8

Part 16

Design and Construction of Reinforced

Concrete Box Culverts

— 2006 —

TABLE OF CONTENTS

Section/Article Description Page

16.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-2 1

16.1.1 Scope (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-2
16.1.2 Units (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-3
16.1.3 Definition (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-3

16.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-4

16.2.1 Existing Foundation Material (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-4
16.2.2 Existing Embankment Material (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-4 3
16.2.3 Backfill and Bedding Materials (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-5
16.2.4 Concrete (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-5
16.2.5 Reinforcement (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-5
16.2.6 Miscellaneous Metal (2006). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-5
16.2.7 Miscellaneous Materials (2006). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-5

16.3 Design Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-6

16.3.1 Design Considerations (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-6
16.3.2 Design to Accommodate Flow (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-6
16.3.3 Structural Design (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-6

16.4 Design Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-6

16.4.1 General (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-6
16.4.2 Dead Load (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-7
16.4.3 Live Load (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-9
16.4.4 Impact Load (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-13
16.4.5 Other Forces (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-13

16.5 Details of Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-13

16.5.1 General (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-13
16.5.2 Wingwalls (2006). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-13
16.5.3 Barrel and Apron (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-13

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TABLE OF CONTENTS (CONT)

Section/Article Description Page

16.5.4 Longitudinal Reinforcement (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-15

16.5.5 Drainage and Waterproofing (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-15
16.5.6 Backfill (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-15

16.6 Manufacture of Precast Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-15

16.6.1 General (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-15
16.6.2 Manufacturing Tolerances (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-16
16.6.3 Physical Requirements (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-16
16.6.4 Marking (2006). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-17

16.7 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-17

16.7.1 Construction Tolerances (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-17
16.7.2 Joints (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-17
16.7.3 Waterproofing or Dampproofing (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-17
16.7.4 Handling Devices (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-17
16.7.5 Foundations (2006). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-18
16.7.6 Backfilling (2006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-18

Commentary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-19

LIST OF FIGURES

Figure Description Page

8-16-1 Uniformly Distributed Load to Top of Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-8

8-16-2 Distribution of Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-9
8-16-3 Design Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-10
8-16-4 Design Equations U.S. Customary Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-11
8-16-5 Design Equations Metric Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-12
8-16-6 Tongue and Groove Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-14
8-16-7 Male and Female Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-14
8-16-8 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16-18

SECTION 16.1 GENERAL

16.1.1 SCOPE (2006)1

a. This recommended practice governs the design and construction of precast or cast-in-place rigid frame reinforced
concrete box culverts on soil foundations.

b. This recommended practice does not apply to installations where the vertical dimension (H) from the top of the
structure to the base of rail is less than 18 inches (450 mm).

1
See Commentary

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 Design and Construction of Reinforced Concrete Box Culverts

c. This recommended practice does not provide for installation of precast units by jacking. Provisions for jacking must
be considered separately and in addition to the recommendations of this Part.

d. This recommended practice applies to installations beneath conventional ballasted track.

16.1.2 UNITS (2006)

This recommended practice uses U. S. customary units. The metric (SI) units in parentheses are approximate, and are
provided for information only.

ASTM Standard Specifications are cited, where available. Corresponding Metric ASTM International Specifications are
shown in parenthesis where available.

16.1.3 DEFINITION (2006)1

A box culvert is a structure which forms one or more rectangular openings through an embankment.

The size designation of a box culvert opening indicates first the width, followed by the height.

16.1.3.1 Notations

U.S. Metric
Customary Units
1
b The width of a box culvert opening. ft m
b´ The horizontal distance between center lines of box culvert ft m
walls.
h The height of a box culvert opening. ft m
h´ The vertical distance between center lines of box culvert ft m
top and bottom slabs. 3
H The vertical distance between the top of a box culvert and ft m
the base of rail.
H´ The vertical distance between the center of a box culvert ft m
opening and the base of rail.
I The impact load applied to the top of a box culvert, as a % %
percentage of WLL. 4
IS Moment of inertia of the box culvert top slab gross section, in4 mm4
per foot (meter) of culvert length.
IW Moment of inertia of the box culvert wall gross section, per in4 mm4
foot (meter) of culvert length.
ke The coefficient of active earth pressure of embankment fill none none
excluding surcharge loading.
ks The coefficient of active earth pressure of embankment fill none none
including surcharge loading.
k The ratio of S to R. none none
Ld Lateral live load distribution length illustrated in Figure 8- ft m
16-2.

