In Labette County, Kansas, a concrete bridge structure was in need of replacement. Originally built in the early 1900s, the structural condition of the bridge was very poor, and the neighboring landowner was experiencing damaging flooding events due to back up from the bridge.
The nominated project was a replacement for a 139’ long 3-span bridge constructed in 1936. The project was designed by Big R Bridge through collaboration with the Vermont Agency of Transportation (VTRANS) and CLD Engineers (project engineer). This project is the first deep corrugated structural plate Buried Bridge project in Vermont.
The Stark St crossing over Beaver Creek consisted of an undersized concrete box culvert with a broken fish ladder that was prohibiting salmon and other fish species from migrating upstream through the culvert.
The original site design for this project consisted of 40,000 ft3 of storm water storage, 20,000 ft3 above grade and 20,000 ft3 below grade built with 60” diameter HDPE and concrete manholes and inlets. The owner requested a redesign of the storm drainage to better utilize his property.
The city of Mountlake Terrace, Washington needed a new stormwater retention facility to provide stormwater treatment and downstream flood control. The facility would treat runoff from an area of about 13 acres in the city’s downtown core and protect the water quality in the Lake Ballinger watershed.
Since 1993, wet conditions have brought water from the upper reaches of this watershed down to the Michigan Spillway Project area. The Nelson County Water Resource District Board has worked toward emergency pumping to lower this flood for many years. This project has had many designs made, with protection for downstream impacts and even concerns of invasive species downstream that could migrate upstream. Hence, a very elaborate pump station is required to control these issues for this project and was permitted.
Industry uses of corrugated steel structural plate goes virtually unnoticed by the public and engineering community alike as it does not involve transportation facilities. However, structural plate is integral to the operations of quarrying and mining industries, and Pennsy Supply’s Millard Quarry Tunnel in Anneville, PA provides an excellent illustration of the varied uses of this engineering material.
In an effort to ensure that an existing creek bank and fish habitat could be restored, engineers in Healdsburg, CA temporarily diverted Dry Creek.
Ultimately, the IDOT selected a proposal by WBK Associates LTD which utilized a 144-inch diameter polymer-coated double wall pipe supplied by Contech Engineered Solutions. The double walled steel pipe with a polymer-coated, 18 gage, smooth interior steel liner and 12 gage, rugged 3x1 corrugated outer steel shell was able to satisfy the AASHTO specification as well as the IDOT section 543.02 requirements.
East of Dallas, Texas, off of I-30, lies the community of McLendon-Chisholm & Sonoma Verde. These new housing developments were built to “ take the rich offerings of Tuscan style & place it within reach of every resident who wants to stop planning for ‘tomorrow’ and start living their dream today.”
Upon reviewing the plans for the housing community the developer’s choose to go with a structural plate arch over traditional TXDOT concrete alternatives.
Pacific Corrugated Pipe Co. (PCP) implemented a variety of actions based on Tier II treatment requirements administered by the Department of Environmental Quality. PCP installed an Electrocoagulation (EC) Stormwater Treatment System at their manufacturing facility. The Design parameters of the EC system allowed for the discharge of clean water.
After extensive spring flooding, ice damage and severe erosion, access to the Sykeston, North Dakota City Park was extremely limited. After assessing the situation FEMA was forced to replace the existing structure with a new 15’ diameter structural plate pipe.
After several peak storm events washed out a section of a North Dakota Badlands Forrest Service access road, the Forrest Service teamed up with Kadrmas Lee Jackson’s engineers and Hlebechuk Construction to make some very quick repairs.
On January 7th of 2015, PCP was approached by Lockheed Martin for some information regarding their culvert capabilities and the potential to start a new, very exciting project. After multiple phone calls and emails a product design was approved that would allow the transport of robotic submarines through the Antarctic Ice Shelf!
This was a very unique project indeed! Engineers reached out to PCP to help with the design of a residential 2 car parking solution that needed to meet a multitude of requirements. The first requirement was that it had to utilized a small and complex space that was being added to the cabin. Next, it had to be an architectural match to the surrounding mountain aesthetics. And finally the garage structure would have to have an outlet or manhole access from the top to allow the owner to leave the cabin or garage without direct interaction to the winter elements.
A signaled level crossing had been holding up traffic and impacting safety on a BNSF Railway spur feeding the La Cygne Generating Station, south of Kansas City. Motorists and railway workers alike all gave it a failing grade.
