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1、Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 02:47:14 MDTNo reproduction or networking permitted without license from IHS -,-,- A A 67 m Ob04500 OOLL2L 4Lb m ! Use of the Information Any
2、data and suggestions contained in this publication were compiled and/or developed by The Aluminum Association, Inc. In view of the variety of conditions and methods of use to which such data and suggestions may be applied, the Aluminum Association and its member companies assume no responsibility or
3、 liability for the use of information con- tained herein. Neither the Aluminurn Association nor any of its member companies give any warranties, expressed or implied, with respect to this in formation. First Edition, First Printing, June 1983 Copyright The Aluminum Association Inc. Provided by IHS u
4、nder license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 02:47:14 MDTNo reproduction or networking permitted without license from IHS -,-,- contents PAGE SUBJECT SECTION 1 SECTION 2 SECTION 3 INTRODUCTION TO ALUMINUM DRAINAGE PRODUCTS History of Corrugated
5、 Aluminum 1-1 Applications Product Development Annular Corrugated Pipe Structural Plate Improved Annular Corrugated Pipe Helical Corrugated Aluminum Pipe Ribbed Structural Plate CORRUGATED ALUMINUM PIPE APPLICATIONS Culvert Storm Sewers Miscellaneous Sewer Uses Sub-surface Drainage Systems Municipal
6、 Drainage Airports Spillways Railroads Bridges Miscellaneous Applications DESIGN AND INSTALLATION STRUCTURAL DESIGN Material Selection Structural Design Finite Element Analysis S.C.I. Design Method S.D.R. Design Method Site Preparation Bedding Backfill Fill Height HYDRAULIC DESIGN Hydrology of Storm
7、 Drains storm drains; sub-drains; municipal storm sewers; power and industrial plant water-cooling intake and exhaust lines; bridges, underpasses for vehicles, livestock and pedestrians; coverings or conduit for conveyors and utility lines; general storage; cellular earth-retaining walls; service co
8、nduit for mine and/or tunnel access;and lining for failing masonry or concrete conduits. Product Development Initial corrugated aluminum pipe product design employed the 2-2/3 in. pitch x 1/2 in. depth corruga- tion used in steel culvert for many years. Metal gauge designation or thickness used in s
9、teel culvert was also retained for aluminum culvert of that profile. Design calculations indicated that gauge equivalence with steel was permissable over a wide spectrum of fill heights. In addition to obvious installation weight cost sav- ings, it seemed likely, based upon excellent corrosion resis
10、tance, that for the great majority of applications, one of the most significant economical advantages of aluminum culvert would be lower maintenance costs throughout a wide range of soils and waters. Accompanying the product development work were comprehensive durability studies, most of which were
11、instituted in the early 1960s and are still being con- Fig. 1-2. Twin lines, each 84 in. diameter x 0.100 in. thickness, used at grade separation beneath Interstate 295. This is a salt water installation used as an outfall line into Back Cove at Port- land, Maine. 1-2 Copyright The Aluminum Associat
12、ion Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 02:47:14 MDTNo reproduction or networking permitted without license from IHS -,-,- A A 67 D ObOY500 OOLL233 89b ducted. These studies include in-ground installation inspecti
13、ons, with accompanying detailed reports; lab- oratory research by aluminum producers and by in- dependent laboratories through Aluminum Association programs; and cooperative studies jointly sponsored by the Aluminum Association and state and other govern- ment agencies. Early predictions of aluminum
14、s durability in drain- age applications have been substantiated by numerous performance evaluations in diverse underground en- vironments conducted by at least a dozen State Highway Departments and Federal agencies. Significant test data are summarized in Section 4. “Durability and Field Experience.