1
See Commentary

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U.S. Metric
Customary Units
MA The maximum negative moment at the exterior corner of a kip.ft kN.m
box culvert per foot (meter) of culvert length.
MB The maximum positive moment in a box culvert top slab kip.ft kN.m
near the center of a culvert opening per foot (meter) of
culvert length.
MC The maximum negative moment in the top slab of a box kip.ft kN.m
culvert at the top of a center wall per foot (meter) of culvert
length.
Pe The uniformly distributed design load on the sides of a box lbs/ft2 kN/m2
culvert, excluding surcharge loading.
Ps The uniformly distributed design load on the sides of a box lbs/ft2 kN/m2
culvert, including surcharge loading.
R The ratio of b´ to h´. none none
S The ratio of Is to Iw none none
VA The maximum vertical shear in the top slab of a box lbs kN
culvert, at the face of support near an exterior corner per
foot (meter) of culvert length.
VC The maximum vertical shear in the top slab of a box lbs kN
culvert, at the face of support near a center wall per foot
(meter) of culvert length.
W The total uniformly distributed load on the top of a box lbs/ft2 kN/m2
culvert; a combination of WLL , WDL , and I.
WDL The uniformly distributed dead load on the top of a box lbs/ft2 kN/m2
culvert.
We Weight density of embankment fill taken as 120 lbs/ft3 lbs/ft3 kg/m3
(Mass density of embankment fill taken as 1900 kg/m3).
WLL The uniformly distributed live load on the top of a box lbs/ft2 kN/m2
culvert.
Ws Weight of concrete per square foot of top slab area (Mass lbs/ft2 kg/m2
of concrete per square meter of top slab area).

SECTION 16.2 MATERIALS

16.2.1 EXISTING FOUNDATION MATERIAL (2006)

The Engineer shall investigate the characteristics of existing foundation materials as recommended in Part 22, Geotechnical
Subsurface Investigation.

16.2.2 EXISTING EMBANKMENT MATERIAL (2006)

The Engineer shall investigate the characteristics of existing embankment materials in conjunction with existing foundation
conditions where existing embankment material will be excavated and reused.

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 Design and Construction of Reinforced Concrete Box Culverts

16.2.3 BACKFILL AND BEDDING MATERIALS (2006)

a. Backfill and bedding materials shall be subject to the approval of the Engineer. Wet or impervious materials shall not
be used except as outlined in Article 16.2.3 g, and all backfill and bedding shall be free from brush and other organic
materials.

b. Crushed stone for bedding shall consist of crushed rock graded such that 100% passes a 2 inch (50 mm) sieve, and
100% is retained on a 3/4 inch (19 mm) sieve.

c. Sand for foundation leveling shall consist of selected excavated sand, free from clay and organic materials, and free
from rock fragments exceeding 3/4 inch (19 mm).

d. Crushed stone placed around drainage pipes shall meet the same requirements for bedding, except that the Engineer
may specify a different grading.

e. Unless otherwise shown on the contract documents, structural granular backfill shall consist of well-graded granular
pit run gravel or crushed stone with 100% passing the 4-1/4 inch (106 mm) sieve and 100% retained on the Number
200 (75 μm) sieve.

f. Native or imported backfill materials not meeting the requirements of structural granular backfill may be used subject
to the approval of the Engineer.

g. Clay for seepage barriers shall consist of clay or silty clay of a medium to high plasticity and of a low permeability, all
subject to the approval of the Engineer. 1
16.2.4 CONCRETE (2006)1

a. The minimum compressive strength of concrete shall be 4000 psi (28 MPa) at 28 days.

b. Concrete materials shall comply with the requirements of Part 1, Materials, Tests and Construction Requirements that
affect the durability of the culvert, including alkali-aggregate reactions, sulfate and other chemical reactions, and 3
freezing and thawing. Use air entraining and other admixtures only when approved by the Engineer. Admixtures
containing chlorides shall not be used.

