The Use of Corrugated Metal Pipe and

Structural Plate for Aggregate Tunnel

and Conveyor Enclosure Applications
By Jim Noll, P.E.; Steve Tysl, P.E.; and Matt Westrich, P.E.

DECEMBER 2009
 Professional Development Series

The Use of Corrugated Metal Pipe and Structural Plate

for Aggregate Tunnel and Conveyor Enclosure Applications
By Jim Noll, P.E.; Steve Tysl, P.E.; and Matt Westrich, P.E.

A
ggregate processing and
handling facilities, mining
sites, and related industrial
operations often need to
transport aggregate and ore across
various points on their properties.
The need to maximize surface area
on such sites necessitates the use of
tunnels for transporting bulk materi-
als under roadways and parking areas
and processing these materials. Some
applications involve tunnels complete
with hopper openings and feeder
chutes located under bulk material
piles. These are used for receiving
and processing the aggregate and ore
material and then transporting this
material to other locations on site.
One of the logical options available
that offers economic advantages in
the design, installation, operation, and
maintenance phases of these projects
involves the use of large corrugated
metal pipes (CMP) or corrugated struc-
tural plate pipes (SPP) and corrugated
structural plate arches (SPA) for these
tunnel structures. Advantages include
reduced design time and related costs;
simplicity of construction; the option
to utilize site personnel for the assem-
bly and installation phases of tunnel
construction; reduced installation
costs; and lower maintenance costs.
While CMP, SPP, and SPA are
viable and attractive options for the
construction of such tunnel structures,
they must be properly designed and
installed to provide the desired level of
structural performance and service life.
Understanding the basic principles of
flexible metal pipe design and installa-
tion is a critical requirement. The need
for appurtenances such as escape
pipes, end walls (bulkheads), utility
connections, hopper and feeder chute
openings, floor slabs, lighting, and
other features unique to such tunnel
applications must be addressed while
keeping the key structural aspects of
flexible corrugated metal pipe design
in mind.
This article will discuss the general
design, installation, and other specific
considerations for aggregate and ore
tunnel applications involving the use
of CMP, SPP, and SPA. The details asso-
ciated with special appurtenances will
also be addressed.
Shape options
CMP aggregate tunnels are
constructed using round CMP, while
structural plate tunnels are either
round or arch shapes (see Figure 1).
Arches typically are half-circle, single-
radius shapes that are placed on rein-

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Learning Objectives
After reading this article you should understand:
The benefits of utilizing CMP, SPP, and SPA for aggre-
gate and conveyor tunnel applications.
The basic design principles that apply to CMP, SPP, and
SPA structures.
The select backfill envelope requirements for such
aggregate and conveyor tunnel structures.
How to handle penetrations in such pipe tunnels for
escape pipes, feeder and hopper penetrations, etc.
How to deal with end walls and bulkheads.
The installation of utility conduits, lighting, etc. in such
tunnel structures.
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forced concrete slab foundations or
raised, pedestal-type footings where
added interior clearance is desired.
Two radius arch shapes (commonly
referred to as horseshoe arches) may
be used when high vertical clearance
is needed and if the site conditions
allow their use.
Normally, the interior of the tunnel
has a concrete floor slab to provide a
reasonably level and uniform working
surface. For full-round pipe shapes,
the floor is constructed by placing
a granular bed on top of the pipe
invert, and then a concrete surface
is poured on top of the bedding.
Flexible metal pipes will experience
slight deflections and shape changes
during installation, backfilling, and
under loads. Therefore, it is recom-
mended to construct concrete floors
after the pipe has been backfilled and
initially loaded to prevent problems
with spalled concrete due to natural
shape changes. Shrinkage is expected
with curing concrete and any gaps at
the edges of the concrete floor can be
sealed with mastic or another type of
suitable sealant material after the floor
slab cures.
Basic flexible corrugated metal
pipe design principles
CMP, SPP, and SPA are classified as
flexible pipe structures. They are by
design less stiff than the surrounding
soil backfill envelope. As such, they
behave as soil-structure interaction
systems that rely on the stiffness and
density of the surrounding backfill for
support under applied loads. Such
structures installed in a competent
backfill envelope that has been prop-
erly placed and compacted can carry
significant amounts of overburden
loads. The proper design and instal-
lation of these CMP and structural
plate structures are covered in nation-
ally recognized specifications such as
American Association of State Highway
and Transportation Officials (AASHTO)
and ASTM, as well as industry-related
references such as those provided by
the National Corrugated Steel Pipe
Association (NCSPA).
Professional Development Advertising Section CONTECH Construction Products Inc. PDH 3
The design premise of CMP is
that these pipes carry loads in ring
compression, with the pipe supported
by the soil envelope and the pipe wall
carrying the applied loads in compres-
sive thrust. The total load pressure
over the pipe consisting of both the
dead loads, represented by the applied
soil and aggregate material overbur-
den weights, and the live loads, repre-
sented by any temporary construction
traffic or more permanent vehicle live
loads operating over the tunnel is
calculated. This combined load pres-
sure is used to determine the ring
compression force acting within the
pipe wall, using Equation 1:
Ring Compression Force (Wall Thrust)
= Pt x Span/2 (Equation 1)
where:
Pt = Pll + Pdl
Pll = live load pressure
Pdl = dead load pressure
Span = maximum horizontal measure-
ment (width) of the pipe tunnel
The unit weight of the aggregate
material, along with the height of the
pile above the pipe, are critical factors
in determining the dead load acting
on the tunnel. Many of these tunnels
have aggregate piles above them
that rise and fall with storage volume
needs. Because the loading is cyclical
in nature, the tunnel is carrying signifi-
cant dead load near maximum cover
heights as well as often carrying live
loads at near minimum cover heights.
Live load pressures are governed by
Figure 1: Shape options for CMP and structural plate tunnels include round, single radius
arch, and horseshoe arch.
factors such as cover
height, load distribu-
tion at the travelling
surface, and load dissipa-
tion through the fill zone above
the crown of the pipe tunnel. The
types of vehicles being considered, the
tire footprint, and the load pattern are
all relevant. Adequate minimum cover
consisting of properly placed select
backfill must be in place and well
maintained for vehicle and equipment
loads operating at low cover heights.
After the ring compression force
value has been determined, the pipe
is checked for wall buckling, required
wall area, required installation stiffness,
and seam strength (if applicable). The
design procedure is outlined in the
referenced documents.
Proper installation and backfill
requirements
These tunnels, as with any buried
flexible structure, require proper instal-
lation to perform structurally. This
starts with installing such structures on
a competent foundation and this
applies to the adjacent side fill embank-
ments as well as to the pipe. The side
fill zones must be supported to prevent
differential settlement and loss of stable
soil support for the pipe. Competent
select fill must be used in the back-
fill envelope. Ideally, this should be a
clean, well-graded, angular road base
fill material with maximum particle
size of 3 inches and a maximum of
15 percent passing the #200 sieve.
The aggregate processed at the site
may meet the requirements for select
 Aggregate Tunnel and Conveyor Enclosures

