Difference between revisions of "Category:1047 Corrugated Polyethylene Culvert Pipe"

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This article establishes procedures for inspecting, accepting and reporting polyethylene culvert pipe. Refer to [http://www.modot.mo.gov/business/standards_and_specs/Sec1047.pdf Sec 1047] for MoDOT’s specifications.  
+
This article establishes procedures for inspecting, accepting and reporting polyethylene culvert pipe. Refer to [https://www.modot.org/missouri-standard-specifications-highway-construction Sec 1047] for MoDOT’s specifications.  Additional information on pipe, selection, inspection and payment can be found in [https://www.modot.org/missouri-standard-specifications-highway-construction Sec 724], [https://www.modot.org/missouri-standard-specifications-highway-construction Sec 730], [[:Category:724 Pipe Culverts|EPG 724 Pipe Culverts]] and [[:Category:730 Corrugated Polyethylene Pipe Culverts|EPG 730 Corrugated Polyethylene Pipe Culverts]].
  
===1047.1 Apparatus===
+
==1047.1 Construction Project Acceptance==
  
:(a) Rule with suitable graduations to accurately measure the material to be inspected.
+
Polyethylene culvert pipe is to be accepted for use on the basis of the pipe manufacturer being on the approved list and the supplier/manufacturer obtaining and providing pipe ID#s for each shipment/lot/size of pipe. A random sampling system is administered by [http://sp/sites/cm/Pages/default.aspx Central Office Construction and Materials] to ensure the quality and engineering properties of the pipe.
:(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) [[:category:1047 Corrugated Polyethylene Culvert Pipe#1047.5 Polyethylene Pipe (HDPE) Pipe Inspection Guide |Polyethylene (HDPE) Pipe Inspection Guide]].
 
  
===1047.2 Procedure===
+
The supplier/manufacture of the pipe should get the ID#s prior to shipment using [http://epg.modot.mo.gov/forms/CM/PipeShippingReportForm_Thermoplastic.pdf Pipe Shipping Report Form for reporting to the Central Office, GS-17 Form 1].  When the ID#s are assigned by Central Office Construction and Materials, the supplier/manufacturer will be notified if the shipment has been selected for sampling.  This gives the supplier/manufacturer an opportunity to ship extra pipe to the jobsite to ensure the sampling process does not leave the contractor short of material. 
  
====1047.2.1 Polyethylene Culvert Pipe====
+
If the supplier/manufacturer of the pipe does not get the ID#s prior to shipment, Central Office Construction and Materials should be notified
  
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 Maintenance Acceptance==
  
=====1047.2.1.1 Manufacturer Approval=====
+
The need to assign ID#s and the random sampling process applies to pipes purchased for maintenance as it does for construction projects. Completion of the sample records for materials purchased under a MoDOT purchase order is to be as described in [[:Category:1101 Materials Purchased by a Department Purchase Order|EPG 1101 Materials Purchased by a Department Purchase Order]].
  
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 [http://www.modot.mo.gov/business/standards_and_specs/Sec1047.pdf Sec 1047].
+
==1047.3 Manufacturer Approval==
  
A list of those manufacturers who have filed acceptable documents is shown below.
+
Prior to supplying 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 [https://www.modot.org/missouri-standard-specifications-highway-construction Sec 1047]. The manufacturer shall specify in their application for placement on the qualified list which standard their pipe is fabricated to; English or metric.  The manufacturer shall provide the definition of a lot or it will be considered one day’s production. See the list of [https://www.modot.org/media/514 Qualified Fabricators of Corrugated Polyethylene Culvert Pipe] for manufacturers who have filed acceptable documents.  
  
======'''Table 1047.2.1.1 Qualified Fabricators of Corrugated Polyethylene Culvert Pipe (1047CPPE)'''======
+
If random sampling results in the rejection of the polyethylene pipe, acceptance on the basis of pipe manufacturer's certified analysis and guarantee may 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.  
  
