2041

AS/NZS 2041:1998
Australian/New Zealand Standard

Buried corrugated metal structures
Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]
AS/NZS 2041:1998 This Joint Australian/New Zealand Standard was prepared by Joint Technical Committee CE/25, Corrugated Metal Pipes and Arches. It was approved on behalf of the Council of Standards Australia on 5 December 1997 and on behalf of the Council of Standards New Zealand on 27 March 1998. It was published on 5 May 1998.
The following interests are represented on Committee CE/25: Austroads Australasian Railway Association Australian Chamber of Commerce and Industry Metal Trades Industry Association of Australia New Zealand Heavy Engineering Research Association Standards New Zealand University 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 issue of amendments or new editions as necessary. It is important therefore that Standards users ensure 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 Standards Australia and Standards New Zealand Catalogue of Publications; this information is supplemented each month by the magazines The Australian Standard and Standards New Zealand, which subscribing members receive, and which give details of new publications, new editions and amendments, and of withdrawn Standards. Suggestions for improvements to Joint Standards, addressed to the head office of either Standards Australia or Standards New Zealand, are welcomed. Notication of any inaccuracy or ambiguity found in a Joint Australian/New Zealand Standard should be made without 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.
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 AUSTRALIA 1 The Crescent, Homebush NSW 2140 Australia STANDARDS NEW ZEALAND Level 10, Radio New Zealand House, 155 The Terrace, Wellington 6001 New Zealand
ISBN 0 7337 1790 X
AS/NZS 2041:1998
PREFACE This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee, Corrugated Metal Pipes and Arches, to supersede AS 2041 1984, Corrugated steel pipes, pipe-arches and arches, and AS 2042 1984, Corrugated steel pipes, pipe-arches and arches Design and installation. The objective of this Standard is to provide manufacturers, designers and users of buried corrugated metal pipes, arch-pipes and arch structures as distinct from those products specified 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, and AS 3703.2 1989, Long-span corrugated steel structures Design and installation, with requirements for manufacture and installation and methods for design of such structures for 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 a single document, as the interaction of these influencing factors determines the behaviour of composite soil-corrugated metal structures. Elimination of Class 1 riveted pipe due to obsolescence and upgrade of Class 1 nestable jointing system. Revision of Class 2 steel grade. Revision of structure dimensions and addition of plate layout, bolting arrangement and tolerances. Addition of metals other than steel, structure shapes, alternative protective coatings and wall thicknesses, and modified fill. Addition of arch footing force design and pipe-arch haunch pressure limits. Revision of live loading to conform to current Australian Bridge Design methods and inclusion of non-standard live loads. Revision of height of cover tables. Addition of durability design information.
(b) (c) (d) (e) (f)

(g) (h) (i)
The term informative has been used in this Standard to define the application of the appendix to which it applies. An informative appendix is only for information and guidance.
Copyright
STANDARDS AUSTRALIA / STANDARDS NEW ZEALAND
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AS/NZS 2041:1998
CONTENTS
Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . 1.2 NEW MATERIALS AND METHODS 1.3 REFERENCED DOCUMENTS . . . . . 1.4 DEFINITIONS . . . . . . . . . . . . . . . . . 1.5 CLASSIFICATION . . . . . . . . . . . . . 1.6 NOTATION . . . . . . . . . . . . . . . . . . 1.7 MARKING OF STRUCTURES . . . . .
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SECTION 2 PREFERRED DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SECTION 3 MATERIALS 3.1 CLASS 1 STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.2 CLASS 2 STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SECTION 4 FABRICATION 4.1 CLASS 1 STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.2 CLASS 2 STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4.3 ASSESSMENT AND REPAIR OF DAMAGED COATINGS . . . . . . . . . . . 37 SECTION 5 DESIGN 5.1 DESIGN PHILOSOPHY . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 DESIGN FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 MINIMUM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 WORKING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 DESIGN SOIL COMPACTION AND ARCHING FACTOR 5.6 DESIGN PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 RING COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 SEAM STRENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 ULTIMATE WALL STRESS . . . . . . . . . . . . . . . . . . . . . 5.10 ALLOWABLE WALL STRESS . . . . . . . . . . . . . . . . . . . . 5.11 WALL THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 RIB STIFFENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 ARCH FOOTING FORCES . . . . . . . . . . . . . . . . . . . . . . . 5.14 END-TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 INSTALLATION 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 METHOD OF INSTALLATION . . . . . . . . . . . . . . . . . . . 6.4 MINIMUM SPACING FOR MULTIPLE INSTALLATIONS 6.5 FOUNDATION AND BEDDING . . . . . . . . . . . . . . . . . . . 6.6 BACKFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 MINIMUM COVER FOR ABNORMAL LOADS . . . . . . . 6.8 STRUCTURE SHAPE . . . . . . . . . . . . . . . . . . . . . . . . . .
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AS/NZS 2041:1998
Page APPENDICES A ORDERING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 B MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD 65 C DURABILITY DESIGN AND PROTECTIVE SYSTEMS . . . . . . . . . . . . . . . 67 D AS 2041 STRUCTURAL DESIGN FLOW CHART . . . . . . . . . . . . . . . . . . . 73 E REFERENCE TABLES FOR MINIMUM COVER FOR STEEL STRUCTURES 74 F REFERENCE TABLES FOR MINIMUM COVER FOR ALUMINIUM STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 G LIVE LOAD COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 H FLOWABLE FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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, design methods and installation of buried corrugated metal pipes, pipearches, arches and special shapes comprising bolted corrugated metal sheets or plates manufactured within the limits given in Table 1.1 and Section 2. It deals only with those structures in which the sheets or plates have circumferential corrugations running normal to the longitudinal axis of the structures. The Standard does not cover the design of arch footings, rib stiffening or those structures covered 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 demonstrating compliance with this Standard for manufacture of the metal components is given in Appendix B. Information on the assessment of durability is given in Appendix C. Buried corrugated metal structures withstand applied loads through the interactive behaviour of the flexible metal ring and the surrounding soil envelope. The stiffness of both of these materials is considered during design.
1.2 NEW MATERIALS AND METHODS This Standard does not preclude the use of corrugated profiles, cross-sections, materials or installation methods other than those specified in this Standard, provided that such new corrugated profiles, cross-sections or materials have been proven by appropriate performance testing to be equal to or better than those described herein.
NOTE: Variations to cross-sectional shape, corrugation profile, material or backfill characteristics, including the degree of compaction, may have significant effects on the performance of these structures.
1.3 REFERENCED DOCUMENTS Standard:
The following documents are referred to in this
NOTE: To facilitate the use of this joint Australian/New Zealand Standard, where references to separate 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 is applicable to the country in which this Standard is being used (see soil tests Clause 6.6 and Appendix C).
AS 1012 1199 1214 1275
Methods of testing concrete (all parts) Sampling procedures and tables for inspection by attributes Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread series) Metric screw threads for fasteners
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AS 1289 1289.3.4.1 1289.3.6.1 1289.4.3.1 1289.4.4.1 1289.5.1.1
1289.5.3.1
1289.5.3.2
1289.5.3.5 1289.5.4.1 1289.5.5.1
1289.5.6.1 1289.5.8.1
Methods of testing soils for engineering purposes Method 3.4.1: Soil classification tests Determination of the linear shrinkage of a soil Standard method Method 3.6.1: Soil classification tests Determination of the particle size distribution of a soil Standard method of analysis by sieving Method 4.3.1: Soil chemical tests Determination of the pH value of a soil Electrometric method Method 4.4.1: Soil chemical tests Determination of the electrical resistivity of a soil Method for sands and granular materials Method 5.1.1: Soil compaction and density tests Determination of the dry density/moisture content relation of a soil using standard compaction Standard method Method 5.3.1: Soil compaction and density tests Determination of the field density of a soil Sand replacement method using a sand-cone pouring apparatus Method 5.3.2: Soil compaction and density tests Determination of the field dry density of a soil Sand replacement method using a sand pouring can, with or without a volume displacer Method 5.3.5: Soil compaction and density tests Determination of the field dry density of a soil Water replacement method Method 5.4.1: Soil compaction and density tests Compaction control test Dry density ratio, moisture variation and moisture ratio Method 5.5.1: Soil compaction and density tests Determination of the minimum and maximum dry density of a cohesionless material Standard method Method 5.6.1: Soil compaction and density tests Compaction control test Density index method for a cohesionless material Method 5.8.1: Soil compaction and density tests Determination of field density and field moisture content of a soil using a nuclear surface moisturedensity gauge Direct transmission mode Methods for tensile testing of metals Steel sheet and strip Hot-dipped zinc-coated or aluminium/zinc coated Guide to AS 1199 Sampling procedures and tables for inspection by attributes Hot-rolled steel flat products Hot-dipped galvanized coatings on ferrous articles Helical lock-seam corrugated steel pipes Helical lock-seam corrugated steel pipes Design and installation Supplementary cementitious materials for use with portland cement Part 1: Fly ash Long-span corrugated steel structures Part 1: Materials and manufacture Part 2: Design and installation Portland and blended cements
1391 1397 1399 1594 1650 1761 1762 3582 3582.1 3703 3703.1 3703.2 3972
4100 Supp1 Supplement 1 Steel structures Commentary
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AS/NZS 1110 1111 1112 1252
ISO metric precision hexagon bolts and screws ISO metric commercial hexagon bolts and screws ISO metric hexagon nuts, including thin nuts, slotted nuts and castle nuts High strength steel bolts with associated nuts and washers for structural engineering 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 Code 3500.0 Part 0: Glossary of terms 3750 Paints for steel structures 3750.9 Part 9: Organic zinc-rich primer ISO 9000 Quality management and quality assurance standards ISO 9000.1 Part 1: Guidelines for selection and use ISO 9004 Quality management and quality system elements ISO 9004.1 Part 1: Guidelines NZS 4402 Methods of testing soil for civil engineering purposes 4402.4.1.1 Method 4.1.1: Soil compaction tests Determination of the dry density/water content relationship New Zealand Standard compaction test 4402.4.2.1 Method 4.2.1: Soil compaction tests Determination of the minimum and maximum dry densities and relative density of cohesionless soil Minimum dry density 4402.4.2.2 Method 4.2.2: Soil compaction tests Determination of the minimum and maximum dry densities and relative density of cohesionless soil Maximum dry density 4402.5.1.1 Method 5.1.1: Soil density tests Determination of the density of soil 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 of soil Water displacement method BS 5400 Steel concrete and composite bridges 5400.2 Part 2: Specification for loads SAA HB18 Guidelines for third-party certification and accreditation HB18.28 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 in AS/NZS 3500.0 and those below apply.
NOTE: Where a definition given conflicts with that given in AS/NZS 3500.0, the definition given below applies.
1.4.1 Administrative definitions 1.4.1.1 Manufacturer the person(s) or corporate body responsible for the manufacture of the pipes, pipe-arches, arches or special shapes.
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1.4.1.2 Purchaser the person(s) or corporate body for whom the manufacturer has contracted 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 the environment. 1.4.2.2 Bedding a prepared layer of uncompacted, non-cohesive material placed over the foundation, below the structure invert. 1.4.2.3 Camber a variation to the bedding grade along the structure invert to compensate 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 mechanical or 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 known properties and grading, placed and compacted in layers around and over the corrugated metal structure. (b) Embankment fill ordinary fill placed beyond the specified zone of compacted select fill. (c) Trench fill ordinary fill placed over the compacted select fill for the purpose of refilling a trench. (d) Modified fill material obtained from the excavation or elsewhere which is combined with additives to achieve a specified strength once placed and compacted in lieu of select fill. (e) Flowable fill modified fill placed as a pourable material in the select fill zone. 1.4.2.7 Flexibility factora measure of wall flexibility of the corrugated metal structure for the purpose of achieving adequate stiffness during handling and installation. 1.4.2.8 Foundation naturally occurring or prepared soil or rock underlying the installation and embankment. 1.4.2.9 Internal diameter minimum clear dimension from internal crest to internal crest. 1.4.2.10 Haunch part of the periphery of pipe-arches and underpasses between the crown and invert with relatively small radius of curvature. 1.4.2.11 Pipe-arch a full periphery shape with crown, small radius haunches between crown and invert, and a large radius invert. 1.4.2.12 Ring compression the circumferential compressive force in the structure wall per 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 the road, railway or other embankment and the centre-line of the structure, measured in a clockwise direction (see Figure A3). 1.4.2.14 Special shapesspecial shapes include ellipses, underpasses and ribbed structures (see Table 1.1). (a) Vertical ellipse a full periphery shape with rise greater than span (see Figure 1.1).
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(b) (c)
Horizontal ellipse a full periphery shape with span greater than rise (see Figure 1.1). Select material material suitable for its intended use.
1.5 CLASSIFICATION Pipes, pipe-arches, arches and special shapes shall be classified as shown in Table 1.1.
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TABLE
1.1
CLASSIFICATION OF CORRUGATED METAL STRUCTURES

Structure shape Class Structure shape reference and corrugation type Pipe (P.S) Pitch mm 68 200 Depth mm 13 55 Range of standard structure spans* in mm Steel 300 to 1 950 1 500 to 8 550 Aluminium 300 to 1 950 1 600 to 4 800
1 2
1 2
Pipe-arch or underpass (PA.S or U.S) Horseshoe arch (HA.S) Elliptical arch (EA.S)
68 200
13 55
450 to 1 800 1 925 to 6 578
450 to 1 800 1 925 to 5 521
2 2
200 200
55 55
2 400 to 8 500 2 334 to 8 468
2 400 to 7 100 2 334 to 7 720
1 2 2
Arch Type A (AA.S) Arch Type B (AB.S)
68 200 200
13 55 55
300 to 1 950 2 000 to 8 500 4 000 to 8 500
300 to 1 950 2 000 to 8 000 4 000 to 8 000
Vertical ellipse (VE.S)
200
55
1 363 to 8 055
1 600 to 4 752
2
Horizontal 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. Other non-standard shapes and larger spans are achieved with greater plate thicknesses or curved structural stiffening ribs. Corrugation Type: S = Sinusoidal. The shape geometries can be seen in the Figures 2.2 to 2.7. The structure number in the tables to Figures 2.2 to 2.7 for Class 2 structures denotes the number of 235 mm modules that comprise the effective structure periphery (see Figure 4.6).
1.6 NOTATION The terms, symbols, units of measurement and text reference, as used in this Standard, are listed in Table 1.2.
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TABLE
1.2
NOTATION
Quantity symbol A As At a b C1 d1 d E Ff Fmax. Fh Fr Fv fa fu fy h hmin. hs H i I
Terms Area of corrugated steel section per unit length Side angle Top angle wheel footprint dimension Wheel footprint dimension Construction load factor Separation of wheel loads Internal diameter of circular pipes Youngs modulus for steel or aluminium Flexibility factor Maximum flexibility factor Horizontal arch footing force Ring compression Vertical arch footing force Allowable compressive wall stress Ultimate compressive wall stress Minimum yield stress Height of cover Minimum allowable height of cover Stockpile height depth of invert from surface Live load impact factor Second moment of area of the corrugated section per millimeter of length Density index Soil arching factor Coefficient of earth pressure at rest Modified soil arching factor Stockpile influence factor Local wheel load Base pressure Dead load pressure Live load pressure Design pressure Haunch pressure Tyre pressure Radius of sinusoidal corrugation Dry density ratio Internal rise of pipe-arch, arch or special shape Radius of gyration of corrugated section Bottom radius
Unit symbol mm2/mm and and m m m m MPa mm/N mm/N kN/m kN/m kN/m MPa MPa MPa m m m mm4/mm kN kPa kPa kPa kPa kPa kPa mm mm mm mm
Text reference Clause 5.12, Tables 5.3, 5.4 Tables 2.6 and 2.7 Tables 2.6 and 2.7 Figure 5.2 Figure 5.2 Clause 5.13 Figure 5.2 Clause 5.12 Clauses 5.2, 5.11.4 Clause 5.11.4 Clause 5.13, Figure 5.6 Clauses 5.2, 5.7, 5.8 Clause 5.13, Figure 5.6 Clauses 5.10 Clauses 5.9.1, 5.9.2 Clauses 5.9.1, 5.9.2 Clauses 5.4.1, 5.5.2 Clauses 5.5.2.2, 5.3 Clause 5.6.1 Clause 5.4.2.4 Table 5.3, Table 5.4 Clause 6.6.4.1 Clauses 5.5.2, 5.6, Appendix C Clause 5.13 Clause 5.5.2.1 Appendix C Clauses 5.5.2.3, 5.6.1 Figure 5.2 Clause 5.6.2 Clauses 5.4.1, 5.6.1 Clauses 5.4.2, 5.6.1 Clauses 5.6.1, 5.6.2 and 5.7 Clause 5.6.2, Figure 5.5 Figure 5.2 Figures 4.1, 4.5 Clause 6.6.4.1 Figures 2.2, 2.3, 2.4, 5.6, Clause 5.13 Clauses 5.9.1, 5.9.2, Tables 5.4, 5.5 Figures 2.2, 2.4 (continued)
ID k ko k ks N pb pd pl pv ph q R RD Rs r rb
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TABLE
Quantity symbol rh rs rt Sb Ss Haunch radius Side radius Top radius Internal bottom span of arch Terms
1.2
(continued)
Unit symbol mm mm mm mm mm Text reference Figure 2.2 Figure 2.3 Clause 5.6.2, Figure 2.2 Figure 2.3 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 Tables 5.1, 5.2, 5.3, 5.4, Figures 4.1, 4.5 Clause 5.8, Tables 5.1, 5.2 Tables 5.3, 5.4 Clause 5.8
3
Clear internal span of pipe-arch, arch and special shapes and internal diameter of pipes measured to internal crests Thickness Ultimate seam strength Section modulus of the corrugated section Safety factor for seam strength Unit weight of fill Unit weight of backfill Unit weight of stockpile Re-entrant angle for arches Angle subtended by the invert arc Angle subtended by the haunch arc Angle subtended by crown arc Wall stress safety factor
t Us Z b s b h t
mm kN/m mm /mm kN/m