fill and, if used, the
separator or indicator
layer that denotes the
top of the minimum select
fill envelope must not be compro-
mised, encroached upon, or removed.
Backfill material should be placed
in balanced, 8- to 10-inch loose lifts
and compacted to 90 percent Modified
Proctor Density (AASTHO T180). Side
fill embankments are to be level and
extend out far enough to provide stable,
lateral resistance for the pipe tunnel.
See Figure 2 for depiction of a proper
backfill envelope for these structures.
Select backfill should be free of
materials that are potentially corro-
sive or harmful to the pipe. If the ore
or aggregate material is corrosive in
nature, then the material must be
isolated from the pipe. Additional
protection is provided by using protec-
tive spray on coatings. Impermeable
barriers such as plastic membranes
combined with subdrains can be
installed within the top fill envelope to
prevent corrosive material or leachate
from reaching the pipe surface.
Escape tunnels or outlet pipes
Mine Safety and Health
Administration (MSHA) regulations
typically require escape or outlet pipes
to provide emergency evacuation.
Such outlet pipes and stubs for escape
tunnels are treated as typical CMP
fittings and will likely need to be framed
with suitable reinforcing members
designed to carry the ring compres-
sion loads around the pipe opening.
Industry guidelines and specifications
are available for reference in the design
and detailing of such reinforcement.
However, a simplistic approach is to use
the ring compression force in the pipe
tunnel wall as a bending load applied
to the reinforcing members spanning
across the opening. Simple span beam
formulas can be used to determine the
bending moment:
M = C x L2/8 (Equation 2)
where:
C = ring compression force (wall
thrust)
L = length of opening
M = bending moment
The ends of the beam members are
tied to compression members (curved
to fit the pipe tunnel wall) that carry the
end thrust from the longitudinal beams.