A new $250 million distribution center code named “Project Jasper” was revealed by Forest Park, Georgia city officials. This expansive distribution center was slated to be built on about 300 acres of land – roughly one-million square feet and anticipated an extremely high volume of stormwater runoff.
During the design of their new retention system, Watson Industrial Park presented 2 unique challenges. The first required a product and logistical solution that would allow for the installation to be completed as it was delivered and the second was a production plan that would allow for everything to be produced AND installed in less than 6 weeks time.
In an effort to create the largest possible interior holding space, Pacific Corrugated Pipe was tasked with the massive challenge of creating the largest possible diameter pipe while maintaining a 20’ length. Due to the limitations on the opening of their stationary mill, PCP had to enlist the use of their mobile mill.
To say water is important to the state of Wisconsin would be an understatement. With over 15,000 lakes in direct proximity to Lakes Michigan and Superior (two of the largest sources of freshwater in the world), and 32,000 miles of streams, Wisconsinites prize their quality water resources. They utilize these resources for drinking water, recreational opportunities, crop irrigation, and as the base of a huge tourism industry.
Hyalite Engineers needed assistance in finding a cost effective alternative to a concrete box culvert crossing for the Rock Creek Golf Club located near Coeur D’Alene, ID. Hyalite Engineers reached out to TrueNorth Steel to help them ensure that the golfers were able to safely cross Loffs Bay Road.
In 2016, the Atlanta Regional Council revised the Georgia Storm Water Management Manual to incorporate LID (Low Impact Development) water quality methods. SEC designed a 42” perforated, aluminized infiltration system that would return the storm water to the soils.
The American Center for Mobility (ACM), recently built a U.S.-based connected and automated vehicle (CAV) research facility in Ypsilanti, Michigan, the heart of the automotive industry. The Center is a proving ground for CAV product testing, development, validation, and certification. The 500-acre site includes a driverless 2.5-mile highway loop, two double overpasses, a railroad crossing, intersections, roundabouts, and a 704-foot long curved tunnel.
The project specifications called for construction of a conventional temporary bridge in the median to carry the 3 lanes of traffic for the northbound or southbound bridge as that bridge was being replaced.
Located on Interstate 20 twenty miles east of Dallas, Talty is ideally suited to those seeking large residential lots within easy commuting distance to the urban center, and as such, the city is constantly assessing road conditions in order to incorporate new improvements and ongoing city road projects and expansions.
Pacific Corrugated Pipe was given the opportunity to value engineer and aid in designing one of the largest rainwater storage retention systems ever installed in the Murrieta, CA area and furnished from their facility.
On this particular bridge replacement, Guthrie County was replacing a 22’ long x 16’ wide timber bridge that had no record of installation date. The Guthrie county engineer considered three replacement options based on the size of the drainage area and required hydraulics at the site. Option 1 was a Single 6’ x 7’ reinforced concrete box; Option 2 was a single 84” corrugated metal pipe; and Option 3 was a twin run of 60” corrugated metal pipes. When the cost analysis was completed, the single run of 84” CMP was the clear winner.
The Bureau of Land Management was in need of a new, eco-friendly culvert solution that would allow for a proper fish passage west of Wolf Creek in Oregon. In addition to providing safe passage for fish, this new design called for construction loading and heavy vehicle traffic support on 2 one-way logging roads.
A research project on the durability of Aluminized Steel Type 2 pipe installed in the metro Atlanta area has resulted in an outstanding report of the product’s performance. The study focused on the performance of pipes in storm sewer applications, so the majority of the pipes are connecting two catch basin structures.
In March of 2016, Crittenden Co., KY decided to replace a structural plate bridge built in approximately 1945. This bridge is located in the most northern part of the county on Hurricane Church Road, approximately five miles south of the "Cave in Rock" ferry, which still crosses over the Ohio River many times each date. This bridge has allowed safe passage over a tributary of Caney Fork Creek for many years providing access to the historic Old Hurricane Methodist Church and Cemetery where you can find some of the oldest graves in Crittenden County - some dating back before the Civil War.
Mar-Jac Poultry in Spruce Pine, AL needed an unconventional storm sewer system for it’s new $35 million feedmill. Because of the nearly 100’ canyon walls at the location, the storm sewer system needed to account for an anticipated height of cover in excess of 80’ – a height that exceeded many allowable limits on all design charts for the typical concrete, corrugated metal and precast box culverts.