3
Clause 5.4.1, Appendices D, and E Clause 5.6.1 Clause 5.6.1 Figures 2.3, 5.6 Figures 2.2, 2.4 Figure 2.2 Figures 2.2, 2.4 Clause 5.10
kN/m3 kN/m3 mm and and and
1.7 MARKING OF STRUCTURES Each structure shall be legibly and permanently marked in a conspicuous place agreed by the purchaser. The marking shall include the following:
(a) (b) (c)
Name of the manufacturer. Date of manufacture including the month and year. A unique number identifying the structure.
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S E C T I O N
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 special shapes covered by this Standard are governed by the dimensions of their component sheets and plates, and are shown in Figures 2.1 to 2.7.
NOTES: 1 2 3 Alternative span and rise combinations are not prevented by their not being listed in this Section. The structure length of Class 1 structures should be specified to the nearest multiple of 610 mm. The structure length of Class 2 structures should be specified to the nearest multiple of 200 mm. The structure numbers given in the tables to Figures 2.2 to 2.7 denote the number of 235 mm modules that comprise the effective structure periphery.
Ss mm
300 450 600 750 900 1 050 1 200 1 350 1 500 1 650 1 800 1 950
Approximate area m2 0.07 0.16 0.28 0.44 0.64 0.87 1.13 1.43 1.77 2.13 2.54 2.99
NOTE: All dimensions are clear internal dimensions to inside crests and are subject to the dimensional tolerances specified in Section 4.
FIGURE 2.1(A)
PIPES (CLASS 1)
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Structure number 20P 22P 24P 26P 28P 30P 32P 36P 40P 44P 48P 52P 56P 60P 64P 68P 72P 76P 80P 84P
Nominal diameter mm 1 500 1 650 1 800 1 950 2 100 2 250 2 400 2 700 3 000 3 300 3 600 3 900 4 200 4 500 4 800 5 100 5 400 5 700 6 000 6 300 6 600 6 900 7 200 7 500 7 800 8 100 8 400 8 550
Ss mm
1 436 1 586 1 735 1 885 2 035 2 184 2 334 2 633 2 932 3 231 3 531 3 830 4 129 4 428 4 727 5 027 5 326 5 625 5 924 6 223 6 523 6 822 7 121 7 420 7 720 8 019 8 318 8 468
Approximate area m2 1.62 1.97 2.36 2.79 3.25 3.75 4.28 5.44 6.75 8.20 9.79 11.52 13.39 15.40 17.55 19.84 22.28 24.85 27.56 30.42 33.41 36.55 39.83 43.24 46.80 50.50 54.34 56.31
88P 92P 96P 100P 104P 108P 112P 114P
NOTE: Internal diameter and end area are measured to inside crest assuming an average plate thickness of 5.0 mm.
FIGURE 2.1(B)
PIPES (CLASS 2)
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NOTE: For pipe-arches t 90, for under-passes t >90.
Ss
mm 450 600 750
Rs
mm 340 430 510 600 680 770 860 940 1 030 1 110
Approximate area m2 0.11 0.18 0.27 0.38 0.51 0.65 0.82 1.00 1.21 1.43
rh
mm 100 100 100 100 100 100 100 100 100 100
rt
mm 225 300 375 450 525 600 675 750 825 900
rb
mm 550 830 1 100 1 370 1 640 1 910 2 190 2 460 2 730 3 000
h deg 74 74 74 74 74 74 74 74 74 74
t deg 90 90 90 90 90 90 90 90 90 90
b deg 16 16 16 16 16 16 16 16 16 16
900 1 050 1 200 1 350 1 500 1 650 1 800
FIGURE 2.2(A)
PIPE-ARCHES (CLASS 1)
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Structure number
Maximum internal span Ss mm 1 925 2 131 2 406 2 692 2 773 2 851 3 145 3 255 3 343 3 507 3 585 3 659 3 798 3 934 3 942 4 085 4 140 4 227 4 452 4 463 4 590 4 689 4 945 4 967 5 145 5 241 5 278 5 513 5 521 5 710 5 782 5 838 5 967 6 049 6 314 6 578
Internal rise Rs mm 1 691 1 782 1 923 2 063 2 111 2 160 2 768 2 285 2 332 2 429 2 477 2 527 3 152 2 668 3 268 3 386 2 759 3 505 3 606 2 835 3 725 2 982 3 876 3 123 4 054 3 265 4 174 3 406 4 272 4 381 3 548 4 501 4 622 3 690 3 833 3 976
End area m2 2.56 2.98 3.66 4.41 4.67 4.94 7.02 5.77 6.06 6.67 6.99 7.31 9.58 8.32 10.38 11.22 9.02 12.09 12.97 9.72 13.90 10.87 15.33 12.08 16.85 13.34 17.91 14.67 18.97 20.08 16.06 21.23 22.41 17.50 19.01 20.59
Internal side radius rh mm 750 750 750 750 750 750 1 020 750 750 750 750 750 1 020 750 1 020 1 020 750 1 020 1 020 750 1 020 750 1 020 750 1 020 750 1 020 750 1 020 1 020 750 1 020 1 020 750 750 750
Internal top radius rt mm 982 1 096 1 218 1 361 1 396 1 430 1 573 1 713 1 740 1 795 1 823 1 851 1 899 1 985 1 971 2 043 2 093 2 113 2 226 2 348 2 295 2 403 2 473 2 535 2 572 2 666 2 639 2 796 2 760 2 855 2 926 2 919 2 983 3 054 3 182 3 310
Internal bottom radius rb mm 1 219 1 428 2 218 2 905 3 527 4 441 3 125 2 627 2 923 3 718 4 270 4 983 3 407 6 018 4 036 4 882 6 106 6 076 5 031 4 178 6 034 5 689 4 950 6 533 6 134 7 475 7 208 8 527 6 257 6 329 9 705 7 227 8 355 11 024 12 504 14 169
Side angle h deg 86.42 86.42 86.42 86.42 86.42 86.42 64.18 86.42 86.42 86.42 86.42 86.42 64.18 86.42 64.18 64.18 86.42 64.18 64.18 86.42 64.18 86.42 64.18 86.42 64.18 86.42 64.18 86.42 64.18 64.18 86.42 64.18 64.18 86.42 86.42 86.42
Top angle t deg 66.61 65.85 75.60 77.51 80.33 83.04 100.88 65.70 68.49 73.82 76.35 78.80 94.27 80.22 97.60 100.74 79.31 103.69 98.53 67.97 101.39 74.74 94.19 76.14 98.34 77.43 100.94 78.63 96.54 95.70 79.75 98.19 100.56 80.79 81.76 82.67
Bottom angle b deg 26.97 27.73 17.98 16.07 13.25 10.54 14.94 27.88 25.09 19.76 17.23 14.78 21.55 13.36 18.22 15.08 14.27 12.13 17.29 25.61 14.43 18.84 21.63 17.44 17.48 16.15 14.88 14.95 19.28 20.12 13.83 17.63 15.26 12.79 11.82 10.91
10PA5-5 11PA5-6 14PA5-6 16PA5-7 17PA5-7 18PA5-7 24U5-7 17PA5-11 18PA5-11 20PA5-11 21PA5-11 22PA5-11 27U5-11 24PA5-12 29U5-11 31U5-11 25PA5-13 33U5-11 33U5-13 24PA5-16 35U5-13 27PA5-16
35U5-16 29PA5-17 38U5-16 31PA5-18 40U5-16 33PA5-19 40U5-18 41U5-19 35PA5-20 43U5-19 45U5-19 37PA5-21 39PA5-22 41PA5-23
NOTE: Internal span, rise, radii and end area are measured to inside crest assuming an average plate thickness of 3.0 mm. Aluminium structures may vary from the shapes given above due to a minimum corner radius greater than 750 mm.
FIGURE 2.2(B)
PIPE-ARCHES AND UNDERPASSES (CLASS 2)
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NOTE: For Class 2 Type A: 0.3 < Rs/Ss < 0.4 and Type B: 0.4 < Rs/Ss < 0.5.
Ss
mm 300 300 450 450 600 600 750 750 900 900 1 050 1 050
Rs
mm 86.6 150.0 129.9 225.0 173.2 300.0 216.5 375.0 259.8 450.0 303.1 525.0 346.4 600.0 389.7 675.0 433.0 750.0 476.3 825.0 519.6 900.0 580.8 1 000.0
Approximate area m2 0.018 0.035 0.041 0.080 0.074 0.141 0.115 0.221 0.166 0.318 0.226 0.433 0.295 0.565 0.373 0.716 0.461 0.884 0.557 1.069 0.663 1.272 0.824 1.571
rt
mm 173.2 150.0 259.8 225.0 346.4 300.0 433.0 375.0 519.6 450.0 606.2 525.0 692.8 600.0 779.4 675.0 866.0 750.0 952.6 825.0 1039.2 900.0 1 151.2 1 000.0
deg 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0
1 200 1 200 1 350 1 350 1 500 1 500 1 650 1 650 1 800 1 800 1 950 1 950
FIGURE 2.3(A)
ARCHES (RISE LESS THAN OR EQUAL TO RADIUS) (CLASS 1)
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Maximum Internal internal rise Structure span Rs number Ss mm 12AA 15AA 18AA 22AA 23AA 26AB 26AA 29AB 29AA 33AB 32AA 36AB 35AA 39AB 37AA 42AB 40AA 46AB 43AA
End area m2 1.28 1.99 2.86 4.29 4.59 5.99 5.87 7.45 7.30 9.64 8.89 11.46 10.63 13.44 11.75 15.58 13.74 18.69 15.89 21.20 18.20 23.86 20.67 27.67
Internal top radius rt mm 1 013 1 267 1 522 1 757 2 065 2 001 2 319 2 253 2 573 2 500 2 827 2 751 3 081 3 002 3 380 3 254 3 633 3 501 3 886 3 752 4 139 4 003 4 392 4 251
Bottom angle deg 9.25 9.49 9.70 5.19 14.45 2.12 14.02 2.98 13.67 0.83 13.39 1.61 13.15 2.27 15.94 2.85 15.54 1.32 15.20 1.87 14.89 2.34 14.62 1.13
mm 850 1 058 1 265 1 598 1 550 1 927 1 757 2 136 1 965 2 464 2 172 2 673 2 380 2 883 2 452 3 092 2 659 3 420 2 867 3 630 3 075 3 839 3 283 4 167
2 000 2 500 3 000 3 500 4 000 4 000 4 500 4 500 5 000 5 000 5 500 5 500 6 000 6 000 6 500 6 500 7 000 7 000 7 500 7 500 8 000 8 000 8 500 8 500
49AB 46AA 52AB 49AA 56AB
NOTE: Internal span, rise top radius and end area are measured to inside crest assuming an average plate thickness of 5.0 mm.
FIGURE 2.3(B)
ARCHES (RISE LESS THAN RADIUS) (CLASS 2)
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Maximum Internal internal rise Structure span Rs number Ss mm HA-22 HA-27 HA-40 HA-54 HA-64 HA-76 16EA-5 22EA-6
End area m2 3.76 5.75 12.52 23.01 32.28 45.82 4.78 8.55 15.67 29.39 50.52 59.41
Bottom internal span Sb mm 2 008 2 570 3 719 5 137 6 066 7 335 1 921 2 803 3 227 4 854 5 623 6 128
Internal top radius rt mm 1 200 1 500 2 200 3 000 3 550 4 250 1 167 1 616 2 064 2 962 3 860 4 234
Internal side radius rs mm 1 200 1 500 2 200 3 000 3 550 4 250 3 600 4 950 6 300 7 600 7 600 7 600
Bottom angle deg 33.21 31.05 32.30 31.11 31.31 30.35 19.49 16.91 21.81 21.63 30.45 32.21
mm 1 857 2 274 3 376 4 550 5 395 6 397 2 368 3 056 4 405 5 763 7 711 8 285
2 400 3 000 4 400 6 000 7 100 8 500 2 334 3 231 4 129 5 924 7 720 8 468
28EA-10 40EA-12 52EA-17 57EA-18
NOTE: Internal span, rise, top radius and end area are measured to inside crest assuming an average plate thickness of 5.0 mm.
FIGURE 2.4
ARCHES (RISE GREATER THAN RADIUS) (CLASS 2)
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FIGURE 2.5 (in part)
HORIZONTAL ELLIPSE (CLASS 2)
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Structure number
Maximum internal span Ss mm 1 509 1 826 2 138 2 306 2 457 2 777 3 095 3 250 3 411 3 731 4 043 4 200 4 362 4 634 4 950 5 106 5 263 5 586 5 902 6 065 6 219 6 525 6 849 7 004 7 175 7 479 7 801 7 953 8 112 8 432 8 750
Internal rise Rs mm 1 363 1 642 1 928 2 079 2 223 2 508 2 795 2 935 3 085 3 371 3 656 3 801 3 942 4 188 4 478 4 612 4 750 5 048 5 338 5 478 5 618 5 901 6 191 6 327 6 483 6 760 7 052 7 194 7 338 7 622 7 908
End area m2 1.62 2.36 3.24 3.74 4.27 5.43 6.73 7.44 8.18 9.76 11.48 12.40 13.35 15.35 17.50 18.60 19.76 22.19 24.75 26.08 27.45 30.30 33.28 34.80 36.38 39.64 43.05 44.80 46.59 50.26 54.08
Internal Internal side top radius radius rh rt mm 640 770 905 919 1 005 1 110 1 215 1 300 1 319 1 414 1 560 1 611 1 654 2 010 2 135 2 203 2 274 2 373 2 493 2 548 2 623 2 775 2 875 2 948 2 948 3 124 3 218 3 298 3 355 3 464 3 574 mm 819 995 1 163 1 206 1 293 1 452 1 609 1 699 1 765 1 925 2 091 2 169 2 251 2 614 2 743 2 850 2 957 3 032 3 178 3 258 3 353 3 540 3 671 3 767 3 791 3 992 4 128 4 218 4 295 4 452 4 608
Side angle As deg 100.61 101.11 100.93 70.98 78.15 70.90 64.92 70.91 59.92 55.97 59.33 57.48 55.98 118.87 112.00 114.55 116.89 100.85 96.06 94.00 96.42 100.80 92.69 94.92 81.36 89.63 82.88 84.93 83.51 80.90 78.42
Top angle At deg 79.39 78.89 79.07 109.02 101.85 109.10 115.08 109.09 120.08 124.03 120.67 122.52 124.02 61.13 68.00 65.45 63.11 79.15 83.94 86.00 83.58 79.20 87.31 85.08 98.64 90.37 97.12 95.07 96.49 99.10 101.56
5HE5 6HE6 7HE7 10HE5 10HE6 12HE6 14HE6 14HE7 16HE6 18HE6 19HE7 20HE7 21HE7 12HE18 14HE18 14HE19 14HE20 18HE18 20HE18 21HE18 21HE19 21HE21 24HE20 24HE21 28HE18 27HE21 30HE20 30HE21 31HE21 33HE21 35HE21 NOTES: 1 2
Internal dimensions and end area are measured to inside crest using 3.0, 5.0, 7.0 or 8.0 mm plate gauge based on the minimum handling stiffness requirements. The above dimensions maintain a maximum structure elongation of 5 percent.
HORIZONTAL ELLIPSE (CLASS 2)
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VERTICAL ELLIPSE (CLASS 2)
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Structure number
Maximum internal span Ss mm 1 363 1 642 1 928 2 080 2 223 2 507 2 795 2 935 3 085 3 371 3 656 3 801 3 942 4 188 4 478 4 615 4 752 5 051 5 340 5 481 5 621 5 902 6 190 6 330 6 486 6 762 7 054 7 197 7 339 7 625 7 911 8 055
Internal rise Rs mm 1 509 1 826 2 138 2 305 2 457 2 778 3 095 3 250 3 410 3 730 4 042 4 201 4 362 4 634 4 950 5 107 5 264 5 587 5 903 6 066 6 220 6 529 6 850 7 004 7 176 7 481 7 802 7 955 8 115 8 435 8 754 8 913
End area m2 1.62 2.36 3.24 3.74 4.27 5.43 6.73 7.44 8.18 9.76 11.48 12.40 13.35 15.35 17.50 18.62 19.78 22.20 24.77 26.10 27.47 30.32 33.28 34.82 36.40 39.67 43.07 44.83 46.61 50.30 54.12 56.08
Internal Internal side top radius radius rh rt mm 819 995 1 163 1 206 1 293 1 452 1 609 1 699 1 765 1 925 2 091 2 169 2 251 2 614 2 743 2 850 2 957 3 032 3 178 3 258 3 353 3 543 3 671 3 767 3 791 3 992 4 128 4 218 4 297 4 454 4 610 4 688 mm 640 770 905 920 1 005 1 110 1 215 1 300 1 320 1 415 1 560 1 610 1 655 2 010 2 135 2 205 2 275 2 375 2 495 2 550 2 625 2 775 2 875 2 950 2 950 3 125 3 220 3 300 3 355 3 465 3 575 3 630
Side angle As deg 79.37 78.89 79.09 109.06 101.87 109.07 115.06 109.08 120.11 124.05 120.68 122.49 124.03 61.14 68.00 65.49 63.12 79.18 83.98 86.03 83.61 79.16 87.30 85.12 98.67 90.38 97.14 95.09 96.47 99.10 101.57 102.74
Top angle At deg 100.63 101.11 100.91 70.94 78.13 70.93 64.94 70.92 59.89 55.95 59.32 57.51 55.97 118.86 112.00 114.51 116.88 100.82 96.02 93.97 96.39 100.84 92.70 94.88 81.33 89.62 82.86 84.91 83.53 80.90 78.43 77.26
5VE5 6VE6 7VE7 5VE10 6VE10 6VE12 6VE14 7VE14 6VE16 6VE18 7VE19 7VE20 7VE21 18VE12 18VE14 19VE14 20VE14 18VE18 18VE20 18VE21
19VE21 21VE21 20VE24 21VE24 18VE28 21VE27 20VE30 21VE30 21VE31 21VE33 21VE35 21VE36 NOTES: 1 2
Internal dimensions and end area are measured to inside crest using 3.0 or 5.0 mm plate gauge based on the minimum handling stiffness requirements. The above dimensions maintain a maximum structure elongation of 5 percent.
VERTICAL ELLIPSE (CLASS 2)
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S E C T I O N
3.1 3.1.1 3.1.1.1 CLASS 1 STRUCTURES Steel sheet Grade
M A T E R I A L S
The base steel shall be Grade G250 in accordance with AS 1397. Tolerances on base metal thickness shall be in accordance
3.1.1.2 Base metal thickness with AS 1365.
3.1.1.3 Coating The base steel shall have a galvanized coating Class of Z600 in accordance with AS 1397, unless an alternative coating is used as specified in Clause 3.1.1.4. 3.1.1.4 Alternative coatings Alternative coatings to that referred to in Clause 3.1.1.3 shall be applied in the following manner: (a) (b) Heavy galvanized coating The base steel shall be hot-dip galvanized in accordance with the requirements for general articles in AS 1650. Aluminized (Type II) coating The base steel shall have an aluminium coating with the following minimum coating mass (total both sides) when determined by testing: (i) (ii) Triple spot test . . . . . . . . . . . . . . . . . . . . . . . . 305 g/m2 (total both sides). Single spot test . . . . . . . . . . . . . . . . . . . . . . . . 275 g/m2 (total both sides).
NOTE: The coating weight is determined by summing the readings from both surfaces of the sheet, determined by magnetic thickness gauge or by stripping test.
(c) (d)
Barrier coating Preparation of the base metal and application of the coating shall be in accordance with the coating manufacturers recommendations. Duplex coatings To protect the structure in abnormally corrosive or abrasive conditions a secondary coating shall be applied over the primary coating (nominated in Clause 3.1.1.3 and Clause 3.1.1.4 (a) and (b)), in accordance with the coating manufacturers recommendations.
NOTE: Appendix C of this Standard provides information on durability of suitable materials and 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 be 12 mm in diameter for lapped Class 1 structures and 10 mm in diameter for flanged Class 1 structures. 3.1.2.2 Dimensions The width across the flats of bolt heads and nuts shall be within the limits specified in AS/NZS 1111. The form of thread and pitch of the bolt threads shall be ISO coarse pitch series in accordance with AS 1275. The threads shall comply with M12 8 g tolerance in accordance with AS 1275 with thread tolerance class at 8 g before zinc coating. Threads for nuts shall be in accordance with AS 1214. 3.1.2.3 Mechanical properties For all structures, the bolts shall comply with the material 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 with AS/NZS 1112 for property Class 8. For fluming and flanged structures, the property class shall be Class 4.6 for bolts (in accordance with AS/NZS 1110) and Class 5 for nuts (in accordance with AS/NZS 1112).
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3.1.2.4 Coating Bolts and nuts shall be zinc-coated by hot-dip galvanizing in accordance 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 oversize allowance specified in AS 1214, so that they are capable of assembly on the galvanized bolts by hand. 3.1.3 Aluminium sheet 3.1.3.1 General The aluminium sheet shall be a clad aluminium alloy with substrate metal classification 3004H34 and cladding metal classification 7072 in accordance with AS/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 be 5 percent of the total composite thickness. The average cladding thickness, when determined by metallurgical microscope, shall not be less than 4 percent of the total composite thickness.
NOTE: Thickness examination should average 10 separate measurements on each side of not less than three polished material samples.
3.1.3.3 Chemical composition The chemical composition of the substrate and cladding shall be as given for alloys 3004 and 7072 respectively in AS/NZS 1734. 3.1.3.4 Mechanical requirements The mechanical properties of the clad aluminium alloy 3004H34 shall be as specified in Table 3.1. TABLE 3.1
MECHANICAL PROPERTIES
Thickness mm 1.2 1.54.0 Tensile strength (MPa) Min. 215 215 Max. 260 260 Yield strength (MPa) (0.2% offset) min. 165 165 Elongation (5%) min. 3 4
3.1.4 Aluminium bolts and nuts Aluminium bolts and nuts for Class 1 structures shall be Alloy 6061T6 with proof stress (0.2 percent) of 240 MPa, ultimate tensile strength of 260 MPa and elongation 8 percent. Other alloys with equal or higher proof stress are permissible substitutes.
NOTE: Stainless steel bolts (SS303) and nuts (SS313) or galvanized steel bolts and nuts as specified in Clause 3.1.2 may be substituted for aluminium bolts and nuts.
3.2 3.2.1
CLASS 2 STRUCTURES Steel plate Grade The base steel shall be Grade 250 in accordance with AS 1594.
3.2.1.1
3.2.1.2 Physical properties When tested in accordance with AS 1391, the base steel shall have the following properties: (a) (b) Yield strength (minimum) of 250 MPa. 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 accordance with the requirements for general articles of AS 1650, unless an alternative coating is used as specified in Clause 3.2.1.4. 3.2.1.4 Alternative coatings Alternative coatings to that referred to in Clause 3.2.1.3 shall be applied in the following manner: (a) (b) Other coating Preparation of the base steel and application of the coating shall be in accordance with the coating manufacturers recommendations. Duplex coating For abnormally adverse conditions, a secondary coating shall be applied over the primary coating (nominated in Clause 3.2.1.3 and in Item (a)) in accordance with the coating manufacturers recommendations.
NOTE: Appendix C of this Standard provides information on durability of suitable materials and 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 be 20 mm diameter, and shall have heads and nuts specially shaped to provide suitable bearing. 3.2.2.2 Dimensions The width across the flats of bolt heads and nuts shall be within the limits specified in AS/NZS 1252. The form of thread and pitch of the bolt threads shall be ISO coarse pitch series in accordance 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 g before 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 mechanical properties specified in AS/NZS 1252. The galvanized nuts shall pass a proof load test carried out in accordance with AS 1112 for property Class 10.
3.2.2.4 Coating Bolts and nuts shall be zinc-coated by hot-dip galvanizing in accordance 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 oversize allowance specified in AS 1214, so that they are capable of assembly on the galvanized bolts by hand. 3.2.2.5 3.2.3 Lubrication Nuts shall be lubricated in accordance with AS/NZS 1252. Aluminium plate
3.2.3.1 General The aluminium plate shall be of structural alloy 5052 in accordance with AS/NZS 1734. 3.2.3.2 Mechanical properties The mechanical properties for alloy 5052 shall conform to the values specified in Table 3.2. TABLE 3.2
MECHANICAL PROPERTIES OF ALLOY 5052

