Structural

Plate
Design
Guide

9th Edition

MULTI-PLATE®

Aluminum Structural Plate

Aluminum Box Culvert

SUPER-SPAN™

BridgeCor®

Steel EXPRESS® Foundations

 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Steel and Aluminum Structural Plate Design Guide

Table of Contents
This design guide is provided by Contech Engineered Solutions to assist designers with most applications and
design aspects of MULTI-PLATE®, Aluminum Structural Plate (ALSP), Aluminum Box Culverts (ALBC), SUPER-SPAN™,
SUPER-PLATE®, BridgeCor®, and Steel EXPRESS®. To support the designer, this written guide along with the provided
standard details can be used to assist in the preparation of the project plans and specifications. For additional
information, contact your local Contech representative or call 800-338-1122 to find a Contech representative near you.

Typical Design Steps Aluminum Box Culvert

Selection of Structure Shape......................................5 Product Overview....................................................62
Designing for Service Life..........................................7 HL-93...............................................................64
Structural Plate Design............................................13 H-20/HS-20......................................................66
MULTI-PLATE and ALSP.......................................13 H-25/HS-25......................................................67
ALBC.................................................................17 Aluminum Box Culverts Plate Make-Up....................68
SUPER-SPAN and SUPER-PLATE...........................18 Prefabricated Aluminum Headwalls..........................69
BridgeCor.........................................................19 Prefabricated Aluminum Full Invert...........................72
Minimum Cover over Plate Structures.......................19 Prefabricated Aluminum Footing Pads......................75
Structure End Treatments.........................................21 Project Specifications...............................................78
Material Design and Installation Specs.....................27
SUPER-SPAN ™/SUPER-PLATE®
MULTI-PLATE ®
Product Overview....................................................79
Product Overview ...................................................28 Steel Project Specifications.......................................83
Bolts and Nuts........................................................30 Aluminum Project Specifications...............................85
Round....................................................................30
Vertical Ellipse.........................................................32 BridgeCor®
Pipe Arch................................................................34 Product Overview ...................................................88
Single Radius Arch..................................................37 Project Specifications...............................................90
Horizontal Ellipse....................................................40 BridgeCor External Rib System.................................95
Underpass..............................................................42 Round Design Details..............................................97
Project Specifications...............................................44 Single Radius Arch Design Details............................99
2-Radius Arch Design Details.................................101
Aluminum Structural Plate Box Culvert Design Details....................................103
Product Overview....................................................46
Bolts and Nuts........................................................48 Steel EXPRESS® Foundations
Handling Weights & Plate Make-Up.........................50 Product Overview .................................................108
Height of Cover Table Instructions............................52 Project Specifications.............................................110
Round....................................................................52
Ellipse....................................................................53
Pipe Arch................................................................54
Single Radius Arch..................................................56
Underpass..............................................................58
Project Specifications...............................................60

2
 Typical Design Steps
Outline of Typical Design Steps
The following steps describe a basic, typical procedure for 6. Specify Bedding, Backfill and Check Foundation
designing a structural plate bridge or culvert but are not • Soil envelope under and around structure
intended to represent all possible considerations that a • Bedding
prudent designer should investigate. Although not all of • Foundation requirements
these steps will be covered in this document, additional x For arch structures, a reinforced concrete footing
design aids are available. If the designer has questions
may be required. Please see page 108 for Contech's
regarding an aspect of structure designs, the designer can
Steel EXPRESS® Foundation option.
contact the local Contech representative for additional
• Backfill envelope – backfill recommendations
information.
7. Structure End Treatment
This guide follows the design methodology of the • Projecting Square Ends
American Association of State Highway and Transportation • Beveled Ends
Officials (AASHTO) LRFD Bridge Design Specifications. The • Skewed Ends
height of cover tables will vary when a different design method • Headwalls
is followed. An HL-93 live load structural check determines
• Toewalls and cutoff walls
if an HS-20 or a tandem axle vehicle controls. For other
design load considerations, please contact your local 8. Structure Installation Specifications
Contech representative. • AASHTO LRFD Bridge Construction Section 26
• ASTM A807 for Steel Structures
Design Sequence • ASTM B789 for Aluminum Structural Plate
1. General Structure Selection References
• Guidelines for selection of hydraulic, roadway, 1. AASHTO Material, Design, and Installation Specifications
pedestrian, or grade separation structure • MULTI-PLATE, SUPER-SPAN, Aluminum Structural Plate,
2. Additional Selection Considerations Box Culvert and BridgeCor – material design and
• Refining structure selection, such as clearance installation
requirements, if applicable • Project specifications

3. Check Service Life and Protection of Structure from 2. CAD Drawings

Environment • Structure shape and detail drawings are available to the
• Environmental effects designer upon request.
3. An NCSPA Corrugated Steel Pipe Design Manual
• Design life
is available from the NCSPA or your local Contech
• Material selection – galvanized steel or aluminum
representative. More specific information on each step or
• Protection from aggressive environments
topic is available from Contech Engineered Solutions.
• De-icing salts
These are the basic steps involved in designing a corrugated
4. Check Structure Hydraulics (not covered herein) flexible structure. This guide contains specific information about
• Perform hydraulic checks MULTI-PLATE, Aluminum Structural Plate, Aluminum Box Culverts,
• Hydraulics of corrugated metal structures SUPER-SPAN/SUPER-PLATE, and BridgeCor.
• Tools for hydraulic analysis*
* Hydraulic nomographs and FHWA HY-8 program
• Scour analysis
assistance is available from your local Contech
5. Check Structural Design representative.
• Design method options ** Structures can be load rated according to AASHTO LRFR
x American Association of State Highway methodology, please contact your Contech representative
for the NCSPA Design Data Sheet 19, which may be used
and Transportation Officials (AASHTO) LRFD or
for guidance.
2002 Standards
x American Iron and Steel Institute (AISI)
x National Corrugated Steel Pipe Association
(NCSPA)
x American Railway Engineering and Maintenance
Association (AREMA)
• Material properties
• Load rating structural plate (not covered herein)**
3
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

STRUCTURE SHAPE GEOMETRY

Shapes Span x Rise Common Uses Steel Aluminum Trade Name
x MULTI-PLATE
Culverts, storm sewers, aggregate tunnels, vehicular and x BridgeCor
Round 5’ to 50’-6” pedestrian tunnels and stream enclosures. Functions well in
all applications, but especially in those with high cover Aluminum Structure
x
Plate

x MULTI-PLATE
4’-8” x 5’-2”
Culverts, storm sewers, service tunnels, recovery tunnels and
Vertical Ellipse to
stream enclosures. Works well in higher cover applications. Aluminum Structure
25’ x 27’-8” x
Plate

12’-2” x 11’-0” x MULTI-PLATE

Offers efficient shape for passage of pedestrians or
Underpass to livestock, vehicular traffic and bicycles with minimal buried
20’-4” x 17’-9” invert. Aluminum Structure
x
Plate

6’-1” x 4’-7” Limited headroom. Has hydraulic advantages at low x MULTI-PLATE

Pipe-Arch to flow levels. Culverts, storm sewer, underpass and stream
20’-7” x 13’-2” enclosures. Aluminum Structure
x
Plate

7’-4” x 5’-6” x MULTI-PLATE

Culverts, bridges, low cover applications, wide centered
Horizontal Ellipse to
flow, good choice when poor foundations are encountered. Aluminum Structure
14’-11” x 11’-2” x
Plate
x MULTI-PLATE
6’ x 1’-10” Low clearance, large waterway opening. Aesthetic shapes x BridgeCor
Arch (single radius)* to and open natural bottoms for environmentally-friendly
54’-4" x 27’-2” crossings. Aluminum Structure
x
Plate
18’-5” x 8’-4” Low clearance, large waterway opening. Aesthetic shapes
Arch (2-radius)* to and open natural bottoms for environmentally-friendly x BridgeCor
50’-7” x 19’-11” crossings.

8’-9” x 2’-6” Very low, wide bridges, culverts and stream enclosures, x BridgeCor
Box Culvert to with limited headroom. Functions well as a fast small-span Aluminum Box
40’9” x 15’2” bridge replacement. x
Culvert

19’-5” x 6’-9” Culvert, storm sewers, low headroom and large opening. x SUPER-SPAN
Low-Profile Arch to Bridge structures, stream enclosures. Aesthetic shapes and
45’-0” x 18’-8” open natural bottoms for environmentally friendly crossings. x SUPER-PLATE***

20’-1” x 9’-1” Culverts, storm sewers, bridges, Higher rise, large area x SUPER-SPAN
High-Profile to opening. Open natural bottoms for environmentally friendly
35’-4” x 20’-0” crossings. x SUPER-PLATE

19’-4” x 12’-9” x SUPER-SPAN

Larger culverts and bridges. Low headroom, wide-centered
Horizontal Ellipse to
flow, good choice when poor foundations are encountered.
37’-2” x 22’-2” x SUPER-PLATE

23’-11” x 23’-4”
to Railroad underpasses or large clearance areas. Open
Pear-Arch x SUPER-SPAN
30'-4" x 25'-10" natural bottoms for environmentally friendly crossings.

23’-8” x 25’-5”
Pear to Railroad underpasses or large clearance areas. x SUPER-SPAN
29'-11" x 31'-3"

Culverts, bridges, tunnels, wetlands crossings, overpass/ CON/SPAN®

Elliptical/Circular
12’ to 102’ underpass, underground containment, wine/cheese cellars BEBO®
Arch **
and shelters. (precast concrete)

Steadfast Bridges®
spans up to 300’ County, city, parks, industrial complexes. Vehicular Truss
Vehicular ** x
spans up to 150’ Recreational, overpasses, industrial conveyor, pipe support. Big R Bridge®
Rolled Girder
* Larger steel sizes are available up through 80-foot spans with external reinforcements in the BridgeCor® product line.
Contact your local Contech representative for more information.
** The design process for these bridge structures is not covered in this document. Contact your local Contech representative for more information.
*** Low-Profile Arch SUPER-PLATE is only available up to 38'-8" x 15'-9".

4
 Typical Design Steps
Selection of Structure Shape
Contech manufactures and supplies structural plate in a wide Additional Considerations
variety of structure shapes and sizes in both galvanized steel
In addition to simple geometric and hydraulic concerns, the
and aluminum alloy. The large selection of structure types
designer should consider other parameters that may
ensures that a designer will be able to select the optimum
influence structure type, shape and material including:
structure for virtually any application from low cover situations
to extreme cover heights and from pedestrian underpasses to • High Cover Applications
grade separations for airport runways or railroad passages.
For fill heights over 30’, the designer should consider
The structures listed on page 4 are generally configured Key-Hole Slot MULTI-PLATE® as discussed on page 16.
for use in specific drainage or traffic passage applications.
They are prioritized from top to bottom to ensure the most • Pipe Structure versus Arch on Footings
efficient usage and best economy. For example, a designer In general, a pipe structure with a full invert or buried invert
should first check to see if a round structure will satisfy the is preferable in terms of cost versus an arch because of the
project requirements. If there is inadequate headroom for a elimination of concrete footings. However, many regulations
round structure, proceed to a pipe-arch, horizontal ellipse, or require natural, undisturbed stream bottoms. In this case, an
arch and on to box culverts. If a larger structure is required, arch on footings is typically less expensive than a traditional
consider a SUPER-SPAN or BridgeCor type structure. More bridge.
detailed structure dimensions and information can be found in
later sections of this document. • Bearing Capacity

Following are some tips on structure shape and size See specific sections in this guide for individual structure types
selection: for recommendations on minimum bearing capacity and
a It is usually best to select a shape that most closely footing designs. Pipe arch design should include
considerations of applied corner bearing pressure.
matches the shape of the drainage channel. For
example, a deep narrow channel will accept a round • Flow Characteristics
structure. horizontal ellipses, low profile arches and box
If flow is to be particularly abrasive, the designer should
culvert shapes are best suited to relatively wide, shallow
consider a natural invert (arch or buried invert), heavier invert
channels. plates, an aluminum structure, or applying a paved invert to
a Determine the end area requirement in square feet for the aid in the long-term durability of the structure.
structure and divide the number by the vertical distance • Corrosive Soils
from the streambed to the surface elevation
Analyze structure life projections based upon the CALTRANS/
less approximately 1.5’ to 3.0’ for fill cover over
AISI method. If design life is not met using galvanized steel,
the structure. This will somewhat underestimate the
consider asphalt coating the steel, adding a concrete field
approximate minimum span required depending upon
paved invert or using aluminum as an alternate. See page 11
the structure shape. for recommendations for protection from de-icing salts.
a Identify the most efficient structure in terms of reducing • Corrosive Effluents
design loads. For box culverts, choose a structure that
meets the hydraulic requirements and provides a cover Analyze structure invert life projections based upon the
CALTRANS/AISI method. If design life is not met using
of 3-4 feet. A taller structure which minimizes cover may
galvanized steel, consider either heavier gage invert
be less cost-effective than one of similar span with slightly
plates, paved invert, natural invert, or aluminum. In
higher cover.
particularly corrosive situations an arch on elevated footing
a For other plate structures: walls (pedestal walls) may be the best solution.
l Where fill over the structure is high, try to utilize the
tallest structure feasible to minimize cover. As cover
increases, so does gage as well as footing sizes.
l Where fill over the structures is low, choose a
structure that maintains the minimum allowable
cover.

5
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Scour Clearance Box Requirements

If scour is a concern, a pipe structure, especially with a buried The following describes the process of selecting a structure
invert, may be more desirable than an arch. The invert with sufficient clearance for the passage of vehicular or
eliminates footings subject to scour. Also, arches with partially pedestrian traffic.
buried structure legs (and footings) may satisfy scour depth.
It should be noted that the dimensions of finished corrugated
Often, when an arch on footings must be used, protecting the
metal structures may differ from the nominal dimensions
footings, may be more cost effective than installing deeper
described in literature. For instance, taller single radius
footings. Products to consider for this type of protection
arches may peak slightly during backfilling, which may
include rip-rap, sheet piling, or as a permanent erosion
infringe upon the required clearance box.
control option, Armortec hard armor solutions. Scour analysis
is outside the scope of this guide. If clearance tolerance is critical, it is recommended that a
slightly larger structure be selected or that the structure
FHWA Hydraulic Engineering Publication HEC-18 outlines the shape be monitored during erection and backfilling.
design for scour. FHWA Hydraulic Engineering Publication Proper control of compaction and the use of high quality
HEC-23 outlines the design procedures for scour counter granular backfill material will minimize structure movement
measures. during backfilling. Contact your Contech representative for
assistance regarding monitoring and the use of particular
shapes.

MULTI-PLATE® and Aluminum Structural Plate vertical

ellipses and underpass shapes are configured specifically for
vehicular and pedestrian traffic. The structure's invert is often
paved to provide a smooth surface. See page 12 for details.

While arch structures often appear to be the best choice for

many applications, the same shape in a round or elliptical
shape may be more economical due to the elimination of
footings. For example, a round structure or horizontal ellipse
with the invert buried and/or paved are often used in lieu of
an arch for grade separation structures.

Protect footings from scour with Armortec® hard armor solution

Horizontal ellipse SUPER-SPAN™

6
 Typical Design Steps
Designing For Service Life Galvanized Steel MULTI-PLATE®

After a structure shape, size, and gage have been selected, With regard to the durability of galvanized steel MULTI-PLATE,
the designer should perform an analysis of the possible this design guide will outline the guidelines established by
environmental effects on the structure's long-term life cycle. the California Department of Transportation (CALTRANS).
This may lead the designer to modify the structure's material, The CALTRANS design method originated from a study that
structure type, coating, or additional invert protection. inspected over 7,000 galvanized steel corrugated metal pipe
(CMP) drainage structures throughout the state of California.
A structure's life cycle can be affected by the corrosive action
Through this field study they were able to develop a reliable
of the backfill in contact with the outside of a structure or
method for predicting the service life of smaller diameter
more commonly by the corrosive and abrasive action of the
corrugated galvanized steel pipes. The data collected
flow in the invert of the structure. The design life analysis of
reflected the combined effects of corrosion and a wide range
the structure should include a check for both water side and
of abrasive levels. The conclusion of the CALTRANS study
soil side environments to determine which is most critical or
defined the end of the structure life to coincide with the first
which governs structure life.
perforation (or approximately 12% metal loss) in the invert of
culverts that have received no special maintenance.

Existing Embankment Soil The service life of 2 oz. per square foot of zinc-coated
galvanized CMP is determined by using the CALTRANS chart
for estimating invert life (see page 8). This chart predicts a
variable service life based on pH and resistivity of water and
soil and has been the industry standard for many years. The
pH
Resistivity results included the combined effects of soil-side and interior
Hardness
corrosion, as well as the average effects of abrasion. For
pipes where the pH was greater than 7.3, soil-side corrosion
controlled and life was predicted by resistivity. For pipes where
pH was less than 7.3, the interior invert corrosion generally
controlled and both pH and resistivity were important.

Select Backfill Zone: If the existing embankment soil is

It is important to note, the consequences of small perforations
to be used in the Select zone, it must be tested to confirm
that its pH and Resistivity is within the recommended ranges.
are minimal in gravity flow pipe systems, such as most storm
sewers and larger culverts, and may not accurately reflect
the estimated service life outlined by CALTRANS. Because of
The choice of material or structure type can be extremely this fact, the original CALTRANS curves have been converted
important to service life. For example, if it is determined that to average service life curves using data on weight loss
water and bedload flowing through a structure is projected and pitting in bare steel developed by National Institute
to reduce the life cycle of the invert through abrasive or of Standards and Technology. Using this information, the
corrosive action, an arch may be used with a natural invert American Iron and Steel Institute (AISI) developed a durability
or the invert may be buried or paved. chart using the end of an average effective service life to be
estimated at approximately a 25% metal loss in the invert. The
Corrosion Studies for Metal Structures
AISI chart can be found at [Link].
Galvanized steel structural plate has been used in the
United States since 1931. Aluminum Structural Plate has In addition, the structural plate covered in this design
been in use since the early 1960’s. Tens of thousands guide utilizes a 3 oz. per square foot of zinc coating
of structures are in use in a wide variety of applications and uses heavier gage material as part of the structural
and environments. This wealth of experience provides design. This is a 50% increase in additional barrier coating and
unsurpassed “in-the-ground” knowledge of performance. adds additional base metal thickness that was not investigated
Several rational methods exist for determination of the in the original CALTRANS study. These two additional key factors
effects of corrosion upon galvanized steel and aluminum will provide a longer service life than predicted in these charts.
drainage structures. Numerous federal agencies, including
the Federal Highway Administration and U.S. Army Corps If the designer has site specific knowledge and understands
of Engineers as well as a large number of state departments the key design parameters, the AISI method may be more
of transportation, have published guidelines on the subject. applicable in the pipe service life design. Many state DOT’s
All have valuable information pertinent to possible corrosive find the CALTRANS method to be a conservative estimate of
effects on both steel and aluminum materials. the average observed service life of galvanized steel
structures in their states.

7
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Figure 1. CALTRANS Chart For Estimating Average Invert Life For Plain Galvanized Culverts

MINIMUM RESISTIVITY (R) ohm cm

0.280

5.51
1
0.249

4.91
3
0.218

4.31
5
0.188

3.71
7
0.168

3.4
8
0.138

2.8
10
0.109

2.2
12
0.079

1.6
14
0.064

1.3
16

Factors extrapolated
0.052

1.0
18
Thickness

Factor
Gage

AVERAGE INVERT LIFE–YEARS 18 GAGE GALVANIZED STEEL SHEET

8
 Typical Design Steps
Although a gravity flow drainage structure of any kind Aluminum Structural Plate
functions properly well beyond the occurrence of the
Studies similar to those conducted by CALTRANS have been
first perforation, the use of the CALTRANS method best
performed upon a large number of Aluminum Structural
illustrates the variety of environmental conditions found
Plate installations for the same purpose although none have
throughout the country.
produced a mathematical model like that for galvanized
steel. Aluminum loss rates have been so low as to preclude
An important factor when choosing a design method,
a reliable model.
either CALTRANS or AISI, is knowledge of the structure
backfill type. A structure backfilled with very fine Aluminum alloy reacts much differently than galvanized steel
material may be affected by the loss of this material when in contact with air, soil, and water. Instead of zinc/steel
through perforations. Thus, the CALTRANS method system of galvanic protection, aluminum resists corrosion
may be valid. If the required backfill is more granular, by a passive formation of a very tenacious aluminum-oxide
which is usually the case with plate structures, then first layer on its surface. This oxide layer has been shown in field
perforation is probably inconsequential and, therefore, and laboratory observation to be stable in an environment
the AISI method would be more appropriate. of pH between 4 and 9 and resistivity greater than 500
ohm-cm. Within this range, corrosion rates are minimal and
For added service life with steel structures, an optional prediction of service life is a matter of assigning a pit rate
polymer coating may be applied to the plates. Please based upon laboratory testing. Conservatively, a pit rate
refer to page 27 for specification information. based on 0.001”/yr may be used.

Hard or Soft Water Considerations In this case:

The designer should note that other factors will 0.100” thick plate 0.001”/yr = 100 yrs design life.
affect the rate of metal loss. The primary factor is
the presence of dissolved salts such as CaCO3 and Actual field observations of aluminum alloy pipe (ALCLAD)
MgCO3. Total hardness is a measure of the level of and Aluminum Structural Plate support this estimation.
dissolved salts and defined water runoff as hard or soft
In tidal brackish and saltwater environments, Aluminum
water.
Structural Plate will perform well if backfilled with free-
Hardness levels greater than 300 mg/L indicate draining material. The pH and resistivity requirements
dissolved salts (hard water) of a level that will cause outlined previously must also be met. Sea water normally
the formation of a mineral “scale” on the galvanized exhibits a pH range of 7.5 through 8.0 and resistivity that
surface that will provide excellent protection and is less than 100/ohm-cm, but given the neutral pH and
increased service life in the absence of abrasion. a free draining backfill, Aluminum Structural Plate still
Inspections have shown 50-year-old structures with performs well.
mineral scale and pristine metal conditions beneath.
For more detailed information on the subject of corrosion or
Hardness levels below 300 mg/L warrant further
copies of the referenced documents or guidelines, contact
consideration by the designer and the possible use of
your Contech representative.
coatings, invert protection/paving or aluminum.

In general, the recommended environmental range for

use of galvanized steel structural plate that will provide
a minimum service life of 50 years is a pH from 6
through 10, and a resistivity of 2,000 ohm-cm through
10,000 ohm-cm.*

* Values greater than 10,000 ohm-cm for water side

resistivity may indicate low level of dissolved salts (soft
water). Water hardness should be tested. Additional
protection may be required to meet the required design
service life.

At the time of inspection in 2012, this Steel Structural

Plate Single Radius Arch was 72-years-old.
Installed c. 1940 | Inspected in 2012

9
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Abrasion Considerations Aluminum may lose its oxide layer when abraded away but
it quickly reforms at low flows, therefore limiting corrosion.
The potential for metal loss in the invert of a drainage
Aluminum does not have a protective coating to lose after
structure due to abrasive flows is often overlooked by
years of abrasive flow.
designers, and its effects are often mistaken for corrosion.
Environments conducive to abrasive flows are well defined This is not meant to suggest that Aluminum Structural Plate
but due to the periodic nature of this event, it is easy to miss. should be used in heavily abrasive environments. However,
its performance can be expected to be superior to plain
Three factors must combine to cause invert abrasion:
galvanized steel.
l Abrasive bedload
FHWA Memorandum on Design Guidance and
l Sufficient velocity to carry the bedload
Specification Changes for Drainage
l Flow duration and frequency
Pipe Alternative Selection
Examples of abrasive materials include but are not limited
The durability and service life of a drainage pipe after
to sands, gravels, and stone. The designer should not
installation is directly related to the environmental
underestimate the abrasive action of sand transported in
conditions encountered at the site and the type of materials
sustained flows. When flow velocities reach approximately
5-6 feet-per-second, sand and gravels can become mobile and coatings from which the culvert was fabricated. Two
or suspended. principal causes of early failure in drainage pipe materials
are corrosion and abrasion. The environmental damage
Most commonly, abrasive bedloads remove protective caused by corrosion and abrasion can be delayed by the type
mineral scale and produce oxidation on galvanized steel of materials, coatings and invert protection.
which will accelerate corrosion. Upstream stilling basins
that allow abrasive particles to settle or drop out prior to It is the Federal Lands Highway (FLH) policy to specify
entering the structure can be very effective in extending the alternative drainage pipe materials on projects where feasible
service life. and to comply with the provisions of the Federal-Aid Policy
Guide Section 611.411(d). All permanent drainage pipe
Guidelines for abrasion levels are excerpted from the FHWA
installations shall be designed for a minimum of 50 years
Memorandum on Design Guidance and Specification
with a maintenance-free service life. A shorter service life may
Changes for Drainage Pipe Alternative Selection and are
be used for temporary installations, and a longer service life
shown on the next page.
may be considered in unusual situations.
Both of these factors, velocity and abrasiveness, may be
All suitable pipe materials, including reinforced concrete,
present at a particular site. However, if the flow necessary to
steel, aluminum and plastic pipe shall be considered as
carry the bedload occurs only a few times during the life of
alternatives on FLH projects. The portion of this pipe
the structure, abrasion may not be a concern. The designer
should refer to the 2- or 5-year event velocity and then use selection criteria covering metal pipe complies with the
this to decide if abrasion is a valid concern. guidance contained in Federal Highway Administration
(FHWA) Technical Advisory T 5040.12 dated October 22,
Should abrasion be determined to be a limiting factor in 1979, and incorporates information contained in FHWA-
structure life, several solutions are available to the designer. FLP-91-006, Durability of Special Coatings for Corrugated
These solutions include:
Steel Pipe.
l Use of a structure with a buried invert
l Use of an arch structure
l Concrete invert pavement (see page 12)
l Heavier gage invert plates
l Stilling basins near the invert

Aluminum performs better than galvanized steel when

subjected to abrasion. In some cases, the formation of the
oxidized steel layer (in hard water) is removed by abrasion,
exposing the galvanized coating beneath. After years of
abrasion have taken place, the protective galvanized coating
is abraded away and corrosion of the bare steel begins.
This corrosion/abrasion cycle continues for the life of the
Bay of Fundy | Robinston, ME
structure.
52-Year-Old Aluminum Structural Plate
Installed in 1966 | Inspected in 2018

10
 Typical Design Steps
Abrasion: An estimate of the potential for abrasion is Adjustments for Abrasion
required at each pipe location in order to determine the
Once the minimum structural gage is selected and the service
need for invert protection. Four levels of abrasion are
life requirement is compared to “The CALTRANS Chart for
referred to in the FHWA guidelines and the following
Estimating Average Invert Life” (on page 8) adjustments
guidelines are established for each level:
should be made based on the abrasion potential of the site.
• Level 1: Nonabrasive conditions exist in areas of no bed
Steel
load and very low velocities. This is the condition
assumed for the soil side of drainage pipes. At non-abrasive or low abrasive sites, no additional
• Level 2: Low abrasive conditions exist in areas of minor protection is needed. At sites that are moderately
bed loads of sand and velocities of 5 feet per second abrasive, increase the thickness of the material by one
(1.5 meters per second) or less. standard thickness or add invert protection like a concrete
• Level 3: Moderate abrasive conditions exist in areas of paved invert. At severely abrasive sites, increase the
moderate bed loads of sand and gravel and velocities thickness of the material by one standard thickness and
between 5 and 15 fps (1.5 m/s and 4.5 m/s). add a concrete paved invert.
• Level 4: Severe abrasive conditions exist in areas of Aluminum
heavy bed loads of sand, gravel, and rock and velocities
exceeding 15 fps (4.5 m/s). At non-abrasive, low abrasive or moderately abrasive
sites, no additional protection is needed. At severely
These definitions of abrasion levels are intended as abrasive sites, increase the thickness of the material by
guidance to help the designer consider the impacts of one standard thickness and add a concrete paved invert.
bedload wear on the invert of pipe materials. Sampling of
the streambed materials is not required, but visual Additional Service Life Considerations
examination and documentation of the size of the materials Dissimilar Metals
in the streambed and the average slope of the channel will
give the designer guidance on the expected level of Metals with a substantial difference in electrical potential
should be insulated from each other. Electrical potential
abrasion. Where existing culverts are in place in the same
may be established by referring to the electromotive scale.
drainage area, the existing conditions of inverts can be used
The only significant concern with regard to structural plate
as guidance. The expected stream velocity should be based
is the use of “black” steel in conjunction with aluminum.
upon a typical flow and not a 10- or 50-year design flood.
Black steel should not be in contact with aluminum. Hot
Corrosion: Alkalinity/Acidity (pH) and Resistivity— Dipped Galvanized steel is compatible with Aluminum
Determinations of pH and resistivity are required at each Structural Plate.
pipe location in order to specify pipe materials capable of
Concrete or Grout in Contact with Aluminum
providing a maintenance free service life. The samples shall
be taken in accordance with the procedures described in During the relatively short period while concrete cures,
AASHTO T 288 and T 289. Samples should be taken from minor etching (<0.001”) of the surface of the plate will
both the soil and water side environments to ensure that the occur. If the designer is concerned with cosmetic etching of
most severe environmental conditions are selected for the aluminum, the surface may be coated with asphalt or
determining the service life of the drainage pipe. Soil primer paint.
samples should be representative of backfill material De-icing Salts
anticipated at the drainage site. Avoid taking water
samples during flood flows or for two days following flood The potential for use of de-icing salts on roadway surfaces
flows to insure more typical readings. In locations where above structural plate must be addressed during the design
phase. Calcium chloride and magnesium chloride as well
streams are dry for much of the year, water samples may
as other de-icing materials can cause corrosion of
not be possible or necessary. In areas of known uniform pH
galvanized steel and aluminum.
and resistivity readings, a random sampling plan may be
developed to obtain the needed information. It is recommended that the designer consider the use of
either an asphalt coating on the exterior of the structure or a
In corrosive soil conditions where water side corrosion is
HDPE membrane over the structure. Details for each of these
not a factor, consider specifying less corrosive backfill
solutions are presented on the following pages.
material to modify the soil side environment. The advantages
of properly specified backfill should be taken into account
In addition, impermeable clay layers above the select backfill
in making alternative pipe materials selections in situations have been used to shed water from the crown of the structure.
where soil side conditions control.

11
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

HDPE Membrane Protection Detail for Structural Plate

12”

30 mil (minimum thickness) HDPE

membrane draped over structures & sloped
to drain water away from structure. The length
of the membrane should cover the top
of the structure.

HDPE Membrane Protection

Structural Plate Detail for Concrete Paved from De-Icing Salts
Invert

12
 Typical Design Steps
Structural Plate Design

MULTI-PLATE® and Aluminum Structural Plate

Determination of Metal Thickness Live Loads
According to the American Association of State Highway Live loads reaching the structure are more complicated to
and Transportation Officials (AASHTO) LRFD Design determine. AASHTO has prepared a very comprehensive
Specification, Section 12.2 for corrugated metal plate method for determination of the loads reaching the
structures “…become part of a composite system comprised corrugated metal structure.
of the metal pipe section and the soil envelope, both of
which contribute to the structural behavior of the system.” Live loads consist of traffic loads applied to the surface
or roadway above the structure. These loads also
Design methods for corrugated metal plate structures are
consider the effect of impact loads. Live loads reaching
well established and provide the designer with
the structure diminish with increasing heights of cover.
straightforward, conservative procedures. Current AASHTO
Overall, this manual considers HL-93 highway loads.
design procedures also address foundations, backfill, and
Other highway loads, such as HS-20 and HS-25, can be
end treatments. (See page 27 for listing of all applicable
addressed. Cooper (E-80) railroad loads are addressed in
design specifications.)
the Amercian Railroad Engineering and Maintenance-of-
The basic plate structural design process for the Way Association (AREMA) specification which is similar to
determination of the structure gage consists of: the procedure outlined. Airport loading and off-highway
loads such as mining equipment are special loading
1. Determine the backfill soil density adjacent to and
conditions. For additional design support, contact your
above the metal structure.
local Contech representative.
2. Calculate the design pressure applied by the soil
column and live load.
3. Compute the compressive thrust in the structure wall. AASHTO Design Load and Redundancy Factors
4. Determine the required thickness based upon checks The AASHTO design load factors that are required to
for wall yielding and buckling using the corrugated perform the calculation are summarized in the table
section properties. below.
5. Check for sufficient bolted longitudinal seam strength
between plates.
6. Check for minimum stiffness required for proper TABLE 1.
handling, assembly, and installation. AASHTO DESIGN LOAD AND REDUNDANCY FACTORS FOR MULTI-PLATE & ALSP
7. Apply appropriate LRFD factors.
Symbol Term Value AASHTO
Dead Loads Φw Wall Area and Buckling 1.00 (Table 12.5.5-1)

Dead loads are those developed by the soil fill above the ΦSS Seam Strength 0.67 (Table 12.5.5-1)
structure plus those of any stationary surcharge loads that ΦBP Backfill Bearing Resistance 1.00 (Table 12.5.5-1)
can influence the structure. Dead loads are calculated ηEV Redundancy Factor 1.05 (1.3.4, 12.5.4)
by multiplying the soil density by the height of cover and ηLL Redundancy Factor 1.00 (1.3.4, 12.5.4)
applicable load and redudancy factors. The unit weight of
ϒEV Dead Load Factor 1.95 (Table 3.4.1-2)
soil is assumed to be 120 pcf unless otherwise stated.
ϒLL Live Load Factor 1.75 (Table 3.4.1-1)

For additional information on the methodology for

developing these load pressures or AASHTO, AISI, and
AREMA tables, contact your local Contech representative.

13
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Structural Plate Design - Seam Strength

When the design analysis shows the seam strength of a structure is the limiting factor, which can occur when fill heights become
significant, the design engineer can increase the material thickness to add seam strength for a particular design.

TABLE 2. TABLE 3.
ULTIMATE SEAM STRENGTH ULTIMATE SEAM STRENGTH
OF BOLTED 6" X 2" STEEL STRUCTURAL PLATE LONGITUDINAL SEAMS OF BOLTED 15" X 5½" STEEL STRUCTURAL PLATE LONGITUDINAL SEAMS
IN POUNDS PER FT OF SEAM IN POUNDS PER FT OF SEAM
6” x 2” 15” x 5½”
Thickness Corrugation Thickness Corrugation
Gage Gage
(Inches) 4 Bolts Per 6 Bolts Per 8 Bolts Per (Inches) 30" long 45" long
Ft. Ft. Ft. plates plates
12 0.111 42,000 8 0.170 109,000 89,000
10 0.140 62,000 7 0.188 126,000 101,000
8 0.170 81,000 5 0.218 155,000 124,000
7 0.188 93,000 3 0.249 181,000 160,000
5 0.218 112,000 1 0.280 187,000 162,000
3 0.249 132,000 5/16 0.318 231,000 n/a
1 0.280 144,000 180,000 194,000 3/8 0.380 252,000 n/a
5/16 0.318 235,000 Notes:
3/8 0.380 285,000 1. Bolts used are 3/4” diameter – high strength bolts with suitable nuts,
meeting ASTM A449.
Notes:
2. Bolts and nuts also used for connecting arch plates to receiving angles
1. Bolts used are 3/4” diameter – high strength bolts with suitable nuts,
and structural reinforcement to structural plates.
meeting ASTM A449.
3. 5/16 and 3/8 require 7/8” fasteners.
2. Bolts and nuts also used for connecting arch plates to receiving angles
4. The values listed above are per ASTM A796.
and structural reinforcement to structural plates.
3. 5/16 and 3/8 require 7/8” fasteners.

TABLE 4.
ULTIMATE SEAM STRENGTH See page 29 for MULTI-PLATE standard detail.
OF BOLTED ALUMINUM STRUCTURAL PLATE LONGITUDINAL SEAMS See page 48 for ALSP standard plate detail.
IN POUNDS PER FT OF SEAM See page 89 for BridgeCor standard plate detail.
Thickness (Inches) Ultimate Seam Strength
0.100 28,000
0.125 41,000
0.150 54,100
0.175 63,700
0.200 73,400
0.225 83,200
0.250 93,100
Note: Bolts used are 3/4” diameter – high strength bolts with suitable nuts,
meeting ASTM A307/A449.

24’-0” diameter steel MULTI-PLATE® designed for 60 feet of fill

owned by VDOT in Dryden, Virginia

14
 Typical Design Steps
Section Properties

TABLE 5. TABLE 6.
STEEL CONDUITS ALUMINUM CONDUITS
6” x 2” Corrugations 9” x 2 1/2” Corrugations
Radius Radius
Area of of Section Moment Area of of Section Moment
Section Gyration Modulus of Inertia Section Gyration Modulus of Inertia
As r S I As r S I
Thickness Thickness
Gage (Inches) Sq. In./Ft. (Inches) In.3/In. In.4/In. (Inches) Sq. In./Ft. (Inches) In.3/In. In.4/In.
12 0.111 1.556 0.682 0.0574 0.0604 0.100 1.404 0.8438 0.767 0.0836
10 0.140 2.003 0.684 0.0733 0.0781
0.125 1.750 0.8444 0.951 0.1040
8 0.170 2.449 0.686 0.0888 0.0962
0.150 2.100 0.8449 1.131 0.1249
7 0.188 2.739 0.688 0.0989 0.1080
5 0.218 3.199 0.690 0.1147 0.1269 0.175 2.449 0.8454 1.309 0.1459

3 0.249 3.650 0.692 0.1302 0.1462 0.200 2.799 0.8460 1.484 0.1670
1 0.280 4.119 0.695 0.1458 0.1658
0.225 3.149 0.8468 1.657 0.1882
5/16 0.318 4.671 0.698 0.1640 0.1900
0.250 3.501 0.8473 1.828 0.2094
3/8 0.380 5.613 0.704 0.1950 0.2320

TABLE 7. TABLE 8.
MECHANICAL PROPERTIES FOR MECHANICAL PROPERTIES FOR
STEEL STRUCTURAL PLATE MATERIAL ALUMINUM STRUCTURAL PLATE MATERIAL
fu fy Em fu fy Em
Minimum Minimum Modulus Minimum Minimum Modulus
Tensile Strength Yield Point of Elasticity Thickness Tensile Strength Yield Point of Elasticity
(psi) (psi) (psi) (Inches) (psi) (psi) (psi)
45,000 33,000 29 x 106 0.100 to 0.175 35,000 24,000 10 x 106
Note: Material requirements based on AASHTO M 167 0.200 to 0.250 34,000 24,000 10 x 106
Note: Material requirements based on AASHTO M 219, Alloy 5052

BridgeCor® with Vist-A-Wall Welded Wire Wall System at

Peabody Coal Mine near Grants, New Mexico.

15
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Key-Hole Slot MULTI-PLATE® Structures

Under High Fill

MULTI-PLATE can be designed to handle high fill heights While specific design criteria must be applied to any
greater than 30' using Key-Hole Slot MULTI-PLATE. The slot project, the use of Key-Hole Slot MULTI-PLATE versus
provides self-indexing, controlled-yield bolted joints along a standard MULTI-PLATE can decrease the gage (material
Key-Hole Slote MULTI-PLATE structure's longitudinal seams. thickness) by one to three gages. A CALTRANS deep burial
These joints yield under compressive loads and thereby reduce study compared standard MULTI-PLATE to Key-Hole Slot
the circumference of the structure, so that much of the load is MULTI-PLATE and found that the average thrust created
carried by the soil instead of by the steel structure. at the springline level of the Key-Hole Slot structure was
approximately 50% of standard structure.
In effect, the Key-Hole Slot MULTI-PLATE becomes a yielding-
ring structure. The design allows the seams to slip under load This reduction in thrust in turn reduces the required seam
without any loss in ultimate seam strength. (See Figure 2). strength, and therefore, the structure wall gage or thickness.
Top Plate The designer is urged to contact a Contech representative
for additional information on Key–Hole Slot MULTI-PLATE.
Top Plate
Bottom Plate

Bottom Plate

Top Plate Top Plate

Top Plate Top Plate

¾” Bolt ¾” Bolt
Load

Load

¾” Bolt ¾” Bolt
Load

Bottom Plate Bottom Plate

Load

Bottom Plate Bottom Plate

Lapped Joint - No Load Lapped Joint - Fully Slipped

Inside View (1" Into Slots)
Inside View Along the Eastern Transportation Corridor in Orange County,
Figure 2. Key-Hole Slot MULTI-PLATE® at work California, this Key-Hole Slot MULTI-PLATE® structure was designed
for the 115 ft. of cover.

Soil Arching

The compressive loads reach a level which varies by gage,

causing the 3/4-inch bolt shank to wedge into the 5/8-inch slot.
This controlled yielding action in the structure seams decreases
the structure circumference, promoting a high degree of soil
arching over the structure. For these deep cover applications,
A-1-a backfill per AASHTO M 145 is required as backfill for
these types of flexible structures.

16
 Typical Design Steps
Aluminum Box Culvert Design

The structural design of an Aluminum Box Culvert (ALBC)

does not follow the processes previously discussed in
this guide. Due to the shape of the box culvert, the “ring
compression” method used to quantify design pressures does
not apply. The relatively large radius crowns are subject to
high moment forces. Therefore, a separate method is used
to ensure that the Aluminum Box Culvert can support both
the earth loads and the live loads applied to these structures
under relatively shallow fills. Primarily, the design procedure Alumnium Box Culvert installation
quantifies the capacity of the corrugated aluminum shell and
reinforcing ribs to resist bending moments.

MpC

(Mp)
MpH
(Mp)

Due to the indeterminate nature of the structural elements,

finite element analysis was developed to evaluate the
plastic moment capacity of the structure. The design
requirements for Aluminum Box Culverts are contained in
the AASHTO Highway Bridge Design Manual Section 12.8.

Contech Engineered Solutions has also generated height

of cover tables that meet the requirements of AASHTO for
HL-93, HS-20, and HS-25 live loads that supply the plate
gages and reinforcing ribs necessary for a given height of
cover. These values are contained in the Aluminum Box Aluminum Box Culvert multi-cell installation
Culvert section of this manual. Note that the allowable
range of minimum and maximum cover heights is limited
for aluminum box culverts. Additionally, live load is restricted
to standard highway vehicles. Heavy construction loads
and other heavy live load traffic are not permitted
over these structures without special provisions.

17
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

SUPER-SPAN™ and SUPER-PLATE® Design l Gage of the top plates and minimum cover are
determined by the top radius (see Table 9)
Design of SUPER-SPAN and SUPER-PLATE (Long Span)
l Maximum central angle of top is 80 degrees
structures follow AASHTO Section 12.7.
l Ratio of top radius to side radius is equal to or greater
SUPER-SPAN and SUPER-PLATE feature relatively large radius than 2.0 and less than or equal to 4.4
or flatter curvature in the top or sides (larger than standard
structural plate designs). These shapes include:

Low Profile Arch

High Profile Arch

Thrust Beam

Horizontal Ellipse

SUPER-SPAN structure near Cumming, Georgia

Gage or thickness for SUPER-SPAN is a function of the

structure's top radius and the live and dead loads. Table 9
Pear Shape Pear Arch below provides the recommended gages and minimum covers
for SUPER-SPAN. The designer should also note that Contech
Engineered Solutions provides a Shape Control Technician as
a condition of the sale of a SUPER-SPAN or SUPER-PLATE. The
Shape Control Technician will be on-site until the select backfill
reaches the minimum height of cover required to ensure proper
finished structure shape.
The primary differences in long span design procedures
and standard plate structures design procedures are: Aluminum SUPER-PLATE long spans are available in most of
l Design checks for buckling and flexibility are not applied the same sizes and shapes as steel SUPER-SPAN.
because of special features not found in other Structural Further information is available in the SUPER-SPAN and
Plate structures and also because of the use of high quality SUPER-PLATE section of this design guide and technical
backfill and shape monitoring during backfill. guidelines contained in this brochure.
l Special features such as longitudinal thrust beams are

incorporated to assist in the ability of the structure to

transfer load to the surrounding soil envelope. Thrust
beams also work to isolate the top arc, diminishing the
need for a buckling analysis.

TABLE 9.
MINIMUM THICKNESS — MININUM COVER TABLE (HL-93, H-20, HS-20, H-25, HS-25 LIVE LOAD)
Wall Thickness (Inches)
Top Radius 0.111 0.140 0.170 or 0.188 0.218 0.249 0.280
RT Ft. (12 Ga.) (10 Ga.) (8 or 7 Ga.) (5 Ga.) (3 Ga.) (1 Ga.)
15’ 2.5’ 2.5’ 2.5’ 2.0’ 2.0’ 2.0’
15’-17’ 3.0’ 3.0’ 2.5’ 2.0’ 2.0’
17’-20’ 3.0’ 2.5’ 2.5’ 2.5’
20’-23’ 3.0’ 3.0’ 3.0’
23’-25’ 4.0’ 4.0’
For additional information regarding this table, refer to notes on page 81. Contact a Contech representative for Pear and Pear-Arch shapes.

18
 Typical Design Steps
BridgeCor® Design Minimum Cover Over Plate Structures
The design procedure for BridgeCor is outlined in AASHTO Establishing minimum cover over plate structure is one
LRFD Section 12.8.9 - Deep Corrugated Structural Plate of the most important factors in ensuring the successful
Structures. These structures are designed as long-span culverts installation of soil-corrugated metal interaction structures.
but must also meet provisions for flexure and general buckling. Properly compacted soil around and over the structure
BridgeCor structures can be made in multiple shapes and sizes plays an important part in distributing the load that reaches
to meet site specific project requirements. the structure. Without minimum cover, loads applied by
vehicles can result in unacceptable structure deformation.
Structures designed under this specification must be analyzed by
Contech Engineered Solutions publishes suggested
accepted finite element analysis. This analysis must consider the
minimum height of cover tables in each following section.
type of soils and loads applied to the system to determine the
When highway type loads are expected, minimum height
thrust, bending and stiffness parameters of the structural plate.
of cover over steel or aluminum structural plate (excluding
SUPER-SPAN or Aluminum Box Culvert structures) amounts
These shapes include:
to one eighth of the span or diameter of the structure with
a minimum of 12” in all cases. In some cases, a reinforced
concrete load-relieving slab may be used when minimum
cover is not achievable.

With the combination of a plate and rib, minimum cover

over Aluminum Box Culverts is often lower than for
ROUND
ROUND SINGLERADIUS
SINGLE RADIUS ARCH
ARCH TWOTWO
standard RADIUS
RADIUS
plate ARCHARCH The required minimum
structures. BOX CULVERT
BOX CULVERT
and
ROUND SINGLE RADIUS ARCH TWO RADIUS ARCH BOX CULVERT
maximum cover are limited to the values indicated in
Tables 48A, 48B, 49A and 49B. They are based on the live
load classification and assuming the proper reinforcing rib
and plate gage combinations shown in the height of cover
tables for Aluminum Box Culverts.
S ARCH TWOARCH
TWO RADIUS RADIUS ARCH BOX CULVERT
BOX CULVERT
Minimum cover over SUPER-SPAN structures is dependent
Custom shapes are available upon request. upon the top radius of the structure. Minimum cover may
To properly analyze these parameters using finite element be determined from Table 9 on the previous page.
analysis it is important to have a geotechnical report for each
Minimum cover is measured from the top of the
specific bridge location. This information will allow the designer
structure to the bottom of a flexible pavement
to optimize both the gage of the steel and the limits of the
and to the top of a rigid pavement. Particular
structural backfill adjacent to the BridgeCor structure.
attention should be given to the height of cover near
roadway shoulders as they slope away from the road
This design procedure is more comprehensive than a typical
crown. Minimum cover heights must be maintained
ring compression design for MULTI-PLATE structures. Therefore,
throughout the life of the structure. Gravel (unpaved)
it will require additional effort to properly evaluate a BridgeCor
roads can be mistakenly graded below the minimum cover
solution for any application. This additional planning is critical
height resulting in unacceptable loading conditions. It is
to a successful project.
recommended that unpaved roads incorporate at
least 6” more than the minimum allowable cover
BridgeCor Monitoring depth to allow for rutting.

It should be understood that often the greatest live load

Due to the potential large sizes of BridgeCor structures and
applied to the structure may be the load applied by
the information outlined in AASHTO Specification Section 26
construction equipment. Refer to page 20 for additional
– Metal Culverts, it is a requirement to monitor the shape of
information and guidance regarding required minimum
the structure during the backfill process. Depending on the size
cover for construction equipment and other heavy vehicle
and complexity of a structure, guidelines have been established
loads. Off-highway live loads such as mine haul trucks
to determine what level of monitoring will be required on
should be evaluated carefully. Contech can assist the
all projects. There are four levels of monitoring outlined for
designer with establishing minimum cover for this type of
BridgeCor. These levels range from a preconstruction meeting
loading condition.
with a contractor to a full monitoring program similar to the
process outlined for a SUPER-SPAN structure. Contact your local
Contech representative for additional information.

