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VIDEO INSPECTION AND LASER DEFLECTION TESTING FOR POST CONSTRUCTION QC/QA SPECIFICATIONS AND MAINTENANCE INSPECTIONS BY JOHN FLECKENSTEIN PIPELINE AND DRAINAGE CONSULTANTS
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
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)
0
5
10
15
20
25
30
35
40
45
Perc
en
t F
ailu
res
Failures Prior to
Cameras
Failures After
Design Changes
Failures After
QC
Failures at Final
Inspection
Failures Prior to Video Inspection/Quality Control
Single Wall Flexible Outlet Pipe
Double Wall Flexible Outlet Pipe
With no Video Inspection
Double Wall Flexible Outlet Pipe
With Video Inspection
(Late 1980’s)
(Early 1990’s)
(Mid 1990’s)
History of Edge Drain Failure Rates
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
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.
Section 701.05
AASHTO SECTION 30.5.6NEW INSPECTION REQUIREMENTS FOR HDPE PIPE(AS ADOPTED BY THE AASHTO SUBCOMMITTEE ON BRIDGES AND STRUCTURES – JUNE 29, 2005)
AASHTO SECTION 30.5.6NEW 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 measurednot 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 andsubmitted 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.
� 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 measurednot 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 andsubmitted 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 26.5.7NEW INSPECTION REQUIREMENTS FOR CMP
(AS ADOPTED BY THE AASHTO SUBCOMMITTEE ON BRIDGES AND STRUCTURES – JUNE 29, 2005)
AASHTO SECTION 26.5.7NEW 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.
� 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 27.6.1NEW INSPECTION REQUIREMENTS FOR RCP
(AS ADOPTED BY THE AASHTO SUBCOMMITTEE ON BRIDGES AND STRUCTURES – JUNE 29, 2005)
AASHTO SECTION 27.6.1NEW 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 pipeinstallations 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.
� Internal inspections shall be conducted on all buried rigid pipeinstallations 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 TESTINGMANDREL 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.
� 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)
0
20
40
60
80
100
120
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)
Pip
e S
ize (
inch
es)
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)
-20.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
20.00
0 25 50 75 100 125 150 175 200 225 250 275 300 325
Distance (Ft.)
% D
eflection
Horizontal Vertical Design Deflection Limits
Horizontal Deflection 10%Vertical Deflection Approx. 11%
CASE STUDIES
MSD LOUISVILLE, KENTUCKY
12-INCH THROUGH 24-INCH
STORM DRAIN
MARCH 25, 2005
HDPE Pipe
Selinda D
r.
Poplar L
evel
Illinois
MH 1-MH 2
NOISEDEFLECTION
DEFLECTIONNOISE AND WATER
Laser Test Site No. 1,
Louisville, Kentucky
Laser Test Site No. 1,
Louisville, KentuckyVIDEO/LASER DEFLECTION
TEST SITE NO. 1
LOUISVILLE, KENTUCKY
36-INCH AND 42-INCHSTORM DRAIN
OCTOBER 12, 2004
Site Layout, Aireal ViewSite Layout, Aireal View
OUTLET
MH 1
MH 2
MH 3
MH 4
MH 5
MH 6
MH 3A
36-Inch HDPE Pipe (MH 3 to MH 2)
-15.00-12.50-10.00-7.50-5.00-2.500.002.505.007.50
10.0012.5015.0017.50
0 20 40 60 80 100 120 140
Distance (Ft.)
% D
eflection
Laser Deflection Method Comparison 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
Laser Ring MH 3 to MH 2
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)
-20.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
20.00
0 25 50 75 100 125 150 175 200 225 250 275 300 325
Distance (Ft.)
% D
efl
ec
tio
n
Horizontal Vertical Design Deflection Limits
Measured Vertical
Deflection -17.5% (-17.5%)
Estimated Percent of Pipe Deflected
Over 5% and 10%
56
93
100
25
100
38
53
89
17
46
17
0
50
25
7
23
0
20
40
60
80
100
120
MH 6 - MH 5
MH 5 - MH 4
MH 4 - MH 3A
MH 3A 0 MH 3
MH 3 - MH 2
MH 2 - MH 1
MH 1 - Outle
t
Average
% o
f P
ipe
De
fle
cte
d
>5% Deflection
>10% Deflection
EVALUATION OF HDPE PIPE PERFORMANCEON 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%
Pipe Compressed and Racked
Bowling GreenUS 68/KY 80
Approximately 14% deflection
36” Cross Drain Bowling Green
Deflection Approximately 15%, Outfall Line
MH 1-Outlet
Severe Pipe Deflection, 20 ft
Deflection Approximately 20%
MH 1-MH 2
Severe Crown Flattening in Cross Drain
Near Manhole Vertical Deflection
Approximately 11%
US 31W, Hodgenville
x
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 Benefit/Cost of
Video Inspection of Under DrainsVideo Inspection of Under Drains
Cost Camera InspectionCost Camera Inspection $0.25 ft $0.25 ft -- $0.35 ft$0.35 ft
Per Mile $1,320 mile Per Mile $1,320 mile -- $1,848 mile$1,848 mile
4 Lane inside and outside 4 Lane inside and outside $5,280 $5,280 -- $7,392 mile$7,392 mile
Cost of Asphalt Overlay, 1 Cost of Asphalt Overlay, 1 ½½ AC AC -- $50,000 mile$50,000 mile
4 lane interstate overlay 4 lane interstate overlay -- $200,000 mile$200,000 mile
(not include shoulders and user delay cost)(not include shoulders and user delay cost)
Complete PCC RehabilitationComplete PCC Rehabilitation -- $2,000,000 mile$2,000,000 mile
(Delayed by 10 years)(Delayed by 10 years)
1/4$
$,$$$,$$$
Cost Camera InspectionCost Camera Inspection $0.25 ft $0.25 ft -- $0.35 ft$0.35 ft
Per Mile $1,320 mile Per Mile $1,320 mile -- $1,848 mile$1,848 mile
4 Lane inside and outside 4 Lane inside and outside $5,280 $5,280 -- $7,392 mile$7,392 mile
Cost of Asphalt Overlay, 1 Cost of Asphalt Overlay, 1 ½½ AC AC -- $50,000 mile$50,000 mile
4 lane interstate overlay 4 lane interstate overlay -- $200,000 mile$200,000 mile
(not include shoulders and user delay cost)(not include shoulders and user delay cost)
Complete PCC RehabilitationComplete PCC Rehabilitation -- $2,000,000 mile$2,000,000 mile
(Delayed by 10 years)(Delayed by 10 years)
$$$,$$$
3-7%
CULVERT INSPECT COST VS.
EMBANKMENT REPAIR COST
(Video Inspection $1.00 - $1.45 ft.)
Total Cost = $507.00
200’ Embankment Repair
$300 - $3,000 per linear ft.
$60,000 - $600,000
(as >1.5 MILLION )
(Not Including Culvert Repair)
$$$,$$$
$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 long-
term performance of the roadway system.