Thickness mm 2.54.0 4.16.35 Tensile strength (MPa) Min. 231 231 Yield strength (MPa) (0.2% offset) Min. 165 165
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3.2.3.3 Plate thickness tolerance The minimum thickness for aluminium plate shall be the specified thickness. Plate thickness shall be measured at any point on a plate not less than 10 mm from an edge, and at the neutral axis (refer to Figure 4.5) of the corrugated plate. 3.2.4 Aluminium bolts and nuts 3.2.4.1 General Aluminium bolts and nuts shall be manufactured from alloy 6061 T6 with dimensions in accordance with Clauses 3.2.2.1 and 3.2.2.2. 3.2.4.2 Mechanical properties Alloy 6061T6 shall have the properties as given in Clause 3.1.4. Other alloys with equal or higher proof stress are permissible substitutes subject to chemical compatibility.
NOTE: Stainless steel bolts (SS303) and nuts (SS313) as specified in Clause 3.2.2 or galvanized steel bolts and nuts as specified in Clause 3.1.2 may be substituted for aluminium bolts and nuts.
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S E C T I O N
4.1 CLASS 1 STRUCTURES
F A B R I C A T I O N
4.1.1 General Class 1 structures shall be fabricated from material as specified in Clause 3.1.1 or 3.1.3 and shall be corrugated, hole punched and curved in accordance with Clauses 4.1.2, 4.1.3 and 4.1.4. Class 1 structures are assembled on site with lapped seams or flanged seams. 4.1.2 (a) (b) (c) (d) Sinusoidal Corrugations Corrugations shall comply with the following: The pitch of the sinusoidal corrugations shall be 68 3.0 mm (see Figure 4.1). The depth of the sinusoidal corrugations shall be 13 +0, 0.7 mm (see Figure 4.1). The corrugations shall form smooth continuous curves and tangents. The inside radius of each corrugation shall be not less than one-half of the depth of the corrugation.
NOTE: Corrugations are designated pitch depth.

DIMENSIONS IN MILLIMETRES Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]
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 shall differ 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 length The actual net length of sheets measured across the corrugations shall be 610 mm 3 mm (see Figure 4.2), or 305 3 mm for closure panels, where continuous longitudinal seams are specified (see Figure 4.3). 4.1.3.3 Sheet curvature The curvature of the sheet, when measured radially, shall not differ from the correct arc by more than 5 mm. 4.1.3.4 Structure end finishing sheets Class 1 structures shall have either a stepped end (see Figure A1) or a vertical end specified. Vertical end structures shall be supplied with special 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 of sheets and field assembly with the prescribed fasteners to achieve the specified structure shape. 4.1.4.2 Longitudinal seams Bolt holes for longitudinal seams shall be 16 mm in diameter prior to sheet curving, located at 102 2 mm centres on alternate crests and valleys 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 seam strength 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 crest nearest the sheet edges. Circumferential seam bolt holes shall be equally spaced along the sheet 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 measured between 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 than 1.75 times their diameter. 4.1.4.6 Hole and slot defects Holes and slots shall be free of cracks and free of ragged edges 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 in Clauses 3.2.1 and 3.2.2 or 3.2.3 and 3.2.4 and shall be corrugated, hole punched and curved to the specified radii so that the cross-sectional dimensions of each structure shall be achieved when it is assembled. Coatings, if required, shall be applied after fabrication. 4.2.2 Sinusoidal following: (a) (b) (c) (d) Corrugations Sinusoidal corrugations shall comply with the
The pitch of the sinusoidal corrugations shall be 200 6 mm (see Figure 4.5) The depth of sinusoidal corrugations shall be 55 3 mm (see Figure 4.5) The corrugations shall form smooth continuous curves and tangents. The inside radius of each corrugation shall be not less than one-half of the depth of the corrugations.
NOTE: Corrugations are designated pitch depth.

DIMENSIONS IN MILLIMETRES Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]
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 shall not 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 the two 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 not differ 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 dimension and curvature and having the same number of bolts per unit length of seam are interchangeable (see Figure 4.6). The diameter of the bolt holes in longitudinal seams shall not exceed the diameter of the bolt by more than 5 mm. 4.2.4.2 Edge distance The distance from the centre of a bolt to any plate edge shall be as specified in AS 4100 Supp 1.
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4.2.4.3 Longitudinal seams The holes for bolts in longitudinal seams shall be in two rows spaced 50 mm apart, centre-to-centre. The minimum hole arrangement shall have holes 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 seam strength 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 in circumferential 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 measured between 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 a configuration that allows staggering of plate laps along longitudinal or circumferential seams (see Figures 4.7 and 4.8). 4.2.4.7 Hole defects Punched bolt holes shall be free of cracks and free of ragged edges and burrs in excess of 2.0 mm. 4.2.5 Plate identification and traceability Plates for Class 2 structures shall be permanently marked to show curvature, thickness and a unique number to achieve quality assurance requirements for identification and traceability. Special plates for skewed structures or for bevelled ends shall be legibly and permanently marked to identify their proper 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 4.3.1
ASSESSMENT AND REPAIR OF DAMAGED COATINGS Zinc
4.3.1.1 General No galvanized sheet or plate shall have uncoated or defective areas which in total exceed the lesser of 0.1 percent of the total surface area or 25000 mm 2.
NOTE: Small localized areas of exposed steel are protected from corrosion by galvanic action from adjacent zinc. Although the rate of corrosion varies widely, depending on conditions, in environments suitable for the use of galvanized steel, it has been demonstrated that protection is afforded to areas of bare steel up to at least 5 mm in diameter. In normal fabrication, the total surface of steel to be protected by the zinc is only marginally increased, and accelerated deterioration does not occur from exposed areas. Such small areas can be afforded additional protection by a coating of zinc-rich organic primer or other suitable paint (see also Table C4 under Tropical).
Where coating repair is deemed necessary, and in areas that have been welded after galvanizing, repair shall be made by careful wire brushing to remove scale followed immediately by application of zinc-rich paint complying with AS/NZS 3750.9 applied in accordance 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, which sometimes forms on galvanized articles in moist, acidic or salty environments, normally is not detrimental to the zinc coating, nor is it indicative of inferior galvanizing. Where medium to heavy build-up has occurred, or brown deposits are visible, or where the product will be subjected to poorly ventilated or humid conditions, white rust shall be removed with a stiff bristle (not wire) brush, and saturated cloth application of (i) a solution of 420 g/l chromium trioxide with 0.5 percent nitric acid then rinsing with cold water; or where practical,
(ii) a solution of 200 g/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 storage conditions, it should be removed and the application of a suitable protective barrier coating should be considered.
4.3.2 Coatings other than zinc The allowable defects in coatings other than zinc shall be determined in consideration of the type of coating, the desired service life and the expected environmental conditions. Repairs, if deemed necessary, shall be in accordance with the manufacturers recommendations.
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S E C T I O N
D E S I G N
5.1 DESIGN PHILOSOPHY 5.1.1 Introduction Buried corrugated metal structures are flexible buried members which rely on soil-structure interaction. Installation shall be in accordance with Section 6 of 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 of Section 6. 5.1.2 Structural failure criteria This Standard only applies to structures that are symmetrical about the vertical axis. The design of metal pipes and arches is based on the ring compression theory. The ring compression in the structure is calculated on the equivalent vertical pressure at the crown on the metal structure (see Figure 5.1). This theory is only valid if the metal structure has a minimum cover of correctly installed fill 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 the horizontal axis defined by the S s dimension. The modes of failure assumed by this Standard 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 ring compression is applicable. 5.1.3 Heavy axle load vehicles including construction equipment This Standard does not provide guidance for minimum cover for vehicles with axle loads heavier than the design vehicles specified in Clause 5.4.2. If a metal structure is being designed for a vehicle with heavy axle loads (e.g. mine haul vehicles, earthmoving plant), specialist advice should be sought to determine the minimum cover, to ensure that the ring compression theory is applicable.
NOTE: If a structure has insufficient cover for arching to occur, failure may be initiated by buckling of the crown of the metal structure. Buckling of the crown may occur at a lower load than 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 of this 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 this Standard is provided in Appendix D. 2 For the convenience of designers, Appendices E and F provide maximum height of cover limits for Class 1 and Class 2 corrugated steel and aluminium structures. Appendix G provides comparisons of various highway live load pressures to allow structural design 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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FIGURE 5.1
RING COMPRESSION IN BURIED FLEXIBLE STRUCTURES
5.2 DESIGN FACTORS The following factors shall be taken into account in the design of corrugated metal pipes, pipe-arches, and arches and special shapes (see also Appendix D): (a) Structure shapes, class and span (S s). (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 compression Fr in the corrugated metal section (see Clauses 5.6 and 5.7). (g) Ultimate seam strength (see Clause 5.8). (h) Ultimate compressive wall stress fu (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 and concentrated loads do not bear directly on the structure, a minimum cover is necessary. Satisfactory results have been established based on long-term observations of performance under live loads.
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5.3.2 Minimum cover for railway live loads Minimum cover (hmin.) for railway live loads shall be Ss/4 or 1.0 m, whichever is greater, but in no case shall the depth of fill above the structures be less than 300 mm, i.e. from top of structure to underside of ballast. 5.3.3 Minimum cover for highway live loads Minimum cover (h min.) for highway live loads shall be Ss/6 or 0.6 m, whichever is the greater. 5.3.4 Variation of minimum cover The minimum cover shall be increased if the engineer 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 the structure and shall be calculated from the following Equation: pd = h . . . 5.4.1 where = unit weight of material above the structure crown, in kilonewtons per cubic metre 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, and has been adopted in determining the height of cover tables in Appendices D and E.
5.4.1.2 Inclined and stockpile loads Where the fill height varies above the structure, the higher value shall be adopted as the design maximum height of cover, and the minimum cover as determined in Clause 5.3 shall be satisfied when measured radially from 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 the structure crown. The specified live load pressure, (p l), shall be chosen from the relevant load 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 in Appendix G (see also SAA HB77). 5.4.2.3 Railway live loads (M250 and M270) Railway live load pressures, with impact allowance, include M250, M270 and 300-A-12 (see SAA HB77). 5.4.2.4 Aircraft loads Required loads and load distributions for the calculation of working 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 5.4.2.2 or Clause 5.4.2.3, shall be calculated from axle loads or footprints using a load dispersion through the soil of 0.725 : 1 (horizontally : vertically), as shown in Figure 5.2. Live loads shall be increased by an appropriate impact factor value (i) but not less than 0.1. For example, values higher than 0.1 may be applicable for haulage roads. For consideration of live loads due to construction refer also to Clause 6.7. 5.4.2.6 Earthquake loads Buried corrugated metal structures in backfills, in accordance with this Standard, are not sensitive to earthquake effects. Where the backfill is prone to liquefaction, arching of the backfill should be ignored and, therefore, k would be equal to 1.0.
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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 structures are installed in accordance with Section 6, the density of the backfill is considered to be not less than 90 percent of the maximum dry density for standard compaction in cohesive soils or 70 percent of the maximum density index for standard compaction in cohesiveless soils. The appropriate value of k is given in Figure 5.3. Higher levels of compaction may be adopted provided it can be ensured that this will be achieved or exceeded on site. For cemented and flowable modified fills, as defined in Clause 6.6.3 and Appendix H, a design value of k equivalent to 90 percent relative density shall be used, unless higher values can be substantiated by testing.
NOTE: Compaction achieved in the field should exceed that assumed in design. A value of 90 percent compaction has been adopted for the calculation of the tables given in Appendices E and F. Soil compaction values less than 90 percent are provided to allow back-calculation of structural capacity where installation practices may have deviated from the specified requirements of Section 6 of this Standard.
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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 metal structure shall be modified to account for soil arching in recognition of the backfill relative density and depth of burial (height of cover) as shown in Clauses 5.5.2.2 and 5.5.2.3. 5.5.2.2 Modified soil arching factor, k follows: (a) For Ss > hmin. for h Ss, for h > S s, for h = hmin., (b) For Ss hmin. k = k k = 1.0 k = k . . . 5.5 The soil arching factor, k, shall be modified as
For vehicle, railway, aircraft or other live loads where hmin. is not given in this Standard k = 1.0. 5.5.2.3 Stockpile influence factor The may be modified using stockpile influence and arching. Where a stockpile influence shall apply. Where stockpile influence is ks = 1.0. vertical load at the base of live stockpiles factor ks which accounts for stockpile geometry factor has been determined, Equation 5.6.1(2) not known, Equation 5.6.1(2) shall apply with
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5.6
DESIGN PRESSURE
5.6.1 General The design pressure is assumed to be applied at the crown of the structure being the result of dead and live loads combined. The design pressure shall be calculated from the following equation: pv pv where k pd pl ks s hs b h = modified soil arching factor = dead load. (See Clause 5.4.1) = live load. (See Clause 5.4.2). = stockpile influence factor (Clause 5.5.2.3) = stockpile density = stockpile height = backfill density = height of cover = k(pd + pl) = ks shs + kbh . . . 5.6.1(1) . . . 5.6.1(2) or for stockpile loads
NOTE: hs varies according to the location being considered.
FIGURE 5.4
STOCKPILE COVER HEIGHTS
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5.6.2 Pipe-arch shapes The pipe-arch shape necessitates a special design approach as pipe-arches generate haunch pressures greater than the pressure generated by comparable circular 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 the same at any point around the pipe-arch. This means the pressure normal to the pipe-arch at 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 be used, unless higher values are determined by testing.
FIGURE 5.5
PRESSURE VARIATION AROUND PIPE-ARCHES
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TABLE
5.1
MAXIMUM DESIGN HAUNCH PRESSURES

Compacted backfill around haunches (see Note 1) Select fill (see Clause 6.6.1) Uniform coarse-crushed stone (<40 mm) Cemented sand/gravel (36 percent) Flowable fill NOTES: 1 Height of cover limits presented in Appendices D and E assume select fill in the haunch zone. The extent of alternative haunch materials shall be determined based on the relative strength of the adjacent soil. Haunch soil pressures and soil shear can also be reduced by ensuring 2 . Maximum design haunch pressure, kPa 300 600 900 50% of specified strength (see Note 2)
See Clause 6.6.2.
5.7 RING COMPRESSION Ring compression (Fr) is the compressive force acting on the corrugated metal section of the structure at any point around its periphery. It shall be calculated from the following equation: . . . 5.7 5.8 SEAM STRENGTH Sheet and plate thickness shall be selected from Tables 5.2 and 5.3 so that, when the appropriate safety factors are applied, the following equation is satisfied: . . . 5.8
where = 2.0 for railway and highway loading. For other loading conditions shall be as given here unless otherwise agreed between the purchaser and the supplier. Values of Us for aluminium shall be determined from appropriate testing. TABLE 5.2
ULTIMATE SEAM STRENGTH OF BOLTED LONGITUDINAL SEAMS FOR CLASS 1 STEEL STRUCTURES
Thickness mm 1.2 1.5 1.6 2.0 2.5 3.0 3.5 Ultimate seam strength (Us) Steel kN/m Lapped seam 75 180 280 390 500 610
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TABLE
5.3
ULTIMATE SEAM STRENGTH OF BOLTED LONGITUDINAL SEAMS FOR CLASS 2 STRUCTURES

Ultimate seam strength (Us) kN/m Thickness (t) mm 10 Bolts/m 1.5 2.0 2.5 3.0 4.0 5.0 6.0 7.0 8.0 155 320 520 650 930 1 180 1 430 1 630 1 800 Steel 15 Bolts/m 580 900 1 220 1 560 1 900 2 080 2 265 20 Bolts/m 640 1 150 1 660 2 170 2 400 2 600 3 200 10 Bolts/m 320 385 450 515 Aluminium 15 Bolts/m 460 555 650 745 20 Bolts/m 580 715 850 985
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, and Equation 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 wall stress (fu) of the corrugated aluminium section (in megapascals) is expressed by Equations 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, and Equation 5.9(6) represents the ring buckling zone.
For
fy 165 MPa: . . . 5.9(4)
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. . . 5.9(5) . . . 5.9(6)
5.10 ALLOWABLE WALL STRESS The allowable compressive wall stress (fa) is determined by applying a safety factor to the ultimate compressive stress (fu) as follows: fa = fu/ where fu is determined from Clause 5.9 = 2.67 for arches with rise = 2 for all other structures 5.11 5.11.1 of (a) (b) WALL THICKNESS Final thickness The final thickness of the sheet or plate shall be the greater on unyielding foundations . . . 5.10
the structural wall thickness required by Clause 5.11.2 plus any durability thickness required by Clause 5.11.3 and shall be selected from Table 5.4 or 5.5; and 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 the calculated 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 using Clause 5.8 and Equation 5.11(1). 5.11.3 Durability allowance In certain conditions of installation, corrugated metal structures may be subjected to corrosion and abrasion. Assessment of expected conditions in service shall be made to determine what protective measures, if any, need to be applied. These may include an increase in wall thickness, protective coatings, selection of suitable backfill or a combination of these.
NOTE: Information on durability design and protective systems is given in Appendix C.
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TABLE
5.4
SECTIONAL PROPERTIES OF CORRUGATED SHEETS FOR CLASS 1 STRUCTURES*

Thickness (t) mm 1.2 1.5 1.6 2.0 2.5 3.0 3.5 * See Figure 4.1 Section area (A) mm2/mm 1.29 1.62 1.73 2.17 2.71 3.25 3.80 Second moment of area (I) mm4/mm 25.6 32.5 34.8 44.0 55.8 68.2 81.1 Section modulus (Z) mm3/mm 3.67 4.49 4.77 5.87 7.21 8.52 9.83 Radius of gyration (r) mm 4.45 4.47 4.48 4.51 4.54 4.58 4.62
TABLE
5.5
SECTIONAL PROPERTIES OF CORRUGATED PLATES FOR CLASS 2 STRUCTURES*

Thickness (t) mm 2.5 3.0 4.0 5.0
Sectional area (A) mm2/mm 2.95 3.54 4.73 5.92 7.10 8.29 9.47
Second moment of area (I) mm4/mm 1 130 1 360 1 820 2 290 2 770 3 250 3 710
Section modulus (Z) mm3/mm 39.0 46.8 61.7 76.3 90.7 104.9 119.9
Radius of gyration (r) mm 19.5 19.6 19.6 19.7 19.7 19.8 19.8
6.0 7.0 8.0 * See Figure 4.5
5.11.4
Handling and installation stiffness shall have sufficient strength to withstand wall loads imposed during side fill operations. Where conditions, the worst case shall be assumed, and the profile shall be used.
5.11.4.1 General The structure deflection caused by compaction uncertainty exists as to installation minimum value of Ff max. given for a
5.11.4.2 Pipes and ellipses Handling and installation stiffness can be assessed using the following equation for flexibility and Table 5.6: . . . 5.11(2)
NOTE: Applicable Youngs Modulus values are: ESteel = 205 000 MPa, E Aluminium = 69 000 MPa
The maximum flexibility (Ff max.) in Table 5.6, for trench and embankment installation conditions, shall not be exceeded unless appropriate structure bracing can be provided or other measures are taken to ensure the structure dimensions are maintained within the tolerances specified in Section 6.
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TABLE
5.6
MAXIMUM FLEXIBILITY (Ff max.) (mm/N)

