Method Statement for Construction of Box

Culvert
Scope:
Box culverts will commence with excavation to achieve desired level. A layer of lean concrete will be
placed to provide an even and clean surface on which to construct the culvert. Construction of the Box
culverts sections as approved shop/construction drawing will involve steel fixing, shuttering, transport of
concrete to the works and placing of concrete within the shuttering. Following the completion of the
concrete works, shuttering will be removed, the concrete will receive surface rendering and the culvert
backfilled, grouted rip rap in apron area and restoration of natural surface.
Materials:
 Class A1 approved concrete shall be used.
 Approved steel reinforcement of specified grade as per drawing/BBS shall be used.
 Concrete Spacer Block.
 Tying wire (16 gauge Annealed black wire).

Man Power:
 Engineer
 Foreman
 Surveyor
 Steel Fixer
 Carpenter
 Mason
 Concrete Pouring team

Note: Subcontractor shall be responsible for supplying some of above working personnel.

Formwork:
Formwork drawing with supporting system and load calculations shall be submitted as per NHA
Specification for approval.

Machinery
 Excavator
 Generator
 Concrete Batching Plant
 Transit Mixers
 Concrete Pump
 Plate and needle vibrators
 Water tanker
 Bar Bending Machine
 Bar Cutting Machine
 Tower Light
 Survey kit etc.
 Sequence of Work
 Survey
 Excavation
 Stone Soling
 Lean Concrete
 Bed Slab
 Wall
 Top Slab
 Cut off Wall
 Wing Wall

Procedure
 Centerline Fixing
The center line shall be marked with the help of Total station or electronic theodolite.
 Setting Out
Reference points shall be fixed on both sides of the culvert.
 Original Ground Levels
The original Natural ground level “NGL” shall be taken on the centerline and on either side of the
centerline of the culvert location to the required width and length as per the drawing. However, the
number of rows to be taken is depending on the width of the culvert.
 Excavation
Before starting of excavation proper Barricading (concrete barrier/plastic cone may be used) with
reflective tape & Precautionary sign boards shall be provided.
Excavation shall be carried out by excavator and excavated material shall be disposed to designated area
by dumper or tippers.
 Bed Preparation for Lean Concrete
Excavated bed shall be compacted and a plate load test shall be conducted to ensure Bearing capacity of
the bed as 1.5 to 2 ton/ft2 as stipulated in contract drawing.
On slushy bed after removing slush its earing capacity to confirm the plate load test as stated above.
Alternatively in case lean concrete is done on stone soling, a check/test shall be carried out to confirm no
settlement on application of stipulated load mentioned in the drawing as 1.5 to 2 ton/ft 2

 Lean Concrete
After approval of prepared bed, lean concrete shall be laid
 Base Slab
After curing period is over steel reinforcement shall be fixed on the lean concrete tied at all intersections
except that where spacing is less than 1 ft (0.3m) in each direction, alternate intersections need to be tied
as per drawing/ BBS. Spacer block shall be used to maintain cover to steel reinforcement rebars. Once
rebars is checked/approved shuttering shall be installed as per approved drawing. Having checked the
completed work by consultants, concrete shall be cast. Concrete shall be supplied from approved concrete
batching plant. Cylinder shall be taken for concrete strength as specified. Slump & temperature of
concrete shall be checked by the lab technicians at site. Curing shall be done for specified period.
 Walls
Steel reinforcement shall be erected as per drawing/BBS. Having checked by the consultants, shuttering
shall be erected and supported as per shop drawing. After approval of the work, wall shall be cast. Care
shall be taken for no segregation during pouring. Vibrator shall be used to achieve a compacted concrete.
Curing shall be done for specified period. Quality assurance work shall be done during concrete pouring.
 Top Slab
After erection of shuttering, steel reinforcement shall be fixed as per drawing/BBS. Having completed the
reinforcement and formwork checking, concrete shall be cast. All quality assurance procedure shall be
carried out as before.
Water curing shall be continued for specified period and shuttering shall be removed after specified
period.
 Construction of Wing Wall, Cut off Wall & Shear Key:
Work shall be carried out as per approved drawing as below
 Survey for location of cut off wall.
 Excavation shall be carried out for cut off wall as per approved drawing.
 Rebars erection for cut off wall & Formwork.
 Cast the cut off wall.
 After Cut off Wall construction, survey for footing of wing walls & Shear key shall be carried
out.
 Next, excavation shall be carried for wing walls, footing & shear key.
 Lean concrete for above footing & shear key on compacted bed (FDT shall be done as needed).
 Wing wall footings reinforcement & formwork erection as per approved drawing.
 Casting shear key & Footing wing walls.
 Next rebars erection for wing walls shall be done.
 Formwork erection.
 Casting wing wall.
 De shuttering after specified period.
 Curing as per specification.
 All quality assurance for concrete pouring during & after pouring shall be carried out as before.
 Head Wall:
These shall be constructed after completion of box culvert barrel construction.
 Grouted Rip Rap:
Grouted rip rap shall be carried out in apron area as per drawing.

NOTE 1:
Barrel of box culvert shall be cast in two half with an expansion joint in the center as shown on the
drawing.
Expansion joint preparation detail to be followed as per drawing.

NOTE 2:
Construction joint shall be scrabbled prior to next item casting.