TECHNICAL NOTE

Page 1 Novem ber

2010
TECHNICAL INFORMATION FROM THE CONCRETE PIPE ASSOCIATION OF AUSTRALASIA

Page 1
INSTALLING SMALL Ø CONCRETE PIPENovember
UNDER 2010 – No.1

INSTALLING SMALL Ø CONCRETE PIPE UNDER ROADS

ROADS
AS/NZS 3725:2007 – Design for installation of buried concrete pipes outlines the minimum requirements for the
AS/NZS 3725:2007 – Design for installation of buried concrete pipes outlines the minimum requirements for
installation of concrete pipes in Australia and New Zealand. It includes typical bedding and trench backfill requirements
the installation of concrete pipes in Australia and New Zealand. It includes typical bedding and trench backfill
for installingfor
requirements concrete pipe,
installing and outlines
concrete typical
pipe, and compaction
outlines levels that are
typical compaction necessary
levels that areto ensure the
necessary requirements
to ensure the of the
specified support
requirements of thetype are met.
specified support type are met.

Unfortunately,too
Unfortunately, toooften
oftenthe
theappropriate
appropriatebedding
beddingtechniques
techniquesare
arenot
not
employed and the minimum compaction standards for bedding and
employed and the minimum compaction standards for bedding and
backfill are not met. Whilst the Standard outlines the recommended
backfill are not met. Whilst the Standard outlines the recommended
minimum compaction levels for each support type, it does not provide
minimum
guidance oncompaction
test methods levels for each
to check thissupport
on site.type, it does not
The outcome provide
is that
guidance
culverts on 225,
using test methods to check
300, & 375mm this on site.
diameter pipesThe outcome is that
become
susceptible to circumferential
culverts using 225, 300, & 375mmcracking during construction.
diameter pipes become
susceptible
This Technicalto circumferential
Note is designed cracking during
to provide construction.
specifiers and contractors
with a practical on site guide to assist achieving the required
This Technical Note is designed to provide specifiers and contractors
compaction levels outlined in AS/NZS3725 and to be able to verify
with An
them. a practical on site guide
HS2 installation, to assist
as per Figure achieving the required
1, has been assumed as this
is compaction levels outlined
a typical requirement in AS/NZS3725
for support under a and to be able to verify
roadway.
them. An HS2 installation, as per Figure 1, has been assumed as this
The minimum compaction requirements that must be achieved when
is a typical
installing requirement
to an for underneath
HS2 support support under a roadway.
a road are outlined in
AS/NZS3725, and require the use of selected materials graded in
The minimum compaction requirements that must be achieved when
accordance with Tables 6 & 7 of the Standard (see Tables 1 & 2 below).
installing to an HS2 support underneath a road are outlined in
AS/NZS3725,
Using and require
the appropriate the use of
materials selected
that complymaterials
with thegraded
gradingin
requirements of these tables will enable the required levels of
accordance with Tables 6 & 7 of the Standard (see Tables 1 & 2 below).
compaction to be achieved without excessive compaction efforts.
AS/NZS3725 notes undermaterials
Using the appropriate both thesethat
tables:
comply with the grading
requirements
Acceptable of these
material tables
within the will enable
(tabled) the required
grading levels of
limits would result in
compaction to be achieved without excessive compaction
material that is well graded and free draining. Granular material efforts.
that Figure 1: Modified HS2 bedding requirements as per AS/NZS3725
AS/NZS3725
may notes
exhibit these under both
qualities thesebreak
but would tables:down when wetted, such Figure 1: Modified HS2 bedding requirements
as shale or gravely conglomerates, are not suitable materials and shall as per AS/NZS3725
Acceptable
not be used. material within the (tabled) grading limits would result in material that is well graded and free draining.
Granular material that may exhibit these qualities but would break down when wetted, such as shale or gravely
conglomerates, are not suitable
Sieve size
materials and shall not be used.
Weight passing Sieve size Weight passing
mm % mm %
Sieve size mm Weight passing % Sieve size mm Weight passing %
19.0 100 75.0 100
19.0
2.36 100
100 – 50 9.5 75.0 100 – 50 100
2.36
0.60 100
90 ––20 50 2.369.5 100 - 100
30 – 50
0.60
0.30 90
60 –– 10
20 0.602.36 100 - 30
50 -15
0.30
0.15 60
25 –– 10
0 0.0750.60 25 - 050 -15
0.15
0.075 25
10 -– 00 0.075 25 - 0
0.075 10 - 0 Table 2: Grading limits for select fill in side zone from
Table 1: Grading limits for select fill in bed Table 2: Grading limits for select fill in side
Table 1: Grading limits for select fill in bed and haunch AS/NZS3725 Table 7
and haunch zone from AS/NZS3725 Table 6 zone from AS/NZS3725 Table 7
zone from AS/NZS3725 Table 6.

