FRANK PKS CIVIL CULVERTS

Designing and delivering trusted pipe solutions

FRANK PKS CIVIL CULVERTS2

To supply site specific underground infrastructure systems to store and move water, stormwater and wastewater. Our product ends up being a significant asset for councils to monitor and provide services to people for the next 100 years.

Our quality and certification of standards will be led by our people, systems and management through accountability, personal ownership and continuous improvement initiatives.

Andrew Howell General Manager

Transmission Gully

FRANK PKS CIVIL CULVERTS

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Contents

FRANK PKS CIVIL CULVERTS

Why choose Frank PKS Civil Culverts? .............................................. 4

Frank PKS Civil Culverts Range and Sizing ....................................... 4

Table 1: Pipe Sizing ......................................................................... 5

Load & Cover Capabilities .................................................................. 5

Table 2: Backfill Material Classifications ......................................... 6

Table 3: SN Rating Selection ........................................................... 6

PROJECTS

Puhoi to Warkworth Highway Upgrade .............................................. 8

Transmission Gully Highway Upgrade ................................................ 9

MANUFACTURING AND DESIGN COMPLIANCE

Design Compliance .......................................................................... 10

Static Load Questionnaire ................................................................ 10

Ring Stiffness Testing Compliance ................................................... 10

Installation Requirements ................................................................. 11

Figure 1: Trench Installation Zones and Dimensions..................... 11

Figure 2: Bank Installation Zones and Dimensions ....................... 11

Table 4: Trench/Bank Installation Dimensions Calculation ............ 11

FRANK PKS CIVIL CULVERTS4

Product AdvantagesFrank PKS culverts are an innovative and reliable product that have been successfully manufactured and installed in Europe since the 1950’s proving that it is fit for purpose with a high life expectancy. As part of the Frank GmbH group, the product has been manufactured and utilised in New Zealand for 14 years. Frank PKS culverts have many attributes that will assist all parties in the design and/or build process, therefore saving time and money:

• Long lengths are easier to install

• Low weight compared to other products

• Less joints results in less risk of leakage

• 100-year design life

• Increased flow rates due to low Manning’s roughness coefficient (0.009-0.012)

• High chemical resistance

• Reliable and easy to use rubber ring jointing system

• Easily fabricated into bends and manholes

Frank PKS Civil Culverts Range and SizingThe HDPE spiral wound pipe technology used to manufacture Frank PKS Civil Culverts makes it practical to manufacture various pipe sizes with specific SN (Ring Stiffness) ratings at a fraction of the weight of other products on the market, see Table 1 opposite. The high strength to weight ratio is due to the use of PP’s (Polypropylene’s) high stiffness to produce the core tube, which is then wrapped in HDPE material.

Frank PKS Civil Culverts

Frank PKS Civil Culverts are a line of robust and durable pipes that are manufactured in New Zealand from virgin HDPE (High Density Polyethylene) material. Frank PKS NZ Ltd is a family owned company that are the sole manufacturer of Frank PKS Civil Culverts that has been employing staff locally since 2005.

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Each pipe is formed on a steel mandrel 6.0m long with a socket mould fixed at one end, which allows a spigot to be formed at any particular length along the mandrel. The manufacturing process means the internal diameter (ID) is consistent with the steel mandrel and the pipe lengths can be manufactured at a maximum of 6.0m or less, to meet the customers required length, and it is cost effective to manufacture small lengths/runs of pipe.

