Box Culvert

Box Culvert is a reinforced concrete structure used as drainage under the road work. It is a small structure of less than
6m span between two wall and one slab.
Dimension details
• Box Culvert (3×2)
Upstream
• 1.2m thick sand filling
• 0.9 m granular filling
• 0.75m thick stone apron
• 150mm flat stone apron embedded in 300mm thick concrete
• Curtain Wall
Downstream
• 1.2m sand filling
• 0.8mm granular filling
• 100mm thick PCC on both ends
• 5m floor apron
• 6m flexible apron
• Curtain wall
• Cutoff wall : 300 mm thick and 2.5 m height on both sides
Fig.1.Sectional view of box culvert
 60m thick raft
450 mm thick slab and walls
600mm thick0m filter media
3.5m length of approach slab
65 mm wearing course

Grade of concrete

RCC - M30
PCC-M15
Cutoff wall - M40
Curtain wall and Toe wall -M20

Steel Fe 500 HYSD

Min dia bars:10mm
Max dia bars:16mm
Fig.2.Plan and section of box culvert
 Construction of box culvert
Machinery used for construction of box culvert

• Excavator
• Generator
• Concrete Batching Plant
• Transit Mixers
• Plate earth compactor
• Needle vibrator
• Water tanker
• Shuttering Plates, Centering plates, Supports
• Bar Bending Machine
• Bar Cutting Machine
• Tower Light
• Survey instrument
 Procedure for construction of box culvert
• Centerline Fixing: The place where the culvert exists shall be located and the center line shall be marked with the
help of Total station to lay pcc on compacted sand and granular filling.
•  
• Setting Out: Reference points have to fix on both sides of the culvert in both traffic and transverse direction.
•  
• Original Ground Levels: The original ground level (OGL) shall be taken on the centerline and either side of the
centerline of the culvert location to the required width and length as per the drawing.
•  
• Excavation : Before staring of excavation, proper barricading along with reflective marking with cautionary
signboards shall be provided.

Dumpers or tippers will help in loading excavated material by removing with help of an excavator. The excavated
portion shall be cleaned off if any slush.
•  
• Sand Filling: Fine to coarse sand shall be laid to the required length, width and thickness. The sand should be
compacted properly with earth plate compactor.
•  
• Levelling Course: The shuttering shall be thoroughly cleaned, aligned and marked to the required thickness.
•  
• Footing/Raft : The inert levels must be kept below the original ground level by at least 300mm.
The reinforcement shall be tied with reference to the centerline of the culvert and shuttering is placed with a
proper cover to the reinforcement.
The Concrete mix shall be laid layer by layer and compacted properly with needle vibrators.
Construction joints will be maintained as desired by providing a groove throughout the length of the wall.
Before placing the concrete slump and required no. of cubes are to be taken.
Proper care shall be taken while placing concrete to avoid develop of any honeycombs.
De-shuttering should be done once the concrete has been thoroughly set, and curing should require at least 14
days.

• Abutment Walls/Side Wall: The alignment of shuttering has to place properly. Additional supports shall be
given to skew wall inner and outer portion. Proper cover shall be maintained to the reinforcement.
•  
• Top Slab: By fixing the bottom level of the top slab, bottom shutters of the top slab to be placed on designed
vertical posts and gaps between shutters shall be packed carefully using masking tape.
Care shall be taken while placing the formwork in position to withstand the lateral loads coming onto the top slab.
After fixing the reinforcement in position concrete of specified grade shall be laid to the required thickness with
proper vibration. Crash barrier reinforcement to be fixed at this stage.
Curing shall be done for minimum 14 days.
 
• Backfilling & Filter Media: Filter media should be laid behind the return/wing walls as per specification. For
backfilling selected material should be laid behind the abutment walls to the top of the embankment upto
approach slab bottom as per specifications and it should be compacted properly.
 
• Approach Slab: The purpose of the approach slab is to lower the overall settlements of the embankment soil
beneath it and the rear wall.
The minimum length of the approach slab shall be 3.5m and 300mm thickness throughout the width of the road.
Road
 MCR( main carriageway)

Carriageway-7. 5m on both side

Median- 5m
Crust layers:

1 BC 40 mm

2 DBM 75 mm

3 WMM 250 mm

4 GSB 200 mm

Camber of 2.5% is provided (minimum)

SR( service road )
Width of serive road -7.5m
Crust layers:
1 BC 40 mm

2 DBM 60 mm

3 WMM 250 mm

4 GSB 200 mm

Camber of 2.5% is provided (minimum)

VUP
Dimensional details
VUP size (15x 26.5x 6)
Approach slab-3.5×10.5m×0.3m
Clear span -15m
Wall thickness-950mm thick
Bottom slab-950mm thick
Top slab-750mm
Wearing course-65mm
Filter media-600mm
Exp. Joint-20mm
Weep holes-100mm dia 1.2 with 1m spacing

Grade of concrete
Crash barrier-M40
RCC box-M30
RCC return wall/cut off wall-M30
Toe wall and curtain wall-M20
RCC course-M15
 
Steel Fe 500 HYSD bars
 Viaduct
No. of piles in each cluster:4
Dimension details
Pile-1.2m dia
Pile cap- 5.1mx 5.1mx 2m
Abutment, Abutment cap
Peir-1.9m dia
Pier cap
Pedestal
Bearing
Girder( PSC\ steel for ROB)
Deck slab-21m width
[Median -1. 5m, Service road-7. 5m, Footpath-1. 5m,
Crash barrier-0. 5m, Handrail-0. 25m]
 
Grades of concrete
 
PSC superstructures(30mspan) =M50
Deck slab =M40
Pedestal =M45
Crash barrier =M45
Fixed pier =M50
Free Pier, Pier Cap, & Pile Cap =M40
Pile =M35
PCC =M15
Other RCC work =M30

Steel –Fe 500D

Min dia bars :10mm
Max dia bars:25mm