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AS/NZS 2041:1998
Australian/New Zealand Standard™
Buried corrugated metal structures
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AS/NZS 2041:1998
This Joint Australian/New Zealand Standard was prepared by Joint TechnicalCommittee CE/25, Corrugated Metal Pipes and Arches. It was approved on behalf ofthe Council of Standards Australia on 5 December 1997 and on behalf of the Councilof Standards New Zealand on 27 March 1998. It was published on 5 May 1998.
The following interests are represented on Committee CE/25:
AustroadsAustralasian Railway AssociationAustralian Chamber of Commerce and IndustryMetal Trades Industry Association of AustraliaNew Zealand Heavy Engineering Research AssociationStandards New ZealandUniversity of Sydney
Review of Standards. To keep abreast of progress in industry, Joint Australian/New Zealand Standards are subject to periodic review and are kept up to date by the issueof amendments or new editions as necessary. It is important therefore that Standards usersensure that they are in possession of the latest edition, and any amendments thereto.Full details of all Joint Standards and related publications will be found in the StandardsAustralia and Standards New Zealand Catalogue of Publications; this information issupplemented each month by the magazines ‘The Australian Standard’ and ‘StandardsNew Zealand’, which subscribing members receive, and which give details of newpublications, new editions and amendments, and of withdrawn Standards.Suggestions for improvements to Joint Standards, addressed to the head office of eitherStandards Australia or Standards New Zealand, are welcomed. Notification of anyinaccuracy or ambiguity found in a Joint Australian/New Zealand Standard should be madewithout delay in order that the matter may be investigated and appropriate action taken.
This Standard was issued in draft form for comment as DR 95262.
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AS/NZS 2041:1998
Australian/New Zealand Standard™
Buried corrugated metal structures
Originated in Australia as AS A128—1962.Previous editions AS 2041—1984 and AS 2042—1984.AS 2041—1984 and AS 2042—1984 jointly revised,
amalgamated and designated AS/NZS 2041:1998.
PUBLISHED JOINTLY BY:
STANDARDS AUSTRALIA1 The Crescent,Homebush NSW 2140 Australia
STANDARDS NEW ZEALANDLevel 10, Radio New Zealand House,155 The Terrace,Wellington 6001 New Zealand
ISBN 0 7337 1790 X
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AS/NZS 2041:1998 2
PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New ZealandCommittee, Corrugated Metal Pipes and Arches, to supersede AS 2041—1984,Corrugated steel pipes, pipe-arches and arches, and AS 2042—1984,Corrugated steelpipes, pipe-arches and arches—Design and installation.
The objective of this Standard is to provide manufacturers, designers and users of buriedcorrugated metal pipes, arch-pipes and arch structures as distinct from those productsspecified in AS 1761—1985,Helical lock-seam corrugated steel pipes, AS 1762—1984,Helical lock-seam corrugated steel pipes—Design and installation, AS 3703.1—1989,Long-span corrugated steel structures — Materials and manufacture, andAS 3703.2—1989,Long-span corrugated steel structures—Design and installation, withrequirements for manufacture and installation and methods for design of such structuresfor use under road, railway and other earthworks as culverts, and access ways.
This edition incorporates the following major changes:
(a) Combination of materials, manufacture, design and installation information into asingle document, as the interaction of these influencing factors determines thebehaviour of composite soil-corrugated metal structures.
(b) Elimination of Class 1 riveted pipe due to obsolescence and upgrade of Class 1nestable jointing system.
(c) Revision of Class 2 steel grade.
(d) Revision of structure dimensions and addition of plate layout, bolting arrangementand tolerances.
(e) Addition of metals other than steel, structure shapes, alternative protective coatingsand wall thicknesses, and modified fill.
(f) Addition of arch footing force design and pipe-arch haunch pressure limits.
(g) Revision of live loading to conform to current Australian Bridge Design methodsand inclusion of non-standard live loads.
(h) Revision of height of cover tables.
(i) Addition of durability design information.
The term ‘informative’ has been used in this Standard to define the application of theappendix to which it applies. An ‘informative’ appendix is only for information andguidance.
© Copyright STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
Users of Standards are reminded that copyright subsists in all Standards Australia and Standards New Zealand publications and software.Except where the Copyright Act allows and except where provided for below no publications or software produced byStandards Australia or Standards New Zealand may be reproduced, stored in a retrieval system in any form or transmitted by any meanswithout prior permission in writing from Standards Australia or Standards New Zealand. Permission may be conditional on anappropriate royalty payment. Australian requests for permission and information on commercial software royalties should be directed tothe head office of Standards Australia. New Zealand requests should be directed to Standards New Zealand.
Up to 10 percent of the technical content pages of a Standard may be copied for use exclusively in-house by purchasers of theStandard without payment of a royalty or advice to Standards Australia or Standards New Zealand.
Inclusion of copyright material in computer software programs is also permitted without royalty payment provided such programsare used exclusively in-house by the creators of the programs.
Care should be taken to ensure that material used is from the current edition of the Standard and that it is updated whenever the Standardis amended or revised. The number and date of the Standard should therefore be clearly identified.
The use of material in print form or in computer software programs to be used commercially, with or without payment, or in commercialcontracts is subject to the payment of a royalty. This policy may be varied by Standards Australia or Standards New Zealand at any time.A
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3 AS/NZS 2041:1998
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL1.1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 NEW MATERIALS AND METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 REFERENCED DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.4 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.5 CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.6 NOTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.7 MARKING OF STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 2 PREFERRED DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 3 MATERIALS3.1 CLASS 1 STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.2 CLASS 2 STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 4 FABRICATION4.1 CLASS 1 STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.2 CLASS 2 STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334.3 ASSESSMENT AND REPAIR OF DAMAGED COATINGS. . . . . . . . . . . 37
SECTION 5 DESIGN5.1 DESIGN PHILOSOPHY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.2 DESIGN FACTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.3 MINIMUM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.4 WORKING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.5 DESIGN SOIL COMPACTION AND ARCHING FACTOR. . . . . . . . . . . . 415.6 DESIGN PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.7 RING COMPRESSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.8 SEAM STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.9 ULTIMATE WALL STRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.10 ALLOWABLE WALL STRESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.11 WALL THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.12 RIB STIFFENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.13 ARCH FOOTING FORCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.14 END-TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SECTION 6 INSTALLATION6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546.2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546.3 METHOD OF INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556.4 MINIMUM SPACING FOR MULTIPLE INSTALLATIONS . . . . . . . . . . . 556.5 FOUNDATION AND BEDDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576.6 BACKFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.7 MINIMUM COVER FOR ABNORMAL LOADS . . . . . . . . . . . . . . . . . . . 616.8 STRUCTURE SHAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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AS/NZS 2041:1998 4
PageAPPENDICES
A ORDERING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62B MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD 65C DURABILITY DESIGN AND PROTECTIVE SYSTEMS . . . . . . . . . . . . . . . 67D AS 2041 STRUCTURAL DESIGN FLOW CHART. . . . . . . . . . . . . . . . . . . 73E REFERENCE TABLES FOR MINIMUM COVER FOR STEEL STRUCTURES 74F REFERENCE TABLES FOR MINIMUM COVER FOR ALUMINIUM
STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90G LIVE LOAD COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100H FLOWABLE FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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5 AS/NZS 2041:1998
STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
Australian/New Zealand Standard
Buried corrugated metal structures
S E C T I O N 1 S C O P E A N D G E N E R A L
1.1 SCOPE This Standard specifies requirements for materials, manufacture, designmethods and installation of buried corrugated metal pipes, pipearches, arches and specialshapes comprising bolted corrugated metal sheets or plates manufactured within the limitsgiven in Table 1.1 and Section 2. It deals only with those structures in which the sheets orplates have circumferential corrugations running normal to the longitudinal axis of thestructures.
The Standard does not cover the design of arch footings, rib stiffening or those structurescovered by AS 1761, AS 1762, AS 3703.1 and AS 3703.2.
NOTES:
1 Ordering guidelines are detailed in Appendix A. Information on the means of demonstratingcompliance with this Standard for manufacture of the metal components is given inAppendix B. Information on the assessment of durability is given in Appendix C.
2 Buried corrugated metal structures withstand applied loads through the interactive behaviourof the flexible metal ring and the surrounding soil envelope. The stiffness of both of thesematerials is considered during design.
1.2 NEW MATERIALS AND METHODS This Standard does not preclude the use ofcorrugated profiles, cross-sections, materials or installation methods other than thosespecified in this Standard, provided that such new corrugated profiles, cross-sections ormaterials have been proven by appropriate performance testing to be equal to or betterthan those described herein.
NOTE: Variations to cross-sectional shape, corrugation profile, material or backfillcharacteristics, including the degree of compaction, may have significant effects on theperformance of these structures.
1.3 REFERENCED DOCUMENTS The following documents are referred to in thisStandard:
NOTE: To facilitate the use of this joint Australian/New Zealand Standard, where references toseparate national Standards exist, these Standards are designated AS XXXX/NZS YYYY.Compliance with this Standard may, therefore, be achieved by reference to the Standard that isapplicable to the country in which this Standard is being used (see soil tests Clause 6.6 andAppendix C).
AS1012 Methods of testing concrete (all parts)
1199 Sampling procedures and tables for inspection by attributes
1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse threadseries)
1275 Metric screw threads for fasteners
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AS/NZS 2041:1998 6
AS1289 Methods of testing soils for engineering purposes1289.3.4.1 Method 3.4.1: Soil classification tests—Determination of the linear
shrinkage of a soil—Standard method1289.3.6.1 Method 3.6.1: Soil classification tests—Determination of the particle size
distribution of a soil—Standard method of analysis by sieving1289.4.3.1 Method 4.3.1: Soil chemical tests—Determination of the pH value of a
soil—Electrometric method1289.4.4.1 Method 4.4.1: Soil chemical tests—Determination of the electrical resistivity
of a soil—Method for sands and granular materials1289.5.1.1 Method 5.1.1: Soil compaction and density tests—Determination of the dry
density/moisture content relation of a soil using standardcompaction—Standard method
1289.5.3.1 Method 5.3.1: Soil compaction and density tests—Determination of the fielddensity of a soil—Sand replacement method using a sand-cone pouringapparatus
1289.5.3.2 Method 5.3.2: Soil compaction and density tests—Determination of the fielddry density of a soil—Sand replacement method using a sand pouring can,with or without a volume displacer
1289.5.3.5 Method 5.3.5: Soil compaction and density tests—Determination of the fielddry density of a soil—Water replacement method
1289.5.4.1 Method 5.4.1: Soil compaction and density tests—Compaction controltest—Dry density ratio, moisture variation and moisture ratio
1289.5.5.1 Method 5.5.1: Soil compaction and density tests—Determination of theminimum and maximum dry density of a cohesionless material—Standardmethod
1289.5.6.1 Method 5.6.1: Soil compaction and density tests—Compaction controltest—Density index method for a cohesionless material
1289.5.8.1 Method 5.8.1: Soil compaction and density tests—Determination of fielddensity and field moisture content of a soil using a nuclear surface moisture-density gauge—Direct transmission mode
1391 Methods for tensile testing of metals
1397 Steel sheet and strip—Hot-dipped zinc-coated or aluminium/zinc coated
1399 Guide to AS 1199—Sampling procedures and tables for inspection byattributes
1594 Hot-rolled steel flat products
1650 Hot-dipped galvanized coatings on ferrous articles
1761 Helical lock-seam corrugated steel pipes
1762 Helical lock-seam corrugated steel pipes—Design and installation
3582 Supplementary cementitious materials for use with portland cement3582.1 Part 1: Fly ash
3703 Long-span corrugated steel structures3703.1 Part 1: Materials and manufacture3703.2 Part 2: Design and installation
3972 Portland and blended cements
4100 Supp1 Supplement 1—Steel structures—Commentary
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7 AS/NZS 2041:1998
AS/NZS1110 ISO metric precision hexagon bolts and screws
1111 ISO metric commercial hexagon bolts and screws
1112 ISO metric hexagon nuts, including thin nuts, slotted nuts and castle nuts
1252 High strength steel bolts with associated nuts and washers for structuralengineering
1365 Tolerances for flat-rolled steel products
1734 Aluminium and aluminium alloys—Flat sheet, coiled sheet and plate
2312 Guide the protection of iron and steel against exterior atmospheric corrosion
3500 National Plumbing and Drainage Code3500.0 Part 0: Glossary of terms
3750 Paints for steel structures3750.9 Part 9: Organic zinc-rich primer
ISO 9000 Quality management and quality assurance standardsISO 9000.1 Part 1: Guidelines for selection and use
ISO 9004 Quality management and quality system elementsISO 9004.1 Part 1: Guidelines
NZS4402 Methods of testing soil for civil engineering purposes4402.4.1.1 Method 4.1.1: Soil compaction tests — Determination of the dry
density/water content relationship—New Zealand Standard compaction test4402.4.2.1 Method 4.2.1: Soil compaction tests—Determination of the minimum and
maximum dry densities and relative density of cohesionless soil—Minimumdry density
4402.4.2.2 Method 4.2.2: Soil compaction tests—Determination of the minimum andmaximum dry densities and relative density of cohesionless soil—Maximumdry density
4402.5.1.1 Method 5.1.1: Soil density tests—Determination of the density ofsoil—Sand replacement method for the determination of in situ density
4402.5.1.5 Method 5.1.5: Soil density tests—Determination of the density ofsoil—Water displacement method
BS5400 Steel concrete and composite bridges5400.2 Part 2: Specification for loads
SAAHB18 Guidelines for third-party certification and accreditationHB18.28 Guide 28—General rules for a model third-party certification system for
products
HB77 Australian Bridge Design Code
Transit New Zealand Bridge Manual 1995
1.4 DEFINITIONS For the purpose of this Standard, the definitions given inAS/NZS 3500.0 and those below apply.
NOTE: Where a definition given conflicts with that given in AS/NZS 3500.0, the definitiongiven below applies.
1.4.1 Administrative definitions
1.4.1.1 Manufacturer—the person(s) or corporate body responsible for the manufactureof the pipes, pipe-arches, arches or special shapes.
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AS/NZS 2041:1998 8
1.4.1.2 Purchaser—the person(s) or corporate body for whom the manufacturer hascontracted to manufacture or supply the pipes, pipe-arches, arches or special shapes.
1.4.2 Technical definitions
1.4.2.1 Barrier coating—a coating designed to isolate the substrate from theenvironment.
1.4.2.2 Bedding—a prepared layer of uncompacted, non-cohesive material placed overthe foundation, below the structure invert.
1.4.2.3 Camber—a variation to the bedding grade along the structure invert tocompensate for differential settlement.
1.4.2.4 Compaction—the process of soil densification, at a specified moisture content,through the application of load by rolling, tamping, rodding or vibration with mechanicalor manual equipment.
1.4.2.5 Cover—the vertical distance between the top of the structure and:
(a) pavement surface of road;
(b) top of rail;
(c) top of trench or embankment where (a) and (b) are not applicable; or
(d) base of a stockpile.
1.4.2.6 Fill —
(a) Select fill—backfill material obtained from the excavation or elsewhere with knownproperties and grading, placed and compacted in layers around and over thecorrugated metal structure.
(b) Embankment fill—ordinary fill placed beyond the specified zone of compactedselect fill.
(c) Trench fill—ordinary fill placed over the compacted select fill for the purpose ofrefilling a trench.
(d) Modified fill—material obtained from the excavation or elsewhere which iscombined with additives to achieve a specified strength once placed and compactedin lieu of select fill.
(e) Flowable fill—modified fill placed as a pourable material in the select fill zone.
1.4.2.7 Flexibility factor—a measure of wall flexibility of the corrugated metal structurefor the purpose of achieving adequate stiffness during handling and installation.
1.4.2.8 Foundation—naturally occurring or prepared soil or rock underlying theinstallation and embankment.
1.4.2.9 Internal diameter—minimum clear dimension from internal crest to internalcrest.
1.4.2.10 Haunch—part of the periphery of pipe-arches and underpasses between thecrown and invert with relatively small radius of curvature.
1.4.2.11 Pipe-arch—a full periphery shape with crown, small radius haunches betweencrown and invert, and a large radius invert.
1.4.2.12 Ring compression—the circumferential compressive force in the structure wallper unit length as a result of external dead and live load pressures.
1.4.2.13 Skew number—a number denoting the angle between the centre-line of theroad, railway or other embankment and the centre-line of the structure, measured in aclockwise direction (see Figure A3).
1.4.2.14 Special shapes—special shapes include ellipses, underpasses and ribbedstructures (see Table 1.1).
(a) Vertical ellipse—a full periphery shape with rise greater than span (see Figure 1.1).
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9 AS/NZS 2041:1998
(b) Horizontal ellipse—a full periphery shape with span greater than rise (seeFigure 1.1).
(c) Select material—material suitable for its intended use.
1.5 CLASSIFICATION Pipes, pipe-arches, arches and special shapes shall beclassified as shown in Table 1.1.
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AS/NZS 2041:1998 10
TABLE 1.1
CLASSIFICATION OF CORRUGATED METAL STRUCTURES
Structureshape
ClassStructure shapereference and
corrugation type†
Pitch DepthRange of standard structure
spans* in mm
mm mm Steel Aluminium
12
—Pipe (P.S)
68200
1355
300 to 1 9501 500 to 8 550
300 to 1 9501 600 to 4 800
12
—Pipe-arch or underpass
(PA.S or U.S)
68200
1355
450 to 1 8001 925 to 6 578
450 to 1 8001 925 to 5 521
22
Horseshoe arch (HA.S)Elliptical arch (EA.S)
200200
5555
2 400 to 8 5002 334 to 8 468
2 400 to 7 1002 334 to 7 720
122
—Arch Type A (AA.S)Arch Type B (AB.S)
68200200
135555
300 to 1 9502 000 to 8 5004 000 to 8 500
300 to 1 9502 000 to 8 0004 000 to 8 000
2 Vertical ellipse (VE.S) 200 55 1 363 to 8 055 1 600 to 4 752
2Horizontal ellipse
(HE.S)200 55 1 509 to 8 750 1 600 to 4 362
* Standard structure spans are based on flexibility limits and normally available plate thicknesses. Othernon-standard shapes and larger spans are achieved with greater plate thicknesses or curved structuralstiffening ribs.
† Corrugation Type: S = Sinusoidal. The shape geometries can be seen in the Figures 2.2 to 2.7. Thestructure number in the tables to Figures 2.2 to 2.7 for Class 2 structures denotes the number of 235 mmmodules that comprise the effective structure periphery (see Figure 4.6).
1.6 NOTATION The terms, symbols, units of measurement and text reference, as usedin this Standard, are listed in Table 1.2.
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11 AS/NZS 2041:1998
TABLE 1.2
NOTATION
Quantitysymbol
TermsUnit
symbolText reference
A Area of corrugated steel section per unit length mm2/mm Clause 5.12, Tables 5.3, 5.4
As Side angle ° and ′ Tables 2.6 and 2.7
At Top angle ° and ′ Tables 2.6 and 2.7
a wheel footprint dimension m Figure 5.2
b Wheel footprint dimension m Figure 5.2
C1 Construction load factor — Clause 5.13
d1 Separation of wheel loads m Figure 5.2
d Internal diameter of circular pipes m
E Young’s modulus for steel or aluminium MPa Clause 5.12
Ff Flexibility factor mm/N Clauses 5.2, 5.11.4
Fmax. Maximum flexibility factor mm/N Clause 5.11.4
Fh Horizontal arch footing force kN/m Clause 5.13, Figure 5.6
Fr Ring compression kN/m Clauses 5.2, 5.7, 5.8
Fv Vertical arch footing force kN/m Clause 5.13, Figure 5.6
fa Allowable compressive wall stress MPa Clauses 5.10
fu Ultimate compressive wall stress MPa Clauses 5.9.1, 5.9.2
fy Minimum yield stress MPa Clauses 5.9.1, 5.9.2
h Height of cover m Clauses 5.4.1, 5.5.2
hmin. Minimum allowable height of cover m Clauses 5.5.2.2, 5.3
hs Stockpile height m Clause 5.6.1
H depth of invert from surface
i Live load impact factor — Clause 5.4.2.4
I Second moment of area of the corrugatedsection per millimeter of length
mm4/mm Table 5.3, Table 5.4
ID Density index — Clause 6.6.4.1
k Soil arching factor — Clauses 5.5.2, 5.6,Appendix C
ko Coefficient of earth pressure at rest — Clause 5.13
k′ Modified soil arching factor — Clause 5.5.2.1 Appendix C
ks Stockpile influence factor — Clauses 5.5.2.3, 5.6.1
N Local wheel load kN Figure 5.2
pb Base pressure kPa Clause 5.6.2
pd Dead load pressure kPa Clauses 5.4.1, 5.6.1
pl Live load pressure kPa Clauses 5.4.2, 5.6.1
pv Design pressure kPa Clauses 5.6.1, 5.6.2 and 5.7
ph Haunch pressure kPa Clause 5.6.2, Figure 5.5
q Tyre pressure kPa Figure 5.2
R Radius of sinusoidal corrugation mm Figures 4.1, 4.5
RD Dry density ratio — Clause 6.6.4.1
Rs Internal rise of pipe-arch, arch or special shape mm Figures 2.2, 2.3, 2.4, 5.6,Clause 5.13
r Radius of gyration of corrugated section mm Clauses 5.9.1, 5.9.2,Tables 5.4, 5.5
rb Bottom radius mm Figures 2.2, 2.4
(continued)
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AS/NZS 2041:1998 12
TABLE 1.2 (continued)
Quantitysymbol
TermsUnit
symbolText reference
rh Haunch radius mm Figure 2.2
rs Side radius mm Figure 2.3
r t Top radius mm Clause 5.6.2, Figure 2.2
Sb Internal bottom span of arch mm Figure 2.3
Ss Clear internal span of pipe-arch, arch andspecial shapes and internal diameter of pipesmeasured to internal crests
mm Figures 2.1, 2.2, 2.3, 2.4, 5.1,5.8 and Clauses 5.2, 5.5, 5.7,5.9, 5.12, Table 5.1
t Thickness mm Tables 5.1, 5.2, 5.3, 5.4,Figures 4.1, 4.5
Us Ultimate seam strength kN/m Clause 5.8, Tables 5.1, 5.2
Z Section modulus of the corrugated section mm3/mm Tables 5.3, 5.4
β Safety factor for seam strength — Clause 5.8
γ Unit weight of fill kN/m3 Clause 5.4.1, Appendices D,and E
γb Unit weight of backfill kN/m3 Clause 5.6.1
γs Unit weight of stockpile kN/m3 Clause 5.6.1
θ Re-entrant angle for arches mm Figures 2.3, 5.6
θb Angle subtended by the invert arc ° and ′ Figures 2.2, 2.4
θh Angle subtended by the haunch arc ° and ′ Figure 2.2
θt Angle subtended by crown arc ° and ′ Figures 2.2, 2.4
Ω Wall stress safety factor — Clause 5.10
1.7 MARKING OF STRUCTURES Each structure shall be legibly and permanentlymarked in a conspicuous place agreed by the purchaser. The marking shall include thefollowing:
(a) Name of the manufacturer.
(b) Date of manufacture including the month and year.
(c) A unique number identifying the structure.
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13 AS/NZS 2041:1998
S E C T I O N 2 P R E F E R R E D D I M E N S I O N S
The preferred dimensions of corrugated metal pipes, pipe-arches, arches and specialshapes covered by this Standard are governed by the dimensions of their componentsheets and plates, and are shown in Figures 2.1 to 2.7.
NOTES:
1 Alternative span and rise combinations are not prevented by their not being listed in thisSection.
2 The structure length of Class 1 structures should be specified to the nearest multipleof 610 mm.
3 The structure length of Class 2 structures should be specified to the nearest multipleof 200 mm. The structure numbers given in the tables to Figures 2.2 to 2.7 denote thenumber of 235 mm modules that comprise the effective structure periphery.
Ss
mm
Approximateaream2
300 0.07450 0.16600 0.28
750 0.44900 0.64
1 050 0.87
1 200 1.131 350 1.431 500 1.77
1 650 2.131 800 2.541 950 2.99
NOTE: All dimensions are clear internal dimensions to inside crests and are subject to the dimensionaltolerances specified in Section 4.