Original plans for a new Chrysler Dealership in Pineville, NC included a modular reinforced concrete storm water detention system – but at a hefty price. After a value engineering process, it was decided to go with an aluminized steel pipe combination storm water management system, saving the owner over $300,000!
A timber bridge in Talpa, TX was in need of emergency repairs after extensive flooding in the area. The project called for a solution that could be designed and implemented quickly as the bridge was part of the local railway system.
This bridge allowed passage over Fish Creek. The updated design required a 5 gauge, 22’x 20′ vertical ellipse, galvanized multi-plate for the main channel with a length of 150′.
On either side of the vertical ellipse a round 14′ diameter, 7 gauge, galvanized multi-plate overflow structure completed the design. Each overflow structure was 140’in length.
The new structure had inside dimensions of 41’4” span and 21’3” rise with an overall length of 200 ft. The new Buried Bridge consisted of hot dipped galvanized steel deep corrugated structural plate with a corrugation profile of 15” peak to peak by 5½” deep, steel thickness of 0.170” (8 gauge), and overall structure weight of about 155,000 lbs. The structure was shipped in standard 30” wide plates and was assembled on site using 5 plates per ring.
A 6” minimum benign envelope around the pipe using pea gravel was incorporated to abate the poor resistivity readings that periodically occurred at this site.
This job consisted of 6300 LF of CSP and 3200 LF of spiral rib pipe including several large tees, elbows, & misc. fittings.
A run of CSP totaling 5700 linear feet of 72” diameter (81” x 59”) arched storm drain was designed to accommodate a section of the project where soil conditions were not conducive to open channel ditch construction.
Access points were placed every 400’ for ventilation and cleanout. 48’ pipe sections were supplied to accommodate contractors request to reduce freight, joint connections and equipment limitations.
Aluminized Type ll steel was selected to provide an extended service life.
With over 14,680 LF (sections varying from 4,594 LF of 15-in diameter to 5,162 LF in 42-in diameter and 263 LF in 60-in), the mobile mill offered the perfect flexibility for the variety of pipe diameters needed to complete the job.
Using a low profile box culverts kept the project on budget, on schedule and provided a sustainable option.
These pipes are set vertically into a concrete base and sealed with silicone or a spray sealant. They are then covered with a solid vented lid and plumbed for use.
Corrugated steel water tanks are designed to be an aesthetically pleasing and cost effective solution used for rain water harvesting.
As the aging infrastructure impact all transportation types, corrugated steel pipe was a solution to the rehabilitation of this old railroad timber structure.
Keeping the transportation running is the most important part of the rehab project. This crossing was not shut down any though the entire installation process.
The deteriorating culvert had experienced major encroachment along the toe of the slope after a major rain event and catastrophic washouts.
Standing the test of time these structures have survived nearly 60 years of service and are being extended to accommodate today’s traffic patterns.
The North Dakota Department of Transportation had a problem with joint separation and spalling concrete in a 10’ x 8’ cast-in-place Reinforced concrete box culvert built in 1934, and extended in 1960.
Fulfilling the order for this project created challenges in that the diameter was barely able to fit through our fabricating plant door, the pipes were so heavy that up to 3 forklifts were used to lift/transport the product.
Constructed in 2011, this is the longest single span box culvert of any material in North America. This was also the first large span steel buried bridge to take advantage of its flexible nature in the foundation design.
This half-round CSP structure, with its own footing plates, was designed by Pacific Corrugated Pipe Co. for bridging small streams on a temporary basis. The installation was along the Smith River access road near Elkton, RO and completed under the auspices of Oregon Department of Fish and Wildlife to ensure compliance with environmental regulations.
The City of Pharr and the Texas General Land Office needed to upgrade a smaller, reinforced concrete pipe (RCP) drainage system that included a main trunk line of large box culverts which intercepted approximately 320 acres of surface runoff in a densely populated area.
To provide ample drainage along the bottom of a ravine, 863-foot long 96″diameter structural steel plate was installed as part of the $23.4 million Coalfields Expressway corridor improvement project.
A 54″ corrugated steel pipe from Contech Engineered Solutions was chosen to reline a concrete equalizer pipe under 30 feet of cover at Mitchell Interchange on I-94 in Milwaukee, WI
NCSPA member Southeast Culvert worked with engineers to re-design the project to pre-treat the detentions using multiple 144″ CMP filters.
