HelCor®& HelCor PA®HELICALLY CORRUGATED STEEL PIPES
HELCOR druk_geosyntetyki II.qxd 2012-09-28 13:22 Strona 2
Table of Contents
2
3
4
5
6
8
13
14
16
18
19
20
22
24
26
1. Applications
2. Steel
3. Plate thickness and corrugation types
4. Production
5. Section lengths and coupling bands
6. Geometric and hydraulic parameters
7. Tolerances
8. Durability
9. Pipe end finishing
10. Fittings
11. Cover depth
12. Bedding and backfilling
13. Structural design
14. Installation and construction procedures
15. Other applications
1.www.viacon.pl
1. Introduction
3.www.viacon.pl
The history of corrugated steel pipes dates back to 1896, when its production was started in the United States.
The first helically corrugated steel pipes were also produced at that time in Russia, where 1300 m of this product was used as culverts under the railway
lines. In Poland, the pipes appeared at the end of the 1970s , and since then they have been increasingly popular among designers and contractors.
Helically corrugated steel pipes HelCor and pipe-arches HelCor PA pro-
duced by ViaCon make up complete systems used in civil engineering as:
- roads and railway culverts
- underground passages
- ecological passages
- hydro technical structures
- relining of existing old structures
Complete system of helically corrugated pipes
includes elbows or T-connections and also
additional elements such as manholes, inspection
chambers etc.
According to the European Standard PN-EN 1991-
2:2007 HelCor and HelCor PA pipes can be used as
engineering structures for every class of road and
railway (up to V=200km/h) load.
HelCor and HelCor PA pipes have Technical
Approval issued by Polish Road and Bridge Research
Institute (IBDiM). They have been approved for use in
Scandinavia, The Baltic States, Switzerland,
Hungary, Slovakia, The Czech Republic, Romania, Austria, The Ukraine,
Belorus and other European countries. HelCor and HelCor PA are
approved by Polish Central Mining Institute (GIG) to be used on subsi-
dence areas.
Installation time for HelCor and HelCor PA is much shorter then for
concrete pipes. Easy and quick assembly helps in limiting time for
construction of culverts or other structures and allows to construct culvert
in stages without stopping the traffic as well as during winter time.
Construction of culverts with the use of HelCor and HelCor PA is much
cheaper than traditional concrete culverts.
Pipes are produced in Rydzyna (PL) and are delivered to many European
countries.
1. Applications
2.
3.www.viacon.pl
2. Steel
Steel used for the production of HelCor and HelCor PA pipes, as well as coupling bands
conform to the European Standards:
- EN 10327:2006 “Continuously hot-dip coated strip and sheet of low carbon steels for
cold forming – Technical delivery conditions”
- EN 10326:2006 “Continuously hot-dip coated strip and sheet of structural steels -
Technical delivery conditions”
- 600 g/m2 zinc coating both sides, equivalent to 42μm on each side
- 1000 g/m2 zinc coating both sides, equivalent to 70μm on each side
- 600 g/m2 zinc coating both sides, equivalent to 42μm on each side, with
an additional 250μm polymer film (TrenchcoatTM or W-Protect®) on one
or both sides
Steel is delivered in coils, with a protection coating in accordance to a/m standards:
EN-10327
EN-10326
[MPa]
-
250
[MPa]
270 - 500
330
[%]
22
19
DX51D
S250GD
Standard Yield point Re Tensile strength Rm
HelCor and HelCor PA pipes steel mechanical properties
Elongation A80minSteel grade
3. Plate thickness and corrugation types
4.