19
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Minimum Cover for Heavy Off-Road Construction As a general guideline, an adequate amount of minimum
Equipment cover can be achieved by providing approximately twice
the depth of fill material required for highway traffic. This
Operating heavy construction equipment over or adjacent
temporary cover is to consist of a quality fill such as an A-1,
to flexible structure installations will likely require additional
A-2-4, A-2-5, or A-3 material per AASHTO M 145 and is
protection for the structure compared to that provided by the
to be placed in a controlled and balanced manner over the
required minimum cover heights for normal highway traffic.
pipe structure and compacted to a minimum 90% density per
Therefore, for temporary construction vehicle loads, additional
AASHTO T-180.
compacted cover may be required over the top of the pipe
structure to help balance loads and dissipate the effects
The cover depth required for protection from
of these larger live loads. The contractor is responsible for
construction equipment loads is measured from the
providing adequate minimum cover to avoid damage
crown of the structure to the top of the maintained
and/or distortion to the metal structure.
construction roadway surface. Additionally, the roadway
surface for the construction loading and vehicular traffic
The actual minimum cover heights required for heavier
conditions shall be well-maintained and free of ruts for the
construction vehicle live loads will vary based on the
duration of the temporary vehicle crossings. Contact your local
anticipated construction equipment (size, weight and axle
Contech representative for additional information.
loads). Other factors influencing the minimum cover height
requirements are structure size, shape and gage combined
Aluminum Box Culverts
with local site conditions. These factors need to be addressed
by the engineer and/or contractor prior to the start of The addition of temporary soil cover for heavy construction
construction. loads is not feasible or permissible for Aluminum Box Culvert
structures. By design, these structures are limited in the range
of permissible fill heights and live loads. Contact your local
Contech representative with questions about permissible
live loads and allowable soil cover heights (minimum and
maximum) for Aluminum Box Culverts.

Temporary Cover For

Construction Loads

Finished
Grade
Height of Cover

Notes:
1. The contractor is responsible for providing adequate minimum
cover to avoid damage and/or distortion to the metal
structure.

2. Minimum cover will vary based on local site conditions.

Requirements shall be based on the structure shape and size,
material gage and anticipated construction equipment (size,
weight, and axle loads).

3. Temporary protection from construction equipment loads is

measured from the crown of the structure to the top of the
maintained construction roadway surface.

Multi-Barrel Installation

20
 Typical Design Steps
Structure End Treatments
Once the designer has selected a structure, it is important Step-Beveled Ends
to design for the proper structure end treatment.
Hydraulic efficiency, protection of the structure backfill and Step-beveled end
foundation materials, and structure alignment may dictate
the usage of modified structure ends (bevels and skews), 1.5 : 1 or 2 : 1
headwalls, or cut-off walls. For any metal structure end
treatment, a headwall and/or toe-wall may be necessary to
prevent inlet flotation.

When structures with full inverts are used, the designer Elevation View
should always consider a concrete or metal toewall to
anchor the leading edge of the invert, thus minimizing the Step-beveled ends minimize the number of cut or incomplete
possibility of hydraulic uplift forces lifting the invert of the plate rings while still providing a sloped end. This option
structure. The range of possible end treatments include but stiffens the invert and crown of the structure minimizing the
are not limited to: overall structure deflection during the backfill process. For
this reason, step-beveled ends are more desirable over fully
Projecting Square End Structures beveled ends.
Projecting square end Recommended step-bevel dimensions are:
o
90 • Round
Top step = Bottom step
(minimum of 6" to 0.25 x structure diameter per step)

Elevation View
• Pipe-Arch and Underpass

Projecting square end structures are generally the most cost- The top step should be a minimum of 6” to 0.25 x
effective end treatment option. The square end must project structure rise and the bottom step dimensions should be at
from sloping side fill enough to allow the invert to meet the the transition of the haunch and top radii.
toe of the slope. All structures can be supplied with projecting
• Horizontal and Vertical Ellipses
square ends.
Top step = Bottom step
Full-Beveled Ends (minimum of 6” to 0.25 x structure rise per step)
The steps should be at the transition of the sides and top
Full-beveled
and/or bottom radii.
(structure cut at an angle relative to horizontal plane)
• Arches

1.5 : 1 or 2 : 1 The top step of 0.25 x rise and the bottom step (minimum
of 6”) are recommended for arch structures.
• Aluminum Box Culverts
Step-beveled and full-beveled ends are not utilized.
Elevation View

Full-beveled ends are used to match the side slope of an

embankment with no exposed protruding metal, to improve
the overall structure aesthetics. In addition, full bevels can
provide an improved hydraulic entrance efficiency when
compared to square-ended structures.
All beveled cuts should be limited to a range of 1.5:1 to
2:1 slopes. A beveled section is comprised of incomplete
rings of plates acting as a thin metal retaining wall system.
Therefore, beveled ends must be side supported during
backfill process and may require a reinforced concrete
slope collar to help stabilize the beveled end of the structure
from erosion and excessive deflection.
MULTI-PLATE® with Step-Beveled End and Concrete Collar
Full-beveled ends are not recommended for pipe-arch and
underpass shapes. 21
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

Skewed Ends Cast-in-place (C.I.P.)

Skewed ends allow the designer to match the skew of the

structure to the roadway alignment. As with beveled ends,
skewed ends are less stable because of incomplete plate
rings. Unbalanced soil loads on the structure ends can cause
unwanted deflection of the extended end of the structure.
A reinforced concrete headwall or collar must be
designed for all skew angles. More commonly, the
structure end will be skewed in combination with a beveled C.I.P. concrete headwalls or collars are recommended for
end (skewed to the roadway and beveled to match the the following:
side slope.) Consult your Contech representative for exact
• Improved hydraulic efficiency
dimensions and a specific plate layout.
• Potential sustained high flows
The engineer/designer is encouraged to consider “warping” • Skewed ends on structures
the side slope fill to balance soil loads on each side of the
structure (see drawing on page 26). By installing a concrete headwall/collar, the structure
becomes more stable and minimizes excessive movement.

C.I.P. concrete headwalls are secured to the plate structure

by the use of anchor bolts placed circumferentially at the
end of the structure. Anchor bolts may either be straight
3/4” diameter or “hook” bolts. The circumferential spacing
and the choice of bolt type is the responsbility of the
designer of headwall. Typical headwall details are shown on
the following pages. CAD details are available on request
from a Contech representative.

C.I.P. Concrete slope collars placed around a beveled end

structure guard against deflection of end plates, provide
erosion erosion, minimize backfill loss, and provide an
aesthetic end treatment. They are anchored to the structure
by the use of anchor bolts as with concrete headwalls.
BridgeCor Arch with Full-Beveled Ends and Slope Collar

22
 Typical Design Steps
C.I.P. Concrete Cut-off or Toewalls should be considered on
every hydraulic structure with an invert. Undercutting on the
inlet end can lead to loss of backfill, piping of water around
the exterior of the structure, and undesirable uplift forces
that can damage the structure. It is the responsibility of the
engineer to determine the appropriate depth of the toewall
to protect the invert bedding. Slope protection is also advised
to preclude water entering the structure backfill.

Aluminum Box Culverts with full inverts are provided with a

bolt-on 27” deep aluminum toewall plate. The designer must
determine the proper depth of the toewall for the structure's
invert protection.

Protection from Hydraulic Forces BridgeCor with Bolt-A-Plate® Metal Wall End Treatments

Contech Engineered Solutions advises the designer to take Metal Wall End Treatments
all necessary precautions to protect the ends of corrugated
Aluminum Structural Plate and Aluminum Box Culverts can
metal hydraulic structures. Damage to the structure ends may
be supplied with a pre-designed corrugated aluminum
result from inlet blockage. The designer is also advised that
headwall and wingwall system. The typical application for
whenever heavy debris flow is expected, the use of a large
metal headwalls is for projecting square ended (non-skew
single span structure is recommended over smaller, multiple
cut) structures. See the Aluminum Box Culvert section starting
structures.
on page 62 for details.
Appropriate end treatment design is beyond the scope of this
Alternative steel headwalls and wingwalls (e.g. Metric
design guide. Additional information can be obtained from
Sheeting or 6x2 Bolt-A-Plate®) can be considered on
the local DOT guidelines, the FHWA Circular Memo, “Plans
a project-by-project basis. Contact your local Contech
for Culvert Inlet and Outlet Structures” and chapters within the
representative.
NCSPA Corrugated Steel Pipe (CSP) Design Manual.
Vist-A-Wall MSE Structural Wall System® and Wire Walls
Modular Block Headwalls
The Vist-A-Wall MSE Structural Wall System®, inclusive of
Modular Block Headwalls can be utilized to provide an
both Welded Wire Walls and MSE Precast Panel Walls, is an
aesthetically pleasing end treatment. If the structure is
ideal end treatment solution for Contech Structural Plate.
expected to be subjected to hydraulic forces, special
The Vist-A-Wall Welded Wire Wall System utilizes black or
consideration must be given to the possible loss of backfill
galvanized wire facing baskets in conjunction with steel
through the block wall face and at the junction of the blocks
reinforcement for use in permanent and temporary wall
with the structure. Geotextile fabrics placed in critical areas
applications. The combination of a flexible Vist-A-Wall Wire
can minimize the loss of fill.
Wall System adjacent to a flexible Structural Plate optimizes
The designer should also consider other factors such as but the design and construction where differential settlement
not limited to: may be anticipated. The Vist-A-Wall MSE Precast Panel
Wall System is optimal for highway infrastructure projects
• Scouring forces acting on the footing of the wall. where complex end treatment geometries and/or panel
• Rapid draw-down forces that can occur if the backfill wall aesthetics are a requirement for design. For more
becomes saturated. information on the Vist-A-Wall MSE Structural Wall System,
• Settlement of the structure relative to the wall. Settlement visit [Link].
joints may be necessary.

Please refer to the details on the next page and contact your
Contech representative for more details on modular block
headwall information.

BridgeCor, SUPER-SPAN and SUPER-PLATE

End Treatments

Any of the previously mentioned headwall options can be used

with these structures. BridgeCor with Vist-A-Wall Welded Wire Wall System in Harper, TX.

23
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

GRANULAR
BACKFILL MATERIAL

MODULAR BLOCK
HEADWALLS
12" MIN.

VARIES
10"

5"X3 1/2"X1/2" ANGLE

GEOTEXTILE ATTACHED 3/4" BOLT - 16" O.C.

W/ CONSTRUCTION ADHESIVE
LOW SHRINK PORTLAND CEMENT
GROUT 1800 PSI MIN. COMPRESSIVE
STRENGTH TO FILL AREA SHOWN.
RECOMMENDED
INSIDE OF STRUCTURAL PLATE
MODULAR BLOCK HEADWALL DETAILS

ENGINEERED SOLUTIONS

24
 Typical Design Steps
Step dimension varies with shape
and diameter. See page 21 for
additional details.

ENGINEERED SOLUTIONS

25
 Steel and Aluminum
Structural Plate
Design Guide
Typical Design Steps

across the barrel of an improper design.

ENGINEERED SOLUTIONS

26
 Typical Design Steps
Material, Design & Installation Specifications
The following is an outline of applicable AASHTO and ASTM specifications. Additional specifications are
available from the American Railroad Engineers and Maintenance of Way Association (AREMA), Manual for
Railway Engineering for railroad projects. For additional assembly and installation guidelines, refer to the
National Corrugated Steel Pipe Association (NCSPA). The Contech Structural Plate Design Guide is based on the
general requirements of AASHTO LRFD Design Specification.

TABLE 10. MATERIAL, DESIGN & INSTALLATION SPECIFICATIONS

DESCRIPTION AASHTO ASTM
MULTI-PLATE®
Material M 167 – Standard Specification for Corrugated Steel Structural Plate A761
Installation Refer to AASHTO LRFD Bridge Construction Specifications (Sec. 26) A807

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 26)

Design Refer to AASHTO LRFD Bridge Design Specifications (Sec. 12) A796

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12)

Optional Polymer Coating* N/A A1113
Aluminum Structural Plate
Material M 219 – Standard Specification for Corrugated Aluminum Structural Plate B746
Installation Refer to AASHTO LRFD Bridge Construction Specifications (Sec. 26) B789

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 26)

Design Refer to AASHTO LRFD Bridge Design Specifications (Sec. 12) B790

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12.6)

Aluminum Box Culverts
Material M 219 – Standard Specification for Corrugated Aluminum Structural Plate B864
Installation Refer to AASHTO LRFD Bridge Construction Specifications (Sec. 26) N/A

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12.8)

Design Refer to AASHTO LRFD Bridge Design Specifications (Sec. 12) N/A

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12.8)

SUPER-SPAN™
Material M 167 – Standard Specification for Corrugated Steel Structural Plate A761
Installation Refer to AASHTO LRFD Bridge Construction Specifications (Sec. 26) A807

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12 and Sec. 26)
Design Refer to AASHTO LRFD Bridge Design Specifications (Sec. 12) N/A

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12.7)

Optional Polymer Coating* N/A A1113
SUPER-PLATE®
Material M 219 – Standard Specification for Corrugated Aluminum Structural Plate A761
Installation Refer to AASHTO LRFD Bridge Construction Specifications (Sec. 26) B789

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12 and Sec. 26)
Design Refer to AASHTO LRFD Bridge Design Specifications (Sec. 12) N/A

Refer to AASHTO Standard Specifications for Highway Bridges (Sec. 12.7)

BridgeCor®
Material M 167 – Standard Specification for Corrugated Steel Structural Plate A761
Installation Refer to AASHTO LRFD Bridge Construction Specifications (Sec. 26) A807
Design Refer to AASHTO LRFD Bridge Design Specifications (Sec. 12.8.9) N/A
Optional Polymer Coating* N/A A1113
Complete copies of these specifications are available from AASHTO & ASTM.
Excerpts of these specifications are available from Contech Engineered Solutions LLC.
* For polymer-coated plates, the galvanized fasteners will be specially treated with an applicable polymer or aluminum coating.

27
 Steel and Aluminum
Structural Plate
Design Guide

MULTI-PLATE®
Made to Perform, Built to Last. A More Efficient Installation

Since 1931, Contech MULTI-PLATE structures have provided Prefabricated plates are assembled in the field, translating
designers of underpasses and bridges with a versatile into finished construction in days instead of weeks as with
method of construction as well as strength, durability, and most concrete structures.
economy. A variety of shapes and sizes ensures that MULTI- Versatility
PLATE structures fit most applications. Ease of design,
construction, and proven reliability make them the frequent MULTI-PLATE structures offer a wide variety of shape and size
choice of experienced engineers. options, which may provide the most cost effective solution to
the site requirements.
MULTI-PLATE structures are made from sturdy, heavy gage,
corrugated steel plates that are pre-formed to various Descriptions of Plates
MULTI-PLATE®

shapes and sizes, then galvanized for long-term protection MULTI-PLATE corrugations of 6-inch pitch and 2-inch depth
and performance. The plates are delivered to the job site are perpendicular to the length of each plate.
and bolted together to form a MULTI-PLATE structure Thickness. Standard specified thickness of the galvanized
optimally suited for the project. plates vary from 0.111 inches (12 gage) to 0.380 inches
MULTI-PLATE is available in round, vertical ellipse, (3/8").
underpass, pipe-arch, horizontal ellipse, and single radius Widths. Standard plates are fabricated in five widths. See
arch shapes — all in a wide range of sizes. Table 11.
Superior Durability The ”Pi” nomenclature (Pi = 3.2) translates circumference
MULTI-PLATE’s heavy gage steel uses an industry standard directly into nominal diameter in inches. For example, four
3 oz. per square foot galvanized coating (both sides) 15-Pi plates give a diameter of 60 inches (60-Pi); four
capable of providing a service life of 75 years or longer. For 21-Pi plates provide a diameter of 84 inches (84-Pi), etc.
additional information, see page 7. Various plate widths may be combined to obtain almost
any diameter.
When selecting the proper material for an application,
designers need to evaluate the soil side of the structure Lengths. MULTI-PLATE plates are furnished in either 10-foot
along with the corrosive and abrasive action due to the flow or 12-foot net lengths. Overall length of the square-end
at the invert of the structure. The use of structural plate gives structure is about four inches longer than its net length
designers more structure shape options to help minimize the because a 2-inch lip protrudes beyond each end of every
impact of abrasion on the invert of the structure. plate for lapping purposes.

High Load-Carrying Capacity Longitudinal bolt holes. The plates are punched with 7/8"
diameter holes on 3" centers to provide the standard four
As a soil-structure interaction system, MULTI-PLATE is bolts per foot of longitudinal seam in two staggered rows on
designed to carry high combined live and dead loads. 2" centers. They may also be punched to provide either six
High traffic loads and deep cover applications are key or eight bolts per foot of longitudinal seam on 0.280 inch
benefits of specifying MULTI-PLATE. (1 gage) thickness material, if required. 1" diameter holes,
punched 8 bolts per foot of longitudinal seam are used for
0.318 (5/16") and 0.380 (3/8") thick material.
Circumferential bolt holes. The inside crests of the end
corrugations are punched with 1" diameter holes for
circumferential seams on centers of 9.6 inches or 9 19/32
inches (equals 3-Pi).

Round Vertical Ellipse Underpass Pipe-Arch Horizontal Ellipse Single Radius Arch

Standard Shapes

28
 Standard Plate Detail

3 3/8" TABLE 11. DETAILS OF UNCURVED MULTI-PLATE® SECTIONS

3" Spacing 2" 2 3/8"
Net Width Overall Spaces Number of
(Inches) Width (9.6 Circumferential
1 3/8" Nominal Detail (Inches) Inches) Bolt Holes
Circumferential Seam

Overall Width
Holes in Inside Crest 9 Pi 28.8 28 13/16 33 9/16 3 4
9.6" Spacing

All Longitudinal Holes 7/8" Dia. 15 Pi 48.0 48 52 3/4 5 6

Net Width
All Circumferential Holes 1"
18 Pi 57.6 57 5/8 62 3/8 6 7
21 Pi 67.2 67 3/16 71 15/16 7 8
3 3/8" 24 Pi 76.8 76 13/16 81 9/16 8 9

2 3/8"
Longitudinal Seam Holes in
Alternate Crest and Valley For MULTI-PLATE, Pi = 3.2

2" ± 2" *

MULTI-PLATE®
1 3/8" Net Length = 10'-0" or 12'-0"
Overall Length = 10'-4" or 12'-4"
Inside Surface Flow

Notes:
1. For square-end structures on which headwalls are to be built, design
should allow for a 2" lip at each end of the structure.
2. A 4-bolt per foot pattern is detailed above.

Standard 6” x 2” Corrugation

TABLE 12. APPROXIMATE WEIGHT OF MULTI-PLATE SECTIONS

Gage Thickness, T (Inches)
Net Length Galvanized, in Pounds, without Fasteners
Pi
(Feet) 12 10 8 7 5 3 1 5/16 3/8
(0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
9 10 161 205 250 272 316 361 405 460 545
9 12 193 246 299 325 379 432 485 551 653
15 10 253 323 393 428 498 568 638 725 859
15 12 303 386 470 511 595 678 762 865 1026
18 10 299 382 465 506 589 671 754 856 1015
18 12 357 456 555 604 703 801 900 1022 1212
21 10 345 441 536 583 679 774 869 987 1170
21 12 412 526 640 697 810 924 1038 1179 1398
24 10 396 504 613 667 775 886 995 N/A N/A
24 12 473 603 732 797 927 1060 1190 N/A N/A
Notes:
1. Weights are based on a zinc coating of 3 oz./sq. ft., total both surfaces.
2. All weights are subject to manufacturing tolerances.
3. Specified thickness is a nominal galvanized thickness. Reference AASHTO M 167.
4. Gages 12 through 1 use 3/4" diameter bolts. 5/16 and 3/8 use 7/8" diameter bolts.


Long Leg of Channel
to the Outside of Arch



Unbalanced Channel for MULTI-PLATE® Arch

Unbalanced Channel Cross Section 29

 Steel and Aluminum
Structural Plate
Design Guide

MULTI-PLATE® Bolts and Nuts

A
3/4”or 7/8" diameter hot-dipped galvanized steel (specially
heat-treated) bolts meeting ASTM A449 specifications (with suitable
nuts) are used to assemble structural plate structures. D
B

The underside of the bolt head is uniformly rounded and ribbed to

1” Radius
prevent bolt head rotation while tightening. Unlike conventional Rib C

bolts, once the nut is finger tight, final tightening can typically be

Length
accomplished by one worker with an air driven impact wrench to 1” Radius

100 – 300 ft.-lbs. of torque. Bolt Diameter

In addition, one side of the nut is spherically formed to help align

MULTI-PLATE®

and center the fastener into the punched holes. The rounded side
shall be placed against the structure.

TABLE 13. BOLT LENGTH AND USAGE TABLE 14. TYPICAL BOLT AND NUT
Plate Gages Bolt Lengths Bolt Diameter Diameter A B C
(Inches) (Inches) (Inches) (Inches)
12, 10 and 8 1¼” and 1½” ¾”
¾ 1¼ 9
/16 13
/16
7 and 5 1½” and 1¾” ¾”
7
/8 17/16 ¾ 7
/8
3 and 1 1½” and 2” ¾”
5/16 and 3/8 2” and 2½” /8”
7

Notes: Flow
1. The longer bolts are used in 3 plate lap seams. Structural Plate
2. For asphalt coated plates, bolts are ¼” longer. Inside Surface Bolt & Nut
3. Service bolts (3" long) are provided to assist with assembly.

Outside (Soil Side)

Proper Shingle at Invert Surface
MULTI-PLATE® Round
TABLE 15. MULTI-PLATE ROUND PIPE
Diameter End Area Diameter End Area Structural Plate
(Sq. Ft.) (Sq. Ft.) Bolt & Nut
(Ft.-In.) (Inches) (Ft.-In.) (Inches) Outside Surface
(Soil Side)

5-0 60 19.1 16-0 192 204.4

5-6 66 23.2 16-6 198 217.5
6-0 72 27.8 17-0 204 231.0
6-6 78 32.7 17-6 210 244.9
7-0 84 38.1 18-0 216 259.2 Flow Inside Surface

7-6 90 43.9 18-6 222 274.0 Optional Shingle

Optional Shingle atat
thethe Crown
Crown

8-0 96 50.0 19-0 228 289.1 Note: The nut may be placed on either side of the plate.

8-6 102 56.6 19-6 234 304.7 Note:The nut may be placed on either side of the plate.
9-0 108 63.6 20-0 240 320.6
9-6 114 71.0 20-6 246 337.0
10-0 120 78.8 21-0 252 353.8
10-6 126 87.1 21-6 258 371.0
11-0 132 95.7 22-0 264 388.6
11-6 138 104.7 22-6 270 406.6
12-0 144 114.2 23-0 276 425.0
12-6 150 124.0 23-6 282 443.8
13-0 156 134.3 24-0 288 463.0
13-6 162 144.9 24-6 294 482.6
14-0 168 156.0 25-0 300 502.7
14-6 174 167.5 25-6 306 523.1
15-0 180 179.4 26-0 312 543.9
15-6 186 191.7
Round and 5% Vertical Ellipse Pipe

30
 ROUND

TABLE 16. MULTI-PLATE ROUND PIPE

WEIGHT TABLES
Gage Thickness (Inches) Plate Make-Up
Weight Shown as Pounds per Foot of Structure (see Note 6)
Diameter 12 10 8 7 5 3 1 5/16 3/8 Pi Total
(Ft.-In.) (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380) 15 18 21 24 Plates
5-0 110 138 166 180 208 236 264 310 376 4 4
5-6 119 150 180 196 227 257 287 336 407 2 2 4
6-0 129 162 195 212 245 277 310 362 439 4 4
6-6 138 174 209 227 263 298 333 387 471 2 2 4
7-0 147 185 223 243 281 318 356 413 502 4 4
7-6 157 198 239 260 300 341 382 465 563 2 2 4
8-0 168 211 254 276 320 364 407 491 595 4 4

MULTI-PLATE®
8-6 184 231 278 302 349 395 442 516 627 2 4 6
9-0 193 242 292 317 367 416 465 542 659 6 6
9-6 202 254 306 333 385 436 488 568 690 4 2 6
10-0 212 266 321 349 403 457 512 594 722 2 4 6
10-6 221 278 335 364 421 478 535 619 754 6 6
11-0 231 291 350 381 440 500 560 671 815 4 2 6
11-6 241 304 366 398 460 523 585 697 847 2 4 6
12-0 251 316 381 415 479 546 611 723 878 6 6
12-6 267 335 404 439 507 575 644 749 910 6 2 8
13-0 276 347 418 454 525 596 667 774 942 4 4 8
13-6 285 359 432 470 543 616 690 800 973 2 6 8
14-0 295 371 447 485 561 637 713 826 1005 8 8
14-6 305 384 462 502 581 660 738 878 1066 6 2 8
15-0 315 396 478 519 600 682 764 904 1098 4 4 8
15-6 325 409 493 536 620 705 789 929 1130 2 6 8
16-0 422 508 553 639 728 814 955 1161 8 8
16-6 440 530 576 666 755 845 981 1193 4 6 10
17-0 452 544 591 684 776 868 1006 1224 2 8 10
17-6 464 559 607 701 796 891 1032 1256 10 10
18-0 574 624 721 819 917 1085 1318 8 2 10
18-6 589 640 741 841 942 1110 1349 6 4 10
19-0 605 657 760 864 967 1136 1381 4 6 10
19-6 620 674 780 887 993 1161 1412 2 8 10
20-0 691 799 909 1018 1187 1444 10 10
20-6 713 824 935 1046 1213 1476 2 10 12
21-0 728 842 955 1069 1238 1507 12 12
21-6 861 978 1095 1291 1569 10 2 12
22-0 881 1001 1120 1316 1600 8 4 12
22-6 900 1023 1145 1342 1632 6 6 12
23-0 1046 1171 1368 1664 4 8 12
23-6 1069 1196 1393 1695 2 10 12
24-0 1091 1222 1419 1727 12 12
24-6 1248 1446 1758 14 14
25-0 1273 1497 1820 12 2 14
25-6 1298 1523 1852 10 4 14
26-0 1548 1883 8 8 16
Notes:
1. Dimensions are to inside crests of corrugations and are subject to manufacturing tolerances.
2. These plate arrangements will be furnished unless noted otherwise on assembly drawings.
3. Approximate weights include galvanized steel material, bolts, and nuts.
4. Specified thickness is a nominal galvanized thickness.
5. Gages 12 thru 1 use 3/4" diameter bolts. 5/16 and 3/8 use 7/8" diameter bolts.
6. 24 pi plates are not available in 5/16 and 3/8. Inquire for number of plates per ring.
7. The pi nomenclature for MULTI-PLATE is 3.2. This variance from mathematical pi means that the inside diameter of a MULTI-PLATE round structure will be slightly
larger for nominal diameter sizes greater than 120”, and the inside diameters will be slightly less for nominal sizes below 120”.

31
 Steel and Aluminum
Structural Plate
Design Guide

MULTI-PLATE® Height of Cover Tables

Height of Cover Tables 17, 21, 24, 26 and 29A are presented for the designer’s convenience for use in routine applications.
These tables are based on the outlined design procedures, using the following values for the soil and steel parameters:
• For live loading other than standard highway vehicles, please contact your Contech representative.
• Unit weight of soil – 120 pcf.
• Relative density of compacted backfill – minimum 90% density per AASHTO T-180.
• Heights of cover are based on 3/4" diameter bolts (4 bolts/ft) except 5/16 and 3/8 which use 7/8" diameter bolts.
(8 bolts/ft). 6 and 8 bolts/ft are available for 1 gage structures.

TABLE 17. MULTI-PLATE® ROUND AND VERTICAL ELLIPSE PIPE 6” X 2”

LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Gage Thickness (Inches)
Maximum Cover Height Shown in Feet
Minimum
MULTI-PLATE®

Diameter Cover 12 10 8 7 5 3 1 5/16 3/8

(Ft.-In.) (Inches) Pi (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
5-0 12 60 46 67 87 100 121 143 156 250 301
5-6 12 66 42 60 79 91 110 130 142 227 273
6-0 12 72 38 55 73 83 101 119 130 208 250
6-6 12 78 35 51 67 77 93 110 120 192 231
7-0 12 84 32 47 62 71 86 102 111 178 214
7-6 12 90 30 44 58 67 80 95 104 166 200
8-0 12 96 28 41 54 62 75 89 97 156 187
8-6 18 102 27 39 51 59 71 84 91 147 176
9-0 18 108 25 37 48 55 67 79 86 138 166
9-6 18 114 24 35 45 52 63 75 82 131 158
10-0 18 120 22 33 43 50 60 71 77 124 150
10-6 18 126 21 31 41 47 57 68 74 118 143
11-0 18 132 20 30 39 45 54 64 70 113 136
11-6 18 138 19 28 37 43 52 62 67 108 130
12-0 18 144 18 27 36 41 50 59 64 104 125
12-6 24 150 18 26 34 40 48 57 62 99 120
13-0 24 156 17 25 33 38 46 54 59 95 115
13-6 24 162 16 24 32 37 44 52 57 92 111
14-0 24 168 16 23 31 35 43 50 55 89 107
14-6 24 174 15 22 29 34 41 49 53 85 103
15-0 24 180 14 21 28 33 40 47 51 83 99
15-6 24 186 13 21 27 32 38 45 50 80 96
16-0 24 192 20 27 31 37 44 48 77 93
16-6 30 198 19 26 30 36 43 47 75 90
17-0 30 204 19 25 29 35 41 45 73 88
17-6 30 210 18 24 28 34 40 44 71 85
18-0 30 216 23 27 33 39 43 69 83
18-6 30 222 23 26 32 38 41 67 80
19-0 30 228 22 26 31 37 40 65 78
19-6 30 234 22 25 30 36 39 63 76
20-0 30 240 24 29 35 38 62 74
20-6 36 246 24 29 34 37 60 73
21-0 36 252 24 28 33 36 59 71
21-6 36 258 27 32 35 57 69
22-0 36 264 27 32 35 56 67
22-6 36 270 26 31 34 55 66
23-0 36 276 30 33 54 65
23-6 36 282 30 32 52 63
24-0 36 288 29 32 51 62
24-6 42 294 31 49 60
25-0 42 300 30 48 58
25-6 42 306 30 46 56
26-0 42 312 44 54
Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of rigid pavement.
3. Minimum cover for heavy off-road construction equipment loads must be checked. Please contact your Contech representative.
32
 VERTICAL ELLIPSE

TABLE 18. MULTI-PLATE® VERTICAL ELLIPSE 6" X 2"

WEIGHT TABLES
5% Vertical Gage Thickness (Inches)
Ellipse Plate Make-Up Weight Shown as Pounds per Foot of Structure
Pi

MULTI-PLATE®
Diameter Horizontal Vertical Area Total 12 10 8 7 5 3 1
(Ft.-In.) (Inches) (Inches) (Sq. Ft.) 15 18 21 24 Plates (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280)
5-0 56 62 19 4 4 110 138 166 180 208 236 264
5-6 62 68 23 2 2 4 119 150 180 196 227 257 287
6-0 68 75 28 4 4 129 162 195 212 245 277 310
6-6 73 81 32 2 2 4 138 174 209 227 263 298 333
7-0 79 88 38 4 4 147 185 223 243 281 318 356
7-6 85 94 44 2 2 4 157 198 239 260 300 341 382
8-0 91 101 50 4 4 168 211 254 276 320 364 407
8-6 97 107 56 2 4 6 184 231 278 302 349 395 442
9-0 103 114 63 6 6 193 242 292 317 367 416 465
9-6 109 120 71 4 2 6 202 254 306 333 385 436 488
10-0 115 127 79 2 4 6 212 266 321 349 403 457 512
10-6 120 133 87 6 6 221 278 335 364 421 478 535
11-0 126 139 95 4 2 6 231 291 350 381 440 500 560
11-6 132 146 104 2 4 6 241 304 366 398 460 523 585
12-0 138 152 114 6 6 251 316 381 415 479 546 611
12-6 142 157 124 6 2 8 267 335 404 439 507 575 644
13-0 148 163 134 4 4 8 276 347 418 454 525 596 667
13-6 154 170 144 2 6 8 285 359 432 470 543 616 690
14-0 159 176 155 8 8 295 371 447 485 561 637 713
14-6 165 183 167 6 2 8 305 384 462 502 581 660 738
15-0 171 189 179 4 4 8 315 396 478 519 600 682 764
15-6 177 195 191 2 6 8 325 409 493 536 620 705 789
16-0 182 202 204 8 8 335 422 508 553 639 728 814
16-6 189 209 217 4 6 10 440 530 576 666 755 845
17-0 195 215 230 2 8 10 452 544 591 684 776 868
17-6 201 222 244 10 10 464 559 607 701 796 891
18-0 206 228 258 8 2 10 476 574 624 721 819 917
18-6 212 235 273 6 4 10 589 640 741 841 942
19-0 218 241 288 4 6 10 605 657 760 864 967
19-6 224 247 303 2 8 10 620 674 780 887 993
20-0 229 253 319 10 10 635 691 799 909 1018
20-6 236 261 336 2 10 12 713 824 935 1046
21-0 242 267 352 12 12 728 842 955 1069
21-6 247 273 370 10 2 12 861 978 1095
22-0 253 280 387 8 4 12 881 1001 1120
22-6 259 286 405 6 6 12 900 1023 1145
23-0 264 291 423 4 8 12 920 1046 1171
23-6 271 299 442 2 10 12 1069 1196
24-0 276 305 461 12 12 1091 1222
24-6 283 312 481 14 14 1115 1248
25-0 289 319 501 12 2 14 1137 1273
25-6 294 325 521 10 4 14 1160 1298
26-0 300 332 542 8 6 14 1183 1324
Notes:
1. Dimensions are to inside crests of corrugations and are subject to manufacturing tolerances.
2. These plate arrangements will be furnished unless noted otherwise on assembly drawings.
3. Approximate weights include galvanized steel material, bolts, and nuts.
4. Specified thickness is a nominal galvanized thickness.
33
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 19. MULTI-PLATE® PIPE-ARCH 6” X 2” DETAILS

Span Rise Area Rt Rb C** Span Rise Area Rt Rb C**
(Ft.-In.) (Ft.-In.) (Sq. Ft.) (Inches) (Inches) (Inches) (Ft.-In.) (Ft.-In.) (Sq. Ft.) (Inches) (Inches) (Inches)
9 Pi Corner Pipe Arch Structure 15 Pi Corner Pipe Arch Structure
6-1 4-7 22 37 77 27 13-3 9-4 98 80 193 47
6-4 4-9 24 38 99 25 13-6 9-6 102 81 220 45
6-9 4-11 26 41 84 29 14-0 9-8 106 84 198 48
7-0 5-1 29 42 105 27 14-2 9-10 111 86 224 46
7-3 5-3 31 44 137 25 14-5 10-0 115 87 256 44
Rc Corner Radius = 18”*

7-8 5-5 33 47 110 28 14-11 10-2 120 90 228 48

Rc Corner Radius = 31”

7-11 5-7 36 48 139 27 15-4 10-4 124 93 209 51
8-2 5-9 38 49 183 25 15-7 10-6 129 94 232 49
8-7 5-11 41 52 141 28 15-10 10-8 134 95 261 47
8-10 6-1 43 53 179 26 16-3 10-10 138 99 237 51
9-4 6-3 46 56 145 30 16-6 11-0 143 100 264 49
MULTI-PLATE®

9-6 6-5 49 57 178 28 17-0 11-2 148 103 241 53

9-9 6-7 52 58 228 26 17-2 11-4 153 104 267 51
10-3 6-9 55 62 179 29 17-5 11-6 158 105 298 49
10-8 6-11 58 65 153 33 17-11 11-8 163 108 271 52
10-11 7-1 61 66 181 31 18-1 11-10 168 109 300 50
11-5 7-3 64 69 158 34 18-7 12-0 174 113 274 54
11-7 7-5 68 70 184 32 18-9 12-2 179 114 302 52
11-10 7-7 71 71 217 30 19-3 12-4 185 117 278 55
12-4 7-9 74 75 187 34 19-6 12-6 191 118 305 53
12-6 7-11 78 76 218 32 19-8 12-8 196 119 337 51
12-8 8-1 82 77 260 30 19-11 12-10 202 120 374 49
12-10 8-4 85 77 315 28 20-5 13-0 208 123 338 53
20-7 13-2 214 124 374 51
* Pipe arch shapes with a corner radius of 18" are available in larger
sizes than 12'-10" x 8'-4".
** "C" is measured from the invert to the top of the corner plate.

Pipe-Arch

End view of an assembled MULTI-PLATE Pipe Arch

34
 PIPE ARCH

TABLE 20. MULTI-PLATE® PIPE-ARCH 6” X 2”

WEIGHT TABLES
Plate Make-Up
Gage Thickness (Inches)
C = Corner B = Bottom T = Top
Total Weight Shown as Pounds per Foot of Structure
(see Note 4)
Plates
Span Rise 9 Pi 15 Pi 18 Pi 21 Pi 24 Pi 12 10 8 7 5 3 1
(Ft.-In.) (Ft.-In.) Pi C B C B T B T B T B T (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280)
9 Pi Corner Pipe Arch Structure*
6-1 4-7 66 2 1 1 1 5 136 158 180 196 227 257 287
6-4 4-9 69 2 1 2 5 142 165 188 204 236 267 299
6-9 4-11 72 2 1 2 5 147 171 195 212 245 277 310
7-0 5-1 75 2 1 1 1 5 152 178 202 219 254 288 322
7-3 5-3 78 2 1 2 5 158 185 209 227 263 298 333

MULTI-PLATE®
7-8 5-5 81 2 1 2 5 163 192 216 235 272 308 345
7-11 5-7 84 2 1 1 1 5 168 198 223 243 281 318 356
Rc Corner Radius = 18”

8-2 5-9 87 2 1 2 5 174 205 231 251 290 330 369

8-7 5-11 90 2 1 2 5 179 212 239 260 300 341 382
8-10 6-1 93 2 1 2 1 6 185 219 246 268 310 352 395
9-4 6-3 96 2 1 1 1 2 7 190 226 258 281 324 368 412
9-6 6-5 99 2 1 1 3 7 195 232 266 289 334 380 425
9-9 6-7 102 2 1 1 2 1 7 201 239 273 296 342 389 435
10-3 6-9 105 2 2 2 1 7 206 246 280 304 352 399 447
10-8 6-11 108 2 1 1 2 1 7 211 253 287 312 361 409 458
10-11 7-1 111 2 1 1 1 2 7 217 259 295 320 370 421 471
11-5 7-3 114 2 2 1 2 7 222 266 302 329 380 432 484
11-7 7-5 117 2 2 3 7 227 273 310 337 390 443 496
11-10 7-7 120 2 2 2 1 7 233 280 321 349 404 458 513
12-4 7-9 123 2 1 1 2 1 7 238 286 329 358 413 469 525
12-6 7-11 126 2 1 1 1 2 7 244 293 336 365 422 480 537
12-8 8-1 129 2 1 1 3 7 249 300 343 373 431 490 549
12-10 8-4 132 2 1 3 1 1 8 254 307 352 382 442 502 562
15 Pi Corner Pipe Arch Structure
13-3 9-4 138 2 2 3 7 308 371 403 466 529 593
13-6 9-6 141 2 2 3 1 8 317 382 415 480 544 609
14-0 9-8 144 2 1 3 1 1 8 323 389 423 489 554 620
14-2 9-10 147 2 1 2 1 2 8 329 397 431 498 565 632
14-5 10-0 150 2 1 1 1 3 8 335 404 439 507 575 644
14-11 10-2 153 2 1 2 3 8 341 411 446 516 585 655
15-4 10-4 156 2 1 1 3 1 8 348 419 455 526 597 668
Rc Corner Radius = 31”

15-7 10-6 159 2 1 4 1 8 354 426 463 535 607 679

15-10 10-8 162 2 1 3 1 1 8 360 434 471 545 618 692
16-3 10-10 165 2 3 2 1 8 366 441 479 554 630 705
16-6 11-0 168 2 2 2 2 8 373 449 488 564 641 717
17-0 11-2 171 2 1 2 2 2 9 383 461 501 579 657 735
17-2 11-4 174 2 1 2 1 3 9 389 468 509 589 668 748
17-5 11-6 177 2 1 2 4 9 395 476 517 598 679 760
17-11 11-8 180 2 3 4 9 401 483 525 607 690 772
18-1 11-10 183 2 3 2 3 10 410 494 537 621 703 787
18-7 12-0 186 2 2 2 1 3 10 416 501 545 629 714 799
18-9 12-2 189 2 2 1 1 4 10 422 508 552 638 724 810
19-3 12-4 192 2 1 1 2 4 10 428 516 560 647 734 822
19-6 12-6 195 2 1 2 5 10 434 523 568 656 745 833
19-8 12-8 198 2 1 2 4 1 10 440 530 576 666 756 846
19-11 12-10 201 2 1 2 3 2 10 447 538 585 676 767 859
20-5 13-0 204 2 3 3 2 10 453 545 592 685 778 870
20-7 13-2 207 2 3 2 3 10 459 553 601 695 789 883

Notes:
1. Dimensions are to inside crests of corrugations and are subject to manufacturing tolerances.
2. These plate arrangements will be furnished unless noted otherwise on assembly drawings.
3. Approximate weights include galvanized steel material, bolts, and nuts.
4. Pipe arch shapes with a corner radius of 18" are available in larger sizes than 12'-10" x 8'-4".
*5. These structures may be supplied with the corner plates in a heavier gage than specified.
35
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 21. MULTI-PLATE® PIPE-ARCH 6” X 2”

LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
9 Pi Corner Pipe Arch Structure
Gage Thickness (Inches)
Maximum Cover Height Shown in Feet
Minimum Corner
Span Rise Cover Radius 12 10 8 7 5 3 1
(Ft.-In.) (Ft.-In.) (Inches) (Inches) (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280)
6-1 4-7 12 18 14 14 14 14 14 14 14
6-4 4-9 12 18 13 13 13 13 13 13 13
6-9 4-11 12 18 12 12 12 12 12 12 12
7-0 5-1 12 18 12 12 12 12 12 12 12
7-3 5-3 12 18 11 11 11 11 11 11 11
7-8 5-5 12 18 10 10 10 10 10 10 10
MULTI-PLATE®

7-11 5-7 12 18 10 10 10 10 10 10 10
8-2 5-9 18 18 10 10 10 10 10 10 10
8-7 5-11 18 18 9 9 9 9 9 9 9
8-10 6-1 18 18 9 9 9 9 9 9 9
9-4 6-3 18 18 8 8 8 8 8 8 8
9-6 6-5 18 18 8 8 8 8 8 8 8
9-9 6-7 18 18 8 8 8 8 8 8 8
10-3 6-9 18 18 7 7 7 7 7 7 7
10-8 6-11 18 18 6 6 6 6 6 6 6
10-11 7-1 18 18 6 6 6 6 6 6 6
11-5 7-3 18 18 6 6 6 6 6 6 6
11-7 7-5 18 18 6 6 6 6 6 6 6
11-10 7-7 18 18 5 5 5 5 5 5 5
12-4 7-9 24 18 5 5 5 5 5 5 5
12-6 7-11 24 18 5 5 5 5 5 5 5
12-8 8-1 24 18 5 5 5 5 5 5 5
12-10 8-4 24 18 5 5 5 5 5 5 5
15 Pi Corner Pipe Arch Structure
13-3 9-4 24 31 11 11 11 11 11 11
13-6 9-6 24 31 11 11 11 11 11 11
14-0 9-8 24 31 10 10 10 10 10 10
14-2 9-10 24 31 10 10 10 10 10 10
14-5 10-0 24 31 10 10 10 10 10 10
14-11 10-2 24 31 9 9 9 9 9 9
15-4 10-4 24 31 9 9 9 9 9 9
15-7 10-6 24 31 9 9 9 9 9 9
15-10 10-8 24 31 9 9 9 9 9 9
16-3 10-10 30 31 8 8 8 8 8 8
16-6 11-0 30 31 8 8 8 8 8 8
17-0 11-2 30 31 8 8 8 8 8 8
17-2 11-4 30 31 8 8 8 8 8 8
17-5 11-6 30 31 8 8 8 8 8 8
17-11 11-8 30 31 7 7 7 7 7 7
18-1 11-10 30 31 7 7 7 7 7 7
18-7 12-0 30 31 7 7 7 7 7 7
18-9 12-2 30 31 7 7 7 7 7 7
19-3 12-4 30 31 7 7 7 7 7 7
19-6 12-6 30 31 7 7 7 7 7 7
19-8 12-8 30 31 6 6 6 6 6 6
19-11 12-10 30 31 6 6 6 6 6 6
20-5 13-0 36 31 6 6 6 6 6 6
20-7 13-2 36 31 6 6 6 6 6 6
Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of rigid pavement.
3. Minimum cover for heavy off-road construction equipment must be checked. Please contact your Contech representative.
4. Maximum cover requires minimum 4,000 psf allowable bearing capacity for backfill around haunch of pipe-arch.
5. Maximum cover limited by corner bearing pressure.

36
 SINGLE RADIUS ARCH

TABLE 22. MULTI-PLATE® SINGLE RADIUS ARCH 6” X 2”

Nominal Arc Plate Make-Up
Dimensions Length (see Note 2)
Span Rise Rise/Span Radius Waterway
(Ft.-In.) (Ft.-In.) Ratio (Inches) (Area Ft. 2) Pi 9 Pi 15 Pi 18 Pi 21 Pi 24 Pi Total Plates
6-0 1-10 0.30 41 7.9 27 1 1 2
2-4 0.38 37 10.0 30 2 2
3-2 0.53 36 15.0 36 1 1 2
7-0 2-5 0.34 45 12.1 33 1 1 2
2-10 0.41 43 14.9 36 1 1 2
3-8 0.52 42 20.4 42 1 1 2
8-0 2-11 0.36 51 17.0 39 1 1 2
3-4 0.42 49 20.3 42 1 1 2
4-2 0.52 48 26.6 48 2 2
9-0 2-11 0.33 59 19.2 42 1 1 2

MULTI-PLATE®
3-11 0.43 55 26.5 48 2 2
4-8 0.52 54 33.6 54 3 3
10-0 3-6 0.35 64 25.4 48 2 2
4-5 0.44 61 33.5 54 3 3
5-3 0.52 60 41.4 60 1 2 3
11-0 3-6 0.32 73 27.8 51 1 2 3
4-6 0.41 68 36.9 57 2 1 3
5-9 0.52 66 50.0 66 2 1 3
12-0 4-1 0.34 78 35.3 57 2 1 3
5-0 0.42 73 45.2 63 3 3
6-3 0.52 72 59.4 72 3 3
13-0 4-1 0.33 87 38.1 60 1 2 3
5-1 0.40 81 48.9 66 2 1 3
6-9 0.52 78 69.7 78 2 2 4
14-0 4-8 0.31 91 47.0 66 2 1 3
5-7 0.38 86 58.5 72 3 3
7-3 0.44 84 80.7 84 2 2 4
15-0 4-8 0.52 101 48.9 69 1 2 3
5-8 0.33 93 62.8 75 3 1 4
6-7 0.44 91 74.8 81 1 3 4
7-9 0.52 90 92.6 90 2 2 4
16-0 5-3 0.31 105 60.1 75 3 1 4
7-1 0.42 97 86.2 87 3 1 4
8-4 0.52 96 105.3 96 3 2 5
17-0 5-3 0.31 115 63.4 78 2 2 4
7-2 0.42 103 91.9 90 2 2 4
8-10 0.52 102 118.8 102 1 4 5
18-0 5-9 0.32 119 74.8 84 2 2 4
7-8 0.43 109 104.6 96 3 2 5
8-11 0.50 108 126.0 105 5 5
19-0 6-4 0.33 123 87.1 90 2 2 4
8-3 0.43 115 118.1 102 1 4 5
9-5 0.50 114 140.7 111 3 2 5
20-0 6-4 0.32 133 91.0 93 1 3 4
8-3 0.42 122 124.4 105 5 5
10-0 0.50 120 156.3 117 1 4 5
21-0 6-11 0.33 137 104.6 99 2 3 5
8-10 0.42 128 139.2 111 3 2 5
10-6 0.50 126 172.6 123 1 5 6
22-0 6-11 0.32 146 109.3 102 1 4 5
8-11 0.40 135 145.9 114 2 3 5
11-0 0.50 132 189.8 129 5 1 6
23-0 8-0 0.35 147 133.6 111 3 2 5
9-10 0.43 140 171.1 123 1 5 6
11-6 0.50 138 207.8 135 3 3 6
24-0 8-6 0.36 152 149.4 117 1 4 5
10-4 0.43 146 188.3 129 5 1 6
12-0 0.50 144 226.6 141 1 5 6
25-0 8-7 0.34 160 155.6 120 5 5
10-10 0.43 152 206.3 135 3 3 6
12-6 0.50 150 246.2 147 7 7
26-0 8-7 0.33 169 161.4 123 1 5 6
11-0 0.42 158 214.9 138 2 4 6
13-1 0.50 156 266.7 153 5 2 7
Notes:
1. Dimensions are to inside crests of corrugations are are subject to manufacturing tolerances.
2. These plate arrangements will be furnished unless otherwise noted on assembly drawings.
3. Additional arch sizes with a Rise-to-Span ratio in the range of 0.30 to 0.65 are available. Contact your Contech representative.