16.2.5 REINFORCEMENT (2006)

Reinforcing steel shall meet the requirements of ASTM 615 (A615M) Grade 60 (Grade 420), or ASTM A706 (A706M), or 4
welded steel wire fabric conforming to ASTM A497 (ASTM A497M), with an allowable tensile stress of 24,000 psi (165
MPa) for service load design.

16.2.6 MISCELLANEOUS METAL (2006)

All hardware for sleeves, anchor bolts, inserts and other hardware shall be either hot-dip galvanized in accordance with ASTM
A153, or epoxy coated in accordance with ASTM A775 (ASTM A775M), or stainless steel in accordance with ASTM A955
(A955M), as approved by the Engineer.

16.2.7 MISCELLANEOUS MATERIALS (2006)

a. Water stops shall meet the requirements of Part 1, Materials, Tests and Construction Requirements for watertight
construction joints.

1
See Commentary

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b. Gasket material shall conform to ASTM C990-03 Preformed Flexible Joint Sealant, as approved by the Engineer.

SECTION 16.3 DESIGN METHODS

16.3.1 DESIGN CONSIDERATIONS (2006)1

a. The design shall consider the following:

(1) The purpose of the structure.

(2) Depth of culvert from base of rail to invert level.

(3) Requirements for soil cover above the top of the structure and below the base of rail, as specified by the Engineer,
in addition to the requirements of these recommendations.

(4) Waterway alignment and skew angle.

(5) Subgrade width and embankment slopes.

(6) Existing foundation conditions.

b. For precast culverts, the design shall consider the following:

(1) Stresses induced by handling and transportation of units.

(2) Methods of installation.

(3) Methods of connecting sections of box culverts together to secure the units in their intended position.

16.3.2 DESIGN TO ACCOMMODATE FLOW (2006)

Calculation of flow rates and the design of the culvert and approaches to accommodate flows in accordance with Chapter 1,
Roadway and Ballast, Part 3, Natural Waterways.

16.3.3 STRUCTURAL DESIGN (2006)2

a. The design shall comply with all provisions of Part 2, Reinforced Concrete Design, except as modified in this part.

b. The structure shall be analyzed assuming that all joints between slabs and walls are rigid, with positive and negative
bending moments determined by the theory of elasticity.

SECTION 16.4 DESIGN LOADS

16.4.1 GENERAL (2006)

a. The design of box culverts supporting track shall consider the following loads:

1
See Commentary
2
See Commentary

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 Design and Construction of Reinforced Concrete Box Culverts

(1) dead load,

(2) live load,

(3) impact load.

b. The loads, uniformly distributed per square foot (per square meter) to the top of the box, are shown in Figure 8-16-1 for
various depths of fill.

16.4.2 DEAD LOAD (2006)1

a. The vertical dead load consists of the estimated weight of the track, fill, and top slab of the structure. Dead load shall be
determined from, and uniformly distributed to the culvert as shown on Figure 8-16-1 and Figure 8-16-2, respectively.

b. The minimum lateral pressure on the sides of the box shall be based on an assumed earth pressure coefficient of 0.33.

c. The maximum lateral pressure on the sides of the box shall be based on an assumed earth pressure coefficient of 1.0.

d. As an alternative to paragraph c, the Engineer may determine the maximum designed density of a fully saturated fill,
and the corresponding earth pressure coefficient that would apply, and use these in the calculation of both vertical and
lateral pressures from dead loads.

e. The lateral pressures on each side of the box may be assumed to be uniformly distributed over the entire height, equal
and opposite in direction. This assumption has been made in the design equations shown in Figure 8-16-4 and 1
Figure 8-16-5. If a more exact distribution is used, Figure 8-16-4 and Figure 8-16-5 do not apply.

1
See Commentary

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Figure 8-16-1. Uniformly Distributed Load to Top of Box

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 Design and Construction of Reinforced Concrete Box Culverts

16.4.3 LIVE LOAD (2006)1

a. Determine live load for each track in accordance with Part 2, Reinforced Concrete Design. Distribution of the live load
to the culvert shall be in accordance with Figure 8-16-2.