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
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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.  
|+
 
! style="background:#BEBEBE" |Plant!!style="background:#BEBEBE"| Fabrication Units
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4" |Metric
 
|-
 
|4640 Trueman Blvd.
 
|-
 
|Hilliard, OH 43026
 
|-
 
|(11/04)
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4"  |Metric
 
|-
 
|100 N.E. 20th Street
 
|-
 
|Eagle Grove, IA 50533
 
|-
 
|(11/04)
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4" |Metric
 
|-
 
|210 Metro Park Blvd.
 
|-
 
|Ennis, TX 75119
 
|-
 
|(11/04)
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4" |Metric
 
|-
 
|205 Apache Drive
 
|-
 
|Jackson, MS 39272
 
|-
 
|(11/04)
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4" |Metric
 
|-
 
|Buck Creek Church Road
 
|-
 
|Livermore, KY 42352
 
|-
 
|(11/04)
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4"  |Metric
 
|-
 
|1600 Industrial Drive
 
|-
 
|Mendota, IL 61342
 
|-
 
|(11/04)
 
|-
 
|Advanced Drainage Systems, Inc. ||rowspan="4"  |Metric
 
|-
 
|820 Lone Star Drive
 
|-
 
|O’Fallon, MO 63366
 
|-
 
|(11/04)
 
|-
 
|Hancor, Inc. ||rowspan="4"  |English
 
|-
 
|8535 W. 147th Terrace
 
|-
 
|Overland Park, KS 66223
 
|-
 
|(9/04)
 
|}
 
 
 
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 Plastic Pipe Institute (PPI) seal, 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 are to be submitted to the Laboratory from approximately 10 percent of the lots of pipe presented for inspection. The sample shall consist of 4 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 shall be obtained from different sections in the lot and shall be taken from the end of the pipe.
 
 
 
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 [[:category:1047 Corrugated Polyethylene Culvert Pipe#1047.5 Polyethylene Pipe (HDPE) Pipe Inspection Guide |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.
+
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.
  
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.
+
==1047.4 Random Sampling==
  
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.
+
Random sample locations will be determined by Central Office Construction and Materials as approximately 10% of shipments statewide.  The specific pipes determined for testing by Central Office will take into account the limitations of MoDOT’s laboratory testing equipment.  The samples are to be obtained by the districts 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 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. 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.  
  
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.
+
==1047.5 Field Inspection==
  
===1047.3 Sample Record===
+
When necessary, field inspection shall be performed using the [[1047.8 Polyethylene Pipe (HDPE) Pipe Inspection Guide|Polyethylene (HDPE) Pipe Inspection Guide]]. For the purposes of field inspection, the definition of a lot shall be the entire quantity shipped.
  
Field inspection shall be recorded in Site Manager, as described in [[Automation Sec 3510]]. 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
+
Apparatus Needed:
result details.
 
  
The manufacturer or shipper is required to notify Construction and Materials of impending shipments using the Pipe Shipping Report Form (GS-17 Form 1). This information will allow MoDOT to track the material, obtain samples, and perform Quality Assurance inspection as necessary.
+
:(a) Rule with suitable graduations to accurately measure the material to be inspected.  
  
A SiteManager sample record shall be created for each size of pipe in each shipment.
+
:(b) Micrometer capable of measuring to 0.0001 in. (0.00254 mm) and accurate to within at least 0.001 in. (0.0254 mm).  
 
 
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 1101 Maintenance Materials.
 
 
 
===1047.4 Tolerance and Deflection Tables===
 
 
 
====Table 1047.4.1 Diameter Dimensional Tolerances (English)====
 
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
 
|+
 
! style="background:#BEBEBE" | Specified Inside Diameter, in.!!style="background:#BEBEBE" | Lower Tolerance, in. !!style="background:#BEBEBE" |Lower Tolerance, mm<sup>a</sup>!! style="background:#BEBEBE" |Upper Tolerance, in.!! style="background:#BEBEBE" |Upper Tolerance, mm<sup>a</sup>
 
|-
 
|align="center"|12|| align="center"| 11 13/16|| align="center"| 300 || align="center"|12 17/32|| align="center"| 318
 
|-
 
|align="center"|15|| align="center"| 14 25/32|| align="center"|375|| align="center"|15 11/16|| align="center"| 398
 
|-
 
|align="center"|18|| align="center"| 17 23/32|| align="center"| 450|| align="center"|18 13/16 || align="center"|478
 
|-
 
|align="center"|21|| align="center"| 20 11/16|| align="center"| 525|| align="center"| 21 15/16|| align="center"| 557
 
|-
 
|align="center"|24|| align="center"| 23 5/8|| align="center"| 600 || align="center"|25 3/32|| align="center"|637
 
|-
 
|align="center"| 27|| align="center"| 26 19/32|| align="center"| 675 || align="center"|28 7/32|| align="center"| 717
 
|-
 
|align="center"|30|| align="center"| 29 9/16|| align="center"| 751|| align="center"| 31 11/32|| align="center"| 796
 
|-
 
|align="center"|36|| align="center"|35 15/32|| align="center"| 901 || align="center"|37 15/32|| align="center"|952
 
|-
 
|align="center"|42|| align="center"|41 3/8 || align="center"|1051 || align="center"|43 15/32|| align="center"|1104
 
|-
 
|align="center"|48|| align="center"|47 9/32|| align="center"|1201 || align="center"|49 15/32|| align="center"|1257
 
|-
 
|align="center"|54|| align="center"|53 3/16|| align="center"|1351|| align="center"|55 15/32|| align="center"|1409
 
|-
 
|align="center"|60|| align="center"| 59 3/32|| align="center"|1501 || align="center"|61 15/32|| align="center"|1561
 
|-
 
|colspan="5" |<sup>a</sup> The metric dimension conversions are approximately converted from their English counterparts.
 
