete Pipe Relieves Flooding ........................................... 13A major flooding problem that had existed in the vicinity of South Grand Boulevard and Bates Street inthe City of St. Louis, Missouri since the 1930s has been solved with a 6,400-foot long, 14.5-footdiameter tunnel that could accommodate a 132-inch diameter reinforced concrete pipeline to carrystorm water to an outfall on the Mississippi River.

Large Diameter CMP Storm Sewer Replaced With RCP After Twenty-Year Service ................... 15A major rainfall on June 16, 2004, saturated soils from a previous storm, and a failing corrugated metalpipe (CMP) storm sewer led to the collapse of a parking lot near a major intersection on ClevelandAvenue in Sioux Falls, South Dakota. The storm sewer was replaced with 430 feet of 84-inch diameterClass 3 reinforced concrete pipe, along with two 84-inch diameter precast concrete apron sections.

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CONCRETE PIPE NEWS www.concrete-pipe.org SUMMER 2005

table ofcontents

John J. Duffy

The first assignment that I was given whenI joined the staff of the American Concrete PipeAssociation in 1974 was to edit Concrete PipeNews. It was a difficult job then, and to this dayCP News demands a great deal of effort fromstaff and industry representatives who authorand peer review its content.

I believe that the benefits of publishing CPNews far outweigh the effort that is required topublish this outstanding publication. It affordsthe concrete pipe industry an opportunity toreach thousands of infrastructure designers,specifiers, contractors and elected representa-tives across the United States and Canada toshowcase the many applications of precast con-crete pipe, boxes and manholes.

Over the last 31 years, articles have cov-ered every facet of precast concrete pipe. Someof the more memorable have been the articleon a 17-foot diameter storm drain in Michigan,articles on the research initiative of the 1970sthat led to standard installations and direct de-sign, articles on jacking concrete pipe and anarticle on recharging ground water using con-crete pipe with an opening cast in the wall.

Farewell to Friendsand Colleagues

This is my last message for publication inConcrete Pipe News, as I am retiring this sum-mer. I am proud of the volumes of some 125issues of Concrete Pipe News that have beenpublished since 1974.

I will be returning to Virginia where mostof my family live. There, I will be redirectingmy efforts to lower my golf handicap. Thisshould be easy as I am starting at a 30. Thebalance of my time will be spent enjoying allthat Chesapeake Bay has to offer.

I extend my sincerest gratitude to all whohave generously volunteered their time andenergy to secure interesting photos and writegreat stories, and to staff for its dedication indelivering the magazine in a timely manner.

Editor's NoteJohn has served longer than any other con-

crete pipe industry state or provincial associa-tion executive in North America, since joiningthe ACPA in 1974. Before then, John worked asa project engineer in the Arlington, Virginia,Public Works Department and as a member ofthe Montgomery County, Maryland, Engineer-ing Department.

John’s first term with ACPA was 1974through 1993. He served as Deputy Director ofTechnical Services and Vice President of Mar-keting Services in the 1980s when theAssociation’s marketing efforts were initiated.He also served as Executive Vice President ofthe Association.

He left the American Concrete Pipe Asso-ciation in 1993 to work in biotechnology, andwas primarily involved with bio-remediation ofpetroleum products.

In 1998, when the ACPA was searching fora staff President to oversee all operations ofthe Association, John returned and served forthe best part of eight years. In total, John hasserved the concrete pipe industry and its mem-bers in the United States, Canada and othercountries for over 26 years.

John is a 1968 civil engineering graduate ofthe Catholic University of America in Washing-ton, D.C.

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SUMMER 2005 www.concrete-pipe.org CONCRETE PIPE NEWS

president'smessage

Concrete pipe is the only pipe that getsstronger as it ages. Increasing strength withage continues as long as any unhydratedcement is still present, provided the concreteremains moist, and the concrete tempera-ture remains favorable. When the tempera-ture of the concrete drops below freezing,hydration and strength gain virtually stops.1

Once temperatures rise above freezing, how-ever, that hydration can resume. Consider-ing that sanitary sewer pipe is generally wetand never subject to freezing temperatures,curing continues indefinitely. The principalfactors affecting strength are water-cementratio and age, or the extent to which hydra-tion has progressed.2 The lower the water-cement ratio, the stronger the concrete.

The binding quality of portland cementpaste is due to the chemical reaction be-tween cement and water, called hydration3.Cement paste is composed of water andextremely fine cement particles. Factors thatinfluence the rate of hydration include fine-ness of cement grinding, admixtures, if any,water and temperature.