Ld

Figure 8-16-2. Distribution of Loads

3
b. No increase in live load shall be used for multiple track loadings.

c. Calculate the minimum lateral pressure induced from live load on the sides of the box using the earth pressure
coefficient determined by Article 16.4.2.

d. The maximum lateral pressures that may be generated on the sides of the box shall be considered in the design, except 4
that the earth pressure coefficient of Article 16.4.2 c need not be applied to live loads. If the provisions of
Article 16.4.2 d are used with respect to dead loads, then they shall be used for the calculation of maximum pressures
from live loads also.

1
See Commentary

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Concrete Structures and Foundations

Figure 8-16-3. Design Data

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 Design and Construction of Reinforced Concrete Box Culverts

Figure 8-16-4. Design Equations U.S. Customary Units

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Figure 8-16-5. Design Equations Metric Units

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 Design and Construction of Reinforced Concrete Box Culverts

16.4.4 IMPACT LOAD (2006)

a. Add impact load to the live load as determined from Figure 8-16-1 or Figure 8-16-4 or Figure 8-16-5, respectively, and
uniformly distributed to the culvert top slab in the same manner as the live load.

b. No impact shall be added to the lateral forces on the sides of the box.

16.4.5 OTHER FORCES (2006)

a. Centrifugal force, wind force, and longitudinal forces resulting from starting and stopping of trains need not be
considered.

SECTION 16.5 DETAILS OF DESIGN

16.5.1 GENERAL (2006)

a. The contract documents shall show construction elements in detail including dimensions, spacing and size of
reinforcement, permitted locations for the placement of handling devices and holes in the case of precast, construction
and expansion joints, water stops, waterproofing, and drainage. The maximum design foundation pressure shall also be
shown.
1
b. When it is anticipated that multiple culverts will be built, standardization of the design and construction details is
recommended.

c. The culvert shall be designed with a camber along its longitudinal axis where required by the Engineer, to counteract
the effects of settlement.
3
16.5.2 WINGWALLS (2006)

a. Wingwalls may be cast-in-place or precast.

b. Wingwalls shall have such slope and length as required to retain the embankment and maintain the culvert opening.

c. Wingwalls may be straight or flared, as local conditions and hydraulic design require. 4

16.5.3 BARREL AND APRON (2006)

a. The minimum concrete cover for reinforcement shall be 2 inches (50 mm) unless approved otherwise by the Engineer.
This requirement does not apply at the joints of precast units.

b. The same barrel section shall be used throughout, except under deep fills where a reduced barrel section may be used
toward the ends of the box. Consideration shall be given to the construction of future tracks.

c. Wall and top and bottom slab thicknesses shall be a minimum of 10 inches (250 mm), or as required by the Engineer.
Greater wall and slab thicknesses should be considered for cast-in-place construction to facilitate concrete placement.

d. A minimum haunch of 6 inches (150 mm) shall be provided.

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e. In long culverts, or culverts under deep fills, consideration should be given to the placement of joints to provide for
possible vertical and longitudinal movements of the barrel of cast-in-place culverts. If joints are used, the first joint
shall be not less than 10 feet (3 meters) from the end of the cast-in-place barrel. For cast-in-place construction, joints
should not be placed in regions of maximum stress.

f. Precast units shall be designed with tongue and groove or male and female ends such as shown in Figure 8-16-6 and
Figure 8-16-7 or as determined by the Engineer. The inside face reinforcement shall extend into the male portion of the
joint, and the outside face reinforcement shall extend into the female portion of the joint.

g. Where differential deflection from live load between units exceeds b/800, (where b is the width of the box opening)
joints between precast units shall be capable of transferring shear loads through the top slab between adjacent units by
a method or devices which may be mutually agreed upon by the box culvert manufacturer and the Engineer. If
individual shear connectors are used to fasten the adjacent top slabs together, they shall be spaced no more than 30
inches (750 mm) on center, with a minimum of two shear connectors per joint.

Figure 8-16-6. Tongue and Groove Joint

Figure 8-16-7. Male and Female Joint

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 Design and Construction of Reinforced Concrete Box Culverts

h. The floor of the barrel and apron may be sloped toward the center. Flow energy dissipation may be provided by
texturing the floor of the culvert if this is taken into account in the flow capacity design.

i. The surface of the top slab in contact with the backfill may be sloped toward the sidewalls for drainage.

j. The length of the apron, and rip-rap requirements, shall be determined by field conditions in accordance with Chapter
1, Roadway and Ballast.

k. Cutoff walls shall be used at inlet and outlet ends to a depth consistent with the field conditions and potential scour.