HelCor and HelCor PA pipes are produced from steel strips with thickness ranging from 1,25mm to 3,5mm in two types of corrugation
- D1 - 68 x 13 mm
- D3 - 125 x 26 mm
Area of sectionA
Moment of InertiaIx
Section ModulusWx
Area of sectionA
Moment of InertiaIx
Section ModulusWx
Sectional properties of corrugated steel
Corrugation 68 x 13 [mm] Corrugation 125 x 26 [mm]
[mm] [mm2/mm] [mm4/mm] [mm3/mm] [mm2/mm] [mm4/mm] [mm3/mm]
Plate thickness
1,62
2,16
2,70
2,92
3,24
3,78
31,5
40,9
52,0
56,2
64,0
74,7
4,4
5,6
6,8
7,3
8,0
9,3
1,66
2,21
2,77
2,99
3,32
3,88
142,8
190,9
239,9
259,1
289,0
337,2
10,4
13,7
16,7
18,1
19,7
23,0
1,5
2,0
2,5
3,0
2,7
3,5
4. Production
5.
HelCor pipes are produced by cold forming of the steel strip into a round corrugated
shape with diameters ranging from 300mm to 3600mm. During forming of the pipe
a lock-seam is performed to keep the pipe integrity.
HelCor Pipe Arches are produced through controlled mechanical deformation of HelCor pipes with the use of hydraulic jacks.
www.viacon.pl
5. Section lengths and coupling bands
6.
The standard lengths of HelCor pipes are 6m, 7m and 8m, however the production process allows the manufacturing of any
length of pipe.
The pipe-arches are produced in 6m long segments from HCPA-01 to HCPA-20 and 7m and 8m long segments from HCPA-
21 to HCPA-50.
Typically the pipes are bevel cut in factory in accordance with the design to conform the slope and the skew angle. Cut ends
are protected against corrosion. In order to obtain the designed length of the pipe, several segments are joined with coupling
bands.
The coupling bands are made out of flat or corrugated steel. Depending on the diameter and purpose of the pipe, different
types and widths of coupling bands are used.
TYPE 1: flat connected by bolts – for diameters 300-1400 mm
TYPE 2: helically corrugated connected by bolts – for diameters 300–3600 mm
TYPE 3: helically corrugated connected by bolts in tubes (for relining)
TYPE 4: annular corrugated for connection of pipes with re-corrugated ends
7.
Coupling band diameter for HelCor pipes and dimensions for
HelCor PA depend on pipe diameter or span/rise of pipe arch
cross section.
TYPE 1 TYPE 4TYPE 2 TYPE 3
Coupling band type Width[mm]
Tolerance[%]
TYPE 1
TYPE 2
TYPE 3
TYPE 4
345 to 729
350 to 800
350 to 800
330
Acc to EN 10143:1997
±2%
±2%
±2%
For HelCor PA pipes only helically corrugated coupling bands (TYPE 2 or TYPE 3) are used.
Coupling bands dimensions and tolerances
www.viacon.pl
6. Geometric and hydraulic parameters
8.
Thickness parameters for respective diameters/dimensions of HelCor and HelCor PA pipes are given in the table below.
Standard plate thickness is shown with bold, but it is possible to manufacture a pipe of a different plate thickness.
Standard plate thickness is calculated for A Class of live load acc to Polish Bridge Standard PN-85/S-10030 (4 x 200kN x 1,5
factor = 1200KN, four axis vehicle), with minimum cover calculated as shown in chapter 11 of this catalogue. If other live load
is expected, plate thickness should be checked assuming respective standard requirements. For more details or other
solutions please contact the ViaCon technical department or your local dealer / representative.
