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.

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.

A list of those manufacturers who have filed acceptable documents is shown below.

Table 1047.2.1.1 Qualified Fabricators of Corrugated Polyethylene Culvert Pipe (1047CPPE)

Plant	Fabrication Units
Advanced Drainage Systems, Inc.	Metric
4640 Trueman Blvd.
Hilliard, OH 43026
(11/04)
Advanced Drainage Systems, Inc.	Metric
100 N.E. 20th Street
Eagle Grove, IA 50533
(11/04)
Advanced Drainage Systems, Inc.	Metric
210 Metro Park Blvd.
Ennis, TX 75119
(11/04)
Advanced Drainage Systems, Inc.	Metric
205 Apache Drive
Jackson, MS 39272
(11/04)
Advanced Drainage Systems, Inc.	Metric
Buck Creek Church Road
Livermore, KY 42352
(11/04)
Advanced Drainage Systems, Inc.	Metric
1600 Industrial Drive
Mendota, IL 61342
(11/04)
Advanced Drainage Systems, Inc.	Metric
820 Lone Star Drive
O’Fallon, MO 63366
(11/04)
Hancor, Inc.	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 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 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 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 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 1101 Maintenance Materials.

1047.4 Tolerance and Deflection Tables

Table 1047.4.1 Diameter Dimensional Tolerances (English)

Specified Inside Diameter, in.	Lower Tolerance, in.	Lower Tolerance, mma	Upper Tolerance, in.	Upper Tolerance, mma
12	11 13/16	300	12 17/32	318
15	14 25/32	375	15 11/16	398
18	17 23/32	450	18 13/16	478
21	20 11/16	525	21 15/16	557
24	23 5/8	600	25 3/32	637
27	26 19/32	675	28 7/32	717
30	29 9/16	751	31 11/32	796
36	35 15/32	901	37 15/32	952
42	41 3/8	1051	43 15/32	1104
48	47 9/32	1201	49 15/32	1257
54	53 3/16	1351	55 15/32	1409
60	59 3/32	1501	61 15/32	1561
a The metric dimension conversions are approximately converted from their English counterparts.

Table 1047.4.2 Diameter Dimensional Tolerances (Metric)

Specified Inside Diameter, in.	Lower Tolerance, mm	Lower Tolerance, in.a	Upper Tolerance, mm	Upper Tolerance, in.a
300	296	11 5/8	314	12 11/32
375	369	14 17/32	392	15 7/16
450	443	17 7/16	470	18 1/2
525	517	20 3/8	549	21 19/32
600	591	23 9/32	627	24 11/16
675	665	26 3/16	705	27 25/32
750	739	29 3/32	784	30 7/8
900	887	34 29/32	937	36 7/8
1050	1034	40 23/32	1087	42 13/16
1200	1182	46 17/32	1237	48 11/16
1350	1330	52 11/32	1387	54 5/8
1500	1478	58 5/32	1537	60 1/2
a The English dimension conversions are approximately converted from their metric counterparts.

Table 1047.4.3 Pipe Deflection (English)

Specified Inside Diameter, in.	Deflected Diameter, in.	Deflected Diameter, mma
12	11 13/32	290
15	14 1/4	362
18	17 3/32	434
21	19 15/16	506
24	22 13/16	579
27	25 21/32	652
30	28 1/2	724
36	34 3/16	868
42	39 29/32	1014
48	45 19/32	1158
54	51 5/16	1303
60	57	1448
a The metric dimension conversions are approximately converted from their English counterparts.

Table 1047.4.4 Pipe Deflection (Metric)

Specified Inside Diameter, mm	Deflected Diameter, mm	Deflected Diameter, in.a
300	285	11 7/32
375	356	14 1/32
450	428	16 27/32
525	499	19 5/8
600	570	22 7/16
675	641	25 ¼
750	713	28 1/16
900	855	33 21/32
1050	998	39 9/32
1200	1140	44 7/8
1350	1283	50 ½
1500	1425	56 3/32
a The English dimension conversions are approximately converted from their metric counterparts.

1047.5 Polyethylene Pipe (HDPE) Pipe Inspection Guide

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.

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 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.

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 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
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
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 Tables 1047.5.3 and 1047.5.4.) If No, stop; the pipe is unacceptable.	Yes	No
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 Table 1047.5.1 or 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
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)

Nominal Size of Pipe, in.	Wall Thickness, in.
12	0.04
15	0.04
18	0.05
21	0.06
24	0.06
27	0.06
30	0.06
36	0.07
42	0.07
48	0.07
54	0.08
60	0.08

Table 1047.5.2 Minimum Wall Thickness (metric)

Nominal Size of Pipe, mm	Wall Thickness, mm
300	0.9
375	1.0
450	1.3
525	1.5
600	1.5
675	1.5
750	1.5
900	1.7
1050	1.8
1200	1.8
1350	2.0
1500	2.0

Table 1047.5.3 Diameter Dimensional Tolerances (English)

Specified Inside Diameter, in.	Lower Tolerance, in.	Lower Tolerance, mma	Upper Tolerance, in.	Upper Tolerance, mma
12	11 13/16	300	12 17/32	318
15	14 25/32	375	15 11/16	398
18	17 23/32	450	18 13/16	478
21	20 11/16	525	21 15/16	557
24	23 5/8	600	25 3/32	637
27	26 19/32	675	28 7/32	717
30	29 9/16	751	31 11/32	796
36	35 15/32	901	37 15/32	952
42	41 3/8	1051	43 15/32	1104
48	47 9/32	1201	49 15/32	1257
54	53 3/16	1351	55 15/32	1409
60	59 3/32	1501	61 15/32	1561
a The metric dimension conversions are approximately converted from their English counterparts.

Table 1047.5.4 Diameter Dimensional Tolerances (Metric)

Specified Inside Diameter, in.	Lower Tolerance, mm	Lower Tolerance, in.a	Upper Tolerance, mm	Upper Tolerance, in.a
300	296	11 5/8	314	12 11/32
375	369	14 17/32	392	15 7/16
450	443	17 7/16	470	18 1/2
525	517	20 3/8	549	21 19/32
600	591	23 9/32	627	24 11/16
675	665	26 3/16	705	27 25/32
750	739	29 3/32	784	30 7/8
900	887	34 29/32	937	36 7/8
1050	1034	40 23/32	1087	42 13/16
1200	1182	46 17/32	1237	48 11/16
1350	1330	52 11/32	1387	54 5/8
1500	1478	58 5/32	1537	60 1/2
a The English dimension conversions are approximately converted from their metric counterparts.