On occasion, where high bed loads andsteep slopes exist, hydraulic structures maybe subjected to abrasion. Results indicatethat abrasion resistance is closely related tothe compressive strength of concrete. Highstrength concrete has more resistance to

Concrete Pipe Is theOnly Pipe That GetsStronger With Ageby Ken Kienow, P.E.President, Kienow Associates, Inc.Civil, Environmental, Forensic, Geotechnical andPipeline EngineersBig Bear Lake, California909-866-8636

abrasion than does lower strength concrete.Since compressive strength depends onwater-cement ratio and curing, low water-cement ratio concrete pipe provides supe-rior abrasion resistance.

Reinforced concrete pipe is designed tocrack and then undergoes a chemical reac-tion called autogenous healing. Cracking un-der load indicates that the tensile stresseshave been transferred to the reinforcing steel.A 0.01-inch wide crack does not indicatestructural distress and is not harmful. Cracksthat are much wider than 0.01-inch may besealed to ensure protection of the reinforc-ing steel. An exception occurs with pipemanufactured with greater than one inchcover over the reinforcing steel. In thesecases acceptable crack width should be in-creased.

Autogenous healing is common when theburied pipe is in the presence of moisture,either on the soil side or inside of the pipeitself. These cracks, when healed autog-enously, are impermeable and stronger thanthe original concrete. One of the reasons isthat the concrete pipe seals the crack withcalcium carbonate crystals. These calciumcarbonate crystals are formed when the car-bon dioxide in the surrounding soil, air andwater carbonates the free calcium oxide inthe cement and the calcium hydroxide liber-ated by the hydration of the tricalcium sili-cate of the cement.

Ca(OH)2 + CO2 = CaCO3 + H20 (1)The first documented discovery of autog-

enous healing was by the French Academyof Science in 1836. Since then, there havebeen numerous examples where cracks inconcrete have been repaired naturally bymoisture reactivating the hydration processof the cement in the concrete.

In most environments, concrete pipe con-tinues to cure at a slower rate than the rateset during production of the pipe. Tests onold pipe discovered during reconstruction

4


and now youknow...

projects, or tested under circumstances de-cades later, repeatedly confirm that thestrength of concrete pipe increases as timepasses.

The American Society of Civil Engineers(ASCE) Pipeline Division’s Inter-national Conference (What’s onthe Horizon, theme) on PipelineEngineering and Constructionwas held from August 1 though4, 2004, in San Diego, Califor-nia. A concrete pipe evaluationpaper was given by Kienow As-sociates, Inc. that detailed thecompressive and D-Loadstrength of reinforced concretepipe that had been recovered and tested forstrength. Following are the data presentedat the conference.

The 27” pipe was recovered from a land-slide that took out 700 feet of 27-inch RCPbelonging to LA County Sanitation Districts.

References:1.) Steven H. Kosmatka and William C. Panarese, “Design andControl of Concrete Mixtures”, Thirteenth Edition, PortlandCement Association, 1988, p. 42.) Ibid, p. 53.) Ibid, p. 3

The D-Load strength of the 27-inch tripled in56 years in service.

The 69-inch unlined RCP was washed outby the Salt River Flood of 1980 near the eastend of the Sky Harbor runway.

The Az or “Life Factor” is a direct mea-sure of the corrosion resistance of the con-crete that is protecting the steel from corro-sion. The 48-inch Tempe RCP (produced with100% limestone aggregates) has four timesthe corrosion resistance of the 69-inch RCPfrom 40th St. (produced with limestone sandand granitic rock). Tests were done in May,1980. The 48-inch RCP from Southern Ave/Priest Road was cored when the top 3-foot x4-foot section was cut out of the pipe to adda manhole or structure in 1980. The top wastrucked to Hydro Conduit’s plant at 43rd Aveand Buckeye Road in Phoenix and cored andtested by Engineers Testing Labs.

Viewing a videotape of the inside of thepipe gives little or no information regardingconcrete cover over the steel, strength, cor-rosion resistance, or life expectancy of thepipe. Pipe inspectors must be aware of theattributes of the pipe material, and coresmust be taken to understand fully what theyare seeing on tape. Specifiers and pipelinedesigners must be aware of the performanceand durability of reinforced concrete pipe tomatch service life of products and materialswith the design life of projects.

C Crown 6000 8620 2.75 inches 0.967 2.66 clear C Crown 6000 9080 2.50 inches 0.975 2.44 clear

REINFORCED CONCRETE PIPE AFTER 16 YEARS

Core # Spec. fc psi Test fc psi Steel Cover Alkalinity AAz (Inches)

CaC03

Core tests on 48-inch RCP at Southern Avenue interceptor (corner of Priest Road and Southern Avenue), Tempe, Arizona, installed in 1964 and tested 05/19/1980, minimum specification “A” of 0.80, limestone aggregates.