Steel pipes and ellipses Structure class Trench 1 2 0.34 0.115 Installation type Embankment and multiple installation 0.25 0.115 Trench 0.54 0.143 Aluminium pipes and ellipses Installation type Embankment and multiple installation 0.39 0.143
NOTE: See Clause 6.3 for trench and embankment installations. The type of installation condition assumed should be noted on the drawing.
5.11.4.3
Arches and pipe-arches
For arches, pipe-arches and underpasses: . . . 5.11(3)
5.12 RIB STIFFENING Where required, structural reinforcement may be provided through the addition of ribs to (a) (b) (c) increase the effective wall area; stiffen the corrugated plate to withstand concentrated loads; or 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, the arch forces exerted on each footing during service is equivalent to the ring compression F r calculated from Clause 5.7. Vertical and horizontal reactions are determined by resolving the ring compression Fr through the arch re-entrant angle (see Figure 5.6(a), 5.6(b) and 5.6(c)). Fv = Fr Cos (kN/m) Fh = Fr Sin (kN/m) . . . 5.13(1) . . . 5.13(2)
The direction of the horizontal force F h shall be noted for the design of appropriate reinforced concrete footings.
NOTES: 1 2 Consideration should be given to vertical and horizontal forces during construction. It is undesirable to make the corrugated metal arch stiffer or unyielding compared to the adjacent side fill. The use of massive footings or piles to prevent any settlement of the arch is generally not recommended. Providing for some arch settlement helps to induce positive soil 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 in load. 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 cutoff walls or invert pavements. Arch footings and invert pavings are typically separated by a construction joint to accommodate differential settlement.
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FIGURE 5.6
50
ARCH FOOTING FORCES
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5.14 END-TREATMENT 5.14.1 General End-treatment design shall consider unbalanced soil loadings due to skewed, bevelled structure ends and skew-cut structure ends, and possible invert uplift or loss of backfill support due to piping or other erosion. If necessary, the embankment adjacent to and around the ends of the corrugated metal structures shall be adequately protected by the following: (a) Batter protection. (b) End-stiffening ring beams. (c) Headwalls. (d) Cut-off walls. Structures with an Ss in excess of 4.5 m shall be anchored at 500 mm maximum centres to the 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 from adverse hydraulic effects. The design shall consider water velocity at each end of the culvert, duration of critical flows and type of foundation and embankment materials. The extent of batter protection shall consider eddies and turbulence at the structure inlet and outlet. Cut-off walls are typically reinforced concrete with a minimum depth of 600 mm depending on site conditions. An adequate means of batter protection includes use of gabions, armour rock, mass concrete, reinforced concrete and similar. 5.14.3 End stiffening ring beams End-stiffening ring beams shall be provided for corrugated metal structures at the soil structure interface in accordance with Table 5.7 and Figure 5.7 for structures with an Ss in excess of 900 mm. Structures over 4500 mm shall be supported by a ring beam. Figure 5.7 shows a typical ring beam design for structures which fit within the limits given in Table 5.7.
NOTE: See Appendix A for end-types and skew numbers.
TABLE 5.7 PROVISION OF END-STIFFENING RING BEAM

End treatment Skew number Vertical square cut end Stepped or beveled to embankment slope 1V : 1H 1V : 1.5H 1V : 2H Flatter than 1V : 2H Skew in degrees
<55 5574 7584 8595 96105 106125 >125 Yes No No No Yes
Skew number not recommended* Yes No No No Yes Yes Yes No Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes
>35 1635 615 5 615 1635 >35
Skew number not recommended*
* Consider realigning embankment (see Figure 5.10).
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5.14.4 Headwalls of headwalls.
Multiple installations shall be supported and protected by provision
For installations with a skew number less than 55 or greater than 125, headwalls may be used to provide resistance to unequal earth loading or embankment modification considered (see Figure 5.8). Specialist advice should be obtained on the design of such headwalls. Headwalls should conform to Figure 5.7.
FIGURE 5.7 TYPICAL END-STIFFENING RING BEAM FOR CORRUGATED METAL STRUCTURES
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FIGURE 5.8
EMBANKMENT MODIFICATION FOR SKEWED STRUCTURES
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S E C T I O N
I N S T A L L A T I O N
6.1 GENERAL The adequacy of the foundation, native embankment and locally available backfill material shall be investigated at each site. Regular monitoring of structure shape and backfill density during construction are important requirements for ensuring a satisfactory installation. 6.2 ASSEMBLY
6.2.1 General The assembly of corrugated metal structures shall be carried out in accordance 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 diagram for 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 longitudinal and circumferential seams prior to backfilling to ensure the lapped corrugations are closely 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 the longitudinal seams shall be selected randomly along the structure prior to backfill placement, 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 both circumferential and longitudinal seams shall then be tested. The installation shall then be considered acceptable if the above torque requirements are satisfied in at least 90 percent of the bolts tested. Otherwise the design shall be checked to determine whether the bolt torque values achieved are acceptable. TABLE 6.1
BOLT TORQUE
Structure class 1 (Bolted) 2 2 NOTES: 1
Plate thickness (mm) 1.23.5 2.55 68
Torque range (Nm) Steel 20 5 310 40 395 25 Aluminium 10 2 170 15 170 15
Bolt torque values at the lower end of the range given in Table 6.1 are preferable to higher values so that the corrugations of lapping plates are closely nested and aligned and not damaged by excessive bolt tightening. Bolts and nuts used in Class 1 flanged-type structures and to connect arch structures to base channels shall be hand-tightened only. Information on inspection of bolt tightness is provided in AS 4100.
2 3
6.2.4
Assembled structure tolerances
6.2.4.1 Structure length The actual structure length shall differ from the specified structure length by no more than 1 percent.
NOTE: Structure length variations arise due to both manufacturing tolerances and erection procedures. In most cases, the assembled structure is longer than the design length.
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6.2.4.2 Structure cross-sectional shape The actual internal span and rise dimensions of the assembled structure after bolt torqueing and prior to backfilling shall not differ from the values given in Section 2 or those specified for other non-referenced shapes by more than 2 percent. 6.3 METHOD OF INSTALLATION
6.3.1 General Structures shall be installed in either trench or embankment conditions as 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 to surround the select fill (native soil, embankment material or trench walls) has strength and stiffness 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 trench condition, the trench width on each side of the structure shall be a minimum of (a) (b) 600 mm, where select fill is to be used; and 150 mm, where flowable fill is to be used.
6.3.3 Installation in embankment condition Where a structure is to be installed in embankment condition, the select fill shall extend to a minimum distance equal to the span of structure on each side (see Figure 6.1). This distance may be reduced where geotechnical advice establishes that the adjacent material has sufficient strength and is non-corrosive. 6.4 MINIMUM SPACING FOR MULTIPLE INSTALLATIONS Spacing shall be sufficient to ensure that adequate backfill support is provided to the structures and the fill above. The minimum spacings for multiple installations with mechanically compacted fills and flowable fills is given in Table 6.2. TABLE 6.2
MINIMUM SPACING FOR MULTIPLE STRUCTURES

Span Ss (mm) Ss 900 900 <Ss 3 000 3 000 <Ss 5 000 Ss >5 000 Select fill 300 Ss/3 Ss/4 Ss/5 Backfill type Flowable fill 150 150 200 300
NOTE: The limits in the above table should be modified as necessary to account for variables such as alternative construction practices, i.e., structure pre-assembly or poor in-situ soils.
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NOTE: Trench and embankment fill should be in accordance with requirements specified in other documents related to the project. In the absence of a specification, compaction should be to the same standard as for the select fill.
FIGURE 6.1
FILL AND STRUCTURE SUPPORT ZONES
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6.5 6.5.1
FOUNDATION AND BEDDING Pipes, pipe-arches and special shapes
6.5.1.1 Foundation The structure foundation shall be sufficiently strong, stable and uniform to support the full length of the installation, but shall not be stiffer than the undisturbed 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 less compressible than the structure so that positive soil arching can occur. It is undesirable to make the pipe stiffer or more unyielding than the adjacent side fill. The use of massive footings or piles to prevent any settlement of the pipe is generally not recommended. Providing for some structure settlement helps to induce positive soil arching and avoids possible drag down due to consolidation of the adjacent side fill. The foundation design may vary along the length of the structure to accommodate variations in load.
Where the natural foundation is assessed as suitable it shall be prepared to a level 75 mm below 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 more efficient and effective compaction of backfill in the haunch zones.
Rock foundation shall be excavated to a depth 250 mm or structure span/4, whichever is the lesser, and replaced with compacted select material to a level 75 mm below the design structure invert level. The minimum width of this zone of select material shall be equal to the structure span, and sufficient to ensure no part of the structure bears directly on rock so that uniform support is provided (see Figure 6.2(b)). Soft or unstable foundation material (such as highly plastic clays or silts) shall be removed and replaced with suitable compacted material to provide adequate support. Where considered necessary, appropriate geotechnical advice shall be obtained. (See Figure 6.2(a).)
FIGURE 6.2
BEDDING ON SOFT, ROCK AND FIRM FOUNDATIONS

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6.5.1.2 Camber Where settlement of the foundation is expected, longitudinal camber of the foundation shall be considered with due regard to hydraulic flow requirements and the integrity of the structure. 6.5.1.3 Bedding A uniform 75 mm deep layer of uncompacted coarse granular bedding material shall be placed over the foundation and prepared to the correct line and level to allow the corrugations of the structure invert to bed in. Bedding material shall be coarse sand or gravel with 12 mm maximum particle size and shall be placed to a minimum width of one third of the structure span. Bedding shall not be placed in the haunch zones of pipe arch and special shape structures. Precautions shall be taken to prevent erosion of bedding material by the use of cut-off walls 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 that sufficient bearing capacity is available to withstand arch footing forces as determined by Clause 5.14. 6.5.2.2 Footings Footings shall be installed in accordance with the information supplied by the designer. Provision shall be made to ensure footings are not undermined by 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 be implemented so as to achieve the desired structure shape required in Clause 6.8. The final shape tolerances of the metal structure as specified in Clause 6.8 shall be achieved at the completion of backfilling and compaction without causing excessive distortion or stress during the process (see also Clause 6.7). 6.6.2 Select fill Select fill shall comply with the grading requirements given in Table 6.3, and have a maximum linear shrinkage, determined in accordance with AS 1289.3.4.1, of 8 percent.
In trench installations, and situations where a free draining fill is required, single sized granular 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 (without segregation) and compaction to achieve the specified density.
TABLE
6.3
SELECT FILL GRADING REQUIREMENTS

Sieve aperture mm 75.0 9.5 2.36 0.60 0.075 Mass of sample passing* percent 100 50100 30100 1550 025
* Determined in accordance with AS 1289.3.6.1.
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6.6.3 Modified fill Flowable and cement modified backfill of the appropriate strength may 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 25 to 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 for select 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 than 90 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 dry density in accordance with AS 1289.5.3.2, AS 1289.5.8.1 and the maximum dry density in accordance with AS 1289.5.1.1/NZS 4402.4.1.1. Cohesionless soils Each layer of select fill shall be compacted to not less than 70 percent of the maximum density index for standard compaction. The density index (I D) shall be determined in accordance with AS 1289.5.6.1, based on the maximum 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 with AS 1289.5.3.1/NZS 4402.5.1.1, AS 1289.5.3.2, AS 1289.5.3.5/NZS 4402.5.1.5 or AS 1289.5.8.1.
(b)
Compaction equipment or methods that produce horizontal or vertical earth pressures which 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 extent The select fill material shall be placed in horizontal, uniform layers not exceeding 300 mm in thickness before compaction. Fill shall be placed in even layers on both sides of the structure with the difference between the 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 or Clause 6.3.3, as appropriate. The select fill shall extend to a minimum of cover height above 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 restraining headwalls (see Figure 6.4).
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(b) (c)
From the centre and progress to each structure end for a structure without restraining headwalls (see Figure 6.5). The arch crown shall then be temporarily restrained against peaking by either temporary top loading or anchoring. Select fill material shall continue over the arch in uniform, compacted curved layers (see Figure 6.6).
NOTE: Trench and embankment fill should be in accordance with requirements specified in other documents related to the project. In the absence of a specification, compaction should be to 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 loads such as heavy construction equipment are required to travel over the structure, the structure shall be checked for this loading condition. Where an overload condition occurs, the amount of temporary additional cover required to permit passage of the equipment over 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 shape shall 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 the specified 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 during installation. Abnormal conditions or loadings should be prevented from causing variation in span or rise by more than 5 percent of the specified dimensions or from causing local distortion of the structure wall. Where internal clearances are critical, adequate allowance should be made for cumulative manufacturing and installation tolerances and seam bolts on internal corrugation crests.
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APPENDIX
ORDERING GUIDELINES
(Informative) A1 GENERAL This Appendix contains a brief check list of some of the more important information that should be supplied by the purchaser at the time of order and by the manufacturer after the order has been placed. It aims to avoid misunderstanding and to result in the purchaser receiving satisfactory products and service. A2 INFORMATION TO BE SUPPLIED TO following minimum information should be provided: (a) (b) (c) (d) (e) (f) (g) (h) (i) Shape and class of structure. Cross-sectional dimensions. Thickness of sheets or plates and number of seam bolts per metre. Invert length and grade. Installation type (trench or embankment) Height of cover and unit weight of fill End type (see Figures A1 and A2). Type of live load applicable. Skew number. Where skew is required, details should be submitted by the purchaser in diagrammatic form in accordance with Figure A3, including an arrow to designate the direction of flow, if applicable. Special requirements such as invert paving and protective coating. MANUFACTURER The THE MANUFACTURER The
(j)
A3 INFORMATION TO BE SUPPLIED BY THE manufacturer should supply the following information: (a) (b) Details of plate layout if applicable. Instructions for field assembly.
FIGURE A1
EXAMPLES OF END TYPES AND SKEW
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METHOD OF SPECIFYING END TYPE
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FIGURE A3
64
METHOD OF SPECIFYING SKEW NUMBER
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APPENDIX
MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD

(Informative) B1 SCOPE This Appendix sets out the following different means by which compliance with this Standard can be demonstrated by the manufacturer or supplier: (a) (b) (c) (d) Evaluation by means of statistical sampling. The use of a product certification scheme. Assurance using the acceptability of the suppliers quality system. Other such means proposed by the manufacturer or supplier and acceptable to the customer.
B2 STATISTICAL SAMPLING Statistical sampling is a procedure which enables decisions to be made about the quality of batches of items after inspecting or testing only a portion of those items. This procedure will only be valid if the sampling plan has been determined on a statistical basis and the following requirements are met: (a) The sample shall be drawn randomly from a population of product of known history. The history shall enable verification that the product was made from known materials at essentially the same time, by essentially the same processes and under essentially the same system of control. For each different situation, a suitable sampling plan needs to be defined. A sampling plan for one manufacturer of given capability and product throughput may not be relevant to another manufacturer producing the same items.
(b)
In order for statistical sampling to be meaningful to the customer, the manufacturer or supplier needs to demonstrate how the above conditions have been satisfied. Sampling and the 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 provide independent assurance of the claim by the manufacturer that products comply with the stated 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 sampled production and subsequent verification of conformance, it requires the manufacturer to maintain effective quality planning to control production. The certification scheme serves to indicate that the products consistently conform to the requirements of the Standard. B4 SUPPLIERS QUALITY SYSTEM Where the manufacturer or supplier can demonstrate an audited and registered quality management system complying with the requirements of the appropriate or stipulated Australian or international Standard for a suppliers quality system or systems, this may provide the necessary confidence that the specified requirements will be met. The quality assurance requirements need to be agreed between the customer and supplier and should include a quality or inspection and test plan to ensure product conformity. Guidance in determining the appropriate quality management system is given in AS/NZS ISO 9000.1 and AS/NZS ISO 9004.1.
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B5 OTHER MEANS OF ASSESSMENT If the above methods are considered inappropriate, determination of compliance with the requirements of this Standard may be assessed from the results of testing coupled with the manufacturers guarantee of product conformance. Irrespective of acceptable quality levels (AQLs) or test frequencies, the responsibility remains with the manufacturer or supplier to supply products that conform with the full requirements of the Standard.
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APPENDIX
DURABILITY DESIGN AND PROTECTIVE SYSTEMS

(Informative) C1 GENERAL Based on long term, detailed and critical investigation of an estimated 50 000 buried corrugated metal structure installations in a number of countries, durability design 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 supported by overseas experience: (a) (b) (b) Soil-side corrosion rate of 10 to 30 m per year for steel expected if the protective zinc coating is expended. Little or no corrosion occurs on the interior surface of the structure above the level to which water regularly rises. 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 similar structures nearby, the use of non-corrosive relatively free draining backfills, and moderate culvert grades normally ensures that the structure wall thickness, required to satisfy the structural 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 wall thickness or by the addition of protective coatings or pavings. Corrosion of buried corrugated metal structures has been found to be most strongly influenced by the acidity, alkalinity, and conductivity or resistivity of the soil and water that is normally in contact with the structure. Soil moisture content or flow and the concentration of soluble salts can also influence metal loss rates.
Measurement of soil and water pH and resistivity is quite straightforward. The possible presence of soluble salts is generally detected by low resistivity measurements. Backfills that satisfy the grading requirements of Clause 6.7.1 of this Standard in most cases are sufficiently free draining to maintain moisture content below 20 percent. For submerged installations a coarse uniformly graded backfill is preferable. Soft water corrosion generally does not occur where the Langelier (or saturation) index is positive and greater than 0.5. Langeliers index is not relevant for determining the corrosion effect on Aluminium Structures. Alternative fills and barrier coatings may be considered in an effort to increase the expected 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 pH should be in accordance with AS 1289.4.3.1 and the Electrical resistivity should be in accordance with AS 1289.4.4.1. C2 SERVICE LIFE ASSESSMENT
C2.1 Recommended pH and resistivity of backfill When the pH and resistivity are well within the limits of the ranges given in Table C1, the service life of the structure may be estimated as follows: (a) (b) For steel 1015 years for galvanized coating life, then an average metal loss rate of 1030 m per year. For aluminium structures average metal loss rates will be negligible.
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TABLE
C1
RECOMMENDED RANGES FOR pH AND RESISTIVITY OF SOIL AND WATER IN CONTACT WITH CORRUGATED METAL STRUCTURES
Acceptable pH range Resistivity (ohm, cm) Galvanized steel 10 000 or more 2 00010 000 5002 000 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/kg and 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 25 years due to blockage of corrosion pits with insoluble corrosion products. For soils and waters with pH outside the 49 range or with high concentrations 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 have lower 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 poorly drained conditions, and above 2000 ohm-cm in drained conditions. However, this varies significantly with soil type. 512 610 Aluminised steel 59 59 Aluminium 49 49 49 Steel or aluminium with barrier coating 412 412 412
C2.2 Aggressive backfill conditions When the pH and resistivity are near the limits given in Table C1, the backfill may be aggressive and the sulphate and chloride concentrations should be checked. If the chlorides exceed 200 mg/kg or the sulphates exceed 100 mg/kg, or both, use the loss rates given in Tables C2 and C3. The life of the coating should be determined before determining the base metal loss. When a coating other than zinc is used, specialist advice should be obtained to determine the coating loss rate. When pH and resistivity are outside the ranges given in Table C1 the metal structures in this 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

