VIDEO INSPECTION AND LASER DEFLECTION TESTING FOR POST CONSTRUCTION QC/QA SPECIFICATIONS AND MAINTENANCE INSPECTIONS

VIDEO INSPECTION AND LASER DEFLECTION TESTING FOR POST CONSTRUCTION QC/QA SPECIFICATIONS AND MAINTENANCE INSPECTIONS BY JOHN FLECKENSTEIN PIPELINE AND DRAINAGE CONSULTANTS

INTRODUCTION History Of Post Construction Inspections Recent Specification Changes (New AASHTO Specification) Laser Deflection Testing and KY Case Studies Economic Cost/Cost Benefits and Maintenance Inspection Needs

Video Inspection Edge Drains (Mid 1990 s)

Failures Prior to Video Inspection/Quality Control History of Edge Drain Failure Rates Percent Failures 45 40 35 30 25 20 15 10 (Late 1980 s) Single Wall Flexible Outlet Pipe Double Wall Flexible Outlet Pipe With no Video Inspection (Early 1990 s) Double Wall Flexible Outlet Pipe With Video Inspection 5 0 Failures Prior to Cameras Failures After Design Changes (Mid 1990 s) Failures After QC Failures at Final Inspection

Quality Control and Quality Assurance Specifications for Cross Drains, Storm Drains, and Culverts Were Initiated in the Early 2000 s

Section 701.03.08 701.03.08 Testing of Pipe. The Engineer will visually inspect all pipe. The Department may require camera or mandrel testing, KM 64-114, for any pipe when deflection, cracking, joint faulting, or any other interior damage is suspected. If the pipe shows damage, repair or replace as the Engineer directs. If the pipe shows deflection of 10 percent or greater, remove and replace the pipe. If the pipe shows deflection greater than 5 percent but less than 10 percent, the Department will allow the pipe to remain in place at a reduced unit price. Do not pave over any pipe until inspection and any required testing is completed. When paving will not be delayed by the wait, test pipe 30 days or more after backfilling is completed. Developed in 2000 during QC/QA specifications, has not been widely enforced

Section 701.05 PIPE DEFLECTION DETERMINED BY CAMERA TESTING Amount of Deflection (%) Payment 0.0 to 5.0 100% of the Unit Bid Price 5.1 to 7.5 75% of the Unit Bid Price 7.6 to 8.5 50% of the Unit Bid Price 8.6 to 9.9 25% of the Unit Bid Price 10 or greater Remove and Replace PIPE DEFLECTION DETERMINED BY MANDREL TESTING Amount of Deflection (%) Payment 0.0 to 5.0 100% of the Unit Bid Price 5.1 to 9.9 50% of the Unit Bid Price 10 or greater Remove and Replace The Department will consider payment as full compensation for all work required under this section.

AASHTO SECTION 30.5.6 NEW INSPECTION REQUIREMENTS FOR HDPE PIPE (AS ADOPTED BY THE AASHTO SUBCOMMITTEE ON BRIDGES AND STRUCTURES JUNE 29, 2005) All pipes shall undergo inspection during and after installation. Final inspections shall be conducted no sooner than 30 days after completion of installation and final fill. The pipe shall be evaluated to determine whether the internal diameter of the barrel has been reduced more than 5 percent when measured not less than 30 days following completion of installation. For locations where pipe deflection exceeds 5 percent of the inside diameter, an evaluation shall be conducted by the Contractor and submitted to the Engineer for review and approval considering the severity of the deflection, structural integrity, environmental conditions, and the design service life of the pipe. Pipe remediation or replacement shall be required for locations where the evaluation finds that the deflection could be problematic. For locations where pipe deflection exceeds 7.5 percent of the inside diameter, remediation or replacement of the pipe is required. Installed pipe deflections that exceed 5 percent of the initial inside diameter may indicate that the installation was substandard. appropriate remediation, if any, will depend upon the severity of the deflection. In all pipe installations, at least 10 percent of the total number of pipe runs representing at least 10 percent of the total project footage on the project shall be randomly selected by the Engineer and inspected for deflection. Also, as determined by the 100 percent visual inspection in Section 30.5.6.1, all areas in which deflection can be visually detected shall be inspected for deflection.

AASHTO SECTION 26.5.7 NEW INSPECTION REQUIREMENTS FOR CMP (AS ADOPTED BY THE AASHTO SUBCOMMITTEE ON BRIDGES AND STRUCTURES JUNE 29, 2005) CMP shall be inspected after placement in the trench, as required during backfilling, and after completion of installation to ensure that final installation conditions allow the pipe to perform as designed. Final internal inspections shall be conducted on all buried CMP installations to evaluate issues that may affect long term performance. Final inspections shall be conducted no sooner than 30 days after completion of installation and final fill. It should be noted that the AASHTO Flexible Culvert Liaison Committee has been directed to write deflection criteria for inclusion in the installation specification for CMP next year.