1800 4489 2700 No Test1800 4399 2700 47941850 3575 2775 44262000 4588 3000 48752000 5722 3000 No Test2500 8055 3750 No Test2500 8375 3750 8934

Los Angeles County sanitary 27-inch unlined reinforced concrete pipe sewer installed 1946, tested 2002 ±.

GETTING OLDER AND BETTER SINCE 1946Spec. 0.01-inch

Crack D-LoadTest 0.01-inch Crack D-Load

RequiredUltimate D-Load

Test Ultimate D-Load

California

A Flowline 6000 14,730 0.319 0.66 B Flowline 6000 14,560 0.309 0.62 E Crown 6000 11,920 0.330 0.62 E Crown 6000 12,720 0.308 0.54

REINFORCED CONCRETE PIPE - 15 YEARS OLD Concrete Compressive Strength More Than Doubled in 16 Years

Core I.D. Spec. fc psi Test fc psi Alkalinity AAz Life Factor

Phoenix Salt River Outfall 69-inch RCP near 40th Street installed 1965, tested 05/16/1980, 0.21 inch loss at crown of pipe.

Arizona

5


Photo: Dannie Pollock

Photos: Rinker Materials – Hydro Conduit Division

Engineers sometimes face a regulatory chal-lenge when designing systems to treat stormwater before it is released into water bodies.When this challenge is coupled with the sys-tem capacity requirements of a densely popu-lated development, the use of storm waterponds for treatment is not always desirable, orfeasible. The Westshore Yacht Club, located inhistoric South Tampa, presented such a chal-lenge. Developed by WCI Communities Inc.,the yacht club is a premier waterfront commu-nity offering residents the splendors of water-front living without sacrificing the conveniencesof city life. It consists of 500 residential unitsincluding town houses, single-family lots, andresidential apartment towers. A 246-slip marina

and yacht club put the finishing touches onthis impressive development. The regulatorypermits for the development required that thefirst inch of storm water runoff be treated priorto discharge into Old Tampa Bay.

Precast concrete retention and/or detentionsystems are a viable alternative to storm waterponds. On this project, the engineer recom-mended a precast concrete system over cast-in-place system due largely to final grade limi-tations, water table concerns, and overall re-duced construction costs. Other common ben-efits of using precast systems include immedi-ate backfilling that results in faster installation,and a reduction in cost for traffic control andproject management.

by Jeffery A. Hite, Rinker Materials - Hydro Conduit Division, Plant City, FloridaMark Pirrello, P.E., Moffatt & Nichol, Tampa, Florida813-220-4076

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Feature Story

3,864 feet of 10-foot x 4-foot precast concrete box sections and 256 feet of 10-foot x 4-foot precast concrete three sided box sections with lids.

Frequently, precast concrete box systemsare compared to cheaper vault systems con-structed of plastic or metal pipes and cham-bers. Such a comparison almost always favorsprecast concrete for a variety of reasons. Theseinclude structural integrity with minimal or nocover, a greater service life, and reduced in-

stallation footprints. Precast concrete box struc-tures, as demonstrated on this project, providea solution that is both environmentally respon-sible and structurally sound.

The project’s civil engineer, Heidt and As-sociates, Inc., proposed a vault system in lieuof traditional ponds because of the density ofthe residential units within the 35-acre phaseone site. The vault required a storage volumeof 65,600 cubic feet. Due to the proximity ofthe vault system toOld Tampa Bay andfinished grade eleva-tion, the total heightof the vault could notexceed six feet. Theproposed vaultwould lay directlyunder the marinaparking lot; thereforeHS20 live loads werecalled for in the de-sign.

Heidt and Associ-ates retained the services of Moffatt & Nicholto perform the structural aspects of the vaultsystem. After evaluating several different vaultsystems, Moffatt & Nichol recommended a de-tention and vault system constructed of pre-cast concrete boxes and three-sided boxes.Mark Pirrello, P.E., of Moffatt & Nichol noted,

“We proposed a precast system given the heightlimitation imposed on the structure which wouldhave made it more difficult to construct othervault systems, including a cast-in-place system.In addition, the elevated water table would haverequired additional dewatering. It was antici-pated that both issues would have resulted in a

significant increase in the total constructioncost.”