Figure 2: Typical aggregate tunnel backfill envelope and installation detail

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 The reinforcing framework can
be comprised of standard structural
shapes for the smaller size openings.
Longer openings in larger-diameter
tunnels under high fills may require a
reinforced concrete collar framework
to carry these loads.
Hopper openings, feeder
chute penetrations, and
conveyor hanger supports
Conveyor tunnels often are installed
under aggregate and ore piles and
have hopper and feeder mechanisms
penetrating through the crowns of the
tunnels. Typically these heavy machine
components are supported indepen-
dently of the pipe tunnel by either an
internal, floor-mounted support system
or an external, footing-supported collar
system above the pipe. The opening in
the pipe tunnel is still reinforced, but
this reinforcement is intended to carry
the ring compression loads around the
opening, not to bear the weight of the
hoppers, feeders, and material inside
of those structures.
In situations where the tunnel is
expected to carry the loads from the
hoppers and feeder chutes, a suitable
heavy structural framework that carries
the loads well beyond the opening
and provides shape control and added
stiffness to the tunnel structure would
be required.
Flashing around such openings may
be incorporated to provide a reason-
Bulk material is piled over this SPA. Material enters the tunnel
through hoppers before it is transported out on the conveyor.
Professional Development Advertising Section CONTECH Construction Products Inc. PDH 5
ably soil-tight seal; however, such
flashing is not intended to carry the
full weight of the hoppers and feeders
and material transported inside.
A fairly common scenario is to
locate hopper penetrations and feeder
chutes at reinforced concrete junction
structures, with the corrugated metal
or structural plate tunnel stubbing into
the concrete structure and thus elimi-
nating some of the above concerns.
Conveyors should be supported on
floor-mounted columns when possi-
ble. In the event that conveyor support
framework is intended to be mounted
or suspended from the crown of
the pipe tunnel, there will need to
be additional structural members
that distribute point loads from the
conveyor supports up to the conveyor
tunnel crown to help retain shape of
the pipe tunnel. These tunnels may
experience slight shape changes and
deflections during installation and
under load cycles. Mechanisms to
adjust the conveyor hanging system
and conveyor belt components should
be used to ensure smooth operation.
End walls (bulkheads)
End walls can be constructed from
reinforced concrete or from metal end
panels. Reinforced concrete end walls
are formed, poured, and cured similarly
to standard headwalls. Typically, prefab-
ricated steel end walls are detailed as
reinforced diaphragms. End walls are
A floor-mounted conveyor on a concrete slab is installed in this
round SPP tunnel.
normally fabricated
from flat steel plates or
corrugated plates that
are reinforced with welded
channels. Such end walls may
have an escape pipe through them for
evacuation.
Lighting, utilities, catwalks,
and platforms
Light fixtures and small service
conduits are readily mounted to the
CMP, SPP, or SPA using self-tapping
or blind hardware. Heavy utilities
such as steam pipes and cable trays
require special detailing similar to the
approach used for conveyor trusses.
Catwalks and platforms should be
supported by the floor.
Maintenance issues
CMP and SPP tunnels with coatings
compatible with the installed envi-
ronment usually require little main-
tenance. Sealing or caulking at the
juncture between the floor slab and
the tunnel wall may be required occa-
sionally to seal any openings caused
by curing of the concrete or by normal
pipe movement and shape changes.
Future modifications
Tunnels can be extended in length
if future needs dictate. The juncture
between old and new sections of tunnel
can be accomplished using reinforced
concrete headwalls or through the
 Aggregate Tunnel and Conveyor Enclosures

use of bands or simi-
lar connections. Care
must be taken during
any future modifications
to keep loads and soil envelope
support for the tunnels balanced and
uniform. Any tap-ins or similar modifica-
tions must be done in a manner to keep
the entire tunnel periphery symmetri-
cally loaded and supported and to
maintain stability of the soil envelope.
Summary and conclusions
CMP, SPP, and SPA tunnels offer an
affordable, practical, and low-main-
tenance alternative to other means
of aggregate tunnel construction.
The combined strength of the pipe
product and the surrounding select
backfill envelope functioning in a soil-
tunnels, installed properly, provide openings, conveyor support, hopper
years of service and offer the flexibility and feeder chute requirements, and
of future modifications. utility needs ensures a functional, safe,
Attention to details such as fittings, and practical tunnel structure.
REFERENCES
AASHTO, 2002, Standard Specification for Highway Bridges, 17th Edition, Section 12
Soil-Corrugated Metal Structure Interaction Systems
AASHTO, 2007, LRFD Bridge Design Specifications, 4th Edition, Section 12 Buried
Structures and Tunnel Liners
AASHTO T 180 Standard Method of Test for Moisture-Density Relations of Soils Using
a 4.54-kg (10-lb) Rammer and a 457-mm (18-in.) Drop
ASTM A-796 Standard Practice for Corrugated Steel Pipe, Pipe-Arches and Arches for
Storm and Sanitary Sewers and Other Buried Applications
ASTM A-798 Standard Practice for Installing Factory-Made Corrugated Steel Pipe for
Sewers and Other Applications
ASTM A-998 Standard Practice for Structural Design of Reinforcements for Fittings in
Factory-Made Corrugated Steel Pipe for Sewers and Other Applications
NCSPA Installation Manual for Corrugated Steel Pipe, Pipe Arches, Structural Plate

structure interaction system provides NCSPA, 1999, Design Data Sheet No. 18A

the load-carrying capability and struc- NCSPA, 2008, Corrugated Steel Pipe Design Manual, First Edition

tural performance required. Such pipe

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Article Title: The Use of Corrugated Metal Pipe and Structural Plate for Aggregate Tunnel and Conveyor Enclosure Applications
Publication Date: December 2009
Sponsors: CONTECH Construction Products Inc. Valid for credit until: December 2011