FIGURE 2.1(A) PIPES (CLASS 1)
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AS/NZS 2041:1998 14
Structurenumber
Nominaldiameter
mm
Ss
mm
Approximateaream2
20P 1 500 1 436 1.62
22P 1 650 1 586 1.97
24P 1 800 1 735 2.36
26P 1 950 1 885 2.79
28P 2 100 2 035 3.25
30P 2 250 2 184 3.75
32P 2 400 2 334 4.28
36P 2 700 2 633 5.44
40P 3 000 2 932 6.75
44P 3 300 3 231 8.20
48P 3 600 3 531 9.79
52P 3 900 3 830 11.52
56P 4 200 4 129 13.39
60P 4 500 4 428 15.40
64P 4 800 4 727 17.55
68P 5 100 5 027 19.84
72P 5 400 5 326 22.28
76P 5 700 5 625 24.85
80P 6 000 5 924 27.56
84P 6 300 6 223 30.42
88P 6 600 6 523 33.41
92P 6 900 6 822 36.55
96P 7 200 7 121 39.83
100P 7 500 7 420 43.24
104P 7 800 7 720 46.80
108P 8 100 8 019 50.50
112P 8 400 8 318 54.34
114P 8 550 8 468 56.31
NOTE: Internal diameter and end area are measured to inside crest assuming an average plate thicknessof 5.0 mm.
FIGURE 2.1(B) PIPES (CLASS 2)
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15 AS/NZS 2041:1998
NOTE: For pipe-archesθt ≤90°, for under-passesθt >90°.
Ss RsApproximate
arearh r t rb θh θt θb
mm mm m2 mm mm mm deg deg deg
450 340 0.11 100 225 550 74 90 16600 430 0.18 100 300 830 74 90 16750 510 0.27 100 375 1 100 74 90 16
900 600 0.38 100 450 1 370 74 90 161 050 680 0.51 100 525 1 640 74 90 161 200 770 0.65 100 600 1 910 74 90 16
1 350 860 0.82 100 675 2 190 74 90 161 500 940 1.00 100 750 2 460 74 90 161 650 1 030 1.21 100 825 2 730 74 90 16
1 800 1 110 1.43 100 900 3 000 74 90 16
FIGURE 2.2(A) PIPE-ARCHES (CLASS 1)
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AS/NZS 2041:1998 16
Structurenumber
Maximuminternal
spanSs
InternalriseRs
Endarea
Internalside
radiusrh
Internaltop
radiusr t
Internalbottomradius
rb
Sideangle
θh
Topangle
θt
Bottomangle
θb
mm mm m2 mm mm mm deg deg deg
10PA5-5 1 925 1 691 2.56 750 982 1 219 86.42 66.61 26.97
11PA5-6 2 131 1 782 2.98 750 1 096 1 428 86.42 65.85 27.73
14PA5-6 2 406 1 923 3.66 750 1 218 2 218 86.42 75.60 17.98
16PA5-7 2 692 2 063 4.41 750 1 361 2 905 86.42 77.51 16.07
17PA5-7 2 773 2 111 4.67 750 1 396 3 527 86.42 80.33 13.25
18PA5-7 2 851 2 160 4.94 750 1 430 4 441 86.42 83.04 10.54
24U5-7 3 145 2 768 7.02 1 020 1 573 3 125 64.18 100.88 14.94
17PA5-11 3 255 2 285 5.77 750 1 713 2 627 86.42 65.70 27.88
18PA5-11 3 343 2 332 6.06 750 1 740 2 923 86.42 68.49 25.09
20PA5-11 3 507 2 429 6.67 750 1 795 3 718 86.42 73.82 19.76
21PA5-11 3 585 2 477 6.99 750 1 823 4 270 86.42 76.35 17.23
22PA5-11 3 659 2 527 7.31 750 1 851 4 983 86.42 78.80 14.78
27U5-11 3 798 3 152 9.58 1 020 1 899 3 407 64.18 94.27 21.55
24PA5-12 3 934 2 668 8.32 750 1 985 6 018 86.42 80.22 13.36
29U5-11 3 942 3 268 10.38 1 020 1 971 4 036 64.18 97.60 18.22
31U5-11 4 085 3 386 11.22 1 020 2 043 4 882 64.18 100.74 15.08
25PA5-13 4 140 2 759 9.02 750 2 093 6 106 86.42 79.31 14.27
33U5-11 4 227 3 505 12.09 1 020 2 113 6 076 64.18 103.69 12.13
33U5-13 4 452 3 606 12.97 1 020 2 226 5 031 64.18 98.53 17.29
24PA5-16 4 463 2 835 9.72 750 2 348 4 178 86.42 67.97 25.61
35U5-13 4 590 3 725 13.90 1 020 2 295 6 034 64.18 101.39 14.43
27PA5-16 4 689 2 982 10.87 750 2 403 5 689 86.42 74.74 18.84
35U5-16 4 945 3 876 15.33 1 020 2 473 4 950 64.18 94.19 21.63
29PA5-17 4 967 3 123 12.08 750 2 535 6 533 86.42 76.14 17.44
38U5-16 5 145 4 054 16.85 1 020 2 572 6 134 64.18 98.34 17.48
31PA5-18 5 241 3 265 13.34 750 2 666 7 475 86.42 77.43 16.15
40U5-16 5 278 4 174 17.91 1 020 2 639 7 208 64.18 100.94 14.88
33PA5-19 5 513 3 406 14.67 750 2 796 8 527 86.42 78.63 14.95
40U5-18 5 521 4 272 18.97 1 020 2 760 6 257 64.18 96.54 19.28
41U5-19 5 710 4 381 20.08 1 020 2 855 6 329 64.18 95.70 20.12
35PA5-20 5 782 3 548 16.06 750 2 926 9 705 86.42 79.75 13.83
43U5-19 5 838 4 501 21.23 1 020 2 919 7 227 64.18 98.19 17.63
45U5-19 5 967 4 622 22.41 1 020 2 983 8 355 64.18 100.56 15.26
37PA5-21 6 049 3 690 17.50 750 3 054 11 024 86.42 80.79 12.79
39PA5-22 6 314 3 833 19.01 750 3 182 12 504 86.42 81.76 11.82
41PA5-23 6 578 3 976 20.59 750 3 310 14 169 86.42 82.67 10.91
NOTE: Internal span, rise, radii and end area are measured to inside crest assuming an average platethickness of 3.0 mm. Aluminium structures may vary from the shapes given above due to a minimum cornerradius greater than 750 mm.
FIGURE 2.2(B) PIPE-ARCHES AND UNDERPASSES (CLASS 2)
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17 AS/NZS 2041:1998
NOTE: For Class 2 — Type A: 0.3 < Rs/Ss < 0.4 and Type B: 0.4 < Rs/Ss < 0.5.
Ss RsApproximate
area rt θ
mm mm m2 mm deg
300 86.6 0.018 173.2 30
300 150.0 0.035 150.0 0
450 129.9 0.041 259.8 30
450 225.0 0.080 225.0 0
600 173.2 0.074 346.4 30
600 300.0 0.141 300.0 0
750 216.5 0.115 433.0 30
750 375.0 0.221 375.0 0
900 259.8 0.166 519.6 30
900 450.0 0.318 450.0 0
1 050 303.1 0.226 606.2 30
1 050 525.0 0.433 525.0 0
1 200 346.4 0.295 692.8 30
1 200 600.0 0.565 600.0 0
1 350 389.7 0.373 779.4 30
1 350 675.0 0.716 675.0 0
1 500 433.0 0.461 866.0 30
1 500 750.0 0.884 750.0 0
1 650 476.3 0.557 952.6 30
1 650 825.0 1.069 825.0 0
1 800 519.6 0.663 1039.2 30
1 800 900.0 1.272 900.0 0
1 950 580.8 0.824 1 151.2 30
1 950 1 000.0 1.571 1 000.0 0
FIGURE 2.3(A) ARCHES (RISE LESS THAN OR EQUAL TO RADIUS) (CLASS 1)
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AS/NZS 2041:1998 18
Structurenumber
Maximuminternal
spanSs
InternalriseRs
Endarea
Internaltop
radiusr t
Bottomangle
θ
mm mm m2 mm deg
12AA 2 000 850 1.28 1 013 9.25
15AA 2 500 1 058 1.99 1 267 9.49
18AA 3 000 1 265 2.86 1 522 9.70
22AA 3 500 1 598 4.29 1 757 5.19
23AA 4 000 1 550 4.59 2 065 14.45
26AB 4 000 1 927 5.99 2 001 2.12
26AA 4 500 1 757 5.87 2 319 14.02
29AB 4 500 2 136 7.45 2 253 2.98
29AA 5 000 1 965 7.30 2 573 13.67
33AB 5 000 2 464 9.64 2 500 0.83
32AA 5 500 2 172 8.89 2 827 13.39
36AB 5 500 2 673 11.46 2 751 1.61
35AA 6 000 2 380 10.63 3 081 13.15
39AB 6 000 2 883 13.44 3 002 2.27
37AA 6 500 2 452 11.75 3 380 15.94
42AB 6 500 3 092 15.58 3 254 2.85
40AA 7 000 2 659 13.74 3 633 15.54
46AB 7 000 3 420 18.69 3 501 1.32
43AA 7 500 2 867 15.89 3 886 15.20
49AB 7 500 3 630 21.20 3 752 1.87
46AA 8 000 3 075 18.20 4 139 14.89
52AB 8 000 3 839 23.86 4 003 2.34
49AA 8 500 3 283 20.67 4 392 14.62
56AB 8 500 4 167 27.67 4 251 1.13
NOTE: Internal span, rise top radius and end area are measured to inside crest assuming an average platethickness of 5.0 mm.
FIGURE 2.3(B) ARCHES (RISE LESS THAN RADIUS) (CLASS 2)
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19 AS/NZS 2041:1998
Structurenumber
Maximuminternal
spanSs
InternalriseRs
Endarea
Bottominternal
spanSb
Internaltop
radiusr t
Internalside
radiusrs
Bottomangle
θ
mm mm m2 mm mm mm deg
HA-22 2 400 1 857 3.76 2 008 1 200 1 200 33.21
HA-27 3 000 2 274 5.75 2 570 1 500 1 500 31.05
HA-40 4 400 3 376 12.52 3 719 2 200 2 200 32.30
HA-54 6 000 4 550 23.01 5 137 3 000 3 000 31.11
HA-64 7 100 5 395 32.28 6 066 3 550 3 550 31.31
HA-76 8 500 6 397 45.82 7 335 4 250 4 250 30.35
16EA-5 2 334 2 368 4.78 1 921 1 167 3 600 19.49
22EA-6 3 231 3 056 8.55 2 803 1 616 4 950 16.91
28EA-10 4 129 4 405 15.67 3 227 2 064 6 300 21.81
40EA-12 5 924 5 763 29.39 4 854 2 962 7 600 21.63
52EA-17 7 720 7 711 50.52 5 623 3 860 7 600 30.45
57EA-18 8 468 8 285 59.41 6 128 4 234 7 600 32.21
NOTE: Internal span, rise, top radius and end area are measured to inside crest assuming an average platethickness of 5.0 mm.
FIGURE 2.4 ARCHES (RISE GREATER THAN RADIUS) (CLASS 2)
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AS/NZS 2041:1998 20
FIGURE 2.5 (in part) HORIZONTAL ELLIPSE (CLASS 2)
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21 AS/NZS 2041:1998
Structurenumber
Maximuminternal
spanSs
InternalriseRs
Endarea
Internalside
radiusrh
Internaltop
radiusr t
Sideangle
As
Topangle
At
mm mm m2 mm mm deg deg
5HE5 1 509 1 363 1.62 640 819 100.61 79.39
6HE6 1 826 1 642 2.36 770 995 101.11 78.89
7HE7 2 138 1 928 3.24 905 1 163 100.93 79.07
10HE5 2 306 2 079 3.74 919 1 206 70.98 109.02
10HE6 2 457 2 223 4.27 1 005 1 293 78.15 101.85
12HE6 2 777 2 508 5.43 1 110 1 452 70.90 109.10
14HE6 3 095 2 795 6.73 1 215 1 609 64.92 115.08
14HE7 3 250 2 935 7.44 1 300 1 699 70.91 109.09
16HE6 3 411 3 085 8.18 1 319 1 765 59.92 120.08
18HE6 3 731 3 371 9.76 1 414 1 925 55.97 124.03
19HE7 4 043 3 656 11.48 1 560 2 091 59.33 120.67
20HE7 4 200 3 801 12.40 1 611 2 169 57.48 122.52
21HE7 4 362 3 942 13.35 1 654 2 251 55.98 124.02
12HE18 4 634 4 188 15.35 2 010 2 614 118.87 61.13
14HE18 4 950 4 478 17.50 2 135 2 743 112.00 68.00
14HE19 5 106 4 612 18.60 2 203 2 850 114.55 65.45
14HE20 5 263 4 750 19.76 2 274 2 957 116.89 63.11
18HE18 5 586 5 048 22.19 2 373 3 032 100.85 79.15
20HE18 5 902 5 338 24.75 2 493 3 178 96.06 83.94
21HE18 6 065 5 478 26.08 2 548 3 258 94.00 86.00
21HE19 6 219 5 618 27.45 2 623 3 353 96.42 83.58
21HE21 6 525 5 901 30.30 2 775 3 540 100.80 79.20
24HE20 6 849 6 191 33.28 2 875 3 671 92.69 87.31
24HE21 7 004 6 327 34.80 2 948 3 767 94.92 85.08
28HE18 7 175 6 483 36.38 2 948 3 791 81.36 98.64
27HE21 7 479 6 760 39.64 3 124 3 992 89.63 90.37
30HE20 7 801 7 052 43.05 3 218 4 128 82.88 97.12
30HE21 7 953 7 194 44.80 3 298 4 218 84.93 95.07
31HE21 8 112 7 338 46.59 3 355 4 295 83.51 96.49
33HE21 8 432 7 622 50.26 3 464 4 452 80.90 99.10
35HE21 8 750 7 908 54.08 3 574 4 608 78.42 101.56
NOTES:
1 Internal dimensions and end area are measured to inside crest using 3.0, 5.0, 7.0 or 8.0 mm plategauge based on the minimum handling stiffness requirements.
2 The above dimensions maintain a maximum structure elongation of 5 percent.
FIGURE 2.5 (in part) HORIZONTAL ELLIPSE (CLASS 2)
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AS/NZS 2041:1998 22
FIGURE 2.6 (in part) VERTICAL ELLIPSE (CLASS 2)
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23 AS/NZS 2041:1998
Structurenumber
Maximuminternal
spanSs
InternalriseRs
Endarea
Internalside
radiusrh
Internaltop
radiusr t
Sideangle
As
Topangle
At
mm mm m2 mm mm deg deg
5VE5 1 363 1 509 1.62 819 640 79.37 100.63
6VE6 1 642 1 826 2.36 995 770 78.89 101.11
7VE7 1 928 2 138 3.24 1 163 905 79.09 100.91
5VE10 2 080 2 305 3.74 1 206 920 109.06 70.94
6VE10 2 223 2 457 4.27 1 293 1 005 101.87 78.13
6VE12 2 507 2 778 5.43 1 452 1 110 109.07 70.93
6VE14 2 795 3 095 6.73 1 609 1 215 115.06 64.94
7VE14 2 935 3 250 7.44 1 699 1 300 109.08 70.92
6VE16 3 085 3 410 8.18 1 765 1 320 120.11 59.89
6VE18 3 371 3 730 9.76 1 925 1 415 124.05 55.95
7VE19 3 656 4 042 11.48 2 091 1 560 120.68 59.32
7VE20 3 801 4 201 12.40 2 169 1 610 122.49 57.51
7VE21 3 942 4 362 13.35 2 251 1 655 124.03 55.97
18VE12 4 188 4 634 15.35 2 614 2 010 61.14 118.86
18VE14 4 478 4 950 17.50 2 743 2 135 68.00 112.00
19VE14 4 615 5 107 18.62 2 850 2 205 65.49 114.51
20VE14 4 752 5 264 19.78 2 957 2 275 63.12 116.88
18VE18 5 051 5 587 22.20 3 032 2 375 79.18 100.82
18VE20 5 340 5 903 24.77 3 178 2 495 83.98 96.02
18VE21 5 481 6 066 26.10 3 258 2 550 86.03 93.97
19VE21 5 621 6 220 27.47 3 353 2 625 83.61 96.39
21VE21 5 902 6 529 30.32 3 543 2 775 79.16 100.84
20VE24 6 190 6 850 33.28 3 671 2 875 87.30 92.70
21VE24 6 330 7 004 34.82 3 767 2 950 85.12 94.88
18VE28 6 486 7 176 36.40 3 791 2 950 98.67 81.33
21VE27 6 762 7 481 39.67 3 992 3 125 90.38 89.62
20VE30 7 054 7 802 43.07 4 128 3 220 97.14 82.86
21VE30 7 197 7 955 44.83 4 218 3 300 95.09 84.91
21VE31 7 339 8 115 46.61 4 297 3 355 96.47 83.53
21VE33 7 625 8 435 50.30 4 454 3 465 99.10 80.90
21VE35 7 911 8 754 54.12 4 610 3 575 101.57 78.43
21VE36 8 055 8 913 56.08 4 688 3 630 102.74 77.26
NOTES:
1 Internal dimensions and end area are measured to inside crest using 3.0 or 5.0 mm plate gauge basedon the minimum handling stiffness requirements.
2 The above dimensions maintain a maximum structure elongation of 5 percent.
FIGURE 2.6 (in part) VERTICAL ELLIPSE (CLASS 2)
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AS/NZS 2041:1998 24
S E C T I O N 3 M A T E R I A L S
3.1 CLASS 1 STRUCTURES
3.1.1 Steel sheet
3.1.1.1 Grade The base steel shall be Grade G250 in accordance with AS 1397.
3.1.1.2 Base metal thicknessTolerances on base metal thickness shall be in accordancewith AS 1365.
3.1.1.3 Coating The base steel shall have a galvanized coating Class of Z600 inaccordance with AS 1397, unless an alternative coating is used as specified inClause 3.1.1.4.
3.1.1.4 Alternative coatings Alternative coatings to that referred to in Clause 3.1.1.3shall be applied in the following manner:
(a) Heavy galvanized coatingThe base steel shall be hot-dip galvanized in accordancewith the requirements for general articles in AS 1650.
(b) Aluminized (Type II) coating The base steel shall have an aluminium coating withthe following minimum coating mass (total both sides) when determined by testing:
(i) Triple spot test . . . . . . . . . . . . . . . . . . . . . . . . 305 g/m2 (total both sides).
(ii) Single spot test. . . . . . . . . . . . . . . . . . . . . . . . 275 g/m2 (total both sides).
NOTE: The coating weight is determined by summing the readings from both surfaces ofthe sheet, determined by magnetic thickness gauge or by stripping test.
(c) Barrier coating Preparation of the base metal and application of the coating shallbe in accordance with the coating manufacturer’s recommendations.
(d) Duplex coatings To protect the structure in abnormally corrosive or abrasiveconditions a secondary coating shall be applied over the primary coating (nominatedin Clause 3.1.1.3 and Clause 3.1.1.4 (a) and (b)), in accordance with the coatingmanufacturer’s recommendations.
NOTE: Appendix C of this Standard provides information on durability of suitable materialsand coatings for various environmental conditions.
3.1.2 Steel bolts and nuts
3.1.2.1 Diameter The bolts for the field assembly of bolted Class 1 structures shall be12 mm in diameter for lapped Class 1 structures and 10 mm in diameter for flangedClass 1 structures.
3.1.2.2 Dimensions The width across the flats of bolt heads and nuts shall be withinthe limits specified in AS/NZS 1111.
The form of thread and pitch of the bolt threads shall be ISO coarse pitch series inaccordance with AS 1275. The threads shall comply with M12 8 g tolerance in accordancewith AS 1275 with thread tolerance class at 8 g before zinc coating. Threads for nuts shallbe in accordance with AS 1214.
3.1.2.3 Mechanical properties For all structures, the bolts shall comply with thematerial and mechanical properties specified in AS/NZS 1110 for property Class 8.8.
The galvanized nuts shall pass a proof load test carried out in accordance withAS/NZS 1112 for property Class 8.
For fluming and flanged structures, the property class shall be Class 4.6 for bolts (inaccordance with AS/NZS 1110) and Class 5 for nuts (in accordance with AS/NZS 1112).
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25 AS/NZS 2041:1998
3.1.2.4 Coating Bolts and nuts shall be zinc-coated by hot-dip galvanizing inaccordance with AS 1214.
The bolts shall be centrifuged to remove surplus zinc from the threads after galvanizing.
The nuts shall be galvanized as blanks and tapped after galvanizing using the oversizeallowance specified in AS 1214, so that they are capable of assembly on the galvanizedbolts by hand.
3.1.3 Aluminium sheet
3.1.3.1 General The aluminium sheet shall be a clad aluminium alloy with substratemetal classification 3004–H34 and cladding metal classification 7072 in accordance withAS/NZS 1734.
NOTE: An example of a clad aluminium alloy, which meets the above requirements, is Alclad.
3.1.3.2 Cladding thickness The nominal cladding thickness on each side shall be5 percent of the total composite thickness. The average cladding thickness, whendetermined by metallurgical microscope, shall not be less than 4 percent of the totalcomposite thickness.
NOTE: Thickness examination should average 10 separate measurements on each side of notless than three polished material samples.
3.1.3.3 Chemical composition The chemical composition of the substrate and claddingshall be as given for alloys 3004 and 7072 respectively in AS/NZS 1734.
3.1.3.4 Mechanical requirementsThe mechanical properties of the clad aluminiumalloy 3004–H34 shall be as specified in Table 3.1.
TABLE 3.1
MECHANICAL PROPERTIES
Thickness Tensile strength (MPa) Yield strength(MPa) (0.2% offset)
Elongation (5%)
mm Min. Max. min. min.
1.2 215 260 165 3
1.5−4.0 215 260 165 4
3.1.4 Aluminium bolts and nuts Aluminium bolts and nuts for Class 1 structures shallbe Alloy 6061–T6 with proof stress (0.2 percent) of 240 MPa, ultimate tensile strength of260 MPa and elongation 8 percent. Other alloys with equal or higher proof stress arepermissible substitutes.
NOTE: Stainless steel bolts (SS303) and nuts (SS313) or galvanized steel bolts and nuts asspecified in Clause 3.1.2 may be substituted for aluminium bolts and nuts.
3.2 CLASS 2 STRUCTURES
3.2.1 Steel plate
3.2.1.1 Grade The base steel shall be Grade 250 in accordance with AS 1594.
3.2.1.2 Physical properties When tested in accordance with AS 1391, the base steelshall have the following properties:
(a) Yield strength (minimum) of 250 MPa.
(b) Elongation (minimum) of 17 percent on 200 mm gauge length.
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3.2.1.3 Coating The fabricated sheet or plate shall be hot-dip galvanized in accordancewith the requirements for general articles of AS 1650, unless an alternative coating isused as specified in Clause 3.2.1.4.
3.2.1.4 Alternative coatings Alternative coatings to that referred to in Clause 3.2.1.3shall be applied in the following manner:
(a) Other coating Preparation of the base steel and application of the coating shall bein accordance with the coating manufacturer’s recommendations.
(b) Duplex coating For abnormally adverse conditions, a secondary coating shall beapplied over the primary coating (nominated in Clause 3.2.1.3 and in Item (a)) inaccordance with the coating manufacturer’s recommendations.
NOTE: Appendix C of this Standard provides information on durability of suitable materialsand coatings for various environmental conditions.
3.2.2 Steel bolts and nuts
3.2.2.1 Diameter The bolts for the field assembly of the sheets and plates shall be20 mm diameter, and shall have heads and nuts specially shaped to provide suitablebearing.
3.2.2.2 Dimensions The width across the flats of bolt heads and nuts shall be withinthe limits specified in AS/NZS 1252.
The form of thread and pitch of the bolt threads shall be ISO coarse pitch series inaccordance with AS 1275. The threads shall comply with M20 6G tolerance in AS 1275,before being zinc-coated in accordance with AS 1275 with thread tolerance class of 6 gbefore zinc coating. Threads for nuts shall be in accordance with AS 1214.
3.2.2.3 Mechanical properties The bolts shall comply with the material and mechanicalproperties specified in AS/NZS 1252.
The galvanized nuts shall pass a proof load test carried out in accordance with AS 1112for property Class 10.
3.2.2.4 Coating Bolts and nuts shall be zinc-coated by hot-dip galvanizing inaccordance with AS 1214.
The bolts shall be centrifuged to remove surplus zinc from the threads after galvanizing.
The nuts shall be galvanized as blanks and tapped after galvanizing using the oversizeallowance specified in AS 1214, so that they are capable of assembly on the galvanizedbolts by hand.