The final design consisted of 3,864 feet of10-foot x 4-foot precast concrete box sectionsand 256 feet of 10-foot x 4-foot precast con-crete three-sided box sections with lids. Thevault system was designed assuming no cover.In total, the system now occupies an area ofapproximately 1.4 acres. The Hydro ConduitDivision of Rinker Materials’, Plant City Florida

Facility, produced all of the box sections. Ac-cording to Tim Jones of Hydro Conduit, 202 ofthe 515 pieces were special, meaning that theyrequired access holes in the top, equalizationholes or pipe inlet holes in the sides, or a bulk-head in one end. The production and supplyprocess went smoothly from the start. Chapman

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Feature Story

Three-sided boxes designed to hold a special sandmedia filter.

Rinker Materials has been a part of Florida’s buildingand construction industry since 1926, when MarshallE. (Doc) Rinker, Sr. started the company. Rinker Mate-rials is a major supplier of precast concrete pipe, boxes,Stormceptor®, construction materials, aggregates, andready-mixed concrete throughout the United States.For more information on Rinker Materials-Hydro Con-duit, visit www.rinkerhydroconduit.com.

Project: Westshore Yacht ClubStorm Water Detention SystemTampa, Florida

Owners: WCI Communities, Inc.Tampa, Florida

Consulting Heidt and Associates, Inc. (civil)Engineers: Tampa, Florida

Moffatt & Nichol (structural)Tampa, FloridaMark Pirrello, P.E

Contracting Company of Tampa, Florida startedconstruction of the storm water detention sys-tem in January, 2005. Chapman reached sub-stantial completion of the system by May, 2005,and did not encounter any major obstaclesduring construction.

The three-sided boxes with lids were used

Contractor: Chapman Contracting CompanyTampa, Florida

Producer: Rinker Materials - Hydro Conduit DivisionPlant City, FloridaJeffery A. Hite

Quantities: 3,864 feet of 10-foot x 4-foot precast boxsections

256 feet of 10-foot x 4-foot precast three-sided box sections with lids.

202 of the 515 pieces were specials withaccess holes in the top, equalization holesor pipe inlet holes in the sides, or abulkhead at one end.

as the treatment vault through the use of a spe-cial sand media filter. The regulating agency,Southwest Florida Water Management District,requires that the engineer certify the vault’scondition each year. According to Mr. Pirrello,“Inspection and certification for a vault this sizewill run $5,000 per year, and every four yearsthe sand media filter will need to be replacedat a cost of approximately $15,000.”

Precast concrete box sections and pipe usedin retention/detention applications are becom-ing increasingly recognized as alternatives tostorm water management ponds. The precastconcrete vault system in place at The WestshoreYacht Club is designed to function for decadesunder a planned maintenance program. Engi-neers weighed the alternatives and specified amaterial and product that best met physical andregulatory challenges. Residents of the area areleft with a healthy and safe environment.

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Feature Story

Photos: Rinker Materials – Sherman-Dixie Concrete Industries, Inc.

Collapse of a twin line of 84-inch diametercorrugated metal storm sewer in Knoxville,Tennessee clearly demonstrates how major cit-ies in the Southeast United States have under-ground infrastructure on the verge of failure,and the impact that failed infrastructure has onlocal businesses. Flooding, followed by thecatastrophic failure of the line in June 2004,and a series of rainstorms including tropicaldepression Ivan on September 17, forced manylocal business owners to close and relocate dueto the lengthy delays in reconstructing the sewerand associated roadwork. Collapse of the cor-rugated metal pipe (CMP) occurred at the in-tersection of Papermill Road and Kingston Pike.

Papermill Road, running parallel to Interstate40, is a key arterial road providing access tonumerous local retailers and restaurants. Theroad was shut down for approximately threemonths.

The CMP structure had lasted 25 years un-der the parking lot of the Papermill Plaza. Atthe time of the failure during a heavy rainfallevent, the section of the parking lot in front ofKnoxville Wholesale Furniture was completelyinundated. In addition, several cars in the park-ing lot in the upstream restaurant of PF Changswere covered by the floodwaters. The stormsewer accommodated runoff from the mall, aswell as storm water from heavily developedneighborhoods. Reconstruction was compli-cated because the collapse occurred on bothprivate and public property. The owner of themall, CBL Associates and the City of Knoxvillehad to come to agreement on the scope of thereconstruction project and costs, before thestorm sewer could be replaced. There are atleast three lawsuits pending and the replace-ment costs of the storm sewer alone were

Continue toMark the Endof Short ServiceLives of CMPby John SimpsonSherman-Dixie Concrete Industries, Inc.800-737-0707

CatastrophicPipe Failures

9


$2,000,000. Unaccounted additional costs in-clude the costs to consumers, the motoringpublic, lost revenues to merchants and restau-rateurs, and the pending lawsuits.

