Standard Specification 1991

Foreword

This specification has been prepared by the Box Culvert Association after
discussion with interested users. It has been written to be compatible with the
requirements of BS 8110. It will also serve as a supplement to BS 5400 as
modified by the standards of the Highways Agency and to the standards of
other specifying authorities.

The specification can be used for the standard sizes of culvert recommended
by the Association and for other sizes within the practical limits for transport,
generally up to 6000 wide and up to 3600 high.

It is important that sufficient information is provided to the manufacturer for the

customer's requirements to be fully understood. The check list given in
Appendix A should ensure that nothing of importance is overlooked.

Installation of box culverts is not covered by this standard but

recommendations are given in the Association's publication, "A Guide to Site
Practice".

In drafting this specification it has been assumed that it will be used by

qualified engineers with experience of box culvert design and the ability
to recognise any special circumstances which would warrant a
departure from the standard.
Contents

Foreword
1. Scope
2. References
3. Definition
4. Concrete materials
5. Steel reinforcement
6. Concrete
7. Spacers
8. Manufacture
9. Geometry
10. Surface finish
11. Marking
12. Structural design
13. Characteristic vertical load
14. Characteristic horizontal load
15. Design loads - BS 8110
16. Design loads - BS 5400
17. Analysis
18. Differential settlement
19. Design strength
20. Stability
21. Reinforcement of inner wall faces
22. Horizontal surface loads
23. Temperature effects
24. Deflection of roof slab
25. Aprons, wing walls and parapets
26. Compliance certificate
Appendix A: lnformation checklist
Appendix B: Compliance certificate
References
1. Scope
This document specifies the requirements for precast concrete box culverts
with an internal width not exceeding 6000 and an internal height not
exceeding 3600. All dimensions are in millimetres unless shown otherwise.

2. References

The titles of publications referred to in this specification are listed at the end of
this page.

3. Definition

Box culvert: A precast concrete unit with a clear opening of rectangular shape
which may have internal splayed corners.

4. Concrete materials

4.1 Cement

Cement shall comply with one of the following:

Ordinary and rapid-hardening Portland - BS 12

Portland-blastfurnace - BS 146
Sulphate-resisting Portland - BS 4027
Portland pulverised-fuel ash cement - BS 6588
Combinations of Portland cement to BS 12 with.-
(a) Pulverised-fuel ash - BS 3892 Part 1
(b) Ground granulated blastfurnace slag - BS 6699

Where combinations of Portland cement with pulverised-fuel ash or ground

granulated blastfurnace slag are used, they shall comply with the limits given
in BS 6588 or BS 146 respectively.

4.2 Aggregates

Coarse aggregates shall comply with BS 882. The nominal maximum size
shall not exceed 20, the flakiness index shall not exceed 35% and the ten per
cent fines value shall be not less than 100kN. Fine aggregates shall comply
with either BS 882 or BS 3892. Shell content shall not exceed 5% for coarse
aggregate or 30% for fine aggregate. The manufacturer shall be permitted to
modify gradings to suit the process.

4.3 Water

Water shall be clean and free from harmful matter in such quantities as would
affect the properties of the concrete in the plastic or hardened state.
4.4 Admixtures

Any admixtures used shall comply with the relevant part of BS 5075. Calcium
chloride or admixtures based on calcium chloride shall not be used.

5. Steel Reinforcement

Steel reinforcement shall comply with one of the following:

Carbon steel bars for the reinforcement of concrete - BS 4449

Cold reduced steel wire for the reinforcement of concrete - BS 4482
Steel fabric for the reinforcement of concrete - BS 4483

6. Concrete

6.1 General

The fully compacted concrete shall have:

A minimum cement content of 350 kg/m3.

A maximum free water/cement ratio of 0.5.
A lowest grade of C40.
A total chloride content expressed as a percentage of chloride ion by
weight of cement not exceeding 0.1%.
A total water-soluble sulphate content expressed as SO3 not exceeding
4%.
An air content of 5% 1.5% when air entrainment is specified and
nominal maximum aggregate size is 20.

Other limits apply to higher grade concrete and to sulphate-resisting concrete.