3.2.2.5 Lubrication Nuts shall be lubricated in accordance with AS/NZS 1252.
3.2.3 Aluminium plate
3.2.3.1 General The aluminium plate shall be of structural alloy 5052 in accordancewith AS/NZS 1734.
3.2.3.2 Mechanical properties The mechanical properties for alloy 5052 shall conformto the values specified in Table 3.2.
TABLE 3.2
MECHANICAL PROPERTIES OF ALLOY 5052
Thickness Tensile strength(MPa)
Yield strength(MPa) (0.2% offset)
Elongation (%)
mm Min. Min. Min.
2.5−4.0 231 165 6
4.1−6.35 231 165 7
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3.2.3.3 Plate thickness toleranceThe minimum thickness for aluminium plate shall bethe specified thickness. Plate thickness shall be measured at any point on a plate not lessthan 10 mm from an edge, and at the neutral axis (refer to Figure 4.5) of the corrugatedplate.
3.2.4 Aluminium bolts and nuts
3.2.4.1 General Aluminium bolts and nuts shall be manufactured from alloy 6061—T6with dimensions in accordance with Clauses 3.2.2.1 and 3.2.2.2.
3.2.4.2 Mechanical properties Alloy 6061–T6 shall have the properties as given inClause 3.1.4. Other alloys with equal or higher proof stress are permissible substitutessubject to chemical compatibility.
NOTE: Stainless steel bolts (SS303) and nuts (SS313) as specified in Clause 3.2.2 or galvanizedsteel bolts and nuts as specified in Clause 3.1.2 may be substituted for aluminium bolts andnuts.
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AS/NZS 2041:1998 28
S E C T I O N 4 F A B R I C A T I O N
4.1 CLASS 1 STRUCTURES
4.1.1 General Class 1 structures shall be fabricated from material as specified inClause 3.1.1 or 3.1.3 and shall be corrugated, hole punched and curved in accordance withClauses 4.1.2, 4.1.3 and 4.1.4. Class 1 structures are assembled on site with lapped seamsor flanged seams.
4.1.2 Sinusoidal Corrugations Corrugations shall comply with the following:
(a) The pitch of the sinusoidal corrugations shall be 68 ±3.0 mm (see Figure 4.1).
(b) The depth of the sinusoidal corrugations shall be 13 +0, −0.7 mm (see Figure 4.1).
(c) The corrugations shall form smooth continuous curves and tangents.
(d) The inside radius of each corrugation shall be not less than one-half of the depth ofthe corrugation.
NOTE: Corrugations are designated pitch × depth.
DIMENSIONS IN MILLIMETRES
FIGURE 4.1 CORRUGATIONS FOR CLASS 1 STRUCTURES
4.1.3 Sheet tolerances
4.1.3.1 Sheet width The actual net width of sheets measured along the corrugation shalldiffer from the specified net width by not more than ±3 mm (see Figure 4.2)
NOTE: Typically, the periphery of Class 1 structures is comprised of two semi-circular sheets.The specified net width can be determined from the structure peripheries given in Section 2.
4.1.3.2 Sheet lengthThe actual net length of sheets measured across the corrugationsshall be 610 mm ±3 mm (see Figure 4.2), or 305 ±3 mm for closure panels, wherecontinuous longitudinal seams are specified (see Figure 4.3).
4.1.3.3 Sheet curvature The curvature of the sheet, when measured radially, shall notdiffer from the correct arc by more than 5 mm.
4.1.3.4 Structure end finishing sheetsClass 1 structures shall have either a stepped end(see Figure A1) or a vertical end specified. Vertical end structures shall be supplied withspecial top closure panels for this purpose.
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DIMENSIONS IN MILLIMETRES
FIGURE 4.2 TYPICAL SHEET LAYOUT FOR CLASS 1 STRUCTURES
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4.1.4 Bolt holes and slots
4.1.4.1 General Bolt holes and slots shall be provided to allow interchangeability ofsheets and field assembly with the prescribed fasteners to achieve the specified structureshape.
4.1.4.2 Longitudinal seams Bolt holes for longitudinal seams shall be 16 mm indiameter prior to sheet curving, located at 102 ±2 mm centres on alternate crests andvalleys of corrugations and offset on opposite sides of the plate lap centre-line by 20 mm(see Figure 4.2).
NOTE: Alternative seam bolting configurations are not precluded, provided the allowable seamstrength used in design calculations is determined by full scale bolted seam compression testing.
4.1.4.3 Circumferential seams Bolt holes for circumferential seams shall be 16 mm ×20 mm slots, prior to sheet curving, located centrally (±2 mm) on the corrugation crestnearest the sheet edges. Circumferential seam bolt holes shall be equally spaced along thesheet edge with centre-to-centre spacing of no more than 1000 mm.
4.1.4.4 Hole alignment Prior to sheet curving, the diagonal dimensions measuredbetween bolt slots at opposite sheet corners shall not differ by more than 5 mm.
4.1.4.5 Edge distance Bolt holes and slots shall be no closer to the sheet edge than1.75 times their diameter.
4.1.4.6 Hole and slot defects Holes and slots shall be free of cracks and free of raggededges and burrs in excess of 1.5 mm.
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FIGURE 4.3 LONGITUDINAL SEAMS FOR LAPPED CLASS 1 STRUCTURES
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FIGURE 4.4 CIRCUMFERENTIAL SEAMS FOR LAPPED CLASS 1 STRUCTURES
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4.2 CLASS 2 STRUCTURES
4.2.1 General Class 2 structures shall be fabricated from material as specified inClauses 3.2.1 and 3.2.2 or 3.2.3 and 3.2.4 and shall be corrugated, hole punched andcurved to the specified radii so that the cross-sectional dimensions of each structure shallbe achieved when it is assembled. Coatings, if required, shall be applied after fabrication.
4.2.2 Sinusoidal Corrugations Sinusoidal corrugations shall comply with thefollowing:
(a) The pitch of the sinusoidal corrugations shall be 200 ±6 mm (see Figure 4.5)
(b) The depth of sinusoidal corrugations shall be 55 ±3 mm (see Figure 4.5)
(c) The corrugations shall form smooth continuous curves and tangents.
(d) The inside radius of each corrugation shall be not less than one-half of the depth ofthe corrugations.
NOTE: Corrugations are designated pitch × depth.
DIMENSIONS IN MILLIMETRES
FIGURE 4.5 CORRUGATIONS FOR CLASS 2 STRUCTURES
4.2.3 Plate tolerances
4.2.3.1 Plate width The actual net width of sheets measured along the corrugation shallnot differ from the specified net width by more than 5 mm (see Figure 4.6).
4.2.3.2 Plate length The actual net length of a plate measured between the crests of thetwo outer corrugations shall have a length tolerance of ±0.5 percent.
4.2.3.3 Plate curvature The curvature of the plate when measured radially shall notdiffer from the specified curvature by more than 10 mm.
4.2.4 Bolt holes
4.2.4.1 General The holes for bolts shall be spaced so that all plates of like dimensionand curvature and having the same number of bolts per unit length of seam areinterchangeable (see Figure 4.6).
The diameter of the bolt holes in longitudinal seams shall not exceed the diameter of thebolt by more than 5 mm.
4.2.4.2 Edge distance The distance from the centre of a bolt to any plate edge shall beas specified in AS 4100 Supp 1.
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AS/NZS 2041:1998 34
4.2.4.3 Longitudinal seams The holes for bolts in longitudinal seams shall be in tworows spaced 50 mm apart, centre-to-centre. The minimum hole arrangement shall haveholes in one row in every crest, and in the other row in every valley of the corrugations.
NOTE: Alternative seam bolting configurations are not precluded, provided the allowable seamstrength used in design calculations is determined by full-scale bolted seam compression testing.
4.2.4.4 Circumferential seams The centre-to-centre spacing of holes for bolts incircumferential seams shall not exceed 235 mm.
DIMENSION IN MILLIMETRES
FIGURE 4.6 TYPICAL SHEET LAYOUT FOR CLASS 2 STRUCTURES
4.2.4.5 Hole alignment Prior to plate curving, the diagonal dimensions measuredbetween bolt holes in opposite corners of the plate shall not differ by more that 1 percent.
4.2.4.6 Hole configuration The bolt holes for fasteners shall be provided in aconfiguration that allows staggering of plate laps along longitudinal or circumferentialseams (see Figures 4.7 and 4.8).
4.2.4.7 Hole defects Punched bolt holes shall be free of cracks and free of raggededges and burrs in excess of 2.0 mm.
4.2.5 Plate identification and traceability Plates for Class 2 structures shall bepermanently marked to show curvature, thickness and a unique number to achieve qualityassurance requirements for identification and traceability. Special plates for skewedstructures or for bevelled ends shall be legibly and permanently marked to identify theirproper positions in the finished structure.
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FIGURE 4.7 CIRCUMFERENTIAL SEAMS FOR CLASS 2 STRUCTURES
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FIGURE 4.8 LONGITUDINAL SEAMS FOR CLASS 2 STRUCTURES
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4.3 ASSESSMENT AND REPAIR OF DAMAGED COATINGS
4.3.1 Zinc
4.3.1.1 General No galvanized sheet or plate shall have uncoated or defective areaswhich in total exceed the lesser of 0.1 percent of the total surface area or 25000 mm2.
NOTE: Small localized areas of exposed steel are protected from corrosion by galvanic actionfrom adjacent zinc. Although the rate of corrosion varies widely, depending on conditions, inenvironments suitable for the use of galvanized steel, it has been demonstrated that protection isafforded to areas of bare steel up to at least 5 mm in diameter. In normal fabrication, the totalsurface of steel to be protected by the zinc is only marginally increased, and accelerateddeterioration does not occur from exposed areas. Such small areas can be afforded additionalprotection by a coating of zinc-rich organic primer or other suitable paint (see also Table C4under Tropical).
Where coating repair is deemed necessary, and in areas that have been welded aftergalvanizing, repair shall be made by careful wire brushing to remove scale followedimmediately by application of zinc-rich paint complying with AS/NZS 3750.9 applied inaccordance with the manufacturers instructions and the requirements of AS 1650.
4.3.1.2 White rust (storage stain) A powdery white to pale grey deposit, whichsometimes forms on galvanized articles in moist, acidic or salty environments, normally isnot detrimental to the zinc coating, nor is it indicative of inferior galvanizing. Wheremedium to heavy build-up has occurred, or brown deposits are visible, or where theproduct will be subjected to poorly ventilated or humid conditions, white rust shall beremoved with a stiff bristle (not wire) brush, and saturated cloth application of—
(i) a solution of 420g/l chromium trioxide with 0.5 percent nitric acid then rinsing withcold water; or where practical,
(ii) a solution of 200g/l chromic acid then rinsing with cold water.
In normal conditions a light, smooth build-up of white rust does not require removal.
NOTE: Where white rusting is due to the installed exposure environment rather than storageconditions, it should be removed and the application of a suitable protective barrier coatingshould be considered.
4.3.2 Coatings other than zinc The allowable defects in coatings other than zinc shallbe determined in consideration of the type of coating, the desired service life and theexpected environmental conditions. Repairs, if deemed necessary, shall be in accordancewith the manufacturer’s recommendations.
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AS/NZS 2041:1998 38
S E C T I O N 5 D E S I G N
5.1 DESIGN PHILOSOPHY
5.1.1 Introduction Buried corrugated metal structures are flexible buried memberswhich rely on soil-structure interaction. Installation shall be in accordance with Section 6of this Standard for the structure to achieve the required design behaviour.
The design philosophy takes into account—
(a) structural failure;
(b) bearing failure of the surrounding soil;
(c) handling stresses; and
(d) durability.
Soil bearing failure is also taken into account in this Standard through the requirements ofSection 6.
5.1.2 Structural failure criteria This Standard only applies to structures that aresymmetrical about the vertical axis.
The design of metal pipes and arches is based on the ring compression theory. The ringcompression in the structure is calculated on the equivalent vertical pressure at the crownon the metal structure (see Figure 5.1).
This theory is only valid if the metal structure has a minimum cover of correctly installedfill and adequate side support so that arching of the surrounding material can occur.Failure of a metal structure designed by ring compression is assumed to occur on thehorizontal axis defined by theSs dimension. The modes of failure assumed by thisStandard are—
(a) crush or yielding;
(b) ring buckling; and
(c) the transition zone between crushing and buckling.
The design and installation criteria of this Standard is intended to ensure that ringcompression is applicable.
5.1.3 Heavy axle load vehicles including construction equipmentThis Standard doesnot provide guidance for minimum cover for vehicles with axle loads heavier than thedesign vehicles specified in Clause 5.4.2. If a metal structure is being designed for avehicle with heavy axle loads (e.g. mine haul vehicles, earthmoving plant), specialistadvice should be sought to determine the minimum cover, to ensure that the ringcompression theory is applicable.
NOTE: If a structure has insufficient cover for arching to occur, failure may be initiated bybuckling of the crown of the metal structure. Buckling of the crown may occur at a lower loadthan the failure load predicted by the ring compression theory specified in this Standard.
5.1.4 Alternative design methods Alternative design methods are outside the scope ofthis Standard and should be subject to agreement between the parties concerned.
NOTES:
1 A flow chart for the design of buried corrugated metal structures in accordance with thisStandard is provided in Appendix D.
2 For the convenience of designers, Appendices E and F provide maximum height of coverlimits for Class 1 and Class 2 corrugated steel and aluminium structures.
Appendix G provides comparisons of various highway live load pressures to allow structuraldesign where the worst load case (as presented in Appendices E and F) does not apply.
Figure 5.2 is provided to allow alternative live loads to be considered in design calculations.
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39 AS/NZS 2041:1998
FIGURE 5.1 RING COMPRESSION IN BURIED FLEXIBLE STRUCTURES
5.2 DESIGN FACTORS The following factors shall be taken into account in thedesign of corrugated metal pipes, pipe-arches, and arches and special shapes (see alsoAppendix D):
(a) Structure shapes, class and span (Ss). (See Table 1.1 and Figures 2.1 to 2.7).
(b) Applicable live load (see Clause 5.4.2).
(c) Minimum cover requirements (see Clause 5.3).
(d) Applicable dead load (see Clause 5.4.1).
(e) Required select backfill compaction and soil arching factor (k′) (see Clause 5.5).
(f) Calculated ring compressionFr in the corrugated metal section (see Clauses 5.6and 5.7).
(g) Ultimate seam strength (see Clause 5.8).
(h) Ultimate compressive wall stressfu (see Clause 5.9).
(i) Minimum wall thickness (see Clauses 5.10 and 5.11).
(j) Handling stiffness (see Clause 5.11).
(k) Footing forces for arches (see Clause 5.13).
(l) End treatment (see Clause 5.14).
(m) Installation requirements (see Section 6).
(n) Durability (see Appendix C)
5.3 MINIMUM COVER
5.3.1 General To ensure a stable soil arch is maintained over the structure crown andconcentrated loads do not bear directly on the structure, a minimum cover is necessary.Satisfactory results have been established based on long-term observations of performanceunder live loads.
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5.3.2 Minimum cover for railway live loads Minimum cover (hmin.) for railway liveloads shall beSs/4 or 1.0 m, whichever is greater, but in no case shall the depth of fillabove the structures be less than 300 mm, i.e. from top of structure to underside ofballast.
5.3.3 Minimum cover for highway live loads Minimum cover (hmin.) for highway liveloads shall beSs/6 or 0.6 m, whichever is the greater.
5.3.4 Variation of minimum cover The minimum cover shall be increased if theengineer considers that the site conditions of any installation warrant it.
5.4 WORKING LOADS
5.4.1 Dead load
5.4.1.1 General Dead load soil pressure shall be taken as the pressure at the top of thestructure and shall be calculated from the following Equation:
pd = γh . . . 5.4.1
where
γ = unit weight of material above the structure crown, in kilonewtons per cubicmetre
h = height of cover in metres (see Clause 1.4.2.5)
NOTE: A value of 20 kN/m3 for unit weight of fill is used for normal overburden material, andhas been adopted in determining the height of cover tables in Appendices D and E.
5.4.1.2 Inclined and stockpile loadsWhere the fill height varies above the structure,the higher value shall be adopted as the design maximum height of cover, and theminimum cover as determined in Clause 5.3 shall be satisfied when measured radiallyfrom the structure wall.
5.4.2 Live loads
5.4.2.1 General Live loads shall be considered as uniform pressure at the level of thestructure crown. The specified live load pressure, (pl), shall be chosen from the relevantload cases given in Clauses 5.4.2.2 to 5.4.2.6, inclusive.
5.4.2.2 Highway live loads Highway live load pressures, including impact allowance,include the following:
(a) W7, T44, HLP320, HLP400 (SAA HB77).
(b) HN-HO-72 (Transit New Zealand Bridge Design Manual).
(c) HA, HB-25 and HB-45 (BS 5400.2).
A comparison of Australian and New Zealand bridge design loadings is given inAppendix G (see also SAA HB77).
5.4.2.3 Railway live loads (M250 and M270)Railway live load pressures, with impactallowance, include M250, M270 and 300-A-12 (see SAA HB77).
5.4.2.4 Aircraft loads Required loads and load distributions for the calculation ofworking pressures due to aircraft shall be obtained from the relevant regulatory authority.
5.4.2.5 Other live loads Live load pressures, other than those covered in Clause 5.4.2.2or Clause 5.4.2.3, shall be calculated from axle loads or footprints using a load dispersionthrough the soil of 0.725 : 1 (horizontally : vertically), as shown in Figure 5.2. Live loadsshall be increased by an appropriate impact factor value (i) but not less than 0.1. Forexample, values higher than 0.1 may be applicable for haulage roads. For consideration oflive loads due to construction refer also to Clause 6.7.
5.4.2.6 Earthquake loads Buried corrugated metal structures in backfills, in accordancewith this Standard, are not sensitive to earthquake effects. Where the backfill is prone toliquefaction, arching of the backfill should be ignored and, therefore,k would be equalto 1.0.
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41 AS/NZS 2041:1998
FIGURE 5.2 DISTRIBUTION OF NON-STANDARD WHEEL LOADS THROUGH COVER
5.5 DESIGN SOIL COMPACTION AND ARCHING FACTOR
5.5.1 Soil compaction For the assessment of soil arching factor, k, where structuresare installed in accordance with Section 6, the density of the backfill is considered to benot less than 90 percent of the maximum dry density for standard compaction in cohesivesoils or 70 percent of the maximum density index for standard compaction in cohesivelesssoils. The appropriate value ofk is given in Figure 5.3.
Higher levels of compaction may be adopted provided it can be ensured that this will beachieved or exceeded on site. For cemented and flowable modified fills, as defined inClause 6.6.3 and Appendix H, a design value ofk equivalent to 90 percent relative densityshall be used, unless higher values can be substantiated by testing.
NOTE: Compaction achieved in the field should exceed that assumed in design. A value of90 percent compaction has been adopted for the calculation of the tables given in Appendices Eand F. Soil compaction values less than 90 percent are provided to allow back-calculation ofstructural capacity where installation practices may have deviated from the specifiedrequirements of Section 6 of this Standard.
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AS/NZS 2041:1998 42
FIGURE 5.3 SOIL ARCHING FACTOR CHART
5.5.2 Soil arching factor
5.5.2.1 General The sum of the dead and live loads acting on the corrugated metalstructure shall be modified to account for soil arching in recognition of the backfillrelative density and depth of burial (height of cover) as shown in Clauses 5.5.2.2and 5.5.2.3.
5.5.2.2 Modified soil arching factor, k′ The soil arching factor,k, shall be modified asfollows:
(a) ForSs > hmin.—
for h ≤ Ss, . . . 5.5
for h > Ss, k′ = k
for h = hmin., k′ = 1.0
(b) For Ss ≤ hmin.— k′ = k
For vehicle, railway, aircraft or other live loads wherehmin. is not given in this Standardk′ = 1.0.
5.5.2.3 Stockpile influence factor The vertical load at the base of live stockpilesmay be modified using stockpile influence factorks which accounts for stockpile geometryand arching. Where a stockpile influence factor has been determined, Equation 5.6.1(2)shall apply. Where stockpile influence is not known, Equation 5.6.1(2) shall apply withks = 1.0.
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43 AS/NZS 2041:1998
5.6 DESIGN PRESSURE
5.6.1 General The design pressure is assumed to be applied at the crown of thestructure being the result of dead and live loads combined. The design pressure shall becalculated from the following equation:
pv = k′(pd + pl) . . . 5.6.1(1)
or for stockpile loads
pv = ksγshs + k′γbh . . . 5.6.1(2)
where
k′ = modified soil arching factor
pd = dead load. (See Clause 5.4.1)
pl = live load. (See Clause 5.4.2).
ks = stockpile influence factor (Clause 5.5.2.3)
γs = stockpile density
hs = stockpile height
γb = backfill density
h = height of cover
NOTE: hs varies according to the location being considered.
FIGURE 5.4 STOCKPILE COVER HEIGHTS
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AS/NZS 2041:1998 44
5.6.2 Pipe-arch shapes The pipe-arch shape necessitates a special design approach aspipe-arches generate haunch pressures greater than the pressure generated by comparablecircular pipes. This becomes the practical limiting design factor rather than wall stress(see Figure 5.5).
Assuming zero moment strength of the corrugated metal section, ring compression is thesame at any point around the pipe-arch. This means the pressure normal to the pipe-archat any point is inversely proportional to the radius at that point.
The limiting design pressure is governed by the allowable soil pressure at the haunches.
The haunch pressure is calculated as follows:
. . . 5.6.2
For design purposes the maximum haunch pressure values given in Table 5.1 shall beused, unless higher values are determined by testing.
FIGURE 5.5 PRESSURE VARIATION AROUND PIPE-ARCHES
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45 AS/NZS 2041:1998
TABLE 5.1
MAXIMUM DESIGN HAUNCH PRESSURES
Compacted backfill around haunches(see Note 1)
Maximum design haunch pressure, kPa
Select fill (see Clause 6.6.1) 300
Uniform coarse-crushed stone (<40 mm) 600
Cemented sand/gravel (3–6 percent) 900
Flowable fill 50% of specified strength (see Note 2)
NOTES:
1 Height of cover limits presented in Appendices D and E assume select fill in the haunchzone. The extent of alternative haunch materials shall be determined based on the relativestrength of the adjacent soil. Haunch soil pressures and soil shear can also be reduced by
ensuring .
2 See Clause 6.6.2.
5.7 RING COMPRESSION Ring compression (Fr) is the compressive force acting onthe corrugated metal section of the structure at any point around its periphery. It shall becalculated from the following equation:
. . . 5.7
5.8 SEAM STRENGTH Sheet and plate thickness shall be selected from Tables 5.2and 5.3 so that, when the appropriate safety factors are applied, the following equation issatisfied:
. . . 5.8
where
β = 2.0 for railway and highway loading.
For other loading conditionsβ shall be as given here unless otherwise agreed between thepurchaser and the supplier.
Values ofUs for aluminium shall be determined from appropriate testing.
TABLE 5.2
ULTIMATE SEAM STRENGTH OF BOLTEDLONGITUDINAL SEAMS FOR CLASS 1
STEEL STRUCTURES
Thickness
mm
Ultimate seam strength (Us)
Steel kN/m
Lapped seam Flanged seam
1.2 75 85
1.5 — —
1.6 180 115
2.0 280 155
2.5 390 195
3.0 500 240
3.5 610 285
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AS/NZS 2041:1998 46
TABLE 5.3
ULTIMATE SEAM STRENGTH OF BOLTED LONGITUDINAL SEAMS FORCLASS 2 STRUCTURES
Thickness (t)mm
Ultimate seam strength (Us) kN/m
Steel Aluminium
10 Bolts/m 15 Bolts/m 20 Bolts/m 10 Bolts/m 15 Bolts/m 20 Bolts/m
1.5 155 — — — — —
2.0 320 — — — — —
2.5 520 580 640 — — —
3.0 650 900 1 150 320 460 580
4.0 930 1 220 1 660 385 555 715
5.0 1 180 1 560 2 170 450 650 850
6.0 1 430 1 900 2 400 515 745 985
7.0 1 630 2 080 2 600 — — —
8.0 1 800 2 265 3 200 — — —
5.9 ULTIMATE WALL STRESS
5.9.1 Steel Given the minimum yield stress (fy), the ultimate compressive wall stress(fu) of the corrugated steel section (in megapascals) is expressed by Equations 5.9(1),5.9(2) and 5.9(3).