|}
 
 
 
====Table 1047.4.2 Diameter Dimensional Tolerances (Metric)====
 
 
 
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
 
|+
 
! style="background:#BEBEBE" | Specified Inside Diameter, in.!!style="background:#BEBEBE" | Lower Tolerance, mm !!style="background:#BEBEBE" |Lower Tolerance, in.<sup>a</sup>!! style="background:#BEBEBE" |Upper Tolerance, mm!! style="background:#BEBEBE" |Upper Tolerance, in.<sup>a</sup>
 
|-
 
| align="center"|300|| align="center"| 296 || align="center"|11 5/8|| align="center"| 314 || align="center"|12 11/32
 
|-
 
| align="center"|375|| align="center"|369|| align="center"|14 17/32|| align="center"| 392|| align="center"|15 7/16
 
|-
 
| align="center"|450|| align="center"| 443|| align="center"| 17 7/16 || align="center"|470|| align="center"|18 1/2
 
|-
 
| align="center"|525|| align="center"| 517|| align="center"|20 3/8|| align="center"| 549|| align="center"|21 19/32
 
|-
 
| align="center"|600|| align="center"| 591|| align="center"|23 9/32|| align="center"| 627|| align="center"|24 11/16
 
|-
 
| align="center"|675|| align="center"| 665|| align="center"| 26 3/16|| align="center"| 705|| align="center"|27 25/32
 
|-
 
| align="center"|750|| align="center"| 739|| align="center"| 29 3/32|| align="center"| 784|| align="center"|30 7/8
 
|-
 
| align="center"|900|| align="center"| 887|| align="center"| 34 29/32|| align="center"|937|| align="center"| 36 7/8
 
|-
 
| align="center"|1050|| align="center"|1034|| align="center"|40 23/32|| align="center"| 1087|| align="center"|42 13/16
 
|-
 
| align="center"|1200|| align="center"|1182|| align="center"| 46 17/32|| align="center"| 1237|| align="center"| 48 11/16
 
|-
 
| align="center"|1350|| align="center"|1330|| align="center"| 52 11/32|| align="center"|1387|| align="center"|54 5/8
 
|-
 
| align="center"|1500 || align="center"|1478|| align="center"| 58 5/32|| align="center"| 1537|| align="center"| 60 1/2
 
|-
 
|colspan="5" |<sup>a</sup> The English dimension conversions are approximately converted from their metric counterparts.
 
|}
 
 
 
 
 
====Table 1047.4.3 Pipe Deflection (English)====
 
 
 
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
 
|+
 
! style="background:#BEBEBE" | Specified Inside Diameter, in.!!style="background:#BEBEBE" | Deflected Diameter, in.!!style="background:#BEBEBE" |Deflected Diameter, mm<sup>a</sup>
 
|-
 
| align="center"|12||align="center"|11 13/32|| align="center"|290
 
|-
 
| align="center"|15|| align="center"| 14 1/4|| align="center"| 362
 
|-
 
| align="center"|18 || align="center"|17 3/32|| align="center"| 434
 
|-
 
| align="center"|21 || align="center"|19 15/16|| align="center"| 506
 
|-
 
| align="center"|24 || align="center"|22 13/16|| align="center"| 579
 
|-
 
| align="center"|27 || align="center"|25 21/32|| align="center"| 652
 
|-
 
| align="center"|30 || align="center"|28 1/2 || align="center"|724
 
|-
 
| align="center"|36 || align="center"|34 3/16|| align="center"| 868
 
|-
 
| align="center"|42 || align="center"|39 29/32 || align="center"|1014
 
|-
 
| align="center"|48 || align="center"|45 19/32|| align="center"| 1158
 
|-
 
| align="center"|54|| align="center"| 51 5/16|| align="center"| 1303
 
|-
 
| align="center"|60|| align="center"| 57 || align="center"|1448
 
|-
 
|colspan="3" |<sup>a</sup> The metric dimension conversions are approximately converted from their English counterparts.
 
|}
 
  
 +
:(c) [[1047.8 Polyethylene Pipe (HDPE) Pipe Inspection Guide|Polyethylene (HDPE) Pipe Inspection Guide]].
  
