California Department of Transportation
 

DIB 83-02

DESIGN INFORMATION BULLETIN No. 83-02
CALTRANS SUPPLEMENT TO FHWA CULVERT REPAIR PRACTICES MANUAL
Photograph of culvert repairs

This document establishes uniform procedures to carry out the highway design functions of the California Department of Transportation.  It is neither intended as, nor does it establish, a legal standard for these functions.  The procedures established herein are for the information and guidance of the officers and employees of the Department.

This document is not a textbook or a substitute for engineering knowledge, experience or judgment.  Many of the instructions given herein are subject to amendment as conditions and experience may warrant.  Special situations may call for variation from the procedures described, subject to the approval of the Division of Design, or such other approval as may be specifically called for.


Table of Contents Page

         
1.1 INTRODUCTION
  1.1.1 Objectives
  1.1.2 Organization
  1.1.3 Overview of Problem
         
2.1 CULVERT STRUCTURES
  2.1.1 Material
    2.1.1.1 Rigid
      2.1.1.1.1 General
      2.1.1.1.2 Concrete Pipe
      2.1.1.1.3 Other Rigid Materials
        2.1.1.1.3.1 Glass Fiber Reinforced Polymer Mortar (Reinforced Polymer Mortar) or Fiber Reinforced Polymer Concrete Pipe
        2.1.1.1.3.2 Polymer Concrete Pipe
        2.1.1.1.3.3 Fiber Reinforced Concrete Pipe
        2.1.1.1.3.4 Ductile Iron
        2.1.1.1.3.5 Fiberglass - Fiber Reinforced Plastic
    2.1.1.2 Flexible
      2.1.1.2.1 Metal Pipe
      2.1.1.2.2 Plastic Pipe
    2.1.1.3 Culvert Coatings
      2.1.1.3.1 Coatings for Concrete and other Culverts
      2.1.1.3.2 Coatings for Metal Culverts
  2.1.2 Service Life for Culvert Rehabilitation; Geotechnical Factors
    2.1.2.1 Hydrogen-Ion Concentration (pH), Soil Resistivity, Chloride and Sulfate Concentration of the Surrounding Soil and Water
    2.1.2.2 Material Characteristics of the Culvert
    2.1.2.3 Abrasion
         
3.1 PROBLEM IDENTIFICATION AND ASSESSMENT
  3.1.1 Inspection
         
4.1 END TREATMENT AND OTHER APPURTENANT STRUCTURE REPAIRS AND RETROFIT IMPROVEMENTS
  4.1.1 Headwalls, Endwalls and Wingwalls
  4.1.2 Outfall Works
         
5.1 PROBLEM IDENTIFICATION AND ASSOCIATED REPAIR FOR CULVERT BARRELS
  5.1.1 Concrete Culverts
    5.1.1.1 Joint Repair
      5.1.1.1.1 Misalignment
      5.1.1.1.2 Exfiltration
      5.1.1.1.3 Infiltration
        5.1.1.1.3.1 Chemical Grouting
        5.1.1.1.3.2 Internal Joint Sealing Systems
      5.1.1.1.4 Cracked and Separated Joints
    5.1.1.2 Cracks
      5.1.1.2.1 Longitudinal Cracks
      5.1.1.2.2 Transverse Cracks
    5.1.1.3 Spalls
    5.1.1.4 Slabbing
    5.1.1.5 Invert Deterioration/Concrete Repairs
    5.1.1.6 Crown Repair/Strengthening
  5.1.2 Corrugated Metal Pipe Culverts
    5.1.2.1 Joint Repair
    5.1.2.2 Abrasion and Invert Durability Repairs
      5.1.2.2.1 Invert Paving with Concrete
      5.1.2.2.2 Invert Paving with Concreted RSP
      5.1.2.2.3 Steel Armor Plating
      5.1.2.2.4 Shape Distortion
    5.1.2.3 Soil Migration
    5.1.2.4 Corrosion
  5.1.3 Structural Plate Pipe
    5.1.3.1 Seam Defects
    5.1.3.2 Joint Repair, Invert Durability and Shape Distortion
  5.1.4 Plastic Pipe
         