6.2 Control of alkali silica reaction

In order to control the possibility of alkali silica reaction, either of the following
conditions shall be met:

The alkali content of the concrete shall not exceed 3.0 kg/m3.
The aggregates, both coarse and fine, shall be of a non-reactive
nature.

In Great Britain, basalt, gabbro, granite, gritstone, hornfels, limestone,

porphyry and schist groups as defined in BS 812: Part 1 have been classified
as non-reactive. When the proportion of chert or flint is greater than 60% by
weight of the total aggregate, it shall also be considered to be non-reactive
provided it contains no opal, tridymite or cristobalite.
6.3 Sampling

Samples of concrete shall be taken at a rate of one per 20 m3 or one per 20

batches, whichever is the lesser. Cubes from these samples shall be
prepared and tested for compressive strength in accordance with BS 1881.

7. Spacers

Bar spacers shall be used to ensure correct cover and they shall be of
adequate strength to resist loads imposed during manufacture. They shall be
of concrete mortar (which may be fibre reinforced) to a specification
compatible with the culvert concrete or, when used against vertical formwork
only, they may be of plastic with perforations of not less than 25% of their
area.

8. Manufacture

8.1 Work in cold weather

Materials and formwork shall be free from snow, ice and frost and concrete
when placed shall have a temperature of at least 5C which shall be
maintained until the concrete reaches a strength of 5N/mm2.

8.2 Curing

Exposed surfaces shall be protected from wind and low humidity until the
concrete has reached sufficient maturity for lifting and storage. Accelerated
curing may be used with a temperature increase and subsequent cooling rate
not exceeding 10C per hour and a maximum concrete temperature of 70C.

8.3 Reinforcement cages

Reinforcement shall be cut and/or bent in accordance with BS 4466 and shall
be assembled into cages and fixed by tack welding or by using soft annealed
iron or stainless steel tying wire.

Tack welding may be employed only on steel complying with BS 4449 and the
welding procedures shall comply with BS 7123. Tack welds shall be of short
length (as permitted by clause 11.6 of BS 7123) sufficient only to provide
adequate stiffness to the reinforcement cage during handling and concrete
placing.

8.4 Cover

Nominal cover shall be provided to the steel as indicated in BS 8110 (or BS

5400 where design to this standard is specifically requested). Where,
exceptionally, a nominal cover is requested higher than the nominal cover
required for the specified exposure condition, the lower cover shall be used in
the calculation of design crack width. The Severe condition of exposure shall
be assumed unless otherwise specified.
8.5 Lifting arrangements

Units shall be provided with lifting points such that they may be safely lifted by
crane.

9. Geometry

9.1 Nominal sizes

Box culverts shall be described by their nominal internal size which shall be
their manufacturing dimensions in millimetres expressed in the sequence:
width of opening x height of opening.

9.2 Corner splays

The opening may be provided with corner splays which reduce the
rectangular area by not more than 10%.

9.3 Joints

Units shall have rebated or keyed joints. For the type of rebated joint
illustrated, the spigot and socket shall have a thickness of not less than 45 at
the root and a length of not less than 45 or more than 105 but not exceeding
one and a half times the root thickness. Early casts from each mould shall be
checked to ensure that joints fit satisfactorily.

9.4 Permissible deviations

9.4.1 Dimensions

The maximum permissible deviation from the manufacturer's mean

dimensions shall be as follows:

Wall thickness 6.
Width and height of opening up to 3000 6; 3000 to 4500 9; 4500 to
6000 12.
Length of unit 12.
9.4.2 Flatness

The maximum deviation from a 1500 straight edge placed in any position on
an internal surface shall not exceed 6.

9.4.3 Squareness

The side of the opening shall not vary in its distance from the perpendicular to
the top or bottom so that the difference between the greatest and shortest
dimensions exceeds:

6 for heights up to 1200

9 for heights 1200-1800
12 for heights over 1800

9.4.4 Twist

Any corner shall not be more than 12 from the plane containing the other
three corners.

9.4.5 Cumulative effect

Deviations can be cumulative and the overall effect may need to be

considered.

10. Surface finish

Moulded surfaces may be slightly imprinted by the grain or joints in the mould
materials. Small blemishes caused by entrapped air or water may be
expected but the surface shall be free from voids, honeycombing or other
large blemishes.