NOTE: Equation 5.9(1) represents the zone where the corrugated section will crush or yield,Equation 5.9(2) represents the interaction zone of yielding and ring buckling, andEquation 5.9(3) represents the ring buckling zone.
For fy = 250 MPa:
. . . 5.9(1)
. . . 5.9(2)
. . . 5.9(3)
5.9.2 Aluminium Given the minimum yield stress (fy), the ultimate compressive wallstress (fu) of the corrugated aluminium section (in megapascals) is expressed byEquations 5.9(4), 5.9(5) and 5.9(6).
NOTE: Equation 5.9(4) represents the zone where the corrugated section will crush or yield,Equation 5.9(5) represents the interaction zone of yielding and ring buckling, andEquation 5.9(6) represents the ring buckling zone.
For fy ≥ 165 MPa:
. . . 5.9(4)
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47 AS/NZS 2041:1998
. . . 5.9(5)
. . . 5.9(6)
5.10 ALLOWABLE WALL STRESS The allowable compressive wall stress (fa) isdetermined by applying a safety factor to the ultimate compressive stress (fu) as follows:
fa = fu/Ω . . . 5.10
wherefu is determined from Clause 5.9
Ω = 2.67 for arches with rise on unyielding foundations
Ω = 2 for all other structures
5.11 WALL THICKNESS
5.11.1 Final thickness The final thickness of the sheet or plate shall be the greaterof—
(a) the structural wall thickness required by Clause 5.11.2 plus any durability thicknessrequired by Clause 5.11.3 and shall be selected from Table 5.4 or 5.5; and
(b) the thickness required for handling and installation as calculated in Clause 5.11.4.
5.11.2 Structural wall thickness The required area (A) shall be calculated from thecalculated ring compression (Fr) and the allowable stress (fa) as follows:
. . . 5.11(1)
The minimum structural wall thickness shall be the higher of the values chosen usingClause 5.8 and Equation 5.11(1).
5.11.3 Durability allowance In certain conditions of installation, corrugated metalstructures may be subjected to corrosion and abrasion. Assessment of expected conditionsin service shall be made to determine what protective measures, if any, need to beapplied. These may include an increase in wall thickness, protective coatings, selection ofsuitable backfill or a combination of these.
NOTE: Information on durability design and protective systems is given in Appendix C.
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AS/NZS 2041:1998 48
TABLE 5.4
SECTIONAL PROPERTIES OF CORRUGATED SHEETSFOR CLASS 1 STRUCTURES*
Thickness (t)
mm
Sectionarea (A)
mm2/mm
Second momentof area (I )
mm4/mm
Sectionmodulus (Z)
mm3/mm
Radius ofgyration (r)
mm
1.2 1.29 25.6 3.67 4.45
1.5 1.62 32.5 4.49 4.47
1.6 1.73 34.8 4.77 4.48
2.0 2.17 44.0 5.87 4.51
2.5 2.71 55.8 7.21 4.54
3.0 3.25 68.2 8.52 4.58
3.5 3.80 81.1 9.83 4.62
* See Figure 4.1
TABLE 5.5
SECTIONAL PROPERTIES OF CORRUGATED PLATESFOR CLASS 2 STRUCTURES*
Thickness(t)
mm
Sectionalarea (A)
mm2/mm
Second momentof area (I )
mm4/mm
Section modulus(Z)
mm3/mm
Radius ofgyration (r)
mm
2.5 2.95 1 130 39.0 19.5
3.0 3.54 1 360 46.8 19.6
4.0 4.73 1 820 61.7 19.6
5.0 5.92 2 290 76.3 19.7
6.0 7.10 2 770 90.7 19.7
7.0 8.29 3 250 104.9 19.8
8.0 9.47 3 710 119.9 19.8
* See Figure 4.5
5.11.4 Handling and installation stiffness
5.11.4.1 General The structure shall have sufficient strength to withstand walldeflection caused by compaction loads imposed during side fill operations. Whereuncertainty exists as to installation conditions, the worst case shall be assumed, and theminimum value ofFf max. given for a profile shall be used.
5.11.4.2 Pipes and ellipses Handling and installation stiffness can be assessed usingthe following equation for flexibility and Table 5.6:
. . . 5.11(2)
NOTE: Applicable Youngs Modulus values are: ESteel = 205 000 MPa,EAluminium = 69 000 MPa
The maximum flexibility (Ff max.) in Table 5.6, for trench and embankment installationconditions, shall not be exceeded unless appropriate structure bracing can be provided orother measures are taken to ensure the structure dimensions are maintained within thetolerances specified in Section 6.
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49 AS/NZS 2041:1998
TABLE 5.6
MAXIMUM FLEXIBILITY ( F f max.) (mm/N)
Structureclass
Steel pipes and ellipses Aluminium pipes and ellipses
Installation type Installation type
TrenchEmbankment and
multiple installationTrench
Embankment andmultiple installation
1 0.34 0.25 0.54 0.39
2 0.115 0.115 0.143 0.143
NOTE: See Clause 6.3 for trench and embankment installations. The type ofinstallation condition assumed should be noted on the drawing.
5.11.4.3 Arches and pipe-archesFor arches, pipe-arches and underpasses:
. . . 5.11(3)
5.12 RIB STIFFENING Where required, structural reinforcement may be providedthrough the addition of ribs to—
(a) increase the effective wall area;
(b) stiffen the corrugated plate to withstand concentrated loads; or
(c) reinforce openings in the corrugated plate.
Design of rib stiffening is outside the scope of this Standard.
5.13 ARCH FOOTING FORCES For the arch structures covered in this Standard, thearch forces exerted on each footing during service is equivalent to the ring compressionFr
calculated from Clause 5.7.
Vertical and horizontal reactions are determined by resolving the ring compressionFr
through the arch re-entrant angleθ (see Figure 5.6(a), 5.6(b) and 5.6(c)).
Fv = Fr Cos θ (kN/m) . . . 5.13(1)
Fh = Fr Sin θ (kN/m) . . . 5.13(2)
The direction of the horizontal forceFh shall be noted for the design of appropriatereinforced concrete footings.
NOTES:
1 Consideration should be given to vertical and horizontal forces during construction.
2 It is undesirable to make the corrugated metal arch stiffer or unyielding compared to theadjacent side fill. The use of massive footings or piles to prevent any settlement of the archis generally not recommended. Providing for some arch settlement helps to induce positivesoil arching and avoids possible drag down due to consolidation of the adjacent side fill.The footing design may vary along the length of the structure to accommodate variations inload.
3 For arches over watercourses, the footings should be protected from scour or undermining.Common practice is to locate them below the scour depth of the watercourse or install cut-off walls or invert pavements.
4 Arch footings and invert pavings are typically separated by a construction joint toaccommodate differential settlement.
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AS/NZS 2041:1998 50
FIGURE 5.6 ARCH FOOTING FORCES
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51 AS/NZS 2041:1998
5.14 END-TREATMENT
5.14.1 General End-treatment design shall consider unbalanced soil loadings due toskewed, bevelled structure ends and skew-cut structure ends, and possible invert uplift orloss of backfill support due to piping or other erosion.
If necessary, the embankment adjacent to and around the ends of the corrugated metalstructures shall be adequately protected by the following:
(a) Batter protection.
(b) End-stiffening ring beams.
(c) Headwalls.
(d) Cut-off walls.
Structures with anSs in excess of 4.5 m shall be anchored at 500 mm maximum centres tothe batter protection material, headwalls, cut-off walls or stiffening ring beams.
Typically, the cut-off walls, batter protection, end-stiffening ring beams and headwalls,where used, are joined into an integral structure.
5.14.2 Batter protection Batter protection shall be designed to protect the end fromadverse hydraulic effects. The design shall consider water velocity at each end of theculvert, duration of critical flows and type of foundation and embankment materials. Theextent of batter protection shall consider eddies and turbulence at the structure inlet andoutlet.
Cut-off walls are typically reinforced concrete with a minimum depth of 600 mmdepending on site conditions.
An adequate means of batter protection includes use of gabions, armour rock, massconcrete, reinforced concrete and similar.
5.14.3 End stiffening ring beams End-stiffening ring beams shall be provided forcorrugated metal structures at the soil structure interface in accordance with Table 5.7 andFigure 5.7 for structures with anSs in excess of 900 mm. Structures over 4500 mm shallbe supported by a ring beam.
Figure 5.7 shows a typical ring beam design for structures which fit within the limitsgiven in Table 5.7.
NOTE: See Appendix A for end-types and skew numbers.
TABLE 5.7
PROVISION OF END-STIFFENING RING BEAM
Skew number
End treatment
Skew indegrees ±
Verticalsquarecut end
Stepped or beveled to embankment slope
1V : 1H 1V : 1.5H 1V : 2HFlatter than
1V : 2H
<55 Skew number not recommended* >35
55–74 Yes Yes Yes Yes Yes 16–35
75–84 No No Yes Yes Yes 6–15
85–95 No No No No Yes 5
96–105 No No Yes Yes Yes 6–15
106–125 Yes Yes Yes Yes Yes 16–35
>125 Skew number not recommended* >35
* Consider realigning embankment (see Figure 5.10).
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AS/NZS 2041:1998 52
5.14.4 Headwalls Multiple installations shall be supported and protected by provisionof headwalls.
For installations with a skew number less than 55 or greater than 125, headwalls may beused to provide resistance to unequal earth loading or embankment modificationconsidered (see Figure 5.8). Specialist advice should be obtained on the design of suchheadwalls.
Headwalls should conform to Figure 5.7.
DIMENSIONS IN MILLIMETRES
FIGURE 5.7 TYPICAL END-STIFFENING RING BEAM FORCORRUGATED METAL STRUCTURES
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53 AS/NZS 2041:1998
FIGURE 5.8 EMBANKMENT MODIFICATION FOR SKEWED STRUCTURES
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AS/NZS 2041:1998 54
S E C T I O N 6 I N S T A L L A T I O N
6.1 GENERAL The adequacy of the foundation, native embankment and locallyavailable backfill material shall be investigated at each site. Regular monitoring ofstructure shape and backfill density during construction are important requirements forensuring a satisfactory installation.
6.2 ASSEMBLY
6.2.1 General The assembly of corrugated metal structures shall be carried out inaccordance with the drawings supplied by and the recommendations of the manufacturer.Where assembled structures are to be lifted, specialist advice should be sought.
6.2.2 Assembly instructions The manufacturer shall supply instructions and a diagramfor the field assembly of the corrugated sheets and plates into designated structure shapes.
6.2.3 Bolt torque All bolts in bolted structures shall be tightened along all longitudinaland circumferential seams prior to backfilling to ensure the lapped corrugations areclosely nested. Bolt torque shall fall within the range given in Table 6.1.
To ensure the specified bolt torque is uniformly achieved, 1 percent of bolts in thelongitudinal seams shall be selected randomly along the structure prior to backfillplacement, and shall be tested to confirm conformance with the values in Table 6.1.Should any tested value fall outside the specified torque range, 5 percent of bolts in bothcircumferential and longitudinal seams shall then be tested. The installation shall then beconsidered acceptable if the above torque requirements are satisfied in at least 90 percentof the bolts tested. Otherwise the design shall be checked to determine whether the bolttorque values achieved are acceptable.
TABLE 6.1
BOLT TORQUE
Structure classPlate thickness
(mm)
Torque range (Nm)
Steel Aluminium
1 (Bolted) 1.2–3.5 20 ±5 10 ±2
2 2.5–5 310 ±40 170 ±15
2 6–8 395 ±25 170 ±15
NOTES:
1 Bolt torque values at the lower end of the range given in Table 6.1 arepreferable to higher values so that the corrugations of lapping plates areclosely nested and aligned and not damaged by excessive bolt tightening.
2 Bolts and nuts used in Class 1 flanged-type structures and to connect archstructures to base channels shall be hand-tightened only.
3 Information on inspection of bolt tightness is provided in AS 4100.
6.2.4 Assembled structure tolerances
6.2.4.1 Structure length The actual structure length shall differ from the specifiedstructure length by no more than 1 percent.
NOTE: Structure length variations arise due to both manufacturing tolerances and erectionprocedures. In most cases, the assembled structure is longer than the design length.
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55 AS/NZS 2041:1998
6.2.4.2 Structure cross-sectional shapeThe actual internal span and rise dimensions ofthe assembled structure after bolt torqueing and prior to backfilling shall not differ fromthe values given in Section 2 or those specified for other non-referenced shapes by morethan ±2 percent.
6.3 METHOD OF INSTALLATION
6.3.1 General Structures shall be installed in either trench or embankment conditionsas specified by the designer in accordance with Clauses 6.3.2 and 6.3.3 respectively.Embankment condition is assumed unless it can be shown that the material intended tosurround the select fill (native soil, embankment material or trench walls) has strength andstiffness not less than the select fill specified in Clause 6.6.
6.3.2 Installation in trench condition Where a structure is to be installed in a trenchcondition, the trench width on each side of the structure shall be a minimum of—
(a) 600 mm, where select fill is to be used; and
(b) 150 mm, where flowable fill is to be used.
6.3.3 Installation in embankment condition Where a structure is to be installed inembankment condition, the select fill shall extend to a minimum distance equal to thespan of structure on each side (see Figure 6.1). This distance may be reduced wheregeotechnical advice establishes that the adjacent material has sufficient strength and isnon-corrosive.
6.4 MINIMUM SPACING FOR MULTIPLE INSTALLATIONS Spacing shall besufficient to ensure that adequate backfill support is provided to the structures and the fillabove. The minimum spacings for multiple installations with mechanically compacted fillsand flowable fills is given in Table 6.2.
TABLE 6.2
MINIMUM SPACING FOR MULTIPLESTRUCTURES
Span Ss
(mm)
Backfill type
Select fill Flowable fill
Ss ≤900 300 150
900 <Ss ≤3 000 Ss/3 150
3 000 <Ss ≤5 000 Ss/4 200
Ss >5 000 Ss/5 300
NOTE: The limits in the above table should be modified asnecessary to account for variables such as alternative constructionpractices, i.e., structure pre-assembly or poor in-situ soils.
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AS/NZS 2041:1998 56
NOTE: Trench and embankment fill should be in accordance with requirements specified in other documentsrelated to the project. In the absence of a specification, compaction should be to the same standard as for theselect fill.
FIGURE 6.1 FILL AND STRUCTURE SUPPORT ZONES
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57 AS/NZS 2041:1998
6.5 FOUNDATION AND BEDDING
6.5.1 Pipes, pipe-arches and special shapes
6.5.1.1 Foundation The structure foundation shall be sufficiently strong, stable anduniform to support the full length of the installation, but shall not be stiffer than theundisturbed material supporting the fill on each side of the structure.
NOTE: For buried flexible structures it is desirable to achieve columns of side fill that are lesscompressible than the structure so that positive soil arching can occur. It is undesirable to makethe pipe stiffer or more unyielding than the adjacent side fill. The use of massive footings orpiles to prevent any settlement of the pipe is generally not recommended. Providing for somestructure settlement helps to induce positive soil arching and avoids possible drag down due toconsolidation of the adjacent side fill. The foundation design may vary along the length of thestructure to accommodate variations in load.
Where the natural foundation is assessed as suitable it shall be prepared to a level 75 mmbelow the design structure invert level over a minimum width of half the structure span.
NOTE: Foundation shaping to conform to the structure invert curvature may allow moreefficient and effective compaction of backfill in the haunch zones.
Rock foundation shall be excavated to a depth 250 mm or structure span/4, whichever isthe lesser, and replaced with compacted select material to a level 75 mm below the designstructure invert level. The minimum width of this zone of select material shall be equal tothe structure span, and sufficient to ensure no part of the structure bears directly on rockso that uniform support is provided (see Figure 6.2(b)).
Soft or unstable foundation material (such as highly plastic clays or silts) shall beremoved and replaced with suitable compacted material to provide adequate support.Where considered necessary, appropriate geotechnical advice shall be obtained. (SeeFigure 6.2(a).)
DIMENSIONS IN MILLIMETRES
FIGURE 6.2 BEDDING ON SOFT, ROCK AND FIRM FOUNDATIONS
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AS/NZS 2041:1998 58
6.5.1.2 Camber Where settlement of the foundation is expected, longitudinal camber ofthe foundation shall be considered with due regard to hydraulic flow requirements and theintegrity of the structure.
6.5.1.3 Bedding A uniform 75 mm deep layer of uncompacted coarse granular beddingmaterial shall be placed over the foundation and prepared to the correct line and level toallow the corrugations of the structure invert to bed in. Bedding material shall be coarsesand or gravel with 12 mm maximum particle size and shall be placed to a minimumwidth of one third of the structure span. Bedding shall not be placed in the haunch zonesof pipe arch and special shape structures.
Precautions shall be taken to prevent erosion of bedding material by the use of cut-offwalls or similar at the ends of hydraulic structures.
6.5.2 Arches
6.5.2.1 Foundation The foundation for arches shall be assessed to determine thatsufficient bearing capacity is available to withstand arch footing forces as determined byClause 5.14.
6.5.2.2 Footings Footings shall be installed in accordance with the informationsupplied by the designer. Provision shall be made to ensure footings are not underminedby stream flows. (See Clause 5.13, Note 3.)
6.6 BACKFILLING
6.6.1 General The backfilling procedures given in Clauses 6.6.2 to 6.6.4 shall beimplemented so as to achieve the desired structure shape required in Clause 6.8. The finalshape tolerances of the metal structure as specified in Clause 6.8 shall be achieved at thecompletion of backfilling and compaction without causing excessive distortion or stressduring the process (see also Clause 6.7).
6.6.2 Select fill Select fill shall comply with the grading requirements given inTable 6.3, and have a maximum linear shrinkage, determined in accordance withAS 1289.3.4.1, of 8 percent.
In trench installations, and situations where a free draining fill is required, single sizedgranular material may be satisfactory.
Select fill which does not fall within the grading limits of Table 6.3 is not precluded,provided it has a consistency and moisture content suitable for placement (withoutsegregation) and compaction to achieve the specified density.
TABLE 6.3
SELECT FILL GRADINGREQUIREMENTS
Sieve aperturemm
Mass of sample passing*percent
75.0 100
9.5 50–100
2.36 30–100
0.60 15–50
0.075 0–25
* Determined in accordance with AS 1289.3.6.1.
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59 AS/NZS 2041:1998
6.6.3 Modified fill Flowable and cement modified backfill of the appropriate strengthmay be used in place of select fill.
Flowable fill shall have a strength of 0.6 to 3 MPa (at 28 days) and a modulus of 25to 100 MPa.
Testing shall be in accordance with the relevant parts of AS 1012.
NOTE: Guidance on flowable fill is given in Appendix H.
6.6.4 Placement
6.6.4.1 General Unless otherwise specified by the designer, compaction values forselect fill shall be measured by one of the following parameters, as applicable:
(a) Cohesive soils Each layer of select fill shall be compacted to not less than90 percent of the dry density ratio for standard compaction. The dry density ratio(RD) shall be determined in accordance with AS 1289.5.4.1, based on the field drydensity in accordance with AS 1289.5.3.2, AS 1289.5.8.1 and the maximum drydensity in accordance with AS 1289.5.1.1/NZS 4402.4.1.1.
(b) Cohesionless soilsEach layer of select fill shall be compacted to not less than70 percent of the maximum density index for standard compaction. The densityindex (ID) shall be determined in accordance with AS 1289.5.6.1, based on themaximum and minimum dry densities in accordance with AS 1289.5.5.1/NZS 4402.4.2.1 and NZS 4402.4.2.2 and the field dry density in accordance withAS 1289.5.3.1/NZS 4402.5.1.1, AS 1289.5.3.2, AS 1289.5.3.5/NZS 4402.5.1.5 orAS 1289.5.8.1.
Compaction equipment or methods that produce horizontal or vertical earth pressureswhich cause damage or excessive distortion shall not be used (see Clauses 6.6.1 and 6.8).
FIGURE 6.3 COMMON FAILURES IN BACKFILLING
6.6.4.2 Placement method and extentThe select fill material shall be placed inhorizontal, uniform layers not exceeding 300 mm in thickness before compaction. Fillshall be placed in even layers on both sides of the structure with the difference betweenthe select fill height on each side not exceeding 300 mm.
The select fill shall be placed in accordance with the limits specified in Clause 6.3.2 orClause 6.3.3, as appropriate. The select fill shall extend to a minimum of cover heightabove the structure as specified in Clause 5.3 (see Figure 6.1).
Select fill shall commence and progress as follows:
(a) From each end and progress to the structure centre for a structure with restrainingheadwalls (see Figure 6.4).
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AS/NZS 2041:1998 60
(b) From the centre and progress to each structure end for a structure withoutrestraining headwalls (see Figure 6.5).
(c) The arch crown shall then be temporarily restrained against peaking by eithertemporary top loading or anchoring. Select fill material shall continue over the archin uniform, compacted curved layers (see Figure 6.6).
NOTE: Trench and embankment fill should be in accordance with requirements specified inother documents related to the project. In the absence of a specification, compaction should beto the same standard as for the select fill.
FIGURE 6.4 BACKFILLING STRUCTURES WITH RESTRAINING HEADWALLS
FIGURE 6.5 BACKFILLING STRUCTURES WITHOUT RESTRAINING HEADWALL
FIGURE 6.6 BACKFILLING PROCEDURE FOR ARCHES
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6.7 MINIMUM COVER FOR ABNORMAL LOADS Where abnormal live loadssuch as heavy construction equipment are required to travel over the structure, thestructure shall be checked for this loading condition. Where an overload condition occurs,the amount of temporary additional cover required to permit passage of the equipmentover the structure shall be calculated in accordance with the requirements of Section 5.Alternatively, appropriate bracing may be used.
6.8 STRUCTURE SHAPE On completion of the installation, the final structure shapeshall not differ from the assembled shape by more than ±2 percent, unless it is within±2 percent of the specified shape.
For arches with a span greater than 6000 mm, the final shape shall not differ from thespecified shape by more than ±2 percent.
NOTES:
1 The flexibility limits in Clause 5.12 and the specified installation procedures in Clauses 6.3,6.4, 6.5 and 6.6 are intended to assist in maintaining acceptable structure shape duringinstallation. Abnormal conditions or loadings should be prevented from causing variation inspan or rise by more than 5 percent of the specified dimensions or from causing localdistortion of the structure wall.
2 Where internal clearances are critical, adequate allowance should be made for cumulativemanufacturing and installation tolerances and seam bolts on internal corrugation crests.
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AS/NZS 2041:1998 62
APPENDIX A
ORDERING GUIDELINES
(Informative)
A1 GENERAL This Appendix contains a brief check list of some of the moreimportant information that should be supplied by the purchaser at the time of order and bythe manufacturer after the order has been placed.
It aims to avoid misunderstanding and to result in the purchaser receiving satisfactoryproducts and service.
A2 INFORMATION TO BE SUPPLIED TO THE MANUFACTURER Thefollowing minimum information should be provided:
(a) Shape and class of structure.
(b) Cross-sectional dimensions.
(c) Thickness of sheets or plates and number of seam bolts per metre.
(d) Invert length and grade.
(e) Installation type (trench or embankment)
(f) Height of cover and unit weight of fill
(g) End type (see Figures A1 and A2).
(h) Type of live load applicable.
(i) Skew number. Where skew is required, details should be submitted by the purchaserin diagrammatic form in accordance with Figure A3, including an arrow todesignate the direction of flow, if applicable.
(j) Special requirements such as invert paving and protective coating.
A3 INFORMATION TO BE SUPPLIED BY THE MANUFACTURER Themanufacturer should supply the following information:
(a) Details of plate layout if applicable.
(b) Instructions for field assembly.
FIGURE A1 EXAMPLES OF END TYPES AND SKEW
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FIGURE A2 METHOD OF SPECIFYING END TYPE
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AS/NZS 2041:1998 64
FIGURE A3 METHOD OF SPECIFYING SKEW NUMBER
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65 AS/NZS 2041:1998
APPENDIX B
MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD
(Informative)
B1 SCOPE This Appendix sets out the following different means by which compliancewith this Standard can be demonstrated by the manufacturer or supplier:
(a) Evaluation by means of statistical sampling.
(b) The use of a product certification scheme.
(c) Assurance using the acceptability of the supplier’s quality system.
(d) Other such means proposed by the manufacturer or supplier and acceptable to thecustomer.
B2 STATISTICAL SAMPLING Statistical sampling is a procedure which enablesdecisions to be made about the quality of batches of items after inspecting or testing onlya portion of those items. This procedure will only be valid if the sampling plan has beendetermined on a statistical basis and the following requirements are met:
(a) The sample shall be drawn randomly from a population of product of knownhistory. The history shall enable verification that the product was made from knownmaterials at essentially the same time, by essentially the same processes and underessentially the same system of control.