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 Jim Noll, P.E., is the director of Engineering Services for CONTECH. He has more than 30 years experience in the corrugated
metal pipe industry and is an active member of various technical organizations, including ASCE, AREMA, and ASTM. Contact him
at jnoll@contech-cpi.com. Steve Tysl, P.E., is a civil engineer for CONTECH and an active member in ASTM and SEAoO. He has
more than 18 years experience in civil engineering and materials/construction engineering. He can be contacted at tysls@contech-cpi.
com. Matt Westrich, P.E., is a civil engineer for CONTECH. He has more than 12 years experience in the civil/structural engineering field. He can
be reached at westrichm@contech-cpi.com.

1. B
 enefits of using corrugated metal tunnels for conveyor
enclosures and aggregate tunnels include:
a) There are different shape options available to fit the site-
specific requirements such as foundation requirements and
conditions and clearance requirements.
b) Reduced design time and ease of construction versus other
tunnel options.
c) Large bulk material piles can be dumped directly on the
tunnel without a backfill envelope.
d) Both a and b
e) Both a and c
2. W
 hat advantage(s) are there to a floor-mounted conveyor
versus supporting a conveyor from the top of the tunnel?
a) A floor-mounted conveyor system does not typically apply
any loads to the tunnel structure that require reinforcing.
b) Changes in shape that occur from hanging loads from the
crown are avoided.
c) Additional reinforcing typically required if the conveyor is
attached to the top of the pipe is not needed.
d) Both a and c
e) All of the above
3. When designing a corrugated metal pipe structure by industry
standards, the ring compression force is first determined using
the applied loads, and then several design checks are required.
Which of the following is not required to be checked?
a) Installation stiffness c) Required wall area
b) Radial tension d) Buckling
6. A corrugated metal tunnel will have a 3-foot x 3-foot opening
that will require reinforcing to span the length of the opening.
The ring compression, C, in the structure is 40,000 pounds
per foot. What is the approximate moment used to size the
reinforcing that will run perpendicular to the corrugations?
a) 45 pound-ft. d) 45,000 pound-ft.
b) 450 pound-ft. e) 540,000 pound-ft.
c) 5,400 pound-ft.
7. W
 hen constructing a concrete paved invert or floor system in
a SPP, the recommended sequence is:
a) Assemble the plate structure without the crown, place
concrete, install crown plates, backfill.
b) Assemble the plate structure completely, install structural
backfill zone, place concrete.
c) Assemble the plate structure completely, place concrete,
install backfill.
d) Precast the concrete on the invert places, set with crane,
assemble the balance of crown plates, backfill.
8. W
 hich of the following are true statements regarding shape
selection for typical aggregate tunnel applications?
a) Use round or half-circle arch shapes that enclose the
required clearances while providing allowances for
installation tolerances and nominal deflection.
b) Use very tall, slender arch shapes with straight sides.
c) Use multiple-radius geometries such as pipe arches and
underpass shapes for tight clearance situations.
d) All of the above

4. If a 12-foot-diameter corrugated metal pipe is used for 9. A

an aggregate tunnel with 3 feet of structural backfill dead
load of 120 pcf, a stockpile dead load of 40 feet of 100-pcf
material, and no live load, what is the ring compression force
acting within the pipe wall (per foot of pipe length)?
a) 3,270 pounds d) 26,160 pounds
b) 6,540 pounds e) 52,320 pounds
c) 13,080 pounds
 common technique to clearly mark the extent of the
structural backfill zone or select fill envelope is to:
a) Use clay as select fill to distinguish it from the aggregate material.
b) Use an indicator layer such as brightly colored paint
between the select fill and aggregate rock layers.
c) Use a non-woven geotextile or a highly visible geogrid
product to mark the separation between granular materials.
d) Both b and c

5. O
 f the following, which would be considered the most
appropriate material for the backfill envelope around a
corrugated metal tunnel structure?
a) Crushed rock varying in size from 1 inch to 4 inches.
b) Well-graded, crushed rock varying in size from inch to 2 inches.
c) Sandy silt.
d) Native soils consisting primarily of clays and silts.
10. A
 general description of the material used as select backfill
for such tunnel structures would include:
a) Well-graded, granular, crushed rock.
b) Chemically inert.
c) Characterized by an established Proctor Curve.
d) Clean and free of deleterious materials.
e) All of the above

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