15、” Annular Corrugated Pipe Structural characteristics of the 2-2/3 in. x 1/2 in. corrugated aluminum profile were verified in an extensive field testing program early in 1961. Aluminum of appropriate standard sheet gauges was corrugated to this profile and fabricated into culvert pipe diameters rangi
16、ng from 24 to 60 in. diameter. Instrumented with pressure, strain and deflection gages, each test section was bedded and backfilled according to standard specifications and practices for flexible metal culvert, and the physical behavior of the corrugated aluminum culvert under load was recorded. H-2
17、0 loading was simulated under minimum-fill con- ditions, and subsequently the overburden was increased in regular increments to 30 ft. All performance speci- fications were readily met. 9 in. x 2-1/2 in. Structural Plate In early 1962, development work was initiated on a bolted corrugated aluminum s
18、tructural plate culvert. Departing from the standard steel profile concept, it was decided to: (1) Optimize the corrugation profile by full utiliza- tion of the unique mechanical and physical properties of the aluminum alloy selected. (2) Employ an entirely new design technique. Two years later a co
19、rrugated aluminum structural plate product had been developed, which at first sight did not appear radically different from the standard steel corrugated structural culvert plate. But with the new aluminum profile, 9 in. pitch x 2-1/2 in. depth, there were several major differences resulting from fu
20、ll utilization of aluminums modulus of elasticity and alloy strength. Aluminum plate thicknesses, ranging from O. 100 in. to 0.250 in. in 0.025 in. increments, were employed with the new profile, rather than the conventional sheet steel gauges, formerly used exclusively in flexible metal culvert. Ne
21、w stock-plate sizes also were established for material in the new corrugated aluminum profile, as were joint locations in the assembled pipe. More subtle but of equal importance were the changes in the shapes of aluminum culvert structures, the new manufacturing techniques employed, and new designs
22、for drainage systems utilizing the new profile. Strength verification of the 9 in. x 2-1/2 in. corru- gated aluminum structural plate culvert was obtained with instrumented tests of full size structures, properly installed. Minimum and deep-fill tests proved con- fig. 1-3. A ribbed structural plate
23、long span structure was assembled on the bank and then lowered into a canal in Dade Count)/, Florida. The structure was back- filled in 77 feet of water and carries a road over the canal. The structure span is 343” with a rise of 2 3 - I” and is 2 4 0 feet long. 1-3 Copyright The Aluminum Associatio
24、n Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 02:47:14 MDTNo reproduction or networking permitted without license from IHS -,-,- A A 67 Ob04500 OOLL234 722 clusively that the new profile provided the required strength for
25、 long spans under highways and railroads. Improved Annular Corrugated Pipe In the 1960s a riveted aluminum culvert was developed, having a deeper profile and employing lighter gauge metal than used in comparable size 2-213 in. x 1/2 in. aluminum culvert. The design goal was to optimize corrugation p
26、rofile to produce improved efficiency, particularly in intermediate pipe diameters. The two profiles to emerge from this study were the 6 x 1 and 3 x 1 in. These one inch depth corrugations have four times the flexural stiffness and improved joint strength as compared to the 2-2/3 x 1/2 profile. Sub
27、stantial savings in material costs are a direct result of the allowable decrease in metal thickness of 1 in. depth corrugated aluminum culvert. Frequently even more significant are the individual or combined indirect savings resulting from the lighter weight cul- vert. Less weight means important sa
28、vings in time and in labor costs for shipping and handling, and in- stallation. Additionally, heavy-duty handling equip ment rarely, if ever, is required for aluminum culvert installation, effecting further savings. e Fig. 7-4. A 20 ft. section of 8 in. helical cor- rugated aluminum drainage pipe we
29、ighing just 43 Ibs., being transferred to a ditch on a con- struction project. A pipe of the same size, and of the same gauge, in steel would weigh more than 129 Ibs. Helical Corrugated Aluminum Pipe All riveted pipe corrugation profiles can also be produced from continuously corrugated sheet into h
30、elical lockseam pipe. After sheet is corrugated, the pipe is formed with the corrugations running helically around the pipe. Helical corrugated aluminum pipe employs an inter- locking crimped seam which is staked every inch, greatly increasing the mechanical strength of the seam. This construction i
31、s particularly useful in storm sewers (See Fig. 1-4) and for numerous industrial applications. Single sections made of one continuous strip of alu- minum are available in lengths up to 40 ft. weighing only 1/3 as much as steel pipe of the same size and gauge. An optional neoprene bead may be include