37
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 23. MULTI-PLATE® SINGLE RADIUS ARCH 6” X 2”

WEIGHT TABLES
Gage Thickness (Inches)
Arc Weight Shown as Pounds per Foot of Structure
Length 12 10 8 7 5 3 1 Rise,
Rise R

(0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280) Radius

R
Pi
24 42 53 64 69 80 91 102
R/S < 0.50
27 50 63 76 82 95 108 120
30 55 69 83 90 104 118 132
33 60 75 90 98 113 128 144 Span,
Span S

36 64 81 97 106 122 139 155

39 69 87 105 114 131 149 167 Single Radius Arch – R/S < 0.50
MULTI-PLATE®

42 74 93 112 121 140 159 178

45 79 99 119 130 150 171 191
48 84 105 127 138 160 182 204
51 92 115 139 151 174 198 221
54 96 121 146 159 184 208 233 Radius

57 101 127 153 167 193 218 244 Rise, R

60 106 133 160 174 201 229 256

63 110 139 168 182 210 239 267
66 116 145 175 190 220 250 280 Varies

69 121 152 183 199 230 262 293

72 126 158 191 207 240 273 305
75 133 168 202 219 254 288 322 Bottom Span

78 138 174 209 227 263 298 333

Maximum Span, S
81 143 179 216 235 272 308 345
84 147 185 223 243 281 318 356
Single Radius Arch – R/S > 0.50
87 152 192 231 251 290 330 369
90 157 198 239 260 300 341 382
93 163 205 246 268 310 352 395
96 168 211 254 276 320 364 407 Corrugated
Steel Plate
99 175 220 265 288 333 377 422
102 179 226 272 296 342 388 434
105 184 232 279 303 351 398 446
108 238 287 312 361 409 458
111 245 295 320 370 421 471
114 251 302 329 380 432 484
117 257 310 337 390 443 496
120 264 318 345 400 455 509
123 328 356 412 467 523 Slotted Concrete Footing
For a single radius arch, the dimensions of the keyway
126 335 364 421 478 535 shall be a minimum of 4" height x 8" wide.
129 343 372 431 489 547
132 381 440 500 560
135 389 450 512 573
138 398 460 523 585
141 406 470 534 598
144 479 546 611
147 491 557 624
150 503 567 636
153 515 575 650
Notes:
1. Approximate weights include galvanized steel material, bolts, and nuts.
2. Gages 5/16 and 3/8 are available. Contact your Contech representative.

MULTI-PLATE Pedestrian Arch Tunnel

38
 SINGLE RADIUS ARCH

TABLE 24. MULTI-PLATE® SINGLE RADIUS ARCH 6” X 2”

LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Gage Thickness (Inches)
Maximum Cover Height Shown in Feet
Minimum
Span Rise Total Cover 12 10 8 7 5 3 1 5/16 3/8
(Ft.-In.) (Ft.-In.) Pi (Inches) (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
6-0 1-10 27 12 38 55 73 83 101 119 130 208 250
2-4 30 12 38 55 73 83 101 119 130 208 250
3-2 36 12 38 55 73 83 101 119 130 208 250
7-0 2-5 33 12 32 47 62 71 86 102 111 178 214
2-10 36 12 32 47 62 71 86 102 111 178 214
3-8 42 12 32 47 62 71 86 102 111 178 214
8-0 2-11 39 12 28 41 54 62 75 89 97 156 187
3-4 42 12 28 41 54 62 75 89 97 156 187

MULTI-PLATE®
4-2 48 12 28 41 54 62 75 89 97 156 187
9-0 2-11 42 18 25 37 48 55 67 79 86 138 166
3-11 48 18 25 37 48 55 67 79 86 138 166
4-8 54 18 25 37 48 55 67 79 86 138 166
10-0 3-6 48 18 22 33 43 50 60 71 77 124 150
4-5 54 18 22 33 43 50 60 71 77 124 150
5-3 60 18 22 33 43 50 60 71 77 124 150
11-0 3-6 51 18 20 30 39 45 54 64 70 113 136
4-6 57 18 20 30 39 45 54 64 70 113 136
5-9 66 18 20 30 39 45 54 64 70 113 136
12-0 4-1 57 18 18 27 36 41 50 59 64 104 125
5-0 63 18 18 27 36 41 50 59 64 104 125
6-3 72 18 18 27 36 41 50 59 64 104 125
13-0 4-1 60 24 17 25 33 38 46 54 59 95 115
5-1 66 24 17 25 33 38 46 54 59 95 115
6-9 78 24 17 25 33 38 46 54 59 95 115
14-0 4-8 66 24 16 23 31 35 43 50 55 89 107
5-7 72 24 16 23 31 35 43 50 55 89 107
7-3 84 24 16 23 31 35 43 50 55 89 107
15-0 4-8 69 24 14 21 28 33 40 47 51 83 99
5-8 75 24 14 21 28 33 40 47 51 83 99
6-7 81 24 14 21 28 33 40 47 51 83 99
7-9 90 24 14 21 28 33 40 47 51 83 99
16-0 5-3 75 24 12 20 27 31 37 44 48 77 93
7-1 87 24 12 20 27 31 37 44 48 77 93
8-4 96 24 12 20 27 31 37 44 48 77 93
17-0 5-3 78 30 12 19 25 29 35 41 45 73 88
7-2 90 30 12 19 25 29 35 41 45 73 88
8-10 102 30 12 19 25 29 35 41 45 73 88
18-0 5-9 84 30 11 17 23 27 33 39 43 69 83
7-8 96 30 11 17 23 27 33 39 43 69 83
8-11 105 30 11 17 23 27 33 39 43 69 83
19-0 6-4 90 30 10 16 22 26 31 37 40 65 78
8-3 102 30 10 16 22 26 31 37 40 65 78
9-5 111 30 10 16 22 26 31 37 40 65 78
20-0 6-4 93 30 15 21 24 29 35 38 62 74
8-3 105 30 15 21 24 29 35 38 62 74
10-0 117 30 15 21 24 29 35 38 62 74
21-0 6-11 99 36 14 20 23 28 33 36 59 71
8-10 111 36 14 20 23 28 33 36 59 71
10-6 123 36 14 20 23 28 33 36 59 71
22-0 6-11 102 36 19 22 27 32 35 56 67
8-11 114 36 19 22 27 32 35 56 67
11-0 129 36 19 22 27 32 35 56 67
23-0 8-0 111 36 18 21 26 30 33 54 65
9-10 123 36 18 21 26 30 33 54 65
11-6 135 36 18 21 26 30 33 54 65
24-0 8-6 117 36 17 20 24 29 32 51 62
10-4 129 36 17 20 24 29 32 51 62
12-0 141 36 17 20 24 29 32 51 62
25-0 8-7 120 42 19 23 28 30 48 58
10-10 135 42 19 23 28 30 48 58
12-6 147 42 19 23 28 30 48 58
26-0 8-7 123 42 22 27 29 44 54
11-0 138 42 22 27 29 44 54
13-1 153 42 22 27 29 44 54
Notes:
1. For live loading other than standard highway vehicles, please contact your Contech representative.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of rigid pavement.
3. Minimum cover for heavy off-road construction equipment loads must be checked.
4. Footing reactions can be provided by Contech. Contact your Contech representative. 39
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 25. MULTI-PLATE® HORIZONTAL ELLIPSE 6” X 2” DETAILS

Structure Number Span Rise Total Area Rt Rs
(Ft.-In.) (Ft.-In.) Pi (Sq. Ft.) (Inches) (Inches)
24E15 7-4 5-6 78 32 54 27
27E15 8-1 5-9 84 36 61 27
30E15 8-10 6-0 90 41 68 27
30E18 9-2 6-9 96 48 68 32
33E15 9-7 6-4 96 47 75 27
33E18 9-11 7-0 102 54 75 32
36E15 10-4 6-7 102 53 82 27
36E18 10-8 7-3 108 60 82 32
36E21 11-0 8-0 114 68 82 38
39E15 11-1 6-10 108 58 88 27
MULTI-PLATE®

39E18 11-4 7-6 114 66 88 32

39E21 11-8 8-3 120 75 88 38
39E24 12-0 8-11 126 84 88 43
42E15 11-9 7-1 114 64 95 27
42E18 12-1 7-10 120 73 95 32
42E21 12-5 8-6 126 82 95 38
42E24 12-9 9-2 132 92 95 43
45E15 12-6 7-4 120 71 102 27
45E18 12-10 8-1 126 80 102 32
45E21 13-2 8-9 132 90 102 38
45E24 13-6 9-6 138 100 102 43
48E18 13-7 8-4 132 87 109 32
48E21 13-11 9-0 138 97 109 38
48E24 14-3 9-9 144 109 109 43
48E27 14-7 10-5 150 119 109 49
48E30 14-11 11-2 156 130 109 54
Notes:
1. Dimensions are to inside crests of corrugations and are subject to manufacturing tolerances.
2. Structure Number 24E15 has 4 plates per ring, Structure Numbers 27E15 through 45E24 have 6 plates, and Structure
Numbers 48E18 through 48E30 have 8 plates.

Horizontal Ellipse

Horizontal Ellipse Assembly

40
 HORIZONTAL ELLIPSE

TABLE 26. MULTI-PLATE® HORIZONTAL ELLIPSE 6” X 2”

LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Maximum Cover (Feet)
Span Rise Total Minimum Cover For Corner Bearing Pressure
Structure Number (Ft.-In.) (Ft.-In.) Pi (Inches) of 4,000 psf
24E15 7-4 5-6 78 12 14
27E15 8-1 5-9 84 18 12
30E15 8-10 6-0 90 18 11
30E18 9-2 6-9 96 18 13
33E15 9-7 6-4 96 18 9
33E18 9-11 7-0 102 18 12
36E15 10-4 6-7 102 18 8
36E18 10-8 7-3 108 18 11

MULTI-PLATE®
36E21 11-0 8-0 114 18 13
39E15 11-1 6-10 108 18 8
39E18 11-4 7-6 114 18 10
39E21 11-8 8-3 120 18 12
39E24 12-0 8-11 126 18 14
42E15 11-9 7-1 114 18 7
42E18 12-1 7-10 120 24 9
42E21 12-5 8-6 126 24 11
42E24 12-9 9-2 132 24 13
45E15 12-6 7-4 120 24 6
45E18 12-10 8-1 126 24 8
45E21 13-2 8-9 132 24 10
45E24 13-6 9-6 138 24 12
48E18 13-7 8-4 132 24 7
48E21 13-11 9-0 138 24 9
48E24 14-3 9-9 144 24 11
48E27 14-7 10-5 150 24 13
48E30 14-11 11-2 156 24 15
Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of rigid pavement.
3. Minimum cover for heavy off-road construction equipment loads must be checked.
4. Maximum cover based on 12 gage. Heavier gages can be supplied.
5. Maximum cover requires minimum 4,000 psf allowable bearing capacity for backfill around haunch of horizontal ellipse.
6. Maximum cover limited by corner bearing pressure.

Horizontal Ellipse Stream Crossing with Aluminum Headwall and Stone Veneer

41
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 27. MULTI-PLATE® UNDERPASS 6" X 2" DETAILS

Span Rise Total Area Rt Rs Rc Rb
(Ft.-In.) (Ft.-In.) Pi (Sq. Ft.) (Inches) (Inches) (Inches) (Inches)
Junior Underpasses
5-8 5-9 72 27 28 53 18 Flat
5-9 6-6 78 31 30 75 18 Flat
5-9 7-4 84 36 29 95 18 Flat
5-10 7-8 87 38 30 113 18 Flat
5-10 8-2 90 40 28 117 18 Flat
Standard Underpasses
12-2 11-0 141 107 67 93 38 134
12-11 11-3 147 116 73 95 38 144
13-2 11-11 153 126 73 103 38 159
MULTI-PLATE®

13-10 12-3 159 136 77 108 38 164

MULTI-PLATE Golf Cart Underpass
14-1 12-10 165 147 77 115 38 182
14-6 13-5 171 158 78 130 38 174
14-10 14-0 177 169 79 136 38 192
15-6 14-4 183 180 84 138 38 201
15-9 15-1 189 192 83 150 38 212
16-4 15-5 195 204 86 157 38 215
16-5 16-1 201 217 88 158 38 271
16-9 16-3 204 224 89 167 38 247
17-3 17-0 210 239 90 174 47 215
18-4 16-11 216 252 100 157 47 249
19-2 17-2 222 266 105 156 47 264
19-6 17-7 228 280 107 158 47 297
20-4 17-10 234 295 113 156 47 314 Underpass

TABLE 28. MULTI-PLATE® UNDERPASS 6" X 2"

PLATE MAKE-UP
Total
Span Rise Total Top Sides Corners Bottom Plates
(Ft.-In.) (Ft.-In.) Pi 15 18 21 24 9 15 18 21 24 9 15 18 9 15 18 21 24 Per Ring
Junior Underpasses
5-8 5-9 72 1 2 2 1 6
5-9 6-6 78 1 2 2 1 6
5-9 7-4 84 1 2 2 1 6
5-10 7-8 87 1 2 2 1 6
5-10 8-2 90 1 2 2 1 6
Standard Underpasses
12-2 11-0 141 1 1 2 2 2 8
12-11 11-3 147 2 2 2 1 1 8
13-2 11-11 153 2 2 2 1 1 8
13-10 12-3 159 1 1 2 2 2 8
14-1 12-10 165 1 1 2 2 2 2 10
14-6 13-5 171 2 2 2 2 1 1 10
14-10 14-0 177 2 4 2 1 1 10
15-6 14-4 183 1 2 4 2 2 11
15-9 15-1 189 1 2 2 2 2 2 11
16-4 15-5 195 3 2 2 2 1 1 11
16-5 16-1 201 2 1 4 2 2 11
16-9 16-3 204 2 1 4 2 1 1 11
17-3 17-0 210 2 1 4 2 1 1 11
18-4 16-11 216 1 2 4 2 2 11
19-2 17-2 222 3 4 2 1 2 12
19-6 17-7 228 3 2 2 2 1 2 12
20-4 17-10 234 2 1 2 2 2 3 12
Notes:
1. These plate arrangements will be furnished unless noted otherwise on assembly drawings.
2. Dimensions are to inside crests of corrugations and are subject to manufacturing tolerances.

42
 UNDERPASS

TABLE 29. MULTI-PLATE® UNDERPASS 6" X 2"

WEIGHT TABLES
Gage Thickness (Inches)
Weight Shown as Pounds per Foot of Structure
Span Rise Area Total 12 10 8 7 5 3 1
(Ft.-In.) (Ft.-In.) (Sq. Ft.) Pi (0.111) (0.140) (0.170) (0.188) (0.218) (0.249) (0.280)
Junior Underpasses
5-8 5-9 27 72 144 167 192 213 246 279 312
5-9 6-6 31 78 155 181 207 231 267 303 339
5-9 7-4 36 84 165 194 223 249 287 326 365
5-10 7-8 38 87 170 200 231 258 298 338 378
5-10 8-2 40 90 176 207 239 266 308 349 391
Standard Underpasses

MULTI-PLATE®
12-2 11-0 107 141 253 318 382 415 480 544 609
12-11 11-3 116 147 262 329 397 431 498 565 632
13-2 11-11 126 153 272 342 412 448 518 587 657
13-10 12-3 136 159 282 354 427 464 536 609 682
14-1 12-10 147 165 299 375 452 491 567 642 719
14-6 13-5 158 171 309 388 466 507 586 664 743
14-10 14-0 169 177 318 399 481 522 604 685 766
15-6 14-4 180 183 331 415 500 543 627 711 795
15-9 15-1 192 189 427 514 558 645 731 818
16-4 15-5 204 195 439 529 575 664 753 843
16-5 16-1 217 201 451 543 590 682 773 865
16-9 16-3 224 204 457 550 598 691 784 877
17-3 17-0 239 210 469 565 614 710 805 901
18-4 16-11 252 216 580 630 728 826 925
19-2 17-2 266 222 599 650 752 852 954
19-6 17-7 280 228 613 666 770 873 977
20-4 17-10 298 234 682 789 894 1001
Notes:
1. Dimensions are to inside crests of corrugations and are subject to manufacturing tolerances.
2. Approximate weights include galvanized steel material, bolts, and nuts.

TABLE 29A. MULTI-PLATE® UNDERPASS 6" X 2"

LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Minimum Minimum Maximum Height
Rise Total Radius, Inches Thickness Cover of Cover
Span (Ft.-In.) (Ft.-In.) Pi Rc Corner (Gage) (Inches) (Feet)
Junior Underpasses
5-8 5-9 72 18 12 12 18
5-9 6-6 78 18 12 12 18
5-9 7-4 84 18 12 12 18
5-10 7-8 87 18 12 12 18
5-10 8-2 90 18 12 12 18
Standard Underpasses
12-2 11-0 141 38 12 24 18
12-11 11-3 147 38 12 24 15
13-2 11-11 153 38 12 24 15
13-10 12-3 159 38 12 24 14
14-1 12-10 165 38 12 24 14
14-6 13-5 171 38 12 24 14
14-10 14-0 177 38 12 24 14
15-6 14-4 183 38 12 24 13
15-9 15-1 189 38 10 24 13
16-4 15-5 195 38 10 36 13
16-5 16-1 201 38 10 36 13
16-9 16-3 204 38 10 36 12
17-3 17-0 210 47 10 36 15
18-4 16-11 216 47 8 36 14
19-2 17-2 222 47 8 36 13
19-6 17-7 228 47 8 36 13
20-4 17-10 234 47 7 36 12

Note:
1. Maximum height of cover over underpass for corner bearing pressures of 4,000 psf.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of rigid pavement.

43
 Steel and Aluminum
Structural Plate
Design Guide

MULTI-PLATE® Galvanized Steel Structure Plate MULTI-PLATE® Galvanized Steel Key-Hole Slot
Project Specification Structural Plate Project Specification
Scope: This specification covers the manufacture and Scope: This specification covers the manufacture and
installation of the galvanized steel structural plate structure installation of the galvanized steel structural plate structure
detailed in the plans. detailed in the plans.

Material: The galvanized steel structural plate structure shall Material: The galvanized steel structural plate structure shall
consist of plate and appurtenant items as shown on the consist of plates and appurtenant items as shown on the plans
plans and shall conform to the requirements of AASHTO and shall conform to the requirements of AASHTO M 167/
M 167/ASTM A761. All manufacturing processes, including ASTM A761 except the longitudinal seam bolt holes shall be
corrugating, punching, curving and galvanizing, shall be key-hole shaped as shown in the plans. All manufacturing
performed within the United States using raw materials made in processes including corrugating, punching, curving and
MULTI-PLATE®

the United States. galvanizing, shall be performed within the United States using
raw materials made in the United States.
Assembly bolts with suitable nuts shall be galvanized and meet
the provisions of ASTM A449, Type 1 and ASTM A563, Grade Assembly bolts and nuts shall be galvanized and meet the
C, respectively. provisions of ASTM A449, Type 1 and ASTM A563, Grade C,
respectively.
Assembly: The structure shall be assembled in accordance with
the shop drawings provided by the manufacturer and per the Assembly: The structure shall be assembled in accordance
manufacturer’s recommendations. Bolts shall be tightened using with the shop drawings provided by the manufacturer and per
an applied torque of between 100 and 300 ft.-lbs. When seam the manufacturer’s recommendations. Bolts shall be tightened
sealant tape is used, bolts shall be installed and retightened using an applied torque of between 100-300 ft.-lbs.
to these torque levels after 24 hours. Torque levels are for
Installation: The structure shall be installed in accordance
installation, not residual, in-service requirements.
with the plans and specifications, the manufacturer’s
Installation: The structure shall be installed in accordance recommendations, and the AASHTO LRFD Specifications for
with the plans and specifications, the manufacturer’s Highway Bridges, Section 26 (Construction).
recommendations, and the AASHTO LRFD Bridge Construction
Backfill: The structure shall be backfilled using clean, well
Specifications (Sec. 26) (Division II).
graded granular material that meets the requirements of
Backfill: The structure shall be backfilled using clean, well AASHTO M 145 for soil classifications A-1-a. Backfill must be
graded granular material that meets the requirements of placed symmetrically on each side of the structure in 8-inch
AASHTO M 145 for soil classification A-1, A-2-4, A-2-5, or uncompacted lifts, with no side-to-side differential exceeding
A-3. Backfill must be placed symmetrically on each side of 24-inches. Each lift shall be compacted to a minimum
the structure in 8-inch uncompacted lifts, with no side-to-side 90% density per AASHTO T-180. Backfill limits shall be in
differentail exceeding 24-inches. Each lift shall be compacted to accordance with the details shown on the plans.
a minimum 90% density per AASHTO T-180.
Notes: Construction loads that exceed highway load limits are
not allowed on the structure without approval from the Project
Notes: Construction loads that exceed highway load limits
Engineer.
are not allowed on the structure without approval from
the Project Engineer.

Black Steel MULTI-PLATE before the Zinc Tank Galvanized MULTI-PLATE removed from the Zinc Tank

44
Installation Recommendations
A successful installation is dependent on these five critical Backfill
components being followed: Satisfactory backfill material, proper placement and
compaction are key factors in obtaining maximum strength
• Proper foundation
and stability. Compaction needs to be achieved under the
• Use of structural backfill
haunches by carefully tamping a granular or select material.
• 8" uncompacted lifts of backfill evenly placed on both
sides of the structure with no side-to-side differential The backfill material should be free of rocks, frozen lumps,
exceeding 24" and foreign material that can cause hard spots or decompose
• Verification of backfill compaction to create voids. Backfill material should be well graded
• Minimum cover over the structure granular material that meets the requirements of AASHTO
M 145 for soil classifications A-1, A-2-4, A-2-5, or A-3.
Required Elements

MULTI-PLATE®
Backfill must be placed symmetrically on each side of the
Satisfactory site preparation, trench excavation and bedding structure in eight-inch loose lifts. Each lift is to be compacted
and backfill operations are essential to develop the strength with no side-to-side differential exceeding 24-inches to a
of any flexible conduit. In order to obtain proper strength minimum 90% density per AASHTO T-180.
while preventing settlement, it is necessary that the soil
envelope around the structure be of good granular material, A high percentage of silt or fine sand in the native soils
properly placed, and carefully compacted. suggests the need for a well graded granular backfill material
Pipe-arch and underpass shapes pose special installation to prevent soil migration.
problems not found in other shapes. These two shapes During backfill, only small tracked vehicles (20,000 lbs. or
generate high corner bearing pressures against the side fill smaller) should be near the structure as fill progresses above
and foundation. Therefore, special installation care must be the crown and to the finished grade. The Engineer and
implemented to achieve a composite soil structure. Contractor are cautioned that the minimum cover may need
A qualified Engineer should be engaged to design a proper to be increased to handle temporary construction vehicle
foundation, adequate bedding, backfill, and erosion control. loads (heavier than the design highway load).
For more information, refer to ASTM A807 and AASHTO
Trench Excavation LRFD Bridge Construction Specifications Section 26.
If the adjacent embankment material is structurally
adequate, the trench requires only a bottom clear width of Bolting
the structure’s span plus sufficient room for compaction A well aligned plate fit is far better than a high torque. Bolts
equipment. should be initially torqued to a minimum of 100 foot pounds
and a maximum of 300 foot pounds.
Bedding
Proper bedding preparation is critical to both structure Complete detailed assembly instructions and drawings
performance and service life. The bedding should be are provided with each structure.
constructed to a uniform line and grade to avoid distortions
that may create undesirable stresses in the structure and/or Erosion Control
rapid deterioration of the roadway. It should be free of rock During installation and prior to the construction of permanent
formations, protruding stones, and frozen matter that may erosion control and end treatment protection, special
cause unequal settlement. precautions may be necessary. The structure must be
protected from unbalanced loads and from any structural
It is recommended that the bedding be a relatively loose loads or hydraulic forces that may bend or distort the
granular material that is roughly shaped to fit the bottom of unsupported ends of the structure. Erosion or washout of
the structure, be a minimum of twice the corrugation depth previously placed soil support must be prevented to ensure
in thickness and have a maximum particle size of one half that the structure maintains its load capacity.
the corrugation depth.

It should be noted that the bedding depth can vary based on

the amount of cover and the shape of the structure’s invert.
The bedding should be shaped to match structures with
flatter inverts.

Please reference the project specifications, drawing

submittals and Contech's Assembly and Installation Guide
for more information.
45
 Steel and Aluminum
Structural Plate
Design Guide

Aluminum Structural Plate

Lightweight and Lower Installed Cost
Contech Aluminum Structural Plate gives you many of the Description of Plates
same advantages as steel MULTI-PLATE. It is also lightweight
Aluminum Structural Plate’s corrugation pattern has a
which adds to the ease of installation when compared to
9-inch pitch and 2-1/2 inch depth. The corrugations are
traditional concrete structures.
perpendicular to the length of the structure.
Aluminum structural plate is approximately one-fiftieth of the
Thickness. Nominal plate thicknesses are available from
weight of reinforced concrete pipe in an equivalent size. This
0.125” to 0.250” in uniform increments of 0.025”.
reduced weight factor minimizes assembly and equipment
Uncurved plates are available in 0.100” plate thickness.
costs, helps gain access to remote sites and allows easy
handling of long, preassembled structures. Widths. Individual circumferential plate widths are noted
in terms of N (N = 9.625” or 3 pi). Standard plates are
Lower Job Site Unloading Costs
fabricated in net widths of one "N" increments from:
Lightweight plates and reinforcing ribs arrive at the job site
8N (77.00”) through 20N (192.50”) (see Table 30).
in strapped and nested bundles. Individual plates and ribs
are generally light enough to be handled by a small crew. The N nomenclature translates circumference directly into
Bundles can be handled with light-duty lifting equipment. nominal diameter in inches. For example, two 10N plates
give a diameter of 60” (2 x 10N x 3 pi), three 12N plates
Lower Job Site Assembly Costs = 108” (3 x 12N x 3 pi), etc. Various plate lengths are
Most structures contain plate and rib sizes that can be used to obtain a specific structure shape and size.
Aluminum Structural Plate

assembled without lifting equipment. As a quality assurance

measure, at least one ring of plates for each order is plant- Lengths. All standard plates have a net length of 4’-6”.
assembled and checked prior to shipment. Longitudinal bolt holes at 4-1/2” centers provide a standard
5.33 bolts per foot of longitudinal seams in two parallel
Aluminum Structural Plate can be manufactured in large rows at 1- 3/4” centers. The outside crests of the end
sections with multiple radii in the same plate. This reduces corrugations are punched for circumferential seam holes on
the number of longitudinal seams, therefore, lowering center of 9.625” (or 3 pi).
assembly costs. Off-site assembly is an added feature of Materials. Plates are fabricated from an aluminum alloy
lightweight aluminum, with obvious cost-saving benefits. with material properties that conform to AASHTO M 219
Typical Aluminum Structural Plate applications include small and ASTM B209 specifications.
bridges, grade separations, underpasses, culverts, stream
enclosures, storm sewers and rehabilitating existing
structures through relining.

National Specifications

Contech’s Aluminum Structural Plate design meets or

exceeds AASHTO LRFD Bridge Design Specifications,
AASHTO Standard Specifications for Highway Bridges and
ASTM. For listed specifications, please refer to page 27.

Lifting of Assembled Aluminum Pipe Arch

Round Vertical Ellipse Underpass Pipe-Arch Horizontal Ellipse Single Radius Arch

Standard Shapes

46
 Aluminum Box Culvert Triple Span

Aluminum Structural Plate Stream Crossing

Aluminum Structural Plate

Aluminum Structural Plate Pipe-Arch

Aluminum Box Culvert Stream Crossing

47
 1-3/4" 1-3/4"
1-1/2"± 1-1/2"±

Steel and Aluminum Corner holes 7/8'' x 1-1/8'' slotted

Structural Plate

1-1/2"±
Design Guide

Gross length 4'-9"±

Net length 4'-6"
4-1/2"
Inside surface
Standard Plate Detail Aluminum Structural Plate Bolts and Nuts
Longitudinal holes @ 7/8" dia.

3/4” diameter hot-dipped galvanized steel (specially heat-treated)

Flow

1-1/2"±
2.25" Nominal
radius
fasteners meeting ASTM A307 or A449 specifications (with suitable
nuts) are used to7/8" x 1-1/8" Slotted
assemble holes plate structures. Aluminum
structural
2.50" @ 9.625" o.c.
fasteners are available for salt water installations and are provided
Depth
upon request. Contact your local Contech representative.
9" Pitch
The underside
7/8" of the bolt head is uniformly rounded
7/8" and ribbed
1-1/2"± 1-1/2"±
9" 9"
x 2-1/2" Corrugation
x 2-1/2" Corrugation to prevent bolt head rotation while tightening. Unlike conventional
Net width
bolts, once the nut is finger tight, final tightening can typically be
Gross width
accomplished by one worker with an air driven impact wrench to
Standard Plate Detail
100-150 ft.-lbs. of torque.
In addition, one side of the nut is spherically formed to help align
and center the fastener into the punched holes. The rounded side
shall be placed against the structure.
Typical Bolt and Nut

1-¼"
A

D
Aluminum Structural Plate

9
/B16"

1” Radius
Rib /16"
13
C

Length
1” Radius

Bolt Diameter

Proper Shingle at Invert

Inside Surface Flow

Standard Plate Detail Structural Plate

Outside Surface
Bolt & Nut

Note: The nut may be placed on either side of the plate.

TABLE 30. DETAILS OF UNCURVED ALSP PLATE TABLE 31. BOLT LENGTH AND USAGE
Net Gross Plate Thickness (Inches) 3/4" Diameter Bolt Lengths
Plate Weight per Plate, lbs (without fasteners)
Width Width (Plate Only)
"N"
(Inches) (Inches) 0.125 0.150 0.175 0.200 0.225 0.250
Plate Thickness 1 Plate 2 Plate 3 Plate 4 Plate
8 77-0 81-3/4 66 79 92 105 119 132 (Inches) Lap Lap Lap
9 86-5/8 91-3/8 74 88 103 118 133 148 0.125 N/A 1¼” 1¼” 1¼”
10 96-1/4 101-0 81 98 114 130 147 164 0.150-0.200 N/A 1¼” 1½” 2"
11 105-7/8 110-5/8 89 107 125 143 161 179 0.225-0.250 N/A 1½” 2" N/A
12 115-1/2 120-1/4 97 116 136 155 175 195 3/4" Diameter Bolt Lengths
(with Reinforcing Rib, if Required)
13 125-1/8 129-7/8 105 126 147 168 189 210
Plate Thickness 1 Plate 2 Plate 3 Plate 4 Plate
14 134-3/4 139-1/2 113 135 157 180 203 226
(Inches) Lap Lap Lap
15 144-3/8 149-1/8 120 144 168 192 217 241
0.125-0.175 1¼” 1½” 2" 2"
16 154-0 158-3/4 128 154 179 205 231 257
0-200-0.250 1½” 2" 2" 2"
17 163-5/8 168-3/8 136 163 190 217 245 273
18 173-1/4 178-0 144 172 201 230 259 288
19 182-7/8 187-5/8 151 182 212 242 273 304
20 192-1/2 197-1/4 159 191 223 254 288 319
For ALSP, 1 N = 9.625"

48
Aluminum Structural Plate and Rib Technical Information Rib Assembly Socket

TABLE 32. SECTION PROPERTIES OF PLATES ONLY

9” X 2-1/2” CORRUGATION Rib Socket
RIB SOCKET
ASSEMBLY

Ultimate Assembly
Moment of Section Radius of Area of Seam
Thickness Inertia Modulus Gyration Section Strength
(Inches) (In.4/Ft.) (In.3/Ft.) (Inches) (In.2/Ft.) (kip/ft.) Type IV
Rib
TYPE IV RIB

0.100 0.997 0.767 0.844 1.404 28.0

0.125 1.248 0.951 0.844 1.750 41.0
0.150 1.499 1.131 0.845 2.100 54.1
0.175 1.751 1.309 0.845 2.449 63.7
0.200 2.004 1.484 0.846 2.799 73.4
Aluminum
0.225 2.258 1.657 0.847 3.149 83.2 ALUMINUM STRUCTURAL

Structural Plate
PLATE

0.250 2.513 1.828 0.847 3.501 93.1

Notes:
1. Yield strength of aluminum is 24 ksi.
2. 0.100” Thickness can not be curved.

TABLE 33. PLATE & RIB COMPOSITE SECTION PROPERTIES

Metal Thickness, Inches Type II Rib
Spacing 0.125 0.150 0.175 0.200 0.225 0.250 XX c
C

(Inches on
Rib Type Center) Plastic Moment Capacity, Mp ( kip-ft./ft. )
No Rib 2.65 3.18 3.71 4.24 4.77 5.30
Type II @ 54 4.62 5.46 6.04 6.61 7.17 7.74
@ 27 6.18 7.25 7.94 8.60 9.25 9.87

Aluminum Structural Plate

@ 18 7.41 8.66 9.48 10.26 11.00 11.71 3"
3"

@ 9 10.63 12.13 13.08 14.05 15.03 16.02

Type IV @ 54 5.87 6.82 7.43 8.04 8.63 9.21
YYc
@ 27 8.32 9.59 10.39 11.14 11.85 12.55
C

@ 18 10.42 11.90 12.84 13.72 14.57 15.39

22 ½"
1"
2

@ 9 16.45 18.46 19.41 20.38 21.37 22.37

TYPE II RIB
Type VI @ 54 8.74 9.51 10.24 10.95 11.64 12.32
@ 27 13.76 14.33 15.16 16.19 17.36 17.48
@ 18 20.09 20.56 20.79 21.30 21.74 22.58 Type IV Rib
XX c
@ 9 32.24 34.35 36.46 38.54 39.88 40.63
C K-FT

TABLE 34. SECTION PROPERTIES OF ALSP REINFORCING RIBS

Type II Rib Type IV Rib Type VI Rib
3 39/16
" "
9
16

Alloy 6061-T6 6061-T6 6061-T6

YY c
Area 1.71 in.2 2.27 in.2 3.62 in.2
C

Xc = 0.645 inches Xc = 0.652 inches Xc = 0.91 inches

Center of Mass
Yc = 1.02 inches Yc = 1.76 inches Yc = 2.27 inches 2 2½"
1"
2

Ixc = 1.802 in. 4

Ixc = 3.555 in. 4
Ixc = 9.700 in. 4
Moment of Inertia
Iyc = 0.787 in.4 Iyc = 1.050 in.4 Iyc = 1.014 in.4 TYPE IV RIB

Rxc = 1.026 inches Rxc = 1.251 inches Rxc = 1.636 inches

Radius of Gyration Type VI Rib
Ryc = 0.678 inches Ryc = 0.680 inches Ryc = 0.529 inches
K-FT

Xc
XC

Section Modulus Sx = 1.046 in.3 Sx = 1.90 in.3 Sx = 4.38 in.3

Plastic Modulus Zx = 1.705 in.3 Zx = 2.68 in.3 Zx = 5.66 in.3

Plastic Moment Mp = 4.97 kip-ft. Mp = 7.81 kip-ft. Mp = 16.52 kip-ft. 4 9/16"

4916"

Yield Strength Fy = 35 ksi Fy = 35 ksi Fy = 35 ksi Yc

YC

Tensile Strength Fu = 38 ksi Fu = 38 ksi Fu = 38 ksi

2 3/8"
23 8"

Rib Weight per Foot 2.055 lbs/ft 2.811 lbs/ft 4.356 lbs/ft
TYPE VI RIB

49
 HANDLING WEIGHTS
Steel and Aluminum
Structural Plate
Design Guide

Aluminum Structural Plate – Handling Weights & Plate Make-Up

TABLE 35. APPROXIMATE HANDLING WEIGHT OF STRUCTURE (POUNDS PER FOOT)
Metal Thickness (Inches) Round or Arch Pipe-Arch
Total
Bolts per Plates per Bolts per Plates per
N .125 .150 .175 .200 .225 .250
Foot Ring Foot Ring
8 19 22 24 27 31 36 6.9 1 6.9 1
9 21 24 27 30 34 39 7.1 1 7.1 1
10 23 26 30 33 37 41 7.3 1 7.3 1
11 24 28 32 36 40 44 7.6 1 7.6 1
12 26 31 35 39 44 48 7.8 1 7.8 1 Notes:
13 28 33 37 42 47 52 8.0 1 8.0 1 1. Handling weights are approximate and include
14 30 35 40 45 50 55 8.2 1 8.2 1 galvanized bolts and nuts.
15 32 37 43 48 53 59 8.4 1 8.4 1 2. Aluminum fasteners are available upon
16 34 39 45 51 57 62 8.7 1 8.7 1 request.
17 36 42 48 54 60 66 8.9 1 8.9 1 3. To obtain the estimated total weight and bolt
18 37 44 50 57 63 70 9.1 1 9.1 1 count per foot of the structure, use the Total N
19 44 50 57 63 71 79 14.4 2 14.4 2 value of a structure (see Tables 39, 40, 41, 42,
20 46 52 60 66 74 82 14.7 2 14.7 2 44 and 46).
21 47 54 62 69 77 85 14.9 2 14.9 2 4. If a structure has reinforcing ribs, see Tables
22 48 56 64 72 80 88 15.1 2 15.1 2 36-38 for additional weight and bolt count.
23 50 59 67 75 84 92 15.3 2 15.3 2 5. For an arch, deduct 5.33 bolts per foot from
24 52 62 70 78 88 96 15.5 2 15.5 2 column titled “Bolts per Foot.”
25 54 64 72 81 91 100 15.8 2 15.8 2 6. On an arch, bolts and nuts for receiving
26 56 66 74 84 94 104 16.0 2 16.0 2 angles are not included above.
27 58 68 77 87 97 107 16.2 2 16.2 2 7. Values in the column titled “Plates per Ring in
28 60 70 80 90 100 110 16.4 2 16.4 2 a Structure” shall be shown on the assembly
29 62 72 83 93 103 114 16.7 2 21.8 3 drawings provided.
30 64 74 86 96 106 118 16.9 2 22.0 3 7. For Ellipse and Underpass shapes, contact
31 66 76 88 99 110 121 17.1 2 22.2 3 your local Contech representative.
32 68 78 90 102 114 124 17.3 2 22.4 3
33 70 81 93 105 117 128 17.5 2 22.7 3
Aluminum Structural Plate

34 72 84 96 108 120 132 17.8 2 22.9 3

35 73 86 98 111 123 136 18.0 2 23.1 3
36 74 88 100 114 126 140 18.2 2 23.3 3
37 80 95 107 121 136 149 23.5 3 23.5 3
38 82 97 109 123 138 152 23.8 3 23.8 3
39 84 99 112 126 141 156 24.0 3 24.0 3
40 86 101 114 129 144 159 24.2 3 24.2 3
41 88 103 117 132 147 162 24.4 3 24.4 3
42 90 105 120 135 150 165 24.7 3 24.7 3
43 92 107 123 138 153 169 24.9 3 30.0 4
44 94 109 126 141 156 173 25.1 3 30.2 4
45 96 111 129 144 160 177 25.3 3 30.4 4
46 98 113 131 147 163 180 25.5 3 30.7 4
47 100 115 133 150 167 183 25.8 3 30.9 4
48 102 117 135 153 171 186 26.0 3 31.1 4
49 104 120 138 156 174 190 26.2 3 31.3 4
50 106 123 141 159 177 194 26.4 3 31.5 4
51 108 126 144 162 180 198 26.7 3 31.8 4
52 109 128 146 165 183 202 26.9 3 32.0 4
53 109 130 148 169 186 208 27.1 3 32.2 4
54 111 132 150 171 189 210 32.4 4 32.4 4
55 116 136 155 176 195 215 32.7 4 32.7 4
56 120 140 160 180 200 220 32.9 4 32.9 4
57 122 142 163 183 203 224 33.1 4 33.1 4
58 124 144 166 186 206 228 33.3 4 33.3 4
59 126 146 169 189 209 232 33.5 4 33.5 4
60 128 148 172 192 212 236 33.8 4 33.8 4
61 130 150 174 195 216 239 34.0 4 34.0 4
62 132 152 176 198 220 242 34.2 4 34.2 4
63 134 154 178 201 224 245 34.4 4 34.4 4
64 136 156 180 204 228 248 34.7 4 34.7 4
65 138 159 183 207 231 252 34.9 4 34.9 4
66 140 162 186 210 234 256 35.1 4 35.1 4
67 142 165 189 213 237 260 35.3 4 35.3 4
68 144 168 192 216 240 264 35.5 4 35.5 4
69 145 170 194 219 243 268 35.8 4 35.8 4
70 146 172 196 222 246 272 36.0 4 36.0 4
71 147 174 198 225 249 276 36.2 4 36.2 4
72 148 176 200 228 252 280 36.4 4 41.5 5
73 153 180 206 233 257 286 36.7 4 41.8 5
74 158 183 212 237 262 291 36.9 4 42.0 5
75 160 185 214 240 266 295 42.2 5 42.2 5
76 162 187 217 243 269 298 42.4 5 42.4 5
77 164 189 219 246 273 301 42.7 5 42.7 5
78 166 191 221 249 277 304 42.9 5 42.9 5
79 168 193 223 252 281 307 43.1 5 43.1 5
80 170 195 225 255 285 310 43.3 5 43.3 5
81 172 198 228 258 288 314 43.5 5 43.5 5
82 174 201 231 261 291 318 43.8 5 43.8 5
83 176 204 234 264 294 322 44.0 5 44.0 5
84 178 207 237 267 297 326 44.2 5 44.2 5

50
Reinforcing Rib - Handling Weights
When circumferential ribs are used with Aluminum Structural Plate, they reinforce the structure to
reduce minimum cover and provide additional stiffness. These circumferential ribs are bolted to
the structure’s crown and haunches (if applicable) at spacings of 9”, 18”, 27” or 54” centers.

TABLE 36. ADDED HANDLING WEIGHT AND ADDITIONAL BOLTS PER FOOT OF STRUCTURE
FOR TYPE II REINFORCING RIB
Total N 9" o.c. 18" o.c. 27" o.c. 54" o.c.
of Rib Wt./Ft. Bolts/ft Wt./Ft. Bolts/Ft. Wt./Ft. Bolts/Ft. Wt./Ft. Bolts/Ft.
Type II Rib
5 15.7 7.3 7.7 3.3 5.0 2.0 2.3 0.7
XC

6 18.6 8.6 9.1 3.9 5.9 2.3 2.7 0.8 Xc

7 21.5 9.8 10.5 4.4 6.8 2.7 3.2 0.9
8 24.3 11.0 11.9 5.0 7.7 3.0 3.6 1.0
9 27.2 12.2 13.3 5.6 8.7 3.3 4.0 1.1
10 30.1 13.4 14.7 6.1 9.6 3.7 4.5 1.2
11 32.9 14.7 16.1 6.7 10.5 4.0 4.9 1.3 3"
3"

12 35.8 15.9 17.5 7.2 11.4 4.3 5.3 1.4

13 38.7 17.1 18.9 7.8 12.3 4.7 5.7 1.6
14 41.5 18.3 20.3 8.3 13.2 5.0 6.2 1.7 YYc C

15 44.4 19.6 21.7 8.9 14.2 5.3 6.6 1.8

16 47.3 20.8 23.1 9.4 15.1 5.7 7.0 1.9 22 ½"
1"
2

17 50.2 22.0 24.5 10.0 16.0 6.0 7.4 2.0 TYPE II RIB

Aluminum Structural Plate

TABLE 37. ADDED HANDLING WEIGHT AND ADDITIONAL BOLTS PER FOOT OF STRUCTURE
FOR TYPE IV REINFORCING RIB K-FT

Total N 9" o.c. 18" o.c. 27" o.c. 54" o.c.

of Rib Wt./Ft. Bolts/ft Wt./Ft. Bolts/Ft. Wt./Ft. Bolts/Ft. Wt./Ft. Bolts/Ft. Type IV Rib
XC
5 20.0 7.3 9.8 3.3 6.4 2.0 3.0 0.7 Xc
6 23.7 8.6 11.6 3.9 7.6 2.3 3.6 0.8
7 27.4 9.8 13.4 4.4 8.8 2.7 4.2 0.9
8 31.0 11.0 15.2 5.0 10.0 3.0 4.7 1.0
9 34.7 12.2 17.1 5.6 11.2 3.3 5.3 1.1
10 38.4 13.4 18.9 6.1 12.4 3.7 5.9 1.2
3916"
11 42.1 14.7 20.7 6.7 13.5 4.0 6.4 1.3 3 9/16"
12 45.8 15.9 22.5 7.2 14.7 4.3 7.0 1.4
13 49.4 17.1 24.3 7.8 15.9 4.7 7.5 1.6 YC
Yc
14 53.1 18.3 26.1 8.3 17.1 5.0 8.1 1.7
15 56.8 19.6 27.9 8.9 18.3 5.3 8.7 1.8
16 60.5 20.8 29.7 9.4 19.5 5.7 9.2 1.9
2 2½"
1"
2

17 64.1 22.0 31.5 10.0 20.7 6.0 9.8 2.0

TYPE IV RIB

TABLE 38. ADDED HANDLING WEIGHT AND ADDITIONAL BOLTS PER FOOT OF STRUCTURE
FOR TYPE VI REINFORCING RIB K-FT

Total N 9" o.c. 18" o.c. 27" o.c. 54" o.c.

of Rib Wt./Ft. Bolts/ft Wt./Ft. Bolts/Ft. Wt./Ft. Bolts/Ft. Wt./Ft. Bolts/Ft. Type VI Rib
5 28.8 7.3 14.2 3.3 9.4 2.0 4.5 0.7 XC

Xc
6 34.1 8.6 16.9 3.9 11.1 2.3 5.3 0.8
7 39.4 9.8 19.5 4.4 12.8 2.7 6.2 0.9
8 44.8 11.0 22.1 5.0 14.6 3.0 7.0 1.0
9 50.1 12.2 24.7 5.6 16.3 3.3 7.8 1.1
10 55.4 13.4 27.4 6.1 18.0 3.7 8.7 1.2
11 60.8 14.7 30.0 6.7 19.8 4.0 9.5 1.3 4916"
4 9/16"
12 66.1 15.9 32.7 7.2 21.5 4.3 10.4 1.4
13 71.4 17.1 35.3 7.8 23.2 4.7 11.2 1.6
YcYC

14 76.8 18.3 37.9 8.3 25.0 5.0 12.0 1.7

15 82.1 19.6 40.6 8.9 26.7 5.3 12.9 1.8
16 87.4 20.8 43.2 9.4 28.5 5.7 13.7 1.9
17 92.8 22.0 45.8 10.0 30.2 6.0 14.5 2.0 2 3/8"
23 8"

TYPE VI RIB
Notes:
1. Bolts and nuts are included in the tables above.
2. For Total N of rib on a structure, see Tables 39, 40, 41, 42, 44 and 46.

51
 ROUND
Steel and Aluminum
Structural Plate
Design Guide

Height of Cover and Details Tables for Aluminum Structural Plate

Instructions to Read Tables 39, 41, 43, 45 and 47:
The tables are presented for the designer’s convenience in selecting metal thickness, reinforcing rib type and rib spacing for
minimum cover applications. For structures with maximum covers greater than those shown in the table, heavier plate and rib
combinations may be possible.