Average zinc coating loss rate (m/yr) Soil pH <4 44.9 57.9 89 >9 Soil resistivity (Ohm, cm) <500 5001000 10002000 20005000 >5000 Drained soils >6.5 2.65.2 2.24.3 3.36.5 >8.6 All soils >3.5 1.53.5 1.31.5 0.91.5 <0.9 Undrained soils >20 6.713.3 5.511.0 6.112.1 >17.2
NOTES: 1 For Class 1 and Class 2 structures which have been hot-dip galvanised a coating thickness of (a) 63 m (per side) is applicable for wall thicknesses less than 5 mm; and (b) 84 m (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 m is applicable. 2 For aluminized Type II coating, a coating thickness of 48 m is applicable. 3 Non-metallic barrier coatings are recommended in coastal installations where extended life is required. 4 In fully submerged conditions, metal loss rates of 1 m 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

pH Chloride concentration In soil (%) <0.5 0.52 25 >5 1.01.5 In water (ppm) >1 000 1 00010 000 10 00020 000 >20 000 <20 000 Resistivity ohm cm Average metal loss rates (m/year) Undrained soils Steel >5 45 34 <3 49 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 25 years due to blockage of corrosion pits with insoluble corrosion products. For soils and waters with pH outside the 49 range or with high concentrations 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 water environment have lower loss rates. 2 For steel in high pH soils with high sulphate or chloride concentrations, average metal loss rates of 2060 /yr can be expected. >5 000 2 0005 000 1 0002 000 <1 000 >500 <10 1020 2040 40300 Aluminium Note 1 513 Drained soils Steel <10 <10 1020 1040 Aluminium Note 1 57
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C2.3 Atmospheric corrosion for exposed surfaces Corrosion due to atmospheric exposure away from coastal areas is generally not a major determinant of service life for buried corrugated metal structures. However, in some cases, aesthetics are of concern in tunnel and underpass structures and paint or similar coatings may be required. Average metal 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 exterior atmospheric corrosion. The recommendations given in AS/NZS 2312 are based on the atmospheric environments summarized in Table C4. For aluminium, the loss rates are negligible. TABLE C4
CORROSIVITY CLASSIFICATIONS
Atmospheric classification Mild Moderate Mild Steel corrosion rate m/year 10 1025 General nature of environment (See AS/NZS 2312) All areas remote from coast, industrial activity and the tropics. Sheltered, inland areas of New Zealand Includes areas with light industrial pollution or very light marine influence and sheltered suburbs of coastal centres. Most of New Zealand is in this zone Coastal tropics except where affected by salt spray. This environment is aggressive to organic coatings From within 1 km to within 10 km from coast depending on winds, topography, etc. Areas around major industrial complexes. Geothermal areas From within 100 m to within 1 km from coast depending on winds, topography, etc.
Tropical Marine Industrial Severe Marine
see AS/NZS 2312 2550 25 to > 50 50190
C3 PERFORATION OF METAL When perforation occurs, it is recommended that the 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 after initial perforation. However, because the structural integrity relies on the compacted condition of the surrounding soil, erosion due to seepage of ground water or other water that flows through such perforations should be controlled. C4 INVERT CONCRETE LINING
C4.1 Abrasion assessment Abrasion of the invert can occur where abrasive materials are transported by high velocity flows. In stormwater applications, low flow velocities and modest pipe grades usually result in negligible invert wear. For culvert design, Figure C1 can be used to determine the need for lining the invert with concrete 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 storm duration and seasonal variations may also effect design. Abrasive conditions may only apply over a quite small proportion of the total design life. Drainage structures can be provided with heavy gauge invert panels to resist mild abrasive conditions. In moderate to severe abrasive conditions, adequate protection can be provided by invert paving in accordance with Figure C1.
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Invert concrete lining should preferably proceed after the full embankment height over the culvert has been constructed and initial pipe flexure ceases. For pipes larger than 1200 mm in diameter, where asset maintenance inspection standards are in place, it may be cost-effective to delay invert paving to determine whether it is necessary based on culvert performance. In multiple cell culvert installations, good practice is to locate one cell at a lower invert level to isolate normal stream flow and abrasion and limit the need for invert paving to a single cell. C4.2 Ponding Severe localized corrosion can occur when the structure is exposed to a constant water level for extended periods. It is recommended that a concrete lining be used 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 continuous ponding in corrugations can result in extreme localized corrosion. Invert lining may be necessary in such cases.
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FIGURE C1
INVERT LINING ARRANGEMENT FOR CORRUGATED METAL STRUCTURES
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APPENDIX
AS 2041 STRUCTURAL DESIGN FLOW CHART

(Informative)
FIGURE D1
FLOW CHART
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APPENDIX
REFERENCE TABLES FOR MINIMUM COVER FOR STEEL STRUCTURES

(Informative) The information and recommendations contained in these Tables are intended for designers convenience in routine applications complying with this Standard. In the preparation of the Tables in this Appendix, the following values were adopted: fy k k = 250 MPa = 1 for height of cover less than span = 0.75 for height of cover equal to or greater than span = 2 = 20.0 kN/m3
The allowance for pavement (road) is 300 mm at 22 kN/m 3. Impact factors used are those given 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 not covered.
LIST OF TABLES E1.1 Cover limits for Class 1 steel pipes with lapped seam highway and railway live load E1.2 Cover limits for Class 1 steel pipes with flanged seam highway and railway live load E1.3 Cover limits for Class 1 steel pipe-arches with lapped seam highway and railway live load E1.4 Cover limits for Class 1 steel pipe-arches with flanged seam highway and railway live load E1.5 Cover limits for Class 1 steel pipe-arches with flanged seam highway live load E1.6 Cover limits for Class 1 steel pipe-arches with flanged seam railway live load E2.1 Cover limits for Class 2 steel pipes highway and railway live load E2.2 Cover limits for Class 2 steel pipe-arches and underpasses highway live load E2.3 Cover limits for Class 2 steel pipe-arches and underpasses railway live load E2.4 Cover limits for Class 2 steel arches (rise less than radius) highway and railway live load E2.5 Cover limits for Class 2 steel horseshoe arches highway and railway live load E2.6 Cover limits for Class 2 steel horizontal ellipses highway and railway live load E2.7 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 Minimum cover, m Pipe diameter Highway loads Railway loads Maximum cover, m 4 5 6 7 8 9 10
Plate thickness, mm 1.2 300 450 600 0.60 0.60 0.60 1.63.5 0.60 0.60 0.60 1.23.5 1.00 1.00 1.00 1.2 16.4 10.6 7.9
h
1.6 40.0 26.6 19.8
2.0 62.2 41.4 31.0
2.5 86.7 57.8 43.3
3.0 111.1 74.1 55.5
3.5 135.6 90.4 67.8
750 900 1 050
0.65 0.73 0.82
0.60 0.60 0.60
1.00 1.00 1.00
6.2 h 5.0 4.1

h h
15.7 13.0 11.0
24.8 20.6 17.6
34.6 28.8 24.6
44.4 37.0 31.7
54.2 45.1 38.7
1 200 1 350 1 500
* * *
0.60 0.60 0.60
1.00 1.00 1.00
9.4
15.3 13.5 12.1
21.5 19.1 17.1
27.7 24.6 22.1
33.8 30.0 27.0
1 650 1 800 1 950

0.60 0.60 0.60
1.00 1.00 1.00
* * *
15.5 * *
20.0 18.3 *
24.5 22.5 20.7
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
E1.2
COVER LIMITS FOR CLASS 1 STEEL PIPES WITH FLANGED SEAM HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 Minimum cover, m Highway loads 5 6 7 Min. cover railway loads, m Plate thickness, mm 1.2 300 450 600 750 900 1 050 1 200 1 350 1 500 1 650 1 800 1 950 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. 0.60 0.60 0.60 0.62 0.68 0.76 * * * * * 1.6 0.60 0.60 0.60 0.60 0.60 0.63 0.69 * * * * * 2.0 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.62 0.66 * * * 2.5 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.61 * * 3.0, 3.5 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 1.23.5 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.2 18.7 12.2 8.8 7.1 h 5.8 4.8
h h
10
11
12
13
Maximum cover, m
Pipe diameter
1.6 25.4 16.8 12.4 9.7 8.1 6.8