Collapse of the twin CSP sewer system waslargely due to performance of pipe material,and matching service life of product with de-sign life of projects. According to publishedinformation and current knowledge of variousmaterials used in the production of pipe forstorm water, sanitary sewers, and culverts, theservice life of CMP manufactured in the 1970smay be expected to last between 25 and 30years. In spite of protective coatings, metal pipemay oxidize and rust. Debris carried by a stormwater event can abrade, dent, and thereby re-move coating. Once portions of the coatinghave been removed, oxidation often begins,followed by pitting and rusting that generallyleads to structural deterioration of the galva-nized metal pipe invert. This typical environ-ment of a storm sewer makes flexible CMP apoor choice for projects with a design lifegreater than 20 years. When pipe is consideredfor deep burials under major roadways, suchas many arterial roads in Knoxville, the selec-tion of pipe material and products during thedesign phase of the project is of utmost impor-tance. Funding for new capital works tend tobe more easily budgeted, while maintenancecosts are often under-funded or overlooked. In

the case of the Nation’s CMP sewersand culverts installed 25 to 30

years ago, few juris-d i c t i o n s

plannedf o r

their replacements, or the costs of replacingthe systems in the event of catastrophic fail-ures. Many CMP sewers and culverts are nowready for replacement, despite the longer de-sign life of the projects where they have beeninstalled. When premature failure of long-temprojects occurs, public agencies are often theones left to repair the works, and the questionis always posed, “From where does the moneycome to fix this type of failure?” Forprojects with long-term designs, re-placement with concrete pipe makesgood economic and safety sense.

Sherman-Dixie was selected tomanufacture the 84-inch reinforcedconcrete pipe for the replacement sec-tion of the sewer. This product will givethe owners the long-term durability,strength, and service life that they didnot purchase 25 years ago. The Cityand CBL Associates understand the dif-ferences between flexible and rigidpipe, along with the risks and liabili-ties associated with flexible pipe thatcan turn out to be very costly. Hind-sight suggests that projects incorporat-ing life cycle cost analysis during thedesign phase, and selection of the ap-propriate product for the application,are less likely to fail prematurely andhave to be replaced. The contractor in-stalled the new reinforced concretepipe system by the open cut method. Depth ofcover to top of pipe ranged from 20 to 25 feet.Total collapse of the CMP and extreme deflec-tions elsewhere along the pipeline, eliminatedthe option of slip lining the pipe. Slip liningwas considered given the depth of cut and to-tal disruption and associated costs that the pub-

lic would have to endure.Installation of the concrete

sewer began in October andwas completed by Janu-

ary 2005. AlthoughP a p e r m i l l

Road

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84-inch diameter RCP with depth of cover to top of pipe rangingfrom 20 to 25 feet.

Sherman-Dixie manufactures and markets precastconcrete pipe and precast concrete storm and sani-tary sewer structures for market areas in the south-east United States. The company has plants locatedin Hermitage, Chattanooga, Franklin and KnoxvilleTennessee, as well as Louisville, Elizabethtown, andLexington, Kentucky, Cullman, Alabama, and Day-ton, Ohio. Its corporate office is located in Nashville,Tennessee. See www.shermandixie.com for detailsabout products and services.

Project: Papermill Plaza and Papermill RoadStorm Sewer ReplacementKnoxville, Tennessee

Owners: The City of KnoxvilleDavid HarrellCBL Associates (Knoxville Mall)Steve Arsndorf

Contractor: City of KnoxvilleBlalock Construction,

Sevierville, TennesseeCBL AssociatesBrabston Trucking, Knoxville,Tennessee

Producer: Sherman-Dixie ConcreteIndustries, Inc.

John Simpson, P.E.Knoxville, Tennessee

Quantities: 1,950 feet of 84-inch diameterClass IV RCP

was closed for approximately three months, thefailure disrupted businesses in the area for overhalf a year. This was too long for some to bearand they relocated. No good has come out ofthis nationally recurring infrastructure problemof unplanned flexible pipe failures or replace-ments after only a few decades of service. Theattraction to save a few thousand dollars on ajob of this magnitude 25 years ago by specify-

ing a flexible pipe, has now turned into a costlysituation for many.

Class IV reinforced concrete pipe was speci-fied for the job because of the 20 to 25 feet offill over the pipe. An alignment change withinthe system was accomplished by employing 84-inch diameter reinforced concrete pipe bends.Access into the system was provided byprecasting saddle tee structure openings on topof the pipe. About 100,000 cubic yards of ma-terial were excavated to prepare for the instal-lation of approximately 1,950 feet of twin 84-inch diameter concrete pipe sewer.