HelCor Pipes
Diameter
[mm]
Cross sectionarea[m2]
CorrugationPlate thickness*
[mm]
Zinc coatingZinc coating
+ TrenchcoatTM layer
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
0,07
0,12
0,19
0,28
0,38
0,50
0,63
0,79
0,95
1,13
1,32
1,54
1,76
2,01
2,27
2,54
2,83
3,14
3,46
3,80
4,15
4,52
4,91
5,30
5,72
6,15
6,60
7,06
7,55
8,04
8,55
9,08
9,62
10,18
D1
D1
D1
D1
D1
D1
D1
D1 / D3
D1 / D3
D1 / D3
D1 / D3
D1 / D3
D1 / D3
D1 / D3
D1 / D3
D1 / D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
1,5
1,5
1,5
1,5 / 2,0
1,5 / 2,0
1,5 / 2,0
1,5 / 2,0
1,5 / 2,0 / 2,5
2,0 / 2,5
2,0 / 2,5
2,0 / 2,5
2,0 / 2,5 / 3,0
2,0 / 2,5 / 3,0
2,0 / 2,5 / 3,0
2,0 / 2,5 / 3,0
2,5 / 3,0 / 3,5
2,5 / 3,0 / 3,5
2,5 / 3,0 / 3,5
2,5 / 3,0 / 3,5
2,5 / 3,0 / 3,5
2,5 / 3,0 / 3,5
2,5 / 3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,5
3,5
3,5
3,5
3,5
3,5
Weight[kg/m]
Plate thickness*[mm]
Weight[kg/m]
13,0
17,3
21,7
34,7
40,5
46,2
52,0
57,8
63,6
69,4
75,1
106,5
114,1
121,7
129,3
164,3
173,5
182,6
191,7
200,8
210,0
219,1
266,3
276,9
287,6
298,2
308,9
319,5
330,2
340,8
351,5
362,1
372,8
383,4
1,6
1,6
1,6
1,6 / 2,0
1,6 / 2,0
1,6 / 2,0
1,6 / 2,0
1,6 / 2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,5 / 2,7 / 3,0 / 3,5
2,5 / 2,7 / 3,0 / 3,5
2,7 / 3,0 / 3,5
2,7 / 3,0 / 3,5
2,7 / 3,0 / 3,5
2,7 / 3,0 / 3,5
2,7 / 3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,0 / 3,5
3,5
3,5
3,5
3,5
3,5
3,5
14,4
19,2
24,0
35,7
41,7
47,7
53,6
59,6
65,5
71,5
77,4
109,1
116,9
124,7
132,5
167,7
177,0
186,3
195,6
205,0
214,3
223,6
271,0
281,8
292,6
303,5
314,3
325,1
336,0
346,8
357,7
368,5
379,3
390,2
9.
HelCor PA Pipes
Span / rise[m]Type
Cross sectionarea[m2]
Corrugation
1,34/1,05
1,44/0,97
1,49/1,24
1,62/1,10
1,65/1,38
1,80/1,20
1,80/1,50
1,84/1,39
1,84/1,48
1,89/1,55
1,91/1,46
1,95/1,32
2,01/1,59
2,04/1,49
2,10/1,45
2,10/1,55
2,14/1,64
2,16/1,62
2,20/1,71
2,23/1,68
2,28/1,70
2,35/1,77
2,35/1,73
2,37/1,83
2,48/1,79
2,49/1,83
2,55/1,86
2,58/1,94
2,60/1,93
2,75/1,95
2,76/2,05
2,80/2,01
2,84/2,02
2,95/2,04
2,96/2,16
2,97/2,00
3,08/2,08
HCPA-01
HCPA-02
HCPA-03
HCPA-04
HCPA-05
HCPA-06
HCPA-07
HCPA-08
HCPA-09
HCPA-10
HCPA-11
HCPA-12
HCPA-13
HCPA-14
HCPA-15
HCPA-16
HCPA-17
HCPA-18
HCPA-19
HCPA-20
HCPA-21
HCPA-22
HCPA-23
HCPA-24
HCPA-25
HCPA-26
HCPA-27
HCPA-28
HCPA-29
HCPA-30
HCPA-31
HCPA-32
HCPA-33
HCPA-34
HCPA-35
HCPA-36
HCPA-37
1,13
1,10
1,46
1,42
1,82
1,70
2,15
2,04
2,16
2,32
2,23
2,04
2,55
2,41
2,42
2,59
2,74
2,80
2,99
2,93
3,03
3,28
3,16
3,45
3,47
3,61
3,73
3,97
3,97
4,20
4,48
4,43
4,58
4,69
5,06
4,57
4,94
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D1
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
2,0 / 2,5
2,0 / 2,5
2,0 / 2,5
2,0 / 2,5
2,0 / 2,5
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
2,5 / 3,0
3,0
3,0
3,0
3,0
3,0
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
86,7
87,4
98,3
97,5
109,1
130,9
143,0
140,4
143,9
149,1
147,4
142,2
156,9
153,5
156,9
158,7
166,5
166,5
169,9
169,9
214,1
219,4
217,3
219,4
227,9
230,1
234,3
240,7
240,7
250,8
255,6
255,6
258,8
267,3
271,6
265,2
274,8
88,8
89,6
100,7
99,9
111,8
133,6
146,0
143,3
146,9
152,2
150,4
145,1
160,1
156,6
160,1
161,9
169,9
169,9
173,4
173,4
217,8
223,3
221,1
223,3
231,9
234,1
238,4
244,9
244,9
255,2
260,1
260,1
263,4
272,0
276,4
269,9
279,6
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,0 / 2,5 / 2,7
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,5 / 2,7 / 3,0
2,7 / 3,0
2,7 / 3,0
2,7 / 3,0
2,7 / 3,0
2,7 / 3,0
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
Plate thickness*[mm]
Zinc coatingZinc coating
+ TrenchcoatTM layer
Weight[kg/m]
Plate thickness*[mm]
Weight[kg/m]
www.viacon.pl
10.