h h
2.0 34.4 22.8 17.0 13.4 11.0 9.3 8.2h 7.2 6.4
h h
2.5 43.3 28.8 21.5 17.1 14.1 12.0 10.3 9.0 8.3
h
3.0 53.3 35.5 26.6 21.2 17.6 15.0 13.0 11.4 10.2 9.1 8.5h
3.5 63.3 42.2 31.6 25.2 21.0 17.9 15.6 13.8 12.3 11.1 10.0 9.1
5.9h
7.5h
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TABLE
E1.3
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH LAPPED SEAM HIGHWAY LIVE LOAD
1 2 3 Minimum cover 4 Maximum cover 5 Minimum cover 6 Maximum cover 7 Minimum cover 8 Maximum cover 9 Minimum cover 10 Maximum cover 11 Minimum cover 12 Maximum cover 13 Minimum cover 14 Maximum cover 15 Minimum cover 16 Maximum cover
Maximum Internal internal rise span
Haunch bearing capacity (kPa) 300 600 to 1000 600 900 to 1000 Plate thickness, mm 600 900 1000
mm 450 600 750
mm 340 430 510
1.2 to 3.5 0.60 0.60 0.71 8.5 6.2 4.7 0.60 0.60 0.65
1.2 10.8 7.9 6.2 0.60 0.60 0.60
1.6 17.6 13.1 10.4 0.60 0.60 0.60
1.6 26.6 19.8 15.8
2.0 to 3.5 0.60 0.60 0.60 17.6 13.1 10.4
2.0 to 3.5 0.60 0.60 0.60 26.6 19.8 15.8
2.0 to 3.5 0.60 0.60 0.60 29.5 22.1 17.6
900 1 050 1 200
600 680 770
0.82 0.94 1.08
3.7 2.9 2.3
0.73 0.82 0.92
5.0 4.1 3.4
0.60 0.62 0.67
8.5 7.2 6.2
0.60 0.60 0.60
13.1 11.1 9.7
0.60 0.62 0.67
8.5 7.2 6.2
0.60 0.60 0.60
13.1 11.1 9.7
0.60 0.60 0.60
14.6 12.4 10.8
1 350 1 500 1 650
860 940 1 030
1.25
1.8
1.03 * *
2.8 * *
0.73 0.79 *
5.4 4.7 *
0.60 0.60 *
8.5 7.6 *
0.73 0.79 0.86
5.4 4.7 4.2
0.60 0.60 0.64
8.5 7.6 6.8
0.60 0.60 0.60
9.5 8.5 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 geotechnical advice.
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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
Maximum Internal internal rise span
Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum cover cover cover cover cover cover cover cover cover cover cover cover Haunch bearing capacity (kPa) 300 600 to 1000 600 900 to 1000 Plate thickness, mm 900 1000
mm 450 600 750 900 1 050 1 200 1 350 1 500 1 650 1 800 NOTES:
mm 340 430 510 600 680 770 860 940 1 030 1 110
1.2 to 3.5 1.0 8.4 1.00 1.00
1.2 10.8 7.8
1.6 to 3.5 1.00 1.00 1.00 1.00 1.00 17.6 13.1 10.3 8.4 7.0 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 *
1.6 26.6 19.9 15.8 13.1 11.1 9.6 8.4 7.3 *
2.0 to 3.5 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 26.6 19.9 15.8 13.1 11.1 9.6 8.4 7.3 6.6
2.0 to 3.5 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 29.6 22.1 17.6 14.6 12.4 10.8 9.5 8.4 7.5 6.8
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 geotechnical advice.
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TABLE
E1.5
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH FLANGED SEAM HIGHWAY LIVE LOAD
1 2 3 Min. cover Internal rise 300 600 to 1000 600 to 1000 4 Max. cover 5 Min. cover 6 Max. cover 7 Min. cover 8 Max. cover 9 Min. cover 10 Max. cover 11 Min. cover 12 Max. cover 13 Min. cover 14 Max. cover 15 Min. cover 16 Max. cover 17 18
Min. cover Max. cover
Max. internal span
Haunch bearing capacity (kPa) 600 900 to 1000 900 1000 1000
Plate thickness, mm mm 450 600 750 mm 340 430 510 1.2 to 3.5 0.60 0.60 0.71 8.5 6.2 4.7 0.60 0.60 0.62 1.2 12.3 9.1 7.1 0.60 0.60 0.60 1.6 16.9 12.5 9.9 2.0 to 3.5 0.60 0.60 0.60 17.6 13.1 10.4 0.60 0.60 0.60 2.0 22.8 17.0 13.5 2.5 to 3.5 0.60 0.60 0.60 26.6 19.8 15.8 0.60 0.60 0.60 2.5 28.8 21.5 17.2 3.0 to 3.5 0.60 0.60 0.60 29.5 22.1 17.6
900 1 050 1 200
600 680 770
0.82 0.94 1.08
3.7 2.9 2.3
0.68 0.76 0.85
5.8 4.8 4.0
0.60 0.63 0.69
8.1 6.8 5.9
0.60 0.62 0.67
8.5 7.2 6.2
0.60 0.60 0.60
11.2 9.5 8.2
0.60 0.60 0.60
13.1 11.1 9.7
0.60 0.60 0.60
14.2 12.1 10.5
0.60 0.60 0.60
14.6 12.4 10.8
1 350 1 500 1 650
860 940 1 030
1.25
1.8
0.94 * *
3.4 * *
0.75 0.82 *
5.1 4.5 *
0.73 0.79 0.86
5.4 4.7 4.2
0.62 0.66 0.71
7.2 6.4 5.7
0.60 0.60 0.64
8.5 7.6 6.8
0.60 0.60 0.61
9.3 8.3 7.5
0.60 0.60 0.60
9.5 8.5 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 geotechnical advice.
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TABLE
E1.6
COVER LIMITS FOR CLASS 1 STEEL PIPE-ARCHES WITH FLANGED SEAM RAILWAY LIVE LOAD
1 2 3 Min. cover Internal rise 300 600 to 1000 600 to 1000 4 Max. cover 5 Min. cover 6 Max. cover 7 Min. cover 8 Max. cover 9 Min. cover 10 Max. cover 11 Min. cover 12 Max. cover 13 Min. cover 14 Max. cover 15 Min. cover 16 Max. cover 17 18
Min. cover Max. cover
Max. internal span
Haunch bearing capacity (kPa) 600 900 to 1000 900 1000 1000
Plate thickness, mm mm 450 600 750 mm 340 430 510 1.2 to 3.5 1.00 8.4 1.00 1.00 1.00 1.2 12.3 9.0 7.0 1.00 1.00 1.00 1.6 16.9 12.5 9.9 2.0 to 3.5 1.00 1.00 1.00 17.6 13.1 10.3 1.00 1.00 1.00 2.0 22.9 17.1 13.6 2.5 to 3.5 1.00 1.00 1.00 26.6 19.9 15.8 1.00 1.00 1.00 2.5 28.8 21.6 17.2 3.0 to 3.5 1.00 1.00 1.00 29.6 22.1 17.6
900 1 050 1 200
600 680 770
1.00 1.00
8.0 6.7
1.00 1.00
8.4 7.0
1.00 1.00 1.00
11.2 9.4 8.1
1.00 1.00 1.00
13.1 11.1 9.6
1.00 1.00 1.00
14.2 12.1 10.5
1.00 1.00 1.00
14.6 12.4 10.8
1 350 1 500 1 650
860 940 1 030
1.00
7.1
1.00 1.00 1.00
8.4 7.3 6.6
1.00 1.00 1.00
9.2 8.2 7.3
1.00 1.00 1.00
9.5 8.4 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 geotechnical advice.
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TABLE
E2.1
COVER LIMITS FOR CLASS 2 STEEL PIPES HIGHWAY AND RAILWAY LIVE LOAD
1 Structure number 2 Nominal diameter mm 20P 22P 24P 26P 28P 30P 32P 36P 40P 44P 48P 52P 56P 60P 64P 68P 72P 76P 80P 84P 88P 92P 96P 100P 104P 108P 112P 114P 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 5 5 5 6 6 6 6 7 7 7 8 8 8 500 650 800 950 100 250 400 700 000 300 600 900 200 500 800 100 400 700 000 300 600 900 200 500 800 100 400 550 3 Minimum cover highway loads m 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.64 0.69 0.74 0.79 0.84 0.89 0.94 0.99 1.04 1.09 1.14 1.19 1.24 1.29 1.34 1.39 1.41 4 Minimum cover railway loads m 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.03 1.11 1.18 1.26 1.33 1.41 1.48 1.56 1.63 1.71 1.78 1.85 1.93 2.00 2.08 2.12 5 6 7 8 9 Maximum cover, m Plate thickness, mm 6.0 Bolts/metre 10 66.4 60.1 54.9 50.5 46.8 43.6 40.8 36.1 32.4 29.4 26.9 24.8 23.0 21.4 20.0 18.8 17.7 16.8 15.9 15.1 14.4 13.8 13.2 12.6 12.1 11.6 * * 10 11 12 13
2.5 10 24.0 21.7 19.8 18.2 16.8 15.7 14.6 12.9 11.5 10.4 9.4 8.6 7.9 7.3 6.7 6.4
3.0 10 30.0 27.2 24.8 22.8 21.2 19.7 18.4 16.3 14.6 13.2 12.0 11.0 10.1 9.4 8.7 8.1 7.6 7.1 *
4.0 10 43.1 39.0 35.6 32.8 30.4 28.3 26.4 23.4 21.0 19.0 17.4 16.0 14.8 13.8 12.9 12.1 11.3 10.7 10.1 9.6 9.1 * * * * * *
5.0 10 54.7 49.6 45.3 41.7 38.6 35.9 33.6 29.8 26.7 24.2 22.1 20.4 18.9 17.6 16.5 15.5 14.6 13.8 13.0 12.4 11.8 11.2 10.7 * * * * *
7.0 10 75.7 68.6 62.6 57.7 53.4 49.7 46.5 41.2 37.0 33.6 30.7 28.3 26.2 24.4 22.9 21.5 20.3 19.2 18.2 17.3 16.5 15.7 15.1 14.4 13.9 13.3 12.7 12.2 15 96.3 87.2 79.7 73.3 67.9 63.3 59.2 52.5 47.1 42.7 39.1 36.0 33.4 31.1 29.1 27.4 25.8 24.5 23.0 21.4 19.9 18.5 17.2 16.0 14.8 13.7 12.7 12.2 15 105.3 95.4 87.1 80.2 74.3 69.2 64.7 57.4 51.5 46.7 42.7 39.4 36.5 34.0 31.9 30.0 28.3 26.8 25.4 24.2 22.8 21.2 19.7 18.3 17.0 15.7 14.6 14.0
8.0 20 110.1 99.7 91.1 83.8 77.6 72.3 67.7 60.0 53.8 48.8 44.7 41.2 38.2 35.6 33.3 31.3 29.6 28.0 26.3 24.5 22.8 21.2 19.7 18.3 17.0 15.7 14.6 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 Maximum cover, m Haunch bearing capacity (kPa) Structure number Maximum internal span Internal rise Minimum cover 300 2.5 mm 10PA5-5 11PA5-6 14PA5-6 16PA5-7 17PA5-7 18PA5-7 17PA5-11 18PA5-11 20PA5-11 21PA5-11 22PA5-11 24PA5-12 25PA5-13 24PA5-16 27PA5-16 29PA5-17 31PA5-18 33PA5-19 35PA5-20 37PA5-21 39PA5-22 41PA5-23 24U5-7 27U5-11 29U5-11 31U5-11 33U5-11 33U5-13 35U5-13 35U5-16 1 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 5 5 5 6 6 6 3 3 3 4 4 4 4 4 925 131 406 692 773 851 255 343 507 585 659 934 140 463 689 967 241 513 782 049 314 578 145 798 942 085 227 452 590 945 mm 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 2 3 3 3 3 3 3 3 691 782 923 063 111 160 285 332 429 477 527 668 759 835 982 123 265 406 548 690 833 976 768 152 268 386 505 606 725 876 m 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.61 0.66 0.69 0.74 0.78 0.83 0.87 0.92 0.96 1.01 1.05 1.10 0.60 0.63 0.66 0.68 0.71 0.74 0.77 0.82 15.1 13.5 12.1 10.7 10.4 10.2 8.4 8.2 8.0 7.8 7.7 7.1 6.7 5.9 5.7 5.3 4.8 4.2 3.7 3.4 3.0 * 10.7 8.8 8.4 8.1 7.8 7.4 7.1 6.5 10 17.8 16.1 14.2 12.6 12.2 11.9 10.3 10.1 9.6 9.3 9.1 8.4 8.0 7.3 6.9 6.5 6.1 5.8 5.2 4.6 4.1 * 10.7 8.8 8.4 8.1 7.8 7.4 7.1 6.5 15.1 13.5 12.1 10.7 10.4 10.2 8.4 8.2 8.0 7.8 7.7 7.1 6.7 5.9 5.7 5.3 4.8 4.2 3.7 3.4 3.0 2.8 12.7 10.4 10.0 9.7 9.3 8.8 8.5 7.8 600 300 3.0 10 22.4 20.2 17.8 15.9 15.4 15.0 13.1 12.7 12.1 11.8 11.6 10.7 10.2 9.4 8.9 8.3 7.9 7.4 7.1 6.7 6.4 5.7 13.6 11.1 10.7 10.3 9.9 9.4 9.1 8.4 30.5 27.3 24.5 21.9 21.4 20.8 17.3 17.1 16.5 16.3 16.0 14.9 14.1 12.5 12.2 11.6 11.0 10.4 9.9 9.5 9.1 8.7 19.6 16.1 15.5 15.0 14.5 13.7 13.3 12.3 600 600 4.0 10 32.1 29.0 25.7 22.9 22.2 21.6 18.9 18.4 17.5 17.1 16.8 15.6 14.8 13.7 13.0 12.2 11.6 11.0 10.4 9.9 9.5 9.1 19.6 16.1 15.5 15.0 14.5 13.7 13.3 12.3 30.5 27.3 24.5 21.9 21.4 20.9 17.4 17.1 16.5 16.3 16.0 14.9 14.1 12.5 12.2 11.6 11.0 10.4 9.9 9.5 9.1 8.7 24.9 20.6 19.8 19.1 18.5 17.5 17.0 15.7 900 600 5.0 Bolts/metre 10 40.8 36.9 32.6 29.2 28.3 27.5 24.1 23.4 22.3 21.8 21.4 19.9 18.9 17.5 16.6 15.7 14.8 14.1 13.4 12.8 12.2 11.7 24.9 20.6 19.8 19.1 18.5 17.5 17.0 15.7 30.5 27.3 24.6 22.0 21.4 20.9 17.4 17.1 16.6 16.3 16.0 14.9 14.1 12.5 12.2 11.6 11.0 10.4 9.9 9.5 9.1 8.7 25.9 21.4 20.6 19.8 19.2 18.2 17.6 16.3 10 45.9 41.1 36.9 33.0 32.2 31.4 26.2 25.8 25.0 24.6 24.2 22.6 21.4 19.0 18.6 17.6 16.7 15.9 15.2 14.5 13.9 13.4 30.2 25.0 24.1 23.2 22.4 21.3 20.6 19.1 49.6 44.8 39.6 35.4 34.3 33.4 29.1 28.5 27.1 26.5 26.0 24.1 22.9 21.2 20.2 19.1 18.0 17.1 16.3 15.6 14.9 14.3 30.2 25.0 24.1 23.2 22.4 21.3 20.6 19.1 45.9 41.1 37.0 33.1 32.2 31.4 26.2 25.8 25.0 24.6 24.2 22.6 21.4 19.0 18.6 17.6 16.7 15.9 15.2 14.5 13.9 13.4 34.5 28.5 27.5 26.5 25.6 24.3 23.6 21.9 10 51.0 45.7 41.1 36.8 35.8 34.9 29.2 28.7 27.8 27.4 27.0 25.1 23.8 21.2 20.7 19.6 18.6 17.7 16.9 16.2 15.5 14.9 34.5 28.5 27.5 26.5 25.6 24.3 23.6 21.9 45.9 41.1 37.0 33.1 32.2 31.4 26.2 25.8 25.0 24.6 24.2 22.6 21.4 19.0 18.6 17.6 16.7 15.9 15.2 14.5 13.9 13.4 38.9 32.2 31.0 29.9 28.9 27.4 26.6 24.7 15 51.0 45.7 41.1 36.8 35.8 34.9 29.2 28.7 27.8 27.4 27.0 25.1 23.8 21.2 20.7 19.6 18.6 17.7 16.9 16.2 15.5 14.9 43.2 35.8 34.5 33.2 32.1 30.5 29.6 27.4 900 600 900 6.0 1 000 900 1 000 7.0 900 1 000 Plate thickness, mm
COPYRIGHT
83 38U5-16 40U5-16 40U5-18 41U5-19 43U5-19 45U5-19 5 5 5 5 5 5 145 278 521 710 838 967 4 4 4 4 4 4 054 174 272 381 501 622 0.86 0.88 0.92 0.95 0.97 1.00 6.2 6.1 5.7 5.4 5.0 4.7 6.2 6.1 5.7 5.4 5.0 4.7 7.5 7.3 6.9 6.7 6.5 6.3 8.0 7.8 7.4 7.1 7.0 6.8 11.8 11.5 10.9 10.6 10.3 10.1 11.8 11.5 10.9 10.6 10.3 10.1 15.1 14.7 14.0 13.6 13.2 12.9 15.1 14.7 14.0 13.6 13.2 12.9 15.7 15.3 14.6 14.1 13.8 13.5 18.4 17.9 17.1 16.5 16.2 15.8 18.4 17.9 17.1 16.5 16.2 15.8 21.0 20.5 19.6 18.9 18.5 18.1 21.0 20.5 19.6 18.9 18.5 18.1
AS/NZS 2041:1998 23.7 23.1 22.1 21.3 20.8 20.4 26.4 25.7 24.5 23.7 23.2 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 geotechnical advice.
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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 Maximum cover, m Haunch bearing capacity (kPa) Structure number Maximum internal span Internal rise Minimum cover 300 2.5 mm 10PA5-5 11PA5-6 14PA5-6 16PA5-7 17PA5-7 18PA5-7 17PA5-11 18PA5-11 20PA5-11 21PA5-11 22PA5-11 24PA5-12 25PA5-13 24PA5-16 27PA5-16 29PA5-17 31PA5-18 33PA5-19 35PA5-20 37PA5-21 39PA5-22 41PA5-23 24U5-7 27U5-11 29U5-11 31U5-11 33U5-11 33U5-13 1 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 5 5 5 6 6 6 3 3 3 4 4 4 925 131 406 692 773 851 255 343 507 585 659 934 140 463 689 967 241 513 782 049 314 578 145 798 942 085 227 452 mm 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 2 3 3 3 3 3 691 782 923 063 111 160 285 332 429 477 527 668 759 835 982 123 265 406 548 690 833 976 768 152 268 386 505 606 m 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.03 1.11 1.17 1.24 1.31 1.38 1.44 1.51 1.58 1.64 1.00 1.00 1.00 1.02 1.06 1.11 15.1 13.5 12.0 10.7 10.4 10.1 8.3 8.1 7.8 7.7 7.6 7.0 10.7 8.7 8.3 8.0 7.7 7.2 10 17.9 16.1 14.2 12.6 12.2 11.9 10.3 10.0 9.5 9.3 9.1 8.3 7.9 7.2 6.8 10.7 8.7 8.3 8.0 7.7 7.2 15.1 13.5 12.0 10.7 10.4 10.1 8.3 8.1 7.8 7.7 7.6 7.0 12.7 10.4 10.0 9.6 9.2 8.7 600 300 3.0 10 22.4 20.2 17.9 15.9 15.4 15.0 13.1 12.7 12.1 11.8 11.6 10.7 10.1 9.3 8.8 8.2 7.7 7.3 6.9 13.6 11.1 10.7 10.3 9.9 9.3 30.5 27.3 24.6 22.0 21.4 20.9 17.4 17.1 16.6 16.3 16.0 14.9 14.1 12.5 12.2 11.5 10.9 10.4 9.9 9.4 9.0 8.6 19.6 16.2 15.6 15.0 14.5 13.7 600 600 4.0 10 32.2 29.1 25.7 22.9 22.3 21.7 18.9 18.4 17.5 17.2 16.8 15.6 14.8 13.7 13.0 12.2 11.5 10.9 10.4 9.9 9.4 9.0 19.6 16.2 15.6 15.0 14.5 13.7 30.5 27.4 24.6 22.0 21.4 20.9 17.4 17.1 16.6 16.3 16.1 14.9 14.1 12.5 12.2 11.6 10.9 10.4 9.9 9.4 9.0 8.6 24.9 20.6 19.8 19.1 18.5 17.5 900 600 5.0 Bolts/metre 10 40.9 36.9 32.7 29.2 28.3 27.6 24.1 23.5 22.4 21.9 21.4 19.9 18.9 17.5 16.6 15.7 14.8 14.1 13.4 12.8 12.2 11.7 24.9 20.6 19.8 19.1 18.5 17.5 30.6 27.3 24.6 22.0 21.4 20.9 17.4 17.1 16.6 16.3 16.1 14.9 14.1 12.5 12.2 11.6 10.9 10.4 9.9 9.4 9.0 8.6 25.9 21.4 20.6 19.9 19.2 18.2 10 45.9 41.1 37.0 33.1 32.2 31.5 26.2 25.8 25.0 24.6 24.3 22.6 21.4 19.1 18.6 17.6 16.7 15.9 15.2 14.5 13.9 13.4 30.3 25.0 24.1 23.3 22.5 21.3 49.6 44.8 39.7 35.4 34.4 33.4 29.2 28.5 27.1 26.6 26.0 24.2 23.0 21.2 20.2 19.1 18.1 17.2 16.3 15.6 14.9 14.3 30.3 25.0 24.1 23.3 22.5 21.3 46.0 41.2 37.0 33.1 32.3 31.5 26.3 25.8 25.0 24.7 24.3 22.6 21.4 19.1 18.6 17.6 16.7 15.9 15.2 14.6 13.9 13.4 34.6 28.6 27.5 26.6 25.7 24.4 10 51.1 45.8 41.1 36.8 35.9 35.0 29.2 28.7 27.8 27.4 27.0 25.1 23.8 21.2 20.7 19.6 18.6 17.8 17.0 16.2 15.5 14.9 34.6 28.6 27.5 26.6 25.7 24.4 46.0 41.2 37.0 33.1 32.3 31.5 26.3 25.8 25.0 24.7 24.3 22.6 21.4 19.1 18.6 17.6 16.7 15.9 15.2 14.6 13.9 13.4 38.9 32.2 31.0 29.9 28.9 27.5 15 51.1 45.8 41.1 36.8 35.9 35.0 29.2 28.7 27.8 27.4 27.0 25.1 23.8 21.2 20.7 19.6 18.6 17.8 17.0 16.2 15.5 14.9 43.3 35.8 34.5 33.3 32.2 30.5 900 600 900 6.0 1 000 900 1 000 7.0 900 1 000 Plate thickness, mm
(continued) COPYRIGHT
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TABLE E2.3 (continued)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Maximum cover, m Haunch bearing capacity (kPa) Structure number Maximum internal span Internal rise Minimum cover 300 2.5 mm 35U5-13 35U5-16 38U5-16 40U5-16 40U5-18 41U5-19 43U5-19 45U5-19 4 590 4 945 5 5 5 5 5 5 145 278 521 710 838 967 mm 3 725 3 876 4 4 4 4 4 4 054 174 272 381 501 622 m 1.15 1.24 1.29 1.32 1.38 1.43 1.46 1.49 6.9 10 6.9 8.4 7.7 7.4 7.2 6.8 600 300 3.0 10 9.0 8.3 7.9 7.7 7.3 7.0 6.8 13.3 12.3 11.8 11.5 10.9 10.5 10.3 10.0 600 600 4.0 10 13.3 12.3 11.8 11.5 10.9 10.5 10.3 10.0 17.0 15.7 15.1 14.7 14.0 13.6 13.2 12.9 900 600 5.0 Bolts/metre 10 17.0 15.7 15.1 14.7 14.0 13.6 13.2 12.9 17.6 16.3 15.7 15.3 14.6 14.1 13.8 13.5 10 20.7 19.2 18.4 17.9 17.1 16.5 16.2 15.8 20.7 19.2 18.4 17.9 17.1 16.5 16.2 15.8 23.6 21.9 21.0 20.5 19.6 18.9 18.5 18.1 10 23.6 21.9 21.0 20.5 19.6 18.9 18.5 18.1 26.6 24.7 23.7 23.1 22.1 21.3 20.9 20.4 15 29.6 27.5 26.4 25.7 24.6 23.8 23.2 22.7 900 600 900 6.0 1 000 900 1 000 7.0 900 1 000 Plate thickness, mm
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 geotechnical advice.
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TABLE
E2.4
COVER LIMITS FOR CLASS 2 STEEL ARCHES (RISE LESS THAN RADIUS) HIGHWAY AND RAILWAY LIVE LOAD
1 Structure number 2 Maximum internal span mm 12AA 15AA 18AA 22AA 23AA 26AA 29AA 32AA 35AA 37AA 40AA 43AA 46AA 49AA 26AB 29AB 33AB 36AB 39AB 42AB 46AB 49AB 52AB 56AB 2 2 3 3 4 4 5 5 6 6 7 7 8 8 4 4 5 5 6 6 7 7 8 8 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 3 4 Minimum cover highway loads m 0.60 0.60 0.60 0.60 0.67 0.75 0.83 0.92 1.00 1.08 1.17 1.25 1.33 1.42 0.67 0.75 0.83 0.92 1.00 1.08 1.17 1.25 1.33 1.42 5 Minimum cover railway loads m 1.00 1.00 1.00 1.00 1.00 1.13 1.25 1.38 1.50 1.63 1.75 1.88 2.00 2.13 1.00 1.13 1.25 1.38 1.50 1.63 1.75 1.88 2.00 2.13 6 7 8 9 Maximum cover, m Plate thickness, mm 5.0 Bolts/metre 10 37.0 29.5 24.6 21.0 18.4 16.3 14.6 13.2 11.9 10.4 9.1 7.9 6.0 5.1 h 18.4 16.3 14.6 13.2 11.9 10.4 9.1 7.9 6.0 5.1 h 10 11 12
Internal rise
2.5 10 17.2 13.6 11.3 9.5 8.2 7.1 6.4 5.8 4.7 8.2 7.1 6.5 5.8 4.7
3.0 10 21.6 17.2 14.2 12.1 10.5 9.2 8.2 7.3 6.8 5.5 10.5 9.2 8.2 7.3 6.8 5.5
4.0 10 29.5 23.6 19.6 16.7 14.6 12.9 11.5 10.4 9.3 8.1 7.0 5.5 4.3 14.6 12.9 11.5 10.4 9.3 8.1 7.0 5.5 4.3
6.0 10 44.4 35.5 29.5 25.3 22.1 19.6 17.6 16.0 14.3 12.6 11.1 9.8 8.5 6.5 22.1 19.6 17.6 16.0 14.3 12.6 11.1 9.8 8.5 6.5
7.0 10 51.8 41.4 34.5 29.6 25.8 22.9 20.6 18.7 16.9 14.9 13.2 11.6 10.2 8.8 25.8 22.9 20.6 18.7 16.9 14.9 13.2 11.6 10.2 8.8
8.0 15 59.2 47.4 39.4 33.8 29.5 26.2 23.6 21.4 19.3 17.1 15.1 13.3 11.7 10.2 29.5 26.2 23.6 21.4 19.3 17.1 15.1 13.3 11.7 10.2
mm 1 1 1 1 1 1 2 2 2 2 2 3 3 1 2 2 2 2 3 3 3 3 4 850 058 265 598 550 757 965 172 380 452 659 867 075 283 927 136 464 673 883 092 420 630 839 167
h h h
h h
h h
h h h
h h
h h
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
E2.5
COVER LIMITS FOR CLASS 2 STEEL HORSESHOE ARCHES HIGHWAY AND RAILWAY LIVE LOAD
1 2 Maximum internal span 3 4 Minimum cover highway loads m 0.60 0.60 0.73 1.00 1.18 1.42 0.60 0.60 0.69 0.99 1.29 1.41 5 Minimum cover railway loads m 1.00 1.00 1.10 1.50 1.78 2.13 1.00 1.00 1.03 1.48 1.93 2.12 6 7 8 9 10 11 12 13 14
Maximum cover, m Structure number Internal rise Plate thickness, mm 2.5 3.0 4.0 5.0 6.0 Bolts/metre mm HA22 HA27 HA40 HA54 HA64 HA76 16EA-5 22EA-6 28EA-10 40EA-12 52EA-17 57EA-18 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. 2 400 3 000 4 400 6 000 7 100 8 500 2 334 3 231 4 129 5 924 7 720 8 468 mm 1 857 2 274 3 376 4 550 5 395 6 397 2 368 3 056 4 405 5 763 7 711 8 285 10 14.2 11.3 7.3 4.7 14.6 10.4 7.9 4.8
h h
7.0
8.0
10 17.9 14.2 9.5 6.8 18.4 13.2 10.1 6.7