====Table 1047.4.4 Pipe Deflection (Metric)====
+
The engineer may inspect the fabricated pipe at the manufacturing plant, intermediate distribution point, or project. 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.  
  
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
+
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.  
|+
 
! style="background:#BEBEBE" | Specified Inside Diameter, mm!!style="background:#BEBEBE" | Deflected Diameter, mm!!style="background:#BEBEBE" |Deflected Diameter, in.<sup>a</sup>
 
|-
 
| align="center"| 300|| align="center"|  285|| align="center"|  11 7/32
 
|-
 
| align="center"| 375 || align="center"| 356 || align="center"| 14 1/32
 
|-
 
| align="center"| 450 || align="center"| 428 || align="center"| 16 27/32
 
|-
 
| align="center"| 525 || align="center"| 499 || align="center"| 19 5/8
 
|-
 
| align="center"| 600|| align="center"|  570|| align="center"|  22 7/16
 
|-
 
| align="center"| 675|| align="center"|  641 || align="center"| 25 ¼
 
|-
 
| align="center"| 750|| align="center"|  713 || align="center"| 28 1/16
 
|-
 
| align="center"| 900|| align="center"|  855 || align="center"| 33 21/32
 
|-
 
| align="center"| 1050 || align="center"| 998 || align="center"| 39 9/32
 
|-
 
| align="center"| 1200|| align="center"|  1140 || align="center"| 44 7/8
 
|-
 
| align="center"| 1350|| align="center"|  1283 || align="center"| 50 ½
 
|-
 
| align="center"| 1500 || align="center"| 1425 || align="center"| 56 3/32
 
|-
 
|colspan="3" |<sup>a</sup> The English dimension conversions are approximately converted from their metric counterparts.
 
|}
 
  
===1047.5 Polyethylene Pipe (HDPE) Pipe Inspection Guide===
+
The specified inside diameter, in accordance with applicable AASHTO, should comply with the table below.  Again, all measurements shall be made using the same units as to which the pipe was fabricated.  
  
This guide will assist in the inspection of all types and configurations of Polyethylene (HDPE) pipe, couplings and fittings. Answer each question and take the action indicated for the answer given. If no condition is provided for a particular answer, move on to the next question. It is the responsibility of the inspector to confirm that this inspection guide is in accordance with current specifications.
+
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.  
  
Every lot should be visually inspected. The lot that appears to have the defects, or a lot selected at random if all lots appear to be of equal quality, shall be inspected in greater detail to generally establish the Quality Control practices of the manufacturer. And at least one pipe per size offered in the lot shall be inspected in detail using this inspection guide. The manufacturer may 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.
+
If pipe is rejected for not being in accordance with specifications and the requirements set forth in the Polyethylene (PE) 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.
  
If this inspection guide is used to inspect a rejected pipe, it shall be submitted with the notification to the manufacturer of the failure to meet specification.
+
==1047.6 Sample Record==
  
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
+
When Central Office Construction and Materials issues ID#s, they will create the corresponding sample record for acceptance of the pipe.  
|+
 
|Has any of the material or pipe included in this lot been rejected during a previous inspection visit? If Yes, the entire lot is unacceptable. ||Yes|| No
 
|-
 
|Is this manufacturer approved for production of HDPE pipe? (Refer to [[:category:1047 Corrugated Polyethylene Culvert Pipe#Table 1047.2.1.1 Qualified Fabricators of Corrugated Polyethylene Culvert Pipe (1047CPPE)| Table 1047.2.1.1 Qualified Fabricators of Corrugated Polyethylene Culvert Pipe (1047CPPE)]]). If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|Is the pipe accompanied by a bill of lading or delivery receipt at this location? If No, stop, the pipe is unacceptable. ||Yes|| No
 
|-
 
|Does the bill of lading or delivery receipt contain an itemized list of the sizes and lengths of pipe? If No, stop; the pipe is unacceptable. || Yes ||No
 
|-
 
|Does the bill of lading or delivery receipt contain a MoDOT sample ID or is it accompanied by a Material Shipping Report Form? If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|colspan="3" |Is the pipe marked (in accordance with AASHTO M 294) with the following:
 
|-
 
|the manufacturer’s name or trademark? If No, stop; the pipe is unacceptable. ||Yes|| No
 