Pipe Size – DN/Internal Diameter (mm)

SN Ratings Available (Ring Stiffness = kN/m2)

Ave. Weight per metre based on SN8 (kg/m)

Maximum Effective Length per pipe (mm)

300 SN4, SN8 & SN16 9.8 6,000

400 SN4, SN8 & SN16 12.8 6,000

500 SN4, SN8 & SN16 19.3 6,000

600 SN4, SN8 & SN16 23.0 6,000

700 SN4, SN8 & SN16 29.5 6,000

800 SN4, SN8 & SN16 33.2 6,000

900 SN4, SN8 & SN16 45.5 6,000

1000 SN4, SN8 & SN16 58.2 6,000

1100 SN4, SN8 & SN16 65.7 6,000

1200 SN4, SN8 & SN16 81.2 5,800

1400 SN4, SN8 & SN16 128.6 5,800

1500 SN4, SN8 & SN16 155.7 5,800

1660 SN4, SN8 & SN16 185.2 5,800

1800 SN4, SN8 & SN16 243.9 5,800

2000 SN4, SN8 & SN16 312.4 5,800

2500 SN4, SN8 & SN16 586.2 5,800

Table 1: Pipe Sizing

Load & Cover CapabilitiesFrank PKS Civil Culverts are designed to handle relatively large traffic/construction loadings and cover heights when installed in specific ground conditions.

Table 2 outlines the different soil classes that can be used as backfill material for Frank PKS Civil Culverts.

The G1, G2 & G3 materials are the most favourable as they are granular backfills and when compacted provide excellent side support for the pipe, meaning a lower strength pipe is required overall.

The G4 material is less favourable as it is a cohesive backfill and provides less side support for the pipe, creating the need for a higher pipe strength.

Frank PKS Civil Culverts

FRANK PKS CIVIL CULVERTS6

Embankment Cover Height (mm)

Pipe Traffic/Construction Loading

500 1,000 2,000 5,000 10,000 20,000

Design Loadings

0.85HN Loading(Non-Highway Loading)

SN4 & Above

SN4 & Above

SN4 & Above

SN4 & Above

SN4 & Above

SN8 & Above

HN-HO-72 Loading (Highway Loading)

SN16SN4 & Above

SN4 & Above

SN4 & Above

SN4 & Above

SN8 & Above

Plant Loading

Moxy MT41 – Max Wheel Load of 11.09T

SN8 & Above

SN4 & Above

SN4 & Above

SN4 & Above

SN4 & Above

SN8 & Above

Cat Scraper 637G – Max Wheel Load of 22.78T

SN16 SN16SN4 & Above

SN4 & Above

SN8 & Above

SN8 & Above

Table 3: SN Rating Selection

Note: Loadings and cover are based on G2 Backfill Material compacted to 95% with no groundwater. If soil is G3 or G4 contact Frank PKS NZ Ltd to carry out static calculation to determine SN rating

If you require further information in regards to the SN rating required, contact Frank PKS NZ Ltd to carry out a static calculation to see what pipe best suits the ground conditions and loading requirements.

Frank PKS Civil Culverts

Granular Backfill Cohesive BackfillG1 G2 G3 G4

• Graded Crushed Rock

• River Gravel and Beach Gravel

• Valley Sand

• Drift & Basin Sand

• Dune Sand

• Beach Sand

• Weathered Gravel

• Clayey Gravel

• Loamy Sand

• Liquid Sand

• Alluvial Clay

• Clay

• Loess

• Loam

• Alluvial Marl

Table 2: Backfill Material Classifications

Table 2 is a guideline as to what pipe SN rating is best for each setting and this meets and exceeds the design requirements outlined in AS/NZS 2566.1:1998 – Buried Flexible Pipelines Structural Design and installed to the requirements outlined in AS/NZS 2566.2:2002 – Buried Flexible Pipelines Installation.

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FRANK PKS CIVIL CULVERTS8

The Puhoi to Warkworth project is a large highway upgrade project that will extend the four-lane Northern Motorway (SH1) 18.5km to just north of Warkworth. It is the first stage of the Ara Tuhono - Puhoi to Wellsford Project.

The new motorway will provide increased safety, more consistent travel times, create a more robust and reliable road between Auckland and Northland, and provide a better freight connection between Northland and the Upper North Island. This is expected to support economic and population growth.