A three mile grading project included a structural steel plate arch as well as over 1,000 feet of culverts on a farm-to-market road.
Contech Engineered Solutions worked closely with the design-build team to design and manufacture a storm drainage system beneath the new interchange
A deep corrugation 15″ x 5 ½” structural plate was used for the reline of the existing culvert arches over bridge M-23-13 Over Wissahickon Creek.
In 1994, BNSF Railway usedOver 26,000 ft of Aluminized Type 2 (ALT2) spiral rib pipe and helically corrugated culvert pipe to build there intermodal facility in Roanoke, Texas
The 41′- 4″ by 11′ – 9″ low profile structural plate arch was installed to span a tributary of Little Seneca Creek as part of the road extension.
The Minnesota Department of Transportation (MnDOT) designed a 144-inch by 180 feet of 10 gauge, Aluminized Type 2, CSP as the replacement.
The residents of Buchanan County, Iowa have a new, durable and cost-effective steel buried bridge in place to handle traffic from their cars, trucks and heavy farm equipment.
An 80-foot run of 8 gauge, polymer-coated, arched pipe with a 137-inch span and a 87-inch rise was installed at Southwestern Illinois College
The concrete structure, part of the Pennsylvania Turnpike infrastructure in Cumberland County, Pennsylvania was relined with 90-in plate arch
The University of West Georgia has installed a three-tank system using 96-inch Aluminized Type 2 CSP.
A landowner in Dallas County replaced a deteriorating bridge with galvanized riveted corrugated steel pipe.
Originally constructed in 1906, the relining design engineer of this project specified two 22-ft long, 19′-0″ x 5′-9½” structural plate arches.
The 28.4 ft diameter pipe consists of galvanized steel deep corrugated structural plate (15” x 5.5” corrugation profile) designed, manufactured, and constructed in accordance with AASHTO LRFD and ODOT requirements.
Located near Philadelphia, a combination system irrigation/detention system with of 1,584 feet of fully perforated, 96-in diameter, aluminized corrugated steel pipe (CSP) epitomizes "Green Infrastructure".
This 15-ft long, 30'-4" span x 7'-8 3/4" rise steel structural plate arch was installed by Union County, Iowa in 1941.
The U.S. Bank Stadium, home of the Minnesota Vikings, installed an underground retention system made from 1,000' of 144" diameter perforated Aluminized Type 2 (ALT2) corrugated steel pipe.
Corrugated steel pipe, supplied by True North Steel, was used by The North Dakota Department of Transportation to extend the structural plate pipe at the U.S. /Canadian border crossing station
The structural plate arch built to help protect visitors from falling results, with the help of NCSPA member Lane Enterprises, had unique specifications to accommodate a local endangered species.
NCSPA member Big R Bridge provided the galvanized steel for a flexible buried bridge with galvanized steel welded wire headwalls to conform to site constraints and aesthetic requirements.
Deep corrugated steel arch provides minimal disruption on New Mexico State highway
The University System of Georgia installs recycled corrugated steel pipe to harvest rainwater to help reach their sustainability goals.
Corrugated steel pipe was introduced to this North Dakota town's stormwater system, in response to the major flooding events plaguing their land.
Undergoing redevelopment, a corrugated steel piping system was implemented to solve a unique storm sever treatment issue.
NCSPA member Big R Bridge utilized corrugated structural steel plate to develop an efficient, yet economical construction solution.
Corrugated steel pipe was used to help restore this aging stone bridge in an Eastern Pennsylvania community
Manufactured from corrugated steel pipe, slotted drain fabricated by NCSPA member Contech Engineered Solutions was selected to complete a recent construction project
Raleigh Highway Goes Deep – June 2011
Georgia Goes Nuclear With First New Reactors Since 1970s … – March – April 2011
Detention System Braves Epic Atlanta Floods – February 2011
Solving the Aging Bridges Quandary – Fall 2010
Replacement of RCP with CSP in Denver – June 2010
Use of CSP in Oregon – June 2010
A Storm Sewer Vision – January 2010
Design Flexibility Meets Long-Term Solutions – December 2009
Campus Designers Look to Underground Solutions – November 2009
Making Corrugated Steel Pipe Culverts Last – January 2006