Concrete Pipe Association

[email protected] www.cpaa.asn.au
of Australasia
 TECHNICAL NOTE
Page 2 INSTALLING SMALL Ø CONCRETE PIPE UNDER ROADS November 2010 – No.1

Tonkin and Taylor Ltd, in a CPAA commissioned report, has provided practical information which is summarised in Table 3
on the compaction testing of pipe support and foundation materials beneath road pavements. This table is a guide which
should assist specifiers and contractors in the prevention of the problems which are generally associated with construction
loading and trench settlement during pavement construction work using steel reinforced concrete pipe. The compaction
and testing guidelines below are considered the minimum likely to produce compliance with the Standard.

Zone Requirement How to achieve Verification/Testing

Foundation Uniform foundation support (refer to Note 1). If CBR is not achieved undercut by 200 to 500 mm Scala Penetrometer, minimum
Minimum CBR of 5% is recommended. (refer to Note 4). value of 1.5 blows/50mm, to
Refill using material from Table 6 of AS/NZS3725 or achieve minimum CBR value of 5%
AP20 material. Compact in 150 mm layers using an refill compaction test by Clegg
80 kg plate compactor with a minimum of 3 to 4 passes. Hammer, minimum CIV of 8.

Bed Compacted uniform bedding support, 100 mm Using material from Table 6 of AS/NZS3725 compacted Using Clegg Hammer,
minimum thickness. ID 60 as per Table 5, using an 80 kg plate compactor with a minimum of minimum CIV of 12 to 15
AS/NZS3725 (refer to Note 2). 3 to 4 passes. (refer to Note 5).
Bed must be prepared to accommodate RRJ
collars with appropriate clearance (refer to Note 3).

Haunch and Haunch and side zone must extend to a minimum Using material from Table 6 of AS/NZS3725 compacted Using Clegg Hammer,
Side depth of 0.5D (minimum 150 mm wide each side). using a 15 to 20 kg hand rammer or “wacker” with a minimum CIV of 12 to 15
ID 60 as per Table 5, AS/NZS3725. Particular attention minimum of 20 to 30 blows on each side. Compact evenly (refer to Note 5).
must be placed on compaction in these zones. on each side.

Overlay Lower overlay extends from top of side zone to 150 mm Using material from Table 6 of AS/NZS3725 compacted using Using Clegg Hammer,
(lower) above the pipe. It is governed by requirements to protect a hand rammer or “wacker” with a minimum of 20 to 30 minimum CIV of 10 to 12
the pipe from damage due to construction equipment. blows on each side. (refer to Note 5).

Overlay Upper overlay extends from 150 mm – 400 mm above Using material from Table 6 of AS/NZS3725 compacted using Using Clegg Hammer,
(upper) the pipe. It is governed by requirements to protect the an 80 kg plate compactor with a minimum of 4 to 5 passes. minimum CIV of 10 to 12
pipe from damage and to provide sufficient strength to (refer to Note 5).
support pavement layers above.

Backfill (2) Backfill extending from 400 mm – 600 mm above pipe. Using GAP 20 or similar approved material compacted in Using Clegg Hammer,
It is governed by requirements to protect the pipe from maximum 150 mm layers using an 80kg plate compactor minimum CIV of 12 to 15
damage and to provide sufficient strength to support with a minimum of 6 to 8 passes. (refer to Note 5).
pavement layers above.

Backfill (1) Backfill extending from 600 mm above pipe to the Using GAP 20 or similar approved material compacted in As per pavement requirements.
underside of the pavement. It is governed by requirements maximum 150 mm layers, standard compaction equipment
to protect the pipe from damage and to provide sufficient may be utilised.
strength to support pavement layers above. Equivalent static axle load must not generate loads in excess
of the pipe class rating. (Check using PipeClass software).

Table 3: Recommendations for small diameter concrete pipe to achieve HS2 compaction requirements
Notes:
1. Uniform support must be achieved in the foundation and bed.
2. The bed zone requires a loosened band, width D/3, immediately under the centre line of the pipe to achieve the uniform support in the bedding required as per
AS/NZS3725. Suggested methods to achieve this are:
a. Rake and loosen D/3 zone no more than 25mm deep.
b. Place 25mm thick loosely compacted even layer of material as per Table 6 AS/NZS3725.
3. Where RRJ pipes are used suitable recesses must be provided in the supporting materials to ensure pipes do not bear on their sockets.
4. Foundation undercut range stated is generally sufficient. Greater undercut may be required in particularly weak foundations.
5. Clegg Hammer values stated are subject to calibration testing for each material type/source against a true density from a testing method such as a Nuclear Densometer.
WARNING: Using material that does not comply with Table 6 AS/NZS3725 may result in a bed zone that does not meet the required uniform support levels.
Applying excessive compaction at a higher trench level in the hope that the desired compaction is achieved in
the critical zones may not only fail to reach the required compaction but could also damage the pipe. This type of
impact is the greatest cause of pipe cracking in Australia and New Zealand today. On this basis it is recommended
that heavy vibratory rollers are only used once a minimum of 600mm cover has been achieved using material and
compaction standards complying with the Standard.
Prevention is always the best cure. To ensure that your concrete pipe culvert requirements are not compromised, ensure that
the appropriate installation techniques and testing requirements are included in specification to AS/NZS3725.

Concrete Pipe Association

[email protected] www.cpaa.asn.au
of Australasia