SPP00595 (04-01-20) (This section requires SPP00530

and SPP00540. Requires SPP00591

when waterproofing membrane
is required.)

SECTION 00595 - REINFORCED CONCRETE BOX CULVERTS

Replace section 00595 of the Standard Construction Specifications with the following
section 00595:

Description

00595.00 Scope - This work consists of constructing cast-in-place reinforced concrete box
culverts, precast reinforced concrete box culverts, precast segmental reinforced concrete
box culverts, and precast reinforced concrete three-sided structures to the lines, grades,
and dimensions shown or directed. Each of these configurations of reinforced concrete box
culvert is referred to as RCBC herein.

00595.02 Definitions:

Box Section - For precast reinforced concrete box culverts, the box section is the individual
precast box culvert piece. For precast segmental reinforced concrete box culverts, the box
section is made of a top and bottom segment adjoined to form a complete box cross section
unit. For precast reinforced concrete three-sided structures, the box section is the individual
precast three-sided structure piece. Box sections are placed and joined together to
construct the reinforced concrete box culvert.

Box Segment - For precast segmental reinforced concrete box culverts, the box segment
is the individual piece (top slab, bottom slab, or U-shape) that is adjoined to the mating box
segment to form a box section.

00595.03 Design of Precast Sections - Perform design according to the current edition
of AASHTO LRFD Bridge Design Specifications.

Unless otherwise shown or specified, precast RCBC may be substituted in place of cast-in-
place RCBC. Precast substitution is not permitted for headwalls, wing walls, or for features
shown as using cast-in-place concrete.

Submit stamped design calculations and stamped working drawings, prepared by the
manufacturer, according to 00150.35. Include the following information:

• Structural analysis methods

• Structural design criteria and calculations
• Structure detail shop drawings
• Detailed plans including culvert geometry
• Line and grade layout
• Joint and connection details
 • Lifting devices

Submit a stamped installation plan, according to 00150.35. Ensure the installation plan is
consistent with the Plans, Specifications and the manufacturer’s design. Include the
following information:

• Methods and equipment to be used for handling

• Methods to ensure uniform bearing of the RCBC base
• Culvert installation
• Requirements for construction loads

Do not begin precast culvert fabrication or construction before receiving written approval
from the Owner’s Representative.

Materials

00595.10 Cast-in-Place Materials - For cast-in-place RCBC, cast-in-place ends, and cast
in place wing walls and aprons, furnish Materials meeting the following requirements:

Reinforcement............................................................00530
Concrete.....................................................................00540

Unless otherwise shown, provide Class 3300 - 1 1/2" or 3/4" portland cement concrete.

00595.11 Precast Materials - Furnish materials meeting the following requirements:

Concrete.............................................................................................02001
Deformed Bar Reinforcement........................................................02510.10
Precast Reinforced Concrete Box Culverts............................ASTM C1577
Precast Segmental Reinforced Concrete Box Culverts..........ASTM C1786
Precast Reinforced Concrete Three-Sided Structures..........ASTM C1504

Unless otherwise shown furnish joint sealing material per manufacturer design and meeting
one or more of the following requirements:

External Sealing Band.......................................ASTM C877

Preformed Flexible Joint Sealant......................ASTM C990
Rubber Gaskets..............................................ASTM C1677
Elastomeric Joint Sealant..................................ASTM C920

Unless otherwise shown, provide portland cement concrete according to the following:

Property Value
Air Entrainment 4.5 - 7.5%
Compressive Strength 5000 psi
Concrete Temperature 50 - 90° F
 Construction

00595.40 Cast-in-Place - Construct cast-in-place RCBC, cast-in-place ends, and cast in

place wing walls and aprons according to the following:

(a) Reinforcement - Place reinforcing steel according to section 00530.

(b) Portland Cement Concrete - Place portland cement concrete according to section
00540 and the following:

(1) Placing Concrete - Allow base slabs or box culvert footings to set at least 12
hours before constructing the remainder of the box culvert.

When constructing box culverts four (4) feet or less in height, the sidewalls and top
slab may be constructed as a monolith, with sidewalls constructed full height. If this
method is used, place construction joints vertical and at right angles to the axis of the
culvert.

When constructing box culverts more than 4 feet in height, place concrete in the walls
to at least the bottom elevation of the top slab. Allow three (3) days before placing the
top slab according to 00595.40(b)(2).

