Laboratory test and design methods of horizontal-ellipse corrugated-steel-plate–utility-tunnel with varying top–side plate ratios

Corrugated steel-plate culverts, particularly in horizontal ellipse form, are commonly used in large-span projects. Despite the guidelines on plate radius ratios, the impact of these ratios on mechanical properties remains unexplored. This gap highlights the need for research to guide utility tunnel design because existing studies mainly focus on round culverts compressed into elliptical shapes. Therefore, this study conducted backfill, simulated vehicle live load, and ultimate-load tests on two horizontal-ellipse corrugated steel utility tunnel structures with different top-side plate ratios to examine their response characteristics under various load conditions. Moreover, they were compared with those of existing design methods to offer new insights for the design analysis of soil–steel structures. The results demonstrated that the ratio significantly influenced bending moment distribution, and the critical section was concentrated beneath the loading pad for live loads. The ultimate capacity varied with the ratio, with the higher ratio specimen reaching approximately 92.5 % of the capacity of its counterpart. Both specimens failed via tri-plastic hinge mechanisms, with reduced capacity as corrugations flattened. The Canadian Highway Bridge Design Code, which considers thrust force and bending moment, accurately predicted bearing capacity than the other methods in this study. These findings are vital for optimising design and ensuring safety in horizontal-ellipse corrugated steel utility tunnels.