6.1 GENERAL CULVERT BARREL REHABILITATION TECHNIQUES
  6.1.1 Caltrans Host Pipe Structural Philosophy
  6.1.2 Grouting Voids in Soil Envelope
  6.1.3 Rehabilitation Families
    6.1.3.1 Sliplining (General)
      6.1.3.1.1 Sliplining using Plastic Pipe Liners
        6.1.3.1.1.1 Allowable Types of Plastic Liners
        6.1.3.1.1.2 Strength requirements
        6.1.3.1.1.3 Pipe Dimensions
        6.1.3.1.1.4 Grouting
        6.1.3.1.1.5 Joints
        6.1.3.1.1.6 Installation
        6.1.3.1.1.7 Other Considerations
    6.1.3.2 Lining with Cured-In-Place pipes
    6.1.3.3 Lining with Folded and Re-Formed PVC Liner (Fold and Form)
    6.1.3.4 Lining with Deformed-Reformed HDPE Liner
    6.1.3.5 Lining with Machine Wound PVC Liner
    6.1.3.6 Sprayed Coatings
      6.1.3.6.1 Air Placed Concrete & Epoxy or Polyurethane Lining for Drainage Structures
      6.1.3.6.2 Cement Mortar Lining
    6.1.3.7 Man-Entry Lining with Pipe Segments
      6.1.3.7.1 Fiberglass Reinforced Cement (FRC)
      6.1.3.7.2 Fiberglass Reinforced Plastic (FRP)
    6.1.3.8 Other Techniques
         
7.1 INFLUENCING FACTORS
  7.1.1 Hydrology
  7.1.2 Hydraulics
  7.1.3 Safety
  7.1.4 Environmental
  7.1.5 Host Pipe Dimensions and Irregularities
  7.1.6 Coordination with Headquarters
    7.1.6.1 Headquarters Approval for Large Diameter Plastic Liners
    7.1.6.2 Headquarters Assistance/Approval for Pipe Replacement using TEC Methods
    7.1.6.3 Coordination with Geotechnical Design
  7.1.7 Maximum Push Distance for Large Diameter Flexible Pipe Liners
8.1 GUIDELINES FOR COMPARISON OF ALTERNATIVE REHABILITATION TECHNIQUES
  8.1.1 Table of Alternative Repair Techniques
  8.1.2 Process Flow Charts
         
9.1 REPLACEMENT
  9.1.1 Repair vs. Replacement
  9.1.2 Replacement Systems
    9.1.2.1 Open Cut (trench) Method
    9.1.2.2 Trenchless Excavation Construction (TEC) Methods
      9.1.2.2.1 Pipe Jacking
      9.1.2.2.2 Microtunneling
      9.1.2.2.3 Pipe Bursting and Pipe Splitting
      9.1.2.2.4 Trenchless Replacement References
    9.1.2.3 Other Considerations for TEC
         
10.1 NEW PRODUCT APPROVAL PROCESS AND CONSTRUCTION-EVALUATED EXPERIMENTAL FEATURE PROGRAM
         
11.1 OTHER CONSIDERATIONS
  11.1.1 Supporting Roadway and Traffic Loads
  11.1.2 Compaction Grouting
  11.1.3 Future Rehabilitation
         
12.1 APPENDIXES
  Appendix A - Butt Fusion Procedures for Solid Wall HDPE Slipliner
  Appendix B - Flow Chart of the New Product Approval Process
  Appendix C - Caltrans Condition Tables Example
  Appendix D - Typical Resistivity Values and Corrosiveness of Soils
  Appendix E - Crack Repair in Concrete Pipe
  Appendix F - Sources of Information and Industry Contacts
  Appendix G - CIPP Guidance for Resident Engineers
  Appendix H - Case Studies

 

 


This page last updated August 20, 2011