Round, Vertical Ellipse

TABLE 39. ROUND & VERTICAL ELLIPSE 9" X 2-1/2" STRUCTURE DETAIL (HL-93 LOADING)

Ellipse Metal Thickness (Inches) — Reinforcing Rib Type

Round Ellipse Total N Rib Spacing (Inches) (Maximum Cover — Ft.)
Dimensions
Approx. (Ft.-In.) Approx. Rib Minimum Height of Cover (Feet)
Diameter Round Area Area
(Ft.-In.) (Inches) (Sq. Ft.) Span Rise (Sq. Ft.) Structure Round Ellipse 1.25 1.50 2.00 2.50 3.00 3.50
.175 .175 .175 .175 .175 .175
7-0 84 37.8 6-7 7-4 37.7 28
(49) (49) (49) (49) (49) (49)
7-6 90 43.6 7-1 7-10 43.4 30 .250 .175 .175 .175 .175 .175
8-0 96 49.7 7-7 8-5 49.6 32 (62) (42) (42) (42) (42) (42)
8-6 102 56.3 8-1 8-11 56.2 34 .200 .150 .150 .150 .150
9-0 108 63.3 8-7 9-6 63.4 36 (43) (32) (32) (32) (32)
9-6 114 70.7 9-1 10-0 70.5 38 .125-II-18 .150 .150 .150 .150
10-0 120 78.5 9-7 10-7 78.3 40 10 (21) (28) (28) (28) (28)
10-6 126 86.7 10-0 11-1 86.5 42 10 .125-II-18 .125-II-27 .150 .150 .150
11-0 132 95.4 10-6 11-7 95.1 44 10 (19) (19) (26) (26) (26)
11-6 138 104.4 11-0 12-2 104.1 46 10 11 .125-IV-18 .125-II-27 .150 .150 .150
12-0 144 113.9 11-6 12-8 113.5 48 12 11 (18) (18) (24) (24) (24)
Aluminum Structural Plate

12-6 150 123.7 11-10 13-1 123.4 50 12 12 .150-IV-18 .125-II-27 .150 .150 .150
13-0 156 134.0 12-4 13-8 133.6 52 12 12 (22) (16) (22) (22) (22)
13-6 162 144.7 12-9 14-2 144.2 54 12 13 .125-VI-18 .125-II-18 .125-II-27 .150 .150
14-0 168 155.7 13-3 14-8 155.3 56 12 13 (15) (15) (15) (20) (20)
14-6 174 167.2 13-9 15-3 166.8 58 13 14 .150-VI-18 .125-II-18 .125-II-27 .125-II-27 .125-II-54
15-0 180 179.1 14-3 15-9 178.6 60 13 14 (19) (13) (13) (13) (13)
15-6 186 191.4 14-9 16-3 190.9 62 14 15 .150-VI-18 .175-II-18 .125-II-27 .150-II-54 .150-II-54
16-0 192 204.2 15-2 16-10 203.6 64 14 15 (17) (21) (12) (17) (17)
16-6 198 217.3 15-9 17-5 216.7 66 15 16 .150-VI-18 .150-II-9 .150-II-27 .150-II-27 .150-II-27
17-0 204 230.8 16-3 17-11 230.2 68 15 16 (16) (16) (16) (16) (16)
17-6 210 274.8 16-8 18-6 244.1 70 16 16 .175-VI-9 .175-IV-18 .175-II-27 .175-II-27 .175-II-27
18-0 216 259.1 17-2 19-0 258.4 72 16 16 (18) (18) (18) (18) (18)
18-6 222 273.9 17-8 19-7 273.1 74 16 17 .175-VI-9 .175-VI-18 .175-IV-27 .175-II-27 .175-IV-54
19-0 228 289.1 18-1 20-1 288.2 76 18 18 (17) (17) (17) (17) (17)
19-6 234 304.7 18-8 20-7 303.8 78 18 17 .200-VI-9 .200-VI-18 .200-IV-27 .200-IV-54 .200-IV-54
20-0 240 321.0 19-1 21-2 319.7 80 18 18 (18) (18) (18) (18) (18)
20-6 246 337.0 19-7 21-8 336.1 82 18 19 .225-VI-9 .225-VI-18 .225-IV-27 .225-II-27 .225-II-27
21-0 252 354.0 20-1 22-3 352.9 84 20 20 (20) (20) (20) (20) (20)
21-6 258 370.7 86 20 .250-VI-9 .250-VI-27 .250-IV-27 .250-IV-27
22-0 264 388.2 88 20 (22) (22) (22) (22)
22-6 270 406.0 90 20 .250-VI-9 .250-VI-27 .250-IV-27 .250-IV-27
23-0 276 424.3 92 22 (21) (21) (21) (21)
23-6 282 442.9 94 22 .250-VI-9 .250-VI-18 .250-IV-27 .250-IV-27
24-0 288 462.0 96 22 (20) (20) (20) (20)
24-6 294 481.4 98 22 .250-VI-9 .250-VI-18 .250-VI-27 .250-VI-27
25-0 300 501.3 100 24 (19) (19) (19) (19)
25-6 306 521.5 102 24 .250-VI-9 .250-VI-18 .250-VI-27 .250-VI-27
26-0 312 542.2 104 24 (18) (18) (18) (18)
26-6 318 563.2 106 24 .250-VI-9 .250-VI-9 .250-VI-27 .250-VI-27
27-0 324 584.7 108 24 (16) (16) (16) (16)
27-6 330 606.5 110 26 .250-VI-9 .250-VI-9 .250-VI-27 .250-VI-27
28-0 336 628.8 112 26 (15) (15) (15) (15)
28-6 342 651.4 114 26 .250-VI-9 .250-VI-18 .250-VI-27
29-0 348 674.5 116 26 (13) (13) (13)
29-6 354 697.9 118 28 .250-VI-9 .250-VI-18 .250-VI-27
30-0 360 721.8 120 28 (11) (11) (11)

Notes: 4. Table based upon AASHTO LRFD Bridge Design Specification for Highway
1. N = 9.625” Bridges.
2. Dimensions are to inside corrugation crests and are subject to 5. Per AASHTO [Link], minimum cover is the vertical distance from the top
manufacturing tolerances. of the corrugated structure to the bottom of flexible or top of rigid
3. For minimum covers that require reinforcing ribs, columns in the table pavement.
show minimum lengths of [Link] covers are also based on checking the 6. Minimum cover for heavy off-road construction equipment loads must be
plastic moment capacity. The required plastic moment of the plate and rib checked.
combination is compared to the plastic moment resistance. The unit weight of 7. Greater cover heights possible with heavier gage and rib combinations.
the backfill material is assumed to be 120 pcf. To find the minimum material 8. Shapes greater than 23-0 span require additional installation procedures.
requirements for the aluminum structural plate structure:
• Locate the structure required.
• Select the cover in the top row that is equal to or less than that required
Example for Note #3: .125-II-27
for the project. (17)
• The table selection shows metal thickness, rib type, rib spacing and
maximum cover. .125” thick plate with Type II ribs at 27” on centers
with a maximum cover of 17'
52
 HORIZONTAL ELLIPSE

Horizontal Ellipse
TABLE 40. HORIZONTAL ELLIPSE 9" X 2-1/2" DETAILS
Approx. Total N
Structure Span Rise Area Rt Rs
Number (Ft.-In.) (Ft.-In.) (Sq. Ft.) (Inches) (Inches) Structure Rib
10E6 9-2 6-8 48.4 68 32 32 11
11E6 9-11 7-0 54.3 75 32 34 12
12E6 10-7 7-3 59.6 81 32 36 13
12E7 10-11 7-11 68.0 81 37 38 13
13E6 11-4 7-6 66.2 88 32 38 14
13E7 11-8 8-3 74.8 88 37 40 14
13E8 12-0 8-11 83.8 88 43 42 14
14E6 12-1 7-9 72.8 95 32 40 15
14E7 12-5 8-6 82.0 95 37 42 15 Installation of Aluminum Horizontal Ellipses
14E8 12-9 9-2 91.5 95 43 44 15
15E6 12-10 8-1 79.7 102 32 42 16
15E7 13-2 8-9 89.4 102 37 44 16
15E8 13-6 9-6 99.4 102 43 46 16
16E6 13-7 8-4 86.8 109 32 44 17
16E7 13-11 9-0 97.1 109 37 46 17
16E8 14-3 9-9 107.6 109 43 48 17
16E9 14-7 10-5 118.5 109 49 50 17
16E10 14-11 11-2 129.7 109 54 52 17

Aluminum Structural Plate

Notes:
1. N = 9.625”
2. Dimensions are to inside corrugation crests and are subject to manufacturing
tolerances.
3. Structure number example: 10E6 = 10N in the top and bottom arc and 6N in each
Horizontal Ellipse
side arc.

TABLE 41. HORIZONTAL ELLIPSE 9" X 2-1/2" STRUCTURES (HL-93 LOADING)

Metal Thickness (Inches) — Reinforcing Rib Type
Rib Spacing (Inches) Maximum Cover (Feet)
Structure Span Rise Total N Minimum Height of Cover (Feet)
Number (Ft.-In.) (Ft.-In.) Structure Rib 1.25 1.50 2.00 2.50 3.00 3.50
10E6 9-2 6-8 32 11 .125-II-9 .125-II-18 .125 .125 .125 .125
11E6 9-11 7-0 34 12 (12) (12) (12) (12) (12) (12)
12E6 10-7 7-3 36 13 .150-ll-9 .125-II-18 .125-ll-27 .125 .125 .125
12E7 10-11 7-11 38 13 (12) (12) (12) (12) (12) (12)
13E6 11-4 7-6 38 14 .125-IV-9 .125-IV-18 .125-ll-27 .125 .125 .125
13E7 11-8 8-3 40 14 (9) (9) (9) (9) (9) (9)
13E8 12-0 8-11 42 14
14E6 12-1 7-9 40 15
14E7 12-5 8-6 42 15 .150-IV-9 .150-IV-18 .125-II-27 .150 .125 .125
14E8 12-9 9-2 44 15 (9) (9) (9) (9) (9) (9)
15E6 12-10 8-1 42 16
15E7 13-2 8-9 44 16 .150-VI-9 .150-VI-18 .150-IV-18 .125-II-27 .150 .150
15E8 13-6 9-6 46 16 (9) (9) (9) (9) (9) (9)
16E6 13-7 8-4 44 17
16E7 13-11 9-0 46 17
16E8 14-3 9-9 48 17 .150-VI-9 .150-VI-18 .150-IV-27 .150-II-27 .175 .175
16E9 14-7 10-5 50 17 (9) (9) (9) (9) (9) (9)
16E10 14-11 11-2 52 17

Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of
rigid pavement.
3. Minimum cover for heavy off-road construction equipment loads must be checked.
4. Minimum cover heights < span/8 determined by moment capacity analysis.
5. Maximum cover based upon a suggested minimum allowable corner bearing capacity of 4,000 psf.

53
 Steel and Aluminum
Structural Plate
Design Guide

Pipe-Arch
TABLE 42. PIPE-ARCH 9" X 2-1/2" DETAILS
Inside Radius
Approx (Inches) Arc Length N Total N
Span Rise Area Crown Invert
(Ft.-In.) (Ft.-In.) (Sq. Ft.) (Rt) (Rb) Crown Haunch Invert Structure Rib Notes:
1. N = 9.625”
Haunch Radius (Rh) = 31.75” 2. Dimensions are to inside corrugation
6-7 5-8 29.6 41.5 69.9 8 7 3 25 crests and are subject to manufacturing
tolerances.
6-11 5-9 31.9 43.7 102.9 9 7 3 26
3. For minimum covers that require
7-3 5-11 34.3 45.6 188.3 10 7 3 27 reinforcing ribs, columns in the table
7-9 6-0 36.8 51.6 83.8 9 7 5 28 show minimum lengths of rib.
4. The “Arc Length N” column indicates the
8-1 6-1 39.3 53.3 108.1 10 7 5 29 peripheral length of each arc segment
8-5 6-3 41.9 54.9 150.1 11 7 5 30 of the shape. The actual plate make-up
of the ring will vary since plates are
8-10 6-4 44.5 63.3 93.0 10 7 7 31 11
double-curved from one arc to another.
9-3 6-5 47.1 64.4 112.6 11 7 7 32 10
9-7 6-6 49.9 65.4 141.6 12 7 7 33 11
9-11 6-8 52.7 66.4 188.7 13 7 7 34 10
10-3 6-9 55.5 67.4 278.8 14 7 7 35 11
10-9 6-10 58.4 77.5 139.6 13 7 9 36 12
11-1 7-0 61.4 77.8 172.0 14 7 9 37 11
11-5 7-1 64.4 78.2 222.0 15 7 9 38 12
11-9 7-2 67.5 78.7 309.5 16 7 9 39 13
12-3 7-3 70.5 90.8 165.2 15 7 11 40 14
Aluminum Structural Plate

12-7 7-5 73.7 90.5 200.0 16 7 11 41 13

12-11 7-6 77.0 90.4 251.7 17 7 11 42 14
13-1 8-2 83.0 88.8 143.6 18 6 13 43 13
13-1 8-4 86.8 81.7 300.8 21 6 11 44 14
13-11 8-5 90.3 100.4 132.0 18 6 15 45 13
14-0 8-7 94.2 90.3 215.7 21 6 13 46 14
13-11 9-5 101.5 86.2 159.3 23 5 14 47 14
14-3 9-7 105.7 87.2 176.3 24 5 14 48 13
14-8 9-8 109.9 90.9 166.2 24 5 15 49 13
14-11 9-10 114.2 91.8 183.0 25 5 15 50 14
15-4 10-0 118.6 95.5 173.0 25 5 16 51 14
15-7 10-2 123.1 96.4 189.6 26 5 16 52 15
16-1 10-4 127.6 100.2 179.7 26 5 17 53 15
16-4 10-6 132.3 101.0 196.1 27 5 17 54 14
16-9 10-8 136.9 105.0 186.5 27 5 18 55 16
17-0 10-10 141.8 105.7 202.5 28 5 18 56 17
17-3 11-0 146.7 106.5 221.7 29 5 18 57 17
17-9 11-2 151.6 110.4 208.9 29 5 19 58 16
18-0 11-4 156.7 111.1 227.3 30 5 19 59 17
18-5 11-6 161.7 115.8 215.3 30 5 20 60 17
18-8 11-8 167.0 115.8 233.7 31 5 20 61 18
19-2 11-9 172.2 119.9 221.5 31 5 21 62 18
19-5 11-11 177.6 120.5 239.7 32 5 21 63 19
19-10 12-1 182.9 124.7 227.7 32 5 22 64 19
20-1 12-3 188.5 125.2 245.3 33 5 22 65 18
20-1 12-6 194.4 122.5 310.8 35 5 21 66 18
20-10 12-7 199.7 130.0 251.2 34 5 23 67 19
21-1 12-9 205.5 130.5 270.9 35 5 23 68 19
21-6 12-11 211.2 134.8 257.3 35 5 24 69 20
Haunch Radius (Rh) = 47.0”
20-1 13-11 216.6 124.0 225.4 34 7 20 68 19
20-7 14-3 224.0 126.2 257.6 36 7 20 70 19
21-5 14-7 241.5 133.0 238.6 36 7 22 72 19
21-11 14-11 254.7 135.0 270.0 38 7 22 74 19

54
 PIPE ARCH

TABLE 43. PIPE-ARCH 9" X 2-1/2" STRUCTURES (HL-93 LOADING)

Metal Thickness (Inches) — Reinforcing Rib Type
Approx. Rib Spacing (Inches) (Maximum Cover — Ft.)
Span Rise Area Minimum Height of Cover (Feet)
(Ft.-In.) (Ft.-In.) (Sq. Ft.) 1.25 1.50 2.00 2.50 3.00 3.50
6-7 5-8 29.6 .175 .150 .150 .150 .150 .150
6-11 5-9 31.9 (24) (24) (24) (24) (24) (24)
7-3 5-11 34.3 .250 .150 .150 .150 .150 .150
7-9 6-0 36.8 (18) (18) (18) (18) (18) (18)
8-1 6-1 39.3
8-5 6-3 41.9 .200 .150 .150 .150 .150
8-10 6-4 44.5 (16) (16) (16) (16) (16) b

9-3 6-5 47.1 .125-II-9 .125-II-27 .125 .125 .125 .125

9-7 6-6 49.9 (15) (15) (15) (15) (15) (15)
9-11 6-8 52.7 Pipe-Arch
10-3 6-9 55.5 .150-II-18 .125-II-27 .125 .125 .125
10-9 6-10 58.4 (13) (13) (13) (13) (13)
11-1 7-0 61.4
11-5 7-1 64.4 .125-II-9 .125-II-27 .125 .125 .125
11-9 7-2 67.5 (13) (13) (13) (13) (13)
12-3 7-3 70.5 .125-II-27 .150 .125 .125
12-7 7-5 73.7 (11) (11) (11) (11)
12-11 7-6 77.0

Aluminum Structural Plate

13-1 8-2 83.0
13-1 8-4 86.8
13-11 8-5 90.3 .125-II-18 .125-II-27 .125 .125
14-0 8-7 94.2 (10) (10) (10) (10)
13-11 9-5 101.5
14-3 9-7 105.7 .150-II-18 .125-II-27 .125 .125
14-8 9-8 109.9 (9) (9) (9) (9)
14-11 9-10 114.2
15-4 10-0 118.6 .125-II-9 .125-II-27 .150 .125
15-7 10-2 123.1 (8) (8) (8) (8)
16-1 10-4 127.6
16-4 10-6 132.3
16-9 10-8 136.9 .125-VI-27 .125-II-18 .125-II-54 .150
17-0 10-10 141.8 (7) (7) (7) (7)
17-3 11-0 146.7
17-9 11-2 151.6
18-0 11-4 156.7 .125-VI-27 .125-IV-27 .125-IV-54 .175
18-5 11-6 161.7 (7) (7) (7) (7)
18-8 11-8 167.0
19-2 11-9 172.2 .150-IV-9 .150-IV-27 .150-IV-54 .200
19-5 11-11 177.6 (6) (6) (6) (6)
19-10 12-1 182.9 Sidefill and Foundation Design
20-1 12-3 188.5 .175-IV-9 .175-IV-27 .175-IV-54 .225 Horizontal ellipse, pipe-arch, and underpass shapes
20-1 12-6 194.4 (6) (6) (6) (6) generate high bearing pressures against the sidefill and
20-1 13-11 216.6 foundation in the areas of the smaller radius haunches.
20-7 14-3 224.0 The height of cover is directly affected by these bearing
pressures. The surrounding soil and foundation,
20-10 12-7 199.7
therefore, must be checked to ensure that they are
21-1 12-9 205.5 .150-VI-18 .175-IV-18 .150-IV-54 .150-IV-54
adequate to react against these pressures without
21-6 12-11 211.2 (7) (7) (7) (7)
excessive strain.
21-5 14-7 241.5
21-11 14-11 254.7

Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the
bottom of flexible or top of rigid pavement.
3. Minimum cover for heavy off-road construction equipment loads must be checked.
4. Minimum cover heights < span/8 determined by moment capacity analysis.
5. Maximum cover based upon a suggested minimum allowable corner bearing capacity of 4,000 psf.

55
 Steel and Aluminum
Structural Plate
Design Guide

Single Radius Arch

TABLE 44. ARCH 9" X 2-1/2" DETAILS
Approx Rise/ Total N Approx Rise/
Span Rise Area Radius Span Total N
Span Rise Area Radius Span
(Ft.-In.) (Ft.-In.) (Sq. Ft.) (Inches) Ratio Structure Rib (Ft.-In.) (Ft.-In.) (Sq. Ft.) (Inches) Ratio Structure Rib
7-0 2-4 12.0 45.25 .34 11 24-0 8-0 139.3 156.0 .33 38 23
2-10 14.8 43.00 .40 12 9-11 179.1 146.5 .41 42 22
3-8 20.3 42.00 .52 14 11-8 217.5 144.0 .49 46 21
8-0 2-11 17.0 50.50 .36 13 12-5 236.5 144.0 .52 48 21
3-4 20.2 48.75 .42 14 25-0 8-1 145.0 164.5 .32 39 24
4-2 26.4 48.00 .52 16 10-0 186.7 153.5 .40 43 23
9-0 2-11 19.1 59.00 .33 14 8 12-2 236.8 150.0 .49 48 22
3-10 26.3 54.50 .43 16 12-11 256.6 150.0 .52 50 22
4-8 33.4 54.00 .50 18 26-0 8-7 161.6 169.5 .33 41 25
10-0 3-6 25.3 64.00 .35 16 10 10-6 204.8 159.5 .41 45 24
4-5 33.3 60.50 .44 18 10 13-0 256.9 156.0 .49 50 23
5-2 41.2 60.00 .52 20 9 13-6 277.5 156.0 .52 52 23
11-0 3-6 27.8 72.75 .32 17 11 27-0 8-8 167.4 178.5 .32 42 26
4-6 36.8 67.50 .41 19 11 10-7 212.9 166.5 .39 46 25
5-9 49.9 66.00 .52 22 10 13-2 277.8 162.0 .49 52 24
12-0 4-1 35.3 77.50 .34 19 11 14-0 299.3 162.0 .52 54 24
5-0 45.0 73.25 .42 21 11 28-0 9-2 185.5 183.0 .33 44 27
6-3 59.3 72.00 .52 24 12 11-2 232.1 172.5 .40 48 26
13-0 4-1 38.1 86.50 .31 20 12
Aluminum Structural Plate

13-8 299.5 168.0 .49 54 25

5-1 48.9 80.50 .39 22 12 14-6 321.8 168.0 .52 56 25
6-9 69.5 78.00 .52 26 12 29-0 9-9 204.1 188.0 .34 46 28
14-0 4-8 46.9 91.25 .33 22 14 11-8 252.4 178.0 .40 50 26
5-7 58.4 86.00 .40 24 14 14-3 322.1 174.0 .49 56 26
7-3 80.6 84.00 .52 28 14 15-0 345.2 174.0 .52 58 26
15-0 4-8 50.0 100.50 .31 23 15 30-0 10-3 223.7 193.0 .34 48 28
5-8 62.6 93.50 .38 25 15 12-2 273.3 184.0 .41 52 27
6-7 74.7 91.00 .44 27 15 14-9 345.5 180.0 .49 58 27
7-9 92.5 90.00 .52 30 14 15-6 369.4 180.0 .52 60 27
16-0 5-3 60.0 105.00 .32 25 15
7-1 86.2 96.75 .44 29 15
8-3 105.2 96.00 .52 32 14
17-0 5-3 63.5 114.25 .31 26 16
7-2 91.7 103.50 .42 30 16
8-10 118.7 102.00 .52 34 16
Radius Rise, R
18-0 5-9 74.8 118.75 .32 28 18
7-8 104.5 109.25 .43 32 18
8-11 125.9 108.00 .50 35 17
19-0 6-4 86.9 123.50 .33 30 18
8-2 118.0 115.25 .43 34 18
9-5 140.7 114.00 .50 37 17 Span, S
20-0 6-4 91.2 132.50 .32 31 19
8-3 124.4 122.25 .41 35 19 Single Radius Arch
10-0 156.3 120.00 .50 39 19
21-0 7-5 113.5 133.75 .35 34 20 Notes:
8-4 130.7 129.25 .40 36 20 1. N = 9.625”
9-3 147.6 127.50 .44 38 20 2. Additional size options are available upon request.
3. Dimensions to inside corrugation crests are subject to
10-1 164.3 126.00 .48 40 20 manufacturing tolerances.
10-10 181.0 126.00 .52 42 20 4. For minimum covers that require reinforcing ribs,
22-0 6-11 109.2 142.25 .31 34 20 columns in the table show minimum lengths of rib.
5. Arch shapes shown are single radius with a rise/span
8-11 146.0 135.00 .40 38 20
ratio of 0.30 or greater.
11-5 198.6 132.00 .52 44 20 6. Shapes greater than 23' span require additional
23-0 8-0 133.6 147.25 .35 37 21 installation procedures.
9-10 171.3 139.50 .43 41 21
11-6 207.9 138.00 .50 45 21

56
 SINGLE RADIUS ARCH

TABLE 45. ARCH 9" X 2-1/2" STRUCTURES (HL-93 LOADING)

Metal Thickness (in.) Metal Thickness (in.)
Reinforcing Rib Type Reinforcing Rib Type
Rib Spacing (in.) Rib Spacing (in.)
Approx (Maximum Cover — Ft.) Approx (Maximum Cover — Ft.)
Span Rise Area Minimum Height of Cover (Feet) Span Rise Area Minimum Height of Cover (Feet)
(Ft.-In.) (Ft.-In.) (Sq. Ft.) 1.25 1.50 2.00 2.50 3.00 3.50 (Ft.-In.) (Ft.-In.) (Sq. Ft.) 2.00 2.50 3.00 3.50
7-0 2-10 14.8 .175 .175 .175 .175 .175 .175 24-0 8-0 139.3 .225-VI-9 .225-VI-18 .225-IV-27 .225-II-27
3-3 17.5 (45) (45) (45) (45) (45) (45) 9-11 179.1 (17) (17) (17) (17)
3-8 20.3 11-8 217.5
8-0 2-11 17.0 .250 .175 .175 .175 .175 .175 12-5 236.5
3-4 20.2 (63) (42) (42) (42) (42) (42) 25-0 8-1 145.0 .225-VI-9 .225-VI-18 .225-VI-27 .225-II-27
4-2 26.4 10-0 186.7 (17) (17) (17) (17)
9-0 2-11 19.1 .200 .150 .150 .150 .150 12-2 236.8
3-10 26.3 (45) (32) (32) (32) (32) 12-11 256.6
4-8 33.4 26-0 8-7 161.6 .250-VI-9 .250-VI-18 .250-VI-27 .250-IV-27
10-0 3-6 25.3 .125-II-9 .125-II-18 .125 .125 .125 .125 10-6 204.8 (18) (18) (18) (18)
4-5 33.3 (21) (21) (21) (21) (21) (21) 13-0 256.9
5-2 41.2 13-6 277.5
11-0 3-6 27.8 .150-II-9 .125-II-18 .125-II-27 .125 .125 .125 27-0 8-8 167.4 .250-VI-9 .250-VI-9 .250-VI-27 .250-IV-27
4-6 36.8 (26) (19) (19) (19) (19) (19) 10-7 212.9 (16) (16) (16) (16)
5-9 49.9 13-2 277.8
12-0 4-1 35.3 .225-II-9 .125-II-9 .125-II-27 .125 .125 .125 14-0 299.3
5-0 45.0 (37) (18) (18) (18) (18) (18) 28-0 9-2 185.5 .250-VI-9 .250-VI-9 .250-VI-27 .250-IV-27
6-3 59.3 11-2 232.1 (15) (15) (15) (15)
13-0 4-1 38.1 .150-II-9 .125-II-27 .150 .125 .125 13-8 299.5
5-1 48.9 (22) (16) (22) (16) (16) 14-6 321.8
6-9 69.5 29-0 9-9 204.1 .250-VI-9 .250-VI-18 .250-VI-27
14-0 4-8 46.9 .200-II-9 .125-II-18 .175 .125 .125 11-8 252.4 (13) (13) (13)
5-7 58.4 (28) (15) (24) (15) (15) 14-3 322.1

Aluminum Structural Plate

7-3 80.6 15-0 345.2
15-0 4-8 50.0 .250-II-9 .125-II-9 .125-II-27 .125 .125 30-0 10-3 223.7 .250-VI-9 .250-VI-18 .250-VI-27
5-8 62.6 (33) (13) (13) (13) (13) 12-2 273.3 (11) (11) (11)
6-7 74.7 14-9 345.5
7-9 92.5 15-6 369.4
16-0 5-3 60.0 .150-IV-9 .125-II-9 .125-II-27 .150 .125
7-1 86.2 (17) (12) (12) (17) (12)
8-3 105.2
17-0 5-3 63.5 .150-VI-18 .225-II-18 .150-II-27 .175 .150
7-2 91.7 (16) (26) (16) (19) (16)
8-10 118.7
18-0 5-9 74.8 .150-VI-9 .175-IV-18 .125-IV-27 .200 .175
7-8 104.5 (15) (18) (11) (21) (18)
8-11 125.9
19-0 6-4 86.9 .150-VI-9 .125-VI-18 .125-IV-27 .125-II-27 .175
8-2 118.0 (14) (10) (10) (10) (17)
9-5 140.7
20-0 6-4 91.2 .150-VI-9 .150-VI-9 .150-IV-27 .150-II-27 .200
8-3 124.4 (13) (13) (13) (13) (19)
10-0 156.3
21-0 7-5 113.5 .175-VI-9 .175-VI-18 .175-IV-18 .175-II-27 .225
8-4 130.7 (15) (15) (15) (15) (20)
9-3 147.6
10-1 164.3
10-10 181.0
22-0 6-11 109.2 .200-VI-9 .175-VI-18 .175-IV-18 .175-IV-27 .250 Aluminum Receiving Channel
8-11 146.0 (17) (14) (14) (14) (22) Weight is equal to 2 lbs per foot per side.
11-5 198.6
23-0 8-0 133.6 .225-VI-9 .225-VI-18 .225-IV-18 .225-IV-54 .250-II-27
9-10 171.3 (18) (18) (18) (18) (21)
11-6 207.9
11-11 217.1

Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated
structure to the bottom of flexible or top of rigid pavement.
3. Minimum cover for off highway construction loads must be checked.
4. Minimum cover heights < span/8 determined by moment capacity analysis.
5. Greater cover heights possible with other plate thickness/rib combinations.
6. Footing reactions are available upon request.
7. Shapes greater than 23' span require additional installation procedures. Slotted Concrete Footing
For a single radius arch, the dimensions of the keyway
shall be a minimum of 4" height x 8" wide.

57
 Steel and Aluminum
Structural Plate
Design Guide

Underpass
TABLE 46. PEDESTRIAN/ANIMAL UNDERPASS DETAILS
Inside Radius (Inches) Arc Length (Inches) Total N
Approx.
Span Rise Area Crown Side Haunch Invert
Crown Side Haunch Bottom Structure Rib
(Ft.-In.) (Ft.-In.) (Sq. Ft.) (Rt) (Rs) (Rh) (Rb)
Junior Underpasses
6-1 5-9 28.0 31.8 48.2 31.8 43.0 20.5 68.6 9.2 24
6-3 6-1 30 31.8 51.3 31.8 50.2 28.6 60.7 11.1 25
6-3 6-6 32 31.8 55.0 31.8 56.5 36.8 53.9 11.6 26
6-2 6-11 34 31.8 71.3 31.8 70.4 38.0 51.3 10.2 27
6-4 7-3 37 31.8 72.4 31.8 67.3 45.0 50.0 11.6 28
6-3 7-9 39 31.8 74.7 31.8 69.2 54.0 45.7 9.8 29
6-5 8-1 42 31.8 75.8 31.8 66.9 60.5 44.4 11.3 30
Standard Underpasses
12-1 11-0 107.5 70 83 38 133 13 8 4 10 47 10
12-10 11-2 116.6 75 83 38 144 14 8 4 11 49 11
13-0 12-0 126.7 74 93 38 152 14 9 4 11 51 11
13-8 12-4 136.7 78 96 38 158 15 9 4 12 53 12
14-0 12-11 147.4 79 102 38 174 15 10 4 12 55 12
14-6 13-5 156.7 76 144 38 192 16 9 5 13 57 12
14-9 14-1 169.8 81 118 38 182 16 11 4 13 59 12
15-5 14-5 179.2 80 158 38 217 17 10 5 14 61 13
Aluminum Structural Plate

15-7 15-2 193.6 85 132 38 195 17 12 4 14 63 13

16-3 15-6 206.1 89 135 38 201 18 12 4 15 65 13
16-5 16-0 216.0 87 170 38 330 19 12 5 14 67 13
16-8 16-4 222.3 86 188 38 277 19 12 5 15 68 13
17-3 17-1 238.4 89 182 48 219 19 12 6 15 70 16
18-5 16-11 252.0 99 159 48 262 20 12 6 16 72 17
19-0 17-3 266.0 103 166 48 264 21 12 6 17 74 18
19-7 17-7 280.2 107 160 48 315 21 13 6 17 76 18
20-5 17-9 294.4 113 158 48 336 22 13 6 18 78 19
Notes:
1. N = 9.625”
2. Dimensions are to inside corrugation crests and are subject to manufacturing tolerances. The designer should allow sufficient
clearance for manufacturing tolerances and installation deflection.
3. To determine proper gage, use information on Page 59, Table 47.
4. The “Arc Length N” column indicates the peripheral length of each arc segment of the shape. The actual plate make-up of the
ring will vary since plates are double-curved from one arc to another.

Junior Underpass Standard Underpass

58
 UNDERPASS

TABLE 47. UNDERPASS STRUCTURES (HL-93 LOADING)

Metal Thickness (Inches) — Reinforcing Rib Type
Rib Spacing (Inches) (Maximum Cover — Ft.)
Span Rise Approx. Area Minimum Height of Cover (Feet)
(Ft.-In.) (Ft.-In.) (Sq. Ft.) 1.25 1.50 2.00 2.50 3.00 3.50
Junior Underpasses
6-1 5-9 28 .150 .150 .150 .150 .150 .150
6-3 6-1 30 (32) (32) (32) (32) (32) (32)
6-3 6-6 32
6-2 6-11 34
6-4 7-3 37
6-3 7-9 39
6-5 8-1 42
Standard Underpasses
12-1 11-0 107.5 .125-IV-18 .125-II-27 .125 .125 .125
(16) (16) (16) (16) (16)
12-10 11-2 116.6 .150-II-9 .125-II-27 .150 .125 .125
13-0 12-0 126.7 (15) (15) (15) (15) (15)
13-8 12-4 136.7 .125-VI-18 .125-II-18 .175 .150 .150
14-0 12-11 147.4 (14) (14) (14) (14) (14)
14-6 13-5 156.7 .125-VI-18 .125-II-18 .200 .150 .150
14-9 14-1 169.8 (13) (13) (13) (13) (13)

Aluminum Structural Plate

15-5 14-5 179.2 .125-VI-18 .125-VI-27 .125-II-27 .175 .175
15-7 15-2 193.6 (12) (12) (12) (12) (12)
16-3 15-6 206.1 .125-VI-18 .125-VI-27 .150-II-27 .150-II-27 .200
16-5 16-0 216.0 (11) (11) (11) (11) (11)
16-8 16-4 222.3
17-3 17-1 238.4 .150-VI-9 .150-VI-18 .150-IV-27 .150-IV-27 .150-VI-54
18-5 16-11 252.0 (14) (14) (14) (14) (14)
19-0 17-3 266.0 .175-VI-9 .175-VI-18 .175-IV-27 .150-IV-27 .150-IV-27
19-7 17-7 280.2 (12) (12) (12) (12) (12)
20-5 17-9 294.4
Notes:
1. Table based upon AASHTO LRFD Bridge Design Specification for Highway Bridges.
2. Per AASHTO [Link], minimum cover is the vertical distance from the top of the corrugated structure to the bottom of flexible or top of rigid pavement.
3. Minimum cover for heavy off-road construction equipment loads must be checked.
4. Minimum cover heights < span/8 determined by moment capacity analysis.
5. Maximum cover based upon a suggested minimum allowable corner bearing capacity of 4,000 psf.

Assembly of Aluminum Structural Plate with Headwalls

59
 Steel and Aluminum
Structural Plate
Design Guide

Aluminum Structural Plate Project Specification

Installation: The structure shall be installed in accordance
Scope: This specification covers the manufacture and
with the plans and specifications, the manufacturer’s
installation of the Aluminum Structural Plate structure
recommendations and the AASHTO LRFD Bridge
detailed in the plans.
Construction Specifications, Section 26.
Material: The Aluminum Structural Plate structure shall
Backfill: The structure shall be backfilled using clean, well
consist of plates and appurtenant items as shown on the
graded granular material that meets the requirements of
plans and shall conform to the requirements of
AASHTO M 145 for soil classifications A-1, A-2-4, A-2-5,
AASHTO M 219 and ASTM B746. The corrugated plate (and
or A-3. Backfill must be placed symmetrically on each side
ribs if required) shall be curved and bolt hole punched at the
of the structure in 8-inch uncompacted lifts with no side-
plant. Plate thickness and rib spacings shall be as indicated
to-side diffferential exceeding 24-inches. Each lift shall be
on the plans. All manufacturing processes including
compacted to a minimum 90% density per AASHTO T-180.
corrugating, punching, and curving, shall be performed
within the United States. Note: Construction loads that exceed highway load limits
are not allowed on the structure without approval
Bolts and suitable nuts shall conform to the requirements of
from the Project Engineer.
ASTM A307 or A449 for steel fasteners or ASTM F467
and F468 for aluminum fasteners.

Assembly: The structure shall be assembled in

accordance with the manufacturer's shop drawings and
recommendations. Bolts shall be tightened using an applied
torque between 100-150 ft.-lbs..
Aluminum Structural Plate

Assembly of Aluminum Structural Plate Single Radius Arch

60
Installation Recommendations Assembly
Assembly drawings and detailed assembly instructions are
Required Elements
shipped with each order. Structures can be preassembled
Satisfactory site preparation, trench excavation, bedding and and lifted into place all at once or in sections, allowing for
backfill operations are essential to develop the strength of staged construction. If the site conditions allow, structures
any flexible conduit. In order to obtain proper strength while can be assembled in place. A qualified engineer should be
preventing settlement, it is necessary that the soil envelope engaged to determine the most appropriate assembly
around the structure be of good granular material, properly method based on the site conditions. For additional
placed, and carefully compacted. information contact your local Contech representative.
Pipe-arch and underpass shapes pose special installation
concerns. These shapes generate high corner bearing Backfill
pressures against the side fill and foundation, see page 55 Satisfactory backfill material, proper placement and
and 59 for the allowable corner bearing capacity. Therefore, compaction are key factors in obtaining maximum strength
special installation care must be implemented to achieve a and stability. Compaction needs to be achieved under the
composite soil structure. haunches by carefully tamping a granular or select material.
A qualified Engineer should be engaged to design a proper The backfill material should be free of rocks, frozen lumps
foundation, adequate bedding, and backfill. and foreign material that could cause hard spots or
decompose to created voids. Backfill material should be
Trench Excavation
well graded granular material that meets the requirements
If the adjacent embankment material is structurally of AASHTO M 145 for soil classifications A-1, A-2-4, A-2-5,
adequate, the trench requires only a bottom clear width of

Aluminum Structural Plate

or A-3. Backfill must be placed symmetrically on each side
the structure’s span plus sufficient room for compaction of the structure in 8-inch uncompacted lifts, with no side-
equipment. to-side diffferential exceeding 24-inches. Each lift is to be
compacted to a minimum 90% density per AASHTO T-180.
Bedding
A high percentage of silt or fine sand in the native soils
Proper bedding preparation is critical to both structure
suggests the need for a well graded granular backfill
performance and service life. The bedding should be
material to prevent soil migration.
constructed to a uniform line and grade to avoid distortions
that may create undesirable stresses in the structure and/or During backfill, only small tracked vehicles (20,000 lbs. or
rapid deterioration of the roadway. It should be free of rock smaller) should be near the structure as fill progresses above
formations, protruding stones, and frozen matter that may the crown and to the finished grade. The engineer and
cause unequal settlement. contractor are cautioned that the minimum cover may need
to be increased to handle temporary construction vehicle
It is recommended that the bedding be a relatively loose loads (heavier than the design highway load).
granular material that is roughly shaped to fit the bottom of
the structure, be a minimum of twice the corrugation depth Precautions
in thickness and have a maximum particle size of one half
During installation and prior to the construction of
the corrugation depth.
permanent erosion control and end treatment protection,
special precautions may be necessary.
It should be noted that the bedding depth can vary based on
the amount of cover and the shape of the structure’s invert. The structure must be protected from unbalanced loading or
The bedding should be shaped to match structures with conditions or hydraulic forces that might bend or distort the
flatter inverts. unsupported ends of the structure.
Erosion or washout of previously placed soil support must
Please reference the project specifications, drawing
be prevented to ensure that the structure maintains its
submittals and Contech's Assembly and Installation Guide
load capacity.
for more information.

Salt Water Installation

In salt water installations, the bedding and backfill around

the structure must be clean, free draining, granular material.
You should consider using aluminum fasteners for these type
of applications. If the backfill is subject to possible infiltration
by the adjacent native soil, the clean granular backfill should
be wrapped in a geotextile.
61
 Steel and Aluminum
Structural Plate
Design Guide

Aluminum Box Culverts

The Solution for Small Bridge Replacement: Aluminum
Box Culverts

Contech Aluminum Box Culverts are a practical and cost-

efficient solution for small bridge replacement. They have an
overall lower installed cost due to material efficiencies when
compared with cast-in-place concrete structures. There are
no forms to set and remove, no delays due to curing time,
large installation crews are unnecessary and no special
equipment is typically needed. Cranes may occasionally be
required to lift fully assembled structures.

These wide-span, low-rise structures are available in a large

range of standard sizes (from 8’-9” span x 2’-6” rise to
35’-3” span x 13’-7” rise) that permit a minimum cover
beginning as low as 1'-5". Information is provided in the
following tables for HL-93, HS-20 and HS-25 live loading,
since these loads are still widely considered in design.

Full Invert Footing Pads

(see page 72) (see page 76)

Typical Metal Foundation Options

Efficient Installations for Lower Installed Costs Lifting of Aluminum Box Culvert

Closing roads for bridge replacement causes extensive

traffic detours, so minimizing installation time is critical.
Depending on length of structure, Aluminum Box Culverts
may be erected in place and are immediately ready to
be backfilled. To aid in accelerated bridge construction,
Aluminum Box Culvert

Aluminum Box Culverts can be completely assembled nearby

while the foundation is being prepared. Light equipment
can then be used to pick and set them in place. For more
information, contact your local Contech representative.

County road bridge replacement made easy

with lightweight, pre-engineered aluminum box
culverts.

Installation of Ribs

Corrugated Aluminum Box Culvert with Headwall Package

62
Outside
Valley
Outside Valley

Structural
StructuralPlate
Plate Inside
InsideCrest
Crest

BoltBolet
&&NutNut

Crown Lapping Detail

(D)

E0 Box Culvert Shell Cross Section

4 9/16”
3 9/16”

3”
Type IV Rib Type VI Rib
Type II Rib

2 ½” 2 ½”
2 3/8”
Box Culvert Rib Geometry

Notes:

1. Structure 1 is a one-plate shell. Structures 2-26 are two plate shells. 4. Select the structure with the lowest alphabetical sub-designation and
Structures 27-143 are three-plate shells. cover range that will include the actual minimum and maximum cover.
2. In Shell Fill Height Tables 48A, 48B, 49A and 49B, the numerical Example: Structure 6 R1 is more economical than 6 R2 if the cover is

Aluminum Box Culvert

designation for HG/CG indicates thickness or gage of haunch (HG) and between 1.7 and 5.0 feet.
crown (CG) plates as follows: 5. Shell weight per foot (Wt./Ft.) of shell includes plates, reinforcing ribs, rib
2=.125” splices, bolts, and nuts.
3=.150” 6. Total structure length can be any dimension, but whenever possible, it is
4=.175” recommended to work with a multiple of 4.5’ (net plate length). This
5=.200” practice usually results in lower total structure cost. Example: 50’
6=.225” proposed structure ÷ 4.5’=11.1, nearest whole number is 11, therefore
7=.250” use 11 x 4.5’= 49.5’ for total structure length. When ordering a structure
Example: The HG/CG for 3/6=.150” haunch and .225” crown plate with headwalls on each end, total structure length must be a multiple of 9
thickness. The HRS/CRS designation indicates the rib spacing on the inches (see page 48 plate detail).
haunch (HRS) and crown (CRS) plates. Example: 27/9=27” o.c. haunch 7. Shell data in Table 48A and 48B is designed for HL-93 loading. Table
rib spacing and 9” o.c. crown rib spacing. 49A is for HS-20 and Table 49B is for HS-25 standard live loadings.
3. Allowable cover (minimum and maximum) is measured from the outside Contact your local Contech representative for design information on
valley (inside rise location) of the crown plate to bottom of the flexible other loadings.
pavement or to the top of rigid pavement. Minimum cover is measured 8. For custom live loads, special rib combinations and spacing are
at the lowest fill area subjected to possible wheel loads (typically at available.
the roadway shoulder). The roadway surface must be maintained to 9. The maximum cover for Aluminum Box Culverts with full inverts and
ensure minimum cover to prevent high-impact loads being imparted footing pads should not exceed 4 feet with a minimum 4,000 psf
to the structure. Maximum cover is measured at the highest fill and/or allowable soil-bearing capacity. Special full invert and footing pad
pavement elevation. Please reference AASHTO [Link]. designs or slotted concrete footings can accommodate maximum covers
to the limits shown in Tables 48A, 48B, 49A, and 49B.

63
 HL-93
Steel and Aluminum
Structural Plate
Design Guide
Box Culvert Shell-Plate and Rib Data (HL-93)
TABLE 48A. SHELL DATA – HL-93 LOADING
PLATE AND RIB COMBINATIONS WITH ALLOWABLE HEIGHT OF COVER
R1 R2 R3
Span Rise HRS/ HR/ Cover Hgt. Shell HRS/ HR/ Cover Hgt. Shell HRS/ HR/ Cover Hgt. Shell
Structure "A" "B" Area HG/CG CRS CR Min. Max. Wt./Ft. HG/CG CRS CR Min. Max. Wt./Ft. HG/CG CRS CR Min. Max. Wt./Ft.
Number Ft.-In. Ft.-In. Sq. Ft. (Gage) (Inches) (Type) (Feet) (Lbs.) (Gage) (Inches) (Type) (Feet) (Lbs.) (Gage) (Inches) (Type) (Feet) (Lbs.)