Reinforced concrete pipe is a strong anddurable product. Unlike a flexible pipe whereits strength is derived from the select granular

backfill placed by the contractor, most of thestrength of the concrete pipe is in the productitself and arrives at the site on the truck. Itsservice life will extend far beyond 100 years,as concrete pipe gets stronger over time. Con-crete pipe was specified for the replacement ofthe failed CMP storm sewer because of its in-herit strength, durability, and long-term perfor-mance. Before the failure, the City of Knoxvillechanged its specifications requiring that all stormsewer systems located within public rights ofway, and drainage easements that the City as-sumes from private and public sectordevelopment, be concrete pipe. This policycontinues.

11


CORPORATE MEMBER OF ASCE

www.concrete-pipe.org972-506-7216 Fax 972-506-7682

E-mail: [email protected]

Program Details:This is a 2 – day training courseconducted by industry experts. Therewill be two general sessions coveringenvironment/sustainability and risk/liability. A variety of breakoutsessions will be available through three tracks on the2nd and 3rd day including topics such as concrete pipebasics, specifications, fill height tables, fiberglassreinforced polymer pipe, installation, oxidation andstress, video inspections, soil structure, jacking andmicro tunneling, pipe repair, detention and retention,flotation, DASH software and buried pipe design. Here’sthe perfect opportunity to learn more about the design,specification and utilization of piping products and tonetwork with peers and industry professionals.

Who Should Attend:Engineers, consultants, designers, and specifiers of concrete pipeproducts for sanitary sewer, storm drain and culvert applications.

Continuing Education Credits:Attendees can earn up to 1.6 CEUs or 13 ProfessionalDevelopment hours based on participation.

Registration and Costs:Registration and complete agenda online:www.concrete-pipe.org.

Space is limited; registration closesOctober 12, 2005.Costs: $825 per person for non-members of the ACPA; $225 forguests when sponsored by an ACPAmember company. Includes coursematerials, group functions, meals andrefreshments. Does not include hotelor travel expenses.

“Over the last several years, my job

duties have included the difficult

issues related to alternative piping

products. I believe that the ACPA

Short Course was an excellent general

overview of issues related to piping

products for the design engineer. I

found the courses related to

durability of concrete pipe and

concrete pipe hydraulics extremely

useful. Classes discussing life cycle

cost analysis and the true cost of

culvert failures showed that a lowest

cost may not always be the best way

to go.”Ray Waters

Assistant - Quality Assurance Supervisor

Clark County Dept. of Public Works

Construction Management Div.

Photos: John Kearns, MSD

Stainless steel helicalramp (drop structure).

The first phase to the solution of a major flood-ing problem that had existed in the vicinity of SouthGrand Boulevard and Bates Street in the City of St.Louis, Missouri since the 1930s has been completed.Railways and roads in the area form depressionsthat block storm water from draining naturally tothe Mississippi River. Sewers were inadequate tocarry any storm surcharges and extensive floodingof basements and roadways would occur. Localrecords suggest that flooding had reached depthsof eight feet in recent years, impacting businessesand residents. Publications by Metropolitan St. LouisSewer District (MSD) note that in 1995 a flash floodturned the area’s residential streets into a deep river,nine feet wide. The solution to the problem was a6,400-foot long, 14.5-foot diameter tunnel that couldaccommodate a 132-inch diameter reinforced con-crete pipeline to carry storm water to an outfall on

the MississippiRiver. The final project

to construct sewers to bringthe stormwater to the tunnel will start

in the summer of 2005.When the project was called for construction

in 2002, only one contractor, Affholder, Inc., ofChesterfield, Missouri (a subsidiary of InsituformTechnologies, Inc.), bid the project. The $32 mil-lion bid was in excess of the MSD’s estimate whichled to a cooperative review of the project by thecontractor and MSD engineers to determine an al-ternate approach to constructing the tunnel. Thesolution included an increase in size of the rein-forced concrete pipe (RCP) that was originally speci-fied from 108-inch diameter to 132-inch diameterpipe. The resizing of the pipe would result in a40% increased in capacity of the pipeline. In addi-tion, the pipe would be buried at a greater depth(increased from 60 feet to 108 feet) than previ-ously considered to accommodate a single tunnelvertical profile and eliminate a costly tunnel bor-

by Lex H. LindholmIndependent ConcretePipe Company314-842-2900

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Inspection of 132-inch diameter RCP usedfor tunneled storm sewer.