Construct each wing wall as a monolith.

(2) Removal of Forms and Falsework and Subsequent Loading - Remove forms
and falsework and place subsequent loading according to Table 00540-1 in section
00540.52.

(3) Concrete Finish - Finish all exposed concrete surfaces with a general finish
according to 00540.53(a).

00595.41 Precast - Fabricate precast boxes according to the following requirements

unless detailed otherwise:

Precast Reinforced Concrete Box Culverts............................ASTM C1577

Precast Segmental Reinforced Concrete Box Culverts..........ASTM C1786
Precast Reinforced Concrete Three-Sided Structures...........ASTM C1504

Prepare at least three acceptance test cylinders per day for each concrete strength used in
the production of box sections.

Expose cylinders to the same curing conditions as the manufactured box sections and keep
cylinders and box sections together until tested.

Transport members from the casting yard only after the following conditions have been met:

• Not less than seven (7) calendar days after casting,

• Not less than seven (7) calendar days after all concrete patching and repairing is
complete, and
 • After 28 calendar days compressive strengths have been achieved.

When the compressive strength of the cylinders tested does not conform to the acceptance
criteria stated in ASTM C1577, ASTM C1786, or ASTM C1504, as applicable to the precast
culvert type, the Owner’s Representative may allow retesting based on compression testing
of cores, reject the sections, or assess a price reduction according to 00150.25.

Be responsible for the safety of precast members during all stages of construction.

Provide structural connections at joints between all segments that fit together to form a
complete box section unit with a structural key or doweled connection. Provide a structural
keyway joint between all mating surfaces of adjacent box sections including adjacent top
slabs.

Align all joints. Staggered joints are not allowed.

Place a continuous flexible watertight seal in the joint, on the sides and top, between each
precast reinforced concrete box section. Install according to Manufacturer’s
recommendations.

Provide a 3/4 inch chamfer on all concrete edges unless otherwise noted.

00595.42 Precast Fabrication Tolerances - Shop assemble adjacent full RCBC sections
and match-mark adjacent sections before shipping. Sections not meeting the following
tolerances will be rejected:

• Precast Reinforced Concrete Box Culverts - Provide RCBC sections that meet the
permissible variations listed in ASTM C1577.
• Precast Segmental Reinforced Concrete Box Culverts - Provide RCBC sections
that meet the permissible variations listed in ASTM C1786.
• Precast Reinforced Concrete Three-Sided Structures - Provide RCBC sections
that meet the permissible variations listed in ASTM C1504.

00595.43 Defects in Precast Sections - Provide repair materials from the QPL according
to 02015.30.

Submit proposed repair plans and revised installation plan to the Owner’s Representative
for review and acceptance before performing the repairs. Provide written confirmation from
the RCBC Design Engineer of Record that the repair methods are appropriate.

Repair or replace damaged precast sections at no additional cost to the Owner, according
to the following criteria:

(a) Repair Cracked or Damaged RCBC - Repair cracked or damaged RCBC sections
when:

• Cracks 0.01 inch or wider and less than 12 inches long that do not pass through
the wall or slab thickness.
• Surface defects including honeycomb, bleedout, or spalls less than four
(4) percent of surface area of the box section face where the defect is located, or
 multiple surface defects with cumulative area less than 10 percent of the box
section surface where the defect is located.
• Chipped or spalled edges one (1) inch and greater in depth from the end of the bell
or spigot and not exceeding the depth of the joint provided the cumulative length of
chip or damage is not more 50 percent of the RCBC span or rise, whichever is
greater, and no individual length of chip or damage is more than 25 percent of the
structure’s span or rise, whichever is greater. The repaired sealing surface shall be
free of spalls, cracks, or imperfections that would adversely affect the performance
of the joint. Sections with chipped or spalled edges exceeding these values must
be replaced.

(b) Replace Cracked or Damaged RCBC - Replace damaged RCBC sections having
defects that that cannot be adequately repaired to full function or design life. Rejectable
defects include:

• Inadequate reinforcing cover

• Cracks that are full depth of the slab or wall thickness
• Any crack that would prevent making a satisfactory joint
• Surface defects including honeycomb, bleedout, or spalls having depth greater
than the size of the coarse aggregate, exposing reinforcing steel, and having a
defect area greater than four (4) percent of surface area of the face where the
defect is located, or multiple surface defects with cumulative area greater than
10 percent of the surface where the defect is located are cause for rejection.