1 8-9 2-6 18.4 3/3 54/18 II/IV 1.4 5.0 53

2 9-2 3-3 25.4 2/2 54/18 II/IV 1.4 5.0 53
3 9-7 4-1 32.6 2/2 54/18 II/IV 1.4 5.0 58
4 10-0 4-10 40.2 2/2 54/18 II/IV 1.4 5.0 62
5 10-6 5-7 48.1 2/2 54/18 II/IV 1.4 5.0 66
6 10-11 6-4 56.4 2/2 54/18 II/IV 1.7 5.0 70 2/2 54/18 II/VI 1.4 5.0 73
7 11-4 7-2 65.0 2/2 54/18 II/IV 1.9 5.0 74 2/2 54/18 II/VI 1.4 5.0 77
8 10-2 2-8 23.0 2/2 54/18 II/IV 1.4 5.0 57
9 10-7 3-5 31.1 2/2 54/18 II/IV 1.4 5.0 62
10 10-11 4-3 39.5 2/2 54/18 II/IV 1.7 5.0 67 2/2 54/18 II/VI 1.4 5.0 72
11 11-4 5-0 48.2 2/2 54/18 II/IV 1.9 5.0 71 2/2 54/18 II/VI 1.4 5.0 76
12 11-8 5-9 57.2 2/2 54/18 II/IV 2.3 5.0 75 2/2 54/18 II/VI 1.4 5.0 80
13 12-1 6-7 66.4 2/2 54/18 II/IV 2.9 5.0 78 2/2 54/18 II/VI 1.4 5.0 83
14 12-5 7-4 76.0 2/2 54/18 II/IV 3.2 5.0 82 2/2 54/18 IV/VI 1.4 5.0 90
15 11-7 2-10 28.1 2/2 54/18 II/IV 2.1 5.0 65 2/2 54/18 II/VI 1.4 5.0 72
16 11-11 3-7 37.4 2/2 54/18 II/IV 2.6 5.0 70 2/2 54/18 II/VI 1.4 5.0 76
17 12-3 4-5 46.9 2/2 54/18 II/IV 3.1 5.0 75 2/2 54/18 IV/VI 1.4 5.0 84
18 12-7 5-2 56.6 2/2 54/18 II/IV 3.4 5.0 78 2/2 54/18 IV/VI 1.4 5.0 87
19 12-11 6-0 66.6 3/3 54/18 II/IV 2.6 5.0 91 2/2 54/18 IV/VI 1.4 5.0 91
20 13-3 6-9 76.9 3/3 54/18 II/IV 3.0 5.0 96 2/2 54/18 IV/VI 1.4 5.0 95
21 13-0 3-0 33.8 3/3 54/18 IV/IV 2.0 5.0 81 2/2 54/18 IV/VI 1.4 5.0 83
22 13-4 3-10 44.2 3/3 54/18 IV/IV 2.3 5.0 87 2/2 54/18 IV/VI 1.4 5.0 88
23 13-7 4-7 54.8 3/3 54/18 IV/IV 2.6 5.0 93 2/2 54/18 IV/VI 1.4 5.0 93
24 13-10 5-5 65.6 3/3 54/18 IV/IV 2.9 5.0 97 2/2 54/18 IV/VI 1.4 5.0 97
25 14-1 6-2 76.6 3/3 54/18 IV/IV 3.1 5.0 102 3/3 54/18 IV/VI 1.4 5.0 110
26 14-5 3-3 40.0 3/3 54/18 IV/VI 1.4 5.0 100
27 14-8 4-1 51.5 3/2 54/18 IV/VI 1.4 5.0 103
28 14-10 4-10 63.2 4/2 54/18 IV/VI 1.4 5.0 109
29 15-1 5-8 75.1 3/2 54/18 IV/VI 1.6 5.0 113 2/2 27/18 IV/VI 1.4 5.0 118
30 15-4 6-5 87.2 3/3 54/18 IV/VI 1.7 5.0 120 3/2 27/18 IV/VI 1.4 5.0 129
31 15-6 7-3 99.4 4/2 54/18 IV/VI 1.7 5.0 131 3/2 27/18 IV/VI 1.4 5.0 134
32 15-9 8-0 111.8 3/3 54/18 IV/VI 1.9 5.0 129 3/2 27/18 IV/VI 1.4 5.0 138
33 15-10 3-6 46.8 2/2 27/18 IV/VI 1.7 5.0 111 3/2 27/18 IV/VI 1.4 5.0 116
34 16-0 4-3 59.5 2/2 27/18 IV/VI 1.8 5.0 117 4/2 27/18 IV/VI 1.4 5.0 130
35 16-2 5-1 72.3 2/2 27/18 IV/VI 1.9 5.0 123 3/2 18/18 IV/VI 1.4 5.0 137
36 16-4 5-11 85.2 2/2 27/18 IV/VI 2.0 5.0 127 3/2 18/18 IV/VI 1.4 5.0 142
37 16-6 6-8 98.3 2/2 27/18 IV/VI 2.2 5.0 131 3/2 18/18 IV/VI 1.4 5.0 147
38 16-8 7-6 111.5 2/2 27/18 IV/VI 2.3 5.0 135 3/2 18/18 IV/VI 1.4 5.0 154
39 16-10 8-3 124.8 2/2 27/18 IV/VI 2.4 5.0 139 3/3 18/18 IV/VI 1.4 5.0 158
40 17-9 3-10 54.4 2/2 54/18 VI/VI 2.9 5.0 115 2/2 27/18 VI/VI 1.7 5.0 128 2/2 18/18 VI/VI 1.4 5.0 136
41 18-2 4-7 68.3 2/3 54/18 VI/VI 3.0 5.0 124 2/2 27/18 VI/VI 2.0 5.0 135 2/2 18/18 VI/VI 1.4 5.0 145
42 18-7 5-4 82.5 3/3 54/18 VI/VI 3.1 5.0 136 3/2 27/18 VI/VI 2.1 5.0 149 2/2 18/18 VI/VI 1.4 5.0 155
43 19-0 6-1 97.1 2/2 27/18 VI/VI 2.5 5.0 150 2/2 18/18 VI/VI 1.6 5.0 164 2/2 27/9 VI/VI 1.4 5.0 195
44 19-5 6-11 111.9 2/2 27/18 VI/VI 2.7 5.0 154 2/2 18/18 VI/VI 1.8 5.0 168 2/2 27/9 VI/VI 1.4 5.0 199
45 19-10 7-8 127.1 2/2 27/18 VI/VI 3.0 5.0 158 2/2 18/18 VI/VI 1.9 5.0 171 2/2 27/9 VI/VI 1.4 5.0 203
46 20-3 8-5 142.6 3/3 27/18 VI/VI 3.0 4.9 175 2/2 18/18 VI/VI 2.1 5.0 175 3/2 27/9 VI/VI 1.4 5.0 216
47 19-1 4-2 63.3 2/2 27/18 VI/VI 2.5 5.0 137 2/2 18/18 VI/VI 1.6 5.0 145 2/2 27/9 VI/VI 1.4 5.0 188
48 19-5 4-11 78.3 2/2 27/18 VI/VI 2.7 5.0 145 2/2 18/18 VI/VI 1.8 5.0 155 2/2 27/9 VI/VI 1.4 5.0 195
49 19-9 5-8 93.6 2/2 27/18 VI/VI 2.9 5.0 152 2/2 18/18 VI/VI 1.9 5.0 164 2/2 27/9 VI/VI 1.4 5.0 203
50 20-1 6-6 109.2 3/2 27/18 VI/VI 3.0 5.0 167 2/2 18/18 VI/VI 2.0 5.0 173 3/2 27/9 VI/VI 1.4 5.0 218
51 20-6 7-3 125.0 3/2 27/18 VI/VI 3.2 4.9 171 2/2 18/18 VI/VI 2.1 5.0 177 2/2 18/9 VI/VI 1.4 5.0 230
52 20-10 8-1 141.2 2/2 18/18 VI/VI 2.2 5.0 181 2/2 18/9 VI/VI 1.4 5.0 234
53 21-2 8-10 157.6 2/2 18/18 VI/VI 2.2 5.0 184 2/2 18/9 VI/VI 1.4 5.0 238
Aluminum Box Culvert

54 20-4 4-6 73.1 2/3 27/18 VI/VI 3.2 5.0 151 2/2 18/18 VI/VI 2.1 5.0 155 2/2 18/9 VI/VI 1.4 5.0 213
55 20-7 5-3 89.2 3/2 27/18 VI/VI 3.3 4.7 160 2/2 18/18 VI/VI 2.1 5.0 164 2/2 18/9 VI/VI 1.4 5.0 223
56 20-11 6-1 105.5 2/2 18/18 VI/VI 2.2 5.0 173 2/2 18/9 VI/VI 1.4 5.0 232
57 21-3 6-10 122.1 2/2 18/18 VI/VI 2.3 5.0 182 2/2 18/9 VI/VI 1.4 5.0 241
58 21-6 7-8 139.0 2/2 18/18 VI/VI 2.4 5.0 186 2/2 18/9 VI/VI 1.4 5.0 245
59 21-10 8-5 156.0 2/2 18/18 VI/VI 2.5 5.0 190 2/2 18/9 VI/VI 1.4 5.0 249
60 22-1 9-3 173.3 2/2 18/18 VI/VI 2.6 5.0 194 2/2 18/9 VI/VI 1.4 5.0 253
61 21-7 4-11 83.8 2/2 18/18 VI/VI 2.4 5.0 164 2/3 9/18 VI/VI 2.2 5.0 208 2/2 18/9 VI/VI 1.4 5.0 228
62 21-10 5-8 101.0 2/2 18/18 VI/VI 2.5 5.0 173 2/3 9/18 VI/VI 2.3 5.0 223 2/2 18/9 VI/VI 1.4 5.0 237
63 22-1 6-6 118.4 2/2 18/18 VI/VI 2.6 5.0 182 2/3 9/18 VI/VI 2.3 5.0 237 2/2 18/9 VI/VI 1.4 5.0 247
64 22-3 7-3 135.9 2/2 18/18 VI/VI 2.6 5.0 191 2/3 9/18 VI/VI 2.4 5.0 252 2/2 18/9 VI/VI 1.4 5.0 256
65 22-6 8-1 153.7 2/2 18/18 VI/VI 2.7 5.0 195 2/3 9/18 VI/VI 2.4 5.0 256 2/2 18/9 VI/VI 1.4 5.0 260
66 22-9 8-10 171.6 2/2 18/18 VI/VI 2.8 5.0 199 2/3 9/18 VI/VI 2.5 5.0 260 2/2 18/9 VI/VI 1.4 5.0 264
67 23-0 9-8 189.8 2/2 18/18 VI/VI 2.9 4.8 203 2/3 9/18 VI/VI 2.5 5.0 263 2/2 18/9 VI/VI 1.4 5.0 267
68 22-9 5-4 95.5 2/2 18/18 VI/VI 2.8 5.0 173 2/3 9/18 VI/VI 2.5 5.0 217 2/2 18/9 VI/VI 1.4 5.0 243
69 23-0 6-1 113.7 2/2 18/18 VI/VI 2.8 4.8 182 2/3 9/18 VI/VI 2.5 5.0 232 2/2 18/9 VI/VI 1.4 5.0 252
70 23-2 6-11 132.1 2/2 18/18 VI/VI 3.0 4.6 196 2/3 9/18 VI/VI 2.5 5.0 247 2/2 18/9 VI/VI 1.4 5.0 261
71 23-4 7-8 150.6 2/3 18/18 VI/VI 2.9 4.7 205 2/3 9/18 VI/VI 2.6 5.0 261 2/2 18/9 VI/VI 1.4 5.0 271
72 23-6 8-6 169.3 2/3 18/18 VI/VI 3.0 4.4 209 2/3 9/18 VI/VI 2.6 5.0 265 2/2 18/9 VI/VI 1.4 5.0 275
73 23-8 9-3 188.1 3/3 18/18 VI/VI 3.0 4.5 223 2/3 9/18 VI/VI 2.7 5.0 269 2/2 18/9 VI/VI 1.4 5.0 278
74 23-10 10-1 207.0 3/3 18/18 VI/VI 3.0 4.3 228 2/3 9/18 VI/VI 2.7 5.0 273 2/2 18/9 VI/VI 1.4 5.0 282
75 24-0 5-9 108.2 2/3 9/18 VI/VI 2.7 5.0 227 2/2 18/9 VI/VI 1.4 5.0 258
76 24-1 6-6 127.5 2/3 9/18 VI/VI 2.7 5.0 242 2/2 18/9 VI/VI 1.4 5.0 267
77 24-3 7-4 146.8 2/3 9/18 VI/VI 2.8 5.0 256 2/2 18/9 VI/VI 1.4 5.0 276
78 24-4 8-2 166.2 2/3 9/18 VI/VI 2.8 5.0 271 2/2 18/9 VI/VI 1.4 5.0 285
79 24-5 8-11 185.7 2/3 9/18 VI/VI 2.8 5.0 275 2/2 18/9 VI/VI 1.4 5.0 289
80 24-7 9-9 205.3 2/3 9/18 VI/VI 2.8 5.0 279 2/2 18/9 VI/VI 1.4 5.0 293
81 24-8 10-6 225.0 2/3 9/18 VI/VI 2.9 5.0 283 2/2 18/9 VI/VI 1.4 5.0 297
82 25-2 6-2 122.0 2/3 9/18 VI/VI 3.0 5.0 236 2/2 18/9 VI/VI 1.4 5.0 273
83 25-2 7-0 142.2 2/3 9/18 VI/VI 3.0 5.0 251 2/2 18/9 VI/VI 1.4 5.0 282
84 25-3 7-9 162.4 2/3 9/18 VI/VI 3.0 5.0 266 2/2 18/9 VI/VI 1.4 5.0 291
85 25-4 8-7 182.6 2/3 9/18 VI/VI 3.0 5.0 280 2/3 18/9 VI/VI 1.4 5.0 306
86 25-4 9-5 202.9 2/3 9/18 VI/VI 3.0 5.0 284 2/3 18/9 VI/VI 1.4 5.0 310
87 25-5 10-2 223.3 2/3 9/18 VI/VI 3.0 4.9 288 2/3 18/9 VI/VI 1.4 5.0 313

See Notes page 63

64
 HL-93

Box Culvert Shell-Plate and Rib Data (HL-93)

TABLE 48B. SHELL DATA – HL-93 LOADING
PLATE AND RIB COMBINATIONS WITH ALLOWABLE HEIGHT OF COVER
R1 R2
Cover Hgt. Shell Cover Hgt. Shell
Structure Span "A" Rise "B" Area HG/CG HRS/CRS HR/CR Min. Max. Wt./Ft. HG/CG HRS/CRS HR/CR Min. Max. Wt./Ft.
Number Ft.-In. Ft.-In. Sq. Ft. (Gage) (Inches) (Type) (Feet) (Lbs.) (Gage) (Inches) (Type) (Feet) (Lbs.)

88 26-7 5-5 111.6 3/3 9/18 VI/VI 4.0 5.0 244 3/4 9/9 VI/VI 1.4 5.0 323
89 27-0 6-3 132.4 3/3 9/18 VI/VI 4.0 5.0 259 3/4 9/9 VI/VI 1.4 5.0 338
90 27-5 7-0 153.4 3/3 9/18 VI/VI 4.0 5.0 275 3/4 9/9 VI/VI 1.4 5.0 353
91 27-10 7-9 174.8 3/3 9/18 VI/VI 4.0 5.0 290 3/4 9/9 VI/VI 1.4 5.0 369
92 28-3 8-7 196.5 3/3 9/18 VI/VI 4.0 5.0 294 3/4 9/9 VI/VI 1.4 5.0 373
93 28-8 9-4 218.6 3/3 9/18 VI/VI 4.0 5.0 299 3/5 9/9 VI/VI 1.4 5.0 384
94 29-2 10-1 241.0 3/3 9/18 VI/VI 4.0 5.0 303 3/5 9/9 VI/VI 1.4 5.0 388
95 27-10 5-10 125.4 3/3 9/18 VI/VI 4.0 5.0 259 3/4 9/9 VI/VI 1.4 5.0 338
96 28-3 6-8 147.3 3/3 9/18 VI/VI 4.0 5.0 275 3/4 9/9 VI/VI 1.4 5.0 353
97 28-7 7-5 169.4 3/3 9/18 VI/VI 4.0 5.0 290 3/5 9/9 VI/VI 1.4 5.0 375
98 29-0 8-3 191.8 3/3 9/18 VI/VI 4.0 5.0 305 3/5 9/9 VI/VI 1.4 5.0 390
99 29-4 9-0 214.6 3/3 9/18 VI/VI 4.0 5.0 310 3/5 9/9 VI/VI 1.4 5.0 394
100 29-8 9-9 237.6 3/3 9/18 VI/VI 4.0 5.0 314 3/5 9/9 VI/VI 1.4 5.0 399
101 30-1 10-7 260.9 3/3 9/18 VI/VI 4.0 5.0 319 3/5 9/9 VI/VI 1.4 5.0 403
102 29-1 6-4 140.2 3/3 9/18 VI/VI 4.0 5.0 275 3/5 9/9 VI/VI 1.4 5.0 361
103 29-5 7-1 163.2 3/3 9/18 VI/VI 4.0 5.0 290 3/5 9/9 VI/VI 1.4 5.0 376
104 29-8 7-11 186.4 3/3 9/18 VI/VI 4.0 5.0 305 3/5 9/9 VI/VI 1.4 5.0 391
105 30-0 8-8 209.8 3/3 9/18 VI/VI 4.0 5.0 320 3/5 9/9 VI/VI 1.4 5.0 407
106 30-4 9-5 233.6 3/3 9/18 VI/VI 4.0 5.0 325 3/5 9/9 VI/VI 1.4 5.0 411
107 30-8 10-3 257.5 3/3 9/18 VI/VI 4.0 5.0 330 3/5 9/9 VI/VI 1.4 5.0 416
108 31-0 11-0 281.8 3/3 9/18 VI/VI 4.0 5.0 334 3/5 9/9 VI/VI 1.4 5.0 420
109 30-3 6-9 156.1 3/3 9/18 VI/VI 4.0 5.0 285 3/5 9/9 VI/VI 1.4 5.0 376
110 30-6 7-7 180.1 3/3 9/18 VI/VI 4.0 5.0 300 3/5 9/9 VI/VI 1.4 5.0 391
111 30-10 8-4 204.4 3/3 9/18 VI/VI 4.0 5.0 315 3/5 9/9 VI/VI 1.4 5.0 407
112 31-1 9-2 228.8 3/3 9/18 VI/VI 4.0 5.0 330 3/5 9/9 VI/VI 1.4 5.0 422
113 31-4 9-11 253.5 3/3 9/18 VI/VI 4.0 5.0 335 3/5 9/9 VI/VI 1.4 5.0 426
114 31-8 10-9 278.4 3/3 9/18 VI/VI 4.0 5.0 339 3/5 9/9 VI/VI 1.4 5.0 431
115 31-11 11-6 303.5 3/3 9/18 VI/VI 4.0 5.0 344 3/5 9/9 VI/VI 1.4 5.0 435
116 31-5 7-3 173.1 3/3 9/18 VI/VI 4.0 5.0 294 3/5 9/9 VI/VI 1.4 5.0 391
117 31-8 8-0 198.2 3/3 9/18 VI/VI 4.0 5.0 310 3/5 9/9 VI/VI 1.4 5.0 407
118 31-10 8-10 223.4 3/3 9/18 VI/VI 4.0 5.0 325 3/5 9/9 VI/VI 1.4 5.0 422
119 32-1 9-8 248.8 3/3 9/18 VI/VI 4.0 5.0 340 3/5 9/9 VI/VI 1.4 5.0 437
120 32-3 10-5 274.4 3/3 9/18 VI/VI 4.0 5.0 345 3/4 9/9 VI/VI 1.4 5.0 435
121 32-7 11-3 300.1 3/3 9/18 VI/VI 4.0 5.0 349 3/4 9/9 VI/VI 1.4 5.0 440
122 32-8 12-0 326.1 3/3 9/18 VI/VI 4.0 5.0 354 3/4 9/9 VI/VI 1.4 5.0 444
123 32-7 7-9 191.3 3/3 9/18 VI/VI 4.0 5.0 304 3/4 9/9 VI/VI 1.4 5.0 401
124 32-9 8-6 217.3 3/3 9/18 VI/VI 4.0 5.0 320 3/4 9/9 VI/VI 1.4 5.0 416
125 32-11 9-4 243.4 3/3 9/18 VI/VI 4.0 5.0 335 3/4 9/9 VI/VI 1.4 5.0 431
126 33-1 10-2 269.7 3/3 9/18 VI/VI 4.0 5.0 350 3/4 9/9 VI/VI 1.4 5.0 447
127 33-3 10-11 296.4 3/3 9/18 VI/VI 4.0 5.0 355 3/4 9/9 VI/VI 1.4 5.0 451
128 33-5 11-9 322.8 3/3 9/18 VI/VI 4.0 5.0 359 3/4 9/9 VI/VI 1.4 5.0 456
129 33-8 12-6 349.5 3/3 9/18 VI/VI 4.0 5.0 364 3/4 9/9 VI/VI 1.4 5.0 460
130 33-8 8-3 210.5 3/3 9/18 VI/VI 4.0 5.0 314 3/4 9/9 VI/VI 1.4 5.0 416
131 33-9 9-1 237.5 3/3 9/18 VI/VI 4.0 5.0 330 3/4 9/9 VI/VI 1.4 5.0 431
132 33-11 9-10 264.5 3/3 9/18 VI/VI 4.0 5.0 345 3/4 9/9 VI/VI 1.4 5.0 447
133 34-0 10-8 291.7 3/3 9/18 VI/VI 4.0 5.0 360 3/4 9/9 VI/VI 1.4 5.0 462
134 34-2 11-5 319.0 3/3 9/18 VI/VI 4.0 5.0 365 3/4 9/9 VI/VI 1.4 5.0 466
135 34-3 12-3 346.4 3/3 9/18 VI/VI 4.0 5.0 369 3/4 9/9 VI/VI 1.4 5.0 471
136 34-5 13-1 373.8 3/3 9/18 VI/VI 4.0 5.0 374 3/4 9/9 VI/VI 1.4 5.0 475

Aluminum Box Culvert

137 34-9 8-9 230.9 3/3 9/18 VI/VI 4.0 5.0 324 3/3 9/9 VI/VI 1.4 5.0 424
138 34-10 9-7 258.1 3/3 9/18 VI/VI 4.0 5.0 339 3/3 9/9 VI/VI 1.4 5.0 439
139 34-11 10-4 286.7 3/3 9/18 VI/VI 4.0 5.0 355 3/3 9/9 VI/VI 1.4 5.0 455
140 35-0 11-2 314.6 3/3 9/18 VI/VI 4.0 5.0 370 3/3 9/9 VI/VI 1.4 5.0 470
141 35-1 12-0 342.7 3/3 9/18 VI/VI 4.0 5.0 375 3/3 9/9 VI/VI 1.4 5.0 474
142 35-2 12-9 370.8 3/3 9/18 VI/VI 4.0 5.0 379 3/3 9/9 VI/VI 1.4 5.0 479
143 35-3 13-7 399.0 3/3 9/18 VI/VI 4.0 5.0 384 3/3 9/9 VI/VI 1.4 5.0 483

See Notes page 63

Fully Assembled Aluminum Box Culvert Being Set in Place

65
 H-20/HS-20
Steel and Aluminum
Structural Plate
Design Guide
Box Culvert Shell-Plate and Rib Data (H-20, HS-20)
TABLE 49A. SHELL DATA – H-20, HS-20 LOADING
PLATE AND RIB COMBINATIONS WITH ALLOWABLE HEIGHT OF COVER
A6 B6
Cover Hgt. Shell Cover Hgt. Shell
Structure Span "A" Rise "B" Area HG/CG HRS/CRS HR/CR Min. Max. Wt./Ft. HG/CG HRS/CRS HR/CR Min. Max. Wt./Ft.
Number Ft.-In. Ft.-In. Sq. Ft. (Gage) (Inches) (Type) (Feet) (Lbs.) (Gage) (Inches) (Type) (Feet) (Lbs.)

1 8-9 2-6 18.4 3/3 54/18 II/IV 1.4 5.0 53

2 9-2 3-3 25.4 2/2 54/18 II/IV 1.4 5.0 53
3 9-7 4-1 32.6 2/2 54/18 II/IV 1.4 5.0 58
4 10-0 4-10 40.2 2/2 54/18 II/IV 1.6 5.0 62 3/3 54/18 II/IV 1.4 5.0 69
5 10-6 5-7 48.1 2/2 54/18 II/IV 1.8 5.0 66 3/3 54/18 II/IV 1.4 5.0 74
6 10-11 6-4 56.4 2/2 54/18 II/IV 2.1 5.0 70 3/3 27/18 II/IV 1.4 5.0 87
7 11-4 7-2 65.0 2/2 54/18 II/IV 2.3 5.0 74 2/2 54/9 II/IV 1.4 5.0 83
8 10-2 2-8 23.0 2/2 54/18 II/IV 1.7 5.0 57 3/3 54/18 II/IV 1.4 5.0 63
9 10-7 3-5 31.1 2/2 54/18 II/IV 1.9 5.0 62 3/3 54/18 II/IV 1.4 5.0 68
10 10-11 4-3 39.5 2/2 54/18 II/IV 2.1 5.0 67 3/3 54/18 II/IV 1.4 5.0 74
11 11-4 5-0 48.2 2/2 54/18 II/IV 2.3 5.0 71 3/3 54/18 IV/IV 1.4 5.0 81
12 11-8 5-9 57.2 2/2 54/18 II/IV 2.4 5.0 75 2/2 54/18 IV/VI 1.4 5.0 82
13 12-1 6-7 66.4 2/2 54/18 II/IV 2.7 5.0 78 2/2 54/18 IV/VI 1.4 5.0 86
14 12-5 7-4 76.0 2/2 54/18 II/IV 2.8 5.0 82 2/2 54/18 IV/VI 1.4 5.0 90
15 11-7 2-10 28.1 2/2 54/18 II/IV 2.4 5.0 65 2/2 54/18 IV/VI 1.4 5.0 73
16 11-11 3-7 37.4 2/2 54/18 II/IV 2.6 5.0 70 2/2 54/18 IV/VI 1.4 5.0 79
17 12-3 4-5 46.9 2/2 54/18 II/IV 2.7 5.0 75 2/2 54/18 IV/VI 1.4 5.0 84
18 12-7 5-2 56.6 2/2 54/18 II/IV 2.9 5.0 78 2/2 54/18 IV/VI 1.4 5.0 87
19 12-11 6-0 66.6 2/2 54/18 II/IV 3.2 5.0 82 2/2 54/18 IV/VI 1.4 5.0 91
20 13-3 6-9 76.9 3/3 54/18 II/IV 2.6 5.0 96 2/2 54/18 IV/VI 1.4 5.0 95
21 13-0 3-0 33.8 3/3 54/18 II/IV 2.5 5.0 79 2/2 54/18 IV/VI 1.4 5.0 83
22 13-4 3-10 44.2 3/3 54/18 II/IV 2.7 5.0 85 2/2 54/18 IV/VI 1.4 5.0 88
23 13-7 4-7 54.8 3/3 54/18 II/IV 2.8 5.0 90 2/2 54/18 IV/VI 1.4 5.0 93
24 13-10 5-5 65.6 3/3 54/18 II/IV 3.2 5.0 95 2/2 54/18 IV/VI 1.4 5.0 97
25 14-1 6-2 76.6 3/3 54/18 II/IV 3.1 5.0 99 2/2 54/18 IV/VI 1.4 5.0 101
26 14-5 3-3 40.0 2/2 54/18 IV/VI 1.6 5.0 92 3/3 54/18 IV/VI 1.4 5.0 100
27 14-8 4-1 51.5 2/2 54/18 IV/VI 1.9 5.0 97 3/2 54/18 IV/VI 1.4 5.0 103
28 14-10 4-10 63.2 2/2 54/18 IV/VI 2.1 5.0 102 3/2 54/18 IV/VI 1.4 5.0 108
29 15-1 5-8 75.1 2/2 54/18 IV/VI 2.3 5.0 106 3/3 54/18 IV/VI 1.4 5.0 116
30 15-4 6-5 87.2 2/2 54/18 IV/VI 2.5 5.0 110 3/5 54/18 IV/VI 1.4 5.0 126
31 15-6 7-3 99.4 3/2 54/18 IV/VI 1.7 5.0 122 3/6 54/18 IV/VI 1.4 5.0 134
32 15-9 8-0 111.8 3/2 54/18 IV/VI 1.8 5.0 126 3/6 27/18 IV/VI 1.4 5.0 150
33 15-10 3-6 46.8 3/2 54/18 IV/VI 1.8 5.0 107 3/2 27/18 IV/VI 1.4 5.0 116
34 16-0 4-3 59.5 3/2 54/18 IV/VI 1.9 5.0 113 3/2 27/18 IV/VI 1.4 5.0 123
35 16-2 5-1 72.3 3/2 54/18 IV/VI 1.9 5.0 118 3/2 27/18 IV/VI 1.4 5.0 130
36 16-4 5-11 85.2 3/2 54/18 IV/VI 2.0 5.0 123 3/2 27/18 IV/VI 1.4 5.0 135
37 16-6 6-8 98.3 3/3 54/18 IV/VI 2.1 5.0 130 3/3 27/18 IV/VI 1.4 5.0 142
38 16-8 7-6 111.5 3/3 54/18 IV/VI 2.2 5.0 135 3/4 27/18 IV/VI 1.4 5.0 150
39 16-10 8-3 124.8 3/3 54/18 IV/VI 2.4 4.9 139 3/5 27/18 IV/VI 1.4 5.0 157
40 17-9 3-10 54.4 2/2 54/18 VI/VI 2.2 5.0 115 2/2 27/18 VI/VI 1.4 5.0 128
41 18-2 4-7 68.3 2/2 54/18 VI/VI 2.3 5.0 120 2/2 27/18 VI/VI 1.4 5.0 135
42 18-7 5-4 82.5 2/2 54/18 VI/VI 2.5 5.0 126 2/2 27/18 VI/VI 1.4 5.0 143
43 19-0 6-1 97.1 2/2 54/18 VI/VI 2.7 5.0 131 3/3 27/18 VI/VI 1.4 5.0 161
44 19-5 6-11 111.9 2/2 54/18 VI/VI 2.9 5.0 135 2/2 18/18 VI/VI 1.4 5.0 168
45 19-10 7-8 127.1 2/2 27/18 VI/VI 2.0 5.0 139 2/2 18/18 VI/VI 1.4 5.0 171
46 20-3 8-5 142.6 2/2 27/18 VI/VI 2.1 5.0 161 2/2 18/18 VI/VI 1.4 5.0 175
47 19-1 4-2 63.3 2/2 54/18 VI/VI 2.7 5.0 124 2/2 18/18 VI/VI 1.4 5.0 145
48 19-5 4-11 78.3 2/2 54/18 VI/VI 2.9 5.0 130 2/2 18/18 VI/VI 1.4 5.0 155
49 19-9 5-8 93.6 2/2 27/18 VI/VI 1.9 5.0 152 2/2 18/18 VI/VI 1.4 5.0 164
50 20-1 6-6 109.2 2/2 27/18 VI/VI 2.1 5.0 159 2/2 18/18 VI/VI 1.4 5.0 173
Aluminum Box Culvert

51 20-6 7-3 125.0 2/2 27/18 VI/VI 2.2 5.0 163 2/2 18/18 VI/VI 1.4 5.0 177
52 20-10 8-1 141.2 2/2 27/18 VI/VI 2.3 5.0 167 2/3 18/18 VI/VI 1.4 5.0 185
53 21-2 8-10 157.6 2/2 27/18 VI/VI 2.4 5.0 171 2/3 18/18 VI/VI 1.4 5.0 189
54 20-4 4-6 73.1 2/2 27/18 VI/VI 2.1 5.0 146 2/2 18/18 VI/VI 1.4 5.0 155
55 20-7 5-3 89.2 2/2 27/18 VI/VI 2.2 5.0 154 2/2 18/18 VI/VI 1.4 5.0 164
56 20-11 6-1 105.5 2/2 27/18 VI/VI 2.3 5.0 161 2/3 18/18 VI/VI 1.4 5.0 178
57 21-3 6-10 122.1 2/2 27/18 VI/VI 2.4 5.0 169 2/3 18/18 VI/VI 1.4 5.0 187
58 21-6 7-8 139.0 2/2 27/18 VI/VI 2.5 5.0 172 2/4 18/18 VI/VI 1.4 5.0 196
59 21-10 8-5 156.0 3/2 27/18 VI/VI 2.5 5.0 185 3/5 18/18 VI/VI 1.4 5.0 214
60 22-1 9-3 173.3 3/2 27/18 VI/VI 2.5 4.9 190 3/5 18/18 VI/VI 1.4 5.0 218
61 21-7 4-11 83.8 2/2 27/18 VI/VI 2.5 5.0 156 3/4 18/18 VI/VI 1.4 5.0 180
62 21-10 5-8 101.0 2/2 27/18 VI/VI 2.6 4.9 163 3/5 18/18 VI/VI 1.4 5.0 195
63 22-1 6-6 118.4 2/2 27/18 VI/VI 2.7 4.7 171 3/5 18/18 VI/VI 1.4 5.0 205
64 22-3 7-3 135.9 2/2 27/18 VI/VI 2.7 4.5 178 3/5 18/18 VI/VI 1.4 5.0 215
65 22-6 8-1 153.7 2/2 27/18 VI/VI 2.8 4.3 182 3/6 18/18 VI/VI 1.4 5.0 224
66 22-9 8-10 171.6 3/3 27/18 VI/VI 2.7 4.5 200 3/6 18/18 VI/VI 1.4 5.0 229
67 23-0 9-8 189.8 3/3 27/18 VI/VI 2.7 4.3 205 3/6 18/18 VI/VI 1.4 5.0 233
68 22-9 5-4 95.5 3/2 27/18 VI/VI 2.8 4.3 172 3/6 18/18 VI/VI 1.4 5.0 200
69 23-0 6-1 113.7 3/2 27/18 VI/VI 2.8 4.1 180 3/6 18/18 VI/VI 1.4 5.0 210
70 23-2 6-11 132.1 3/3 27/18 VI/VI 2.8 4.1 193 2/2 18/9 VI/VI 1.4 5.0 261
71 23-4 7-8 150.6 3/3 27/18 VI/VI 2.9 4.0 201 2/2 18/9 VI/VI 1.4 5.0 271
72 23-6 8-6 169.3 3/3 27/18 VI/VI 2.9 3.9 206 2/2 18/9 VI/VI 1.4 5.0 275
73 23-8 9-3 188.1 2/2 18/18 VI/VI 1.9 5.0 208 2/2 18/9 VI/VI 1.4 5.0 278
74 23-10 10-1 207.0 2/2 18/18 VI/VI 1.9 5.0 212 2/2 18/9 VI/VI 1.4 5.0 282
75 24-0 5-9 108.2 2/2 18/18 VI/VI 1.9 5.0 182 2/2 18/9 VI/VI 1.4 5.0 258
76 24-1 6-6 127.5 2/2 18/18 VI/VI 1.9 5.0 191 2/2 18/9 VI/VI 1.4 5.0 267
77 24-3 7-4 146.8 2/2 18/18 VI/VI 1.9 5.0 201 2/2 18/9 VI/VI 1.4 5.0 276
78 24-4 8-2 166.2 2/2 18/18 VI/VI 1.9 5.0 210 2/2 18/9 VI/VI 1.4 5.0 285
79 24-5 8-11 185.7 2/2 18/18 VI/VI 2.0 5.0 214 2/2 18/9 VI/VI 1.4 5.0 289
80 24-7 9-9 205.3 2/2 18/18 VI/VI 2.0 5.0 218 2/2 18/9 VI/VI 1.4 5.0 293
81 24-8 10-6 225.0 2/2 18/18 VI/VI 2.0 5.0 221 2/2 18/9 VI/VI 1.4 5.0 297
82 25-2 6-2 122.0 2/2 18/18 VI/VI 2.0 4.7 191 2/2 18/9 VI/VI 1.4 5.0 273
83 25-2 7-0 142.2 2/2 18/18 VI/VI 2.0 4.7 201 2/2 18/9 VI/VI 1.4 5.0 282
84 25-3 7-9 162.4 2/2 18/18 VI/VI 2.1 4.7 210 2/2 18/9 VI/VI 1.4 5.0 291
85 25-4 8-7 182.6 2/2 18/18 VI/VI 2.1 4.6 219 2/2 18/9 VI/VI 1.4 5.0 300
86 25-4 9-5 202.9 2/2 18/18 VI/VI 2.1 4.6 223 2/2 18/9 VI/VI 1.4 5.0 304
87 25-5 10-2 223.3 2/2 18/18 VI/VI 2.1 4.6 227 2/2 18/9 VI/VI 1.4 5.0 308

66 See Notes page 63

 H-25/HS-25

Box Culvert Shell-Plate and Rib Data (H-25, HS-25)

TABLE 49B. SHELL DATA – H-25, HS-25 LOADING
PLATE AND RIB COMBINATIONS WITH ALLOWABLE HEIGHT OF COVER
D6 E6
Cover Hgt. Shell Cover Hgt. Shell
Structure Span "A" Rise "B" Area HG/CG HRS/CRS HR/CR Min. Max. Wt./Ft. HG/CG HRS/CRS HR/CR Min. Max. Wt./Ft.
Number Ft.-In. Ft.-In. Sq. Ft. (Gage) (Inches) (Type) (Feet) (Lbs.) (Gage) (Inches) (Type) (Feet) (Lbs.)

1 8-9 2-6 18.4 3/3 54/18 II/IV 1.4 5.0 53

2 9-2 3-3 25.4 2/2 54/18 II/IV 1.9 5.0 53 3/3 54/18 II/IV 1.4 5.0 59
3 9-7 4-1 32.6 2/2 54/18 II/IV 2.1 5.0 58 3/3 54/18 IV/IV 1.4 5.0 67
4 10-0 4-10 40.2 2/2 54/18 II/IV 2.3 5.0 62 3/3 54/18 IV/IV 1.4 5.0 71
5 10-6 5-7 48.1 2/2 54/18 II/IV 2.6 5.0 66 2/2 54/18 IV/VI 1.4 5.0 71
6 10-11 6-4 56.4 2/2 54/18 II/IV 2.8 5.0 70 2/2 54/18 IV/VI 1.4 5.0 75
7 11-4 7-2 65.0 2/2 54/18 II/IV 3.0 5.0 74 2/2 54/18 IV/VI 1.4 5.0 79
8 10-2 2-8 23.0 2/2 54/18 II/IV 2.4 5.0 57 2/2 54/18 IV/VI 1.4 5.0 64
9 10-7 3-5 31.1 2/2 54/18 II/IV 2.6 5.0 62 2/2 54/18 IV/VI 1.4 5.0 69
10 10-11 4-3 39.5 2/2 54/18 II/IV 2.8 5.0 67 2/2 54/18 IV/VI 1.4 5.0 74
11 11-4 5-0 48.2 2/2 54/18 II/IV 3.0 5.0 71 2/2 54/18 IV/VI 1.4 5.0 78
12 11-8 5-9 57.2 2/2 54/18 II/IV 3.2 5.0 75 2/2 54/18 IV/VI 1.4 5.0 82
13 12-1 6-7 66.4 3/3 54/18 II/IV 2.8 5.0 87 2/2 54/18 IV/VI 1.4 5.0 86
14 12-5 7-4 76.0 2/2 27/18 II/IV 3.1 5.0 92 3/3 54/18 IV/VI 1.4 5.0 95
15 11-7 2-10 28.1 2/2 54/18 II/IV 3.2 5.0 65 2/2 54/18 IV/VI 1.4 5.0 73
16 11-11 3-7 37.4 2/2 54/18 IV/IV 2.9 5.0 72 2/2 54/18 IV/VI 1.4 5.0 79
17 12-3 4-5 46.9 2/2 54/18 IV/IV 3.1 5.0 77 2/2 54/18 IV/VI 1.4 5.0 84
18 12-7 5-2 56.6 2/2 54/18 IV/IV 3.4 5.0 81 3/3 54/18 IV/VI 1.4 5.0 96
19 12-11 6-0 66.6 3/3 54/18 IV/IV 2.8 5.0 93 3/3 54/18 IV/VI 1.4 5.0 100
20 13-3 6-9 76.9 3/3 54/18 IV/IV 3.0 5.0 98 2/2 27/18 IV/VI 1.4 5.0 107
21 13-0 3-0 33.8 3/3 54/18 IV/IV 2.9 5.0 81 2/2 27/18 IV/VI 1.4 5.0 92
22 13-4 3-10 44.2 3/3 54/18 IV/IV 3.0 5.0 87 2/2 27/18 IV/VI 1.4 5.0 98
23 13-7 4-7 54.8 3/3 54/18 IV/IV 3.2 5.0 93 3/3 27/18 IV/VI 1.4 5.0 113
24 13-10 5-5 65.6 3/3 54/18 IV/IV 3.5 5.0 97 3/3 27/18 IV/VI 1.4 5.0 118
25 14-1 6-2 76.6 2/2 54/18 IV/VI 2.8 5.0 101 3/3 27/18 IV/VI 1.4 5.0 122
26 14-5 3-3 40.0 2/2 54/18 IV/VI 3.1 5.0 92 4/4 27/18 IV/VI 1.4 5.0 117
27 14-8 4-1 51.5 3/2 54/18 IV/VI 2.2 5.0 103 4/4 27/18 IV/VI 1.4 5.0 125
28 14-10 4-10 63.2 3/2 54/18 IV/VI 2.3 5.0 108 3/3 18/18 IV/VI 1.4 5.0 130
29 15-1 5-8 75.1 3/2 54/18 IV/VI 2.5 5.0 113 3/3 18/18 IV/VI 1.4 5.0 135
30 15-4 6-5 87.2 3/3 54/18 IV/VI 2.6 5.0 120 4/4 18/18 IV/VI 1.4 5.0 150
31 15-6 7-3 99.4 3/3 54/18 IV/VI 2.7 5.0 125 4/4 18/18 IV/VI 1.4 5.0 156
32 15-9 8-0 111.8 3/3 54/18 IV/VI 2.9 5.0 129 4/4 18/18 IV/VI 1.4 5.0 150
33 15-10 3-6 46.8 2/2 27/18 IV/VI 2.3 5.0 111 2/2 27/9 IV/VI 1.4 5.0 151
34 16-0 4-3 59.5 2/2 27/18 IV/VI 2.4 5.0 117 2/2 27/9 IV/VI 1.4 5.0 157
35 16-2 5-1 72.3 2/2 27/18 IV/VI 2.4 5.0 123 3/3 27/9 IV/VI 1.4 5.0 173
36 16-4 5-11 85.2 2/2 27/18 IV/VI 2.5 5.0 127 3/3 27/9 IV/VI 1.4 5.0 177
37 16-6 6-8 98.3 2/2 27/18 IV/VI 2.6 5.0 131 3/3 27/9 IV/VI 1.4 5.0 182
38 16-8 7-6 111.5 2/2 27/18 IV/VI 2.6 5.0 135 3/3 27/9 IV/VI 1.4 5.0 186
39 16-10 8-3 124.8 2/2 27/18 IV/VI 2.7 5.0 139 3/3 27/9 IV/VI 1.4 5.0 191
40 17-9 3-10 54.4 2/2 27/18 VI/VI 2.1 5.0 128 2/3 18/18 VI/VI 1.4 5.0 140
41 18-2 4-7 68.3 2/2 27/18 VI/VI 2.3 5.0 135 2/5 18/18 VI/VI 1.4 5.0 156
42 18-7 5-4 82.5 2/2 27/18 VI/VI 2.4 5.0 143 2/2 18/9 VI/VI 1.4 5.0 202
43 19-0 6-1 97.1 2/2 18/18 VI/VI 1.8 5.0 164 2/2 18/9 VI/VI 1.4 5.0 212
44 19-5 6-11 111.9 2/2 18/18 VI/VI 1.9 5.0 168 2/2 18/9 VI/VI 1.4 5.0 215
45 19-10 7-8 127.1 2/2 18/18 VI/VI 2.0 5.0 171 2/2 18/9 VI/VI 1.4 5.0 219
46 20-3 8-5 142.6 2/2 18/18 VI/VI 2.1 5.0 175 2/2 18/9 VI/VI 1.4 5.0 223
47 19-1 4-2 63.3 2/2 18/18 VI/VI 1.8 5.0 145 2/2 18/9 VI/VI 1.4 5.0 199
48 19-5 4-11 78.3 2/2 18/18 VI/VI 1.9 5.0 155 2/2 18/9 VI/VI 1.4 5.0 208
49 19-9 5-8 93.6 2/2 18/18 VI/VI 2.0 5.0 164 2/2 18/9 VI/VI 1.4 5.0 217
50 20-1 6-6 109.2 2/2 18/18 VI/VI 2.1 5.0 173 2/2 18/9 VI/VI 1.4 5.0 226

Aluminum Box Culvert

51 20-6 7-3 125.0 2/2 18/18 VI/VI 2.1 5.0 177 2/2 18/9 VI/VI 1.4 5.0 230
52 20-10 8-1 141.2 2/2 18/18 VI/VI 2.2 5.0 181 2/2 18/9 VI/VI 1.4 5.0 234
53 21-2 8-10 157.6 2/2 18/18 VI/VI 2.2 5.0 184 2/2 18/9 VI/VI 1.4 5.0 238
54 20-4 4-6 73.1 2/2 18/18 VI/VI 2.1 5.0 155 2/2 18/9 VI/VI 1.4 5.0 213
55 20-7 5-3 89.2 2/2 18/18 VI/VI 2.2 5.0 164 2/2 18/9 VI/VI 1.4 5.0 223
56 20-11 6-1 105.5 2/2 18/18 VI/VI 2.2 5.0 173 2/2 18/9 VI/VI 1.4 5.0 232
57 21-3 6-10 122.1 2/2 18/18 VI/VI 2.3 5.0 182 2/2 18/9 VI/VI 1.4 5.0 241
58 21-6 7-8 139.0 2/2 18/18 VI/VI 2.3 5.0 186 2/2 18/9 VI/VI 1.4 5.0 245
59 21-10 8-5 156.0 2/2 18/18 VI/VI 2.4 5.0 190 2/2 18/9 VI/VI 1.4 5.0 249
60 22-1 9-3 173.3 2/2 18/18 VI/VI 2.5 5.0 194 2/2 18/9 VI/VI 1.4 5.0 253
61 21-7 4-11 83.8 2/2 18/18 VI/VI 2.3 5.0 164 2/2 18/9 VI/VI 1.4 5.0 228
62 21-10 5-8 101.0 2/2 18/18 VI/VI 2.4 5.0 173 2/2 18/9 VI/VI 1.4 5.0 237
63 22-1 6-6 118.4 2/2 18/18 VI/VI 2.5 5.0 182 2/2 18/9 VI/VI 1.4 5.0 247
64 22-3 7-3 135.9 2/2 18/18 VI/VI 2.5 5.0 191 2/2 18/9 VI/VI 1.4 5.0 256
65 22-6 8-1 153.7 3/5 18/18 VI/VI 2.2 5.0 219 2/2 18/9 VI/VI 1.4 5.0 260
66 22-9 8-10 171.6 3/5 18/18 VI/VI 2.3 5.0 224 2/2 18/9 VI/VI 1.4 5.0 264
67 23-0 9-8 189.8 3/5 18/18 VI/VI 2.4 5.0 228 2/2 18/9 VI/VI 1.4 5.0 267
68 22-9 5-4 95.5 3/6 18/18 VI/VI 2.3 5.0 200 2/2 18/9 VI/VI 1.4 5.0 243
69 23-0 6-1 113.7 3/6 18/18 VI/VI 2.4 5.0 210 2/2 18/9 VI/VI 1.4 5.0 252
70 23-2 6-11 132.1 3/6 18/18 VI/VI 2.4 5.0 220 2/2 18/9 VI/VI 1.4 5.0 261
71 23-4 7-8 150.6 3/6 18/18 VI/VI 2.4 5.0 230 2/2 18/9 VI/VI 1.4 5.0 271
72 23-6 8-6 169.3 3/6 18/18 VI/VI 2.5 5.0 234 2/2 18/9 VI/VI 1.4 5.0 275
73 23-8 9-3 188.1 3/6 18/18 VI/VI 2.5 5.0 239 2/2 18/9 VI/VI 1.4 5.0 278
74 23-10 10-1 207.0 3/6 18/18 VI/VI 2.5 5.0 243 2/2 18/9 VI/VI 1.4 5.0 282
75 24-0 5-9 108.2 3/6 18/18 VI/VI 2.6 5.0 212 2/2 18/9 VI/VI 1.4 5.0 258
76 24-1 6-6 127.5 3/6 18/18 VI/VI 2.6 5.0 222 2/2 18/9 VI/VI 1.4 5.0 267
77 24-3 7-4 146.8 3/6 18/18 VI/VI 2.6 5.0 232 2/2 18/9 VI/VI 1.4 5.0 276
78 24-4 8-2 166.2 3/6 18/18 VI/VI 2.7 4.9 242 2/2 18/9 VI/VI 1.4 5.0 285
79 24-5 8-11 185.7 3/6 18/18 VI/VI 2.7 4.8 246 2/2 18/9 VI/VI 1.4 5.0 289
80 24-7 9-9 205.3 3/6 18/18 VI/VI 2.7 4.7 251 2/2 18/9 VI/VI 1.4 5.0 293
81 24-8 10-6 225.0 3/6 18/18 VI/VI 2.7 4.6 255 2/2 18/9 VI/VI 1.4 5.0 297
82 25-2 6-2 122.0 3/5 18/18 VI/VI 2.7 3.9 216 2/3 18/9 VI/VI 1.4 5.0 278
83 25-2 7-0 142.2 3/5 18/18 VI/VI 2.9 3.9 226 2/3 18/9 VI/VI 1.4 5.0 287
84 25-3 7-9 162.4 3/5 18/18 VI/VI 3.0 3.9 236 2/3 18/9 VI/VI 1.4 5.0 297
85 25-4 8-7 182.6 3/5 18/18 VI/VI 3.0 3.8 246 2/3 18/9 VI/VI 1.4 5.0 306
86 25-4 9-5 202.9 3/5 18/18 VI/VI 3.0 3.8 250 2/3 18/9 VI/VI 1.4 5.0 310
87 25-5 10-2 223.3 3/5 18/18 VI/VI 3.0 3.8 255 2/3 18/9 VI/VI 1.4 5.0 313

See Notes page 63 67

 Steel and Aluminum
Structural Plate
Design Guide
TABLE 49C. ALBC STRUCTURE AREA, PLATE AND RIB MAKE-UP
Inside Inside
Crown Haunch Crown Haunch
Dimensions Dimensions
Straight Side Straight Side
Box Total Rib Leg Angle Box Total Rib Leg Angle
# Span Rise (N) Arc Lengths Rib Length E # Span Rise (N) Arc Lengths Rib Length E
Plate Plate Plate Plate
Length Long/ Length D (N) (deg.) Length Long/ Length D (N) (deg.)
(Ft.-In.) (Ft.-In.) (N) (N) (Ft.-In.) (Ft.-In.) (N) (N)
(N) Short (N) (N) Short (N)
(N) (N)
1 8-9 2-6 14 NA 14 5.5 .5 68 22-9 5-4 34 10 6.5 .5
2 9-2 3-3 16 8 6.5 1.5 69 23-0 6-1 36 11 7.5 1.5
3 9-7 4-1 18 9 7.5 2.5 70 23-2 6-11 38 12 8.5 2.5
4 10-0 4-10 20 5 5/3 10 7.5 3.5 15.40 71 23-4 7-8 40 25 14 25/21 13 9.5 3.5 6.42
5 10-6 5-7 22 11 7.5 4.5 72 23-6 8-6 42 14 9.5 4.5
6 10-11 6-4 24 12 7.5 5.5 73 23-8 9-3 44 15 9.5 5.5
7 11-4 7-2 26 13 7.5 6.5 74 23-10 10-1 46 16 9.5 6.5
8 10-2 2-8 16 8 6.5 .5 75 24-0 5-9 36 10 6.5 .5
9 10-7 3-5 18 9 7.5 1.5 76 24-1 6-6 38 11 7.5 1.5
10 10-11 4-3 20 10 8.5 2.5 77 24-3 7-4 40 12 8.5 2.5
11 11-4 5-0 22 7 7/3 11 8.5 3.5 13.55 78 24-4 8-2 42 27 16 27/23 13 9.5 3.5 4.30
TWO PLATE SHELL

12 11-8 5-9 24 12 8.5 4.5 79 24-5 8-11 44 14 9.5 4.5

13 12-1 6-7 26 13 8.5 5.5 80 24-7 9-9 46 15 9.5 5.5
14 12-5 7-4 28 14 8.5 6.5 81 24-8 10-6 48 16 9.5 6.5
15 11-7 2-10 18 9 6.5 .5 82 25-2 6-2 38 11 6.5 .5
16 11-11 3-7 20 10 7.5 1.5 83 25-2 7-0 40 12 7.5 1.5
17 12-3 4-5 22 11 8.5 2.5 84 25-3 7-9 42 13 8.5 2.5
9 9/5 11.70 29 16 29/25 2.18
18 12-7 5-2 24 12 8.5 3.5 85 25-4 8-7 44 14 9.5 3.5
19 12-11 6-0 26 13 8.5 4.5 86 25-4 9-5 46 15 9.5 4.5
20 13-3 6-9 28 14 8.5 5.5 87 25-5 10-2 48 16 9.5 5.5
21 13-0 3-0 20 10 6.5 .5 88 26-7 5-5 38 11 6.5 .5
22 13-4 3-10 22 11 7.5 1.5 89 27-0 6-3 40 12 7.5 1.5
23 13-7 4-7 24 11 11/7 12 8.5 2.5 9.87 90 27-5 7-0 42 13 8.5 2.5
24 13-10 5-5 26 13 8.5 3.5 91 27-10 7-9 44 29 16 29/25 14 9.5 3.5 15.22
25 14-1 6-2 28 14 8.5 4.5 92 28-3 8-7 46 15 9.5 4.5
26 14-5 3-3 22 11 6.5 .5 93 28-8 9-4 48 16 9.5 5.5
27 14-8 4-1 24 8 7.5 1.5 94 29-2 10-1 50 17 9.5 6.5
28 14-10 4-10 26 9 8.5 2.5 95 27-10 5-10 40 12 7.5 .5
29 15-1 5-8 28 13 13/9 10 8.5 3.5 8.02 96 28-3 6-8 42 13 8.5 1.5
8
30 15-4 6-5 30 11 8.5 4.5 97 28-7 7-5 44 14 9.5 2.5
31 15-6 7-3 32 12 8.5 5.5 98 29-0 8-3 46 31 16 31/25 15 10.5 3.5 13.45
32 15-9 8-0 34 13 8.5 6.5 99 29-4 9-0 48 16 10.5 4.5
33 15-10 3-6 24 8 6.5 .5 100 29-8 9-9 50 17 10.5 5.5
34 16-0 4-3 26 9 7.5 1.5 101 30-1 10-7 52 18 10.5 6.5
35 16-2 5-1 28 10 8.5 2.5 102 29-1 6-4 42 12 8.5 .5
36 16-4 5-11 30 15 8 15/11 11 8.5 3.5 6.17 103 29-5 7-1 44 13 9.5 1.5
37 16-6 6-8 32 12 8.5 4.5 104 29-8 7-11 46 14 10.5 2.5
38 16-8 7-6 34 13 8.5 5.5 105 30-0 8-8 48 33 18 33/25 15 11.5 3.5 11.68
39 16-10 8-3 36 14 8.5 6.5 106 30-4 9-5 50 16 11.5 4.5
40 17-9 3-10 26 8 6.5 .5 107 30-8 10-3 52 17 11.5 5.5
41 18-2 4-7 28 9 7.5 1.5 108 31-0 11-0 54 18 11.5 6.5
42 18-7 5-4 30 10 8.5 2.5 109 30-3 6-9 44 13 8.5 .5
43 19-0 6-1 32 17 10 17/13 11 9.5 3.5 14.90 110 30-6 7-7 46 14 9.5 1.5
Aluminum Box Culvert

44 19-5 6-11 34 12 9.5 4.5 111 30-10 8-4 48 15 10.5 2.5

45 19-10 7-8 36 13 9.5 5.5 112 31-1 9-2 50 35 18 35/27 16 11.5 3.5 9.92
46 20-3 8-5 38 14 9.5 6.5 113 31-4 9-11 52 17 11.5 4.5
47 19-1 4-2 28 8 6.5 .5 114 31-8 10-9 54 18 11.5 5.5
48 19-5 4-11 30 9 7.5 1.5 115 31-11 11-6 56 19 11.5 6.5
49 19-9 5-8 32 10 8.5 2.5 116 31-5 7-3 46 14 8.5 .5
50 20-1 6-6 34 19 12 19/15 11 9.5 3.5 12.78 117 31-8 8-0 48 15 9.5 1.5
51 20-6 7-3 36 12 9.5 4.5 118 31-10 8-10 50 16 10.5 2.5
52 20-10 8-1 38 13 9.5 5.5 119 32-1 9-8 52 37 18 37/29 17 11.5 3.5 8.15
53 21-2 8-10 40 14 9.5 6.5 120 32-3 10-5 54 18 11.5 4.5
54 20-4 4-6 30 8 6.5 .5 121 32-7 11-3 56 19 11.5 5.5
55 20-7 5-3 32 9 7.5 1.5 122 32-8 12-0 58 20 11.5 6.5
56 20-11 6-1 34 10 8.5 2.5 123 32-7 7-9 48 14 8.5 .5
57 21-3 6-10 36 21 14 21/17 11 9.5 3.5 10.67 124 32-9 8-6 50 15 9.5 1.5
58 21-6 7-8 38 12 9.5 4.5 125 32-11 9-4 52 16 10.5 2.5
59 21-10 8-5 40 13 9.5 5.5 126 33-1 10-2 54 39 20 39/31 17 11.5 3.5 6.37
60 22-1 9-3 42 14 9.5 6.5 127 33-3 10-11 56 18 11.5 4.5
61 21-7 4-11 32 9 6.5 .5 128 33-5 11-9 58 19 11.5 5.5
62 21-10 5-8 34 10 7.5 1.5 129 33-8 12-6 60 20 11.5 6.5
63 22-1 6-6 36 11 8.5 2.5 130 33-8 8-3 50 15 8.5 .5
64 22-3 7-3 38 23 14 23/19 12 9.5 3.5 8.53 131 33-9 9-1 52 16 9.5 1.5
65 22-6 8-1 40 13 9.5 4.5 132 33-11 9-10 54 17 10.5 2.5
66 22-9 8-10 42 14 9.5 5.5 133 34-0 10-8 56 41 20 41/33 18 11.5 3.5 4.62
67 23-0 9-8 44 15 9.5 6.5 134 34-2 11-5 58 19 11.5 4.5
135 34-3 12-3 60 20 11.5 5.5
Notes: Box #1 is a one plate shell. 136 34-5 13-1 62 21 11.5 6.5
See page 63 for "D" and "E" designations. 137 34-9 8-9 52 16 8.5 .5
138 34-10 9-7 54 17 9.5 1.5
139 34-11 10-4 56 18 10.5 2.5
140 35-0 11-2 58 43 20 43/35 19 11.5 3.5 2.85
141 35-1 12-0 60 20 11.5 4.5

68 142 35-2 12-9 62 21 11.5 5.5

143 35-3 13-7 64 22 11.5 6.5
 Vertical Joint

Headwall width (90º to structure) Wingwall (3,4)

Wing Panel (2) End Panel (2) End Panel (2) Corner Panel Wing Panel
Center Panels
Headwall Cap A 3”

Elbow Cap (3,4)

Wale Beam A
Anchor Rod (Typical)
2: Attached to Type VI Rib
1 Filler reinforcing rib to be
Sid or S
or Beam Wale Beam
punched and fitted to box
Height (2) e S tee culvert and headwall Reinforcing Rib
(See Table lop per Rise “B”
e (each side if required.)
50B)
Invert Plate

Footing Pad or Less Than 2:1(6)

Concrete Footing (9) Side Slope
Span “A”
Section A-A (see page 70)
Panel Entrenchment (2)
(Approx. 2’)

ALBC Headwall and Wingwall Details

Approximate limits of
select backfill (11)
Approximate limits of
select backfill (11)
Crown Rib
Aluminum deadman anchor required in
center of each wing panel and corner Minimum 6"
panel. (8) Headwall anchor
rod to structure
from cap at center
Anchor Rod of each panel.
3"x3" Corner
Joint (4’6
Co ” Typi Deadman
Elbow Cap rne c
r Pa al)
(3,4)
Anchor (8)
nel (4’6
”
Win Typic
gP a
Varies (3) ane l)

Aluminum Box Culvert

l
of Box Culvert Headwall Cap
Wale Beam
3”
Wa
le Bea
(4’-6” Typical) m
Headwall
Wing Panel
Win
Section A-A (see page 72) gw
Typical Headwall Plan all
Typical Plan View (4)

Notes:
1. All panels are fabricated from aluminum structural plate as specified in 8. For details on single and dual deadman anchors, refer to next page.
ASTM B746. 9. Structures on concrete footings with headwalls require field modification
2. Height of headwall listed in Table 50B permits approximately 24” of the headwall plates to fit around the footings.
entrenchment depth below the invert. All wingwall and headwall end 10. Aluminum headwalls may be used only on square-ended structures.
panels must be trenched into existing ground. Structure length must be an increment of 9 inches, if these headwalls are
3. Horizontal rotation on the wingwall should not exceed 90°. utilized at both ends.
4. The top of a headwall and its wingwall are always horizontal, unless 11. If an aluminum headwall and/or wingwall system is specified, the select
beveled wingwalls are required. granular structural backfill shall extend past the deadman anchor system
5. Standard headwalls shown are for vertical orientation only. a minimum of 6". Contact your Contech representative if stiff material or
6. If side slope is flatter than 2:1, a double tieback assembly is required for rock is encountered where the wingalls and deadman are to be installed.
each deadman.
7. Standard headwalls are shown. HL-93, HS-20 and HS-25 wheel loads
must be kept a minimum distance of 36” from the wall face. Special
headwall packages can be fabricated to meet other loading requirements.