16.5.4 LONGITUDINAL REINFORCEMENT (2006)

a. The minimum longitudinal reinforcement in the top slab, bottom slab and walls shall be as follows:

(1) 0.4% of concrete cross sectional area for fill depths over the top of the top slab equal to or less than 10 feet (3
meters).

(2) For fill depths greater than 10 feet (3 meters), this percentage shall be increased proportionally to 1.0% for fills of
100 feet (30 meters).

b. The minimum reinforcement determined from paragraph a shall be provided half on each face of the slab or wall.

16.5.5 DRAINAGE AND WATERPROOFING (2006)1

1
a. Pipe drains in the backfill adjacent to the side walls shall be shown on the contract drawings when necessary.
Horizontal drain pipes shall be not less than 8 inches (200 mm) in diameter, perforated, and in such a position that they
will function properly. Provisions shall be made for cleaning drainage pipes.

b. Special provision may be made for waterproofing by use of non-corrosive water stops in accordance with Part 1,
Materials, Tests and Construction Requirements for watertight construction joints, and/or by use of a waterproofing
membrane in accordance with Part 29, Waterproofing. 3

16.5.6 BACKFILL (2006)

a. The limits of structural granular backfill shall be shown on the contract drawings.

b. Where structural granular backfill is not required, the Engineer shall specify the materials to be used. 4
c. When a seepage barrier is required, the details of its location and thickness shall be shown on the contract drawings.

d. The Engineer shall specify any other backfill details required.

SECTION 16.6 MANUFACTURE OF PRECAST UNITS

16.6.1 GENERAL (2006)

a. Manufacturer’s shop drawings shall be submitted to the Engineer for review and approval.

1
See Commentary

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b. Precast reinforced concrete culvert units shall be manufactured using steel forms and cured in accordance with Part 1,
Materials, Tests and Construction Requirements.

c. Concrete shall be placed by the wet cast method when air-entrainment is specified in the contract documents. When
air-entrainment is not specified, the precast reinforced concrete culvert units may be manufactured by the dry cast
method if approved by the Engineer.

d. Handling devices or holes shall be provided where shown on the contract drawings. Details of handling devices shall
be shown on the shop drawings and shall be subject to the approval of the Engineer, and shall also satisfy the
requirements of Article 16.7.4.

16.6.2 MANUFACTURING TOLERANCES (2006)

a. Opening Dimensions — The dimensions of the culvert opening shall vary by not more than +/– 1% from the
dimensions shown on the contract documents. Such variations shall also satisfy the requirements of Article 16.6.3 a.
The haunch dimensions shall vary by not more than 1/4 inch (7 mm) from the dimensions shown on the contract
documents.

b. Slab and Wall Thickness — The slab and wall thickness shall not be less than 95% of that shown on the contract
documents. A thickness more than that shown on the contract documents shall not be cause for rejection.

c. Length of Opposite Surfaces — Variations in laying lengths of two opposite surfaces of the box unit shall not be more
than 1/8 inch per foot (10 mm per meter) of span, with a maximum of 3/4 inch (20 mm) in any box unit, except where
beveled ends for laying on curves are specified on the contract documents.

d. Length of Precast Unit — The length of a precast unit shall vary by not more than 1/8 inch per foot (10 mm per meter)
of length from that shown on the contract documents with a maximum variation of 1/2 inch (12 mm) in any box unit.

e. Position of reinforcement — The maximum variation in the position of reinforcement shall be 3/8 inch (10 mm) from
that shown on the contract documents. In no case, however, shall the as-manufactured cover over the reinforcement be
less than 1-1/2 inch (40 mm) as measured to the internal surface or the external surface of the completed box unit
unless approved otherwise by the Engineer. This minimum cover limitation does not apply at the mating surfaces of
joints.

f. Area of Reinforcement — The areas of steel reinforcement shall be as required by the contract documents. Steel areas
greater than those required shall not be cause for rejection.