h
10 25.8 20.6 13.9 10.0 8.3 26.5 19.1 14.8 10.1 7.2
10 32.7 26.1 17.7 12.9 10.8 8.1 33.7 24.3 18.9 13.0 9.8 8.3
10 39.7 31.7 21.6 15.7 13.2 10.2 40.8 29.5 23.0 15.9 12.1 10.3
10 45.3 36.2 24.6 18.0 15.1 12.1 46.6 33.6 26.3 18.2 13.9 12.2
15 57.6 46.0 31.3 22.6 17.3 12.1 59.2 42.8 33.4 23.0 14.8 12.2
15 62.9 50.3 34.3 25.1 19.8 13.9 64.8 46.7 36.6 25.4 17.0 14.0
20 65.8 52.6 35.8 25.9 19.8 13.9 67.7 48.9 38.2 26.4 17.0 14.0
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TABLE
E2.6
COVER LIMITS FOR CLASS 2 STEEL HORIZONTAL ELLIPSES HIGHWAY AND RAILWAY LIVE LOAD
1 Structure number 2 Maximum internal span 3 Internal rise 4 Minimum cover highway loads 5 Minimum cover railway loads 6 7 8 9 10 Maximum cover, m Plate thickness, mm 6.0 Bolts/metre 10 63.3 52.3 44.6 41.3 38.8 34.3 30.8 29.3 27.9 25.5 23.5 22.6 21.8 20.5 19.1 18.5 18.0 16.9 16.0 15.5 15.1 14.4 13.7 13.4 13.0 12.5 11.9 11.7 * * * 11 12 13 14
2.5 10 22.9 18.9 16.0 14.8 13.9 12.2 10.9 10.3 9.8 8.9 8.1 7.7 7.4 6.9 6.5 6.3
3.0 10 28.7 23.6 20.1 18.7 17.5 15.4 13.8 13.1 12.4 11.3 10.4 10.0 9.5 8.9 8.3 8.0 7.7 7.2 *
4.0 10 41.1 33.9 28.9 26.8 25.2 22.2 19.9 19.0 18.0 16.5 15.2 14.6 14.0 13.1 12.3 11.9 11.5 10.8 10.2 9.9 9.6 9.1 * * * * * * *
5.0 10 52.2 43.1 36.8 34.1 32.0 28.3 25.3 24.1 23.0 21.0 19.3 18.6 17.9 16.8 15.7 15.2 14.8 13.9 13.1 12.7 12.4 11.8 11.2 10.9 10.6 * * * * * *
7.0 10 72.1 59.6 50.9 47.2 44.2 39.1 35.1 33.4 31.8 29.1 26.8 25.8 24.8 23.4 21.9 21.2 20.5 19.3 18.3 17.8 17.3 16.5 15.7 15.3 15.0 14.3 13.7 13.4 13.2 12.3 11.3 15 91.7 75.8 64.7 60.0 56.3 49.8 44.6 42.5 40.5 37.0 34.1 32.9 31.6 29.8 27.9 27.0 26.2 24.7 23.2 22.3 21.4 19.9 18.4 17.7 17.0 15.7 14.5 14.0 13.4 12.3 11.3 15 100.3 82.8 70.7 65.5 61.5 54.4 48.8 46.5 44.3 40.5 37.3 35.9 34.6 32.6 30.5 29.5 28.6 27.0 25.5 24.8 24.2 22.8 21.1 20.3 19.4 18.0 16.6 16.0 15.4 14.1 13.0
8.0 20 104.8 86.6 73.9 68.5 64.3 56.9 51.0 48.6 46.3 42.3 39.0 37.6 36.2 34.0 31.9 30.9 29.9 28.2 26.5 25.5 24.5 22.8 21.1 20.3 19.4 18.0 16.6 16.0 15.4 14.1 13.0
mm mm m m 5HE-5 1 509 1 363 0.60 1.00 6HE-6 1 826 1 642 0.60 1.00 7HE-7 2 138 1 928 0.60 1.00 2 306 2 079 0.60 1.00 10HE-5 10HE-6 2 457 2 223 0.60 1.00 12HE-6 2 777 2 508 0.60 1.00 14HE-6 3 095 2 795 0.60 1.00 14HE-7 3 250 2 935 0.60 1.00 16HE-6 3 411 3 085 0.60 1.00 18HE-6 3 731 3 371 0.62 1.00 19HE-7 4 043 3 656 0.67 1.01 20HE-7 4 200 3 801 0.70 1.05 21HE-7 4 362 3 942 0.73 1.09 12HE-18 4 634 4 188 0.77 1.16 14HE-18 4 950 4 478 0.83 1.24 14HE-19 5 106 4 612 0.85 1.28 14HE-20 5 263 4 750 0.88 1.32 18HE-18 5 586 5 048 0.93 1.40 20HE-18 5 902 5 338 0.98 1.48 21HE-18 6 065 5 478 1.01 1.52 21HE-19 6 219 5 618 1.04 1.56 21HE-21 6 525 5 901 1.09 1.63 24HE-20 6 849 6 191 1.14 1.71 24HE-21 7 004 6 327 1.17 1.75 28HE-18 7 175 6 483 1.20 1.79 27HE-21 7 479 6 760 1.25 1.87 30HE-20 7 801 7 052 1.30 1.95 30HE-21 7 953 7 194 1.33 1.99 8 112 7 338 1.35 2.03 31HE-21 33HE-21 8 432 7 622 1.41 2.11 35HE-21 8 750 7 908 1.46 2.19 NOTES: 1 This Table can be used for Australian W7, T44, HLP320, HLP400 and 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.
h h
New Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
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TABLE
E2.7
COVER LIMITS FOR CLASS 2 STEEL VERTICAL ELLIPSES HIGHWAY AND RAILWAY LIVE LOAD
1 Structure number 2 Maximum internal span 3 Internal rise 4 Minimum cover highway loads 5 Minimum cover railway loads 6 7 8 9 10 Maximum cover, m Plate thickness, mm 6.0 Bolts/metre 10 70.0 58.1 49.5 45.9 42.9 38.0 34.1 32.4 30.9 28.2 26.0 25.0 24.1 22.7 21.2 20.6 19.9 18.7 17.7 17.2 16.8 16.0 15.2 14.9 14.5 13.9 13.3 3.0 12.7 12.2 11.8 11.5 11 12 13 14
2.5 10 25.4 21.0 17.8 16.5 15.4 13.6 12.1 11.5 10.9 9.9 9.1 8.7 8.3 7.8 7.2 6.9 6.7 6.4
3.0 10 31.7 26.3 22.4 20.7 19.4 17.1 15.3 14.6 13.8 12.6 11.6 11.1 10.7 10.0 9.3 9.0 8.7 8.1 7.6 7.3 7.1
4.0 10 45.5 37.7 32.1 29.8 27.8 24.6 22.1 21.0 20.0 18.3 16.8 16.1 15.5 14.6 13.6 13.2 12.8 12.0 11.3 11.0 10.7 10.2 9.6 9.4 9.1 * * * * * * *
5.0 10 57.8 47.9 40.8 37.8 35.4 31.3 28.1 26.7 25.4 23.3 21.4 20.6 19.8 18.7 17.4 16.9 16.4 15.4 14.5 14.1 13.8 13.1 12.5 12.2 11.9 11.3 10.8 10.6 10.4 * * *
7.0 10 79.8 66.2 56.4 52.3 48.9 43.4 38.9 37.0 35.2 32.2 29.7 28.5 27.5 25.9 24.2 23.5 22.8 21.4 20.2 19.7 19.2 18.3 17.4 17.0 16.6 15.9 15.2 14.9 14.6 14.0 13.5 13.3 15 101.5 84.2 71.7 66.5 62.2 55.1 49.5 47.1 44.8 41.0 37.8 36.3 35.0 33.0 30.8 29.9 29.0 27.3 25.8 25.1 24.5 23.2 21.6 20.9 20.1 18.8 17.5 16.9 16.3 15.2 14.1 13.6 15 111.0 92.0 78.4 72.7 68.0 60.3 54.1 51.5 49.0 44.8 41.3 39.7 38.3 36.0 33.7 32.7 31.7 29.8 28.2 27.5 26.8 25.5 24.3 23.8 23.0 21.5 20.0 19.3 81.7 17.4 16.2 15.6
8.0 20 116.0 96.2 82.0 76.0 71.1 63.0 56.5 53.8 51.2 46.8 43.2 41.5 40.0 37.7 35.2 34.2 33.2 31.2 29.5 28.7 28.0 26.5 24.7 23.9 23.0 21.5 20.0 19.3 18.7 17.4 16.2 15.6
mm mm m m 5VE-5 1 363 1 509 0.60 1.00 6VE-6 1 642 1 826 0.60 1.00 7VE-7 1 928 2 138 0.60 1.00 5VE-10 2 080 2 305 0.60 1.00 6VE-10 2 223 2 457 0.60 1.00 2 507 2 778 0.60 1.00 6VE-12 6VE-14 2 795 3 095 0.60 1.00 7VE-14 2 935 3 250 0.60 1.00 6VE-16 3 085 3 410 0.60 1.00 6VE-18 3 371 3 730 0.60 1.00 7VE-19 3 656 4 042 0.61 1.00 7VE-20 3 801 4 201 0.63 1.00 7VE-21 3 942 4 362 0.66 1.00 18VE-12 4 188 4 634 0.70 1.05 18VE-14 4 478 4 950 0.75 1.12 19VE-14 4 615 5 107 0.77 1.15 20VE-14 4 752 5 264 0.79 1.19 18VE-18 5 051 5 587 0.84 1.26 18VE-20 5 340 5 903 0.89 1.34 18VE-21 5 481 6 066 0.91 1.37 19VE-21 5 621 6 220 0.94 1.41 21VE-21 5 902 6 529 0.98 1.48 20VE-24 6 190 6 850 1.03 1.55 21VE-24 6 330 7 004 1.06 1.58 18VE-28 6 486 7 176 1.08 1.62 21VE-27 6 762 7 481 1.13 1.69 20VE-30 7 054 7 802 1.18 1.76 21VE-30 7 197 7 955 1.20 1.80 21VE-31 7 339 8 115 1.22 1.84 21VE-33 7 625 8 435 1.27 1.91 21VE-35 7 911 8 754 1.32 1.98 21VE-36 8 055 8 913 1.34 2.01 NOTES: 1 This Table can be used for Australian W7, T44, HLP320, HLP400 and New 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.
Zealand HO-HN Highway Loads and for Australian 300-A-14, M250, M270 Railway Loads.
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APPENDIX
REFERENCE TABLES FOR MINIMUM COVER FOR ALUMINIUM STRUCTURES

The information and recommendations contained in these tables are intended for designers convenience in routine applications complying with this Standard. In the preparation of the Tables in this Appendix, the following values were adopted: fy k k = 165 MPa = 1 for height of cover less than span = 0.75 for height of cover equal to or greater than span = 2 = 20.0 kN/m3
The allowance for pavement (road) is 300 mm at 22 kN/m 3. Impact factors used are those given in the relevant references given in Clause 5.4.2.2. LIST OF TABLES F1 F2 F3 F4 Cover limits for Class 2 aluminium pipes highway and railway live load Cover limits for Class 2 aluminium pipe-arches and underpasses highway live load Cover limits for Class 2 aluminium pipe-arches and underpasses railway live load Cover limits for Class 2 aluminium arches (rise less than radius) highway and railway live load F5 Cover limits for Class 2 aluminium horseshoe arches highway and railway live load F6 Cover limits for Class 2 aluminium horizontal ellipses highway and railway live load F7 Cover limits for Class 2 aluminium vertical ellipses highway and railway live load
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TABLE
F1
COVER LIMITS FOR CLASS 2 ALUMINIUM PIPES: HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 Minimum cover highway loads Structure number Nominal diameter 3.0 m 5 6 Minimum cover railway loads Plate thickness, mm 4.0 3.0, 4.0, 5.0, 6.0 3.0 4.0 Bolts/metre mm 20P 22P 24P 26P 28P 30P 32P 36P 40P 44P 48P 52P 56P 60P 64P 68P 1 500 1 650 1 800 1 950 2 100 2 250 2 400 2 700 3 000 3 300 3 600 3 900 4 200 4 500 4 800 5 100 10 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.64 0.69 0.74 * * * * * 10 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.61 0.64 0.69 0.73 * * * 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.64 0.69 0.74 0.79 0.84
a a a a a
10
11
12
13
14
15
16
17
18
Maximum cover, m
5.0
6.0
10, 15, 20 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.03 1.11 1.18 1.26
10 14.6 13.2 12.0 11.0 10.2 9.4 8.8 7.7 6.8 6.1 5.5 * * * * *
h h
15 21.2 19.2 17.5 16.1 14.9 13.8 12.9 11.4 10.1 9.1 8.3 * * * * *
20 26.8 24.2 22.1 20.3 18.8 17.5 16.4 14.5 12.9 11.7 10.7 * * * * *
10 17.7 16.0 14.6 13.4 12.4 11.5 10.7 9.4 8.4 7.5 6.8 6.2 5.7 * * *
15 25.6 23.2 21.2 19.5 18.0 16.8 15.7 13.8 12.4 11.2 10.2 9.3 8.6 * * *
20 33.1 29.9 27.3 25.2 23.3 21.7 20.3 17.9 16.1 14.5 13.3 12.2 11.3 * * *
10 20.7 18.8 17.1 15.7 14.5 13.5 12.6 11.1 9.9 8.9 8.1 7.4 6.8 6.3 5.8 *
15 30.1 27.2 24.9 22.9 21.2 19.7 18.4 16.3 14.6 13.2 12.0 11.0 10.2 9.5 8.8 *
20 39.4 35.7 32.6 30.0 27.7 25.8 24.2 21.4 19.2 17.4 15.9 14.6 13.5 12.5 11.7 *
10 23.8 21.5 19.6 18.1 16.7 15.5 14.5 12.8 11.4 10.3 9.4 8.6 7.9 7.3 6.8 6.3
15 34.5 31.2 28.5 26.3 24.3 22.6 21.2 18.7 16.8 15.2 13.8 12.7 11.8 10.9 10.2 9.6
20 45.7 41.4 37.8 34.8 32.2 30.0 28.0 24.8 22.3 20.2 18.4 17.0 15.7 14.6 13.7 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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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 Minimum cover Haunch bearing capacity (kPa) 300 Plate thickness, mm 3.0 4.0 3.0 to 6.0 3.0 4.0 Bolts/metre 10 15 20 10 15 20 10 15 20 10 15 20 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 Plate thickness, mm 5.0 6.0 600 900
Maximum Structure Internal internal number rise span
Bolts/metre mm 10PA5-5 11PA5-6 14PA5-6 16PA5-7 17PA5-7 18PA5-7 17PA5-11 18PA5-11 20PA5-11 21PA5-11 22PA5-11 24PA5-12 25PA5-13 24PA5-16 27PA5-16 29PA5-17 31PA5-18 33PA5-19 35PA5-20 37PA5-21 39PA5-22 41PA5-23 1 925 2 131 2 406 2 692 2 773 2 851 3 255 3 343 3 507 3 585 3 659 3 934 4 140 4 463 4 689 4 967 5 241 5 513 5 782 6 049 6 314 6 578 mm 1 691 1 782 1 923 2 063 2 111 2 160 2 285 2 332 2 429 2 477 2 527 2 668 2 759 2 835 2 982 3 123 3 265 3 406 3 548 3 690 3 833 3 976 10 0.60 0.60 0.60 0.61 0.62 0.63 0.69 0.71 0.74 0.75 0.76 0.81 0.85 0.91 * * * * * 10 0.60 0.60 0.60 0.60 0.60 0.60 0.61 0.62 0.64 0.65 0.66 0.70 0.73 0.78 0.81 0.86 * * * * * * 10, 15, 20 0.60 0.60 0.60 0.60a 0.60a 0.60
a
10.8 15.1 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 9.7 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 26.5 13.5 16.0 13.5 23.2 13.5 27.3 30.8 8.5 12.1 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 7.5 10.7 11.1 10.7 14.1 7.3 10.4 10.8 10.4 13.7 7.0 10.2 10.5 10.2 13.3 6.0 8.4 5.9 8.2 5.5 8.0 5.4 7.8 5.3 7.7 4.8 7.1 4.5 6.7 3.7 5.9 * * * * * * * * * * * * * 9.1 8.8 8.4 8.2 8.0 7.4 7.0 6.4 * * * * * * * * 8.4 11.6 8.2 11.3 8.0 10.7 7.8 10.5 7.7 10.3 7.1 6.7 5.9 * * * * * * * * 9.5 9.0 8.3 * * * * * * * * 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 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 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 7.5 7.2 6.9 6.7 6.5 6.0 5.7 5.2 4.9 4.2 * * * * * * 8.4 11.1 8.2 10.8 8.0 10.2 7.8 10.0 7.7 7.1 6.7 5.9 5.7 5.4 * * * * * * 9.8 9.1 8.6 7.9 7.5 7.0 * * * * * * 8.4 14.4 8.2 14.0 8.0 13.4 7.8 13.1 7.7 12.8 7.1 11.9 6.7 11.2 5.9 10.4 5.7 5.4 * * * * * * 9.8 9.3 * * * * * * 8.4 8.2 8.0 7.8 7.7 7.1 6.7 5.9 5.7 5.4 4.9 4.2 3.8 * * * 8.9 8.6 8.2 8.0 7.8 7.2 6.8 6.2 5.9 5.5 5.1 4.4 3.8 * * * 8.4 13.1 8.2 12.7 8.0 12.1 7.8 11.8 7.7 11.5 7.1 10.7 6.7 10.2 5.9 5.7 5.4 4.9 4.2 3.8 * * * 9.4 8.9 8.4 7.9 7.4 7.1 * * * 8.4 17.2 8.2 16.8 8.0 16.0 7.8 15.6 7.7 15.3 7.1 14.2 6.7 13.5 5.9 12.5 5.7 11.8 5.4 11.1 4.9 10.5 4.2 10.0 3.8 * * * 9.5 * * * 8.4 10.3 8.3 10.0 8.0 7.8 7.7 7.1 6.7 5.9 5.7 5.4 4.9 4.2 3.8 3.4 3.0 * 9.5 9.2 9.0 8.4 7.9 7.3 6.9 6.4 6.0 5.7 5.1 4.5 4.1 * 8.4 15.1 8.3 14.7 8.0 14.0 7.8 13.6 7.7 13.4 7.1 12.4 6.7 11.7 5.9 10.9 5.7 10.3 5.4 4.9 4.2 3.8 3.4 3.0 * 9.7 9.1 8.7 8.2 7.8 7.4 * 8.4 17.4 20.1 8.3 17.1 19.5 8.0 16.6 18.6 7.8 16.3 18.2 7.7 16.0 17.8 7.1 14.9 16.5 6.7 14.1 15.7 5.9 12.5 14.5 5.7 12.2 13.8 5.4 11.6 13.0 4.9 11.0 12.3 4.2 10.4 11.7 3.8 3.4 3.0 * 9.9 11.1 9.5 10.6 9.1 10.1 *
0.60a 0.60
a
0.60a 0.60
a
0.61a 0.66a 0.69