Project: Grand and Bates Relief Phase II (Tunnel)St. Louis, Missouri

Owner: Metropolitan St. Louis Sewer DistrictJohn Kearns, Project Inspector

ConsultingEngineers: TSI Engineering, Inc.

St. Louis, MissouriPeter Merten

David Masson & AssociatesSt. Louis MissouriMarc Bucchetti

Contractor: Affholder, Inc.Chesterfield, MissouriCharlie Hodge

Producer: Independent Concrete Pipe Co., MissouriDivisionSt. Louis, Missouri

Quantities: 6,300 feet, 132-inch diameter Special D-Load Design Reinforced Concrete Pipe.

727 feet, 90-inch diameter precastconcrete manhole risers.

416 feet, 84-inch diameter precastconcrete manhole risers.

160 feet (twin 80-foot lines), 10-foot x 8-foot box sections.

The Independent Concrete Pipe Company (ICPC) hasbeen manufacturing reinforced concrete pipe for stormand sanitary sewers across the United States since1912. ICPC was founded by Howard Schurmann andbegan as a family-owned and operated business. Itremains so today, one of the few concrete pipeproducers in the United States that can make that claim.See www.hyspanbridge.com/icpc/htm.

ing machine (TBM) remobilization at a shaft origi-nally designed for the project. Vertical tunnel shaftswere constructed using 84-inch and 90-inch man-hole risers, and the outfall to the river was con-structed using 80 feet of twin 10-foot x 8-foot boxsections. Apart from the increased tunnel bore, pipesize, and precast concrete box outfall, the revisedproject included relocation and redesign of dropshafts, pump station structure, and horizontal andvertical alignment. The revisions to the project didnot reduce the bid price, but did reduce disruptionto the daily affairs of the neighborhood during con-struction, increased the service life of the system,and required the contractor to assume all risk forany changed underground conditions.

Construction of the tunnel began in May 2002,and ended May 2004. Independent Concrete PipeCompany of St. Louis, Missouri supplied precastreinforced concrete pipe, boxes and manhole ris-ers. The 14.5-foot diameter, 190-ton tunnel boringmachine remained underground for approximately

one year, mov-ing at a rate of50 to 100 feetper shift. Work-ers descendedto the tunnelinside a 32-footdiameter shaftand traveled byopen train tothe TBM. Therotating cutterhead of the ma-chine bored therock at thefront of the ma-

chine. Buckets in the head of the machine col-lected bored rock, which was transported to a pointbehind the machine and carried to the surface.

Concrete pipe was lowered into the shaft,loaded onto a rail cart and transported to the in-stallation site. All units of 132-inch diameter RCPused for the tunnel liner were shipped in 2003.The pipe weighed 41,000 lbs. each and had a laylength of 7.7 feet in the tunnel. The 90-inch and84-inch diameter manhole risers were shipped inearly 2004.

The Metropolitan Sewer District of St. Louis hasa service area of 524 square miles including all 62square miles of the City of St. Louis. The currentpopulation served by MSD is approximately 1.4million. The Grand and Bates Relief Phase II (Tun-nel) project was a major initiative to reduce flood-ing and sewer backups. The concrete pipe used inthe tunnel is the principal structure that will ex-tend its service life. Because of the deep bury re-quirements and proven performance of reinforcedconcrete pipe, there were no other options for theliner of the tunnel that could meet theexpectations of the MSD and the contractor’s projectcosts.

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Failed CMP storm sewer replaced with 84-inchdiameter Class III RCP.

Photos: Hanson Pipe & Products, Inc.

A major rainfall on June 16, 2004, soils saturated from aprevious storm, and a failing corrugated metal pipe (CMP) stormsewer led to the collapse of a parking lot near a major intersec-tion on Cleveland Avenue in Sioux Falls, South Dakota. Failureof the 84-inch diameter CMP, buried 25 feet below the surface,caused a sinkhole 75 feet wide and 250 feet long. Backfill overthe pipe had infiltrated the sewer during earlier flood eventsand washed away the soil foundation of the parking lot. Whenthe remaining soil structure supporting the walls of the pipebecame saturated, the load over the pipe became too great forthe rusting walls and invert to bear and the collapse occurred.The failed CMP, along with an additional run of 200 feet be-neath a heavily traveled roadway were replaced with reinforcedconcrete pipe.

The storm that triggered the collapse dropped 7.79 inchesof rain on the south west area of the city over a two hour period.It was the worst flooding in Sioux Falls in ten years. Many homesand businesses were flooded, as storm sewers overflowed leav-ing storm water to accumulate in basements, streets and otherlow-lying areas.

