Construction and

Design of HDPE Pipe

Under Rail Loading

By:
Joe Babcanec, PE
Advanced Drainage Systems, Inc. OTEC 2015
 Outline

Structural Design Guidelines

Standards and Acceptance
AREMA Acceptance / TTCI Testing
Installation Criteria
Sample Rail Projects
Culvert Rehabilitation (Slip Lining)
 National & International
Pipe Standards
ASTM
ASTM F 2306-11 (300-1500 mm HDPE)
ASTM F 667-12 (200-600 mm HDPE)
ASTM F 2648-11 (100-1500 mm HDPE)
ASTM F2736 (300 mm-750 mm Dual Wall PP)
ASTM F2764 (750 mm-1500 mm Triple Wall PP)
ASTM F881 (300 mm-1500 mm Dual Wall PP)
ASTM D2321-11 (Installation)
AASHTO
AASHTO M 252-09 (100-250mm HDPE)
AASHTO M 294-11 (300-1500mm HDPE)
AASHTO M330 (300 mm-1500 mm Dual Wall & Triple Wall PP)
CSA
B182.8-11 (100 -1500 mm HDPE)
B182.13 (300 mm -1500 mm Dual Wall & Triple Wall PP)
B182.11-11 (Installation)
OPSS
OPSS 1840 (100-1500 mm HDPE)
OPSS 1843 (300-1500 mm PP)
STRUCTURAL DESIGN
STRUCTURAL DESIGN
Rigid vs. Flexible Design Concepts
Structural Design Theory AASHTO LRFD
Load Resistance Factor Design
Service Limits
Deflection
Strength Limits
Wall Area
Buckling
Flexibility Limit
Structural Design of Rigid Pipe

Rigid pipe is designed

to resist shear and
bending moment in
the pipe wall

Rigid pipe cannot

deflect without
structural distress
 Structural Design of Flexible Pipe
Flexible pipe is designed to resist ring
compression the in pipe wall
Steel, aluminum and plastic pipes are
considered to be flexible, but they
fail at different deflection rates

Ductile Iron Metal Pipe PVC Pipe HDPE Pipe

Fails at 2% Fails at 10% Fails at 20% Fails at 40%
Deflection Deflection Deflection Deflection
Structural Design of Flexible Pipe

Ring Compression
STRUCTURAL DESIGN
Modes of Failure
Thermoplastic Pipe Design

AASHTO LRFD Bridge Design

Specification
Section 12 Buried Structures and
Tunnel Liners
Section 12.12 Thermoplastic
Pipes
Soil Structure Interaction Systems and
Soil Envelopes
Vertical Arching Factor (VAF) to
reduce loads
Thermoplastic Pipe Design
Flexible Pipe
Thermoplastic Pipe Design
 Why HDPE Pipe?

Excellent Performance
History (Since 1966)
Resists Corrosion (Stray Current)
Durable (Abrasion & Impact Resistant)
Industry Interest (AREMA)
 Installation
Recommendations
Trench Installation

Sub-Ballast
Note:
Reduce Max fill height by 1 for E-80 loading. Light rail and other commuter rail
loading conditions meet given values.
Use Class 1 or Class 2 backfill unless a geotechnical engineer verifies soil type, in
which case a Class 3 soil may be used for backfill, when ground water isnt present.
Do not use a Class IV Backfill.
 Minimum Cover
for Cooper E-80 Loading
Diameter Class 1 Class 2 Class 3
in (mm) Compacted 95% 90% 95%
2 2 2 2
4 to 24
(0.6) (0.6) (0.6) (0.6)
3.5 3.5 3.5 3.5
30 to 42
(1.1) (1.1) (1.1) (1.1)
4 4 4 4
48 to 60
(1.2) (1.2) (1.2) (1.2)
Foundations