16.6.3 PHYSICAL REQUIREMENTS (2006)

a. The ends of the units shall be produced with joints as shown on the contract documents, and so formed that when the
units are laid together they will make a continuous line of box units with a smooth interior free of irregularities
exceeding 3/8 inch (10 mm) at the joints.

b. The manufacturer may use alternate joint details to those shown on the contract documents subject to the approval of
the Engineer.

c. When concrete is placed by the wet cast method concrete compressive strength shall be determined from cylindrical
concrete specimens made in conformance with ASTM Standard C39/C39M, and prepared in conformance with ASTM
Standard C31/C31M.

d. When units are manufactured by the dry cast method, cylinders shall be made in conformance with ASTM Standard
C361, Article 10.3.2.

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 Design and Construction of Reinforced Concrete Box Culverts

e. At least five test cylinders shall be prepared from each day’s production of concrete.

f. Compression test requirements shall be in accordance with ASTM Standard C361, Article 10.3.3.

16.6.4 MARKING (2006)

a. The following information shall be clearly marked on each box unit by indentation, waterproof paint, or other
approved means:

(1) Project name.

(2) Date of manufacture.

(3) Name or trademark of the manufacturer.

(4) Identification of the plant.

(5) Location number/match mark.

(6) Identification of top slab.

(7) Weight (mass) of unit.

SECTION 16.7 CONSTRUCTION

16.7.1 CONSTRUCTION TOLERANCES (2006)

The construction tolerances of Article 16.6.2 a, b, e, and f shall also apply for cast-in-place concrete.
3

16.7.2 JOINTS (2006)

a. Joints shall be located as shown on the contract drawings or as approved by the Engineer. Joints in cast-in-place box
culverts shall be formed as prescribed in Part 1, Materials, Tests and Construction Requirements.
4
b. Premolded bituminous filler at least 1/2 inch (12 mm) thick may be used at joints in cast-in-place box culverts.

c. Precast units shall be placed against previously completed units in such a manner as to assure an adequate seal.

16.7.3 WATERPROOFING OR DAMPPROOFING (2006)

a. Waterproofing, if any, shall be provided in accordance with Part 29, Waterproofing, or as specified by the Engineer.

b. Where no waterproofing is specified, the surface in contact with the backfill may be dampproofed. Dampproofing, if
any, shall be in accordance with the provisions of Part 29, Waterproofing.

16.7.4 HANDLING DEVICES (2006)

Following installation of precast units, and before waterproofing or backfilling, all protruding handling devices shall be
removed, and all holes and pockets shall be filled with a non-shrink grout approved by the Engineer.

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16.7.5 FOUNDATIONS (2006)1

a. The foundation requirements apply where the reinforced concrete box culvert is to be constructed by open cut.

b. Foundation conditions shall be inspected and approved by the Engineer.

c. Existing unsuitable foundation materials shall be excavated and replaced with new material as required by the
Engineer.

d. A compacted crushed stone bed shall be provided under precast reinforced concrete box culverts. The depth of the
crushed stone bed shall be a minimum of 12 inches (300 mm), and shall extend 12 inches (300 mm) on each side of the
precast reinforced concrete box culvert with a minimum one to one side slope as shown on Figure 8-16-8.

Figure 8-16-8. Backfilling

e. In cast-in-place construction, the crushed stone bed may be omitted if foundation conditions are favorable, as
determined by the Engineer.

f. The foundation surface upon which the reinforced concrete box culvert is to be supported shall be carefully graded to
the required line and grade. A well compacted sand layer not exceeding 4 inches (100 mm) in thickness may be
provided directly under a precast culvert, and on top of the crushed stone bedding, to facilitate this.

16.7.6 BACKFILLING (2006)

a. The backfilling requirements apply where the reinforced concrete box culvert is to be constructed by open cut.

b. Structural granular backfill shall be used for the entire backfill area unless shown otherwise on the contract drawings,
and except as required for:

(1) foundations, as recommended in Article 16.7.5; and

(2) drainage materials, as recommended in Article 16.2.3 d; and

(3) parallel installations as recommended by Article 16.7.6 c.

c. When reinforced concrete culverts are used in parallel for multicell installations, positive means of ensuring lateral
support shall be provided by grouting with non-shrink grout between the units or by filling the space between adjacent
units with compacted granular or cementitious material as approved by the Engineer.