Over 1.3km of DN2500 and DN2000 Frank PKS Civil Culverts have been used on the project as a substitute for concrete pipes. Frank PKS Civil Culverts were selected for their lightweight nature, ability to handle large cover heights of more than 40metres and a reduction in installation costs.

The fact the Frank PKS Civil Culverts are a fraction of the weight when compared to concrete pipes, the contractor could use the excavators they had onsite for installation as opposed to hiring large and expensive cranes.

The location of the two culverts Franks PKS has supplied were in hard to reach locations. This meant it was considerably safer to carry in the lighter HDPE pipes. From a risk management/health & safety perspective this made Frank PKS Civil Culverts the better option than traditional concrete

Puhoi to Warkworth Highway Upgrade

Projects

Frank PKS Civil Culverts have been used on several large projects around New Zealand due to their ease of install and durability. They have saved contractors time on installation and given the asset owner a reliable system with reduced costs when compared to other pipe options.

Frank PKS Civil Culverts have also been used across New Zealand in stop banks for flood protection and under highways, airports, roads and access tracks.

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Transmission Gully is a major component of the Wellington Northern Corridor Road of National Significance and when fully completed will provide a safer, more reliable and more efficient highway connection from Levin to Wellington. The goal is to connect the city to the growing economic centres of Kapiti, Manawatu and the wider North Island. One of the most important aspects is that in the event of a major earthquake, it will be quicker to reinstate the Transmission Gully motorway than the existing State Highway 1.

Over 12km of Frank PKS Civil Culverts, ranging from DN300 to DN2500, were supplied to the Transmission Gully Project to be installed as culverts under the main alignment. The contractor found the long lengths meant less joints and less risk posed by culverts under the main alignment.

The ability to fabricate bends, reducers, Y junctions and manholes out of the Frank PKS Civil Culverts was taken full advantage of by the contractor, which meant they could build curved culverts under the alignment with no manholes or access shafts around the fabricated items.

On the project there were six Major Culverts that were designed to the NZTA Bridge Manual and required an FEM (Finite Elemental Modelling) analysis to be carried out on each individual pipe size to determine what SN rating would be able to handle some unique loading. The extremities of the design parameters on the six Major Culverts were:

• 27.00m of soil cover above the pipe

• 5.95m of groundwater above the pipe bed

• Ability to handle a major earthquake and minimise culvert deformation

• Allow for 0.1m of settlement over 6.0m

• High construction loadings of Moxy’s and Scrapers

The pipe sizes calculated to handle the above loads ranged from DN1500 to DN2500 and were installed with two different connection types, double rubber ring and integrated electro-fusion.

2 x DN2000 and 1 x DN2500 being installed. The photo was taken from finished design level.

Transmission Gully Highway Upgrade

FRANK PKS CIVIL CULVERTS10

Design ComplianceFor Frank PKS NZ Ltd to check that the PKS Civil pipe SN4, SN8 & SN16 ratings (ring stiffness) meet the design requirements of AS/NZS 2566.1:1998 – Buried Flexible Pipelines Structural Design, a Frank PKS Static Load Questionnaire (http://www.frankpksnz.com/download/) must be filled out by the customer outlining the cover height, loading and backfill materials. The static load information is incorporated with the appropriate parameters from AS/NZS 2566.2:2002 – Buried Flexible Pipelines Installation and entered in a pipe design software called EasyPipe98 which calculates an SN rating to the German ATV DVWK 127E Standard. The following proofs need to be checked to insure design compliance with AS/NZS 2566.1:1998 – Buried Flexible Pipelines Structural Design:

• Short-term deformation is less than 5%

• Long-term deformation is less than 7.5%

• Factor of safety against buckling is no less than 2.50

Upon request, PKS civil pipe can be designed to meet the NZTA Bridge Manual and FEM Analysis (Finite Elemental Modelling).

Static Load QuestionnaireThere are some critical parameters that need to be considered when filling out the Frank PKS Static Load Questionnaire that will have significant impact on the required SN rating of PKS Civil pipe. The critical parameters are:

• Trench Width – This can be specified if it is a requirement for the job, otherwise Frank PKS will determine the trench width in relation to the pipe OD to AS/NZS 2566.2:2002 – Buried Flexible Pipelines Installation.