* Plate thickness tolerances acc. to EN 10143:1997.
3,14/2,27
3,17/2,06
3,23/2,12
3,23/2,15
3,28/2,17
3,33/2,23
3,33/2,39
3,35/2,19
3,38/2,25
3,49/2,27
3,52/2,49
3,65/2,39
3,67/2,61
HCPA-38
HCPA-39
HCPA-40
HCPA-41
HCPA-42
HCPA-43
HCPA-44
HCPA-45
HCPA-46
HCPA-47
HCPA-48
HCPA-49
HCPA-50
5,63
5,12
5,41
5,39
5,67
5,97
6,29
5,65
5,60
6,28
6,91
6,85
7,52
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
D3
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
288,6
279,1
285,4
288,6
289,7
298,2
305,7
297,2
300,9
306,8
319,5
323,8
336,6
293,7
284,0
290,5
293,7
294,8
303,5
311,1
302,4
306,2
312,1
325,1
329,5
342,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
For the same water level the pipe-arch shape has 65% - 100% better water flow capacity than a round
pipe with the same rise.
HelCor PA Pipes
Span / rise[m]Type
Cross sectionarea[m2]
CorrugationPlate thickness*
[mm]
Zinc coatingZinc coating
+ TrenchcoatTM layer
Weight[kg/m]
Plate thickness*[mm]
Weight[kg/m]
11.
Hydraulic parameters
The
abov
e ta
ble
show
s th
e re
fere
nce
wat
er fl
ow Q
mfo
r H
elC
or p
ipes
with
wat
er le
vel a
t 75%
hei
ght b
ut a
t lea
st 2
5 cm
from
the
crow
n, a
ccor
ding
to P
olis
h na
tiona
l
regu
latio
ns.
Wat
er-fl
ow r
egul
atio
ns m
ay d
iffer
slig
htly
dep
endi
ng o
n na
tiona
l st
anda
rds.
For
mor
e de
tails
or
othe
r so
lutio
ns p
leas
e co
ntac
t th
e V
iaC
on t
echn
ical
depa
rtm
ent o
r yo
ur lo
cal d
eale
r /
repr
esen
tativ
e.
www.viacon.pl
12.
Hydraulic parameters
The
abov
e ta
ble
show
s th
e re
fere
nce
wat
er f
low
Qm
for
Hel
Cor
PA
pip
es w
ith w
ater
leve
l at
75%
hei
ght
but
at le
ast
25 c
m f
rom
the
cro
wn,
acc
ordi
ng t
o P
olis
h
natio
nal
regu
latio
ns.
Wat
er-fl
ow r
egul
atio
ns m
ay d
iffer
slig
htly
dep
endi
ng o
n na
tiona
l st
anda
rds.
For
mor
e de
tails
or
othe
r so
lutio
ns p
leas
e co
ntac
t th
e V
iaC
on
tech
nica
l dep
artm
ent o
r yo
ur lo
cal d
eale
r /
repr
esen
tativ
e.
