Category:1047 Corrugated Polyethylene Culvert Pipe

This article establishes procedures for inspecting, accepting and reporting polyethylene culvert pipe. Refer to Sec 1047 for MoDOT’s specifications.

Field inspection shall be performed using the Polyethylene (HDPE) Pipe Inspection Guide.

For Laboratory testing and sample reporting procedures, refer to EPG 1047.6 Laboratory Testing Guidelines for Sec 1047.

1047.1 Apparatus

(a) Rule with suitable graduations to accurately measure the material to be inspected.

(b) Micrometer capable of measuring to 0.0001 in. (0.00254 mm) and accurate to within at least 0.001 in. (0.0254 mm).

(c) Polyethylene (HDPE) Pipe Inspection Guide.

1047.2 Procedure

1047.2.1 Polyethylene Culvert Pipe

Polyethylene culvert pipe is to be accepted for use on the basis of the pipe manufacturer having filed the required documents set forth in the Specifications, the plant being approved and qualified, certification by the manufacturer, manufacturer quality control documentation, identification marking, random sampling and testing and field inspection.

1047.2.1.1 Manufacturer Approval

Prior to acceptance of polyethylene culvert pipe, the manufacturer shall have furnished Central Office – Construction and Materials, a "Pipe Manufacturer's Certified Analysis" and "Pipe Manufacturer's Guarantee" as required by Sec 1047.

See the list of Qualified Fabricators of Corrugated Polyethylene Culvert Pipe for manufacturers who have filed acceptable documents.

If random sampling results in the rejection of the polyethylene pipe, acceptance on the basis of pipe manufacturer's certified analysis and guarantee shall immediately be discontinued and all polyethylene pipe of that brand shall then be sampled, tested, and approved prior to use until such time as shall be determined by Construction and Materials. Construction and Materials will advise all districts should acceptance of a brand by pipe manufacturer's certified analysis and guarantee be discontinued. When test results again indicate consistent compliance to specification requirements, Construction and Materials will notify all districts to reinstate that brand to the approved list of manufacturers.

During any visit to the manufacturer, the manufacturer’s records shall be reviewed for test result and inspection documentation. The records shall be specific to each shipment of pipe, and shall indicate the purchase order number or project number, route, a county, date of inspection, quantity (ft or m), and pipe diameter.

If a manufacturer is found not to be in compliance with the specifications, notify Construction and Materials so the manufacturer’s approval can be reconsidered.

If the manufacturer is found falsifying documentation, Construction and Materials is to be notified immediately for removal of that manufacturer or plant from the approval list.

1047.2.1.2 Identification Markings

Each pipe and fitting is to be clearly marked, in accordance with AASHTO M 294, at not more than 10 ft. (3 m) intervals by the manufacturer and the marking is to contain the manufacturer's name or trademark, nominal size, AASHTO M 294, the plant designation code, and the date of manufacture or an appropriate code.

1047.2.1.3 Random Sampling

Random samples are to be obtained from fabricated culvert sections and submitted to the Laboratory for determination of physical properties. Samples may be taken at the point of manufacture, intermediate distribution point, or at the project. The manufacturer shall provide the definition of a lot. If no definition is provided, a lot will be one day’s production. Or, if at the project, a lot shall be the entire quantity shipped.

Samples and tests will be performed on 10 percent of pipe shipped from a manufacturer. These samples will be requested at random by the Construction and Materials Division. Upon issue of the pipe identification number, the Construction and Materials Division will notify the manufacturer /supplier and the district of the sample request, to meet the 10 percent requirement. The manufacturer of the pipe is responsible to supply the quantity of pipe needed for testing. The sample quantity shall not impact the quantity needed for incorporation into the project. The sample shall consist of 2 specimens, each a minimum of one diameter in length plus two additional corrugations, not including the bell or the spigot ends. The end of the pipe with the gasket is the spigot end, the other end with the flared section is the bell. The specimens may be taken from the same section of pipe, but shall be cut into the two required specimens for testing purposes.

If the sample fails to meet the physical requirements, the pipe sampled will be rejected and the lot re-sampled. A resample will be the same number of specimens as the original sample. The resample must comply in all respects or the entire lot will be rejected.

1047.2.1.4 Field Inspection

Field inspection shall be performed using the Polyethylene (HDPE) Pipe Inspection Guide.

Frequency of inspection shall be at the discretion of the engineer, but shall be performed on approximately 10 percent of shipments and a minimum of once per month.

The engineer may inspect the fabricated pipe at the manufacturing plant, intermediate distribution point, or project. The engineer shall be furnished by the manufacturer, and itemized statement of the sizes and lengths of pipe in each shipment. The engineer shall have free access to the manufacturing plant or intermediate distribution point for inspection, and every facility shall be extended for this purpose. Any pipe, which has been previously rejected and included in a later lot, will be considered sufficient cause for rejection of the entire lot.

The manufacturer shall specify in their application for placement on the qualified list to which standards their pipe is fabricated; English or metric. The standard fabrication units will be designated on the qualified list for each manufacturer. All measurements shall be made using the applicable units when determining compliance with specification.

The specified inside diameter, in accordance with AASHTO M 294, shall not vary more than 1.5 percent undersize and 4.5 percent oversize. However, the specified inside diameter shall not vary more than 1.5 in. (37 mm) oversize. Again, all measurements shall be made using the same units as to which the pipe was fabricated.

The specified inside diameter, in accordance with AASHTO M 294, shall be reduced by no more than 5 percent by deflection when installed. All pipe installed shall be tested for deflection.

Pipe that has been rejected at the origin shall be marked with a small, filled circle or orange paint on the inside of the barrel, in the downstream end. The pipe is subject to inspection and rejection at destination for any damage that may have occurred in handling. Pipe that is rejected at destination shall be marked in the same manner as pipe rejected at the origin. The inspector may choose to mark inspected pipe to prevent inspection of the same pipe more than once. However, the “MoDOT OK” stamp should not be used.

If pipe is rejected for not being in accordance with specifications and the requirements set forth in the Polyethylene (HDPE) Pipe Inspection Guide, a letter documenting the failure shall be provided to the manufacturer, with a copy to Construction and Materials. The inspection guide used to inspect the rejected pipe shall be included with the letter to the manufacturer and Construction and Materials. The letter should include the location of the plant at which the failure occurred.

1047.3 Sample Record

Field inspection shall be recorded in Site Manager, as described in Sample Record General Information . The sample record shall include the brand name, manufacturer's name, size and lengths. The sample record is to indicate acceptance or rejection. If the sample record indicates rejection, the reason for rejection shall be stated in the remarks or the test result details.

The manufacturer or shipper is required to notify Construction and Materials of impending shipments using the Pipe Shipping Report Form for reporting to the Central Office, GS-17 Form 1. This information will allow MoDOT to track the material, obtain samples, and perform Quality Assurance inspection as necessary.

A SiteManager sample record shall be created for each size of pipe in each shipment.

Each SiteManager sample record will be created by Construction and Materials.

Polyethylene Culvert Pipe

If the sample record indicates acceptance, the basis of acceptance of the pipe shall be that the material is an approved brand and that examination of the material indicates that the material conforms to all of the requirements of the specifications.

Completion of the sample records for materials purchased under a MoDOT purchase order is to be as described in EPG 1101 Materials Purchased by a Department Purchase Order.

1047.4 Tolerance and Deflection Tables

Table 1047.4.1 Diameter Dimensional Tolerances (English)

Table 1047.4.2 Diameter Dimensional Tolerances (Metric)

Table 1047.4.3 Pipe Deflection (English)

Table 1047.4.4 Pipe Deflection (Metric)