11. Marking

Each unit shall be clearly identified so that the manufacturer can trace its date
of manufacture, specification and design.

12. Structural design

Box culverts shall be designed to resist the worst co-existent combination of

vertical load acting on the roof and floor and horizontal load acting on the
walls. Load combinations shall be considered at maximum and minimum fill
depths; intermediate depths need not be considered.

It is recommended that the minimum fill depth should be not less than 200 or
one-fifteenth of the internal width of the box culvert if greater.
13. Characteristic vertical load

13.1 Surface load

Surface load may be specified as a uniformly distributed load extending over

a limited or unlimited area; a line load; a point load; a wheel load with an
associated contact pressure; or any group or combination of such loads.
However, in most cases it is sufficient to specify a standard loading. Field
loading and types HA and HB highway loading shall be as described below.
Where loads from construction plant are imposed at shallow fill depth without
protection of the box culvert, it may be necessary to specify an increased
surface load.

13.2 Field loading

Two wheel loads 1000 apart, each of 60kN including impact allowance.
Contact pressure is 0.4N/mm2.

13.3 Type HA highway loading

A single wheel load of 100kN including impact allowance. Contact pressure is

1.1N/mm2. When the fill depth does not exceed 600, the following alternative
shall also be considered: a uniformly distributed load of unlimited extent
having an intensity of

plus a 120 kN knife edge load of 3.65m length applied in any position, both
loads including impact allowance. In all cases, the alternative of 30 units of
type HB loading (see 13.4) shall be considered where it produces a more
severe load effect.

13.4 Type HB highway loading

Eight wheel loads with four wheels at 1000 centres on each of two axles 1800
apart. Each wheel load including impact allowance is equal to 2.5kN multiplied
by the specified number of HB units. Contact pressure is 1.1 N/mm2. The
alternative of type HA loading (see 13.3) shall be considered where it
produces a more severe load effect.

13.5 Highway loading serviceability limit state

When considering the serviceability limit state, highway loading shall be taken
as 25 units of type HB loading in all cases. The single wheel of type HA
loading shall be disregarded but, when the fill depth does not exceed 600, the
HA UDL and KEL alternative shall be considered where it produces a more
severe load effect.
13.6 Railway loading

There are two types of railway loading, RU and RL, which consist of a
combination of uniformly distributed and point loads. A variable dynamic factor
is applied for impact allowance. A full description is given in BS 5400: Part 2.

13.7 Contact area of wheel loads

Wheel loads may be assumed to be uniformly distributed over a circular or

square contact area derived from the load and the contact pressure.

13.8 Dispersal of surface loads

Concentrated loads or uniformly distributed load extending over a limited area

may be reduced in intensity by dispersal through the fill from the ground
surface to the roof of the box culvert. All surface loads must be considered.

Uniform pressure may be assumed to exist within the outer boundary of any
dispersed area or group of overlapping areas obtained by spreading each
surface load area at a spread to depth ratio of one horizontally to two
vertically. Alternatively, Boussinesq's theory may be used to calculate the
variation of v pressure across the roof of the box culvert due to surface loads.

The knife edge load of type HA highway loading may be dispersed at 1 to 2

below a fill depth of 200. For dispersal of railway loading through the rail,
sleeper and ballast, see BS 5400: Part 2. Below the level of ballast, dispersal
may be assumed by the methods given above.

13.9 Superimposed fill load

For all conditions of installation, the vertical pressure due to the superimposed
fill shall be taken as a maximum of Kf dfH and a minimum of dfH

where Kf = 1.1 for design to BS 8110 (or 1.15 where design to BS 5400 is
specifically requested)*

df = density of fill (which shall be taken as 19kN/m3 unless otherwise

specified)

and H = height of fill above the box culvert including the thickness of any
surface layer.

* The BS811O value of 1.1 times the vertical column of fill with a partial safety factor of 1.4 is
consistent with the BS 5400 value of 1.15 times the vertical column of fill with a partial safety
factor of 1.2 x 1.1.
13.10 Weight of box culvert

The vertical pressure due to the weight of the roof slab shall be taken as dch

where dc = density of concrete (which shall be taken as 24kN/m3 unless

otherwise specified)

and h = thickness of roof slab.