13.
7. Tolerances
Manufacturing tolerance of HelCor
and HelCor PA length is ±0,5% of the
designed length.
A gap between two pipes connected
with a coupling band should not
exceed 30 mm.
Parameter Unit Acceptable tolerance
Diameter deviation % of nominal diameter
% of pipe diameterDiameter deformationafter backfilling
± 1,5
± 2,0
Parameter Unit Acceptable tolerance
Dimensions deviationfor pipe corrugation
68x13mm
Dimensions deviationfor pipe corrugation
125x26mm
Dimensions deformationafter backfilling
% of nominal equivalentdiameter
% of nominal equivalentdiameter
% of pipe span
± 2,0
± 5,0
± 2,0
Manufacturing tolerances of HelCor pipes
Manufacturing tolerances of HelCor PA pipes
www.viacon.pl
14.
8. Durability
Type of corrosion protection of HelCor and HelCor PA pipes determines
the durability of the culvert. ViaCon offers three types of corrosion
protection, which allows the long term operation of the culvert in any given
environmental condition in the most economical way.
TRENCHCOATTM and W-Protect® coating
Coating steel with a polymer film, called trenchcoating, is a technique invented, patented and used in USA since 1974
and in Europe since the beginning of 1998. The zinc coated steel strip is covered with a polymer foil in a fully controlled in-house
process. As a result a very smooth and highly adhesive layer of polymer film protects galvanized coating. Production process
conforms to EN 10169 (W-Protect®) and ASTM 742 (TrenchcoatTM). TrenchcoatTM film can be applied on either one or both sides
of the pipe. Protection obtained in such a process is the best way to prevent natural corrosion in zinc and steel, it also protects
against mechanical damage and chemical corrosion. Research findings indicate that TrenchcoatTM film resists aggressive
chemicals in excellent way. This is the best corrosion protection that is available on the culvert market today. It guarantees over
100 years life-time in most environmental conditions.
Non-aggressive environment Aggressive environment
Atmosphere aggressivenesscategory according to EN ISO 12944-2
Zinc coating 42 μm(600g/m2)
Zinc coating 70 μm(1000g/m2)
Zinc coating 42 μm (600g/m2) +polymer coating 250 μm
Water parameters
Cor
rosi
on p
rote
ctio
n en
dura
nce
Soil parameters
- C1- C2
- C3- C4- C5-I, C5-M
- pH from 6,5 to 8,0- hardness of water ≥ 20 mg Ca/I- speed of water ≤ 1,5 m/s
- pH from 6,0 to 8,0- soil permeability
k ≥ 8,0 m/24h- no organic parts- non-uniformity Cu ≥ 5 - humidity ≤ 17%
- pH from 3,0 to 6,0 & from 8,0 to 12,0
- soil permeability k < 6,0 m/h
- contains organic parts- non-uniformity Cu < 5- humidity > 17%
- pH from 3,0 to 6,5 & from 8,0 to 12,0
- hardness of water < 20 mg Ca/I- speed of water > 1,5 m/s
min. 40 years
50 - 70 years
Not recommended
20 – 50 years
over 100 years 80 to 100 years
15.
Dielectric strength of TrenchcoatTM
is 86,6 kV/mm which gives
21,6 kV for the thickness of
250 μm. This considerably out-
numbers the value of the stray
currents arising within the electri-
fied railway lines sub grade. Using
TrenchcoatTM guarantees 100%
protection against the corrosion
that may be caused by stray
currents.
* - NH4OH, H2SO4, HNO3 test at 80OC stopped due to formation of gases
** - (CH3)2CHOH, CO(CH3)2, CH3CO-O-C2H5 test at 80OC stopped due to achieve the
boiling point
Additional corrosion protection by painting
In special cases it is possible to protect the galvanized pipes with
the paint of the thickness up to 400μm. Please contact the ViaCon
technical department or your local dealer / representative.