|-
 
|the nominal pipe size? If No, stop; the pipe is unacceptable. ||Yes|| No
 
|-
 
|the designation of “AASHTO M 294”? If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|the Plastic Pipe Institute (PPI) seal? If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|the plant designation code? If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|the date of manufacture or an appropriate code? (If unsure, contact the manufacturer.) If No, stop; the pipe is unacceptable. ||Yes|| No
 
|-
 
|Do the markings repeat on the pipe on intervals not exceeding 10 ft.? If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|Are there any visible cracks, holes, creases, foreign materials, or other injurious defects that would be an indication of poor workmanship? If Yes, stop; the pipe is unacceptable. ||Yes|| No
 
|-
 
|Does the pipe have either, corrugated surfaces inside and out, or a corrugated surface outside and a smooth inner liner? If No, stop; the pipe is unacceptable (unless otherwise specified). ||Yes ||No
 
|-
 
|Are the color, density, and other physical properties uniform along the length of the pipe? If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
|Are the ends of the pipe cut squarely and cleanly (where applicable)? If No, stop; the pipe is unacceptable. ||Yes|| No
 
|-
 
|colspan="3" |The average inside diameter shall be measured using a tapered plug gage and the procedure set forth in ASTM D 2122. In the event that a tapered plug gage is not available, the measurement shall be made using a suitable device accurate to at least 1/8 in.” (standard tape measure). Eight measurements should be taken equally spaced around the circumference of the pipe. This should be done on two sections of the pipe (upstream and downstream ends). Average these 16 measurements to obtain the average inside diameter.
 
|-
 
|Is the average inside diameter within the specified tolerance of the nominal pipe size? (Refer to [[:category:1047 Corrugated Polyethylene Culvert Pipe#Table 1047.5.3 Diameter Dimensional Tolerances (English)|Tables 1047.5.3]] and [[:category:1047 Corrugated Polyethylene Culvert Pipe#Table 1047.5.4 Diameter Dimensional Tolerances (Metric)|1047.5.4]].) If No, stop; the pipe is unacceptable. ||Yes ||No
 
|-
 
| colspan="3" |The wall thickness is measured using a cylindrical or ball anvil tubing micrometer (preferably accurate to within 0.001 in.). A minimum of 8 measurements are made at closely spaced intervals to ensure that the minimum and maximum wall thicknesses have been determined. The values are then averaged to obtain the average wall thickness.
 
|-
 
|Is the wall thickness greater than or equal to the corresponding minimum specified wall thickness? (Refer to [[:category:1047 Corrugated Polyethylene Culvert Pipe#Table 1047.5.1 Minimum Wall Thickness (English)|Table 1047.5.1]] or [[:category:1047 Corrugated Polyethylene Culvert Pipe#Table 1047.5.2 Minimum Wall Thickness (Metric)|Table 1047.5.2]]). If No, stop; the pipe is unacceptable. ||Yes|| No
 
|-
 
|Has 10 percent of the pipe in the same lot of pipe been rejected? If Yes, stop; the entire lot of pipe is unacceptable. ||Yes|| No
 
|-
 
! colspan="3"|Couplings and Fittings (where applicable)
 
|-
 
|Are the couplings for fittings made of the same base material as the pipe? If No, stop; the couplings or fittings are unacceptable. ||Yes|| No
 
|-
 
|Do the corrugations of the couplings or fittings have the same corrugation configuration in the pipe ends that are being connected? If No, stop; the couplings or fittings are unacceptable. ||Yes ||No
 
|-
 
|Does the coupling or fitting reduce the inside diameter of the pipe being joined by more than 1/2 in.? If Yes, stop, the coupling or fitting is unacceptable. ||Yes|| No
 
|-
 
|If the coupling is a “split coupling,” does it engage at least two full corrugations? If No, stop; the coupling is unacceptable. ||Yes|| No
 
|-
 
|Is the fitting length within ½ in. of the manufacturer’s specified dimension? If No, stop; the fitting is unacceptable. ||Yes|| No
 
|-
 
|Do the fittings noticeably reduce or impair the overall integrity or function of the pipe line? If Yes, stop; the pipe is unacceptable. ||Yes|| No
 
|}
 
  
====Table 1047.5.1 Minimum Wall Thickness (English)====
+
When samples are taken by the districts, the inspector should create a sample record representing the sample.
  