1
See Commentary

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 Design and Construction of Reinforced Concrete Box Culverts

d. Backfill shall be placed alternately on each side of the box and deposited in layers not more than 12 inches (300 mm)
thick. The layers shall be horizontal or sloping away from the structure, with each layer carefully tamped.

e. Care shall be taken in selecting and placing the backfill to prevent damage when the exterior of the culvert has a
waterproofing coating or membrane. Protective cover material may be used to prevent damage to the waterproofing
system.

COMMENTARY

C - 16.1 GENERAL

C - 16.1.1 SCOPE (2006)

The design and construction of reinforced concrete box culverts having more than two openings may be modeled upon these
recommendations, but the design equations of Figure 8-16-4 and Figure 8-16-5 will not apply.

For culverts of more than two openings the effects of unbalanced loading or pattern loading should be considered.

The design of box culverts on pile or rock foundations is governed by support conditions, and box culverts on pile foundations
will require a special analysis because of these different support conditions. However, the design of box culverts on rock
foundations may be based on these recommendations if the Engineer ensures that there is sufficiently elastic backfill bedding
between the culvert and the rock.
1
The design and construction of reinforced concrete box structures having a vertical dimension from the top of the structure to
the base of rail of less than 18 inches (450 mm) may be modeled upon these recommendations, but the effects of impact
loading will require special determination. The design equations of Figure 8-16-4 and Figure 8-16-5 will not apply,
particularly with regard to impact.

Reinforced concrete box culvert installations will normally be by open cut, and the reference to jacking in Article 16.1.1 c will
not apply. 3
C - 16.1.3 DEFINITION (2006)

Box culverts are used principally for waterways, but may also be used as pedestrian or livestock underpasses, or for other
purposes.
4
C - 16.2 MATERIALS

C - 16.2.4 CONCRETE (2006)

Air entrainment should always be provided where concrete will be subjected to freeze-thaw cycles. To increase the
imperviousness of the concrete, air entrainment should also be considered in chemically aggressive environments including
dissolved sulfates, industrial effluent, and acid rain. Since the dry cast method is not compatible with air entrainment, the
Engineer should consider this when preparing the contract specifications.

The preparation of cylinders for determining concrete compressive strength differs for wet cast and dry cast concrete. The
Engineer should determine the methods employed by potential manufacturers when preparing the contract specifications.

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C - 16.3 DESIGN METHODS

C - 16.3.1 DESIGN CONSIDERATIONS (2006)

Shallow boxes or boxes without much fill may be subject to heaving depending on conditions of the soil below the box.

C - 16.3.3 STRUCTURAL DESIGN (2006)

A box culvert may be designed as a rigid “U” shape, with a top slab acting as a simple span without negative corner moments.
A box culvert may also be designed as an inverted U-shape and placed upon a separate footing slab. Design of such culverts
may be modeled upon these recommendations but the design equations of Figure 8-16-4 and Figure 8-16-5 will not apply.

C - 16.4 DESIGN LOADS

C - 16.4.2 DEAD LOAD (2006) and

C - 16.4.3 LIVE LOAD (2006)

Pressures applied to a box culvert will vary with soil moisture content, and over time with increased compaction under traffic.
To accurately account for these changes, it would be necessary to determine a range of soil density, earth pressure coefficients,
and hydrostatic conditions. These would then be applied in combinations to determine both maximum positive and maximum
negative moments.

Article 16.4.2 and Article 16.4.3 permit such an approach, but also offer a simplified method. The intent of Article 16.4.2 c
with regard to a maximum design earth pressure coefficient for the application of dead loads is to approximate the more
rigorous analysis of maximum negative moments.

C - 16.5 DETAILS OF DESIGN

C - 16.5.5 DRAINAGE AND WATERPROOFING (2006)

Waterproofing will not normally be required for reinforced concrete box culverts. However, the Engineer may require
waterproofing at special installations, such as where culverts are to serve as pedestrian underpasses.

C - 16.7 CONSTRUCTION

C - 16.7.5 FOUNDATIONS (2006)

The Engineer may determine that special foundation requirements should apply, for example, where precast culverts are to
serve as pedestrian underpasses. In such cases, grillage supports may be considered in order to control differential
displacements.

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