Test
TrenchcoatTM layer chemical aggression resistance test results
Research method Outcome
Resistance to 10% concentration of HCl
Resistance to HNO3
Resistance to NH4OH
Resistance to NaOH
Resistance to 30% concentration of H2SO4
Resistance to NaOH
Resistance to 10% concentration of NaCl
Resistance to SO2 steam
Resistance to chloroform (trichlorometan CHCI3)
ASTM D1308
ASTM D1308
ASTM D1308
ASTM D1308
ASTM D543, A742
ASTM D543, A742
ASTM D543, A742
DIN 50018, 2.0L
ISO 175, 28 days, 230C
ISO 175, 28 days, 230
C
ISO 175, 28 days, 230
C
ISO 175, 28 days, 230
C
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
ISO 175, 90 days
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
No decrease in coating thickness
Resistance to DMSO (dimetylosulfoxyde) (CH3)2SO
Resistance to THF (tetrahydrofuran) C4H8O
Resistance to 20% concentration of NaOHin water
Resistance to 10% concentration of ammoniaCO(NH2)2 in water
Resistance to i-propanol (CH3)2CHOH(izopropyl alkohol)
Resistance to aceton CO(CH3)2
(propanon)
Resistance to C6H5(CH3)(metylobenzen)
Resistance to poliethylen glicol C2nH4n+2On+1
Resistance to 25% concentration of NH4OH
Resistance to 25% concentration of H2SO4
Resistance to 20% concentration of HNO3
Resistance to CH3CO-O-C2H5
Resistance to MeCI2(chloro- metylene)
230C800C230C800C230C800C230C800C230C800C230C800C230C800C230C800C230C800C230C800C
No decrease in coating thickness8% decrease in coating thicknessNo decrease in coating thicknessNo decrease in coating thickness
3% decrease in coating thickness*
4% decrease in coating thickness**
3% decrease in coating thickness**
No decrease in coating thickness*No decrease in coating thickness*
No decrease in coating thickness**
No decrease in coating thickness4% decrease in coating thickness
4% decrease in coating thicknessDestruction of the coating
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Using HelCor and HelCor PA pipes enables an accurate adjustment of both ends to fit the slope and in the required angle. Bevel
cut can be done on one or both sides with full bevel or step bevel. It is recommended to use a vertical step of 1/3 the height of
the pipe.
The embankment slopes in the in- and outlet areas can be reinforced in several ways:
Vertical end pipe:
- vertical reinforced concrete head wall
- vertical wall made of gabions
Bevel end pipe:
- reinforcement of the slope with concrete or stone blocks placed
on sand-cement mix
- reinforcement with perforated concrete panels
- reinforcement with stone rip rap
- reinforcement with reinforced concrete collar
16.
9. Pipe end finishing
It is possible for both skewed inlet/outlet of the culvert (at the culvert
and road axis intersection angle ≠ 90°) to be square beveled.
Minimum allowable skew angle is 55°.
In special cases it is necessary to make additional reinforcements
in the skewed area.
17.www.viacon.pl
18.
10. Fittings
Depending on the function of the structure, HelCor and HelCor PApipes can be equipped with additional elements, e.g.
fittings
connection pipes
grids
latches, walls throttles, etc.
elbows, three-way adapters, flanges
manholes, pumping stations equipment
steel shelves for animals
19.
11. Cover depth
Culvert cover under road can be described as a vertical distance between the top of the culvert and the road grade-line,
including the road pavement construction.
Culvert cover under railway can be described as a vertical distance between the top of the culvert and the bottom of the railway
sleeper, including the construction layers of the railroad.
Below formulas can be used for calculation of the depth of cover for the A-class road live load or the k+2 class railway live load
(UIC-71), respectively to the Polish Bridge Standard PN-85/S-10030, providing that the standard thickness of the pipe wall is
applied (as described in chapter 6). If other live load is expected, plate thickness should be matched with respective standard
requirements.