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
+
When field inspection is performed by the district the results should be recorded in AASHTOWARE Project (AWP) by either adding the template and details to the original sample record created by Central Office or by creating a new sample record with a contract tab quantity of 0 to avoid double reporting the pipe.
|+
 
! style="background:#BEBEBE" | Nominal Size of Pipe, in.!!style="background:#BEBEBE" | Wall Thickness, in.
 
|-
 
| align="center"| 12|| align="center"|  0.04
 
|-
 
| align="center"| 15|| align="center"|  0.04
 
|-
 
| align="center"|  18|| align="center"|  0.05
 
|-
 
| align="center"|  21 || align="center"|  0.06
 
|-
 
| align="center"|  24 || align="center"|  0.06
 
|-
 
| align="center"|  27 || align="center"|  0.06
 
|-
 
| align="center"|  30 || align="center"|  0.06
 
|-
 
| align="center"|  36 || align="center"|  0.07
 
|-
 
| align="center"|  42 || align="center"|  0.07
 
|-
 
| align="center"|  48 || align="center"|  0.07
 
|-
 
| align="center"|  54 || align="center"|  0.08
 
|-
 
| align="center"|  60 || align="center"|  0.08
 
|}
 
  
====Table 1047.5.2 Minimum Wall Thickness (metric)====
+
Individual AWP sample records should be created for each size of pipe.
  
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
+
==1047.7 Polyethylene Culvert Pipe Properties==
|+
 
! style="background:#BEBEBE" | Nominal Size of Pipe, mm!!style="background:#BEBEBE" | Wall Thickness, mm
 
|-
 
| align="center"|  300 || align="center"|  0.9
 
|-
 
| align="center"|  375 || align="center"|  1.0
 
|-
 
| align="center"|  450 || align="center"|  1.3
 
|-
 
| align="center"|  525 || align="center"|  1.5
 
|-
 
| align="center"|  600 || align="center"|  1.5
 
|-
 
| align="center"|  675 || align="center"|  1.5
 
|-
 
| align="center"|  750 || align="center"|  1.5
 
|-
 
| align="center"|  900 || align="center"|  1.7
 
|-
 
| align="center"|  1050 || align="center"|  1.8
 
|-
 
| align="center"|  1200 || align="center"|  1.8
 
|-
 
| align="center"|  1350 || align="center"|  2.0
 
|-
 
| align="center"|  1500 || align="center"|  2.0
 
|}
 
  
====Table 1047.5.3 Diameter Dimensional Tolerances (English)====
+
===1047.7.1 Identification Markings===
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
+
Each pipe and fitting is to be clearly marked, in accordance with the [http://engineers.ihs.com/document/abstract/RNIJJBAAAAAAAAAA AASHTO M294], 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 designation, the plant designation code, and the date of manufacture or an appropriate code.  
|+
 
! style="background:#BEBEBE" | Specified Inside Diameter, in.!!style="background:#BEBEBE" | Lower Tolerance, in. !!style="background:#BEBEBE" |Lower Tolerance, mm<sup>a</sup>!! style="background:#BEBEBE" |Upper Tolerance, in.!! style="background:#BEBEBE" |Upper Tolerance, mm<sup>a</sup>
 
|-
 
| align="center"|  12 || align="center"|  11 13/16|| align="center"|  300|| align="center"|  12 17/32|| align="center"|  318
 
|-
 
| align="center"|  15 || align="center"|  14 25/32|| align="center"|  375|| align="center"|  15 11/16|| align="center"|  398
 
|-
 
| align="center"|  18 || align="center"|  17 23/32|| align="center"|  450|| align="center"|  18 13/16 || align="center"|  478
 
|-
 
| align="center"| 21|| align="center"|  20 11/16|| align="center"|  525 || align="center"|  21 15/16|| align="center"|  557
 
|-
 
| align="center"|  24 || align="center"|  23 5/8 || align="center"|  600 || align="center"|  25 3/32|| align="center"|  637
 
|-
 
| align="center"|  27 || align="center"|  26 19/32|| align="center"|  675 || align="center"|  28 7/32 || align="center"|  717
 
|-
 
| align="center"|  30 || align="center"|  29 9/16 || align="center"|  751 || align="center"|  31 11/32 || align="center"|  796
 
|-
 
| align="center"|  36|| align="center"|  35 15/32 || align="center"|  901 || align="center"|  37 15/32 || align="center"|  952
 
|-
 
| align="center"|  42|| align="center"|  41 3/8 || align="center"|  1051 || align="center"|  43 15/32 || align="center"|  1104
 
|-
 
| align="center"|  48 || align="center"|  47 9/32 || align="center"|  1201 || align="center"|  49 15/32|| align="center"|  1257
 
|-
 
| align="center"|  54 || align="center"|  53 3/16|| align="center"|  1351 || align="center"|  55 15/32 || align="center"|  1409
 
|-
 
| align="center"|  60 || align="center"|  59 3/32|| align="center"|  1501 || align="center"|  61 15/32 || align="center"|  1561
 
|-
 
|colspan="5" |<sup>a</sup> The metric dimension conversions are approximately converted from their English counterparts.
 