Unstable foundations and embankments

will result in damaged or failed pipe.
Jointing (Installing HDPE)
Diagonally press backfill
into haunch zone of pipe
with boot.
Compact soil backfill
in 6 to 8 loose lifts
to 6 over top of pipe.
Make sure stone is worked
under the haunch of the
pipe.
Compact stone backfill
in 8 to 12 loose lifts
to 6 over top of pipe.
48 HDPE pipe Designed
w/ 2.5 of cover from top of
pipe to bottom tie.
Use lighter compaction
equipment until backfill
and embankment material
at least two feet over top
of pipe.
Larger construction equipment
may be used over pipe to
when fill is at 2 over pipe.
TTCI - FAST
Transportation Technology Center Inc.
Facility for Accelerated Service Testing
FAST Train 4 - Locomotives & 80 - 315,000 lbs (143,000kg) Cars
Passed over 2 - 48 HDPE pipes at 40 mph (64km/hr)
for 100 MGT
 AASHTO Cooper
H-25 or HS-25(1) E-80(1)
Live Load Transferred to Pipe, psi Live Load Transferred to Pipe, psi
Cover, ft. (m) (N/mm2) (N/mm2)
1(0.3) 15.63(0.108) N/R
2(0.6) 6.95(0.048) 26.39(0.1824)
3(0.9) 5.21(0.036) 23.61(0.1632)
4(1.2) 3.48(0.024) 18.40(0.1272)
5(1.5) 2.18(0.015) 16.67(0.1152)
6(1.8) 1.74(0.012) 15.63(0.1080)
7(2.1) 1.53(0.011) 12.15(0.0840)
8(2.4) 0.86(0.006) 11.11(0.0768)
10(3.0) Negligible 7.64(0.0528)
12(3.7) 5.56(0.0384)
14(4.3) 4.17(0.0288)
16(4.9) 3.47(0.0240)
18(5.5)
20(6.1)
Live Load 2.78(0.0192)
2.08(0.0144)
22(6.7) 1.91(0.0132)
24(7.3) 1.74(0.0120)
26(7.9) 1.39(0.0096)
28(8.5) 1.04(0.0072)
30(9.1) 0.69(0.0048)
35(10.7) Negligible
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Pipe 1

3 3
1 ~3.5 1
Pipe 2
 Pipe 2

Keeping bedding loose

in the middle 1/3 of trench

Project temperature
ranged from 12 degrees
Fahrenheit in the morning
to 78 degrees in the
afternoons.
Each pipe was
installed with a fabric
wrapped split
coupler and a WT
bell / spigot joint.
Each connection is
located directly
Pipe #1
under rail to
maximize loading.

Pipe #2
 Pipe #2 Pipe #1
Soil Backfill First foot over pipe - Compacted to 94% Stone Backfill
SPD with small vibratory roller.
Second foot over pipe Compacted to
98% SPD with loader and large
vibratory larger roller.
Train Loading and Test Results
 TTCI FAST - TEST RESULTS
After 96 MGT
Max. Deflection 1.26% (0.3 change)
Max. Circum. Short. 0.54% (0.4 change)
Max. Dynamic Deflection 0.14% (0.065)
Max. Compressive Strain 0.88% (0.15% change)
No Maintenance needed
Ride Quality Good
Pipe looked Excellent
 Conclusions:
The HDPE pipe and Soil Structure at
TTCI behaves elastically under the
FAST 315,000 lbs rail cars.
Corrugated HDPE pipe is an excellent choice for
use under Railroads provided it is installed with a
minimum ASTM D2321 Class III backfill at 95%
SPD, in a non-saturated condition. In saturated
conditions, only non-plastic soils must be used.

For Full TTCI Report go to:

http://www.ads-pipe.com/pdf/en/ttci_report-p-09-
052_final_ppi_polyethylene_pipe_testing_011810.pdf
AREMA added Corrugated
HDPE pipe to their
2012 -Manual for Railway
Engineering.
Railroad
Applications
February 22, 2012
Memphis, TN (Intermodal)
Birmingham, AL (Intermodal)
Charlotte, NC (Intermodal)
Greencastle, PA (Intermodal)
Mechanicsville, NY (Rail Yard)
Chicago, IL (63rd Street Yard)
Chicago, IL (47th Street Yard)
Passenger Rail
Culvert Rehabilitation
Railroad in Madison Indiana - 48 in Jasper, IN

Short Line
Railroad Utility Conduit
 Thank You!

Joe Babcanec, PE
Advanced Drainage Systems, Inc.
419-681-0459
Joe.babcanec@ads-pipe.com