a
0.74a 0.78
a
0.83a 0.87 0.92 0.96 1.01 1.05 *
COPYRIGHT
93 24U5-7 27U5-11 29U5-11 31U5-11 33U5-11 33U5-13 35U5-13 35U5-16 38U5-16 40U5-16 40U5-18 41U5-19 43U5-19 45U5-19 3 145 3 798 3 942 4 085 4 227 4 452 4 590 4 945 5 145 5 278 5 521 5 710 5 838 5 967 2 768 3 152 3 268 3 386 3 505 3 606 3 725 3 876 4 054 4 174 4 272 4 381 4 501 4 622 0.68 0.79 0.81 0.84 0.87 0.91 * * * * * * 0.60 0.68 0.70 0.72 0.74 0.78 0.80 0.85 0.89 * * * * * 0.60a 0.63a 0.66
a
AS/NZS 2041:1998 9.2 7.5 7.2 6.9 6.6 6.2 6.0 5.5 5.3 4.9 4.3 4.0 * * 9.2 12.7 13.6 12.7 17.9 10.6 10.6 12.7 15.6 12.7 20.8 20.8 7.5 10.4 11.1 10.4 14.7 7.2 10.0 10.7 10.0 14.2 6.9 6.6 6.2 6.0 5.5 5.3 4.9 4.3 4.0 * * 9.7 10.3 9.3 8.8 8.5 7.9 7.5 7.3 6.9 6.7 * * 9.9 9.4 9.1 8.4 8.0 7.8 7.4 7.2 * * 9.7 13.7 9.3 13.2 8.8 12.5 8.5 12.1 7.9 11.2 7.5 10.7 7.3 10.4 6.9 10.0 6.7 * * 9.6 * * 8.7 8.3 8.0 7.7 7.3 7.0 6.5 6.2 6.0 5.7 5.3 4.9 4.7 8.7 10.5 12.8 10.5 17.1 17.1 8.3 10.0 12.4 10.0 16.5 16.5 8.0 7.7 7.3 7.0 6.5 6.2 6.0 5.7 5.3 4.9 4.7 9.7 11.9 9.3 11.5 8.8 10.9 8.5 10.5 7.9 7.5 7.3 6.9 6.7 6.5 6.4 9.7 9.3 9.1 8.6 8.3 8.1 7.9 9.7 15.9 15.9 9.3 15.3 15.3 8.8 14.6 14.6 8.5 14.1 14.1 7.9 13.1 13.1 7.5 12.5 12.5 7.3 12.2 12.2 6.9 11.6 11.6 6.7 11.2 11.2 6.5 11.0 11.0 6.4 10.7 10.7
6.3 9.4 5.0 7.7 4.8 7.4 4.6 7.1 4.4 6.8 3.8 6.4 * * * * * * * * * * * * * *
9.4 12.0 12.0 7.7 7.4 7.1 6.8 6.4 * * * * * * * * 9.9 9.5 9.1 8.8 8.3 * * * * * * * * 9.9 9.5 9.1 8.8 8.3 * * * * * * * *
7.8 11.5 11.5 12.7 15.0 6.3 6.0 5.8 5.5 5.2 5.0 4.2 3.8 * * * * * 9.4 9.0 8.7 8.4 7.9 7.7 7.0 6.7 * * * * * 9.4 10.4 12.3 9.0 10.0 11.8 8.7 8.4 7.9 7.7 7.0 6.7 * * * * * 9.7 11.4 9.3 11.0 8.8 10.4 8.5 10.1 7.8 7.5 * * * * * 9.3 8.9 * * * * *
0.68a 0.70
a
0.74a 0.76
a
0.82a 0.86
a
0.88 0.92 0.95 0.97 0.99
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 Geotechnical Advice. 5 a denotes use solution for 3.0 and 4.0 mm 10 bolts/m from columns 4 and 5.
COPYRIGHT
AS/NZS 2041:1998
94
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 Maximum cover, m Haunch bearing capacity (kPa) Structure number Maximum Internal Minimum 300 300 600 300 600 300 300 600 300 600 300 600 300 600 300 600 300 600 300 600 300 internal rise cover Plate thickness, mm span 3.0 4.0 5.0 6.0 Bolts/metre mm 10PA5-5 11PA5-6 14PA5-6 16PA5-7 17PA5-7 18PA5-7 17PA5-11 18PA5-11 20PA5-11 21PA5-11 22PA5-11 24PA5-12 25PA5-13 24PA5-16 27PA5-16 29PA5-17 31PA5-18 33PA5-19 35PA5-20 37PA5-21 39PA5-22 41PA5-23 1 925 2 131 2 406 2 692 2 773 2 851 3 255 3 343 3 507 3 585 3 659 3 934 4 140 4 463 4 689 4 967 5 241 5 513 5 782 6 049 6 314 6 578 mm 1 691 1 782 1 923 2 063 2 111 2 160 2 285 2 332 2 429 2 477 2 527 2 668 2 759 2 835 2 982 3 123 3 265 3 406 3 548 3 690 3 833 3 976 m 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.03 1.11 1.17 1.24 1.31 1.38 1.44 1.51 1.58 * 10 10.8 9.6 8.4 7.4 7.1 6.9 15 20 10 15 20 10 15 20 10 15 20 34.1 30.8 27.3 24.3 23.6 23.0 20.1 19.6 18.6 18.2 17.8 16.5 15.7 14.5 13.8 13.0 12.3 11.6 11.1 10.5 10.1 * 600 900
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 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 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 10.7 11.1 10.7 14.2 10.4 10.7 10.4 13.7 10.1 10.4 10.1 13.3 8.3 8.1 7.8 7.7 7.6 7.0 9.0 8.7 8.3 8.1 7.9 7.2 6.8 8.3 11.6 8.1 11.3 7.8 10.7 7.7 10.4 7.6 10.2 7.0 9.4 8.9 8.2 * * * 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 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 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 7.3 7.1 6.7 8.3 11.1 8.1 10.8 7.8 10.2 7.7 10.0 7.6 7.0 9.7 9.0 8.5 7.8 7.3 6.8 8.3 14.4 8.1 14.1 7.8 13.4 7.7 13.1 7.6 12.8 7.0 11.8 11.2 10.3 9.8 9.2 * * * * 8.3 8.1 7.9 7.7 7.6 7.0 8.8 8.5 8.1 7.9 7.7 7.0 8.3 13.1 8.1 12.7 7.9 12.1 7.7 11.8 7.6 11.6 7.0 10.7 10.1 9.3 8.8 8.3 7.8 7.3 6.9 8.3 17.3 8.1 16.8 7.9 16.0 7.7 15.6 7.6 15.3 7.0 14.2 13.5 12.5 11.8 11.1 10.5 9.9 9.4 * * * 8.3 10.2 8.1 7.9 7.7 7.6 7.0 9.9 9.4 9.2 9.0 8.3 7.8 7.1 6.7 8.3 15.1 8.1 14.7 7.9 14.0 7.7 13.7 7.6 13.4 7.0 12.4 11.7 10.8 10.3 9.6 9.1 8.6 8.1 7.7 7.3 * 8.3 17.4 8.1 17.1 7.9 16.6 7.7 16.3 7.6 16.1 7.0 14.9 14.1 12.5 12.2 11.6 10.9 10.4 9.9 9.4 9.0 *
COPYRIGHT
95 24U5-7 27U5-11 29U5-11 31U5-11 33U5-11 33U5-13 35U5-13 35U5-16 38U5-16 40U5-16 40U5-18 41U5-19 43U5-19 45U5-19 3 145 3 798 3 942 4 085 4 227 4 452 4 590 4 945 5 145 5 278 5 521 5 710 5 838 5 967 2 768 3 152 3 268 3 386 3 505 3 606 3 725 3 876 4 054 4 174 4 272 4 381 4 501 4 622 1.00 1.00 1.00 1.02 1.06 1.11 1.15 1.24 1.29 1.32 1.38 1.43 1.46 1.49 9.4 7.5 7.2 6.9 9.4 12.0 12.0 7.5 7.2 6.9 9.8 9.4 9.0 8.7 8.2 * * * * 9.8 9.4 9.0 8.7 8.2 * * * * 7.6 11.5 11.5 12.7 15.0 9.3 9.0 8.6 8.3 7.8 7.5 6.9 9.3 10.4 12.3 9.0 10.0 11.8 8.6 8.3 7.8 7.5 6.9 9.6 11.4 9.3 11.0 8.7 10.4 8.4 10.0 7.7 7.4 * * 9.2 8.8 * * * * * 9.1 7.3 7.0 6.7
AS/NZS 2041:1998 9.1 12.7 13.6 12.7 17.9 10.6 10.6 12.7 15.6 12.7 20.8 7.3 10.4 11.1 10.4 14.7 7.0 10.0 10.7 10.0 14.2 6.7 9.6 10.3 9.3 8.7 8.4 7.7 7.4 7.2 6.8 9.9 9.3 9.0 8.3 7.9 7.7 7.3 7.0 * 9.6 13.6 9.3 13.2 8.7 12.5 8.4 12.1 7.7 11.2 7.4 10.7 7.2 10.4 6.8 9.9 9.5 * * 8.6 8.2 7.9 7.6 7.1 6.9 8.6 10.4 12.8 10.4 17.2 8.2 10.0 12.3 10.0 16.5 7.9 7.6 7.1 6.9 9.6 11.9 9.3 11.5 8.7 10.8 8.4 10.5 7.7 7.4 7.2 6.8 9.7 9.3 9.0 8.6 8.2 8.0 7.8 9.6 15.9 9.3 15.4 8.7 14.6 8.4 14.1 7.7 13.1 7.4 12.5 7.2 12.2 6.8 11.6 11.2 10.9 10.7 20.8 17.2 16.5 15.9 15.4 14.6 14.1 13.1 12.5 12.2 11.6 11.2 10.9 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 geotechnical advice.
COPYRIGHT
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 Maximum internal span mm 12AA 15AA 18AA 22AA 23AA 26AA 29AA 32AA 35AA 37AA 40AA 43AA 46AA 49AA 26AB 29AB 33AB 36AB 39AB 42AB 46AB 49AB 52AB 56AB 2 2 3 3 4 4 5 5 6 6 7 7 8 8 4 4 5 5 6 6 7 7 8 8 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 000 500 3 4 Minimum cover highway loads m 0.60 0.60 0.60 0.60 0.67 0.75 0.83 0.92 1.00 * * * * * 0.67 0.75 0.83 0.92 1.00 * * * * * 5 Minimum cover railway loads m 1.00 1.00 1.00 1.00 1.00 1.13 1.25 1.38 1.50 * 1.00 1.13 1.25 1.38 1.50 * 10 10.3 8.0 6.6 5.5 4.7 4.7
h
10
11
12
13
14
15
16
17
Maximum cover, m Plate thickness, mm 3.0 4.0 Bolts/metre 15 14.4 11.4 9.3 7.8 6.7 6.7 20 14.4 11.4 9.3 7.8 6.7 6.7 10 12.6 9.9 8.1 6.7 5.9 5.1 4.1 5.9 5.1 4.1
h h h h h h
Structure number
Internal rise
5.0
6.0
mm 850 1 058 1 265 1 598 1 1 1 2 2 2 2 2 3 3 1 2 2 2 2 3 3 3 3 4 550 757 965 172 380 452 659 867 075 283 927 136 464 673 883 092 420 630 839 167
15 18.4 14.6 12.1 10.2 8.8 7.7 6.8 8.8 7.7 6.8
20 19.4 15.4 12.8 10.8 9.4 8.2 7.2 9.4 8.2 7.2
10 14.8 11.7 9.6 8.1 6.9 6.2 5.4 4.4 6.9 6.2 5.4 4.4
h h h h h h
15 21.6 17.2 14.2 12.1 10.5 9.2 8.2 7.3 10.5 9.2 8.2 7.3
20 24.3 19.4 16.1 13.7 11.9 10.5 9.4 8.2 * 11.9 10.5 9.4 8.2 *
10 17.0 13.5 11.1 9.4 8.1 7.0 6.4 5.7 4.6 8.1 7.0 6.4 5.7 4.6
15 24.8 19.8 16.4 14.0 12.2 10.7 9.5 8.6 7.8 * 12.2 10.7 9.5 8.6 7.8 *
20 29.2 23.3 19.4 16.6 14.4 12.8 11.4 10.1 8.5 * 14.4 12.8 11.4 10.1 8.5 *
h h h
h h h
h h h
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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97
AS/NZS 2041:1998
TABLE
F5
COVER LIMITS FOR CLASS 2 ALUMINIUM HORSESHOE ARCHES HIGHWAY AND RAILWAY LIVE LOAD
1 2 3 4 5 6 7 Minimum cover railway loads m 1.00 1.00 1.10 1.50 * 1.00 1.00 1.03 1.48 10 8.4 6.6 3.9 8.7 6.1 4.5
h h h h
10
11
12
13
14
15
16
17
18
19
Maximum cover, m Minimum cover highway loads Structure Maximum Internal number internal span rise 3.0 4.0 Bolts/metre mm HA22 HA27 HA40 HA54 HA64 HA76 16EA-5 22EA-6 28EA-10 40EA-12 52EA-17 57EA-18 2 400 3 000 4 400 6 000 7 100 8 500 2 334 3 231 4 129 5 924 7 720 8 468 mm 1 857 2 274 3 376 4 550 5 395 6 397 2 368 3 056 4 405 5 763 7 711 8 285 10 0.60 0.65 0.90 0.60 0.69 0.85 10 0.60 0.60 0.77 * 0.60 0.61 0.73 * 10, 15, 20 0.60 0.60 0.73 1.00 * * 0.60 0.60 0.69 0.99 * 15 12.5 9.9 6.5 12.9 9.1 6.8
h
Plate thickness, mm 3.0 4.0 Bolts/metre 20 15.9 12.6 8.3 16.4 11.7 8.9 10 10.4 8.1 5.3 10.7 7.4 5.7
h h
3.0 to 6.0
5.0
6.0
15 15.2 12.1 7.9 15.7 11.1 8.5
20 19.7 15.7 10.5 * 20.3 14.5 11.2 *
10 12.2 9.6 6.3 12.6 8.9 6.8

h h
15 17.9 14.2 9.5 18.4 13.2 10.1 *
20 23.5 18.8 12.6 * 24.2 17.4 13.5 *
10 14.1 11.1 7.2 4.6 14.5 10.3 7.8 4.7

h h
15 20.6 16.4 11.0 7.8 21.2 15.2 11.8 7.9
20 27.3 21.8 14.7 10.6 * 28.1 20.2 15.7 10.8
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 no solution for this gauge and bolt density. 3 h denotes solution for highway load only.
COPYRIGHT
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 Minimum cover railway loads m 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.01 1.05 1.09 1.16 1.24 1.28 10 13.9 11.4 9.6 8.8 8.2 7.1 6.4
h
10
11
12
13
14
15
16
17
18
19
Maximum cover, m Minimum cover highway loads Structure Maximum Internal number internal span rise 3.0 4.0 Bolts/metre mm 5HE-5 6HE-6 7HE-7 10HE-5 10HE-6 12HE-6 14HE-6 14HE-7 16HE-6 18HE-6 19HE-7 20HE-7 21HE-7 12HE-18 14HE-18 14HE-19 1 509 1 826 2 138 2 306 2 457 2 777 3 095 3 250 3 411 3 731 4 043 4 200 4 362 4 634 4 950 5 106 mm 1 363 1 642 1 928 2 079 2 223 2 508 2 795 2 935 3 085 3 371 3 656 3 801 3 942 4 188 4 478 4 612 10 0.60 0.60 0.60 0.60 0.60 0.62 0.67 0.69 0.72 10 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.61 0.63 0.67 0.72 0.74 10, 15, 20 0.60 0.60 0.60 0.60 0.60 0.60a 0.60
a
Plate thickness, mm 3.0 4.0 Bolts/metre 15 20.2 16.6 14.1 13.1 12.2 10.7 9.5 9.0 8.5 * * * 20 25.5 21.0 17.9 16.6 15.5 13.7 12.2 11.6 11.0 * * * * * * * 10 16.8 13.8 11.7 10.8 10.1 8.8 7.8 7.3 6.9 6.4 5.8
h h
3.0 to 6.0
5.0
6.0
15 24.4 20.1 17.1 15.9 14.9 13.1 11.7 11.1 10.5 9.5 8.7 8.3 * * *
20 31.5 26.0 22.2 20.5 19.2 17.0 15.2 14.5 13.7 12.5 11.5 11.0 * * * *
10 19.8 16.3 13.8 12.8 11.9 10.5 9.3 8.8 8.3 7.5 6.8 6.7 h 6.4 h 6.0
h
15 28.6 23.6 20.1 18.6 17.5 15.4 13.8 13.1 12.5 11.3 10.4 10.0 9.5 8.9 * *
20 37.6 31.0 26.4 24.5 23.0 20.3 18.2 17.3 16.5 15.0 13.8 13.3 12.7 12.0 * *
10 22.7 18.7 15.9 14.7 13.8 12.1 10.8 10.2 9.7 8.8 8.0 7.7 7.3 6.8 6.5 h 6.2
h
15 32.9 27.1 23.1 21.4 20.1 17.7 15.9 15.1 14.4 13.1 12.0 11.5 11.1 10.4 9.7 9.3
20 43.5 35.9 30.6 28.4 26.6 23.5 21.1 20.1 19.1 17.4 16.1 15.4 14.9 14.0 13.0 12.6
0.60a 0.60a 0.62 0.67

a a
6.1 h 5.7 h
0.70a 0.73 0.77 0.83 0.85
5.6 h
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
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 Minimum cover railway loads m 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.05 1.12 1.15 1.19 1.26
a
10
11
12
13
14
15
16
17
18
19
Maximum cover, m Minimum cover highway loads Structure Maximum Internal number internal span rise 3.0 4.0 Bolts/metre mm 5VE-5 6VE-6 7VE-7 5VE-10 6VE-10 6VE-12 6VE-14 7VE-14 6VE-16 6VE-18 7VE-19 7VE-20 7VE-21 18VE-12 18VE-14 19VE-14 20VE-14 18VE-18 1 363 1 642 1 928 2 080 2 223 2 507 2 795 2 935 3 085 3 371 3 656 3 801 3 942 4 188 4 478 4 615 4 752 5 051 mm 1 509 1 826 2 138 2 305 2 457 2 778 3 095 3 250 3 410 3 730 4 042 4 201 4 362 4 634 4 950 5 107 5 264 5 587 10 0.60 0.60 0.60 0.60 0.60 0.60 0.62 0.64 0.67 0.71 0.76 * * * * * * * 10 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.62 0.66 0.68 0.70 0.74 * * * * 10, 15, 20 0.60 0.60 0.60 0.60 0.60 0.60 0.60a 0.60 10 15.5 12.7 10.7 9.9 9.2 8.0 7.0 6.6 6.4 h 5.8
h
Plate thickness, mm 3.0 4.0 Bolts/metre 15 22.4 18.5 15.7 14.5 13.6 12.0 10.6 10.1 9.6 8.7 7.9 * * * 20 28.3 23.4 19.9 18.4 17.2 15.2 13.6 12.9 12.3 11.2 10.2 * * * * * * * 10 18.7 15.4 13.1 12.1 11.2 9.9 8.7 8.3 7.8 7.0 6.5 h 6.3 h 6.0 5.6
h h
3.0 to 6.0
5.0
6.0
15 27.1 22.4 19.0 17.6 16.5 14.5 13.0 12.3 11.7 10.7 9.7 9.3 9.0 8.4 * * * *
20 34.9 28.9 24.6 22.8 21.3 18.9 16.9 16.1 15.3 13.9 12.8 12.3 11.8 11.1 * * * *
10 21.9 18.1 15.4 14.2 13.3 11.7 10.4 9.9 9.3 8.4 7.7 7.3 7.0 6.7
h
15 31.7 26.3 22.4 20.7 19.4 17.1 15.3 14.6 13.8 12.6 11.6 11.1 10.7 10.0 9.3 9.0 8.7 *
20 41.5 34.4 29.3 27.2 25.4 22.5 20.1 19.2 18.2 16.6 15.3 14.7 14.2 13.3 12.4 12.0 11.6 *
10 25.1 20.8 17.6 16.3 15.3 13.5 12.0 11.4 10.8 9.8 9.0 8.6 8.2 7.7 7.1 6.8 6.8
h
15 36.4 30.2 25.7 23.8 22.2 19.7 17.6 16.8 15.9 14.5 13.4 12.8 12.3 11.6 10.8 10.4 10.1 9.4
20 48.2 39.9 34.0 31.5 29.5 26.1 23.4 22.3 21.2 19.3 17.8 17.1 16.5 15.5 14.5 14.0 13.6 12.8
0.60a 0.60
a
0.61a 0.63a 0.66 0.70 0.75 0.77 0.79 0.84

a a
5.3 h
6.2 h 6.0 h 5.8

h
6.3 h
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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AS/NZS 2041:1998
100
APPENDIX
LIVE LOAD COMPARISON

(Informative) The relationship of live load pressure to cover height for various standard vehicles is shown in Figure G1. Impact factors are included.
FIGURE G1
LIVE LOAD COMPARISON
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101
AS/NZS 2041:1998
APPENDIX
FLOWABLE FILL
(Informative) H1 GENERAL Controlled low strength material (flowable fill) may provide a material of suitable stiffness to be a viable alternative to the usual mechanically compacted soil backfill where any or all of the following apply: (a) (b) (c) (d) Installation speed is critical. Narrow trench widths make compaction around the structure haunches difficult. The spacing for multiple cell structures is less than that specified in Clause 6.4. The local native soil does not satisfy the preferred select fill grading requirements of 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 and water 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 specified strength: Material Portland cement Fly ash Granular material Water
The following typical flowable mix should achieve the
% by weight 3 8 72 17
Standard AS 3972 (GP) AS 3582.1
NOTE: The above mix proportions are provided as a guide only.
H3 MIX FLOWABILITY Flowability of flowable fill is important to achieve adequate support around structure haunches. A high slump of 160200 mm is recommended and typically achieved with the above mix proportions. If required, aggregate fillers with rounded, rather than angular, particles will improve the mix flowability. H4 GRANULAR MATERIALS GRADING material grading for flowable fill is as follows: Sieve size 19 mm 0.075 mm Where applicable, a suitable granular
% passing 100 010
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AS/NZS 2041:1998
102
H5 STRENGTH Flowable fill strength is controlled by the cement and fly ash contents. The mix proportions in Paragraph H4 have been shown to achieve a modulus of elasticity which is similar to that of typical (graded) backfill compacted to 8595 percent relative density. Higher strength flowable fills can achieve improved support around the haunches of pipe arches and underpass shapes. Consideration should also be given to the possibility of future backfill excavation when specifying higher strengths for general use. H6 PLACEMENT Flowable fill is normally transported to site in ready-mixed form with normal care being taken to minimize segregation during transportation or is mixed using mobile batching equipment, where fill quantities are sufficient to make that economically feasible. Placement into the trench around the structure should be directly from the transit mix chute. Mechanical vibration may be necessary to ensure penetration of 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 the structure are sufficiently stiff to ensure positive soil arching occurs. Typically, the zone of flowable fill placed around haunches, beside and/or over the structure is equal in stiffness to that specified for select compacted fill. Where native or embankment material in the trench wall exhibits strength equal to or exceeding select compacted fill, trench widths may be reduced and a higher strength flowable fill may be adopted. Flowable fill normally requires 1 to 4 hours to achieve sufficient stiffness to provide support to a corrugated metal structure. However, the time period required for the fill to gain sufficient strength to carry live loads should be determined, based on information provided by the flowable fill supplier. The appropriate lift height for flowable fill depends on the structure size, the extent of the fill 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 avoid flotation. Flotation calculations should be carried out to determine a suitable flowable fill lift thickness. 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 of placement depending on site drainage conditions and temperature. At all times, structure shape and position should be monitored and maintained within the tolerances specified. Where deep flowable fills are to be used over the structure crown, the designer should allow for reduced soil arching during construction and check that an adequate safety factor has been allowed. H7 DURABILITY Flowable fill is less susceptible to erosion or loss of fines during flooding than compacted fill. However, culvert inlet and outlet protection against scour or fill saturation should still be evaluated for each specific site. Acceptable pH and resistivity limits are provided in Table C1 of this Standard. In poorly drained conditions, modified fills may initiate higher soil-side corrosion rates on metal structures.
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AS/NZS 2041:1998

Australian/New Zealand Standard

Accessed by Cardno Holdings Pty Ltd on 01 Sep 2012 [AVAILABLE SUPERSEDED]

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This Standard was issued in draft form for comment as DR 95262.

Australian/New Zealand Standard

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(b) (c) (d) (e) (f)

(g) (h) (i)

STANDARDS AUSTRALIA / STANDARDS NEW ZEALAND

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.... .... .... ... .... .... .... ....

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1.3 REFERENCED DOCUMENTS Standard:

The following documents are referred to in this

AS 1012 1199 1214 1275

AS 1289 1289.3.4.1 1289.3.6.1 1289.4.3.1 1289.4.4.1 1289.5.1.1

1289.5.3.5 1289.5.4.1 1289.5.5.1

4100 Supp1 Supplement 1 Steel structures Commentary

AS/NZS 1110 1111 1112 1252

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CLASSIFICATION OF CORRUGATED METAL STRUCTURES

450 to 1 800 1 925 to 6 578

450 to 1 800 1 925 to 5 521

2 400 to 8 500 2 334 to 8 468

2 400 to 7 100 2 334 to 7 720

Arch Type A (AA.S) Arch Type B (AB.S)

300 to 1 950 2 000 to 8 500 4 000 to 8 500

300 to 1 950 2 000 to 8 000 4 000 to 8 000

Vertical ellipse (VE.S)

Horizontal ellipse (HE.S)

mm kN/m mm /mm kN/m

kN/m3 kN/m3 mm and and and

(a) (b) (c)

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88P 92P 96P 100P 104P 108P 112P 114P

NOTE: For pipe-arches t 90, for under-passes t >90.

900 1 050 1 200 1 350 1 500 1 650 1 800

PIPE-ARCHES AND UNDERPASSES (CLASS 2)

ARCHES (RISE LESS THAN OR EQUAL TO RADIUS) (CLASS 1)

49AB 46AA 52AB 49AA 56AB

ARCHES (RISE LESS THAN RADIUS) (CLASS 2)

28EA-10 40EA-12 52EA-17 57EA-18

ARCHES (RISE GREATER THAN RADIUS) (CLASS 2)

FIGURE 2.5 (in part)

HORIZONTAL ELLIPSE (CLASS 2)

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FIGURE 2.5 (in part)

HORIZONTAL ELLIPSE (CLASS 2)

FIGURE 2.6 (in part)

VERTICAL ELLIPSE (CLASS 2)

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FIGURE 2.6 (in part)

VERTICAL ELLIPSE (CLASS 2)

3.1.1.2 Base metal thickness with AS 1365.

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Steel bolts and nuts

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Steel bolts and nuts