Reconstruction of the collapsed portion of the sewer and200-foot section under Cleveland Avenue that showed clear signs

Project: Storm Sewer ReplacementSioux Falls, South Dakota

Owner: Sioux Falls Public WorksLyle Johnson, Director of Public WorksJeff Dunn, Sioux Falls Drainage Engineer

Contractor: H&W Contracting,Sioux Falls, Minnesota

Producer: Hanson Pipe & Products, Inc.Apple Valley, MinnesotaScott Hofer, Sales ManagerJohn LeGros, Western Region Engineer

Quantities: 430 feet of 84-inch Class III reinforcedconcrete pipe

84-inch diameter precast concrete apronsections.

Hanson Pipe & Products, Inc. is a diversifiedmanufacturer of concrete pipe and a variety ofsupporting products including manholes, drainagestructures, box culverts, bridge components, retainingwalls and concrete block. Its plant locationsthroughout North America enable the company toserve the most rapidly growing parts of the U.S. andCanada. Hanson is an international building materialscompany. It is one of the world’s largest producers ofconstruction aggregates, and concrete gravity andpressure pipe, precast concrete, and is the leadingmanufacturer of facing bricks in Europe. Seewww.hansonconcreteproducts.com for details.

of pending failure had to begin immediately, as water contin-ued to flow through the channel of the crumbled parking lot.Hanson Pipe & Products, Inc. was contacted by the City of SiouxFalls Drainage Engineer early June 17 to place an order for 84-inch diameter reinforced concrete pipe. Hanson staff calculatedthe strength of the pipe required to replace the CMP. Immedi-ately upon the City’s acceptance of the calculation, 12 truck-loads of concrete pipe were dispatched from Hanson’s Apple Val-ley Minnesota plant to cover the first 200 feet of the project. TheCity held an emergency bid letting for the project and selectedH&W Contracting of Sioux Falls for the installation. A total of430 feet of 84-inch diameter Class III reinforced concrete pipewas supplied to the contractor, along with two 84-inch diameterprecast concrete apron sections.

The total project cost was nearly $500,000, a hefty price topay to replace a 27-year-old pipeline. Concrete pipe, althoughmore expensive initially than corrugated metal pipe, is a muchbetter value in the long run. That’s why the City of Sioux Fallsprefers concrete pipe for its storm drain needs. The failure couldhave been catastrophic had the pipeline collapsed an hour laterwhen employees were in the parking lot or if the pipeline underthe city street had failed.

Large Diameter CMP Storm Sewer Replaced With RCP after Twenty-Year Service

by Scott HoferHanson Pipe & Products, Inc.605-335-7807

15


American Concrete Pipe Association222 W. Las Colinas Blvd., Suite 641

Irving, TX 75039-5423

www.concrete-pipe.org

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Thank you all who tookthe time to complete theConcretePipe NewsReaderSurveydistributedin theSpring, 2005 issue. Your inputinto the content of thepublication is very important tous, and it will help our writersto provide information that isuseful and relevant. Changes toConcrete Pipe News occur inpartnership with our readers.

Congratulations to thewinner of the digital camera,D. Steele of J-U-B Engi-neers, Inc. located in Utah.

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Announcing First Annual Project AchievementAward Program for DOT Departments

The ACPA has launched a new award program to recognize state DOT departments andleaders that have demonstrated creativity and innovation using precast concrete pipe or boxes.The award has been established to promote public awareness of the activities and contributions ofstate Departments of Transportation, the American Concrete Pipe Association and its members.

A state DOT official or ACPA member may enter as many qualified projects as they wish.Projects that have received awards from other organizations may be entered. All projectssubmitted for the award must have been completed and in use between January 1, 2001 andFebruary 1, 2006.

Judges will evaluate and compare projects based on the following:• Overall aesthetics and incorporation into surrounding infrastructure• Public involvement and education• Use of innovative materials• Use of new technologies• Complexity• Cost effectiveness• Environmental benefitsA plaque will be presented to the award winners during a special breakfast held by the ACPA

in conjunction with the AASHTO Bridge and Structures Subcommittee meeting in June 2006. Thewinning project will be featured in an upcoming issue of Concrete Pipe News, and a press releaseissued to publicize the award program and the award-winning project. The due date forsubmissions is February 1, 2006. Contact Matt Childs at [email protected], or 972-506-7216 for details.

Documents

The Magazine of the American Concrete Pipe Association · Gary Wilder Wilder Studios Production Published by: American Concrete Pipe Association 222 W. Las Colinas Blvd., Suite 641