AASHTO SECTION 27.6.1 NEW INSPECTION REQUIREMENTS FOR RCP (AS ADOPTED BY THE AASHTO SUBCOMMITTEE ON BRIDGES AND STRUCTURES JUNE 29, 2005) Internal inspections shall be conducted on all buried rigid pipe installations to evaluate issues that may affect long-term performance, such as cracks, joint quality and alignment. Inspections shall be conducted no sooner than 30 days after completion of installation and final fill. Hairline longitudinal cracks in the crown or invert indicate that the steel has accepted part of the load. Cracks equal to or less than 0.01 in. (0.25 mm) in width are considered minor and only need to be noted in the inspection report. Inspection records for pipes with crack widths exceeding 0.01 in. (0.25 mm), shall be kept on file for monitoring conditions during subsequent inspections. Crack measurements and photographs shall be taken for monitoring conditions during subsequent inspections.

New AASHTO VIDEO INSPECTION REQUIREMENTS Visual inspection of all structures, video inspect 24-inch and smaller Deflection testing on flexible pipes and crack testing on rigid pipes How do we measure and quantify?

Measuring Pipe Deflection

MANDREL TESTING Go-No-Go device. 5% Deflection. Stuck if deflection is exceeded. 30+Days Prior to Final Acceptance Takes two men approx. 10 minutes to do 100 yards.

Laser Deflection Testing

Laser Process

ClearLine Profiler Accuracy (inches) 120 Pipe Size (inches) 100 80 60 40 20 0 0.04 0.08 0.12 0.16 0.2 0.24 0.28 0.32 0.36 0.4 0.44 0.48 Accuracy (inches) Pipe Size (in) Accuracy (in) Percentage 8 0.04 0.5 16 0.08 0.5 24 0.12 0.5 32 0.16 0.5 40 0.2 0.5 48 0.24 0.5 56 0.28 0.5 64 0.32 0.5 72 0.36 0.5 80 0.4 0.5 88 0.44 0.5 96 0.48 0.5 The WRc (ref: PT/235/0904) has certified the ClearLine Profiler to accuracy of 1mm in 200mm pipe (0.5%) for manual measurements. Similar accuracy obtained for the automated graphs (Ovality, capacity etc).

36-Inch HDPE Pipe (MH 5 to MH 4) %Deflection 20.00 15.00 Horizontal Vertical Design Deflection Limits 10.00 5.00 0.00-5.00 0 25 50 75 100 125 150 175 200 225 250 275 300 325-10.00-15.00-20.00 Distance (Ft.)

Horizontal Deflection 10% Vertical Deflection Approx. 11%

CASE STUDIES MSD LOUISVILLE, KENTUCKY 12-INCH THROUGH 24-INCH STORM DRAIN MARCH 25, 2005

HDPE Pipe

Illinois Selinda Dr. Poplar Level

MH 1-MH 2

NOISE DEFLECTION DEFLECTION NOISE AND WATER

Laser Test Site No. 1, VIDEO/LASER DEFLECTION TEST SITE NO. 1 LOUISVILLE, KENTUCKY 36-INCH AND 42-INCH STORM DRAIN OCTOBER 12, 2004 Louisville, Kentucky

MH 6 Site Layout, Aireal MH 5 View MH 4 MH 3A MH 3 MH 2 MH 1 OUTLET

Laser Deflection 36-Inch Method HDPE Pipe Comparison (MH 3 to MH MH 2) 3 to MH 2 % Deflection 17.50 15.00 12.50 10.00 7.50 5.00 2.50 0.00-2.50-5.00-7.50-10.00-12.50-15.00 0 20 40 60 80 100 120 140 Distance (Ft.)

Laser Ring MH 3 to MH 2

Laser Ring MH 3 to MH 2 13.6% Change in Ovality % Ovality Change = 100 x Max I.D-Mean I.D Mean I.D

10.8% Ovality Change MH 3 to MH 2 Crown Flattening

14% Ovality Change MH 3 to MH 2 DIMPLING SHOWN AT 3 O CLOCK

8.1% Ovality Change MH 3 to MH 2

9.8% Ovality Change MH 3 to MH 2

36-Inch HDPE Pipe (MH 5 to MH 4) % Deflection 20.00 15.00 10.00 5.00 0.00-5.00-10.00-15.00-20.00 Horizontal Vertical Design Deflection Limits 0 25 50 75 100 125 150 175 200 225 250 275 300 325 Distance (Ft.) Measured Vertical Deflection -17.5% (-17.5%)