(b) For each different situation, a suitable sampling plan needs to be defined. Asampling plan for one manufacturer of given capability and product throughput maynot be relevant to another manufacturer producing the same items.
In order for statistical sampling to be meaningful to the customer, the manufacturer orsupplier needs to demonstrate how the above conditions have been satisfied. Sampling andthe establishment of a sampling plan should be carried out in accordance with AS 1199,guidance to which is given in AS 1399.
B3 PRODUCT CERTIFICATION The purpose of product certification is to provideindependent assurance of the claim by the manufacturer that products comply with thestated Standard.
The certification scheme should meet the criteria described in SAA HB18.28(SANZ HB18.28) in that, as well as full type testing from independently sampledproduction and subsequent verification of conformance, it requires the manufacturer tomaintain effective quality planning to control production.
The certification scheme serves to indicate that the products consistently conform to therequirements of the Standard.
B4 SUPPLIER’S QUALITY SYSTEM Where the manufacturer or supplier candemonstrate an audited and registered quality management system complying with therequirements of the appropriate or stipulated Australian or international Standard for asupplier’s quality system or systems, this may provide the necessary confidence that thespecified requirements will be met. The quality assurance requirements need to be agreedbetween the customer and supplier and should include a quality or inspection and test planto ensure product conformity.
Guidance in determining the appropriate quality management system is given inAS/NZS ISO 9000.1 and AS/NZS ISO 9004.1.
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AS/NZS 2041:1998 66
B5 OTHER MEANS OF ASSESSMENT If the above methods are consideredinappropriate, determination of compliance with the requirements of this Standard may beassessed from the results of testing coupled with the manufacturer’s guarantee of productconformance.
Irrespective of acceptable quality levels (AQLs) or test frequencies, the responsibilityremains with the manufacturer or supplier to supply products that conform with the fullrequirements of the Standard.
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APPENDIX C
DURABILITY DESIGN AND PROTECTIVE SYSTEMS
(Informative)
C1 GENERAL Based on long term, detailed and critical investigation of an estimated50 000 buried corrugated metal structure installations in a number of countries, durabilitydesign can be performed for a wide range of soil and water conditions.
Investigations in Australia, notably Victoria (CRB 1972 (now VicRoads)) and Queensland(MRD 1974/80/87 (now Qld DMR)) document the following effects which are supportedby overseas experience:
(a) Soil-side corrosion rate of 10 to 30 µm per year for steel expected if the protectivezinc coating is expended.
(b) Little or no corrosion occurs on the interior surface of the structure above the levelto which water regularly rises.
(b) The invert of the structure below the usual waterline may, under certain conditions,be subjected to abrasion and corrosion.
Confirmation that the site is not highly corrosive or abrasive by examination of similarstructures nearby, the use of non-corrosive relatively free draining backfills, and moderateculvert grades normally ensures that the structure wall thickness, required to satisfy thestructural requirements of this Standard, will provide service life in excess of 50 years.The durability of buried corrugated metal structures can be extended by increasing wallthickness or by the addition of protective coatings or pavings.
Corrosion of buried corrugated metal structures has been found to be most stronglyinfluenced by the acidity, alkalinity, and conductivity or resistivity of the soil and waterthat is normally in contact with the structure. Soil moisture content or flow and theconcentration of soluble salts can also influence metal loss rates.
Measurement of soil and water pH and resistivity is quite straightforward. The possiblepresence of soluble salts is generally detected by low resistivity measurements. Backfillsthat satisfy the grading requirements of Clause 6.7.1 of this Standard in most cases aresufficiently free draining to maintain moisture content below 20 percent. For submergedinstallations a coarse uniformly graded backfill is preferable. Soft water corrosiongenerally does not occur where the Langelier (or saturation) index is positive and greaterthan 0.5. Langelier’s index is not relevant for determining the corrosion effect onAluminium Structures.
Alternative fills and barrier coatings may be considered in an effort to increase theexpected life. Appropriate protective coatings can extend the service life by 10-15 years.Information on coating systems is available in AS/NZS 2312. Determination of the fill pHshould be in accordance with AS 1289.4.3.1 and the Electrical resistivity should be inaccordance with AS 1289.4.4.1.
C2 SERVICE LIFE ASSESSMENT
C2.1 Recommended pH and resistivity of backfill When the pH and resistivity arewell within the limits of the ranges given in Table C1, the service life of the structuremay be estimated as follows:
(a) For steel 10–15 years for galvanized coating life, then an average metal loss rate of10–30 µm per year.
(b) For aluminium structures average metal loss rates will be negligible.
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TABLE C1
RECOMMENDED RANGES FOR pH AND RESISTIVITY OF SOILAND WATER IN CONTACT WITH CORRUGATED
METAL STRUCTURES
Resistivity (ohm, cm)
Acceptable pH range
Galvanized steel Aluminised steel AluminiumSteel or aluminiumwith barrier coating
10 000 or more 5–12 5–9 4–9 4–12
2 000–10 000 6–10 5–9 4–9 4–12
500–2 000 — — 4–9 4–12
NOTES:
1 Measurements of soluble salts should be taken where site conditions approach the limits given above.Acceptable concentrations of soluble salts in the backfill are normally chlorides less than 200 mg/kgand sulphates less than 1000 mg/kg.
2 Refer to manufacturers for barrier coatings appropriate to the pH being considered.
3 For aluminium in contact with soils and water exhibiting properties within the limits given in Table C3,the metal loss rate becomes almost negligible after 2–5 years due to blockage of corrosion pits withinsoluble corrosion products. For soils and waters with pH outside the 4–9 range or with highconcentrations of soluble salts, a protective barrier coating is required to prevent accelerated corrosion.Studies done for the Florida Department of Transport show structures in a salt water environment havelower loss rates.
4 In mining areas, concentrations of some metals in solution can increase corrosion of aluminium.
5 Cement modified soils typically exhibit pH≥9 and resistivity values below 1000 ohm-cm, in poorlydrained conditions, and above 2000 ohm-cm in drained conditions. However, this varies significantlywith soil type.
C2.2 Aggressive backfill conditions When the pH and resistivity are near the limitsgiven in Table C1, the backfill may be aggressive and the sulphate and chlorideconcentrations should be checked. If the chlorides exceed 200 mg/kg or the sulphatesexceed 100 mg/kg, or both, use the loss rates given in Tables C2 and C3. The life of thecoating should be determined before determining the base metal loss.
When a coating other than zinc is used, specialist advice should be obtained to determinethe coating loss rate.
When pH and resistivity are outside the ranges given in Table C1 the metal structures inthis Standard are not recommended and an alternative backfill should be sought.
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TABLE C2
ZINC COATING LOSS RATE VERSUS SOIL pH OR RESISTIVITY
Soil pHAverage zinc coating loss rate (µm/yr)
Drained soils Undrained soils
<4 >6.5 >20
4–4.9 2.6–5.2 6.7–13.3
5–7.9 2.2–4.3 5.5–11.0
8–9 3.3–6.5 6.1–12.1
>9 >8.6 >17.2
Soil resistivity (Ohm, cm) All soils
<500 >3.5
500–1000 1.5–3.5
1000–2000 1.3–1.5
2000–5000 0.9–1.5
>5000 <0.9
NOTES:
1 For Class 1 and Class 2 structures which have been hot-dip galvanised a coating thicknessof —
(a) 63 µm (per side) is applicable for wall thicknesses less than 5 mm; and
(b) 84 µm (per side) is applicable for wall thicknesses equal to or greater than 5 mm.
For Class 1 structures with Z600 coating, a coating thickness of 49 µm is applicable.
2 For aluminized Type II coating, a coating thickness of 48 µm is applicable.
3 Non-metallic barrier coatings are recommended in coastal installations where extended life isrequired.
4 In fully submerged conditions, metal loss rates of 1 µm per year can be expected.
5 In splash zones, metal loss rates may exceed those given for severe coastal conditions.
TABLE C3
AVERAGE METAL LOSS RATES IN VARIOUS SOILS
pHChloride concentration Resistivity
ohm cmAverage metal loss rates (µm/year)
In soil (%) In water (ppm) Undrained soils Drained soils
Steel Steel
>5 <0.5 >1 000 >5 000 <10 <10
4–5 0.5–2 1 000–10 000 2 000–5 000 10–20 <10
3–4 2–5 10 000–20 000 1 000–2 000 20–40 10–20
<3 >5 >20 000 <1 000 40–300 10–40
Aluminium Note 1 Aluminium Note 1
4–9 1.0–1.5 <20 000 >500 5–13 5–7
NOTES:
1 For aluminium in contact with soils and water exhibiting properties within the limits given in Table C3,the metal loss rate becomes almost negligible after 2–5 years due to blockage of corrosion pits withinsoluble corrosion products. For soils and waters with pH outside the 4–9 range or with highconcentrations of soluble salts, a protective barrier coating is required to prevent accelerated corrosion.Studies done for the Florida Department of Transport show aluminium structures in a salt waterenvironment have lower loss rates.
2 For steel in high pH soils with high sulphate or chloride concentrations, average metal loss rates of20–60 µ/yr can be expected.
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AS/NZS 2041:1998 70
C2.3 Atmospheric corrosion for exposed surfaces Corrosion due to atmosphericexposure away from coastal areas is generally not a major determinant of service life forburied corrugated metal structures. However, in some cases, aesthetics are of concern intunnel and underpass structures and paint or similar coatings may be required. Averagemetal loss rates due to exposure to various environments are provided in Table F4.
AS/NZS 2312 gives guidance on the protection of iron and steel against exterioratmospheric corrosion. The recommendations given in AS/NZS 2312 are based on theatmospheric environments summarized in Table C4.
For aluminium, the loss rates are negligible.
TABLE C4
CORROSIVITY CLASSIFICATIONS
Atmosphericclassification
Mild Steelcorrosion rate
µm/year
General nature of environment(See AS/NZS 2312)
Mild 10 All areas remote from coast, industrial activity and thetropics. Sheltered, inland areas of New Zealand
Moderate 10–25 Includes areas with light industrial pollution or very lightmarine influence and sheltered suburbs of coastalcentres. Most of New Zealand is in this zone
Tropical see AS/NZS 2312 Coastal tropics except where affected by salt spray. Thisenvironment is aggressive to organic coatings
Marine 25–50 From within 1 km to within 10 km from coast dependingon winds, topography, etc.
Industrial 25 to > 50 Areas around major industrial complexes. Geothermalareas
Severe Marine 50–190 From within 100 m to within 1 km from coast dependingon winds, topography, etc.
C3 PERFORATION OF METAL When perforation occurs, it is recommended thatthe structure be lined in accordance with Paragraph C4 to reduce further deterioration.
Long term field studies confirm that a structure may sustain loading for some time afterinitial perforation. However, because the structural integrity relies on the compactedcondition of the surrounding soil, erosion due to seepage of ground water or other waterthat flows through such perforations should be controlled.
C4 INVERT CONCRETE LINING
C4.1 Abrasion assessment Abrasion of the invert can occur where abrasive materialsare transported by high velocity flows. In stormwater applications, low flow velocities andmodest pipe grades usually result in negligible invert wear.
For culvert design, Figure C1 can be used to determine the need for lining the invert withconcrete given pipe grade, mean stream velocity and type of abrasive load (e.g. fine sand,sharp gravel).
High flow velocities (e.g. more than 5 m/s) and steep pipe grades (e.g. more than 1:20)may not constitute abrasive conditions where abrasive bed-loads are not present upstream.The duration or frequency of peak and main flow velocities associated with stormduration and seasonal variations may also effect design. Abrasive conditions may onlyapply over a quite small proportion of the total design life.
Drainage structures can be provided with heavy gauge invert panels to resist mild abrasiveconditions. In moderate to severe abrasive conditions, adequate protection can be providedby invert paving in accordance with Figure C1.
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Invert concrete lining should preferably proceed after the full embankment height over theculvert has been constructed and initial pipe flexure ceases. For pipes larger than1200 mm in diameter, where asset maintenance inspection standards are in place, it maybe cost-effective to delay invert paving to determine whether it is necessary based onculvert performance.
In multiple cell culvert installations, good practice is to locate one cell at a lower invertlevel to isolate normal stream flow and abrasion and limit the need for invert paving to asingle cell.
C4.2 Ponding Severe localized corrosion can occur when the structure is exposed to aconstant water level for extended periods. It is recommended that a concrete lining beused and that the constant water level should be kept below the top of the lining.
C4.3 Trickle flows Where flow is continuous and low in volume, the continuousponding in corrugations can result in extreme localized corrosion. Invert lining may benecessary in such cases.
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AS/NZS 2041:1998 72
DIMENSIONS IN MILLIMETRES
FIGURE C1 INVERT LINING ARRANGEMENT FOR CORRUGATED METALSTRUCTURES
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APPENDIX D
AS 2041 STRUCTURAL DESIGN FLOW CHART
(Informative)
FIGURE D1 FLOW CHART
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AS/NZS 2041:1998 74
APPENDIX E
REFERENCE TABLES FOR MINIMUM COVER FOR STEELSTRUCTURES
(Informative)
The information and recommendations contained in these Tables are intended fordesigners’ convenience in routine applications complying with this Standard.
In the preparation of the Tables in this Appendix, the following values were adopted:
fy = 250 MPa
k = 1 for height of cover less than span
k = 0.75 for height of cover equal to or greater than span
β = 2
γ = 20.0 kN/m3
The allowance for pavement (road) is 300 mm at 22 kN/m3. Impact factors used are thosegiven in the relevant references given in Clause 5.4.2.2.
NOTE: These tables are relevant to the design thickness and any losses due to corrosion are notcovered.
LIST OF TABLES
E1.1 Cover limits for Class 1 steel pipes with lapped seam—highway and railwaylive load
E1.2 Cover limits for Class 1 steel pipes with flanged seam—highway and railwaylive load
E1.3 Cover limits for Class 1 steel pipe-arches with lapped seam—highway and railwaylive load
E1.4 Cover limits for Class 1 steel pipe-arches with flanged seam—highway and railwaylive load
E1.5 Cover limits for Class 1 steel pipe-arches with flanged seam—highway live loadE1.6 Cover limits for Class 1 steel pipe-arches with flanged seam—railway live loadE2.1 Cover limits for Class 2 steel pipes—highway and railway live loadE2.2 Cover limits for Class 2 steel pipe-arches and underpasses—highway live loadE2.3 Cover limits for Class 2 steel pipe-arches and underpasses—railway live loadE2.4 Cover limits for Class 2 steel arches (rise less than radius)—highway and railway
live loadE2.5 Cover limits for Class 2 steel horseshoe arches—highway and railway live loadE2.6 Cover limits for Class 2 steel horizontal ellipses—highway and railway live loadE2.7 Cover limits for Class 2 steel vertical ellipses—highway and railway live load
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TABLE E1.1
COVER LIMITS FOR CLASS 1 STEEL PIPES WITH LAPPED SEAM—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10
Pipediameter
Minimum cover, m
Maximum cover, mHighway loads
Railwayloads
Plate thickness, mm
1.2 1.6–3.5 1.2–3.5 1.2 1.6 2.0 2.5 3.0 3.5
300 0.60 0.60 1.00 16.4 40.0 62.2 86.7 111.1 135.6
450 0.60 0.60 1.00 10.6 26.6 41.4 57.8 74.1 90.4
600 0.60 0.60 1.00 7.9h 19.8 31.0 43.3 55.5 67.8
750 0.65 0.60 1.00 6.2h 15.7 24.8 34.6 44.4 54.2
900 0.73 0.60 1.00 5.0h 13.0 20.6 28.8 37.0 45.1
1 050 0.82 0.60 1.00 4.1h 11.0 17.6 24.6 31.7 38.7
1 200 * 0.60 1.00 † 9.4 15.3 21.5 27.7 33.8
1 350 * 0.60 1.00 † † 13.5 19.1 24.6 30.0
1 500 * 0.60 1.00 † † 12.1 17.1 22.1 27.0
1 650 * 0.60 1.00 † † * 15.5 20.0 24.5
1 800 † 0.60 1.00 † † * * 18.3 22.5
1 950 † 0.60 1.00 † † * * * 20.7
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN highway loads andfor Australian 300-A-14, M250, M270 railway loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge.
4 ‘h’ denotes solution for highway load only.
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TABLE E1.2
COVER LIMITS FOR CLASS 1 STEEL PIPES WITH FLANGED SEAM—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13
Pipediameter
Minimum cover, mHighway loads
Min.cover
railwayloads, m
Maximum cover, m
Plate thickness, mm
1.2 1.6 2.0 2.5 3.0, 3.5 1.2–3.5 1.2 1.6 2.0 2.5 3.0 3.5
300 0.60 0.60 0.60 0.60 0.60 1.00 18.7 25.4 34.4 43.3 53.3 63.3
450 0.60 0.60 0.60 0.60 0.60 1.00 12.2 16.8 22.8 28.8 35.5 42.2
600 0.60 0.60 0.60 0.60 0.60 1.00 8.8 12.4 17.0 21.5 26.6 31.6
750 0.62 0.60 0.60 0.60 0.60 1.00 7.1h 9.7 13.4 17.1 21.2 25.2
900 0.68 0.60 0.60 0.60 0.60 1.00 5.8h 8.1h 11.0 14.1 17.6 21.0
1 050 0.76 0.63 0.60 0.60 0.60 1.00 4.8h 6.8h 9.3 12.0 15.0 17.9
1 200 * 0.69 0.60 0.60 0.60 1.00 † 5.9h 8.2h 10.3 13.0 15.6
1 350 * * 0.62 0.60 0.60 1.00 † † 7.2h 9.0 11.4 13.8
1 500 * * 0.66 0.60 0.60 1.00 † † 6.4h 8.3h 10.2 12.3
1 650 * * * 0.61 0.60 1.00 † † † 7.5h 9.1 11.1
1 800 * * * * 0.60 1.00 † † † † 8.5h 10.0
1 950 † * * * 0.60 1.00 † † † † † 9.1
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN highway loads and for Australian 300-A-14, M250, M270 railway loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge.
4 ‘h’ denotes solution for highway load only.
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TABLE E1.3
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH LAPPED SEAM—HIGHWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Maximuminternal
span
Internalrise
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Haunch bearing capacity (kPa)
300 600 to 1000 600 900 to 1000 600 900 1000
Plate thickness, mm
mm mm 1.2 to 3.5 1.2 1.6 1.6 2.0 to 3.5 2.0 to 3.5 2.0 to 3.5
450 340 0.60 8.5 0.60 10.8 0.60 17.6 0.60 26.6 0.60 17.6 0.60 26.6 0.60 29.5
600 430 0.60 6.2 0.60 7.9 0.60 13.1 0.60 19.8 0.60 13.1 0.60 19.8 0.60 22.1
750 510 0.71 4.7 0.65 6.2 0.60 10.4 0.60 15.8 0.60 10.4 0.60 15.8 0.60 17.6
900 600 0.82 3.7 0.73 5.0 0.60 8.5 0.60 13.1 0.60 8.5 0.60 13.1 0.60 14.6
1 050 680 0.94 2.9 0.82 4.1 0.62 7.2 0.60 11.1 0.62 7.2 0.60 11.1 0.60 12.4
1 200 770 1.08 2.3 0.92 3.4 0.67 6.2 0.60 9.7 0.67 6.2 0.60 9.7 0.60 10.8
1 350 860 1.25 1.8 1.03 2.8 0.73 5.4 0.60 8.5 0.73 5.4 0.60 8.5 0.60 9.5
1 500 940 † † * * 0.79 4.7 0.60 7.6 0.79 4.7 0.60 7.6 0.60 8.5
1 650 1 030 † † * * * * * * 0.86 4.2 0.64 6.8 0.60 7.7
1 800 1 110 † † † † * * * * 0.93 3.7 0.68 6.2 0.63 7.0
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
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TABLE E1.4
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH LAPPED SEAM—RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Maximuminternal
span
Internalrise
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Minimumcover
Maximumcover
Haunch bearing capacity (kPa)
300 600 to 1000 600 900 to 1000 900 1000
Plate thickness, mm
mm mm 1.2 to 3.5 1.2 1.6 to 3.5 1.6 2.0 to 3.5 2.0 to 3.5
450 340 1.0 8.4 1.00 10.8 1.00 17.6 1.00 26.6 1.00 26.6 1.00 29.6
600 430 † † 1.00 7.8 1.00 13.1 1.00 19.9 1.00 19.9 1.00 22.1
750 510 † † † † 1.00 10.3 1.00 15.8 1.00 15.8 1.00 17.6
900 600 † † † † 1.00 8.4 1.00 13.1 1.00 13.1 1.00 14.6
1 050 680 † † † † 1.00 7.0 1.00 11.1 1.00 11.1 1.00 12.4
1 200 770 † † † † † † 1.00 9.6 1.00 9.6 1.00 10.8
1 350 860 † † † † † † 1.00 8.4 1.00 8.4 1.00 9.5
1 500 940 † † † † † † 1.00 7.3 1.00 7.3 1.00 8.4
1 650 1 030 † † † † † † * * 1.00 6.6 1.00 7.5
1 800 1 110 † † † † † † † † † † 1.00 6.8
NOTES:
1 This Table can be used for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
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TABLE E1.5
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH FLANGED SEAM—HIGHWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Max.internal
span
Internalrise
Min.cover
Max.cover
Min.cover
Max.cover
Min. coverMax.cover
Min. coverMax.cover
Min. coverMax.cover
Min.cover
Max.cover
Min.cover
Max.cover
Min. cover Max. cover
Haunch bearing capacity (kPa)
300 600 to 1000 600 to 1000 600 900 to 1000 900 1000 1000
Plate thickness, mm
mm mm 1.2 to 3.5 1.2 1.6 2.0 to 3.5 2.0 2.5 to 3.5 2.5 3.0 to 3.5
450 340 0.60 8.5 0.60 12.3 0.60 16.9 0.60 17.6 0.60 22.8 0.60 26.6 0.60 28.8 0.60 29.5
600 430 0.60 6.2 0.60 9.1 0.60 12.5 0.60 13.1 0.60 17.0 0.60 19.8 0.60 21.5 0.60 22.1
750 510 0.71 4.7 0.62 7.1 0.60 9.9 0.60 10.4 0.60 13.5 0.60 15.8 0.60 17.2 0.60 17.6
900 600 0.82 3.7 0.68 5.8 0.60 8.1 0.60 8.5 0.60 11.2 0.60 13.1 0.60 14.2 0.60 14.6
1 050 680 0.94 2.9 0.76 4.8 0.63 6.8 0.62 7.2 0.60 9.5 0.60 11.1 0.60 12.1 0.60 12.4
1 200 770 1.08 2.3 0.85 4.0 0.69 5.9 0.67 6.2 0.60 8.2 0.60 9.7 0.60 10.5 0.60 10.8
1 350 860 1.25 1.8 0.94 3.4 0.75 5.1 0.73 5.4 0.62 7.2 0.60 8.5 0.60 9.3 0.60 9.5
1 500 940 † † * * 0.82 4.5 0.79 4.7 0.66 6.4 0.60 7.6 0.60 8.3 0.60 8.5
1 650 1 030 † † * * * * 0.86 4.2 0.71 5.7 0.64 6.8 0.61 7.5 0.60 7.7
1 800 1 110 † † * * * * 0.93 3.7 0.76 5.2 0.68 6.2 0.64 6.8 0.63 7.0
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
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TABLE E1.6
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH FLANGED SEAM—RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Max.internal
span
Internalrise
Min.cover
Max.cover
Min.cover
Max.cover
Min. coverMax.cover
Min. coverMax.cover
Min. coverMax.cover
Min.cover
Max.cover
Min.cover
Max.cover
Min. cover Max. cover
Haunch bearing capacity (kPa)
300 600 to 1000 600 to 1000 600 900 to 1000 900 1000 1000
Plate thickness, mm
mm mm 1.2 to 3.5 1.2 1.6 2.0 to 3.5 2.0 2.5 to 3.5 2.5 3.0 to 3.5
450 340 1.00 8.4 1.00 12.3 1.00 16.9 1.00 17.6 1.00 22.9 1.00 26.6 1.00 28.8 1.00 29.6
600 430 † † 1.00 9.0 1.00 12.5 1.00 13.1 1.00 17.1 1.00 19.9 1.00 21.6 1.00 22.1
750 510 † † 1.00 7.0 1.00 9.9 1.00 10.3 1.00 13.6 1.00 15.8 1.00 17.2 1.00 17.6
900 600 † † † † 1.00 8.0 1.00 8.4 1.00 11.2 1.00 13.1 1.00 14.2 1.00 14.6
1 050 680 † † † † 1.00 6.7 1.00 7.0 1.00 9.4 1.00 11.1 1.00 12.1 1.00 12.4
1 200 770 † † † † † † † † 1.00 8.1 1.00 9.6 1.00 10.5 1.00 10.8
1 350 860 † † † † † † † † 1.00 7.1 1.00 8.4 1.00 9.2 1.00 9.5
1 500 940 † † † † † † † † † † 1.00 7.3 1.00 8.2 1.00 8.4
1 650 1 030 † † † † † † † † † † 1.00 6.6 1.00 7.3 1.00 7.5
1 800 1 110 † † † † † † † † † † † † † † 1.00 6.8
NOTES:
1 This Table can be used for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
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TABLE E2.1
COVER LIMITS FOR CLASS 2 STEEL PIPES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13
Structurenumber
Nominaldiameter
Minimumcover
highwayloads
Minimumcover
railwayloads
Maximum cover, m
Plate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0 8.0
Bolts/metremm m m 10 10 10 10 10 10 15 15 20
20P 1 500 0.60 1.00 24.0 30.0 43.1 54.7 66.4 75.7 96.3 105.3 110.122P 1 650 0.60 1.00 21.7 27.2 39.0 49.6 60.1 68.6 87.2 95.4 99.724P 1 800 0.60 1.00 19.8 24.8 35.6 45.3 54.9 62.6 79.7 87.1 91.126P 1 950 0.60 1.00 18.2 22.8 32.8 41.7 50.5 57.7 73.3 80.2 83.8
28P 2 100 0.60 1.00 16.8 21.2 30.4 38.6 46.8 53.4 67.9 74.3 77.630P 2 250 0.60 1.00 15.7 19.7 28.3 35.9 43.6 49.7 63.3 69.2 72.332P 2 400 0.60 1.00 14.6 18.4 26.4 33.6 40.8 46.5 59.2 64.7 67.736P 2 700 0.60 1.00 12.9 16.3 23.4 29.8 36.1 41.2 52.5 57.4 60.0
40P 3 000 0.60 1.00 11.5 14.6 21.0 26.7 32.4 37.0 47.1 51.5 53.844P 3 300 0.60 1.00 10.4 13.2 19.0 24.2 29.4 33.6 42.7 46.7 48.848P 3 600 0.60 1.00 9.4 12.0 17.4 22.1 26.9 30.7 39.1 42.7 44.752P 3 900 0.64 1.00 8.6 11.0 16.0 20.4 24.8 28.3 36.0 39.4 41.2
56P 4 200 0.69 1.03 7.9 10.1 14.8 18.9 23.0 26.2 33.4 36.5 38.260P 4 500 0.74 1.11 7.3 9.4 13.8 17.6 21.4 24.4 31.1 34.0 35.664P 4 800 0.79 1.18 6.7 8.7 12.9 16.5 20.0 22.9 29.1 31.9 33.3
68P 5 100 0.84 1.26 6.4 h 8.1 12.1 15.5 18.8 21.5 27.4 30.0 31.372P 5 400 0.89 1.33 † 7.6 11.3 14.6 17.7 20.3 25.8 28.3 29.676P 5 700 0.94 1.41 † 7.1 10.7 13.8 16.8 19.2 24.5 26.8 28.0
80P 6 000 0.99 1.48 † * 10.1 13.0 15.9 18.2 23.0 25.4 26.384P 6 300 1.04 1.56 † † 9.6 12.4 15.1 17.3 21.4 24.2 24.588P 6 600 1.09 1.63 † † 9.1 11.8 14.4 16.5 19.9 22.8 22.892P 6 900 1.14 1.71 † † * 11.2 13.8 15.7 18.5 21.2 21.2
96P 7 200 1.19 1.78 † † * 10.7 13.2 15.1 17.2 19.7 19.7100P 7 500 1.24 1.85 † † * * 12.6 14.4 16.0 18.3 18.3104P 7 800 1.29 1.93 † † * * 12.1 13.9 14.8 17.0 17.0
108P 8 100 1.34 2.00 † † * * 11.6 13.3 13.7 15.7 15.7112P 8 400 1.39 2.08 † † * * * 12.7 12.7 14.6 14.6114P 8 550 1.41 2.12 † † † * * 12.2 12.2 14.0 14.0
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 ‘h’ Denotes solution for highway load only.