32、d in the seam to protect against leakage. Ribbed Structural Plate Culvert size and the loads it can support are related to strength of the corrugation in compression and bending. As size and loadings increased it was realized that increased metal thickness was no longer eco- nomically acceptable. In
33、 factory made culvert the solution was to go to deeper corrugations. In the range of product sizes using structural plate, the alternative of a deeper corrugation was not acceptable. The alternate solution was to add circumferential ribs. Such a rib could be attached to any increment of the corrugat
34、ion pitch. In combination with varying corrugation thickness, a wide range of moment and thrust capacity can thus be achieved. This ability to dramatically improve structural per- formance created a new market opportunity that could functionally and economically be competitive with reinforced concre
35、te box culverts. The functionally equivalent aluminum box culvert, in spans up to 25 feet and at covers of only one tenth span, have received wide market acceptance. Ribbed structures of the more conventional culvert shapes are now possible in spans over forty feet. A common use for this new family
36、of structures is an alternate to conventional bridges. To confirm the use of circumferential ribs (see Fig. 1-3) for both conventional structures and box culverts, extensive laboratory and field testing was conducted. Concurrent with this was extensive finite element studies of soil-structure intera
37、ction. The end result of this ac- tivity was the development of proven design procedures commonly referred to as the SCI design method. The combination of in-depth understanding of soil- structure behaviour and the cost effectiveness of ribbed structures confirm this approach to drainage and bridge
38、requirements. 1-4 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 02:47:14 MDTNo reproduction or networking permitted without license from IHS -,-,- AA 67 = Ob04500 OOLL235 669 Section 2 cor
39、rugated aluminum pipe applications Widest possible utilization of the economy and reliable service provided by aluminum drainage products in a full range of ap- plications may be aided by the following review of standard corrugated pipe uses. Drainage systems consist principally of storm sewers and
40、culverts. Both are usually installed in developed, level or rolling terrain but are also used in steep inaccessible loca- tions. Culverts and sewers comprise the largest volume of corrugated aluminum pipe installations. Pipe seams may be rivet- ed, lock-formed, or bolted, depending upon the given re
41、quirements. of a single length of corrugated pipe, ranging from 6 in. to 20 ft. or more in diameter, open at both ends. However, extensive and sometimes quite complex sys- tems of culvert of several types are used to drain roadways and other areas. Gener- ally, pipe is termed “culvert” when it passe
42、s under roads, levees, or embankments for the purpose of protecting the embankment from erosion. The culvert contains and directs the flow of surface water. A drainage system sometimes employs a series of culvert courses, arranged to intercept and redirect the water as desired, as in draining a wind
43、ing logging road. Culvert Storm Sewers Generally considered the simplest type of drainage conduit, culvert often consists While the definitions are not completely 2-1 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie No
44、t for Resale, 04/18/2007 02:47:14 MDTNo reproduction or networking permitted without license from IHS -,-,- A A 67 m 060500 OOLL236 5T5 rigid, storm sewers are generally longer and more complex, (see Fig. 2-1), than culverts, and are usually, though not always, buried. Elbows, Ts and other fittings
45、are employed as required. Lengths and contours of the sewer systems inlets and outlets are designed to accommodate the specific characteristics of the antici- pated water flow. In addition to storm-produced water, storm sewers also carry all other flows of surface water, including street wash, yard
46、and swimming pool excess, and commercial and industrial flows. Aluminum with proven durability is an ideal product for municipality sewer systems. It gives a combination of long service life and economy. In addition to municipal storm sewers it has been used extensively for commercial developments s
47、uch as airports, shop- ping centers and industrial parks. Large diameter corrugated aluminum pipe is also particularly well suited for use as underground storage tanks in a detention system to hold excess storm water and permit only a limited amount of runoff. They can be installed under parking are
48、as with access by man- holes. Aluminum pipe is an ideal solution for storage tanks (see Fig. 2-2) because it has excellent durability and its light weight reduces the size equipment required to handle large diameter pipes usually required for detention tanks. Aluminum pipe is available with perforat
49、ion patterns for use in recharge storm water control systems. The surface runoff rate usually exceeds the pipes exfiltration capacity and may require some detention holding as well. If the collection area for storm runoff is small, it may be handled by “dry wells” consisting of vertically installed perforated pipe surroun