|}
 
  
====Table 1047.5.4 Diameter Dimensional Tolerances (Metric)====
+
===1047.7.2 Diameter Dimensional Tolerances for English Pipe Table===
  
{| border="1" class="wikitable" style="margin: 1em auto 1em auto"
+
<center>
 +
{| border="1" class="wikitable" style="margin: 1em auto 1em auto" style="text-align:center"
 
|+  
 
|+  
! style="background:#BEBEBE" | Specified Inside Diameter, in.!!style="background:#BEBEBE" | Lower Tolerance, mm !!style="background:#BEBEBE" |Lower Tolerance, in.<sup>a</sup>!! style="background:#BEBEBE" |Upper Tolerance, mm!! style="background:#BEBEBE" |Upper Tolerance, in.<sup>a</sup>
+
! style="background:#BEBEBE" width="120"|English Nominal Inside Diameter, in.!! style="background:#BEBEBE" width="120"|Lower Tolerance, in. !! style="background:#BEBEBE" width="120" |Upper Tolerance, in.!! style="background:#BEBEBE" width="10"| !!style="background:#BEBEBE" width="120"|Metric Nominal Inside Diameter, mm!! style="background:#BEBEBE" width="120"|Lower Tolerance, mm !! style="background:#BEBEBE" width="120" |Upper Tolerance, mm
|-
 
| align="center"| 300 || align="center"|  296 || align="center"| 11 5/8|| align="center"|  314|| align="center"|   12 11/32
 
 
|-
 
|-
| align="center"| 375 || align="center"| 369 || align="center"| 14 17/32 || align="center"| 392 || align="center"| 15 7/16
+
|12|| 11 13/16|| 12 17/32||style="background:#BEBEBE"| ||300|| 296|| 314
 
|-
 
|-
| align="center"| 450 || align="center"| 443|| align="center"|   17 7/16 || align="center"| 470 || align="center"| 18 1/2
+
|15|| 14 25/32|| 15 11/16||style="background:#BEBEBE"| ||375|| 369|| 392
 
|-
 
|-
| align="center"| 525 || align="center"| 517|| align="center"|   20 3/8|| align="center"|   549 || align="center"| 21 19/32
+
|18|| 17 23/32|| 18 13/16||style="background:#BEBEBE"| ||450|| 443|| 470
 
|-
 
|-
| align="center"| 600|| align="center"|   591|| align="center"|   23 9/32|| align="center"|   627|| align="center"|   24 11/16
+
|21|| 20 11/16|| 21 15/16||style="background:#BEBEBE"| ||525|| 517|| 549
 
|-
 
|-
| align="center"| 675 || align="center"| 665|| align="center"|   26 3/16|| align="center"|   705|| align="center"|   27 25/32
+
|24|| 23 5/8|| 25 3/32 ||style="background:#BEBEBE"| ||600|| 591|| 627
 
|-
 
|-
| align="center"| 750 || align="center"| 739|| align="center"|   29 3/32|| align="center"|   784|| align="center"|   30 7/8
+
|27|| 26 19/32|| 28 7/32 ||style="background:#BEBEBE"| ||675|| 665|| 705
 
|-
 
|-
| align="center"| 900 || align="center"| 887|| align="center"|   34 29/32|| align="center"|   937|| align="center"|   36 7/8
+
|30|| 29 9/16|| 31 11/32||style="background:#BEBEBE"| ||750|| 739|| 784
 
|-
 
|-
| align="center"| 1050|| align="center"|   1034|| align="center"|   40 23/32|| align="center"|   1087|| align="center"|   42 13/16
+
|36|| 35 15/32|| 37 15/32||style="background:#BEBEBE"| ||900|| 887|| 937
 
|-
 
|-
| align="center"| 1200|| align="center"|   1182|| align="center"|   46 17/32|| align="center"|   1237 || align="center"| 48 11/16
+
|42|| 41 3/8|| 43 15/32||style="background:#BEBEBE"| ||1050|| 1034|| 1087
 
|-
 
|-
| align="center"| 1350 || align="center"| 1330|| align="center"|   52 11/32 || align="center"| 1387 || align="center"| 54 5/8
+
|48|| 47 9/32|| 49 15/32||style="background:#BEBEBE"| ||1200|| 1182|| 1237
 
|-
 
|-
| align="center"| 1500 || align="center"| 1478 || align="center"| 58 5/32|| align="center"|   1537 || align="center"| 60 ½
+
|54|| 53 3/16|| 55 15/32||style="background:#BEBEBE"| ||1350|| 1330|| 1387
 