For road applications, the minimum allowable depth of cover is the largest of:
H=B/6 [m], H=B/8+0,2 [m], H≥0,6 m
For the railway applications, the minimum allowable depth of cover is the largest of:
H=B/4 [m], H≥0,6 mwhere:
H – depth of cover [m]
B – diameter or span of a pipe [m]
When the thickness of road surface structure
is greater then minimum cover, the aggre-
gate thickness over the structure should be
at least 0,10 – 0,15 m, measured from the top
of the pipe.
For the road culverts in special conditions,
e.g. exits from main roads, the minimum
depth of cover can be 0,3m. In a case when
it is necessary to build a culvert with a lower cover or with a non-standard thickness of the steel, a static calculations should
be performed.
When technological traffic should run over the culvert on a job site, special features should apply. The minimum cover must
be adjusted to extreme construction. It can be performed as placing concrete slabs over the culvert or adding another layer
of compacted soil. Stopping of the construction equipment directly over or directly next to a culvert is not allowed.
For more details or other solutions please contact the ViaCon technical department or your local dealer / representative.
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20.
12. Bedding and backfilling
Requirements for bedding preparation:
- bedding should extend transversely to at least half of pipe’s diameter or span, and not less than 0,60m on each side of the culvert
- thickness of bedding should not be smaller than 20cm (30cm recommended)
- aggregate degree of compaction should not be smaller than Is=0,98 according to standard Proctor density
- extra layer with 5cm of loose sand material should be made on the bedding so that the pipe corrugation can be seated on the
bedding.
HelCor and HelCor PA pipes tolerates uneven settlements of the subsoil very well. They can be successfully used on soft soils
and subsidence areas. It is related to distribution of pressure around the pipes which in contrary to concrete pipes, limits the
downward pressure directly under pipe.
In order to ensure correct work of flexible pipe several conditions must be fulfilled, i.e. concerning bedding preparation, making of
aggregate foundation as well as proper backfilling of the structure. Appropriate performance of structure and its durability depends
on quality of these steps. The designer should specify the load bearing capacity of the subsoil on which HelCor pipe should be
placed. Subsoil which does not meet the demands should be reinforced with use of geotextile or other common geotechnical
means.
Graining of the bedding and backfilling material (gravel, coarse, gravel-sand mixture) depends on the corrugation type. Maximum
size of grain in the vicinity ( 0,3m - 0,5m) of HelCor and HelCor PA is 31,5mm. For remaining zone bigger grains can be used.
Material for bedding and backfill should meet the following demands:
non-uniformity index
curvature index
permeability
Cu>5,0
1<Cc<3
U>6 m/24 hours
21.
Requirements for backfill preparation:
- backfill adjacent to pipe should exceed its perimeter by half its diameter or
span and not less than 0,60m on each side of the pipe (for installation in
trench minimum is 0,30m).
- backfill should be evenly laid in not compacted layers at maximum 30cm
thick, on each side of the pipe, no more than one layer difference
in elevation on each side of the pipe should be allowed
- degree compaction of each layer should not be less than Is=0,98
standard Proctor density, however, directly near the pipe, Is=0,95 is
allowed
Backfill compaction should be carried out using light backfilling equipment
(vibrating plates or jumping jacks). Heavy backfilling equipment is not
allowed until the full backfill height has been laid. Appropriate compaction in
haunch area of the pipe is very important due to load bearing capacity
of a culvert.
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22.
13. Structural design
Each application of HelCor and HelCor PA pipes requires a technical design, including
estimated loads, hydrological conditions or clearance to choose the appropriate diameter or
dimensions of the pipe. Life-time analysis should specify corrosion protection to be applied.
The design should follow the guidelines issued by ViaCon and local requirements.
HelCor and HelCor PA culverts are produced according to the technical design in its final
form, i.e. length, bevel, skew. All cutting, welding, corrosion protection and coupling bands
are performed by the producer in the factory.
Designing guideline
- selection of pipe diameter or dimensions depending on the function
of a structure (hydraulics, clearance, etc.)