120 100 80 60 40 20 0 56 17 Estimated Percent of Pipe Deflected Over 5% and 10% 93 100 100 46 50 38 17 25 0 25 >5% Deflection >10% Deflection 53 7 89 23 Average MH 5 - MH 4 MH 4 - MH 3A MH 3A 0 MH 3 MH 3 - MH 2 MH 2 - MH 1 MH 1 - Outlet MH 6 - MH 5 % of Pipe De fle cte d

EVALUATION OF HDPE PIPE PERFORMANCE ON KENTUCKY DOT CONSTRUCTION PROJECTS

KY PROJECT LIST LOCATION FEET INSPECTED NICHOLASVILLE ROAD, LEXINGTON 983.6 US 68/KY 80, BOWLING GREEN 658.0 KY 210, HODGENVILLE 130.0 US 31E, HODGENVILLE 239.5 US 150, STANFORD 676.0 US 127, OWEN COUNTY 300.0 KY 207, FLATWOODS 905.0 3,727.1

58 ft. Deflection Approx. 6.6%

Deflection Approximately 8.3%

Bowling Green US 68/KY 80 Pipe Compressed and Racked

36 Cross Drain Bowling Green Approximately 14% deflection

Deflection Approximately 15%, Outfall Line

MH 1-Outlet Severe Pipe Deflection, 20 ft Deflection Approximately 20%

x MH 1-MH 2 Severe Crown Flattening in Cross Drain Near Manhole Vertical Deflection Approximately 11% US 31W, Hodgenville

x MH 2-MH 3 Failure 18-inch storm drain Deflection Approximately 50% US 31W, Hodgenville

Deflection Approx. 10% Median Drain, US 150, Stanford

Crown flattening, crack in crown MH1-MH2 18-inch cross drain Crown flattening and cracking at 41.5 ft. KY 210, Hodgenville

Estimated Vertical Deflection 11% KY 210, Flatwoods, KY

KENTUCKY PROJECT SUMMARY LOCATION DEFLECTION (MAX/MAX AVG) NICHOLASVILLE ROAD, LEXINGTON 10/6 US 68/KY 80, BOWLING GREEN 20/12.4 KY 210, HODGENVILLE 15/12.5 US 31E, HODGENVILLE 50/17.1 US 150, STANDFORD 10/9 US 127, OWEN COUNTY 4.2/3.5 KY 207, FLATWOODS 11/8.4 17/9.8

Culvert Evaluation on I-65, by KY Transportation Center RCP and Galvanized Metal Structures Inspected = 830 Structures Needing Remedial Action = 313 (37%) Structures Needing Repair or Replacement = 134 (16%) Structures Needing Cleaning/Possible Repair = 179 (21%)

Kentucky DOT is Currently Evaluating The Need For QC/QA Video Inspection Of All Drainage Structures. (Includes Pavement Edge Drains, Embankment/ Bench Drains, Bridge End Drains, Cross Drains, Storm Drains, Etc.)

Benefit/Cost of Video Inspection of Under Drains Cost Camera Inspection $0.25 ft - $0.35 ft Per Mile $1,320 mile - $1,848 mile 4 Lane inside and outside $5,280 - $7,392 mile Cost of Asphalt Overlay, 1 ½ AC - $50,000 mile 4 lane interstate overlay - $200,000 mile (not include shoulders and user delay cost) 1/4$ 3-7% Complete PCC Rehabilitation - $2,000,000 mile (Delayed by 10 years) $$$,$$$ $,$$$,$$$

CULVERT INSPECT COST VS. EMBANKMENT REPAIR COST $$$,$$$ 200 Embankment Repair $300 - $3,000 per linear ft. $60,000 - $600,000 (as >1.5 MILLION ) (Not Including Culvert Repair) $507.00 (Video Inspection $1.00 - $1.45 ft.) Total Cost = $507.00

Drainage Maintenance Inspection Needs (Need to Inspect, Clean, and Repair Existing Structures Prior to Failure)

The Economic Costs of Culvert Failures Transportation Research Board January 2004 Joseph Perrin Jr. Research Assistant Professor Civil Engineering Dept., University of Utah

Conclusions 1. Laser deflection provides significantly more Information than camera inspection alone. 2. Must set quality control video specifications for all drainage structures. 3. Must set deflection limits on flexible structures and crack limits on rigid structures. 4. Must Inspect, clean, and repair existing structures. 5. Reevaluate drainage specifications, and make changes where necessary to insure the longterm performance of the roadway system.

John Fleckenstein HighwayDrainage@AOL.com Cell: 859-393-4291