69
 0.150” Structural Plate
1’-8”x2’-4 3/4”

Reinforcing Rib
Steel and Aluminum
Structural Plate
Design Guide

TABLE 50A. HEADWALL AND WINGWALL DETAILS

Wingwalls
Headwall
Single Anchor Dual Anchor Triple Anchors
"D" "D" 3/4" Dia.
"D" 0.150" thick
Wall Height Wale Beam Wale Beam Rod Length
Center End Wale Beam Deadman
(Ft.-In.) Panel - Distance Panel Panel - Distance Min.
Panel Panel - Distance Size
Thickness from top of Thickness Thickness from top of (Ft.-In.)
Thickness Thickness see detail
HW Cap HW Cap
(Ft.-In.)
(Ft.-In.) (Ft.-In.)
6-2 to 8-6 0.125" 0.150" 0.125" 3-0 N/A N/A N/A N/A 1'8" x 2' 4 3/4" 12-6
9-4 to 11-9 0.125" 0.150" 0.150" 3-6 0.125" 3-0 N/A N/A 1'8" x 2' 4 3/4" 12-6
12-7 to 14-2 0.125" 0.150" N/A N/A 0.150" 3-8 N/A N/A 1'8" x 2' 4 3/4" 12-6
14-11 0.175" 0.175" N/A N/A N/A N/A 0.175" 3-6, 8-0, 12-9 3'2" x 2' 5 1/2" 20-0
15-9 0.175" 0.175" N/A N/A N/A N/A 0.175" 3-6, 8-0, 12-9 3'2" x 2' 5 1/2" 20-0
16-7 0.200" 0.200" N/A N/A N/A N/A 0.200" 3-9, 8-9, 13-8 3'2" x 2' 5 1/2" 20-0
17-4 0.200" 0.200" N/A N/A N/A N/A 0.200" 3-9, 8-9, 13-8 3'2" x 2' 5 1/2" 20-0
18-2 0.200" 0.200" N/A N/A N/A N/A 0.225" 3-9, 8-9, 13-8 3'2" x 2' 5 1/2" 20-0
Notes:
1. Any wall heights greater than 18'-2": Inquire
2. HW = Headwall, WW = Wingwall

HEADWALL ATTACHMENT TO CROWN

1’-6” = #1-39
2’-0” = #40-143

WINGWALL SINGLE ANCHOR DESIGN

Deadman Anchor Aluminum
0.150” Structural Plate
1’-8”x2’-4
Deadman Anchor 3/4”
Aluminum
Aluminum Box Culvert

0.150” Structural Plate

Reinforcing Rib
1’-8”x2’-4 3/4”

Reinforcing Rib

WINGWALL DUAL ANCHOR DESIGN

Note: Triple anchor design required wall heights greater than 14'-2". See table above for additional options.

70
Headwall Dimensions for HL-93, H-20, HS-20, H-25, HS-25 Loading
TABLE 50B. HEADWALL
Width Height No. of Anchor Width Height No. of Anchor
No. No.
(Ft.-In.) (Ft.-In.) Rods (Ft.-In.) (Ft.-In.) Rods
1 13-6 6-2 3 88 33-0 9-4 7
2 13-6 6-11 3 89 33-0 10-11 7
3 13-6 7-9 3 90 33-0 10-11 7
4 13-6 8-6 3 91 33-0 11-9 7
5 13-6 9-4 3 92 33-0 12-7 7
6 13-6 10-2 3 93 33-0 13-4 7
7 13-6 10-11 3 94 33-0 14-2 7
8 15-0 6-2 3 95 34-6 10-2 8
9 15-0 6-11 3 96 34-6 10-11 8
10 15-0 7-9 3 97 34-6 11-9 8
11 15-0 8-6 3 98 34-6 12-7 8
12 15-0 9-4 3 99 34-6 13-4 8
13 15-0 10-2 3 100 34-6 14-2 8
14 15-0 10-11 3 101 34-6 14-11 8
15 16-6 6-11 4 102 36-0 10-11 8
16 16-6 7-9 4 103 36-0 11-9 8
17 16-6 8-6 4 104 36-0 12-7 8
18 16-6 9-4 4 105 36-0 13-4 8
19 16-6 10-2 4 106 36-0 13-4 8
20 16-6 10-11 4 107 36-0 14-2 8
21 18-0 6-11 4 108 36-0 14-11 8
22 18-0 7-9 4 109 37-6 10-11 8
23 18-0 8-6 4 110 37-6 11-9 8
24 18-0 9-4 4 111 37-6 12-7 8
25 18-0 10-2 4 112 37-6 13-4 8
26 19-6 6-11 4 113 37-6 14-2 8
27 19-6 7-9 4 114 37-6 14-11 8
28 19-6 8-6 4 115 37-6 15-9 8
29 19-6 9-4 4 116 37-6 11-9 8
30 19-6 10-2 4 117 37-6 12-7 8
31 19-6 10-11 4 118 37-6 13-4 8
32 19-6 11-9 4 119 37-6 14-2 8
33 21-0 6-11 5 120 37-6 14-11 8
34 21-0 7-9 5 121 37-6 15-9 8
35 21-0 8-6 5 122 37-6 16-7 8
36 21-0 9-4 5 123 37-6 11-9 8
37 21-0 10-2 5 124 37-6 12-7 8
38 21-0 10-11 5 125 37-6 13-4 8
39 21-0 11-9 5 126 37-6 14-2 8
40 22-6 7-9 5 127 37-6 14-11 8
41 22-6 8-6 5 128 37-6 15-9 8
42 22-6 9-4 5 129 37-6 16-7 8
43 22-6 10-2 5 130 40-6 12-7 9
44 22-6 10-11 5 131 40-6 13-4 9
45 22-6 11-9 5 132 40-6 14-2 9
46 22-6 12-7 5 133 40-6 14-11 9
47 24-0 8-6 5 134 40-6 15-9 9
48 24-0 9-4 5 135 40-6 16-7 9
49 24-0 10-2 5 136 40-6 17-4 9
50 24-0 10-11 5 137 42-0 13-4 9
51 24-0 11-9 5 138 42-0 14-2 9
52 24-0 12-7 5 139 42-0 14-11 9

Aluminum Box Culvert

53 24-0 13-4 5 140 42-0 15-9 9
54 25-6 8-6 6 141 42-0 16-7 9
55 25-6 9-4 6 142 42-0 17-4 9
56 25-6 10-2 6 143 42-0 18-2 9
57 25-6 10-11 6
58 25-6 11-9 6
59 25-6 12-7 6
60 25-6 13-4 6
61 27-0 9-4 6
62 27-0 10-2 6
63 27-0 10-11 6
64 27-0 11-9 6
65 27-0 12-7 6
66 27-0 13-4 6
67 27-0 14-2 6
68 28-6 9-4 6
69 28-6 10-2 6
70 28-6 10-11 6
71 28-6 11-9 6
72 28-6 12-7 6
73 28-6 13-4 6
74 28-6 14-2 6
75 30-0 10-2 7
76 30-0 10-11 7
77 30-0 11-9 7
78 30-0 12-7 7
79 30-0 13-4 7
80 30-0 14-2 7
81 30-0 14-11 7
82 31-6 10-2 7
83 31-6 10-11 7
84 31-6 11-9 7
85 31-6 12-7 7
86 31-6 13-4 7
87 31-6 14-2 7
Aluminum Box Culvert with Full Aluminum Headwall Package

71
 Steel and Aluminum
Structural Plate
Design Guide

Geotextile Reinforcing Rib

Geotextile

Corrugated Shell Scallop Plate

Supplemental Plate (5)

9” x 2-1/2” Corrugated Invert (5,7)

Span “A” (See “A” on Pages 64 through 67)

Width
Receiving Channel Toewall “G”

Full Invert Width “F” (See page 72 and 73)

Aluminum Full Invert Option

Notes:
¾” Bolts 3” 9”x 2-½” Corrugation 1. N=9.625” or 9 5/8”. Use N as a conversion factor. For example, for Structure No. 1, Width “F” is 13
@ 9 ⁵/8” O.C. x N, or 125.13”.
2. Minimum allowable (unfactored) soil-bearing pressure is 4,000 psf for structures and details shown
in this catalog. This applies specifically for width “G” below the receiving channel. Other conditions
can be accommodated. Contact a Contech Representative for more information.
3. The maximum cover for Aluminum Box Culverts with full inverts and footing pads should not exceed
4 feet. Special full invert and footing pad designs or slotted concrete footings can accommodate
engineer’s design
or as required by

maximum covers to the limits shown in Tables 48A-48B and 49A-49B.

27” (Typical)

4. Weight per foot of full invert includes receiving channels, scallop plates, nuts, bolts, and all plates.
5. Full invert plates thickness are as shown. When reactions to the invert require additional thickness,
supplemental plates of the thickness and width listed in Table 51 are furnished to bolt between the
full invert and the receiving channel.
6. Invert widths 21N and greater are two-pieces.
7. Invert plates must not be overlapped on adjacent structures unless appropriate design modifications
are incorporated.
8. Bent sheet toewalls are supplied for structures having a full corrugated aluminum invert.
Aluminum Bent Sheet Toewall Detail

I:\CORPORATE\MARKET\DRAINAGE SOLUTIONS\ACAD DATA\1 - NON-MERLIN PROJECT START 2010\PROJECTS\MIKE OBRINGER\ALBC TOEWALL OPTIONS\ALBC TOE WALL - POLY [Link] 1/2/2020 9:18 AM

9"x2 21" CORRUGATION

SPRING-HOLDING CLIP 2" WIDE x 0.250" THICK
INVERT
ALUMINUM FLAT PLATE
3
4"Ø x 114" STEEL BOLTS
SAME DETAIL 19 1/4" O.C.
BOTH ENDS TYPE II RIB
Aluminum Box Culvert

STEEL SELF
DRILLING SCREWS

5" MINIMUM
BEDDING / FOUNDATION
MATERIAL

INSTALLATION SEQUENCE:
INSTALLATION SEQUENCE:
1. Cut
1) CUT THEtheTRENCH
trenchAS asSHOWN
shown.
2. Place bedding material in trench.
POLY-FABRIC 2) PLACE
3. PlaceBEDDING MATERIAL
the invert IN TRENCH
on bedding material.
60 MIL. THICKNESS
36" WIDE 4. Place the flat plate
3) PLACE THE INVERT ON BEDDING on a level surface.
MATERIAL
TRENCH TO 5. Position the poly-fabric on top of the flat plate, with
MINIMUM 4) PLACE THE FLAT PLATE
approximately ON
3" of A LEVEL
the fabricSURFACE
on top of the plate.
SCOUR DEPTH
27" STANDARD OR
AS REQUIRED
If your poly-fabric
5) POSITION toe wall
THE POLY-FABRIC ON does
TOP OF not
THEcome
FLAT pre-rolled,
PLATE, WITH please
BY ENGINEER TRENCH follow steps3"#6
APPROXIMATELY OF and #7 below.
THE FABRIC ABOVE THE TOP OF THE PLATE
OF RECORD
ANGLE OF POLY-FABRIC
LOOSE FOR BACKFILL
6. Position the Type II rib on top of the fabric, with the top of the
6) POSITION THE TYPE II RIB ON TOP OF THE FABRIC, WITH THE TOP OF
OR BEDDING MATERIAL rib MATCHING
THE RIB matching the THEtop
TOPof OFthe
THEflat
FLATplate. Clamp
PLATE. CLAMPboth
BOTHends
ENDS toTO
hold
HOLDtheTHE assembly
ASSEMBLY inINplace.
PLACE
BACKFILL 7. Secure the rib to the fabric and the flat plate with self-drilling
MATERIAL 7) SECURE THE RIB TO THE FABRIC AND THE FLAT PLATE WITH
screws on
SELF-DRILLING approximately
SCREWS 10" centers.
ON APPROXIMATE Remove the
10" CENTERS. clamps
REMOVE THEonce
screws
CLAMPS ONCEareSCREWS
in [Link] IN PLACE
8. Attached ¾" Ø bolt to other leg of the rib. Use spring clip to
8) ATTACH 3/4"Ø BOLT TO OTHER LEG OF THE RIB USE SPRING CLIP TO
HOLDhold
IT INitPLACE
in place.
9. Attach the assembly to the invert using ¾" diameter steel bolts
9) ATTACH
on 19-¼" THE ASSEMBLY TO THE
centers (every INVERT
other USING
hole in the3/4" DIAMETER
invert plates).STEEL
BOLTS ON 19-1/4" CENTERS (EVERY OTHER HOLE IN THE INVERT PLATES)
BEDDING 10. Place backfill material in the trench on top of the fabric.
MATERIAL
TRENCH WIDTH 10) PLACE BACKFILL MATERIAL IN THE TRENCH ON TOP OF THE FABRIC
ALBC TOE WALL - POLY FABRIC
PROJECT No. SEQ. No.: DATE:
Poly-Fabric Toewall Detail N/A N/A 12/13/2019
PLANT ORDER: DRAWN:
ALUMINUM BOX CULVERT TOE WALL - POLY-FABRIC N/A FCS

72 [Link]
INSTALLATION DETAILS SCALE:
NOT TO SCALE
CHECKED:
MJO
9025 Centre P ointe Dr., S uite 400, Wes t Ches ter, OH 45069
SHEET NO:
800-338-1122 513-645-7000 513-645-7993 FAX 1 OF 1
Full Invert Details
TABLE 51A TABLE 51B
FULL INVERT DETAILS (H-20, HS-20) FULL INVERT DETAILS (HL-93, H-25, HS-25)
Structure Width "F" Supplemental Plate Width "G" Weight/Ft. Bolts/Ft. Structure Width "F" Supplemental Plate Width "G" Weight/Ft. Bolts/Ft.
No. (N) Thickness (Inches) (N) (Lbs.) (Each) No. (N) Thickness (Inches) (N) (Lbs.) (Each)
1 13 25.9 5.8 1 13 25.9 5.8
2 14 27.3 6.0 2 14 27.3 6.0
3 14 27.3 6.0 3 14 27.3 6.0
4 15 28.8 6.2 4 15 28.8 6.2
5 16 30.2 6.4 5 16 30.2 6.4
6 16 30.2 6.4 6 16 30.2 6.4
7 17 31.7 6.7 7 17 31.7 6.7
8 15 28.8 6.2 8 15 28.8 6.2
9 16 30.2 6.4 9 16 30.2 6.4
10 16 30.2 6.4 10 16 30.2 6.4
11 17 31.7 6.7 11 17 31.7 6.7
12 17 31.7 6.7 12 17 31.7 6.7
13 18 33.1 6.9 13 18 .100 2 38.4 6.9
14 18 33.1 6.9 14 18 .100 2 38.4 6.9
15 17 31.7 6.7 15 17 .100 2 37.0 6.7
16 17 31.7 6.7 16 17 .100 2 37.0 6.7
17 18 33.1 6.9 17 18 .100 2 38.4 6.9
18 18 33.1 6.9 18 18 .100 2 38.4 6.9
19 19 34.6 7.1 19 19 .100 2 39.9 7.1
20 19 34.6 7.1 20 19 .100 2 39.9 7.1
21 19 34.6 7.1 21 19 .100 2 39.9 7.1
22 19 34.6 7.1 22 19 .100 2 39.9 7.1
23 19 34.6 7.1 23 19 .100 2 39.9 7.1
24 20 36.0 7.3 24 20 .100 2 41.3 7.3
25 20 36.0 7.3 25 20 .100 2 41.3 7.3
26 20 .100 2 41.3 7.3 26 20 .100 2.5 42.6 7.3
27 21 .100 2 46.4 12.9 27 21 .100 2 46.4 12.9
28 21 .100 2 46.4 12.9 28 21 .100 2 46.4 12.9
29 21 .100 2 46.4 12.9 29 21 .100 2 46.4 12.9
30 22 .100 2 47.8 13.1 30 22 .100 2 47.8 13.1
31 22 .100 2 47.8 13.1 31 22 .100 2 47.8 13.1
32 22 .100 2 47.8 13.1 32 22 .100 2 47.8 13.1
33 22 .100 2 47.8 13.1 33 22 .100 2.5 49.1 13.1
34 22 .100 2 47.8 13.1 34 22 .100 2.5 49.1 13.1
35 23 .100 2 49.3 13.3 35 23 .100 2.5 50.6 13.3
36 23 .100 2 49.3 13.3 36 23 .100 2.5 50.6 13.3
37 23 .100 2 49.3 13.3 37 23 .100 2.5 50.6 13.3
38 23 .100 2 49.3 13.3 38 23 .100 2.5 50.6 13.3
39 24 .100 2 50.7 13.6 39 24 .100 3 53.4 13.6
40 26 .100 3 56.3 14.0 40 26 .150 3 60.2 14.0
41 26 .100 3 56.3 14.0 41 26 .150 3 60.2 14.0
42 27 .100 3 57.7 14.2 42 27 .150 3 61.7 14.2
43 27 .100 3 57.7 14.2 43 27 .150 3 61.7 14.2
44 28 .100 3 59.2 14.4 44 28 .150 3 63.1 14.4
45 28 .100 3 59.2 14.4 45 28 .150 3 63.1 14.4
46 29 .100 3 60.6 14.7 46 29 .150 3 64.6 14.7
47 27 .100 3 57.7 14.2 47 27 .150 3 61.7 14.2
48 28 .100 3 59.2 14.4 48 28 .150 3 63.1 14.4
49 28 .100 3 59.2 14.4 49 28 .150 3 63.1 14.4
50 29 .100 3 60.6 14.7 50 29 .150 3 64.6 14.7
51 29 .100 3 60.6 14.7 51 29 .150 3 64.6 14.7
52 29 .125 3 62.6 14.7 52 29 .150 3 64.6 14.7
53 30 .125 3 64.0 14.9 53 30 .175 3 68.0 14.9
54 29 .125 3 62.6 14.7 54 29 .175 3 66.6 14.7
55 29 .125 3 62.6 14.7 55 29 .175 3 66.6 14.7

Aluminum Box Culvert

56 30 .125 3 64.0 14.9 56 30 .175 3 68.0 14.9
57 30 .125 3 64.0 14.9 57 30 .175 3 68.0 14.9
58 30 .125 3 64.0 14.9 58 30 .175 3 68.0 14.9
59 31 .125 3 65.5 15.1 59 31 .175 3 69.5 15.1
60 31 .125 3 65.5 15.1 60 31 .175 3 69.5 15.1
61 30 .125 3 64.0 14.9 61 30 .175 3 68.0 14.9
62 31 .125 3 65.5 15.1 62 31 .175 3 69.5 15.1
63 31 .150 3 67.5 15.1 63 31 .175 3 69.5 15.1
64 31 .150 3 67.5 15.1 64 31 .175 3 69.5 15.1
65 32 .150 3 68.9 15.3 65 32 .175 3 70.9 15.3
66 32 .150 3 68.9 15.3 66 32 .175 3 70.9 15.3
67 32 .150 3 68.9 15.3 67 32 .175 3 70.9 15.3
68 32 .150 3 68.9 15.3 68 32 .225 3 74.9 15.3
69 32 .150 3 68.9 15.3 69 32 .225 3 74.9 15.3
70 32 .150 3 68.9 15.3 70 32 .225 3 74.9 15.3
71 33 .150 3 70.4 15.6 71 33 .225 3 76.4 15.6
72 33 .150 3 70.4 15.6 72 33 .225 3 76.4 15.6
73 33 .150 3 70.4 15.6 73 33 .225 3 76.4 15.6
74 33 .150 3 70.4 15.6 74 33 .225 3 76.4 15.6
75 33 .175 3 72.4 15.6 75 33 .225 3.5 79.3 15.6
76 34 .175 3 73.8 15.8 76 34 .225 3.5 80.8 15.8
77 34 .175 3 73.8 15.8 77 34 .225 3.5 80.8 15.8
78 34 .175 3 73.8 15.8 78 34 .225 3.5 80.8 15.8
79 34 .175 3 73.8 15.8 79 34 .225 3.5 80.8 15.8
80 34 .175 3 73.8 15.8 80 34 .225 3.5 80.8 15.8
81 34 .175 3 73.8 15.8 81 34 .225 3.5 80.8 15.8
82 35 .200 3.5 79.9 16.0 82 35 .250 3.5 84.6 16.0
83 35 .200 3.5 79.9 16.0 83 35 .250 3.5 84.6 16.0
84 35 .200 3.5 79.9 16.0 84 35 .250 3.5 84.6 16.0
85 36 .200 3.5 81.4 16.2 85 36 .250 3.5 86.0 16.2
86 36 .200 3.5 81.4 16.2 86 36 .250 3.5 86.0 16.2
87 36 .200 3.5 81.4 16.2 87 36 .250 3.5 86.0 16.2

Note:
1. For structures 1-87, invert plates are 0.100” thick.
73
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 51C. FULL INVERT DETAILS (HL-93, H-25, HS-25)

Supplemental
Invert Plate Plate Supplemental Supplemental
Structure Thickness Invert Width Thickness Plate Plate Weight
No. (Inches) (N) (Inches) Quantity Width (N) (Lbs.-Ft.) Bolts/Ft.
88 0.125 37 0.175 2 4 114.0 16.4
89 0.125 38 0.175 2 4 115.8 16.7
90 0.125 38 0.175 2 4 115.8 16.7
91 0.125 39 0.175 2 4 117.6 16.9
92 0.125 40 0.175 2 4 119.3 17.1
93 0.125 40 0.175 2 4 119.3 17.1
94 0.125 40 0.175 2 4 119.3 17.1
95 0.125 39 0.175 2 4 117.6 16.9
96 0.125 39 0.175 2 4 117.6 16.9
97 0.125 40 0.175 2 4 119.3 17.1
98 0.125 40 0.200 2 4 124.6 17.1
99 0.125 41 0.200 2 4 126.4 17.3
100 0.125 41 0.225 2 4 131.7 17.3
101 0.125 42 0.250 2 6 165.4 17.6
102 0.125 40 0.250 2 6 161.8 17.1
103 0.125 41 0.250 2 6 163.6 17.3
104 0.125 41 0.250 2 6 163.6 17.3
105 0.125 42 0.250 2 6 165.4 17.6
106 0.125 44 0.250 2 6 168.9 18.0
107 0.125 45 0.250 2 6 170.7 18.2
108 0.125 45 0.250 2 6 170.7 18.2
109 0.125 44 0.250 2 6 168.9 18.0
110 0.125 44 0.250 2 6 168.9 18.0
111 0.125 45 0.250 2 6 170.7 18.2
112 0.125 45 0.250 2 6 170.7 18.2
113 0.125 45 0.250 2 6 170.7 18.2
114 0.125 46 0.250 2 6 172.5 18.4
115 0.125 46 0.250 2 6 172.5 18.4
116 0.125 45 0.250 2 6 170.7 18.2
117 0.125 46 0.250 2 6 172.5 18.4
118 0.125 46 0.250 2 6 172.5 18.4
119 0.125 46 0.250 2 6 172.5 18.4
120 0.125 47 0.250 2 6 174.3 18.7
121 0.125 47 0.250 2 6 174.3 18.7
122 0.125 47 0.250 3 6 214.1 18.7
123 0.125 47 0.250 3 6 214.1 18.7
124 0.125 47 0.250 3 6 214.1 18.7
125 0.125 47 0.250 3 6 214.1 18.7
126 0.125 48 0.250 3 6 215.9 18.9
127 0.125 48 0.250 3 6 215.9 18.9
128 0.125 48 0.250 3 6 215.9 18.9
Aluminum Box Culvert

129 0.125 48 0.250 3 6 215.9 18.9

130 0.125 48 0.250 3 6 215.9 18.9
131 0.125 48 0.250 3 6 215.9 18.9
132 0.125 49 0.250 3 6 217.6 19.1
133 0.125 49 0.250 3 6 217.6 19.1
134 0.125 49 0.250 3 6 217.6 19.1
135 0.125 49 0.250 3 6 217.6 19.1
136 0.125 49 0.250 3 6 217.6 19.1
137 0.125 49 0.250 3 6 217.6 19.1
138 0.125 50 0.250 3 6 219.4 19.3
139 0.125 50 0.250 3 6 219.4 19.3
140 0.125 50 0.250 3 6 219.4 19.3
141 0.125 50 0.250 3 6 219.4 19.3
142 0.125 50 0.250 3 6 219.4 19.3
143 0.125 50 0.250 3 6 219.4 19.3

Assembly of ALBC Shell onto Full Invert

74
 TABLE 52A. FOOTING PAD DETAILS TABLE 52B. FOOTING PAD DETAILS (HL-93)
H-20, HS-20 Loading HL-93, H-25, HS-25 Loading HL-93 Loading
Plate Width Weight Plate Total Plate Width
Structure Thickness "G" (Lbs.- Thickness Width Weight Structure Thickness Thickness “G” Weight
No. (Inches) (N) Ft.) Bolts-Ft. (Inches) "G" (N) (Lbs.-Ft.) Bolts-Ft. No. (Inches) Quantity (Inches) (N) (Lbs.-Ft.) Bolts-Ft.
1 0.100 2 12.4 3.3 0.100 2 12.4 3.3 88 0.500 2 0.250 4 65.6 3.8
2 0.100 2 12.4 3.3 0.100 2 12.4 3.3 89 0.500 2 0.250 4 65.6 3.8
3 0.100 2 12.4 3.3 0.100 2 12.4 3.3 90 0.500 2 0.250 4 65.6 3.8
4 0.100 2 17.0 4.2 0.100 2 17.0 4.2 91 0.500 2 0.250 4 70.2 4.7
5 0.100 2 17.0 4.2 0.100 2 17.0 4.2 92 0.500 2 0.250 4 70.2 4.7
6 0.100 2 17.0 4.2 0.100 2 17.0 4.2 93 0.500 2 0.250 4 70.2 4.7
7 0.100 2 17.0 4.2 0.100 2 17.0 4.2 94 0.500 2 0.250 4 70.2 4.7
8 0.100 2 12.4 3.3 0.100 2 12.4 3.3 95 0.500 2 0.250 4 65.6 3.8
9 0.100 2 12.4 3.3 0.100 2 12.4 3.3 96 0.500 2 0.250 4 65.6 3.8
10 0.100 2 12.4 3.3 0.100 2 12.4 3.3 97 0.500 2 0.250 4 65.6 3.8
11 0.100 2 17.0 4.2 0.100 2 17.0 4.2 98 0.500 2 0.250 4 70.2 4.7
12 0.100 2 17.0 4.2 0.100 2 17.0 4.2 99 0.550 2 0.275 4 76.2 4.7
13 0.100 2 17.0 4.2 0.125 2 18.6 4.2 100 0.550 2 0.275 4 76.2 4.7
14 0.100 2 17.0 4.2 0.125 2 18.6 4.2 101 0.600 3 0.200 6 115.8 5.1
15 0.100 2 12.4 3.3 0.125 2 14.0 3.3 102 0.600 3 0.200 6 111.2 4.2
16 0.100 2 12.4 3.3 0.125 2 14.0 3.3 103 0.600 3 0.200 6 111.2 4.2
17 0.100 2 12.4 3.3 0.125 2 14.0 3.3 104 0.600 3 0.200 6 111.2 4.2
18 0.100 2 17.0 4.2 0.125 2 18.6 4.2 105 0.600 3 0.200 6 115.8 5.1
19 0.100 2 17.0 4.2 0.125 2 18.6 4.2 106 0.600 3 0.200 6 115.8 5.1
20 0.100 2 17.0 4.2 0.125 2 18.6 4.2 107 0.600 3 0.200 6 115.8 5.1
21 0.100 2 12.4 3.3 0.125 2 14.0 3.3 108 0.600 3 0.200 6 115.8 5.1
22 0.100 2 12.4 3.3 0.125 2 14.0 3.3 109 0.600 3 0.200 6 111.2 4.2
23 0.100 2 12.4 3.3 0.125 2 14.0 3.3 110 0.600 3 0.200 6 111.2 4.2
24 0.100 2 17.0 4.2 0.125 2 18.6 4.2 111 0.600 3 0.200 6 111.2 4.2
25 0.100 2 17.0 4.2 0.125 2 18.6 4.2 112 0.600 3 0.200 6 115.8 5.1
26 0.125 2 14.0 3.3 0.150 2.5 17.7 3.3 113 0.600 3 0.200 6 115.8 5.1
27 0.125 2 14.0 3.3 0.150 2.5 17.7 3.3 114 0.600 3 0.200 6 115.8 5.1
28 0.125 2 14.0 3.3 0.150 2 15.7 3.3 115 0.600 3 0.200 6 115.8 5.1
29 0.125 2 18.6 4.2 0.150 2 20.3 4.2 116 0.675 3 0.225 6 122.6 4.2
30 0.125 2 18.6 4.2 0.150 2 20.3 4.2 117 0.675 3 0.225 6 122.6 4.2
31 0.125 2 18.6 4.2 0.150 2 20.3 4.2 118 0.675 3 0.225 6 122.6 4.2
32 0.125 2 18.6 4.2 0.150 2 20.3 4.2 119 0.675 3 0.225 6 127.2 5.1
33 0.125 2 14.0 3.3 0.175 2.5 19.6 3.4 120 0.675 3 0.225 6 127.2 5.1
34 0.125 2 14.0 3.3 0.175 2.5 19.6 3.4 121 0.675 3 0.225 6 127.2 5.1
35 0.125 2 14.0 3.3 0.175 2.5 19.6 3.4 122 0.900 4 0.225 6 167.5 5.1
36 0.125 2 18.6 4.2 0.175 2.5 24.2 4.3 123 0.900 4 0.225 6 162.9 4.2
37 0.125 2 18.6 4.2 0.175 2.5 24.2 4.3 124 0.900 4 0.225 6 162.9 4.2
38 0.125 2 18.6 4.2 0.175 2.5 24.2 4.3 125 0.900 4 0.225 6 162.9 4.2
39 0.125 2 18.6 4.2 0.200 3 28.8 4.4 126 0.900 4 0.225 6 167.5 5.1
40 0.200 3 24.4 3.6 0.250 3 29.1 3.6 127 0.900 4 0.225 6 167.5 5.1
41 0.200 3 24.4 3.6 0.250 3 29.1 3.6 128 0.900 4 0.225 6 167.5 5.1
42 0.200 3 24.4 3.6 0.250 3 29.1 3.6 129 0.900 4 0.225 6 167.5 5.1
43 0.200 3 29.0 4.4 0.250 3 33.7 4.4 130 0.900 4 0.225 6 162.9 4.2
44 0.200 3 29.0 4.4 0.250 3 33.7 4.4 131 0.900 4 0.225 6 162.9 4.2
45 0.200 3 29.0 4.4 0.250 3 33.7 4.4 132 0.900 4 0.225 6 162.9 4.2
46 0.200 3 29.0 4.4 0.250 3 33.7 4.4 133 0.900 4 0.225 6 167.5 5.1
47 0.200 3 24.4 3.6 0.250 3 29.1 3.6 134 0.900 4 0.225 6 167.5 5.1
48 0.200 3 24.4 3.6 0.250 3 29.1 3.6 135 0.900 4 0.225 6 167.5 5.1
49 0.200 3 24.4 3.6 0.250 3 29.1 3.6 136 0.900 4 0.225 6 167.5 5.1
50 0.200 3 29.0 4.4 0.250 3 33.7 4.4 137 0.900 4 0.225 6 162.9 4.2
51 0.200 3 29.0 4.4 0.250 3 33.7 4.4 138 0.900 4 0.225 6 162.9 4.2
52 0.225 3 31.3 4.4 0.250 3 33.7 4.4 139 0.900 4 0.225 6 162.9 4.2
53 0.225 3 31.3 4.4 0.275 3 36.0 4.4 140 0.900 4 0.225 6 167.5 5.1
54 0.225 3 26.7 3.6 0.275 3 31.4 3.6 141 0.900 4 0.225 6 167.5 5.1

Aluminum Box Culvert

55 0.225 3 26.7 3.6 0.275 3 31.4 3.6 142 0.900 4 0.225 6 167.5 5.1
56 0.225 3 26.7 3.6 0.275 3 31.4 3.6 143 0.900 4 0.225 6 167.5 5.1
57 0.225 3 31.3 4.4 0.275 3 36.0 4.4
58 0.225 3 31.3 4.4 0.275 3 36.0 4.4 Notes:
59 0.225 3 31.3 4.4 0.275 3 36.0 4.4
60 0.225 3 31.3 4.4 0.275 3 36.0 4.4
61 0.225 3 26.7 3.6 0.275 3 31.4 3.6
62 0.225 3 26.7 3.6 0.275 3 31.4 3.6
1. N=9.625”. Use N as a conversion factor. For example, for Structure No.
63 0.250 3 29.1 3.6 0.275 3 31.4 3.6 1, Width “G” is 2 x N, or 19.25”.
64 0.250 3 33.7 4.4 0.275 3 36.0 4.4
65 0.250 3 33.7 4.4 0.275 3 36.0 4.4 2. Minimum allowable (unfactored) soil-bearing pressure is 4,000 psf for
66 0.250 3 33.7 4.4 0.275 3 36.0 4.4
structures and details shown in this catalog. This applies specifically
67 0.250 3 33.7 4.4 0.275 3 36.0 4.4
68 0.250 3 29.1 3.6 0.300 3.5 37.7 3.7 for width “G” below the footing pad. Other conditions can be
69 0.250 3 29.1 3.6 0.300 3.5 37.7 3.7
70 0.250 3 29.1 3.6 0.300 3.5 37.7 3.7 accommodated. Contact a Contech representative for more information.
71 0.250 3 33.7 4.4 0.300 3.5 42.3 4.6
3. The maximum cover for Aluminum Box Culverts with full inverts and
72 0.250 3 33.7 4.4 0.300 3.5 42.3 4.6
73 0.250 3 33.7 4.4 0.300 3.5 42.3 4.6 footing pads should not exceed 4 feet. Special full invert and footing pad
74 0.250 3 33.7 4.4 0.300 3.5 42.3 4.6
75 0.275 3 31.4 3.6 0.325 3.5 43.0 3.7 designs or slotted concrete footings can accommodate maximum covers
76 0.275 3 31.4 3.6 0.325 3.5 43.0 3.7 to the limits shown in Tables 48A-48B and 49A-49B.
77 0.275 3 31.4 3.6 0.325 3.5 43.0 3.7
78 0.275 3 36.0 4.4 0.325 3.5 47.6 4.6 4. Weight per foot of footing pads includes receiving channels, nuts, bolts,
79 0.275 3 36.0 4.4 0.300 3.5 43.7 4.6
80 0.275 3 36.0 4.4 0.300 3.5 43.7 4.6 and plates.
81 0.275 3 36.0 4.4 0.300 3.5 43.7 4.6 5. When the thickness listed is greater than .250”, the footing pads will be
82 0.300 3.5 37.8 3.7 0.350 3.5 44.5 3.7
83 0.300 3.5 37.8 3.7 0.350 3.5 44.5 3.7 two or more pieces equaling the composite thickness required.
84 0.300 3.5 37.8 3.7 0.350 3.5 44.5 3.7
85 0.300 3.5 42.4 4.6 0.350 3.5 49.1 4.6
6. Footing pads must not be overlapped on adjacent structures unless
86 0.300 3.5 42.4 4.6 0.350 3.5 49.1 4.6 appropriate design modifications are incorporated.
87 0.300 3.5 42.4 4.6 0.350 3.5 49.1 4.6

75
 Steel and Aluminum
Structural Plate
Design Guide

Inside of Aluminum Aluminum

Box Culvert Inside of Aluminum
Reinforcing Rib
Box Culvert
Aluminum Reinforcing Rib

Reinforcing Rib Notes: Lean, Non-Shrink Grout

Box Culverts #1-#39 with Working Point

leg lengths (D) of 0.5N thru
2.5N will have ribs extending
into the footing slots Flexible Aluminum
Footing Pad Receiving Channel Footing Pad
*Box Culverts #40-#143 Below Anticipated
with leg lengths (D) of 0.5N Slotted Concrete
thru 3.5N will have ribs that Footing Scour Depth
extend into the footing slots
Slot must be 10" wide in
these cases, otherwise it is
8" wide

Working Point Span Width ”G“

(Span Between Slots)
Slot Size
4" Height x Width Structure Span Aluminum Footing Pad Option
(see page 75)
Certain shapes will have a longitudinal stiffener between the
Aluminum Box Culvert Slotted bottom of the haunch rib and the top of the footing pad plates.
Concrete Footing Option
*See note above. For D dimension see page 68.

Aluminum
Scour Considerations Structural Plate

In most cases, using a full aluminum invert with toe plate Side
Angle
extensions at the inlet and outlet ends will eliminate the
potential for scour through the structure. If it is desirable
to span the stream crossing, scour should be investigated. 0.20”

The most efficient counter measure, as listed below,

0.1875” Bolt
should be chosen based on site specific conditions. The Holes 7/8”
selected alternative should be designed by the registered 3.0”
professional engineer for the project. 7/8” 1.80”
1.75”
Aluminum Box Culvert

These counter measures include:

l Rip rap protection 0.20”
3.70"
l Concrete paving
l Lower footings below anticipated scour depth
l Bearing foundation on competent rock
l Undercut erodible soils and replace with non- Aluminum Receiving Channel

erodible material Weight is equal to 2 lbs per foot per side.

l Construction of guide banks including sheet piling
l Implementation of hard armor interlocking blocks
where vegetation cannot be established, such as
ArmorFlex® or A-Jacks®

Please contact your Contech representative for more details

and design information.

76
 Typical Backfill Cross Section

Shoulder Roadway Roadway Shoulder

Embankment
Anchor Rod Crown Ribs
Crown Ribs Slope
Cover (3)
Rib Splice Cover (3)
Minimum
Haunch Cover
Ribs

Corrugated
Full Invert, Aluminum
Footing Pads Haunch Ribs Headwall(6)
Full Invert, Footing Pads or or Concrete Rib Splice
Toe Wall Concrete Footing Footing Toe Wall

End Treatment With Projecting End Structure End Treatment With Headwall

Typical End Treatments

Notes:

Aluminum Box Culvert

1. If the select backfill width (W) is less than the required width, a concrete 5. When using a full invert or footing pads, the foundation shall have a
grout material may be required as backfill. minimum of 4,000 psf bearing capacity and include a 6” well graded
2. Select backfill zone to be well graded granular backfill material, per granular bed. Lower bearing capacities can be accommodated through
AASHTO M 145, placed in 6" to 8" lifts symmetrically, with no side- special design or the use of concrete footings.
to-side differential exceeding 24-inches, on each side compacted to 6. Standard aluminum headwalls shown are for vertical orientation only.
a minimum 90% density per AASHTO T-180. For structure numbers 7. The type and extent of end treatment on the box culvert should be
1 through 87, the material must be classified as A-1, A-2-4, A-2-5, chosen and designed to prevent the loss of backfill due to high flow
or A-3. For structure numbers 88 through 143, the material must be conditions.
classified as A-1, A-2-4, or A-2-5 for cover heights 2.0' and greater, 8. Bolt torque requirements - plate lap must be well aligned in a tangent
and it must be an A-1 only if the cover height is less than 2.0'. D4 fashion using proper techniques and adequate bolt torque to seat the
dozer or smaller to operate near and above structure during backfilling corrugation. The recommended installation bolt torque for Aluminum
to finish grade. Refer to AASHTO Sec. 26 installation specification. Box Culverts is 100-150 ft-lbs.
3. Fill in these zones, must be placed in 8” maximum loose lifts and 9. For assembly information, see the manufacturer’s detailed assembly
compacted to a minimum 90% density per AASHTO T-180. drawings and instructions.
4. The addition of temporary soil cover for heavy construction loads is not
feasible or permissible for Aluminum Box Culvert structures. By design,
these structures are limited in the range of permissible fill heights and
live loads.

77
 Steel and Aluminum
Structural Plate
Design Guide

Aluminum Box Culvert Project Specification

Scope
Assembly
This specification covers the manufacture and installation of
the aluminum box culvert structure detailed in the plans.

Material

The aluminum box culvert shall consist of plates, ribs, and

appurtenant items as shown on the plans and shall conform
to the requirements of ASTM B864 and AASHTO M 219.
Plate thicknesses, rib spacings, end treatment, and type of
invert and foundation shall be as indicated on the plans.

Bolts with suitable nuts shall conform to the requirements of

ASTM A307 or ASTM A449 and shall be galvanized in
accordance with ASTM A153.

Assembly

The box culvert shall be assembled in accordance with the Lifting

shop drawings provided by the manufacturer and per the
manufacturer’s recommendations. Bolts shall be tightened
using an applied torque between 100-150 ft-lbs.

Installation

The box culvert shall be installed in accordance with

the plans and specifications, the manufacturer’s
recommendations and the AASHTO Standard Specification
for Highway Bridges, Section 26 (Division II).

Bedding

The bedding should be constructed to a uniform line and

grade using material outlined in the backfill section. The
foundation must be capable of providing a bearing capacity
Aluminum Box Culvert

of at least two tons per square foot. Backfill Operation

Please reference the project specifications, drawing

submittals and Contech's Assembly and Installation Guide
for more information.

Backfill

Select backfill zone to be well graded granular backfill

material, per AASHTO M 145, placed in 6" to 8" lifts
symmetrically, with no side-to-side differential exceeding
24-inches, on each side compacted to a minimum 90%
density per AASHTO T-180. For structure numbers 1 through
87, the material must be classified as A-1, A-2-4, A-2-5, or
A-3. For structure numbers 88 through 143, the material
must be classified as A-1, A-2-4, or A-2-5 for cover heights
2.0' and greater, and it must be an A-1 only if the cover
height is less than 2.0'. D4 dozer or smaller to operate near
and above structure during backfilling to finish grade. Refer
to AASHTO Sec. 26 installation specification.
.

78
SUPER-SPAN™ and SUPER-PLATE® Acceptance

Many state and federal agencies recognize the excellent

Over 4,000 SUPER-SPANS in Place
performance and economy of SUPER-SPAN corrugated
Since 1967, more than 4,000 structures have been built on structures. In a 1979 memorandum, the chief of FHWA’s
five continents. That makes SUPER-SPAN the most widely Bridge Division noted that in the previous 15 years, several
accepted, long-span corrugated steel design in the world. hundred Contech SUPER-SPAN Culverts had been erected in
the United States and Canada and their performance had
SUPER-SPAN structures with individual spans up to 45
been excellent.
feet are serving as bridges, railroad overpasses, stream
enclosures, vehicular tunnels, culverts, and conveyor In a 1983 report to the Secretary of Transportation, the
conduits. Installations have been completed under a wide General Accounting Office stated, “Some innovations, such as
variety of conditions, including severe weather and unusual using certain long-span culverts rather than building conventional
construction time constraints. bridges, have substantially lowered bridge costs.”
National Specifications Aluminum Long-Span Structures (SUPER-PLATE)
SUPER-SPAN’s popularity has resulted in a national SUPER-PLATE structures add both longitudinal stiffeners
specification written for long-span corrugated metal (thrust beams) and circumferential stiffeners (reinforcing ribs)
structures by the American Association of State Highway to conventional Aluminum Structural Plate to achieve larger
and Transportation Officials. AASHTO LRFD Bridge Design sizes. Clear spans in excess of 35 feet and clear areas over
Specifications (Sec. 12) for Highway Bridges and AASHTO 475 square feet are achievable with SUPER-PLATE. Available
Standard Specifications (Section 12.7) provide for the shapes include low-profile and high-profile arch and
selection of acceptable combinations of plate thickness, horizontal ellipse (as seen below).
minimum cover requirements, plate radius and other
design factors. Material is covered by AASHTO M 167 Contact your local Contech representative for
and ASTM A761. Installation is covered by AASHTO LRFD additional information about SUPER-SPAN and
Bridge Design Specifications (Sec. 12), AASHTO Standard SUPER-PLATE structures.
Specification for Highway Bridges (Sec. 12 and 26), LRFD
Construction Specifications (Sec. 26) and ASTM A807/A789.