The effect of the weight of walls, floor and culvert contents may be
disregarded.

14. Characteristic horizontal load

Maximum and minimum horizontal loads from fill pressure shall be assessed
by the principles of soil mechanics from the surface load and the depth of fill.
Alternatively, for design to BS 8110 the horizontal pressure may be taken as a
maximum of 0.5 and a minimum of 0.25 times the vertical pressure at the
level considered due to a vertical column of fill and any dispersed surface
load. Where design to BS 5400 is specifically requested, a maximum of 0.6
and a minimum of 0.2 shall be taken. The mid-height pressure may be
considered to be uniformly applied over the full height of the wall.

15. Design loads - BS 8110

The following partial safety factors shall be applied to the characteristic loads
when design is carried out by the method of BS 8110:

Ultimate Serviceability
Type HA loading 1.65 1.2
Type HB loading 1.43 1.1
Railway loading 1.54 1.1
Other surface load 1.6 1.0
Superimposed fill 1.4 (1.0) 1.0
Weight of concrete 1.4 (1.0) 1.0
Horizontal pressure 1.4 1.0

The lower factors for ultimate limit state shall be applied to loads which have a
relieving effect at the section considered.
16. Design loads - BS 5400

Where design to BS 5400 is specifically requested, the following partial safety

factors shall be applied to the characteristic loads with a further factor of
1.1 applied at ultimate limit state only:

Ultimate Serviceability
Type HA loading 1.5 1.2
Type HB loading 1.3 1.1
Railway loading 1.4 1.1
Superimposed fill 1.2 (1.0) 1.0
Weight of concrete 1.15 (1.0) 1.0
Horizontal pressure 1.5 (1.0) 1.0

The lower factors for ultimate limit state shall be applied to loads which have a
relieving effect at the section considered.

17. Analysis

For all conditions of installation, it will be sufficient to assume a compressible

support to the underside of the box culvert giving a uniform distribution of
support pressure.

At each fill depth considered, maximum and minimum vertical loads shall be
combined with maximum and minimum horizontal loads to calculate the worst
load effects.

Mid-span and corner moments shall be obtained from an elastic analysis

which shall take into account the stiffness of any corner splays.

18. Differential settlement

Box culverts may be subject to differential settlement which will be

accommodated by relative movement at the joints. Such settlement shall be
considered to have no effect upon the design loads or structural analysis and
no allowance shall be made for transfer of forces between the units.

19. Design strength

Design and detailing of sections to resist moments and shear forces shall be
in accordance with BS 8110 (or BS 5400 where design to this standard is
specifically requested).
20. Stability

Considerations of stability such as allowable bearing pressure and resistance

to sliding or overturning do not influence the design for culvert strength and
they are not within the scope of this standard. It shall be assumed that, if any
such investigations are considered to be necessary, they will be undertaken
by the engineer responsible for the works which incorporate the box culverts.

21. Reinforcement of inner wall faces

Nominal reinforcement capable of resisting a design ultimate moment of not

less than kNm/m (where Y is the effective span of the wall in metres)
shall be provided in the inner wall faces even where the analysis indicates
that the outer faces are permanently in tension. This does not apply, however,
to the corner splays of culverts nor to the inner wall faces of culverts less than
600 in internal height.

22. Horizontal surface loads

It shall be assumed that any horizontal loads due to surface traffic will be
safely dispersed through a road slab or other surface layer without effect upon
the box culvert. Where, exceptionally, a customer specifically requests that
transfer of such load across the box culvert shall be considered, passive
resistance of the fill shall be assumed to vary linearly from a maximum value
at the top of the culvert to zero at the base of the box culvert. The effect upon
the culvert shall be considered only at the ultimate limit state with a single
partial safety factor of 1.2 applied to all loads.

23. Temperature effects

Experience has shown that temperature effects may safely be disregarded in

the design of box culverts. Where, exceptionally, a customer specifically
requests that differential temperature within a section shall be checked, it will
be sufficiently accurate to assume the equivalent additional design ultimate
moment causing tension on the cooler face to be 20Th2kNm/m

where t = maximum temperature difference within the section (C)

and h = thickness of section (m).

For limestone aggregate the design ultimate moment may be reduced to

12Th2 kNm/m.