- setting bottom-line of the culvert (proper grade should be designed to
prevent erosion under the pipe)
- checking minimum cover condition for expected live load
- specifying corrosion protection required durability
- specifying thickness of steel wall and corrugation type
- bedding (foundation) and backfill designing
- calculation of culvert length
- selection of pipe end finish type (inlet and outlet)
- other features design
23.
Relining
HelCor and HelCor PA can be used for relining purposes. Prior to relining a good
check of internal dimensions of existing culverts or bridges that will be relined is
required. Also, the bedding conditions need to be investigated. Space in between
existing structures and HelCor or HelCor PA should be filled with concrete
semi-liquid or liquid mixture pressurised in order to fill in the space completely.
A minimum of 10 cm space is recommended (15cm strongly recommended). Load
bearing capacity of the concrete filling the gap is neglected in the static
calculations. The culvert should be secured from any movement when filling the
gap with concrete . Ballasting with sandbags and staged pouring with concrete is
recommended. For HelCor arches determination of placing them on foundations
should be done.
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14. Installation and construction procedures
Soil-structure interaction is a main concept when building flexible culverts. Appropriate assembly in accordance with
the producers guidelines, as well as appropriate backfilling procedures are the key factors in successful installations.
24.
Pipes are delivered to the job site by trucks. Unloading and placing of the pipes should be performed with a use of light
mechanical devices (crane or pay-loaders) with the help of textile belts. Pipes should not be dumped from the truck.
Pipes are connected with coupling-bands. Separate elements (pipes and
coupling-bands) are marked by the producer in a way allowing for fast and cor-
rect assembly.
The process of assembling HelCor and HelCor PA pipes is not complicated
and can be performed by a group of unskilled workers under the supervision
of an engineer. It allows for a quick work, without the use of heavy or specia-
lized mechanical equipment, even in bad weather conditions. Short construc-
tion time reduces the inconvenience in traffic related to blocking of a road, and
the relining allows for carrying out the construction work without stopping the
traffic and dismantling the old structure.
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15. Other applications
HelCor and HelCor PA can be used when building orre-building of the following
26.
underground retention tanks
lightening of concrete decks in bridges
manholes, pump stations,
27.
under- and on-ground ventilation systems
technological tunnels, escape routes, conveyor protection
For further questions, please contact ViaCon technicaldepartment or local dealer or representative.
www.viacon.pl
ViaCon Sp. z o.o.
ViaCon Sp. z o.o. is a member of ViaCon Group established in Sweden and Norway in 1986. At present ViaCon Group operates in a dozen or so European countries and belongs to SAFEROAD® Group. Thanks to the support from the entire group and the possibility of using the shared experience, each member company can offer professional technical consulting and top quality products.
Business profile of the company:
• manufacture, design, sale and installation of plastic and steel pipes and flexible structures used for construction and repair of culverts, bridges, overpasses, tunnels, farm accommodation underpasses, wildlife crossings, other engineering structures, and used also as belt conveyor housings,
• manufacture, design and sale of storm water drainage systems and holding tanks,
• design, sale and installation of geosynthetics, such as non-woven geotextile fabrics, woven geotextile fabrics, geogrids, geomembranes, and bentonite mats,
• sale and lease of temporary bridges,• sale of gabions,• design, manufacture and sale of three
retaining structure systems from reinforced soil.
Woven and non-woven geotextiles
HelCor® MultiPlate MP200HelCor PA®PECOR OPTIMA®
Gabions
Acrow® 700XS® - temporary bridges
HelCor® wells
PECOR OPTIMA® M wells
SuperCor® Geogrids
HelCor® TC holding tanks Pecor Quattro sewage system
ViaWall B retaining walls ViaBlock retaining wallsViaWall A retaining walls
MP200 pl ok_folder-srodek2.qxd 2012-10-08 15:00 Strona 13
ViaCon Sp. z o.o. ul. Przemysłowa 6 64-130 Rydzyna, Polandphone: +48 65 525 45 45fax: +48 65 525 45 55e-mail: [email protected]
Our goal is to improve products and to cooperate closely with customers, scientific and research centres, public administration and suppliers.
That’s why our motto is:
”Let’s Create a Better Future Together”
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