SUPER-SPAN/SUPER-PLATE

High-profile arch SUPER-SPAN in Puerto Rico

spanning a wetland and providing a wildlife crossing

Low-Profile Arch High-Profile Arch Horizontal Ellipse Pear Pear-Arch

Standard Shapes

79
 Steel and Aluminum
Structural Plate
Design Guide
The thrust beam is the key element to SUPER-SPAN and
General design and installation characteristics SUPER-PLATE success. Besides providing perfect backfill in
the important area above the spring line, it acts as a floating
As conventional round structures increase in diameter footing for the critical large radius top arch of the structure.
beyond 16 -18 feet, they become more flexible which It fixes the end of the arch, stiffening it and reducing
requires more attention during the installation. It becomes deflection as backfill goes over the top.
increasingly difficult to both control the shape and to achieve
good backfill support. Contech’s SUPER-SPAN and The thrust beam also provides a solid vertical surface that
SUPER-PLATE help overcome these problems through the use is easy to backfill against to obtain excellent compaction*.
of both special shapes and concrete thrust beams. After installation, the beam effectively controls possible
horizontal spreading of the top arch.
SUPER-SPAN/SUPER-PLATE Solves the Problem
The horizontal ellipse, low-profile and high-profile arch
shapes are wide-span, reduced-rise structures. They provide
Thrust Beam Function
large open areas with less rise than comparable circular
Compaction Difficult Compaction Easier
shapes. Sidewalls have a tighter radius to provide a more
rigid pipe wall to compact the backfill against(see Figure 9). R R

Restraining Large Circular Shape SUPER-SPAN

Thrust, T
RT With the shape on the left, it is difficult to obtain adequate compaction of the
backfill at the critical 3/4 rise point.
Compare it to the SUPER-SPAN on the right. Excellent compaction* and a
RS high restraining force (R) is readily obtained against the vertical surface of
the thrust beam. Force (R) acts on the vertical surface to prevent significant
horizontal movement on the pipe wall at the 3/4 rise point under dead and
live loads.
*See Backfilling and Backfill material on page 82.

Figure 9
SUPER-SPAN and SUPER-PLATE structures, by means of their
shape and thrust beams (which reduce the central angle of
By contrast, Pear and Pear-Arch shapes provide relatively
the effective top arch to 80 degrees) have added stability
high-rise structures. These shapes orient their sides at the
against deflection and snap-through buckling. They can
derivable angle to the soil pressures (see Figure 10). Their
be economically designed and installed within recognized
smaller radius crowns are typically heavy gage to provide
AASHTO critical stresses and seam strength limits.
the necessary restraint at the top.

Restraining Thrust Horizontal

from Top Arc, T reinforcement bars
are tied to Contech
bent and threaded
P rods to provide
reinforcement
Retaining Wall
Soil Pressure, P for the concrete
thrust beam.
A
SUPER-SPAN/SUPER-PLATE

Slope of
Sidewall at A

Figure 10

Low-Profile Arch High-Profile Arch Horizontal Ellipse Pear Pear-Arch

Standard Shapes

80
Structural Design
TABLE 53
MINIMUM THICKNESS — MININUM COVER TABLE (HL-93, H-20, HS-20, H-25, HS-25 LIVE LOAD)
Gage Thickness (Inches)
Top Radius 12 10 8 or 7 5 3 1
RT Ft. (0.111) (0.140) (0.170 or 0.188) (0.218) (0.249) (0.280)
15’ 2.5’ 2.5’ 2.5’ 2.0’ 2.0’ 2.0’
15’-17’ 3.0’ 3.0’ 2.5’ 2.0’ 2.0’
17’-20’ 3.0’ 2.5’ 2.5’ 2.5’
20’-23’ 3.0’ 3.0’ 3.0’
23’-25’ 4.0’ 4.0’

Notes:
1. Designs listed are for steel 6” x 2” corrugation only. For aluminum 9” x 21/2” corrugation design, please contact your local Contech representative.
2. Heights of cover for highway live loads given are to top of concrete pavement or bottom of flexible pavement.
3. Minimum covers for E 80 live loads are approximately twice those for HS-20. However, E 80 minimums must be established for individual applications.
4. Minimum covers for construction loads and similar heavy wheel loads must be established for individual applications.
5. The table assumes a granular backfill over the crown of the structure to the full minimum cover depth (height) compacted to not less than a minimum 90%
density per AASHTO T-180.
6. Pear and Pear-Arch shape gages are determined on an "as-needed" basis.

Installation Recommendations
Foundation
A SUPER-SPAN or SUPER-PLATE structure is a composite
The foundation under the structure and sidefill zones must
system combining steel and soil. Maximum fill heights
be evaluated by the design engineer to ensure adequate
are calculated on the basis of AASHTO LRFD design
bearing capacity. Differential settlement between the
methods. The thrust in the wall for a long span structure
structure and side fill must be minimal.
is determined by using twice the value of the top arc
radius along with appropriate load factors.
Hydraulic Design
The most commonly used SUPER-SPAN and SUPER-PLATE
In accordance with AASHTO, buckling and flexibility
hydraulic shapes are the horizontal ellipse, the low-profile
factors are not calculated. These factors are covered by
arch, and the high-profile arch. Hydraulic data for these
the minimum thickness/minimum cover table on this
shapes are presented in tabular and graphical form in the
page and special geometry limitations spelled out by
current edition of the NCSPA CSP Design Manual. Standard
AASHTO.
procedures are presented in the Hydraulics chapter of the
design manual to determine the headwater depth required
Shallow Fill
for a given flow through these structures under both inlet
Minimum designs are shown in Table 53. Shallow cover
and outlet control conditions.
structures will be at the minimum thickness indicated for
installation and to prevent against buckling.
In addition, the hydraulic design series of publications from
FHWA offers guidance regarding hydraulic capacity of
When adding the total live load over the structure, it is
these structures.
necessary to distribute it over an appropriate area of the
structure which varies with the fill height.
Installation Precautions
During the installation and prior to the construction of
Minimum covers shown in Table 53 are based on
permanent erosion control and end-treatment protection,
standard construction. Somewhat lower covers are
special precautions may be necessary. The structure
possible with special measures such as using concrete
must be protected from unbalanced loads and from
relieving slabs. Special designs are also available for
any structural loads or hydraulic forces that might bend
SUPER-SPAN/SUPER-PLATE

fill heights exceeding the normal limitations of standard

or distort the unsupported ends of the structure. Base
structures. Contact your local Contech representative for
channels for arches must be square to the centerline on
additional information on special requirements.
arch [Link] wash out of previously placed soil
support must be prevented to ensure that the structure
maintains its load-carrying capacity.

81
 Steel and Aluminum
Structural Plate
Design Guide

Contech SUPER-SPAN structures have proven both practical proper frequencies and procedures for testing. The equipment
and economical to construct in a wide range of applications used to place and compact fill around and over the structure
and conditions. Nevertheless, there are basic rules of should be selected based on the quality of the backfill and the
installation that must be obeyed to ensure acceptable shape of the SUPER-SPAN. Such plans should be verified in the
performance. initial backfilling stages. Compaction needs to be achieved
under the haunches by carefully tamping a granular or select
Comprehensive installation and inspection standards material.
are furnished with every SUPER-SPAN installation. These
documents should be studied thoroughly by the contractor Use only backfilling methods and equipment that obtain
and engineer prior to beginning construction. The following specified density without excessive movement or deformation of
material highlights the key elements involved in the proper the structure.
construction of a Contech SUPER-SPAN.
Backfill Material
Foundation and Bedding
Contech’s specification for backfill material contains the
There must be adequate distance between the SUPER-SPAN
and questionable in-situ soils. Proper bedding preparation following as listed in the AASHTO Bridge Specification:
is critical to both structure performance and service life. The
bedding should be constructed to a uniform line and grade to 1. Granular type soils shall be used as structure backfill (the
avoid distortions that may create undesirable stresses in the envelope next to the metal structure). Well graded sand and
structure and/or rapid deterioration of the roadway. It should gravel that is sharp, rough, and angular is preferred.
be free of rock formations, protruding stones, and frozen 2. Approved stabilized soil shall be used only under direct
matter that may cause unequal settlement. supervision of a competent, experienced soils engineer.
Plastic or cohesive soils should not be used.
It is recommended that the bedding be a relatively loose 3. The structure backfill material shall conform to one of the
granular material that is roughly shaped to fit the bottom of following soil classifications from AASHTO Specification
the structure, be a minimum of twice the corrugation depth in M 145, Table 62 . Structure backfill shall be placed and
thickness and have a maximum particle size of one half the compacted to a minimum 90% density per AASHTO T-180.
corrugation depth. 4. The extent of the select structural backfill outside the
maximum span is dependent on the quality of the adjacent
It should be noted that the bedding depth can vary based on embankment, loading and shape of the structure. It
the amount of cover and the shape of the structure’s invert. may be necessary to excavate native soil at the sides to
The bedding should be shaped to match structures with flatter provide an adequate width needed for compaction. For
inverts. ordinary installations with a good quality, well-compacted
embankment or in situ soil adjacent to the structure backfill,
Please reference the project specifications, drawing submittals
a minimum width of structural backfill six feet beyond the
and Contech's Assembly and Installation Guide for more
structure is usually required. The engineer must evaluate
information.
the in situ conditions to ensure adequate bearing capacity.
Assembly The structure backfill shall extend to the minimum cover
Plates can be placed either one at a time or in preassembled elevation
units of two or more plates in a ring. (Table 53—page 81) above the structure.

All bolts in a newly hung plate or assembly should be Monitoring Backfill

tightened before adding the next unit above it. This should Regular monitoring is required during backfilling to ensure a
be done only with the plates in proper relation to each other structure with a proper shape and that compaction levels are
for correct curvature and alignment in the structure. It may be achieved. A Shape Control Technician will confirm the structure’s
necessary to use cables, props, or jigs to keep the plates in shape before backfilling, then monitor the shape and verify
position during tightening. compaction readings until the backfill reaches the minimum
cover level.
The structure cross-section must be checked regularly during
assembly. Its shape must be symmetrical, with the plates Special Requirements
forming smooth, continuous curves. Longitudinal seams should Very large or high structures sometimes call for additional
SUPER-SPAN/SUPER-PLATE

be tight and plate ends should be parallel to each other. special provisions for shape control during backfilling.

Backfilling The minimum stiffness requirements for some structures shown

SUPER-SPANs are flexible structures, therefore care is required in Table 53 on Page 81 may need to be augmented by increased
during the placement and compaction of backfill. An effective
design stiffness or mandatory top loading. Top loading requires
system to monitor the structure during the backfilling process
the placement of a modest blanket of soil on the crown when
must be established.
backfill is approximately at the springline height.
Select an approved structure backfill material for the zone
around the SUPER-SPAN. Establish soil density curves to a For specific shape reference, contact Contech
minimum 90% density per AASHTO T-180 and determine Engineering.

82
SUPER-SPAN™ TABLE 62. - AASHTO M 145

Galvanized Steel Long Span Structures — GROUP CLASSIFICATION A-1-a

A-1
A-1-b
A-2(Modified)
A-2-4 A-2-5
6” x 2” Corrugation Project Specification Sieve Analysis, Percent Passing:
No.10 (2.00 mm) 50 Max. —— —— ——
General Description No. 40 (0.425 mm) 30 Max. 50 Max. —— ——
No. 100 (0.150 mm) —— —— 50 Max. 50 Max.
The long span steel structural plate structure, conforming No. 200 (0.075 mm) 15 Max. 25 Max. 20 Max. 20 Max.
to the dimensions shown on the plans and specifications, Characteristics of Fraction Passing No. 40 (0.425 mm)
shall be installed at the location designated. The design and Liquid Limit — 40 Max. 41 Min.
Plasticity Index 6 Max. 10 Max. 10 Max.
installation shall conform to AASHTO LRFD Specifications for
Usual Types of Significant Stone Fragments Silty or Clayey
Highway Bridges, Division I, “Soil-Corrugated Metal Structure Constituent Materials Gravel and Sand Gravel and Sand
Interaction Systems”, Section 12, “Long Span Structural Plate
Structures”, and Division II, Section 26, “Metal Culverts.” * Modified to be more select than M 145.

Materials Additional Requirements

The galvanized steel structural plate shall have 6” x 2” l Materials must be dense graded (open graded or gap
corrugations and shall be of the gage as shown on the plans. graded materials are not allowed).
The plates shall be manufactured in conformance with l Fine beach sands, windblown sands, and stream
AASHTO Specification M 167. Bolts with suitable nuts shall deposited sands all of which exhibit fine, rounded
meet the provisions of ASTM A449, Type 1 and ASTM A563, particles and typically are classified by AASHTO M 145
Grade C. The steel anchor bolts shall conform to ASTM as A-3 materials are not allowed.
A307, Grade A. l On site mixing or blending to achieve specified gradation
is not allowed.
Longitudinal Structural Stiffeners (Thrust Beams)
Maximum particle size shall not exceed 3 inches. For the A-2
Longitudinal stiffeners shall be located at the radius
materials, moisture content must be between -3% and +2%
transition at the ends of the top arc. The thrust beams shall
optimum as defined by AASHTO T 180. All soil classifications
consist of reinforced concrete having a compression strength
are limited to the following height of cover limits and structure
of 2400 psi, and the reinforcing steel shall conform to
shape applications:
ASTM A615, Grade 40, having a minimum yield strength
of 40,000 psi. Thrust beams shall be formed and poured l A-1-a material is suitable for all long span shapes, sizes
conforming to the plan dimensions when the backfill and fill heights.
reaches the bottom elevation of the thrust beams. l A-1-b material is suitable only for use with high profile
arch and pear shape structures to a 12’ maximum fill
Design
height and for use with elliptical and low profile arch
The long span structure shall be designed in accordance structures to a 20’ maximum fill height.
with the latest AASHTO design criteria and shall be required l A-2-4 and A-2-5 materials are restricted to maximum
to incorporate the use of continuous longitudinal structural heights of cover of 12’. These materials are not allowed
stiffeners (concrete thrust beams). for use with pear, pear arch or high profile arches
Structure Assembly with more than 30 Pi in the side arc.

The structure shall be assembled in strict accordance with Other backfill materials which provide equivalent structural
the manufacturer’s instructions and to the design shape properties, longterm, in the environmental conditions
shown on the plans. Plates shall be assembled according to expected (saturation, freeze-thaw, etc.) may be used. Such
plate assembly drawings supplied by the manufacturer. materials shall be approved only after thorough investigation
and testing by a soils engineer familiar with the requirements
Structural Backfill Material for structural backfill of long span structures.
SUPER-SPAN/SUPER-PLATE

A granular type of material shall be used around and over

the structure. This select structural backfill material shall Backfill Envelope Limits
conform to one of the following classifications of soil from
AASHTO Specification M 145, as modified in the following The backfill envelope limits are as detailed on the plans.
table for A-1, A-2-4 or A-2-5. Backfill Placement
Before backfilling, the erected structure shall meet the
tolerance and symmetry requirements of AASHTO and the
manufacturer.

83
 Steel and Aluminum
Structural Plate
Design Guide

Approved backfill material shall be placed in horizontal, Preconstruction Meeting

uniform layers not exceeding 8” in thickness, before
Prior to construction, a meeting will be held to review the
compaction, and shall be brought up uniformly on both sides
construction procedures. A qualified representative of the
of the structure. Each layer of backfill shall be compacted to
manufacturer of the structure will be present to discuss methods
a relative density of not less than 90%, modified proctor
and responsibility for shape monitoring and control, backfill
per AASHTO T 180. Field density tests of compacted backfill
material selection, testing and placement, and compaction
will be made at regular intervals
methods and testing. A representative of the Engineer, Prime
during backfill.
Contractor, and any involved sub-contractors must be present.
Long span structures, due to their size and shape, are sensitive
Alternate Structures
to the types and weights of equipment used to place and
compact the select backfill material. This is especially critical in The Contractor may furnish an alternate structure to the long
the areas immediately adjacent to and above the structure. span shown on the plans and these specifications but the
Therefore, equipment types will be restricted in those critical following conditions must be met:
zones. Compaction equipment or methods that produce 1. The structure must be designed using the AASHTO Long
horizontal or vertical earth pressures which cause excessive Span criteria and these plans and specifications. Steel
distortion or damage to structures shall not be used. structural plate shall conform to the requirements of
Contractors should plan to have a D4 (approximately 20,000 AASHTO M 167.
lbs.) or similar weight tracked dozer to place and grade backfill 2. The corrugated metal plate thickness specified is considered
immediately alongside and radially above the structure until the minimum acceptable for the structure(s) on this project
minimum cover level is reached. Lightweight vibratory plate or based on structural and durability requirements. Any other
roller type compaction equipment must be used to compact the structure, regardless of “special features”, must be of the
backfill in these zones. Use of heavier equipment and/or rubber same thickness or greater.
tired equipment such as scrapers, graders, and front end 3. “Special Features”, such as hot rolled structural steel
loaders will likely be prohibited inside the select fill envelope ribs, shall be hot-dip galvanized after fabrication per
zone until appropriate minimum cover height has been ASTM A123. Ribs shall be placed across the top 180°, i.e.,
obtained. to the springline of all structures. Maximum rib spacing shall
be two (2) feet. Ribs shall be placed over the same length of
Shape Control Monitoring
structure that the thrust beams would apply. No allowance
Contech shall provide a Shape Control Technician who is a for composite action between the rib and plate will be
qualified representative of a professional soils engineering firm, allowed. The combined moment of inertia of both plate
or other qualified organization, to ensure a properly shaped and rib must satisfy the normal flexibility factor as shown in
structure. The Shape Control Technician shall take AASHTO Section [Link]. The span in the formula for the
initial measurements of the erected structure before backfilling, flexibility factor shall be replaced by twice the top arc radius.
observe all backfill materials and their placement, and record 4. Alternate structures meeting the above criteria will only be
compaction densities. The Technician shall record all density considered for use if pre-approved in writing by the
readings and ensure they meet the requirements of the plans Engineer prior to the bid date. To qualify for pre-approval,
and specifications. However, in no case shall the relative an alternate submittal package must be submitted to the
densities be less than 90% per AASHTO T 180. The Shape Engineer a minimum of 15 days prior to the bid date.
Control Technician shall monitor the structure shape during the 5. The material supplier shall be a qualified manufacturer of
placement of structural backfill to the minimum cover height steel structural plate and long span structures with a
over the structure. No structural backfill shall be placed minimum of 50 successful installations. The foundation,
without the Shape Control Technician on site. structural backfill and end treatment shall be as required
herein and detailed on the plans.
The Shape Control Technician Shall:
l Monitor the structure’s shape throughout the backfilling Contact your local Contech representative for
SUPER-SPAN/SUPER-PLATE

operation and report shape change rates to the contractor. additional information about SUPER-SPAN structures.
l Contact the Contech representative immediately if there
are problems in meeting the established tolerances.
l Have full authority to stop backfill work if necessary.

84
SUPER-PLATE® Design
The long span structure shall be designed in accordance with
Aluminum Long Span Structures the latest AASHTO design criteria and shall be required to
incorporate the use of continuous longitudinal structural
9" x 2-1/2" Corrugation Project Specification stiffeners (concrete thrust beams). The material supplier shall be
General Description a qualified manufacturer of aluminum structural plate and long
span structures with a minimum of 50 successful installations.
The long span aluminum structural plate structure,
The foundation, structural backfill, and end treatment shall be
conforming to the dimensions shown on the plans and
as required herein and detailed on the plans.
specifications, shall be installed at the location designated.
The design and installation shall conform to AASHTO Structure Assembly
LRFD Specifications for Highway Bridges, Division I, “Soil- The structure shall be assembled in strict accordance with the
Corrugated Metal Structure Interaction Systems”, Section manufacturer’s instructions and to the design shape shown on
12, “Long Span Structural Plate Structures”, and Division II, the plans. Plates shall be assembled according to plate
Section 26, “Metal Culverts.” assembly drawings supplied by the manufacturer.
Materials Structural Backfill
The aluminum structural plate shall have 9” x 2-1/2”
Material
corrugations and shall be of the gage as shown on the plans.
The plates shall be manufactured in conformance with A granular type of material shall be used around and over the
AASHTO Specification M 219 and ASTM B209. Bolts with structure. This select structural backfill material shall conform to
suitable nuts shall meet the provisions of ASTM A307/A449 one of the following classifications of soil from AASHTO
and ASTM A563, and shall be galvanized in accordance with Specification M 145, as modified in the following table for
the requirements of ASTM A153 or B695. Steel anchor bolts A-1, A-2-4 or A-2-5.
shall conform to ASTM A307.
Required stiffening ribs for the crown portion shall be extruded
bulb angles produced from 6061-T6 alloy providing a
minimum 35 ksi yield strength.

Long Span Special Features

Aluminum Long Span Structures will require transverse
stiffening ribs as well as longitudinal stiffeners.

Transverse Stiffeners
Transverse stiffeners will be bolted to the crown portion of the
structure on 1 N (9.625”) maximum circumferential centers.
Their size and longitudinal spacing must adequately stiffen the
top portion of the crown over a minimum 55 degree arc.

Longitudinal Structural Stiffeners (Thrust Beams)

Longitudinal stiffeners shall be located at the radius transition
at the ends of the top arc. The thrust beams shall consist of
reinforced concrete having a compression strength of 2400
psi, and the reinforcing steel shall conform to ASTM A615,
Grade 40, having a minimum yield strength of 40,000 psi.
Black reinforcing steel shall in no instance come in contact
SUPER-SPAN/SUPER-PLATE

with the Aluminum Structural Plate. Thrust beams shall be

formed and poured conforming to the plan dimensions
when the backfill reaches the bottom elevation of the thrust
beams.

SUPER-SPAN horizontal ellipse with reinforced concrete headwall

for a mining application.

85
 Steel and Aluminum
Structural Plate
Design Guide

TABLE 66. - AASHTO M 145 Backfill Envelope Limits

A-1 A-2 (Modified)
The backfill envelope limits are as detailed on the plans.
GROUP CLASSIFICATION A-1-a A-1-b A-2-4 A-2-5
Sieve Analysis, Percent Passing: Backfill Placement
No. 10 (2.00 mm) 50 Max. —— —— ——
No. 40 (0.425 mm) 30 Max. 50 Max. —— —— Before backfilling, the erected structure shall meet the
No. 100 (0.150 mm) —— —— 50 Max. 50 Max. tolerance and symmetry requirements of AASHTO and the
No. 200 (0.075 mm) 15 Max. 25 Max. 20 Max. 20 Max. manufacturer.
Characteristics of Fraction Passing No. 40 (0.425 mm)
Approved backfill material shall be placed in horizontal,
Liquid Limit — 40 Max. 41 Min.
uniform layers not exceeding 8” in thickness, before
Plasticity Index 6 Max. 10 Max. 10 Max.
Usual Types of Significant Stone Fragments Silty or Clayey
compaction, and shall be brought up uniformly on both
Constituent Materials Gravel and Sand Gravel and Sand sides of the structure. Each layer of backfill shall be
* Modified to be more select than M 145. compacted to a minimum 90% density per AASHTO T-180.
Field density tests of compacted backfill will be made at
Additional Requirements
regular intervals during backfill.
1. Materials must be dense graded (open graded or gap
Long span structures, due to their size and shape, are
graded materials are not allowed).
sensitive to the types and weights of equipment used to
2. Fine beach sands, windblown sands, and stream place and compact the select backfill material. This is
deposited sands, all of which exhibit fine, rounded especially critical in the areas immediately adjacent to and
particles and typically are classified by AASHTO above the structure. Therefore, equipment types will be
M 145 as A-3 materials, are not allowed. restricted in those critical zones. Compaction equipment or
3. On site mixing or blending to achieve specified methods that produce horizontal or vertical earth pressures
gradation is not allowed. which cause excessive distortion or damage to structures
Maximum particle size shall not exceed 3 inches. For the shall not be used.
A-2 materials, moisture content must be between -3%
and +2% optimum as defined by AASHTO specification Contractors should plan to have a D4 (approximately
T 180. All soil classifications are limited to the following 20,000 lbs.) or similar weight tracked dozer to place and
height of cover limits and structure shape applications: grade backfill immediately alongside and radially above the
structure until minimum cover level is reached. Lightweight
l A-1-a material is suitable for all long span shapes, vibratory plate or roller type compaction equipment must be
sizes and fill heights. used to compact the backfill in these zones. Use of heavier
l A-1-b material is suitable only for use with high equipment and/or rubber tired equipment such as scrapers,
profile arch structures to a 12’ maximum fill height graders, and front end loaders will likely be prohibited
and for use with elliptical and low profile arch inside the select fill envelope zone until appropriate
structures to a 20’ maximum fill height. minimum cover height has been obtained.
l A-2-4 and A-2-5 materials are restricted to maximum
heights of cover of 12’. Shape Control Monitoring

Other backfill materials, which provide equivalent The material supplier or the manufacturer shall provide a
structural properties, long-term, in the environmental Shape Control Technician who is a qualified representative
conditions expected (saturation, freeze-thaw, etc.), may of a professional soils engineering firm, or other qualified
be used. Such materials shall be approved only after organization, to ensure properly shaped structure. The
thorough investigation and testing by a soils engineer Shape Control Technician shall take initial measurements of
familiar with the requirements for structural backfill of the erected structure before backfilling, observe all backfill
long span structures. materials and their placement, and record compaction
densities. The Technician shall record all density readings
SUPER-SPAN/SUPER-PLATE

and ensure they meet the requirements of the plans and

specifications. However, in no case shall the relative density
be less than a minimum 90% density per AASHTO T-180.
The Shape Control Technician shall monitor the structure
shape during the placement of structural backfill to the
minimum cover height over the structure. No structural
backfill shall be placed without the Shape Control
Technician on site.

86
The Shape Control Technician shall: 1. The structure must be designed using the AASHTO Long
Span criteria and these plans and specifications. Aluminum
l Monitor the structure’s shape throughout the backfilling
alloy structural plate shall conform to the requirements of
operation and report shape change rates to the contractor.
AASHTO M 219.
l Contact the material supplier or the manufacturer
2. The corrugated metal plate thickness specified is considered
immediately if there are problems in meeting the
the minimum acceptable for the structure(s) on this project,
established tolerances.
based on structural and durability requirements. Any other
l Have full authority to stop backfill work if necessary.
structure, regardless of “special features”, must be of the
Preconstruction Meeting same thickness or greater.
3. When longitudinal reinforcements are not used, the
Prior to construction, a meeting will be held to review the
“Special Features”, such as aluminum structural ribs, shall
construction procedures. A qualified representative of the
be aluminum alloy 6061-T6. Ribs shall be placed over the
manufacturer of the structure will be present to discuss
same length of structure that the thrust beams would apply.
methods and responsibility for shape monitoring and control,
4. Alternate structures meeting the above criteria will only
backfill material selection, testing and placement, and
be considered for use if pre-approved in writing by the
compaction methods and testing. A representative of the
Engineer prior to the bid date. To qualify for pre-approval,
Engineer, Prime Contractor and any involved sub-contractors
an alternate submittal package must be submitted to the
must be present.
Engineer a minimum of 15 days prior to the bid date.

Alternate Structures
Contact your local Contech representative for
The Contractor may furnish an alternate structure to the long additional information about SUPER-PLATE structures.
span shown on the plans and these specifications but the
following conditions must be met:

SUPER-SPAN/SUPER-PLATE

SUPER-SPAN Single Radius Arch with Keystone Headwalls for a Residential Development.

87
 Steel and Aluminum
Structural Plate
Design Guide

BridgeCor®
BridgeCor

Deep Corrugation Expands Structural Plate

Corrugated steel structural plate has a long history dating Versatility
back to 1931. It is a proven buried bridge standard due
BridgeCor structures offer a wide variety of shape and size
to its strength, durability, and economy. BridgeCor, a deep
options, which may provide the most cost effective solution to
corrugation pattern, provides designers of bridge systems
the site requirements.
the option to use structural plate bridges with wider spans
and taller rises. BridgeCor is manufactured in a 15” X 5.5”
Description of Plates
corrugation pattern and Contech has improved on the
manufacturing process to provide a three corrugation plate. BridgeCor plates are field assembled into round, arch, and
box culvert structures. Corrugations of 15-inch pitch and 5.5-
BridgeCor structures are made from sturdy, heavy gage, inch depth are perpendicular to the length of each plate.
corrugated steel plates that are pre-formed to various shapes
and sizes, then galvanized for long-term protection and Thickness. Standard specified thickness of the galvanized
performance. The plates are delivered to the job site and plates vary from 0.170 (8 gage) to 0.380 inches (3/8").
bolted together to form a BridgeCor structure specifically
chosen for the project. Lengths. BridgeCor plates are furnished in either 2.50 foot
net lengths or 3.75 foot net lengths. Please refer to the
BridgeCor is available in Round, Single and 2-Radius Arches assembly drawings for the specific plate sizes. Actual length
and Box Culverts - all in a wide range of sizes. Custom of a square-ended structure is three inches longer than its net
shapes, such as Ellipses and 3-Radius Arches, are also an length because a 1 ½-inch lip protrudes beyond each end of
option. BridgeCor and its associated shapes are accepted by every plate for lapping purposes.
AASHTO and have been installed around the world.
Widths. Standard plates come in multiples of 16 inches
Superior Durability (S=16 inches or 5 * Pi) and are fabricated in eleven net
covering widths. The “S” nomenclature translates
BridgeCor is similar to MULTI-PLATE and is manufactured
circumference directly into nominal diameter in inches
from heavy gage steel using an industry standard of 3 oz. per
(for additional detail see Table 67).
square foot galvanized coating. The long history of structural
plate installations have shown these designs can provide a
Bolt holes. BridgeCor plates are punched with 1 inch holes
service life of 75 years or longer.
for 8 gage through 1 gage plates to accommodate a ¾
inch bolt. Circumferential holes are punched on 16 inch (1
When selecting the proper material for an application,
S) centers. All BridgeCor requires a staggered longitudinal
designers need to evaluate the soil side of the structure along
seam. These seams have a three-hole bolt pattern in the crest
with the corrosive and abrasive action due to the flow at
and valley of the corrugations along the length of structure
the invert of the structure. The use of structural plate gives
to help provide additional seam strength. For heavier plate
designers more structure shape options to help minimize the
structures (0.318" and 0.380"), the holes are punched to
impact of abrasion on the invert of the structure.
1.125 inch diameter along the seams to accommodate a 7∕8
inch bolt. Bolt lengths will vary depending on the location of
High Load-Carrying Capacity
the bolt and the number of plates in a given location.
As a steel-soil interaction system, BridgeCor is designed to
carry high combined live and dead loads. High traffic loads
and deep cover applications are a structural plate specialty.

More Efficient Installation Process

Prefabricated plates are assembled in the field, translating into ROUNDROUND
ROUND ROUND SINGLESINGLE
RADIUS
SINGLERADIUS
RADIUS
ARCH
SINGLE
ARCH
ARCH
RADIUS ARCH TWO RADIUS
TWO
TWORADIUS
RADIUS
ARCHTWO
ARCH
ARCH
RADIUS ARCH BOX CULVERT
BOX
BOXCULVERT
CULVERT
BOX CULVERT

finished construction in days instead of weeks as with most Standard Shapes

cast-in-place concrete structures.

88
 Standard Plate Detail

BridgeCor
15” x 5.5” Corrugation, 45" Long Detail

TABLE 68 A. APPROXIMATE WEIGHT OF BRIDGECOR SECTIONS (45" PLATES)

Plate Width Overall 8 7 5 3 1
15” x 5.5” Corrugation, 30" Long Detail S Width (Feet) (0.170) (0.188) (0.218) (0.249) (0.280)
4S 6.1 219 242 280 321 361
Notes: 5S 7.4 267 295 342 391 440
1. The plate length is subject to manufacturing capabilities. 6S 8.8 315 348 404 461 519
2. All bolts are per ASTM A449 (with suitable nuts) and are 3/4"
7S 10.1 363 401 465 531 598
diameter for all thicknesses except 5/16" and 3/8", which are 7/8"
diameter. 8S 11.4 411 454 527 602 677
9S 12.8 459 507 588 672 756

TABLE 67. DETAILS OF UNCURVED BRIDGECOR SECTIONS TABLE 68 B. APPROXIMATE WEIGHT OF BRIDGECOR SECTIONS (30" PLATES)
Net Overall Spaces Number of Plate Overall 8 7 5 3 1 5/16* 3/8*
Width Width
Nominal Width Width (16 Circumferential S (Feet) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Inches) (Inches) inches) Bolt Holes 4S 6.1 152 165 192 218 250 285 339
4S 64 73 4 5 5S 7.4 185 201 234 267 305 347 414
5S 80 89 5 6 6S 8.8 218 248 276 315 360 409 489
6S 96 105 6 7 7S 10.1 251 286 318 362 414 471 563
7S 112 121 7 8 8S 11.4 284 323 360 410 469 534 638
9S 12.8 317 361 402 458 524 596 712
8S 128 137 8 9
10 S 14.1 350 381 444 506 578 637 n/a
9S 144 153 9 10
11 S 15.4 384 436 486 554 633 704 n/a
10 S 160 169 10 11 12 S 16.8 417 474 528 601 688 765 n/a
11 S 176 185 11 12 13 S 18.1 450 512 570 649 742 826 n/a
12 S 192 201 12 13 14 S 19.4 483 549 612 697 797 878 n/a
13 S 208 217 13 14 1. Weights are based on a zinc coating of 3 oz./sq. ft. of double-exposed surface.
14 S 224 233 14 15 2. All weights are subject to manufacturing tolerances and do not include fasteners.
3. Specified thickness is a nominal galvanized thickness. Reference AASHTO M 167.
For BridgeCor, S = 16 inches. 4. S = 16 inches
* For 5/16" or 3/8" the net length is 2.5' (30")

Unbalanced Channel Cross Section Unbalanced Channel for BridgeCor® Arch

Note: Weight is 10 lbs per foot per side. "Unfolded View"

89
 Steel and Aluminum
Structural Plate
Design Guide

BridgeCor®
BridgeCor

Galvanized Steel Project Specification

Scope: This specification covers the manufacture and
installation of the galvanized steel BridgeCor structure as
detailed in the plans.

2.0 GENERAL CONDITIONS

I - GENERAL
1.0 STANDARDS AND DEFINITIONS
2.1 The Contractor shall furnish all labor, material and
1.1.1 ASTM A761 “Corrugated Steel Structural Plate, Zinc
equipment and perform all work and services except
Coated for Field-Bolted Pipe, Pipe-Arches and Arches”
those set out and furnished by the Owner, necessary to
(AASHTO Designation M 167).
complete in a satisfactory manner the site preparation,
1.1.2 AASHTO LRFD Bridge Design Specification for excavation, filling, compaction, grading as shown
Highway Bridges - Section 12.8.9. on the plans and as described therein. This work
1.1.3 AASHTO LRFD Bridge Construction Specification for shall consist of all mobilization clearing and grading,
Highway Bridges - Section 26. grubbing, stripping, removal of existing material
unless otherwise stated, preparation of the land to be
filled, filling of the land, spreading and compaction of
1.2 DEFINITIONS the fill, and all subsidiary work necessary to complete
the grading of the cut and fill areas to conform with
1.2.1 Owner - In these specifications the word “Owner”
the lines, grades, slopes, and specifications. This work
shall mean the site owner or the purchaser.
is to be accomplished under the observation of the
1.2.2 Engineer - In these specifications the word “Engineer” Owner or his designated representative.
shall mean the Engineer of Record or Owner’s
2.2 Prior to bidding the work, the Contractor shall
designated engineering representative.
examine, investigate and inspect the construction
1.2.3 Manufacturer - In these specifications the word site as to the nature and location of the work, and
“Manufacturer” shall mean Contech Engineered the general and local conditions at the construction
Solutions at 800-338-1122. Manufacturers, other site, including without limitation, the character of
than Contech Engineered Solutions, shall provide surface or subsurface conditions and obstacles to
to the Owner proof of 10 years of manufacturing be encountered on and around the construction site
experience of Deep Corrugated structures meeting and shall make such additional investigation as he
AASHTO M 167. may deem necessary for the planning and proper
1.2.4 Contractor - In these specifications the word execution of the work.
“Contractor” shall mean the firm or corporation If conditions other than those indicated are discovered
undertaking the execution of any installation work by the Contractor, the Owner shall be notified
under the terms of these specifications. immediately. The material which the Contractor
1.2.5 Approved - In these specifications the word believes to be a changed condition shall not be
“approved” shall refer to the approval of the Engineer disturbed so that the owner can investigate the
or their designated representative. condition.

1.2.6 As Directed - In these specifications the words “as 2.3 The construction shall be performed under the
directed” shall refer to the directions to the Contractor direction of the Engineer.
from the Owner or his designated representative. 2.4 All aspects of the structure design and site layout
including foundations, backfill, end treatments and
necessary scour consideration shall be performed by
the Engineer.
Any installation guidance provided herein shall be
endorsed by the Engineer or superseded by the
Engineer’s plans and specifications.

90
II - CONTECH BRIDGECOR – ROUND, SINGLE RADIUS It is recommended that the bedding be a relatively

BridgeCor
ARCH, 2-RADIUS ARCH, 3-RADIUS ARCH, loose granular material that is roughly shaped to fit
ELLIPSE OR BOX the bottom of the structure, be a minimum of twice the
corrugation depth in thickness and have a maximum
1.0 GENERAL particle size of one half the corrugation depth. It
should be noted that the bedding depth can vary
1.1 Manufacturer shall fabricate the selected shape as
based on the amount of cover and the shape of the
shown on the plans. Fabrication shall conform to
structure’s invert. The bedding should be shaped to
the requirements of ASTM A761 and shall consist of
match structures with flatter inverts.
plates, fasteners, and appurtenant items.
3.5 Adequate soil bearing capacity or strength shall be
Plate thickness, end treatment and type of invert
provided to the Engineer. Foundation details shall be
and foundation shall be as indicated on the plans.
provided by the Engineer.
All manufacturing processes including corrugating,
punching, curving and required galvanizing shall be 3.6 The structure shall be assembled in accordance with
performed within the United States of America. the Manufacturer’s instructions. All plates shall be
unloaded and handled with reasonable care. Plates
1.2 The contractor shall verify all field dimensions and
shall not be rolled or dragged over gravel rock and
conditions prior to ordering materials.
shall be prevented from striking rock or other hard
objects during placement in trench or on bedding.
2.0 DIMENSIONS When assembled on a cast in place spread footing,
2.1 The proposed structure shall be a Contech BridgeCor the structure shall be assembled in the footing starting
with the following dimensions, as an example: at the upstream end. When assembled on a full invert,
the invert shall be placed starting at the downstream
Span: 49'-11"; Rise: 22'-10"; Gage: 1(0.280); "S": 57 end. The structure shell shall be assembled on
2.2 All plan dimensions on the contract drawings are the invert starting at the inlet end. Circumferential
measured in a true horizontal plan unless otherwise seams shall be installed with the plate laps shingled
noted. downstream as viewed from the inside of the structure.
The structure shall be backfilled using clean well
3.0 ASSEMBLY AND INSTALLATION graded granular material that meets the requirements
3.1 Bolts with suitable nuts shall conform to the of a finite element analysis, which may concur with
requirements of ASTM A449. The Contech BridgeCor AASHTO M 145 for soil classifications A-1, A-2-4,
shall be assembled in accordance with the plate layout A-2-5 or A-3 according to Table 69.
drawings provided by the manufacturer and per the Backfill must be placed symmetrically on each side of
manufacturer’s recommendations. the structure in 6-to-8-inch loose lifts, with no side-to-
Bolts shall be tightened using an applied torque of side differential exceeding 24-inches. Each lift shall be
between 150-300 ft-lbs for ¾” diameter bolts and compacted to a minimum 90% density per AASHTO
200-350 ft-lbs for 7/8” diameter bolts. T-180. At no time shall the backfill be more than 2’
higher on one side of the structure than the other side.
3.2 The structure shall be installed in accordance with
the plans and specifications, the manufacturer’s The structure must be shape monitored until the
recommendations, and AASHTO LRFD Bridge backfill level reaches the minimum cover elevation.
Construction Specification for Highway Bridges - Shape monitoring is the responsibility of the contractor
Section 26. and needs to follow the guidelines of the AASHTO
LRFD Bridge Construction Specifications, Section
3.3 Trench excavation shall be made in embankment
26. When the shape monitoring is complete, a
material that is structurally adequate. The trench
documented report will be provided to the Owner.
width shall be shown on the plans. Poor quality in situ
embankment material must be removed and replaced 3.7 Construction loads that exceed highway load limits
with suitable backfill as directed by the Engineer. are not allowed to cross the structure without approval
from the Engineer. Normal highway traffic is not
3.4 For structures with inverts, the bedding should be
allowed to cross the structure until the structure has
constructed to a uniform line and grade to avoid
been backfilled and paved. If the road is unpaved,
distortions that may create undesirable stresses in the
cover allowance to accommodate rutting shall be as
structure and/or rapid deterioration of the roadway. It
directed by the Engineer.
should be free of rock formations, protruding stones,
and frozen matter that may cause unequal settlement. Normal highway traffic is not allowed to cross the
A shaped bedding layer consisting of uncompacted structure until the structure has been backfilled and
granular fill shall be prepared prior to the placement paved. If the road is unpaved, cover allowance to
of the structure’s invert plates. accommodate rutting shall be as directed by the
Engineer.

91
 Steel and Aluminum
Structural Plate
Design Guide

Installation Recommendations
It is recommended that the bedding be a relatively loose
BridgeCor

A successful installation is dependent on these six critical granular material that is roughly shaped to fit the bottom of
components being followed: the structure, be a minimum of twice the corrugation depth
in thickness and have a maximum particle size of one half
1. Proper foundation. the corrugation depth.
2. Proper structure assembly.
3. Use of select structural backfill. It should be noted that the bedding depth can vary based on
4. 8” maximum thick lifts of backfill evenly placed on the amount of cover and the shape of the structure’s invert.
both sides of the structure. The bedding should be shaped to match structures with
5. Verification of backfill compaction. flatter inverts.
6. Minimum cover over the structure.
Please reference the project specifications, drawing
Required Elements submittals and Contech's Assembly and Installation Guide
Satisfactory site preparation, trench excavation and bedding for more information.
and backfill operations are essential to develop the strength
of any flexible conduit. In order to obtain proper strength Bolting
while preventing settlement, it is necessary that the soil If the plates are well aligned, the torque applied with a
envelope around the structure be of good quality, well power wrench need not be excessive. Bolts should be
graded granular material, properly placed, and carefully torqued initially to a minimum 150 foot pounds and a
compacted. maximum 300 foot pounds. A good plate fit is far better
than high torque.
A qualified Engineer should be engaged to design a proper
foundation, adequate bedding, and backfill material. Complete detailed assembly instructions and drawings are
provided with each structure.
Trench Excavation
If the adjacent embankment material is structurally adequate Erosion Control
per the Engineer of Record, the trench requires a bottom During installation and prior to the construction of
clear width of the structure’s span plus sufficient room for permanent erosion control and end treatment protection,
proper compaction equipment. special precautions may be necessary. The structure must be
protected from unbalanced loads and from any structural
Bedding loads or hydraulic forces that may bend or distort the
The bedding should be constructed to a uniform line and unsupported ends of the structure. Erosion or wash out of
grade to avoid distortions that may create undesirable previously placed soil support must be prevented to ensure
stresses in the structure and/or rapid deterioration of the that the structure maintains its load capacity.
roadway. It should be free of rock formations, protruding
stones, and frozen matter that may cause unequal
settlement.

BridgeCor grade separation for an airport application.

92
Backfill Material

BridgeCor
Satisfactory backfill material, proper placement and compaction
are key factors in obtaining maximum strength and stability.

The backfill material should be free of rocks, frozen lumps, and

foreign material that can cause hard spots or decompose to create
voids. Backfill material should be well graded granular material
that meets the requirements of a finite element analysis, which
may concur with AASHTO M 145 for soil classifications A-1, A-2-
4, A-2-5, or A-3 in Table 69. Backfill must be placed symmetrically
on each side of the structure in eight-inch loose lifts, with no side-
to-side differential exceeding 24-inch. Each lift shall be compacted
to a minimum 90% density per AASHTO T-180.

A high percentage of silt or fine sand in the native soils suggests

the need for a well graded granular backfill material to prevent
soil migration.

Contractors should plan to have a maximum 20,000 lbs. tracked

dozer to place and grade backfill immediately alongside and
radially above the structure until minimum cover level is reached.
Lightweight vibratory plate or roller type compaction equipment
must be used to compact the backfill in these zones. Use of
heavier equipment and/or rubber tired equipment such as
scrapers, graders, and front end loaders will likely be prohibited
inside the select fill envelope zone until appropriate minimum
cover height has been obtained. Each lift shall be compacted to a minimum 90% density
per AASHTO T-180.
The Engineer and Contractor are cautioned that the minimum
cover may need to be increased to handle temporary construction
vehicle loads (heavier than the design highway load).

For more information, refer to ASTM A807 and AASHTO LRFD

Bridge Construction Specifications for Highway Bridges Div. II –
Construction Section 26.

TABLE 69. STRUCTURAL PLATE BACKFILL GROUP CLASSIFICATION, REFERENCE AASHTO M 145
Group Classification A-1-a A-1-b A-2-4 A-2-5 A-3
Sieve Analysis Percent Passing
No. 10 (2.000 mm) 50 max ---- ---- ---- ----
No. 40 (0.425 mm) 30 max 50 max ---- ---- 51 max*
No. 200 (0.075 mm) 15 max 25 max 35 max 35 max 10 max
Atterberg Limits for Fraction Passing No. 40 (0.425 mm)
Liquid Limits ---- ---- 40 max 41 min ----
Plasticity Index 6 max 6 max 10 max 10 max Non-Plastic
Usual Materials Stone Fragment, Gravel Silty or Clayey Gravel Coarse Sand
and Sand and Sand
Most Probable GW, GP SW, SP, GM, SM GM, SM GM, SM SP
Comparable Soil
Groups In The Unified
Soil Classification
System Reference ASTM
D2487
* Modified from M 145. Material shall be a 3" maximum particle size.
Fine Beach Sands, Windblown Sands, Stream Deposited Sands, etc., Exhibiting Fine, Rounded Particles And Typically Classified By AASHTO M 145
as A-3 Materials Should Not Be Used.