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TABLE E2.2
COVER LIMITS FOR CLASS 2 STEEL PIPE-ARCHES AND UNDERPASSES—HIGHWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
Maximum cover, m
Haunch bearing capacity (kPa)
300 ≥600 300 ≥600 600 ≥900 600 ≥900 600 900 1 000 900 1 000 900 1 000
Plate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0
Bolts/metre
mm mm m 10 10 10 10 10 10 15
10PA5-5 1 925 1 691 0.60 15.1 17.8 15.1 22.4 30.5 32.1 30.5 40.8 30.5 45.9 49.6 45.9 51.0 45.9 51.011PA5-6 2 131 1 782 0.60 13.5 16.1 13.5 20.2 27.3 29.0 27.3 36.9 27.3 41.1 44.8 41.1 45.7 41.1 45.714PA5-6 2 406 1 923 0.60 12.1 14.2 12.1 17.8 24.5 25.7 24.5 32.6 24.6 36.9 39.6 37.0 41.1 37.0 41.116PA5-7 2 692 2 063 0.60 10.7 12.6 10.7 15.9 21.9 22.9 21.9 29.2 22.0 33.0 35.4 33.1 36.8 33.1 36.817PA5-7 2 773 2 111 0.60 10.4 12.2 10.4 15.4 21.4 22.2 21.4 28.3 21.4 32.2 34.3 32.2 35.8 32.2 35.818PA5-7 2 851 2 160 0.60 10.2 11.9 10.2 15.0 20.8 21.6 20.9 27.5 20.9 31.4 33.4 31.4 34.9 31.4 34.9
17PA5-11 3 255 2 285 0.60 8.4 10.3 8.4 13.1 17.3 18.9 17.4 24.1 17.4 26.2 29.1 26.2 29.2 26.2 29.218PA5-11 3 343 2 332 0.60 8.2 10.1 8.2 12.7 17.1 18.4 17.1 23.4 17.1 25.8 28.5 25.8 28.7 25.8 28.720PA5-11 3 507 2 429 0.60 8.0 9.6 8.0 12.1 16.5 17.5 16.5 22.3 16.6 25.0 27.1 25.0 27.8 25.0 27.821PA5-11 3 585 2 477 0.60 7.8 9.3 7.8 11.8 16.3 17.1 16.3 21.8 16.3 24.6 26.5 24.6 27.4 24.6 27.422PA5-11 3 659 2 527 0.61 7.7 9.1 7.7 11.6 16.0 16.8 16.0 21.4 16.0 24.2 26.0 24.2 27.0 24.2 27.024PA5-12 3 934 2 668 0.66 7.1 8.4 7.1 10.7 14.9 15.6 14.9 19.9 14.9 22.6 24.1 22.6 25.1 22.6 25.1
25PA5-13 4 140 2 759 0.69 6.7 8.0 6.7 10.2 14.1 14.8 14.1 18.9 14.1 21.4 22.9 21.4 23.8 21.4 23.824PA5-16 4 463 2 835 0.74 5.9 7.3 5.9 9.4 12.5 13.7 12.5 17.5 12.5 19.0 21.2 19.0 21.2 19.0 21.227PA5-16 4 689 2 982 0.78 5.7 6.9 5.7 8.9 12.2 13.0 12.2 16.6 12.2 18.6 20.2 18.6 20.7 18.6 20.729PA5-17 4 967 3 123 0.83 5.3 6.5 5.3 8.3 11.6 12.2 11.6 15.7 11.6 17.6 19.1 17.6 19.6 17.6 19.6
31PA5-18 5 241 3 265 0.87 4.8 6.1 4.8 7.9 11.0 11.6 11.0 14.8 11.0 16.7 18.0 16.7 18.6 16.7 18.633PA5-19 5 513 3 406 0.92 4.2 5.8 4.2 7.4 10.4 11.0 10.4 14.1 10.4 15.9 17.1 15.9 17.7 15.9 17.735PA5-20 5 782 3 548 0.96 3.7 5.2 3.7 7.1 9.9 10.4 9.9 13.4 9.9 15.2 16.3 15.2 16.9 15.2 16.9
37PA5-21 6 049 3 690 1.01 3.4 4.6 3.4 6.7 9.5 9.9 9.5 12.8 9.5 14.5 15.6 14.5 16.2 14.5 16.239PA5-22 6 314 3 833 1.05 3.0 4.1 3.0 6.4 9.1 9.5 9.1 12.2 9.1 13.9 14.9 13.9 15.5 13.9 15.541PA5-23 6 578 3 976 1.10 * * 2.8 5.7 8.7 9.1 8.7 11.7 8.7 13.4 14.3 13.4 14.9 13.4 14.9
24U5-7 3 145 2 768 0.60 10.7 10.7 12.7 13.6 19.6 19.6 24.9 24.9 25.9 30.2 30.2 34.5 34.5 38.9 43.227U5-11 3 798 3 152 0.63 8.8 8.8 10.4 11.1 16.1 16.1 20.6 20.6 21.4 25.0 25.0 28.5 28.5 32.2 35.829U5-11 3 942 3 268 0.66 8.4 8.4 10.0 10.7 15.5 15.5 19.8 19.8 20.6 24.1 24.1 27.5 27.5 31.0 34.5
31U5-11 4 085 3 386 0.68 8.1 8.1 9.7 10.3 15.0 15.0 19.1 19.1 19.8 23.2 23.2 26.5 26.5 29.9 33.233U5-11 4 227 3 505 0.71 7.8 7.8 9.3 9.9 14.5 14.5 18.5 18.5 19.2 22.4 22.4 25.6 25.6 28.9 32.133U5-13 4 452 3 606 0.74 7.4 7.4 8.8 9.4 13.7 13.7 17.5 17.5 18.2 21.3 21.3 24.3 24.3 27.4 30.535U5-13 4 590 3 725 0.77 7.1 7.1 8.5 9.1 13.3 13.3 17.0 17.0 17.6 20.6 20.6 23.6 23.6 26.6 29.635U5-16 4 945 3 876 0.82 6.5 6.5 7.8 8.4 12.3 12.3 15.7 15.7 16.3 19.1 19.1 21.9 21.9 24.7 27.4
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38U5-16 5 145 4 054 0.86 6.2 6.2 7.5 8.0 11.8 11.8 15.1 15.1 15.7 18.4 18.4 21.0 21.0 23.7 26.440U5-16 5 278 4 174 0.88 6.1 6.1 7.3 7.8 11.5 11.5 14.7 14.7 15.3 17.9 17.9 20.5 20.5 23.1 25.740U5-18 5 521 4 272 0.92 5.7 5.7 6.9 7.4 10.9 10.9 14.0 14.0 14.6 17.1 17.1 19.6 19.6 22.1 24.541U5-19 5 710 4 381 0.95 5.4 5.4 6.7 7.1 10.6 10.6 13.6 13.6 14.1 16.5 16.5 18.9 18.9 21.3 23.743U5-19 5 838 4 501 0.97 5.0 5.0 6.5 7.0 10.3 10.3 13.2 13.2 13.8 16.2 16.2 18.5 18.5 20.8 23.245U5-19 5 967 4 622 1.00 4.7 4.7 6.3 6.8 10.1 10.1 12.9 12.9 13.5 15.8 15.8 18.1 18.1 20.4 22.7
NOTES TO TABLE E2.2:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
COPYRIGHT
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AS/NZS 2041:1998 84
TABLE E2.3
COVER LIMITS FOR CLASS 2 STEEL PIPE-ARCHES AND UNDERPASSES—RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
Maximum cover, m
Haunch bearing capacity (kPa)
300 ≥600 300 ≥600 600 ≥900 600 ≥900 600 900 1 000 900 1 000 900 1 000
Plate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0
Bolts/metre
mm mm m 10 10 10 10 10 10 15
10PA5-5 1 925 1 691 1.00 15.1 17.9 15.1 22.4 30.5 32.2 30.5 40.9 30.6 45.9 49.6 46.0 51.1 46.0 51.1
11PA5-6 2 131 1 782 1.00 13.5 16.1 13.5 20.2 27.3 29.1 27.4 36.9 27.3 41.1 44.8 41.2 45.8 41.2 45.8
14PA5-6 2 406 1 923 1.00 12.0 14.2 12.0 17.9 24.6 25.7 24.6 32.7 24.6 37.0 39.7 37.0 41.1 37.0 41.1
16PA5-7 2 692 2 063 1.00 10.7 12.6 10.7 15.9 22.0 22.9 22.0 29.2 22.0 33.1 35.4 33.1 36.8 33.1 36.8
17PA5-7 2 773 2 111 1.00 10.4 12.2 10.4 15.4 21.4 22.3 21.4 28.3 21.4 32.2 34.4 32.3 35.9 32.3 35.9
18PA5-7 2 851 2 160 1.00 10.1 11.9 10.1 15.0 20.9 21.7 20.9 27.6 20.9 31.5 33.4 31.5 35.0 31.5 35.0
17PA5-11 3 255 2 285 1.00 8.3 10.3 8.3 13.1 17.4 18.9 17.4 24.1 17.4 26.2 29.2 26.3 29.2 26.3 29.2
18PA5-11 3 343 2 332 1.00 8.1 10.0 8.1 12.7 17.1 18.4 17.1 23.5 17.1 25.8 28.5 25.8 28.7 25.8 28.7
20PA5-11 3 507 2 429 1.00 7.8 9.5 7.8 12.1 16.6 17.5 16.6 22.4 16.6 25.0 27.1 25.0 27.8 25.0 27.8
21PA5-11 3 585 2 477 1.00 7.7 9.3 7.7 11.8 16.3 17.2 16.3 21.9 16.3 24.6 26.6 24.7 27.4 24.7 27.4
22PA5-11 3 659 2 527 1.00 7.6 9.1 7.6 11.6 16.0 16.8 16.1 21.4 16.1 24.3 26.0 24.3 27.0 24.3 27.0
24PA5-12 3 934 2 668 1.00 7.0 8.3 7.0 10.7 14.9 15.6 14.9 19.9 14.9 22.6 24.2 22.6 25.1 22.6 25.1
25PA5-13 4 140 2 759 1.03 † 7.9 † 10.1 14.1 14.8 14.1 18.9 14.1 21.4 23.0 21.4 23.8 21.4 23.8
24PA5-16 4 463 2 835 1.11 † 7.2 † 9.3 12.5 13.7 12.5 17.5 12.5 19.1 21.2 19.1 21.2 19.1 21.2
27PA5-16 4 689 2 982 1.17 † 6.8 † 8.8 12.2 13.0 12.2 16.6 12.2 18.6 20.2 18.6 20.7 18.6 20.7
29PA5-17 4 967 3 123 1.24 † † † 8.2 11.5 12.2 11.6 15.7 11.6 17.6 19.1 17.6 19.6 17.6 19.6
31PA5-18 5 241 3 265 1.31 † † † 7.7 10.9 11.5 10.9 14.8 10.9 16.7 18.1 16.7 18.6 16.7 18.6
33PA5-19 5 513 3 406 1.38 † † † 7.3 10.4 10.9 10.4 14.1 10.4 15.9 17.2 15.9 17.8 15.9 17.8
35PA5-20 5 782 3 548 1.44 † † † 6.9 9.9 10.4 9.9 13.4 9.9 15.2 16.3 15.2 17.0 15.2 17.0
37PA5-21 6 049 3 690 1.51 † † † † 9.4 9.9 9.4 12.8 9.4 14.5 15.6 14.6 16.2 14.6 16.2
39PA5-22 6 314 3 833 1.58 † † † † 9.0 9.4 9.0 12.2 9.0 13.9 14.9 13.9 15.5 13.9 15.5
41PA5-23 6 578 3 976 1.64 † † † † 8.6 9.0 8.6 11.7 8.6 13.4 14.3 13.4 14.9 13.4 14.9
24U5-7 3 145 2 768 1.00 10.7 10.7 12.7 13.6 19.6 19.6 24.9 24.9 25.9 30.3 30.3 34.6 34.6 38.9 43.3
27U5-11 3 798 3 152 1.00 8.7 8.7 10.4 11.1 16.2 16.2 20.6 20.6 21.4 25.0 25.0 28.6 28.6 32.2 35.8
29U5-11 3 942 3 268 1.00 8.3 8.3 10.0 10.7 15.6 15.6 19.8 19.8 20.6 24.1 24.1 27.5 27.5 31.0 34.5
31U5-11 4 085 3 386 1.02 8.0 8.0 9.6 10.3 15.0 15.0 19.1 19.1 19.9 23.3 23.3 26.6 26.6 29.9 33.3
33U5-11 4 227 3 505 1.06 7.7 7.7 9.2 9.9 14.5 14.5 18.5 18.5 19.2 22.5 22.5 25.7 25.7 28.9 32.2
33U5-13 4 452 3 606 1.11 7.2 7.2 8.7 9.3 13.7 13.7 17.5 17.5 18.2 21.3 21.3 24.4 24.4 27.5 30.5
(continued)
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85 AS/NZS 2041:1998
TABLE E2.3 (continued)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
Maximum cover, m
Haunch bearing capacity (kPa)
300 ≥600 300 ≥600 600 ≥900 600 ≥900 600 900 1 000 900 1 000 900 1 000
Plate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0
Bolts/metre
mm mm m 10 10 10 10 10 10 15
35U5-13 4 590 3 725 1.15 6.9 6.9 8.4 9.0 13.3 13.3 17.0 17.0 17.6 20.7 20.7 23.6 23.6 26.6 29.6
35U5-16 4 945 3 876 1.24 † † 7.7 8.3 12.3 12.3 15.7 15.7 16.3 19.2 19.2 21.9 21.9 24.7 27.5
38U5-16 5 145 4 054 1.29 † † 7.4 7.9 11.8 11.8 15.1 15.1 15.7 18.4 18.4 21.0 21.0 23.7 26.4
40U5-16 5 278 4 174 1.32 † † 7.2 7.7 11.5 11.5 14.7 14.7 15.3 17.9 17.9 20.5 20.5 23.1 25.7
40U5-18 5 521 4 272 1.38 † † 6.8 7.3 10.9 10.9 14.0 14.0 14.6 17.1 17.1 19.6 19.6 22.1 24.6
41U5-19 5 710 4 381 1.43 † † † 7.0 10.5 10.5 13.6 13.6 14.1 16.5 16.5 18.9 18.9 21.3 23.8
43U5-19 5 838 4 501 1.46 † † † 6.8 10.3 10.3 13.2 13.2 13.8 16.2 16.2 18.5 18.5 20.9 23.2
45U5-19 5 967 4 622 1.49 † † † † 10.0 10.0 12.9 12.9 13.5 15.8 15.8 18.1 18.1 20.4 22.7
NOTES:
1 This Table can be used for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
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AS/NZS 2041:1998 86
TABLE E2.4
COVER LIMITS FOR CLASS 2 STEEL ARCHES (RISE LESS THAN RADIUS)—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12
Structurenumber
Maximuminternal span Internal rise
Minimumcover
highwayloads
Minimumcover railway
loads
Maximum cover, m
Plate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0 8.0
Bolts/metremm mm m m 10 10 10 10 10 10 15
12AA 2 000 850 0.60 1.00 17.2 21.6 29.5 37.0 44.4 51.8 59.215AA 2 500 1 058 0.60 1.00 13.6 17.2 23.6 29.5 35.5 41.4 47.418AA 3 000 1 265 0.60 1.00 11.3 14.2 19.6 24.6 29.5 34.5 39.422AA 3 500 1 598 0.60 1.00 9.5 12.1 16.7 21.0 25.3 29.6 33.8
23AA 4 000 1 550 0.67 1.00 8.2 10.5 14.6 18.4 22.1 25.8 29.526AA 4 500 1 757 0.75 1.13 7.1 9.2 12.9 16.3 19.6 22.9 26.229AA 5 000 1 965 0.83 1.25 6.4 h 8.2 11.5 14.6 17.6 20.6 23.632AA 5 500 2 172 0.92 1.38 5.8 h 7.3 10.4 13.2 16.0 18.7 21.4
35AA 6 000 2 380 1.00 1.50 4.7 h 6.8 h 9.3 11.9 14.3 16.9 19.337AA 6 500 2 452 1.08 1.63 † 5.5 h 8.1 10.4 12.6 14.9 17.140AA 7 000 2 659 1.17 1.75 † † 7.0 9.1 11.1 13.2 15.143AA 7 500 2 867 1.25 1.88 † † 5.5 h 7.9 9.8 11.6 13.346AA 8 000 3 075 1.33 2.00 † † 4.3 h 6.0 8.5 10.2 11.749AA 8 500 3 283 1.42 2.13 † † † 5.1 h 6.5 8.8 10.2
26AB 4 000 1 927 0.67 1.00 8.2 10.5 14.6 18.4 22.1 25.8 29.529AB 4 500 2 136 0.75 1.13 7.1 9.2 12.9 16.3 19.6 22.9 26.233AB 5 000 2 464 0.83 1.25 6.5 h 8.2 11.5 14.6 17.6 20.6 23.636AB 5 500 2 673 0.92 1.38 5.8 h 7.3 10.4 13.2 16.0 18.7 21.4
39AB 6 000 2 883 1.00 1.50 4.7 h 6.8 h 9.3 11.9 14.3 16.9 19.342AB 6 500 3 092 1.08 1.63 † 5.5 h 8.1 10.4 12.6 14.9 17.146AB 7 000 3 420 1.17 1.75 † † 7.0 9.1 11.1 13.2 15.149AB 7 500 3 630 1.25 1.88 † † 5.5 h 7.9 9.8 11.6 13.352AB 8 000 3 839 1.33 2.00 † † 4.3 h 6.0 8.5 10.2 11.756AB 8 500 4 167 1.42 2.13 † † † 5.1 h 6.5 8.8 10.2
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 † Denotes no solution for this gauge and bolt density.
3 ‘h’ Denotes solution for highway load only.
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87 AS/NZS 2041:1998
TABLE E2.5
COVER LIMITS FOR CLASS 2 STEEL HORSESHOE ARCHES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Structurenumber
Maximuminternal
spanInternal
rise
Minimumcover
highwayloads
Minimumcover
railwayloads
Maximum cover, m
Plate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0 8.0
Bolts/metre
mm mm m m 10 10 10 10 10 10 15 15 20
HA22 2 400 1 857 0.60 1.00 14.2 17.9 25.8 32.7 39.7 45.3 57.6 62.9 65.8
HA27 3 000 2 274 0.60 1.00 11.3 14.2 20.6 26.1 31.7 36.2 46.0 50.3 52.6
HA40 4 400 3 376 0.73 1.10 7.3 9.5 13.9 17.7 21.6 24.6 31.3 34.3 35.8
HA54 6 000 4 550 1.00 1.50 4.7 h 6.8 h 10.0 12.9 15.7 18.0 22.6 25.1 25.9
HA64 7 100 5 395 1.18 1.78 † † 8.3 10.8 13.2 15.1 17.3 19.8 19.8
HA76 8 500 6 397 1.42 2.13 † † † 8.1 10.2 12.1 12.1 13.9 13.9
16EA-5 2 334 2 368 0.60 1.00 14.6 18.4 26.5 33.7 40.8 46.6 59.2 64.8 67.7
22EA-6 3 231 3 056 0.60 1.00 10.4 13.2 19.1 24.3 29.5 33.6 42.8 46.7 48.9
28EA-10 4 129 4 405 0.69 1.03 7.9 10.1 14.8 18.9 23.0 26.3 33.4 36.6 38.2
40EA-12 5 924 5 763 0.99 1.48 4.8 h 6.7 10.1 13.0 15.9 18.2 23.0 25.4 26.4
52EA-17 7 720 7 711 1.29 1.93 † † 7.2 9.8 12.1 13.9 14.8 17.0 17.0
57EA-18 8 468 8 285 1.41 2.12 † † † 8.3 10.3 12.2 12.2 14.0 14.0
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 † Denotes no solution for this gauge and bolt density.
3 ‘h’ Denotes solution for highway load only.