|-
 
|-
|colspan="5" |<sup>a</sup> The English dimension conversions are approximately converted from their metric counterparts.
+
|60|| 59 3/32|| 61 15/32||style="background:#BEBEBE"| ||1500|| 1478|| 1537
 
|}
 
|}
 +
</center>

Latest revision as of 13:52, 1 October 2021

This article establishes procedures for inspecting, accepting and reporting polyethylene culvert pipe. Refer to Sec 1047 for MoDOT’s specifications. Additional information on pipe, selection, inspection and payment can be found in Sec 724, Sec 730, EPG 724 Pipe Culverts and EPG 730 Corrugated Polyethylene Pipe Culverts.

1047.1 Construction Project Acceptance

Polyethylene culvert pipe is to be accepted for use on the basis of the pipe manufacturer being on the approved list and the supplier/manufacturer obtaining and providing pipe ID#s for each shipment/lot/size of pipe. A random sampling system is administered by Central Office Construction and Materials to ensure the quality and engineering properties of the pipe.

The supplier/manufacture of the pipe should get the ID#s prior to shipment using Pipe Shipping Report Form for reporting to the Central Office, GS-17 Form 1. When the ID#s are assigned by Central Office Construction and Materials, the supplier/manufacturer will be notified if the shipment has been selected for sampling. This gives the supplier/manufacturer an opportunity to ship extra pipe to the jobsite to ensure the sampling process does not leave the contractor short of material.

If the supplier/manufacturer of the pipe does not get the ID#s prior to shipment, Central Office Construction and Materials should be notified

1047.2 Maintenance Acceptance

The need to assign ID#s and the random sampling process applies to pipes purchased for maintenance as it does for construction projects. 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.

1047.3 Manufacturer Approval

Prior to supplying 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. The manufacturer shall specify in their application for placement on the qualified list which standard their pipe is fabricated to; English or metric. The manufacturer shall provide the definition of a lot or it will be considered one day’s production. 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 may 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.

1047.4 Random Sampling

Random sample locations will be determined by Central Office Construction and Materials as approximately 10% of shipments statewide. The specific pipes determined for testing by Central Office will take into account the limitations of MoDOT’s laboratory testing equipment. The samples are to be obtained by the districts 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 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. 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.

1047.5 Field Inspection

When necessary, field inspection shall be performed using the Polyethylene (HDPE) Pipe Inspection Guide. For the purposes of field inspection, the definition of a lot shall be the entire quantity shipped.

Apparatus Needed:

(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.

The engineer may inspect the fabricated pipe at the manufacturing plant, intermediate distribution point, or project. 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 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 applicable AASHTO, should comply with the table below. Again, all measurements shall be made using the same units as to which the pipe was fabricated.

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 (PE) 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.

1047.6 Sample Record

When Central Office Construction and Materials issues ID#s, they will create the corresponding sample record for acceptance of the pipe.

When samples are taken by the districts, the inspector should create a sample record representing the sample.

When field inspection is performed by the district the results should be recorded in AASHTOWARE Project (AWP) by either adding the template and details to the original sample record created by Central Office or by creating a new sample record with a contract tab quantity of 0 to avoid double reporting the pipe.

Individual AWP sample records should be created for each size of pipe.

1047.7 Polyethylene Culvert Pipe Properties

1047.7.1 Identification Markings

Each pipe and fitting is to be clearly marked, in accordance with the AASHTO M294, 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 designation, the plant designation code, and the date of manufacture or an appropriate code.

1047.7.2 Diameter Dimensional Tolerances for English Pipe Table

English Nominal Inside Diameter, in. Lower Tolerance, in. Upper Tolerance, in. Metric Nominal Inside Diameter, mm Lower Tolerance, mm Upper Tolerance, mm
12 11 13/16 12 17/32 300 296 314
15 14 25/32 15 11/16 375 369 392
18 17 23/32 18 13/16 450 443 470
21 20 11/16 21 15/16 525 517 549
24 23 5/8 25 3/32 600 591 627
27 26 19/32 28 7/32 675 665 705
30 29 9/16 31 11/32 750 739 784
36 35 15/32 37 15/32 900 887 937
42 41 3/8 43 15/32 1050 1034 1087
48 47 9/32 49 15/32 1200 1182 1237
54 53 3/16 55 15/32 1350 1330 1387
60 59 3/32 61 15/32 1500 1478 1537

Articles in "1047 Corrugated Polyethylene Culvert Pipe"

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