93
 Steel and Aluminum
Structural Plate
Design Guide
BridgeCor

BridgeCor Box Culvert Assembly

BridgeCor Tunnel Installation

BridgeCor with a MSE Precast Panel

Wall System on a DOT Project

BridgeCor with a Vist-A-Wall Welded Wire Wall

System for a Private Development

94
BridgeCor® - External Rib System

BridgeCor
Deep Corrugation Expands Structural Plate
Contech innovations continue to take structural plate buried Features and Benefits
bridge systems to the next level with the new BridgeCor
External Rib System. The BridgeCor External Rib System • Spans between 40’ - 80’
optimizes structure designs, reduces the amount of material • Complete bridge system – Rapid installation
required, increases spans up to 80’, and maximizes the • Material optimization for steel and backfill savings
overall structure stability. • Cost-savings vs. conventional bridge structures
• Suitable for new construction, retrofit, deep cover and
rehabilitation applications
• Ideal for DOTs, Counties/Municipalities, Residential,
Railroad and Mining market projects
• AASHTO Section 12 includes external ribs as part of the
overall design specification
• Patent Pending Design

Typical External Rib Detail

Typical External Rib System Assembly

95
 Steel and Aluminum
Structural Plate
Design Guide
BridgeCor

BridgeCor (64’-2” x 19’-7”) External Rib System with BridgeCor External Rib System
Vist-A-Wall Welded Wire Wall System during construction after construction

BridgeCor Beam Platform

BridgeCor External Rib System

96
 ROUND

TABLE 70. BRIDGECOR ROUND PIPE 15" X 5½"

BridgeCor
LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Gage Thickness (Inches)
Dimensions to Inside Corrugation
Maximum Cover Height Shown in Feet
Approx. Min. Precon
Diameter 8 7 5 3 1 5/16 3/8
Area Cover Total S (Min.
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Sq. Ft.) (Feet) Level)
19-11 311 2.5 48 21 25 30 35 40 45 50 1
20-9 339 2.5 50 20 23 28 33 38 43 48 1
21-7 367 2.5 52 18 21 26 31 36 41 46 1
22-6 396 2.5 54 17 19 25 29 33 38 43 1
23-4 427 2.5 56 16 19 24 28 32 37 42 1
24-2 459 2.5 58 15 18 23 27 30 35 40 1
25-0 491 2.5 60 14 17 22 26 29 34 39 1
25-10 525 2.5 62 14 17 22 25 28 32 37 1
26-8 560 2.5 64 13 16 21 24 27 31 35 1
27-7 596 2.5 66 13 15 21 24 26 30 34 1
28-5 634 2.5 68 12 15 20 23 25 29 33 1
29-3 672 2.5 70 12 15 20 22 24 28 32 1
30-1 712 2.5 72 12 14 19 21 23 26 30 1
30-11 752 2.5 74 11 14 18 20 22 25 29 2
31-10 794 3.0 76 11 14 18 20 22 25 28 2
32-8 837 3.0 78 11 13 17 19 21 24 27 2
33-6 881 3.0 80 10 13 17 19 20 23 26 2
34-4 926 3.0 82 10 13 17 18 20 23 26 2
35-2 973 3.0 84 9 13 16 18 19 22 25 2
36-0 1020 3.0 86 13 16 17 18 21 24 2
36-11 1069 3.0 88 12 15 17 18 21 24 3
37-9 1119 3.0 90 15 16 17 20 23 3
38-7 1170 3.0 92 15 16 17 20 22 3
39-5 1222 3.0 94 14 15 16 19 21 3
40-3 1275 3.0 96 15 16 19 21 3
41-2 1329 3.0 98 15 16 18 20 3
42-0 1384 3.0 100 14 15 17 19 4
42-10 1441 3.0 102 14 15 17 19 4
43-8 1499 3.0 104 14 16 18 4
44-6 1557 3.0 106 14 16 19 4
45-5 1617 3.0 108 13 15 16 4
46-3 1679 3.0 110 13 14 15 4
47-1 1741 3.0 112 15 16 4
47-11 1804 3.0 114 15 16 4
48-9 1868 3.0 116 14 15 4
49-7 1934 3.5 118 14 15 4
50-6 2001 3.5 120 15 4

Notes:
1. Not for a specific structural design. Use for budget estimating only. Finite Element Analysis (CANDE) is required for final design and quotation.
2. The above table is based upon the general requirements of the AASHTO LRFD Design Specification, Section 12, and:
a. These tables are based upon a trench condition installation. A finite element analysis is required to determine this width in an embankment installation.
b. Backfill material per AASHTO M 145. For estimating, assume any A-1 material.
With specific site information, alternate backfill materials may be allowed. Refer to Table 69 (pg. 93).
c. Select backfill 120 pcf in density and compacted to a minimum 90% density per AASHTO T-180.
d. The minimum cover is the vertical distance from the mid-depth (neutral axis) of the corrugations to the top of rigid or bottom of flexible
pavement per AASHTO [Link]
e. A minimum select backfill width of 8 feet was used when analyzing the table above. Other widths may be acceptable based on an alternate finite element
analysis. This width was measured from outside the maximum span on each side of the structure. This width only applies when the material adjacent to the select
zone is determined to be competent, well consolidated material.
3. Select backfill width may increase for situations where lower strength fill exists in either the select fill zone or the adjacent embankment zone.
4. This estimate is for single barrel structures. For multiple barrels, more investigation is required.

97
 ROUND
Steel and Aluminum
Structural Plate
Design Guide

TABLE 71. BRIDGECOR ROUND PIPE 15" X 5½"

BridgeCor

WEIGHT TABLES
Gage Thickness (Inches)
Inside Diameter
Weight Shown as Pounds per Foot of Structure

Diameter 8 7 5 3 1 5/16 3/8

Total S
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)

19-11 48 680 750 867 987 1107 1325 1574

20-9 50 706 779 900 1025 1149 1375 1635
21-7 52 731 808 933 1063 1191 1426 1696
22-6 54 757 837 966 1101 1234 1476 1757
23-4 56 793 875 1012 1152 1292 1546 1837
24-2 58 819 904 1045 1190 1334 1596 1898
25-0 60 845 933 1078 1227 1376 1646 1958
25-10 62 870 962 1111 1265 1418 1697 2019
26-8 64 907 1001 1156 1316 1476 1766 2099
27-7 66 932 1029 1189 1354 1518 1817 2160
28-5 68 958 1058 1222 1392 1561 1867 2221
29-3 70 983 1087 1255 1430 1603 1918 2282
30-1 72 1009 1116 1289 1468 1645 1968 2342
30-11 74 1046 1154 1334 1519 1703 2038 2422
31-10 76 1071 1183 1367 1557 1745 2088 2483
32-8 78 1097 1212 1400 1594 1787 2138 2544
33-6 80 1122 1241 1433 1632 1829 2189 2605
34-4 82 1159 1279 1478 1683 1887 2258 2685
35-2 84 1185 1308 1511 1721 1930 2309 2746
36-0 86 1337 1545 1759 1972 2359 2806
36-11 88 1366 1578 1797 2014 2410 2867
37-9 90 1611 1835 2056 2460 2928
38-7 92 1656 1886 2114 2530 3008
39-5 94 1689 1923 2156 2580 3069
40-3 96 1961 2198 2630 3130
41-2 98 1999 2241 2681 3190
42-0 100 2050 2299 2750 3270
42-10 102 2088 2341 2801 3331
43-8 104 2383 2851 3392
44-6 106 2425 2902 3453
45-5 108 2467 2952 3514
46-3 110 2525 3022 3594
47-1 112 3072 3654
47-11 114 3122 3715
48-9 116 3173 3776
49-7 118 3242 3856
50-6 120 3917
Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Weights include fasteners for assembly.
3. Weights include a galvanized coating which is 3 ounces per square foot, total both sides.
4. For structure plate make-up information, please contact your Contech representative.

98
 SINGLE RADIUS ARCH

TABLE 72. BRIDGECOR SINGLE RADIUS ARCH 15" X 5½"

BridgeCor
LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Gage Thickness (Inches)
Dimensions to Inside Corrugation
Maximum Height of Cover Shown in Feet
Bottom Approx. Min Precon
Rise 8 7 5 3 1 5/16 3/8
Span Area Cover Total S (min
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Ft.-In.) (Sq. Ft.) (Feet) Level)
19-7 9-9 150 2.0 23 20 24 29 34 39 44 49 1
19-10 5-0 66 2.0 17 19 23 28 32 36 41 46 1
20-5 10-2 164 2.0 24 19 22 27 32 37 42 47 1
21-3 10-7 177 2.0 25 18 21 26 31 36 40 45 1
22-1 11-0 192 2.0 26 17 20 25 30 34 39 44 1
22-10 11-6 207 2.0 27 17 20 25 29 33 37 42 1
23-10 11-11 222 2.0 28 16 19 24 28 32 36 40 1
24-8 12-4 238 2.0 29 15 18 23 27 30 34 38 1
24-8 6-0 103 2.0 21 15 17 21 25 28 31 34 1
25-6 12-9 255 2.0 30 14 17 21 25 29 33 37 1
26-4 13-2 272 2.0 31 14 17 21 25 28 31 35 1
27-2 13-7 290 2.0 32 13 16 20 24 27 30 34 2
28-0 14-0 309 2.0 33 12 15 19 23 26 29 33 2
28-10 7-5 149 2.0 25 11 13 16 20 24 27 30 2
28-10 14-5 328 2.0 34 12 14 18 21 25 28 32 2
29-8 14-10 347 2.0 35 11 14 17 21 24 28 31 2
30-6 15-3 367 2.0 36 11 13 16 19 23 26 29 2
31-6 15-9 388 2.0 37 11 13 16 19 22 25 28 2
32-4 16-1 409 2.0 38 10 12 15 18 21 24 27 2
33-2 16-7 431 2.0 39 10 11 14 17 20 23 26 2
34-0 17-0 453 2.0 40 10 11 14 17 19 23 25 2
34-1 9-2 219 2.0 30 10 11 14 17 19 21 23 2
35-8 17-10 500 2.0 42 9 11 13 16 18 20 22 2
37-0 18-9 548 2.0 44 11 13 15 17 19 21 2
38-11 10-2 278 2.0 34 10 12 14 16 18 20 2
39-0 19-6 599 2.0 46 10 12 14 16 18 19 2
40-8 20-4 653 2.0 48 12 13 15 16 17 3
42-6 21-3 708 2.0 50 12 13 14 15 16 3
44-2 22-1 766 2.0 52 11 12 13 14 15 3
45-10 22-11 826 2.0 54 10 11 12 13 14 3
46-0 11-9 380 2.0 40 12 12 13 14 3
49-2 24-7 953 2.5 58 11 13 14 3
51-0 25-6 1019 2.5 60 10 13 14 3
52-8 26-4 1088 3.0 62 12 13 3
54-4 27-2 1160 3.5 64 11 12 3

Notes:
1. Not for a specific structural design. Use for budget estimating only. Finite Element Analysis (CANDE) is required for final design and quotation.
2. The above table is based upon the general requirements of the AASHTO LRFD Design Specification, Section 12, and:
a. These tables are based upon a trench condition installation. A finite element analysis is required to determine this width in an embankment installation.
b. Backfill material per AASHTO M 145. For estimating, assume any A-1 material.
With specific site information, alternate backfill materials may be allowed. Refer to Table 69 (pg. 93).
c. Select backfill 120 pcf in density and compacted to a minimum 90% density per AASHTO T-180.
d. The minimum cover is the vertical distance from the mid-depth (neutral axis) of the corrugations to the top of rigid or bottom of flexible
pavement per AASHTO [Link]
e. A minimum select backfill width of 8 feet was used when analyzing the table above. Other widths may be acceptable based on an alternate finite element analysis.
This width was measured from outside the maximum span on each side of the structure. This width only applies when the material adjacent to the select zone is
determined to be competent, well consolidated material.
3. Select backfill width may increase for situations where lower strength fill exists in either the select fill zone or the adjacent embankment zone.
4. This estimate is for single barrel structures. For multiple barrels, more investigation is required.

99
 SINGLE RADIUS ARCH
Steel and Aluminum
Structural Plate
Design Guide

TABLE 73. BRIDGECOR SINGLE RADIUS ARCH 15" X 5½"

BridgeCor

WEIGHT TABLES
Gage Thickness (Inches)
Dimensions to Inside Corrugation
Weight Shown as Pounds per Foot of Structure
Bottom
Rise 8 7 5 3 1 5/16 3/8
Span Total S
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Ft.-In.)
19-7 9-9 23 325 358 414 472 530 631 751
19-10 5-0 17 237 262 303 345 387 461 549
20-5 10-2 24 337 373 431 491 551 656 781
21-3 10-7 25 350 387 447 510 572 681 811
22-1 11-0 26 363 401 464 529 593 707 842
22-10 11-6 27 386 427 493 561 629 751 893
23-10 11-11 28 399 440 509 580 650 776 923
24-8 12-4 29 412 455 526 599 671 801 953
24-8 6-0 21 299 330 381 434 487 581 691
25-6 12-9 30 425 469 542 618 693 827 983
26-4 13-2 31 438 483 559 636 714 852 1013
27-2 13-7 32 451 498 575 655 735 877 1044
28-0 14-0 33 463 512 592 674 756 902 1074
28-10 7-5 25 350 387 447 510 572 681 811
28-10 14-5 34 476 526 608 693 778 927 1104
29-8 14-10 35 489 541 625 712 799 953 1135
30-6 15-3 36 513 566 654 744 835 997 1186
31-6 15-9 37 525 580 670 763 856 1022 1216
32-4 16-1 38 538 594 687 782 877 1047 1246
33-2 16-7 39 551 608 703 801 899 1073 1276
34-0 17-0 40 564 623 720 820 920 1098 1306
34-1 9-2 30 425 469 542 618 693 827 983
35-8 17-10 42 590 651 753 858 962 1148 1367
37-0 18-9 44 680 786 896 1004 1199 1427
38-11 10-2 34 526 608 693 778 927 1104
39-0 19-6 46 719 831 947 1062 1268 1508
40-8 20-4 48 864 984 1104 1319 1569
42-6 21-3 50 898 1022 1147 1369 1629
44-2 22-1 52 931 1060 1189 1419 1690
45-10 22-11 54 976 1111 1246 1489 1771
46-0 11-9 40 820 920 1098 1306
49-2 24-7 58 1331 1590 1891
51-0 25-6 60 1373 1640 1952
52-8 26-4 62 2013
54-4 27-2 64 2093
Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Weights include fasteners for assembly.
3. Weights include a galvanized coating which is 3 ounces per square foot, total both sides.
4. For structure plate make-up information, please contact your Contech representative.
5. If Unbalanced Channels are supplied, add 20 pounds per foot to the structure length.

100
 2-RADIUS ARCH

TABLE 74. BRIDGECOR 2-RADIUS ARCH 15 X 5½

BridgeCor
LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Gage Thickness (Inches) - Height of Cover Shown in Feet
Dimensions to Inside Corrugation
Maximum Height of Cover (Minimum Height of Cover)
Maximum Approx.
Rise 8 7 5 3 1 5/16 3/8 Precon
Span Area Total S
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380) (min Level)
(Ft.-In.) (Sq. Ft.)
20 24 28 33 38 43 48
18-5 8-4 124 21 2
(2.0) (2.0) (1.5) (1.5) (1.5) (1.5) (1.5)
17 21 25 29 34 39 44
22-0 10-0 173 25 2
(2.0) (2.0) (1.5) (1.5) (1.5) (1.5) (1.5)
15 18 21 24 27 30 33
23-5 9-3 172 25 2
(2.0) (2.0) (1.5) (1.5) (1.5) (1.5) (1.5)
14 17 20 23 26 29 33
25-5 11-7 228 29 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
13 16 19 22 25 29 33
26-11 10-10 233 29 2
(2.5) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
12 14 16 18 20 23 26
27-2 9-10 212 28 2
(2.5) (2.5) (2.0) (2.0) (2.0) (2.0) (2.0)
12 15 18 21 24 27 30
28-11 13-2 306 33 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
10 12 15 18 21 24 27
31-8 12-8 320 34 2
(2.5) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
10 12 14 16 18 20 23
31-11 11-8 295 33 2
(2.5) (2.5) (2.0) (2.0) (2.0) (2.0) (2.0)
9 10 11 12 14 16 18
32-2 10-8 271 32 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
9 11 14 17 20 23 26
32-5 14-9 385 37 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
7 8 9 10 11 12 14
35-10 11-4 318 35 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
9 11 13 15 17 20 23
35-11 16-5 473 41 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
9 11 13 15 17 20 23
36-5 14-5 420 39 2
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
8 11 13 14 16 18 20
37-10 13-8 412 39 2
(2.5) (2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
8 9 10 11 12 14 16
38-1 12-9 382 38 3
(2.0) (2.0) (2.0) (2.0) (2.0) (2.5) (2.0)
10 12 14 16 18 20
39-5 18-0 569 45 3
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
10 12 14 16 18 21
39-11 16-1 512 43 3
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
6 7 8 9 10
40-10 12-2 387 39 3
(2.0) (2.0) (2.0) (2.0) (2.0)
9 11 13 15 17 19
42-7 15-6 525 44 3
(2.0) (2.0) (2.0) (2.0) (2.0) (2.0)
12 14 15 17 18
42-11 19-7 675 49 3
(2.0) (2.0) (2.0) (2.0) (2.0)
8 9 10 11 12
43-1 13-7 458 42 3
(2.0) (2.0) (2.0) (2.0) (2.0)
9 10 11 12 13
44-1 14-9 513 44 3
(2.0) (2.0) (2.0) (2.0) (2.0)
11 13 14 16 18
44-7 17-10 637 48 3
(2.0) (2.0) (2.0) (2.0) (2.0)
10 12 13 14 16
46-5 21-2 790 53 3
(2.0) (2.0) (2.0) (2.0) (2.0)
10 11 12 14 16
47-4 17-4 652 49 4
(2.0) (2.0) (2.0) (2.0) (2.0)
5 6 7 8 9
48-0 14-5 539 46 4
(2.0) (2.0) (2.0) (2.0) (2.0)
10 12 13 14 16
48-1 19-6 749 52 4
(2.0) (2.0) (2.0) (2.0) (2.0)
9 11 12 14 16
48-7 17-7 676 50 4
(2.0) (2.0) (2.0) (2.0) (2.0)
10 11 13 15
49-11 22-10 914 57 4
(2.0) (2.0) (2.0) (2.0)
8 10 12 14
50-0 16-10 662 50 4
(2.5) (2.5) (2.5) (2.0)
7 8 9 10
50-3 15-10 623 49 4
(2.5) (2.5) (2.5) (2.0)
11 12 13 15
50-7 19-11 804 54 4
(2.5) (2.5) (2.5) (2.0)
Notes:
1. Not for a specific structural design. Use for budget estimating only. Finite Element Analysis (CANDE) is required for final design and quotation.
2. The above table is based upon the general requirements of the AASHTO LRFD Design Specification, Section 12, and:
a. These tables are based upon a trench condition installation. A finite element analysis is required to determine this width in an embankment installation.
b. Backfill material per AASHTO M 145. For estimating, assume any A-1 material.
With specific site information, alternate backfill materials may be allowed. Refer to Table 69 (pg. 93).
c. Select backfill 120 pcf in density and compacted to a minimum 90% density per AASHTO T-180.
d. The minimum cover is the vertical distance from the mid-depth (neutral axis) of the corrugations to the top of rigid or bottom of flexible
pavement per AASHTO [Link]
e. A minimum select backfill width of 8 feet was used when analyzing the table above. Other widths may be acceptable based on an alternate finite element analysis.
This width was measured from outside the maximum span on each side of the structure. This width only applies when the material adjacent to the select zone is
determined to be competent, well consolidated material.
3. Select backfill width may increase for situations where lower strength fill exists in either the select fill zone or the adjacent embankment zone.
4. This estimate is for single barrel structures. For multiple barrels, more investigation is required.
101
 2-RADIUS ARCH
Steel and Aluminum
Structural Plate
Design Guide

TABLE 75. BRIDGECOR 2-RADIUS ARCH 15" X 5½"

BridgeCor

WEIGHT TABLES
Gage Thickness (Inches)
Dimensions to Inside Corrugation
Weight Shown as Pounds per Foot of Structure
Maximum
Rise 8 7 5 3 1 5/16 3/8
Span Total S
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Ft.-In.)
18-5 8-4 21 299 330 381 434 487 581 691
22-0 10-0 25 350 387 447 510 572 681 811
23-5 9-3 25 350 387 447 510 572 681 811
25-5 11-7 29 412 455 526 599 672 801 954
26-11 10-10 29 412 455 526 599 672 801 954
27-2 9-10 28 399 441 509 580 650 776 923
28-11 13-2 33 474 523 604 687 771 921 1096
31-8 12-8 34 476 526 608 693 778 927 1104
31-11 11-8 33 463 512 592 674 756 902 1074
32-2 10-8 32 451 498 575 655 735 877 1044
32-5 14-9 37 525 580 670 763 856 1022 1216
35-10 11-4 35 489 541 625 712 799 953 1135
35-11 16-5 41 577 637 736 839 941 1123 1337
36-5 14-5 39 571 620 716 814 913 1092 1298
37-10 13-8 39 561 608 703 801 898 1072 1276
38-1 12-9 38 538 594 687 782 877 1047 1246
39-5 18-0 45 705 815 928 1040 1243 1478
39-11 16-1 43 676 782 890 998 1192 1418
40-10 12-2 39 703 801 899 1073 1276
42-7 15-6 44 702 811 922 1034 1237 1470
42-11 19-7 49 871 1003 1126 1344 1599
43-1 13-7 42 753 858 962 1148 1367
44-1 14-9 44 786 896 1004 1199 1427
44-7 17-10 48 864 984 1104 1319 1569
46-5 21-2 53 947 1079 1210 1445 1720
47-4 17-4 49 883 1016 1140 1363 1621
48-0 14-5 46 831 947 1062 1268 1508
48-1 19-6 52 931 1060 1189 1419 1690
48-7 17-7 50 910 1035 1162 1388 1651
49-11 22-10 57 1167 1310 1565 1861
50-0 16-10 50 1048 1176 1407 1673
50-3 15-10 49 1003 1126 1344 1599
50-7 19-11 54 1111 1246 1489 1771
Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Weights include fasteners for assembly.
3. Weights include a galvanized coating which is 3 ounces per square foot, total both sides.
4. For structure plate make-up information, please contact your Contech representative.
5. If Unbalanced Channels are supplied, add 20 pounds per foot to the structure length.

102
 BOX CULVERT

TABLE 76. BRIDGECOR BOX CULVERT 15 X 5½

BridgeCor
LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Dimensions to Inside Gage Thickness (Inches) - Minimum Height of Cover Shown in Feet
Corrugation 5' Maximum Height of Cover (See Note 6)
Bottom Approx. Precon
Rise 8 7 5 3 1 5/16 3/8
Span Area Total S (min
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Ft.-In.) (Sq. Ft.) Level)

20-0 5-7 93 19 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

20-7 6-10 119 21 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

20-10 8-2 145 23 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

21-0 5-10 102 20 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

21-5 7-2 130 22 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

21-9 8-6 157 24 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

22-0 9-10 186 26 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

22-4 6-1 112 21 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

22-10 7-4 141 23 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

23-3 8-8 171 25 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

23-6 6-4 123 22 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

23-6 10-0 200 27 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

24-0 7-8 153 24 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

24-4 8-11 184 26 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

24-8 6-7 133 23 2.25 2.0 1.5 1.5 1.5 1.5 1.5 1

25-2 7-11 165 25 2.25 2.0 2.0 2.0 2.0 2.0 2.0 1

25-6 9-3 198 27 2.25 2.0 2.0 2.0 2.0 2.0 2.0 1

25-9 10-6 231 29 2.25 2.0 2.0 2.0 2.0 2.0 2.0 1

26-0 6-10 145 24 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

26-6 8-1 178 26 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

26-11 7-2 157 25 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

27-3 10-9 247 30 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

27-8 9-10 227 29 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

28-2 8-10 192 27 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Not for a specific structural design. Use for budget estimating only. Finite Element Analysis (CANDE) is required for final design and quotation.
3. The above table is based upon the general requirements of the AASHTO LRFD Design Specification, Section 12, and:
a. These tables are based upon a trench condition installation. A finite element analysis is required to determine this width in an embankment installation.
b. Backfill material per AASHTO M 145. For estimating, assume any A-1 material.
With specific site information, alternate backfill materials may be allowed. Refer to Table 69 (pg. 93).
c. Select backfill 120 pcf in density and compacted to a minimum 90% density per AASHTO T-180.
d. The minimum cover is the vertical distance from the mid-depth (neutral axis) of the corrugations to the top of rigid or bottom of flexible
pavement per AASHTO [Link]
e. A minimum select backfill width of 8 feet was used when analyzing the table above. Other widths may be acceptable based on an alternate finite element analysis.
This width was measured from outside the maximum span on each side of the structure. This width only applies when the material adjacent to the select zone is
determined to be competent, well consolidated material.
4. Select backfill width may increase for situations where lower strength fill exists in either the select fill zone or the adjacent embankment zone.
5. This estimate is for single barrel structures. For multiple barrels, more investigation is required.
6. If the maximum cover on the box culvert structure exceeds 5', please consider changing the structure to a 2-radius arch for more efficient load handling capability.

103
 BOX CULVERT
Steel and Aluminum
Structural Plate
Design Guide

TABLE 77. BRIDGECOR BOX CULVERT 15 X 5½

BridgeCor

LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)

Gage Thickness (Inches) - Minimum Height of Cover Shown in Feet
Dimensions to Inside Corrugation
5' Maximum Height of Cover (See Note 6)
Bottom Approx. Precon
Rise 8 7 5 3 1 5/16 3/8
Span Area Total S (Min
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Ft.-In.) (Sq. Ft.) Level)

27-11 11-1 263 31 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

28-3 7-5 169 26 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

28-9 8-11 206 28 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

29-2 10-0 243 30 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

29-5 11-4 280 32 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

29-7 7-7 182 27 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

30-1 8-11 220 29 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

30-7 10-3 259 31 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

30-10 11-6 298 33 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

31-3 9-3 236 30 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

31-7 8-4 210 29 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

31-8 10-6 275 32 2.25 2.0 2.0 2.0 2.0 2.0 2.0 2

32-1 9-7 251 31 2.0 2.0 2.0 2.0 2.0 2.0 2

32-8 12-3 334 35 2.0 2.0 2.0 2.0 2.0 2.0 2

32-11 8-6 224 30 2.0 2.0 2.0 2.0 2.0 2.0 2

33-5 9-10 267 32 2.0 2.0 2.0 2.0 2.0 2.0 2

33-10 11-2 310 34 2.0 2.0 2.0 2.0 2.0 2.0 2

34-0 8-10 240 31 2.0 2.0 2.0 2.0 2.0 2.0 2

34-6 10-2 284 33 2.0 2.0 2.0 2.0 2.0 2.0 2

34-11 11-6 328 35 2.0 2.0 2.0 2.0 2.0 2.0 2

35-1 9-2 255 32 2.0 2.0 2.0 2.0 2.0 2.0 2

35-2 12-9 373 37 2.0 2.0 2.0 2.0 2.0 2.0 2

35-7 10-6 301 34 2.0 2.0 2.0 2.0 2.0 2.0 2

36-2 9-6 272 33 2.5 2.5 2.5 2.5 2.5 2.5 2

36-2 13-1 393 38 2.5 2.5 2.5 2.5 2.5 2.5 2

Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Not for a specific structural design. Use for budget estimating only. Finite Element Analysis (CANDE) is required for final design and quotation.
3. The above table is based upon the general requirements of the AASHTO LRFD Design Specification, Section 12, and:
a. These tables are based upon a trench condition installation. A finite element analysis is required to determine this width in an embankment installation.
b. Backfill material per AASHTO M 145. For estimating, assume any A-1 material.
With specific site information, alternate backfill materials may be allowed. Refer to Table 69 (pg. 93).
c. Select backfill 120 pcf in density and compacted to a minimum 90% density per AASHTO T-180.
d. The minimum cover is the vertical distance from the mid-depth (neutral axis) of the corrugations to the top of rigid or bottom of flexible
pavement per AASHTO [Link]
e. A minimum select backfill width of 8 feet was used when analyzing the table above. Other widths may be acceptable based on an alternate finite element analysis.
This width was measured from outside the maximum span on each side of the structure. This width only applies when the material adjacent to the select zone is
determined to be competent, well consolidated material.
4. Select backfill width may increase for situations where lower strength fill exists in either the select fill zone or the adjacent embankment zone.
5. This estimate is for single barrel structures. For multiple barrels, more investigation is required.
6. If the maximum cover on the box culvert structure exceeds 5', please consider changing the structure to a 2-radius arch for more efficient load handling capability.

104
 BOX CULVERT

TABLE 78. BRIDGECOR BOX CULVERT 15 X 5½

BridgeCor
LRFD HEIGHT OF COVER GUIDE (HL-93 LOADING)
Gage Thickness (Inches) - Minimum Height of Cover Shown in Feet
Dimensions to Inside Corrugation
5' Maximum Height of Cover (See Note 6)
Bottom Approx. Precon
Rise 8 7 5 3 1 5/16 3/8
Span Area Total S (Min
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
(Ft.-In.) (Sq. Ft.) Level)

36-8 10-10 318 35 2.5 2.5 2.5 2.5 2.5 2.5 2

37-0 12-2 366 37 2.5 2.5 2.5 2.5 2.5 2.5 2

37-3 13-5 414 39 2.5 2.5 2.5 2.5 2.5 2.5 2

37-6 9-9 288 34 2.5 2.5 2.5 2.5 2.5 2.5 2

38-7 10-1 306 35 3.0 3.0 3.0 3.0 3.0 3.0 2

38-8 13-8 435 40 3.0 3.0 3.0 3.0 3.0 3.0 2

39-1 11-5 355 37 3.0 3.0 3.0 3.0 3.0 3.0 2

39-9 14-0 456 41 3.0 3.0 3.0 3.0 3.0 3.0 2

39-10 10-4 323 36 3.0 3.0 3.0 3.0 3.0 3.0 3

40-5 11-7 375 38 3.0 3.0 3.0 3.0 3.0 3.0 3

40-10 12-11 426 40 3.0 3.0 3.0 3.0 3.0 3.0 3

41-2 14-3 479 42 3.0 3.0 3.0 3.0 3.0 3.0 3

40-11 10-8 342 37 3.0 3.0 3.0 3.0 3.0 3.0 4

41-6 11-11 394 39 3.0 3.0 3.0 3.0 3.0 3.0 4

41-11 13-3 448 41 3.0 3.0 3.0 3.0 3.0 3.0 4

42-2 14-7 501 43 3.0 3.0 3.0 3.0 3.0 3.0 4

42-8 11-7 384 39 3.0 3.0 3.0 3.0 3.0 3.0 4

43-0 12-11 441 41 3.0 3.0 3.0 3.0 3.0 3.0 4

43-4 14-2 499 43 3.0 3.0 3.0 3.0 3.0 3.0 4

44-3 12-6 431 41 3.0 3.0 3.0 3.0 3.0 3.0 4

44-8 15-2 550 45 3.0 3.0 3.0 3.0 3.0 3.0 4

45-0 13-0 456 42 3.0 3.0 3.0 3.0 3.0 3.0 4

45-3 14-4 517 44 3.0 3.0 3.0 3.0 3.0 3.0 4

45-4 15-8 577 46 3.0 3.0 3.0 3.0 3.0 3.0 4

46-3 13-3 481 43 3.0 3.0 3.0 3.0 3.0 3.0 4

Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Not for a specific structural design. Use for budget estimating only. Finite Element Analysis (CANDE) is required for final design and quotation.
3. The above table is based upon the general requirements of the AASHTO LRFD Design Specification, Section 12, and:
a. These tables are based upon a trench condition installation. A finite element analysis is required to determine this width in an embankment installation.
b. Backfill material per AASHTO M 145. For estimating, assume any A-1 material.
With specific site information, alternate backfill materials may be allowed. Refer to Table 69 (pg. 93).
c. Select backfill 120 pcf in density and compacted to a minimum 90% density per AASHTO T-180.
d. The minimum cover is the vertical distance from the mid-depth (neutral axis) of the corrugations to the top of rigid or bottom of flexible
pavement per AASHTO [Link]
e. A minimum select backfill width of 8 feet was used when analyzing the table above. Other widths may be acceptable based on an alternate finite element analysis.
This width was measured from outside the maximum span on each side of the structure. This width only applies when the material adjacent to the select zone is
determined to be competent, well consolidated material.
4. Select backfill width may increase for situations where lower strength fill exists in either the select fill zone or the adjacent embankment zone.
5. This estimate is for single barrel structures. For multiple barrels, more investigation is required.
6. If the maximum cover on the box culvert structure exceeds 5', please consider changing the structure to a 2-radius arch for more efficient load handling capability.

105
 BOX CULVERT
Steel and Aluminum
Structural Plate
Design Guide

TABLE 79. BRIDGECOR BOX CULVERT 15" X 5½"

BridgeCor

WEIGHT TABLES
Gage Thickness (Inches)
Dimensions to Inside Corrugation
Weight Shown as Pounds per Foot of Structure
Bottom
Rise 8 7 5 3 1 5/16 3/8
Total S Span (Ft.-
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
In.)
19 20-0 5-7 273 301 348 396 445 530 631
21 20-7 6-10 299 330 381 434 487 581 691
23 20-10 8-2 325 358 414 472 530 656 781
20 21-0 5-10 286 315 365 415 466 555 661
22 21-5 7-2 312 344 398 453 508 606 721
24 21-9 8-6 337 373 431 491 551 656 781
26 22-0 9-10 363 401 464 529 593 707 842
21 22-4 6-1 299 330 381 434 487 581 691
23 22-10 7-4 325 358 414 472 530 656 781
25 23-3 8-8 350 387 447 510 572 681 811
22 23-6 6-4 312 344 398 453 508 606 721
27 23-6 10-0 386 427 493 561 629 751 893
24 24-0 7-8 337 373 431 491 551 656 781
26 24-4 8-11 363 401 464 529 593 707 842
23 24-8 6-7 335 369 426 485 565 674 802
25 25-2 7-11 360 398 459 523 587 699 832
27 25-6 9-3 386 427 493 561 629 751 893
29 25-9 10-6 412 455 526 599 671 801 953
24 26-0 6-10 347 384 443 504 566 674 802
26 26-6 8-1 373 412 476 542 608 725 863
25 26-11 7-2 360 398 459 523 587 699 832
30 27-3 10-9 425 469 542 618 693 827 983
27 28-2 8-10 386 427 493 561 629 751 893
29 27-8 9-10 412 455 526 599 671 801 953
31 27-11 11-1 438 483 559 636 714 852 1013
26 28-3 7-5 373 412 476 542 608 725 863
28 28-9 8-11 399 440 509 580 650 753 923
30 29-2 10-0 425 469 542 618 693 827 983
32 29-5 11-4 451 498 575 655 735 877 1044
27 29-7 7-7 386 427 493 561 629 751 893
29 30-1 8-11 412 455 526 599 671 801 953
31 30-7 10-3 438 483 559 636 714 852 1013
33 30-10 11-6 466 512 592 674 756 902 1074
30 31-3 9-3 425 469 542 618 693 827 983
29 31-7 8-4 412 455 526 599 671 801 953
32 31-8 10-6 451 498 575 655 735 877 1044
31 32-1 9-7 483 559 636 714 852 1013
35 32-8 12-3 666 769 876 983 1174 1397
30 32-11 8-6 469 542 618 693 827 983

Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Weights include fasteners for assembly.
3. Weights include a galvanized coating which is 3 ounces per square foot, total both sides.
4. For structure plate make-up information, please contact your Contech representative.
5. If Unbalanced Channels are supplied, add 20 pounds per foot to the structure length.
6. If the maximum cover on the box culvert structure exceeds 5', please consider changing the structure to a 2-radius arch for more efficient load handling capability.

106
 BOX CULVERT

TABLE 80. BRIDGECOR BOX CULVERT 15" X 5½"

BridgeCor
WEIGHT TABLES
Gage Thickness (Inches)
Dimensions to Inside Corrugation
Weight Shown as Pounds per Foot of Structure
Bottom
Rise 8 7 5 3 1 5/16 3/8
Total S Span (Ft.-
(Ft.-In.) (0.170) (0.188) (0.218) (0.249) (0.280) (0.318) (0.380)
In.)
32 33-5 9-10 498 575 655 735 877 1044
34 33-10 11-2 526 608 693 778 927 1104
31 34-0 8-10 483 559 636 714 852 1013
33 34-6 10-2 512 592 674 756 902 1074
35 34-11 11-6 541 625 712 799 953 1135
32 35-1 9-2 509 587 668 750 895 1065
37 35-2 12-9 591 682 776 871 1022 1216
34 35-7 10-6 537 620 706 793 945 1125
33 36-2 9-6 523 604 687 671 920 1095
38 36-2 13-1 594 687 782 877 1048 1546
35 36-8 10-10 552 637 725 814 971 1156
37 37-0 12-2 591 682 776 871 1022 1216
39 37-3 13-5 608 703 801 898 1197 1276
34 37-6 9-9 537 620 706 793 945 1125
38 38-5 12-4 594 687 782 877 1048 1246
35 38-7 10-1 552 637 725 814 971 1156
40 38-8 13-8 623 720 820 919 1098 1306
37 39-1 11-5 591 682 776 871 1022 1216
41 39-9 14-0 637 736 839 941 1123 1336
36 39-10 10-4 569 654 744 834 997 1186
38 40-5 11-7 594 687 782 877 1065 1246
40 40-10 12-11 623 720 820 919 1098 1306
37 40-11 10-8 591 682 776 871 1040 1237
42 41-2 14-3 651 753 858 962 1148 1367
39 41-6 11-11 608 703 801 898 1073 1276
41 41-11 13-3 637 736 839 941 1123 1336
43 42-2 14-7 666 769 876 983 1174 1397
39 42-8 11-7 608 703 801 898 1073 1276
41 43-0 12-11 637 736 839 941 1123 1336
41 44-3 12-6 637 736 839 941 1123 1336
43 43-4 14-2 666 769 876 983 1174 1397
45 44-8 15-2 705 806 920 1035 1244 1475
42 45-0 13-0 651 753 858 962 1148 1367
44 45-3 14-4 681 785 894 1004 1200 1427
46 45-4 15-8 720 822 938 1056 1270 1505
43 46-3 13-3 666 769 876 983 1174 1397

Notes:
1. Custom shapes and alternate sizes are available. Please contact your Contech representative.
2. Weights include fasteners for assembly.
3. Weights include a galvanized coating which is 3 ounces per square foot, total both sides.
4. For structure plate make-up information, please contact your Contech representative.
5. If Unbalanced Channels are supplied, add 20 pounds per foot to the structure length.
6. If the maximum cover on the box culvert structure exceeds 5', please consider changing the structure to a 2-radius arch for more efficient load handling capability.

107
 Steel and Aluminum
Structural Plate
Steel EXPRESS® Foundations

Design Guide

Steel EXPRESS® Foundations

Contech offers a prefabricated steel stay-in-place bridge Design

foundation form that blends the economy and speed of Steel EXPRESS Foundations are designed to follow the
Contech structural plate with the use of traditional cast-in- current AASHTO LRFD Methodology. This methodology is
place concrete foundations. Steel EXPRESS Foundations similar to a typical cast-in-place strip foundation design.
(SEF) were introduced to the market in 2017 and have been The parameters needed to design the SEF include the live
widely accepted and provided on numerous installations condition (i.e. HL-93, HS-25, HS-20, etc…), the allowable
throughout the United States. There are numerous features bearing capacity, the height of cover and the backfill unit
and benefits associated with the SEF product. For more weight.
information on these and the installation process, please
refer to the SEF brochure - [Link]/plate. Sizing and Details
SEF are provided in unit lengths of 24’-0” long, typically.
Advantages However, the length can be modified to fit the required
Our SEF improves installation efficiency and accuracy by length of the structure. When multiple units are needed
minimizing construction time in difficult field conditions. for structures lengths longer than 24’-0”, the units are
Apart from the splice bars between multiple units, there field bolted and rebar spliced, end-to-end, to provide a
is no need to install any rebar on-site, as it comes pre- continuous form.
installed from our plant. This reduces the risks of any
on-site errors for crews with minimal cast-in-place formwork Ideally SEF widths are 8’-0” wide or less, to be able to fit as
experience, which simplifies field inspections and quality standard load on a flat-bed truck. However, custom widths
control requirements. SEF sizes and pick weights may be over 8’-0” wide can be accommodated to meet the required
customized to be handled by available on-site equipment. design.

Applications SEF heights range from 1’-9” to 4’-0”. Custom heights may
Steel EXPRESS Foundations can be used in a variety of be provided. In addition, a pedestal combination with the
applications. With open bottom buried bridges and foundation can be provided to achieve greater heights.
culverts, they have been used in stream enclosure and 0.275

wetland crossing project sites. These foundations have also

0.184

0.1
42
been used in pedestrian, wildlife and vehicular underpass 1.119

projects. Another application has been as bridge abutments

0.5
52

0.420

for bridges at grade. These foundations can be adapted for

0.727

0.627
pedestal wall applications and foundations on pile caps.
0.950

4.242

0.120

88
0.5

89
3.4

HDPE Rebar Isolator

0.132
0.646

END MEMBER

ATTACHMENT
CROSS BARS FLANGE

CROSS MEMBERS

SIDE MEMBERS

SIDE ANGLES

HOLD DOWN STRAPS

Steel EXPRESS Foundation Cross Member

108
 Steel EXPRESS Foundations
Steel EXPRESS Foundations are typically provided in unit length of 24'

Set footers in place Pre-assembled plate structure can be set on footers

109
 Steel and Aluminum
Structural Plate
Steel EXPRESS® Foundations

Design Guide

Steel EXPRESS® Foundations Project Specification 4.1. Prefabricated Metal Footing Forms-Permissible
Variations
1. Description 4.1.1. Length, height and width of prefabricated metal
footing forms shall not vary from that shown in the
1.1. Steel EXPRESS® Foundations are a prefabricated design by more than ½ inch.
metal footing form system that includes all required
steel reinforcement. 4.1.2. Size of Reinforcement - The permissible variation in
diameter of any reinforcing shall conform to the
1.1.1. Type- This specification applies to the manufacture tolerances prescribed in the ASTM Specification for
and installation of the Steel EXPRESS® Foundations as that type of reinforcing. Steel area greater than that
detailed in the project plans. required shall not be cause for rejection.
1.1.2. Designation- Steel EXPRESS® Foundation units 4.2. Placement of Reinforcement
manufactured in accordance with this specification
shall be designated by length, height and width. 4.2.1. Placement of reinforcement for prefabricated metal
Foundations shall conform to the lines, grades, footing forms – The cover of concrete over the
design and dimensions shown on the plans or as bottom reinforcement shall be 3 inches minimum.
established by the Engineer. The cover of concrete for all other reinforcement shall
be 2 inches minimum. The clear distance from the
2. Design end of each steel element to the end of reinforcing
2.1. Specifications – The foundation is designed in steel shall not be less than 2 inches nor more than 3
accordance with the "AASHTO LRFD Bridge Design inches. Reinforcement shall be assembled utilizing a
Specifications" 8th Edition, adopted by the American single layer of deformed billet-steel bars.
Association of State Highway and Transportation 4.3. Storage, Handling & Delivery
Officials, 2017.
4.3.1. Storage – The Prefabricated Metal Footing Forms
3. Materials shall be stored in such a manner to prevent damage.
3.1. Steel Forms- The steel utilized in the prefabricated Units shall be stored on a flat, level surface to avoid
metal footing form system shall conform to AASHTO twisting, bending or any deformation of the form.
and ASTM requirements listed below. 4.3.2. Handling – Handling devices shall be permitted
3.1.1. Steel shall meet the requirements of ASTM A 1011. for the weight of each steel foundation unit for the
purpose of handling and setting. Units are to be
[Link]. All manufacturing processes, including punching,
picked from (4) side lifting ports / (2) on each side.
curving and galvanizing shall be performed within
Units shall not be pushed or dragged.
the United States using raw materials made in the
United States. 4.3.3. Delivery – Prefabricated Metal Footing Forms may
be unloaded and placed on a level surface at the site
[Link]. Galvanizing (if applicable) shall be within industry
until installed.
standard of 3 oz/per square foot total (both sides of
galvanized coating) and shall be performed at the 5. Joints
Manufacturer owned location. Galvanizing for the 5.1. The steel foundation units shall be produced with flat
prefabricated metal footing form should follow A123. flanged ends. The ends shall be such that when the
3.2. Steel Reinforcement sections are laid together they will bolt together with
¾” diameter hardware provided, all compatible with
3.2.1. The minimum steel yield strength shall be 60,000 psi,
the permissible variations in section 4.1, above.
unless otherwise noted on the shop drawings.
6. Repairs
3.2.2. All reinforcing steel for the cast-in-place elements
shall be fabricated and placed in accordance 6.1. Prefabricated metal footing forms may be repaired, if
with the detailed shop drawings submitted by the necessary, because of imperfections in manufacture
manufacturer. or handling damage. If galvanized coating is to be
repaired, repair must be performed to ASTM A761
3.2.3. Reinforcement shall consist of deformed billet steel
(Section 8.4). Manufacturer to work in conjunction
bars conforming to ASTM Specification A 615, Grade
with the engineer to determine if the prefabricated
60.
metal foundation needs to be repaired.
3.2.4. Reinforcement shall be isolated from all cross
7. Installation Preparation – To ensure proper installation
members with Contech Rebar Isolator.
of the Prefabricated Metal Footing Forms, care and
3.3. Steel Hardware caution must be exercised in shaping the foundation
3.3.1. Hardware shall be a maximum of ¾” diameter hot- subgrade to allow for the installation of the steel
dipped galvanized steel (specifically heat-treated) components.
fasteners meeting ASTM A307/A449 specifications 7.1. Footings – The contractor shall be responsible for the
are used to assemble joints and members for the construction of the foundations per the plans and
steel foundation and galvanized per ASTM A153. specifications.
4. Manufacture of Prefabricated Metal Footing Forms Do not over excavate foundations to remove
Subject to the provisions of Section 5, enclosed, the unsuitable soils, unless directed by site soil engineer.
prefabricated metal footing forms dimensions and
The site soils engineer shall certify that the
reinforcement details shall be as prescribed in the
bearing capacity meets or exceeds the footing
plan and shop drawings.

110
 Steel EXPRESS Foundations
design requirements prior to the contractor setting [Link]. Backfill around sides of Prefabricated Steel Footing
Prefabricated Metal Footing Forms. The size and Forms shall be performed prior to setting structure
elevation of the footings shall be as designed by the on foundation. The backfill material shall meet the
Engineer. specifications and compacting procedures equal to that
for normal road embankments.
The contractor shall prepare a 4-inch thick minimum
base layer of compacted granular material the full [Link]. The site soils engineer shall review gradations of all
width of the footing prior to placing the prefabricated interfacing materials and, if necessary, recommend
metal footing forms. geotextile filter fabric (provided by contractor).
The finished steel footing surface shall be constructed 8.3.5. Placing and Compacting Backfill – Dumping for
in accordance with grades shown on the plans. When backfilling is not allowed any nearer than 3 ft from the
tested with a 4 foot (min) straight edge, the surface prefabricated metal footing forms.
shall not vary more than ¼ inch per ten feet. The fill must be placed and compacted in layers not
The prefabricated steel footing forms must be exceeding 12 inches uncompacted.
connected by splice bar reinforcement to form The backfill shall be compacted to a minimum 90%
one monolithic body. Splice bars to be supplied by density per AASHTO T-180.
manufacturer and installed by contractor onsite.
Hand equipment may be used to compact next to the
8. Installation foundations, within 3’-4’. Small tracked vehicles (D4
8.1. General – The installation of the prefabricated steel or smaller) should remain at least 3’-4’ away from the
footing forms shall be per the following; foundation.
8.1.1. Lifting – The contractor is responsible for using 8.4. Grouting (if required)
equipment with the correct lifting capacity to handle 8.4.1. Grouting shall not be performed when temperatures
the Prefabricated Metal Footing Form. This can be are expected to go below 35° for a period of 72 hours.
accomplished by using the weights given for the
prefabricated steel footing form in the Bill of Materials 8.4.2. Grout shall be non-metallic, non-shrink material, with
and by determining the lifting reach for the piece of a minimum 4,000 psi compressive strength.
lifting equipment that will be used to handle the units 8.4.3. If pouring concrete prior to setting the structure,
on site. Site conditions must be evaluated prior to keyway must be blocked out to allow for grouting once
shipping to ensure proper equipment location and to structure is set on finished concrete.
avoid any lifting restrictions. The lifting ports provided
in each unit are the only means to be used to lift the 8.5. Cast-in-place Concrete
elements, all (4) lifting ports should be utilized. 8.5.1. Cast-in-place concrete portion of Steel EXPRESS®
8.2. Placement of Prefabricated Metal Footing Forms Foundations shall be in accordance with the design
requirements provided by the Engineer of Record notes
The prefabricated steel footing forms shall be on the foundation plan.
placed as shown on the plans. Special care shall
be taken in setting the elements to the proper line 8.5.2. The footings shall be given a smooth float finish and
and grade. Once the prefabricated steel footing shall reach 75% compressive strength prior to any
forms are set, insert plastic caps into lifting ports to backfilling of the structure.
ensure no backfill/concrete is lost. Prefabricated 8.6. Monitoring – The contractor shall check settlements
steel footing forms shall be staked into the ground and horizontal displacements of the foundations to
using the provided stakes. For installations on rock, ensure that they are within the allowable limit provided
concrete anchor bolts shall be drilled into the rock by the engineer. These measurements should give an
and used instead of the stakes. Consult with Contech indication of the settlements and deformations along
Engineering for type of anchor bolt and procedure. the length of the foundations.
8.3. Backfill The first measurement should take place after the
8.3.1. Do not perform backfilling during freezing weather. placement of all prefabricated metal footing forms,
a second after completion of backfilling of the
8.3.2. No backfill shall be placed against any structural prefabricated metal footing forms, and a third after the
elements until the steel footing location, grade, superstructure is assembled, prior to pouring cast in
alignment and squareness has been approved by the place concrete. Further measurements may be made
Engineer. according to local conditions.
8.3.3. The project construction and material specifications,
which include the specifications for excavation for
structures and roadway excavation and embankment
construction, shall apply except as modified in this
section.
8.3.4. Backfill material should be free of rocks, frozen lumps,
and foreign material that can cause hard spots or
decompose to create voids. Backfill material should
be well graded granular material that meets the
requirements of AASHTO M 145 for soil classification
A-1, A-2-4, A-2-5 or A-3, at a minimum.

111
 For more information, call Contech Engineered Solutions:
800-338-1122
[Link]
9100 Centre Point Drive, Suite 400
West Chester, Ohio 45069
Fax: (513) 645-7993

NOTHING IN THIS CATALOG SHOULD BE CONSTRUED AS A WARRANTY. APPLICATIONS SUGGESTED HEREIN ARE DESCRIBED ONLY TO HELP READERS
MAKE THEIR OWN EVALUATIONS AND DECISIONS, AND ARE NEITHER GUARANTEES NOR WARRANTIES OF SUITABILITY FOR ANY APPLICATION.
CONTECH MAKES NO WARRANTY WHATSOEVER, EXPRESS OR IMPLIED, RELATED TO THE APPLICATIONS, MATERIALS, COATINGS, OR PRODUCTS
DISCUSSED HEREIN. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND ALL IMPLIED WARRANTIES OF FITNESS FOR ANY PARTICULAR PURPOSE ARE
DISCLAIMED BY CONTECH. SEE CONTECH’S CONDITIONS OF SALE (AVAILABLE AT [Link]/COS) FOR MORE INFORMATION.

© 2024 Contech Engineered Solutions LLC, a QUIKRETE Company

BRO-SPDESIGN 12/29/2024 PDF All rights reserved. Printed in USA.