• Groundwater Level – The ground water level is specified from the bottom of the trench. It is a critical aspect because the design process allows for the water to be at that level all of the time, meaning the forces on the pipe are always present.

• Pipe Bedding Support Angle – The pipe bedding support angle is determined by how far up the pipe the bedding material comes before compaction starts. If it comes all the way to 180°, or halfway up the pipe, it allows the pipe the best possible conditions and will lower the pipe strength required for the job, in turn lowering cost.

Ring Stiffness Testing ComplianceFrank PKS ensure that before manufacturing any pipe ring stiffness testing has been performed for the specific profile and pipe diameter ordered.

All previous tests are valid for up to 5 years. Ring Stiffness Tests are performed in accordance with ISO 9969: 2016 – Thermoplastics – Determination of Ring Stiffness. The ring stiffness testing is carried out inhouse with a hydraulic testing rig and test certificates can be supplied to all customers upon request and an independent third-party laboratory can oversee any testing at the customers expense.

Manufacturing and Design Compliance

Frank PKS Civil Culverts are manufactured in Christchurch, New Zealand by skilled machine operators and fabricators.

The product is manufactured in accordance with a Quality Management System (QMS) certified by SAI Global to comply with the requirements of ISO 9001:2015 – Quality Management Systems – Requirements. The QMS was last audited by SAI Global in May 2018 (Certificate No: QMS42476). A Quality Control team adheres to strict tolerances of pipe dimensions.

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Installation RequirementsPKS Civil pipe is required to be installed to AS/NZS 2566.2:2002 – Buried Flexible Pipelines Installation to help it meet and exceed its intended design life, whether its 50 or 100 years. See Figure 1 & 2 below that outline the zones and required dimensions around the pipe.

Table 4: Trench/Bank Installation Dimensions CalculationIt is important to ensure that the E1 & E2 zone is a gravel or sand material that is sufficiently compacted, to a minimum of 95%, in 300mm layers to support the sides of the pipe, which helps the pipe withstand the large loads that it is capable of withstanding.

In trench installations and bank installations, the pipe zones of E3 and E4 still need to be sufficiently compacted to a minimum of 95% as this benefits the pipe by acting as a solid surround for the E1 and E2 zones to be compacted against.

For further information or technical inquiries, please visit the downloads page on our website (http://www.frankpksnz.com/download/) or call 03 384 6294.

Minimum Embedment Zone Dimensions as per AS/NZS 2566.2:2002

(De) (mm) Pipe Outside Diameter(Lc) (mm) Minimum distance - Can be enlarged to fit compaction equipment

(B) (mm) Trench Width to AS/NZS 2566.2:2002 (B=De+2Lc)

>300 ≤450 200 700 - 850

>450 ≤900 300 1050 - 1500

>900 ≤1500 350 1600 - 2200

>1500 ≤4000 0.25D 2250 - 6000

Figure 1: Trench Installation Zones and Dimensions

Figure 2: Bank Installation Zones and Dimensions

Lc

300mm MIN

150mm MIN

Pipe Bedding Angle Can Vary

Lc

B

E3 E3De

E1 - Backfill

E4 - Native Soil

Top of E4 to be 11MPa

E2 Embedment Zone

Lc

300mm MIN

150mm MIN

Pipe Bedding Angle Can Vary

Lc

B

E3 - Haunching E3 - Haunching

De

E1 - Backfill

E4 - Native SoilTop of E4 to be 11MPa

E2 Embedment Zone

Frank PKS New Zealand Limited

80 Francella Street, Bromley, Christchurch 8062, New Zealand P +64 3 384 6294 | E enquiries@frankpksnz.com | W frankpksnz.com

DESIGNING AND DELIVERING TRUSTED PIPE SOLUTIONS