(c) Minor Defects - Acceptable minor defects not requiring repair:

• A single end crack that does not exceed the depth of the joint.
• Cracks less than 0.01 inch wide and not passing through the wall or slab
thickness.
• A crack greater than 0.01 inch wide and less than 12 inches long that does not
pass through the wall or slab thickness.

00595.44 Precast Installation:

• Perform excavation, bedding and leveling course preparation, and backfill according
to 00510 and 00405 as applicable.
• Cushion RCBC installed over unyielding foundation, including concrete, to prevent
non-uniform bearing with a minimum three (3)-inch deep bedding and leveling course
of granular material meeting 00405.12. Spread the leveling course the width and
length of the RCBC plus a minimum six (6) inches all around. A concrete slab as
leveling course is not allowed.
• Use lifting, lowering, and pulling construction equipment according to the written
installation plan. Do not use excessive force or unapproved equipment to push box
sections into place. Handle box sections with care and prevent damage from
cracking, dragging, and impact.
• Ensure the prepared foundation surface provides uniform bearing and proper line and
grade for the RCBC. Do not rut or disturb the prepared foundation bedding and
 leveling course. If bearing, line and grade are not achieved, remove the RCBC
section and make foundation corrections.
• Maintain the ends of box sections free of any deleterious materials that would prevent
proper joining or sealing of adjacent sections.
• Assemble box sections within the following tolerances:
• Horizontal and Vertical Joint Variation - The maximum variation between mating
surfaces in any assembled transverse joint, between box sections before grouting,
shall be no more than 1/2 inch. The joint width shall vary no more than 3/8 inch
over the length of the joint.
• Longitudinal Surfaces - Fit box sections together to form a smooth, uniform line of
sections. The variation between internal surfaces of two adjoining precast box
sections shall not be more than 1/4 inch, measured with a 12-foot straight edge
across joints.

(Include the following bullet if welding is to be performed. Select the appropriate

00560.26(a) for bridge size culverts or 00560.26(b) for non-bridge culverts. Check
with the designer.)

• Perform structural steel welding according to section 00560.26.

00595.80 Measurement - The quantities of cast-in-place RCBC will be measured on the

length basis, along the centerline of the RCBC, from end to end as shown.

The quantities of precast RCBC will be measured on the length basis along the centerline
of the RCBC from end to end as shown, including cast in place ends.

No measurement of quantities will be made for wing walls and aprons. Estimated quantities
of concrete and reinforcement for wing walls and aprons will be listed in the Contract
Documents.

The estimated quantities of reinforcement and concrete for wing walls and aprons are:

(Fill in the appropriate amount of wing wall and apron reinforcement and
concrete. Obtain information from the Designer.)

Reinforcement Concrete
(Pound) (Cubic Yard)

Wing Walls ............................................... .............................................

Aprons ..................................................... .............................................

00595.90 Payment - The accepted quantities of work performed under this section will be
paid for at the Contract unit price, per unit of measurement, for the following items:

(Delete pay item(s) from the list that are not included in the Schedule of Items,
but do not change the alpha characters next to the pay items.)

Pay Item Unit of Measurement

(a) Cast-In-Place Reinforced Concrete Box Culverts...........Foot

 (b) Precast Reinforced Concrete Box Culverts....................Foot
(c) Precast Split Reinforced Concrete Box Culverts............Foot
(d) Precast Reinforced Concrete Three Sided Structures....Foot
(e) Wing Walls ................................................................Lump Sum
(f) Aprons.......................................................................Lump Sum

(Delete pay item letters from the following paragraph if those pay items are not
included in the pay item list above. Delete parentheses, "(s)" and "(and)" as
applicable. When more than one item is listed, move the word "and" to the
appropriate location.)

Item(s) (b), (c), (and) (d) include(s) (cast-in-place ends).

No separate or additional payment will be made for closure pours, weldments, and structure
connection systems; this work is included in payment made for the applicable items in
which they are used.

Payment will be payment in full for furnishing and placing all materials, and for furnishing all
equipment, labor, and incidentals necessary to complete the Work as specified.