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AS/NZS 2041:1998 88
TABLE E2.6
COVER LIMITS FOR CLASS 2 STEEL HORIZONTAL ELLIPSES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
highwayloads
Minimumcover
railwayloads
Maximum cover, mPlate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0 8.0Bolts/metre
mm mm m m 10 10 10 10 10 10 15 15 205HE-5 1 509 1 363 0.60 1.00 22.9 28.7 41.1 52.2 63.3 72.1 91.7 100.3 104.86HE-6 1 826 1 642 0.60 1.00 18.9 23.6 33.9 43.1 52.3 59.6 75.8 82.8 86.67HE-7 2 138 1 928 0.60 1.00 16.0 20.1 28.9 36.8 44.6 50.9 64.7 70.7 73.910HE-5 2 306 2 079 0.60 1.00 14.8 18.7 26.8 34.1 41.3 47.2 60.0 65.5 68.510HE-6 2 457 2 223 0.60 1.00 13.9 17.5 25.2 32.0 38.8 44.2 56.3 61.5 64.312HE-6 2 777 2 508 0.60 1.00 12.2 15.4 22.2 28.3 34.3 39.1 49.8 54.4 56.914HE-6 3 095 2 795 0.60 1.00 10.9 13.8 19.9 25.3 30.8 35.1 44.6 48.8 51.014HE-7 3 250 2 935 0.60 1.00 10.3 13.1 19.0 24.1 29.3 33.4 42.5 46.5 48.616HE-6 3 411 3 085 0.60 1.00 9.8 12.4 18.0 23.0 27.9 31.8 40.5 44.3 46.318HE-6 3 731 3 371 0.62 1.00 8.9 11.3 16.5 21.0 25.5 29.1 37.0 40.5 42.319HE-7 4 043 3 656 0.67 1.01 8.1 10.4 15.2 19.3 23.5 26.8 34.1 37.3 39.020HE-7 4 200 3 801 0.70 1.05 7.7 10.0 14.6 18.6 22.6 25.8 32.9 35.9 37.621HE-7 4 362 3 942 0.73 1.09 7.4 9.5 14.0 17.9 21.8 24.8 31.6 34.6 36.212HE-18 4 634 4 188 0.77 1.16 6.9 8.9 13.1 16.8 20.5 23.4 29.8 32.6 34.014HE-18 4 950 4 478 0.83 1.24 6.5 h 8.3 12.3 15.7 19.1 21.9 27.9 30.5 31.914HE-19 5 106 4 612 0.85 1.28 6.3 h 8.0 11.9 15.2 18.5 21.2 27.0 29.5 30.914HE-20 5 263 4 750 0.88 1.32 † 7.7 11.5 14.8 18.0 20.5 26.2 28.6 29.918HE-18 5 586 5 048 0.93 1.40 † 7.2 10.8 13.9 16.9 19.3 24.7 27.0 28.220HE-18 5 902 5 338 0.98 1.48 † * 10.2 13.1 16.0 18.3 23.2 25.5 26.521HE-18 6 065 5 478 1.01 1.52 † † 9.9 12.7 15.5 17.8 22.3 24.8 25.521HE-19 6 219 5 618 1.04 1.56 † † 9.6 12.4 15.1 17.3 21.4 24.2 24.521HE-21 6 525 5 901 1.09 1.63 † † 9.1 11.8 14.4 16.5 19.9 22.8 22.824HE-20 6 849 6 191 1.14 1.71 † † * 11.2 13.7 15.7 18.4 21.1 21.124HE-21 7 004 6 327 1.17 1.75 † † * 10.9 13.4 15.3 17.7 20.3 20.328HE-18 7 175 6 483 1.20 1.79 † † * 10.6 13.0 15.0 17.0 19.4 19.427HE-21 7 479 6 760 1.25 1.87 † † * * 12.5 14.3 15.7 18.0 18.030HE-20 7 801 7 052 1.30 1.95 † † * * 11.9 13.7 14.5 16.6 16.630HE-21 7 953 7 194 1.33 1.99 † † * * 11.7 13.4 14.0 16.0 16.031HE-21 8 112 7 338 1.35 2.03 † † * * * 13.2 13.4 15.4 15.433HE-21 8 432 7 622 1.41 2.11 † † † * * 12.3 12.3 14.1 14.135HE-21 8 750 7 908 1.46 2.19 † † † * * 11.3 11.3 13.0 13.0
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 ‘h’ Denotes solution for highway load only.
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Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]
89 AS/NZS 2041:1998
TABLE E2.7
COVER LIMITS FOR CLASS 2 STEEL VERTICAL ELLIPSES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
highwayloads
Minimumcover
railwayloads
Maximum cover, mPlate thickness, mm
2.5 3.0 4.0 5.0 6.0 7.0 8.0Bolts/metre
mm mm m m 10 10 10 10 10 10 15 15 205VE-5 1 363 1 509 0.60 1.00 25.4 31.7 45.5 57.8 70.0 79.8 101.5 111.0 116.06VE-6 1 642 1 826 0.60 1.00 21.0 26.3 37.7 47.9 58.1 66.2 84.2 92.0 96.27VE-7 1 928 2 138 0.60 1.00 17.8 22.4 32.1 40.8 49.5 56.4 71.7 78.4 82.05VE-10 2 080 2 305 0.60 1.00 16.5 20.7 29.8 37.8 45.9 52.3 66.5 72.7 76.06VE-10 2 223 2 457 0.60 1.00 15.4 19.4 27.8 35.4 42.9 48.9 62.2 68.0 71.16VE-12 2 507 2 778 0.60 1.00 13.6 17.1 24.6 31.3 38.0 43.4 55.1 60.3 63.06VE-14 2 795 3 095 0.60 1.00 12.1 15.3 22.1 28.1 34.1 38.9 49.5 54.1 56.57VE-14 2 935 3 250 0.60 1.00 11.5 14.6 21.0 26.7 32.4 37.0 47.1 51.5 53.86VE-16 3 085 3 410 0.60 1.00 10.9 13.8 20.0 25.4 30.9 35.2 44.8 49.0 51.26VE-18 3 371 3 730 0.60 1.00 9.9 12.6 18.3 23.3 28.2 32.2 41.0 44.8 46.87VE-19 3 656 4 042 0.61 1.00 9.1 11.6 16.8 21.4 26.0 29.7 37.8 41.3 43.27VE-20 3 801 4 201 0.63 1.00 8.7 11.1 16.1 20.6 25.0 28.5 36.3 39.7 41.57VE-21 3 942 4 362 0.66 1.00 8.3 10.7 15.5 19.8 24.1 27.5 35.0 38.3 40.018VE-12 4 188 4 634 0.70 1.05 7.8 10.0 14.6 18.7 22.7 25.9 33.0 36.0 37.718VE-14 4 478 4 950 0.75 1.12 7.2 9.3 13.6 17.4 21.2 24.2 30.8 33.7 35.219VE-14 4 615 5 107 0.77 1.15 6.9 9.0 13.2 16.9 20.6 23.5 29.9 32.7 34.220VE-14 4 752 5 264 0.79 1.19 6.7 8.7 12.8 16.4 19.9 22.8 29.0 31.7 33.218VE-18 5 051 5 587 0.84 1.26 6.4 h 8.1 12.0 15.4 18.7 21.4 27.3 29.8 31.218VE-20 5 340 5 903 0.89 1.34 † 7.6 11.3 14.5 17.7 20.2 25.8 28.2 29.518VE-21 5 481 6 066 0.91 1.37 † 7.3 11.0 14.1 17.2 19.7 25.1 27.5 28.719VE-21 5 621 6 220 0.94 1.41 † 7.1 10.7 13.8 16.8 19.2 24.5 26.8 28.021VE-21 5 902 6 529 0.98 1.48 † † 10.2 13.1 16.0 18.3 23.2 25.5 26.520VE-24 6 190 6 850 1.03 1.55 † † 9.6 12.5 15.2 17.4 21.6 24.3 24.721VE-24 6 330 7 004 1.06 1.58 † † 9.4 12.2 14.9 17.0 20.9 23.8 23.918VE-28 6 486 7 176 1.08 1.62 † † 9.1 11.9 14.5 16.6 20.1 23.0 23.021VE-27 6 762 7 481 1.13 1.69 † † * 11.3 13.9 15.9 18.8 21.5 21.520VE-30 7 054 7 802 1.18 1.76 † † * 10.8 13.3 15.2 17.5 20.0 20.021VE-30 7 197 7 955 1.20 1.80 † † * 10.6 3.0 14.9 16.9 19.3 19.321VE-31 7 339 8 115 1.22 1.84 † † * 10.4 12.7 14.6 16.3 81.7 18.721VE-33 7 625 8 435 1.27 1.91 † † * * 12.2 14.0 15.2 17.4 17.421VE-35 7 911 8 754 1.32 1.98 † † * * 11.8 13.5 14.1 16.2 16.221VE-36 8 055 8 913 1.34 2.01 † † * * 11.5 13.3 13.6 15.6 15.6
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 ‘h’ Denotes solution for highway load only.
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AS/NZS 2041:1998 90
APPENDIX F
REFERENCE TABLES FOR MINIMUM COVER FOR ALUMINIUMSTRUCTURES
The information and recommendations contained in these tables are intended fordesigners’ convenience in routine applications complying with this Standard.
In the preparation of the Tables in this Appendix, the following values were adopted:
fy = 165 MPa
k = 1 for height of cover less than span
k = 0.75 for height of cover equal to or greater than span
β = 2
γ = 20.0 kN/m3
The allowance for pavement (road) is 300 mm at 22 kN/m3. Impact factors used are thosegiven in the relevant references given in Clause 5.4.2.2.
LIST OF TABLES
F1 Cover limits for Class 2 aluminium pipes—highway and railway live loadF2 Cover limits for Class 2 aluminium pipe-arches and underpasses—highway live loadF3 Cover limits for Class 2 aluminium pipe-arches and underpasses—railway live loadF4 Cover limits for Class 2 aluminium arches (rise less than radius)—highway and
railway live loadF5 Cover limits for Class 2 aluminium horseshoe arches—highway and railway live loadF6 Cover limits for Class 2 aluminium horizontal ellipses—highway and railway live
loadF7 Cover limits for Class 2 aluminium vertical ellipses—highway and railway live load
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91 AS/NZS 2041:1998
TABLE F1
COVER LIMITS FOR CLASS 2 ALUMINIUM PIPES: HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Structurenumber
Nominaldiameter
Minimum coverhighway loads
Minimumcover
railwayloads
Maximum cover, m
m
Plate thickness, mm
3.0 4.0 3.0, 4.0, 5.0, 6.0 3.0 4.0 5.0 6.0
Bolts/metre
mm 10 10 10, 15, 20 10 15 20 10 15 20 10 15 20 10 15 20
20P 1 500 0.60 0.60 0.60 1.00 14.6 21.2 26.8 17.7 25.6 33.1 20.7 30.1 39.4 23.8 34.5 45.7
22P 1 650 0.60 0.60 0.60 1.00 13.2 19.2 24.2 16.0 23.2 29.9 18.8 27.2 35.7 21.5 31.2 41.4
24P 1 800 0.60 0.60 0.60 1.00 12.0 17.5 22.1 14.6 21.2 27.3 17.1 24.9 32.6 19.6 28.5 37.8
26P 1 950 0.60 0.60 0.60 1.00 11.0 16.1 20.3 13.4 19.5 25.2 15.7 22.9 30.0 18.1 26.3 34.8
28P 2 100 0.60 0.60 0.60 1.00 10.2 14.9 18.8 12.4 18.0 23.3 14.5 21.2 27.7 16.7 24.3 32.2
30P 2 250 0.60 0.60 0.60 1.00 9.4 13.8 17.5 11.5 16.8 21.7 13.5 19.7 25.8 15.5 22.6 30.0
32P 2 400 0.60 0.60 0.60 1.00 8.8 12.9 16.4 10.7 15.7 20.3 12.6 18.4 24.2 14.5 21.2 28.0
36P 2 700 0.60 0.60 0.60 1.00 7.7 11.4 14.5 9.4 13.8 17.9 11.1 16.3 21.4 12.8 18.7 24.8
40P 3 000 0.64 0.60 0.60 a 1.00 6.8 10.1 12.9 8.4 12.4 16.1 9.9 14.6 19.2 11.4 16.8 22.3
44P 3 300 0.69 0.61 0.60 a 1.00 6.1 h 9.1 11.7 7.5 11.2 14.5 8.9 13.2 17.4 10.3 15.2 20.2
48P 3 600 0.74 0.64 0.60 a 1.00 5.5 h 8.3 10.7 6.8 10.2 13.3 8.1 12.0 15.9 9.4 13.8 18.4
52P 3 900 * 0.69 0.64 a 1.00 * * * 6.2 9.3 12.2 7.4 11.0 14.6 8.6 12.7 17.0
56P 4 200 * 0.73 0.69 a 1.03 * * * 5.7 8.6 11.3 6.8 10.2 13.5 7.9 11.8 15.7
60P 4 500 * * 0.74 1.11 * * * * * * 6.3 9.5 12.5 7.3 10.9 14.6
64P 4 800 * * 0.79 1.18 * * * * * * 5.8 8.8 11.7 6.8 10.2 13.7
68P 5 100 * * 0.84 1.26 * * * * * * * * * 6.3 9.6 12.8
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 ‘h’ Denotes solution for highway load only.
5 ‘a’ Denotes use solution for 3.0 & 4.0 mm 10 bolts/m from columns 3 & 4.
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AS/NZS 2041:1998 92
TABLE F2
COVER LIMITS FOR CLASS 2 ALUMINIUM PIPE-ARCHES AND UNDERPASSES—HIGHWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28
Structurenumber
Maximuminternal
span
Internalrise
Minimum cover Maximum cover, m
Haunch bearingcapacity (kPa)
Haunch bearing capacity (kPa)
≥300 ≥300 300 ≥600 300 ≥600 ≥300 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 600 ≥900
Plate thickness, mm Plate thickness, mm
3.0 4.0 3.0 to 6.0 3.0 4.0 5.0 6.0
Bolts/metre Bolts/metre
mm mm 10 10 10, 15, 20 10 15 20 10 15 20 10 15 20 10 15 20
10PA5-5 1 925 1 691 0.60 0.60 0.60 10.815.1 15.7 15.1 19.9 13.1 15.1 19.1 15.1 24.7 15.1 15.4 15.1 22.4 15.1 29.4 15.2 17.7 15.2 25.7 15.2 30.5 34.1
11PA5-6 2 131 1 782 0.60 0.60 0.60 9.713.5 14.2 13.5 18.0 11.8 13.5 17.2 13.5 22.3 13.5 13.9 13.5 20.2 13.5 26.5 13.5 16.0 13.5 23.2 13.5 27.3 30.8
14PA5-6 2 406 1 923 0.60 0.60 0.60 8.512.1 12.5 12.1 15.9 10.4 12.1 15.2 12.1 19.7 12.1 12.2 12.1 17.9 12.1 23.5 12.1 14.1 12.1 20.5 12.1 24.6 27.2
16PA5-7 2 692 2 063 0.61 0.60 0.60a 7.510.7 11.1 10.7 14.1 9.2 10.7 13.5 10.7 17.5 10.7 10.9 10.7 15.9 10.7 20.9 10.8 12.5 10.8 18.3 10.8 22.0 24.3
17PA5-7 2 773 2 111 0.62 0.60 0.60a 7.310.4 10.8 10.4 13.7 8.9 10.5 13.1 10.5 17.0 10.5 10.5 10.5 15.4 10.5 20.3 10.5 12.1 10.5 17.8 10.5 21.4 23.6
18PA5-7 2 851 2 160 0.63 0.60 0.60a 7.010.2 10.5 10.2 13.3 8.6 10.2 12.7 10.2 16.5 10.2 10.2 10.2 15.0 10.2 19.7 10.2 11.8 10.2 17.3 10.2 20.9 22.9
17PA5-11 3 255 2 285 0.69 0.61 0.60a 6.0 8.4 9.1 8.4 11.6 7.5 8.4 11.1 8.4 14.4 8.4 8.9 8.4 13.1 8.4 17.2 8.4 10.3 8.4 15.1 8.4 17.4 20.1
18PA5-11 3 343 2 332 0.71 0.62 0.60a 5.9 8.2 8.8 8.2 11.3 7.2 8.2 10.8 8.2 14.0 8.2 8.6 8.2 12.7 8.2 16.8 8.3 10.0 8.3 14.7 8.3 17.1 19.5
20PA5-11 3 507 2 429 0.74 0.64 0.60a 5.5 8.0 8.4 8.0 10.7 6.9 8.0 10.2 8.0 13.4 8.0 8.2 8.0 12.1 8.0 16.0 8.0 9.5 8.0 14.0 8.0 16.6 18.6
21PA5-11 3 585 2 477 0.75 0.65 0.60a 5.4 7.8 8.2 7.8 10.5 6.7 7.8 10.0 7.8 13.1 7.8 8.0 7.8 11.8 7.8 15.6 7.8 9.2 7.8 13.6 7.8 16.3 18.2
22PA5-11 3 659 2 527 0.76 0.66 0.61a 5.3 7.7 8.0 7.7 10.3 6.5 7.7 9.8 7.7 12.8 7.7 7.8 7.7 11.5 7.7 15.3 7.7 9.0 7.7 13.4 7.7 16.0 17.8
24PA5-12 3 934 2 668 0.81 0.70 0.66a 4.8 7.1 7.4 7.1 9.5 6.0 7.1 9.1 7.1 11.9 7.1 7.2 7.1 10.7 7.1 14.2 7.1 8.4 7.1 12.4 7.1 14.9 16.5
25PA5-13 4 140 2 759 0.85 0.73 0.69a 4.5 6.7 7.0 6.7 9.0 5.7 6.7 8.6 6.7 11.2 6.7 6.8 6.7 10.2 6.7 13.5 6.7 7.9 6.7 11.7 6.7 14.1 15.7
24PA5-16 4 463 2 835 0.91 0.78 0.74a 3.7 5.9 6.4 5.9 8.3 5.2 5.9 7.9 5.9 10.4 5.9 6.2 5.9 9.4 5.9 12.5 5.9 7.3 5.9 10.9 5.9 12.5 14.5
27PA5-16 4 689 2 982 * 0.81 0.78a * * * * * 4.9 5.7 7.5 5.7 9.8 5.7 5.9 5.7 8.9 5.7 11.8 5.7 6.9 5.7 10.3 5.7 12.2 13.8
29PA5-17 4 967 3 123 * 0.86 0.83a * * * * * 4.2 5.4 7.0 5.4 9.3 5.4 5.5 5.4 8.4 5.4 11.1 5.4 6.4 5.4 9.7 5.4 11.6 13.0
31PA5-18 5 241 3 265 * * 0.87 * * * * * * * * * * 4.9 5.1 4.9 7.9 4.9 10.5 4.9 6.0 4.9 9.1 4.9 11.0 12.3
33PA5-19 5 513 3 406 * * 0.92 * * * * * * * * * * 4.2 4.4 4.2 7.4 4.2 10.0 4.2 5.7 4.2 8.7 4.2 10.4 11.7
35PA5-20 5 782 3 548 * * 0.96 * * * * * * * * * * 3.8 3.8 3.8 7.1 3.8 9.5 3.8 5.1 3.8 8.2 3.8 9.9 11.1
37PA5-21 6 049 3 690 † * 1.01 † * * * * * * * * * * * * * * * 3.4 4.5 3.4 7.8 3.4 9.5 10.6
39PA5-22 6 314 3 833 † * 1.05 † * * * * * * * * * * * * * * * 3.0 4.1 3.0 7.4 3.0 9.1 10.1
41PA5-23 6 578 3 976 † * * † * * * * * * * * * * * * * * * * * * * * *
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24U5-7 3 145 2 768 0.68 0.60 0.60a 6.3 9.4 9.4 12.0 12.0 7.8 11.5 11.5 12.7 15.0 9.2 9.2 12.7 13.6 12.7 17.9 10.6 10.6 12.7 15.6 12.7 20.8 20.8
27U5-11 3 798 3 152 0.79 0.68 0.63a 5.0 7.7 7.7 9.9 9.9 6.3 9.4 9.4 10.4 12.3 7.5 7.5 10.4 11.1 10.4 14.7 8.7 8.7 10.5 12.8 10.5 17.1 17.1
29U5-11 3 942 3 268 0.81 0.70 0.66a 4.8 7.4 7.4 9.5 9.5 6.0 9.0 9.0 10.0 11.8 7.2 7.2 10.0 10.7 10.0 14.2 8.3 8.3 10.0 12.4 10.0 16.5 16.5
31U5-11 4 085 3 386 0.84 0.72 0.68a 4.6 7.1 7.1 9.1 9.1 5.8 8.7 8.7 9.7 11.4 6.9 6.9 9.7 10.3 9.7 13.7 8.0 8.0 9.7 11.9 9.7 15.9 15.9
33U5-11 4 227 3 505 0.87 0.74 0.70a 4.4 6.8 6.8 8.8 8.8 5.5 8.4 8.4 9.3 11.0 6.6 6.6 9.3 9.9 9.3 13.2 7.7 7.7 9.3 11.5 9.3 15.3 15.3
33U5-13 4 452 3 606 0.91 0.78 0.74a 3.8 6.4 6.4 8.3 8.3 5.2 7.9 7.9 8.8 10.4 6.2 6.2 8.8 9.4 8.8 12.5 7.3 7.3 8.8 10.9 8.8 14.6 14.6
35U5-13 4 590 3 725 * 0.80 0.76a * * * * * 5.0 7.7 7.7 8.5 10.1 6.0 6.0 8.5 9.1 8.5 12.1 7.0 7.0 8.5 10.5 8.5 14.1 14.1
35U5-16 4 945 3 876 * 0.85 0.82a * * * * * 4.2 7.0 7.0 7.8 9.3 5.5 5.5 7.9 8.4 7.9 11.2 6.5 6.5 7.9 9.7 7.9 13.1 13.1
38U5-16 5 145 4 054 * 0.89 0.86a * * * * * 3.8 6.7 6.7 7.5 8.9 5.3 5.3 7.5 8.0 7.5 10.7 6.2 6.2 7.5 9.3 7.5 12.5 12.5
40U5-16 5 278 4 174 * * 0.88 * * * * * * * * * * 4.9 4.9 7.3 7.8 7.3 10.4 6.0 6.0 7.3 9.1 7.3 12.2 12.2
40U5-18 5 521 4 272 * * 0.92 * * * * * * * * * * 4.3 4.3 6.9 7.4 6.9 10.0 5.7 5.7 6.9 8.6 6.9 11.6 11.6
41U5-19 5 710 4 381 * * 0.95 * * * * * * * * * * 4.0 4.0 6.7 7.2 6.7 9.6 5.3 5.3 6.7 8.3 6.7 11.2 11.2
43U5-19 5 838 4 501 † * 0.97 † * * * * * * * * * * * * * * * 4.9 4.9 6.5 8.1 6.5 11.0 11.0
45U5-19 5 967 4 622 † * 0.99 † * * * * * * * * * * * * * * * 4.7 4.7 6.4 7.9 6.4 10.7 10.7
NOTES TO TABLE F2:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate GeotechnicalAdvice.
5 ‘a’ denotes use solution for 3.0 and 4.0 mm 10 bolts/m from columns 4 and 5.