The value of T should not normally exceed 10C. Only the ultimate limit state
shall be considered with a single partial safety factor of 1.2 applied to all
loads.
24. Deflection of roof slab

It is not usually necessary to check the deflection of the roof slab. If however
the fill depth is less than the minimum recommended in clause 12 and an
assessment of live load deflection is required, it will be sufficiently accurate to
assume that

where M = maximum free span moment* per unit due to surface load only at
the serviceability limit state (kNm)

X = effective roof span (mm)

L = length of unit (mm)

and h = thickness of roof slab (mm).

* The free span moment is calculated assuming the roof slab to be simply supported over its
effective span.

25. Aprons, wing walls and parapets

Aprons, wing walls and parapets shall be designed as free-standing structures

although projecting reinforcement may be provided in a box culvert as a
means of connection. The engineer responsible for these elements shall
satisfy himself of the stability of the combined construction.

26. Compliance Certificate

Provision may be made for the purchaser to receive from the culvert
manufacturer a statement signed by a chartered civil or structural engineer
which certifies that the manufacturer has exercised and will exercise all
reasonable skill and care in the design, detailing and manufacture of the
precast concrete box culverts in accordance with the requirements of this
specification. A suitable form is available here.
Appendix A

Information check list

It is important that sufficient information is provided to the manufacturer for the

customer's requirements to be fully understood. Although standard
dimensions have been agreed for box culverts, the structures are individually
designed for each contract. The check list given below should ensure that
nothing of importance is overlooked.

Internal width and internal height. They shall be given in this sequence
and they should preferably be taken from manufacturers' standard
sizes.
Total length, divided where necessary on long runs into different
ranges of fill depth and surface loading.
Minimum and maximum fill depth above culvert. It is recommended that
the minimum fill depth should be not less than 200 or one fifteenth of
the internal width of the culvert if greater.
Surface loading. This may be HA highway loading, HB with the
required number of units, Field, Railway or other load which should be
specified.
Any special requirements which may include:
o (a) exposure conditions if other than Severe.
o (b) resistance to sulphate attack (specify class).
o (c) details of starter bars.
o (d) end details.
o (e) details of chambers or tanks.
o (f) changes in direction.
o (g) angle of skew to traffic lanes.
o (h) protective coatings.
Delivery location
Intended use such as culverted stream, sea outfall, pedestrian or traffic
access.
Any variation required from this standard.
References
BSEN 197-1 : 2000
Specification for Portland cements.
Cement composition, specifications and
conformity criteria for common cements.
BS 146
Specification for Portland-blastfurnace
cement.
Part 1 Specification for accelerating admixtures.,
retarding admixtures and water reducing
admixtures.
Part 3 Specification for superplasticising
admixtures.
BS 5400
Steel, concrete and composite bridges.

BS 812 Part 4 Code of practice for design of concrete

Testing aggregates. bridges.

BS 882 : 1992 BS 6588

Specification for aggregates from natural Specification for Portland pulverised-fuel ash
sources for concrete. cement.

BS 1881 BS 6699
Testing concrete. Specification for ground granulated blast-
furnaced slag for use with Portland cement.
Part 108 Method for making test cubes from
fresh concrete. BS 7123
Specification for metal arc welding of steel for
Part 116 Method for determination of concrete reinforcement.
compressive strength of concrete cubes.
BS 8110
BS 3892 Structural use of concrete.
Pulverised-fuel ash.
BS 8666 : 2000
Specification for pfa for use with Portland Specification for scheduling, dimensioning,
cement. bending and cutting of steel reinforcement for
concrete.
BS 4027
Specification for sulphate-resisting Portland BD 31/87
cement. Buried concrete box type structures.
Department of Transport
BS 4449
Specification for carbon steel bars for the BD 37/01
reinforcement of concrete. Loads for highway bridges.
Department of Transport
BS 4482
Specification for cold reduced steel wire for SB 3/88
the reinforcement of concrete. Rigid buried concrete structures.
Scottish Development Department
BS 4483
Specification for steel fabric for the Standard precast concrete box culverts.
reinforcement of concrete. Applications guide.
Box Culvert Association
BS 5075
Concrete Admixtures. Standard Precast concrete box culverts
A guide to site practice. Box Culvert Association