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TABLE F3
COVER LIMITS FOR CLASS 2 ALUMINIUM PIPE-ARCHES AND UNDERPASSES—RAILWAY LIVE LOAD
1 2 3 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
Maximum cover, m
Haunch bearing capacity (kPa)
≥300 300 ≥600 300 ≥600 ≥300 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 ≥600 300 600 ≥900
Plate thickness, mm
3.0 4.0 5.0 6.0
Bolts/metre
mm mm m 10 15 20 10 15 20 10 15 20 10 15 20
10PA5-5 1 925 1 691 1.00 10.8 15.1 15.8 15.1 20.0 13.1 15.1 19.1 15.1 24.7 15.1 15.4 15.1 22.4 15.1 29.4 15.1 17.7 15.1 25.8 15.1 30.6 34.1
11PA5-6 2 131 1 782 1.00 9.6 13.5 14.2 13.5 18.0 11.8 13.5 17.2 13.5 22.3 13.5 13.9 13.5 20.2 13.5 26.6 13.5 16.0 13.5 23.3 13.5 27.3 30.8
14PA5-6 2 406 1 923 1.00 8.4 12.0 12.5 12.0 15.9 10.3 12.1 15.2 12.1 19.7 12.1 12.2 12.1 17.9 12.1 23.5 12.1 14.1 12.1 20.6 12.1 24.6 27.3
16PA5-7 2 692 2 063 1.00 7.4 10.7 11.1 10.7 14.2 9.1 10.7 13.5 10.7 17.6 10.7 10.8 10.7 15.9 10.7 21.0 10.7 12.5 10.7 18.3 10.7 22.0 24.3
17PA5-7 2 773 2 111 1.00 7.1 10.4 10.7 10.4 13.7 8.8 10.4 13.1 10.4 17.0 10.4 10.5 10.4 15.5 10.4 20.3 10.4 12.1 10.4 17.8 10.4 21.4 23.6
18PA5-7 2 851 2 160 1.00 6.9 10.1 10.4 10.1 13.3 8.6 10.1 12.7 10.1 16.6 10.1 10.2 10.1 15.0 10.1 19.8 10.2 11.8 10.2 17.3 10.2 20.9 23.0
17PA5-11 3 255 2 285 1.00 † 8.3 9.0 8.3 11.6 7.3 8.3 11.1 8.3 14.4 8.3 8.8 8.3 13.1 8.3 17.3 8.3 10.2 8.3 15.1 8.3 17.4 20.1
18PA5-11 3 343 2 332 1.00 † 8.1 8.7 8.1 11.3 7.1 8.1 10.8 8.1 14.1 8.1 8.5 8.1 12.7 8.1 16.8 8.1 9.9 8.1 14.7 8.1 17.1 19.6
20PA5-11 3 507 2 429 1.00 † 7.8 8.3 7.8 10.7 6.7 7.8 10.2 7.8 13.4 7.9 8.1 7.9 12.1 7.9 16.0 7.9 9.4 7.9 14.0 7.9 16.6 18.6
21PA5-11 3 585 2 477 1.00 † 7.7 8.1 7.7 10.4 † 7.7 10.0 7.7 13.1 7.7 7.9 7.7 11.8 7.7 15.6 7.7 9.2 7.7 13.7 7.7 16.3 18.2
22PA5-11 3 659 2 527 1.00 † 7.6 7.9 7.6 10.2 † 7.6 9.7 7.6 12.8 7.6 7.7 7.6 11.6 7.6 15.3 7.6 9.0 7.6 13.4 7.6 16.1 17.8
24PA5-12 3 934 2 668 1.00 † 7.0 7.2 7.0 9.4 † 7.0 9.0 7.0 11.8 7.0 7.0 7.0 10.7 7.0 14.2 7.0 8.3 7.0 12.4 7.0 14.9 16.5
25PA5-13 4 140 2 759 1.03 † † 6.8 † 8.9 † † 8.5 † 11.2 † † † 10.1 † 13.5 † 7.8 † 11.7 † 14.1 15.7
24PA5-16 4 463 2 835 1.11 † † † † 8.2 † † 7.8 † 10.3 † † † 9.3 † 12.5 † 7.1 † 10.8 † 12.5 14.5
27PA5-16 4 689 2 982 1.17 † † † † * † † 7.3 † 9.8 † † † 8.8 † 11.8 † 6.7 † 10.3 † 12.2 13.8
29PA5-17 4 967 3 123 1.24 † † † † * † † 6.8 † 9.2 † † † 8.3 † 11.1 † † † 9.6 † 11.6 13.0
31PA5-18 5 241 3 265 1.31 † † † † * † † † † * † † † 7.8 † 10.5 † † † 9.1 † 10.9 12.3
33PA5-19 5 513 3 406 1.38 † † † † † † † † † * † † † 7.3 † 9.9 † † † 8.6 † 10.4 11.6
35PA5-20 5 782 3 548 1.44 † † † † † † † † † * † † † 6.9 † 9.4 † † † 8.1 † 9.9 11.1
37PA5-21 6 049 3 690 1.51 † † † † † † † † † * † † † † † * † † † 7.7 † 9.4 10.5
39PA5-22 6 314 3 833 1.58 † † † † † † † † † † † † † † † * † † † 7.3 † 9.0 10.1
41PA5-23 6 578 3 976 * † † † † † † † † † † † † † † † * † † † * † * *
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24U5-7 3 145 2 768 1.00 † 9.4 9.4 12.0 12.0 7.6 11.5 11.5 12.7 15.0 9.1 9.1 12.7 13.6 12.7 17.9 10.6 10.6 12.7 15.6 12.7 20.8 20.8
27U5-11 3 798 3 152 1.00 † 7.5 7.5 9.8 9.8 † 9.3 9.3 10.4 12.3 7.3 7.3 10.4 11.1 10.4 14.7 8.6 8.6 10.4 12.8 10.4 17.2 17.2
29U5-11 3 942 3 268 1.00 † 7.2 7.2 9.4 9.4 † 9.0 9.0 10.0 11.8 7.0 7.0 10.0 10.7 10.0 14.2 8.2 8.2 10.0 12.3 10.0 16.5 16.5
31U5-11 4 085 3 386 1.02 † 6.9 6.9 9.0 9.0 † 8.6 8.6 9.6 11.4 6.7 6.7 9.6 10.3 9.6 13.6 7.9 7.9 9.6 11.9 9.6 15.9 15.9
33U5-11 4 227 3 505 1.06 † † † 8.7 8.7 † 8.3 8.3 9.3 11.0 † † 9.3 9.9 9.3 13.2 7.6 7.6 9.3 11.5 9.3 15.4 15.4
33U5-13 4 452 3 606 1.11 † † † 8.2 8.2 † 7.8 7.8 8.7 10.4 † † 8.7 9.3 8.7 12.5 7.1 7.1 8.7 10.8 8.7 14.6 14.6
35U5-13 4 590 3 725 1.15 † † † * * † 7.5 7.5 8.4 10.0 † † 8.4 9.0 8.4 12.1 6.9 6.9 8.4 10.5 8.4 14.1 14.1
35U5-16 4 945 3 876 1.24 † † † * * † 6.9 6.9 7.7 9.2 † † 7.7 8.3 7.7 11.2 † † 7.7 9.7 7.7 13.1 13.1
38U5-16 5 145 4 054 1.29 † † † * * † † † 7.4 8.8 † † 7.4 7.9 7.4 10.7 † † 7.4 9.3 7.4 12.5 12.5
40U5-16 5 278 4 174 1.32 † † † * * † † † * * † † 7.2 7.7 7.2 10.4 † † 7.2 9.0 7.2 12.2 12.2
40U5-18 5 521 4 272 1.38 † † † † † † † † * * † † 6.8 7.3 6.8 9.9 † † 6.8 8.6 6.8 11.6 11.6
41U5-19 5 710 4 381 1.43 † † † † † † † † † * † † † 7.0 † 9.5 † † † 8.2 † 11.2 11.2
43U5-19 5 838 4 501 1.46 † † † † † † † † † * † † † * † * † † † 8.0 † 10.9 10.9
45U5-19 5 967 4 622 1.49 † † † † † † † † † * † † † † † * † † † 7.8 † 10.7 10.7
NOTES TO TABLE F3:
1 This Table can be used for Australian 300-A-14, M250, M270 Railway Loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 Haunch bearing capacities over 300 kPa require special installation of stiff backfill material. In these cases, refer to appropriate geotechnicaladvice.
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Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]
AS/NZS 2041:1998 96
TABLE F4
COVER LIMITS FOR CLASS 2 ALUMINIUM ARCHES (RISE LESS THAN RADIUS)—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Structurenumber
Maximuminternal
span
Internalrise
Minimumcover
highwayloads
Minimumcover
railwayloads
Maximum cover, m
Plate thickness, mm
3.0 4.0 5.0 6.0
Bolts/metre
mm mm m m 10 15 20 10 15 20 10 15 20 10 15 20
12AA 2 000 850 0.60 1.00 10.3 14.4 14.4 12.6 18.4 19.4 14.8 21.6 24.3 17.0 24.8 29.2
15AA 2 500 1 058 0.60 1.00 8.0 11.4 11.4 9.9 14.6 15.4 11.7 17.2 19.4 13.5 19.8 23.3
18AA 3 000 1 265 0.60 1.00 6.6 h 9.3 9.3 8.1 12.1 12.8 9.6 14.2 16.1 11.1 16.4 19.4
22AA 3 500 1 598 0.60 1.00 5.5 h 7.8 7.8 6.7 10.2 10.8 8.1 12.1 13.7 9.4 14.0 16.6
23AA 4 000 1 550 0.67 1.00 4.7 h 6.7 6.7 5.9 h 8.8 9.4 6.9 10.5 11.9 8.1 12.2 14.4
26AA 4 500 1 757 0.75 1.13 † † † 5.1 h 7.7 8.2 6.2 h 9.2 10.5 7.0 10.7 12.8
29AA 5 000 1 965 0.83 1.25 † † † 4.1 h 6.8 7.2 5.4 h 8.2 9.4 6.4 h 9.5 11.4
32AA 5 500 2 172 0.92 1.38 † † † † † † 4.4 h 7.3 8.2 5.7 h 8.6 10.1
35AA 6 000 2 380 1.00 1.50 † † † † † † † † * 4.6 h 7.8 8.5
37AA 6 500 2 452 * * † † † † † † † † † † * *
40AA 7 000 2 659 * † † † † † † † † † † † † †
43AA 7 500 2 867 * † † † † † † † † † † † † †
46AA 8 000 3 075 * † † † † † † † † † † † † †
49AA 8 500 3 283 * † † † † † † † † † † † † †
26AB 4 000 1 927 0.67 1.00 4.7 h 6.7 6.7 5.9 h 8.8 9.4 6.9 10.5 11.9 8.1 12.2 14.4
29AB 4 500 2 136 0.75 1.13 † † † 5.1 h 7.7 8.2 6.2 h 9.2 10.5 7.0 10.7 12.8
33AB 5 000 2 464 0.83 1.25 † † † 4.1 h 6.8 7.2 5.4 h 8.2 9.4 6.4 h 9.5 11.4
36AB 5 500 2 673 0.92 1.38 † † † † † † 4.4 h 7.3 8.2 5.7 h 8.6 10.1
39AB 6 000 2 883 1.00 1.50 † † † † † † † † * 4.6 h 7.8 8.5
42AB 6 500 3 092 * * † † † † † † † † † † * *
46AB 7 000 3 420 * † † † † † † † † † † † † †
49AB 7 500 3 630 * † † † † † † † † † † † † †
52AB 8 000 3 839 * † † † † † † † † † † † † †
56AB 8 500 4 167 * † † † † † † † † † † † † †
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 † Denotes no solution for this gauge and bolt density.
3 ‘h’ denotes solution for highway load only.
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TABLE F5
COVER LIMITS FOR CLASS 2 ALUMINIUM HORSESHOE ARCHES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Structurenumber
Maximuminternal span
Internalrise
Minimum cover highway loads Minimumcover
railwayloads
Maximum cover, m
Plate thickness, mm
3.0 4.0 3.0 to 6.0 3.0 4.0 5.0 6.0
Bolts/metre Bolts/metre
mm mm 10 10 10, 15, 20 m 10 15 20 10 15 20 10 15 20 10 15 20
HA22 2 400 1 857 0.60 0.60 0.60 1.00 8.4 12.5 15.9 10.4 15.2 19.7 12.2 17.9 23.5 14.1 20.6 27.3
HA27 3 000 2 274 0.65 0.60 0.60 1.00 6.6 h 9.9 12.6 8.1 12.1 15.7 9.6 14.2 18.8 11.1 16.4 21.8
HA40 4 400 3 376 0.90 0.77 0.73 1.10 3.9 h 6.5 h 8.3 5.3 h 7.9 10.5 6.3 h 9.5 12.6 7.2 11.0 14.7
HA54 6 000 4 550 † * 1.00 1.50 † † † † † * † † * 4.6 h 7.8 10.6
HA64 7 100 5 395 † † * * † † † † † † † † † † † *
HA76 8 500 6 397 † † * † † † † † † † † † † † † †
16EA-5 2 334 2 368 0.60 0.60 0.60 1.00 8.7 12.9 16.4 10.7 15.7 20.3 12.6 18.4 24.2 14.5 21.2 28.1
22EA-6 3 231 3 056 0.69 0.61 0.60 1.00 6.1 h 9.1 11.7 7.4 11.1 14.5 8.9 13.2 17.4 10.3 15.2 20.2
28EA-10 4 129 4 405 0.85 0.73 0.69 1.03 4.5 h 6.8 8.9 5.7 h 8.5 11.2 6.8 h 10.1 13.5 7.8 11.8 15.7
40EA-12 5 924 5 763 † * 0.99 1.48 † † † † † * † * * 4.7 h 7.9 10.8
52EA-17 7 720 7 711 † † * † † † † † † † † † † † † †
57EA-18 8 468 8 285 † † † † † † † † † † † † † † † †
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
2 † Denotes no solution for this gauge and bolt density.
3 ‘h’ denotes solution for highway load only.
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AS/NZS 2041:1998 98
TABLE F6
COVER LIMITS FOR CLASS 2 ALUMINIUM HORIZONTAL ELLIPSES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Structurenumber
Maximuminternal span
Internalrise
Minimum cover highway loads Minimumcover
railwayloads
Maximum cover, m
Plate thickness, mm
3.0 4.0 3.0 to 6.0 3.0 4.0 5.0 6.0
Bolts/metre Bolts/metre
mm mm 10 10 10, 15, 20 m 10 15 20 10 15 20 10 15 20 10 15 20
5HE-5 1 509 1 363 0.60 0.60 0.60 1.00 13.9 20.2 25.5 16.8 24.4 31.5 19.8 28.6 37.6 22.7 32.9 43.5
6HE-6 1 826 1 642 0.60 0.60 0.60 1.00 11.4 16.6 21.0 13.8 20.1 26.0 16.3 23.6 31.0 18.7 27.1 35.9
7HE-7 2 138 1 928 0.60 0.60 0.60 1.00 9.6 14.1 17.9 11.7 17.1 22.2 13.8 20.1 26.4 15.9 23.1 30.6
10HE-5 2 306 2 079 0.60 0.60 0.60 1.00 8.8 13.1 16.6 10.8 15.9 20.5 12.8 18.6 24.5 14.7 21.4 28.4
10HE-6 2 457 2 223 0.60 0.60 0.60 1.00 8.2 12.2 15.5 10.1 14.9 19.2 11.9 17.5 23.0 13.8 20.1 26.6
12HE-6 2 777 2 508 0.62 0.60 0.60a 1.00 7.1 10.7 13.7 8.8 13.1 17.0 10.5 15.4 20.3 12.1 17.7 23.5
14HE-6 3 095 2 795 0.67 0.60 0.60a 1.00 6.4h 9.5 12.2 7.8 11.7 15.2 9.3 13.8 18.2 10.8 15.9 21.1
14HE-7 3 250 2 935 0.69 0.61 0.60a 1.00 6.1h 9.0 11.6 7.3 11.1 14.5 8.8 13.1 17.3 10.2 15.1 20.1
16HE-6 3 411 3 085 0.72 0.63 0.60a 1.00 5.7h 8.5 11.0 6.9 10.5 13.7 8.3 12.5 16.5 9.7 14.4 19.1
18HE-6 3 731 3 371 † 0.67 0.62a 1.00 † * * 6.4h 9.5 12.5 7.5 11.3 15.0 8.8 13.1 17.4
19HE-7 4 043 3 656 † 0.72 0.67a 1.01 † * * 5.8h 8.7 11.5 6.8 10.4 13.8 8.0 12.0 16.1
20HE-7 4 200 3 801 † 0.74 0.70a 1.05 † * * 5.6h 8.3 11.0 6.7h 10.0 13.3 7.7 11.5 15.4
21HE-7 4 362 3 942 † † 0.73 1.09 † † * † * * 6.4h 9.5 12.7 7.3 11.1 14.9
12HE-18 4 634 4 188 † † 0.77 1.16 † † * † * * 6.0h 8.9 12.0 6.8 10.4 14.0
14HE-18 4 950 4 478 † † 0.83 1.24 † † * † * * † * * 6.5h 9.7 13.0
14HE-19 5 106 4 612 † † 0.85 1.28 † † * † † * † * * 6.2h 9.3 12.6
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN highway loads and for Australian 300-A-14, M250, M270 railway loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 ‘h’ denotes solution for highway load only.
5 ‘a’ for 3.0 and 4.0 mm 10 bolts/m use solution from columns 3 and 4.
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99 AS/NZS 2041:1998
TABLE F7
COVER LIMITS FOR CLASS 2 ALUMINIUM VERTICAL ELLIPSES—HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Structurenumber
Maximuminternal span
Internalrise
Minimum cover highway loads Minimumcover
railwayloads
Maximum cover, m
Plate thickness, mm
3.0 4.0 3.0 to 6.0 3.0 4.0 5.0 6.0
Bolts/metre Bolts/metre
mm mm 10 10 10, 15, 20 m 10 15 20 10 15 20 10 15 20 10 15 20
5VE-5 1 363 1 509 0.60 0.60 0.60 1.00 15.5 22.4 28.3 18.7 27.1 34.9 21.9 31.7 41.5 25.1 36.4 48.2
6VE-6 1 642 1 826 0.60 0.60 0.60 1.00 12.7 18.5 23.4 15.4 22.4 28.9 18.1 26.3 34.4 20.8 30.2 39.9
7VE-7 1 928 2 138 0.60 0.60 0.60 1.00 10.7 15.7 19.9 13.1 19.0 24.6 15.4 22.4 29.3 17.6 25.7 34.0
5VE-10 2 080 2 305 0.60 0.60 0.60 1.00 9.9 14.5 18.4 12.1 17.6 22.8 14.2 20.7 27.2 16.3 23.8 31.5
6VE-10 2 223 2 457 0.60 0.60 0.60 1.00 9.2 13.6 17.2 11.2 16.5 21.3 13.3 19.4 25.4 15.3 22.2 29.5
6VE-12 2 507 2 778 0.60 0.60 0.60 1.00 8.0 12.0 15.2 9.9 14.5 18.9 11.7 17.1 22.5 13.5 19.7 26.1
6VE-14 2 795 3 095 0.62 0.60 0.60a 1.00 7.0 10.6 13.6 8.7 13.0 16.9 10.4 15.3 20.1 12.0 17.6 23.4
7VE-14 2 935 3 250 0.64 0.60 0.60a 1.00 6.6 10.1 12.9 8.3 12.3 16.1 9.9 14.6 19.2 11.4 16.8 22.3
6VE-16 3 085 3 410 0.67 0.60 0.60a 1.00 6.4h 9.6 12.3 7.8 11.7 15.3 9.3 13.8 18.2 10.8 15.9 21.2
6VE-18 3 371 3 730 0.71 0.62 0.60a 1.00 5.8h 8.7 11.2 7.0 10.7 13.9 8.4 12.6 16.6 9.8 14.5 19.3
7VE-19 3 656 4 042 0.76 0.66 0.61a 1.00 5.3h 7.9 10.2 6.5h 9.7 12.8 7.7 11.6 15.3 9.0 13.4 17.8
7VE-20 3 801 4 201 * 0.68 0.63a 1.00 † * * 6.3h 9.3 12.3 7.3 11.1 14.7 8.6 12.8 17.1
7VE-21 3 942 4 362 * 0.70 0.66a 1.00 † * * 6.0h 9.0 11.8 7.0 10.7 14.2 8.2 12.3 16.5
18VE-12 4 188 4 634 * 0.74 0.70a 1.05 † * * 5.6h 8.4 11.1 6.7h 10.0 13.3 7.7 11.6 15.5
18VE-14 4 478 4 950 * * 0.75 1.12 † † * † * * 6.2h 9.3 12.4 7.1 10.8 14.5
19VE-14 4 615 5 107 * * 0.77 1.15 † † * † * * 6.0h 9.0 12.0 6.8 10.4 14.0
20VE-14 4 752 5 264 * * 0.79 1.19 † † * † * * 5.8h 8.7 11.6 6.8h 10.1 13.6
18VE-18 5 051 5 587 * * 0.84 1.26 † † * † * * † * * 6.3h 9.4 12.8
NOTES:
1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New Zealand HO-HN highway loads and for Australian 300-A-14, M250, M270 railway loads.
2 * Denotes structure exceeds AS/NZS 2041 flexibility limits.
3 † Denotes no solution for this gauge and bolt density.
4 ‘h’ denotes solution for highway load only.
5 ‘a’ for 3.0 and 4.0 mm 10 bolts/m use solution from columns 3 and 4.
COPYRIGHT
Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]
AS/NZS 2041:1998 100
APPENDIX G
LIVE LOAD COMPARISON
(Informative)
The relationship of live load pressure to cover height for various standard vehicles isshown in Figure G1. Impact factors are included.
FIGURE G1 LIVE LOAD COMPARISON
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101 AS/NZS 2041:1998
APPENDIX H
FLOWABLE FILL
(Informative)
H1 GENERAL Controlled low strength material (flowable fill) may provide a materialof suitable stiffness to be a viable alternative to the usual mechanically compacted soilbackfill where any or all of the following apply:
(a) Installation speed is critical.
(b) Narrow trench widths make compaction around the structure haunches difficult.
(c) The spacing for multiple cell structures is less than that specified in Clause 6.4.
(d) The local native soil does not satisfy the preferred select fill grading requirementsof Clause 6.6.1 or the acceptable corrosion limits of Table C1.
Flowable fill is typically composed of a mixture of granular material, fly ash, cement andwater proportioned to achieve a compressive strength in the range 0.6 to 3 MPa at 28 days(see Clause 6.6.2 and Table 5.2).
H2 MIX PROPORTIONS The following typical flowable mix should achieve thespecified strength:
Material % by weight Standard
Portland cement 3 AS 3972 (GP)
Fly ash 8 AS 3582.1
Granular material 72 —
Water 17 —
NOTE: The above mix proportions are provided as a guideonly.
H3 MIX FLOWABILITY Flowability of flowable fill is important to achieveadequate support around structure haunches. A high slump of 160–200 mm isrecommended and typically achieved with the above mix proportions. If required,aggregate fillers with rounded, rather than angular, particles will improve the mixflowability.
H4 GRANULAR MATERIALS GRADING Where applicable, a suitable granularmaterial grading for flowable fill is as follows:
Sieve size % passing
19 mm 100
0.075 mm 0–10
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AS/NZS 2041:1998 102
H5 STRENGTH Flowable fill strength is controlled by the cement and fly ashcontents. The mix proportions in Paragraph H4 have been shown to achieve a modulus ofelasticity which is similar to that of typical (graded) backfill compacted to 85–95 percentrelative density. Higher strength flowable fills can achieve improved support around thehaunches of pipe arches and underpass shapes. Consideration should also be given to thepossibility of future backfill excavation when specifying higher strengths for general use.
H6 PLACEMENT Flowable fill is normally transported to site in ready-mixed formwith normal care being taken to minimize segregation during transportation or is mixedusing mobile batching equipment, where fill quantities are sufficient to make thateconomically feasible. Placement into the trench around the structure should be directlyfrom the transit mix chute. Mechanical vibration may be necessary to ensure penetrationof the fill around the structure and, in particular, the structure haunches.
Flowable fill should not be used as bedding unless the columns of soil on each side of thestructure are sufficiently stiff to ensure positive soil arching occurs. Typically, the zone offlowable fill placed around haunches, beside and/or over the structure is equal in stiffnessto that specified for select compacted fill. Where native or embankment material in thetrench wall exhibits strength equal to or exceeding select compacted fill, trench widthsmay be reduced and a higher strength flowable fill may be adopted.
Flowable fill normally requires 1 to 4 hours to achieve sufficient stiffness to providesupport to a corrugated metal structure. However, the time period required for the fill togain sufficient strength to carry live loads should be determined, based on informationprovided by the flowable fill supplier.
The appropriate lift height for flowable fill depends on the structure size, the extent of thefill zone, the practicality of loading the structure against flotation and the pouring rate.For large fill areas, typically the flow rate dictates shallow lift heights, which avoidflotation.
Flotation calculations should be carried out to determine a suitable flowable fill liftthickness. Uplift forces are equal to the mass of flowable fill displaced by the structure,minus the mass of the structure. Flowable fill ceases to be fluid within about one hour ofplacement depending on site drainage conditions and temperature.
At all times, structure shape and position should be monitored and maintained within thetolerances specified.
Where deep flowable fills are to be used over the structure crown, the designer shouldallow for reduced soil arching during construction and check that an adequate safetyfactor has been allowed.
H7 DURABILITY Flowable fill is less susceptible to erosion or loss of fines duringflooding than compacted fill. However, culvert inlet and outlet protection against scour orfill saturation should still be evaluated for each specific site.
Acceptable pH and resistivity limits are provided in Table C1 of this Standard. In poorlydrained conditions, modified fills may initiate higher soil-side corrosion rates on metalstructures.
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