SECTION 610 CONCRETE BOX CULVERTS AND CONCRETE HEADWALLS
610.01 DESCRIPTION. Build all concrete box culverts and concrete headwalls
according to the Contract. For box culverts constructed using precast sections, conform to Section 611. For precast headwalls, conform to Section 710.
610.02 Materials.
610.02.01 Concrete. Conform to Subsection 601.02 and 601.03.
610.02.02 Steel Reinforcement. Conform to Section 811.
610.02.03 Concrete Pipe. Conform to Section 810.
610.02.04 Joint Materials. Conform to Section 807.
610.02.05 Masonry Coating. Conform to Section 828.
610.02.06 Concrete Curing Materials . Conform to Section 823.
610.03 CONSTRUCTION. Conform to Subsection 601.03 for all concrete construction.
610.03.01 Footings. Construct footings to the elevation specified in the Plans, and
increase the depth when the Engineer determines that it is necessary to provide sufficient bearing or to prevent undermining. Only rais e footing elevations when encountering solid rock at elevations above those specified in th e Plans and with the approval of the Engineer. Form the outside face of all footings of concrete headwalls for pipe, box, or arch culverts to the full depth of the footing. Do not place any concrete in the foundation until the Engineer has inspected and approved the depth of excavation and character of the foundation material. Whenever the natural foundation material is not sufficiently stable to support the structure or whenever it is anticipated that high water may cause excessive erosion around the footings, the Engineer may order Extra Work to provide the structure with adequate support or protection according to Subsection 109.04. When the condition of excavation for footings is otherwise satisfactory but is such that concrete cannot be placed without mud becoming mixed with the concrete, remove the entire mass of mud and replace it with stable material or prevent infiltration of mud by methods such as a layer of coarse aggregate and geotextile fabric or a layer of plastic material. Perform work by methods other than removing and replacing the entire mass of mud according to Subsection 109.04.
610.03.02 Apron Walls and Headwalls.
A.Apron Walls. The Engineer may require additional depth than that specified in the Plans if necessary to prevent undermining. Form the outside faces of all concrete apron walls for the full depth. When necessary to form the back face or the end of apron walls due to the lack of solid material, do not exceed the excavation limits specified for footing structure excavation. Pave the space between wings when the Engineer directs. In this event, relocate the apron walls so that they are in a straight line between the ends of the wings, or at locations to provide the best protection.
B.Headwalls. Construct headwalls according to the Standard Drawings for Headwall Supplement. When headwalls for pipe culverts are located at the shoulder, construct the top of the headwalls parallel to the shoulder line for both line and grade. 610-1
610.03.03 Drainage. Place weep holes consisting of 4-inch pipe or formed to 4 inches
in diameter at intervals not to exceed 25 feet in retaining walls, nor exceeding 10 feet in box culverts. Place the outlet invert elevation of weep holes in box culverts 4 inches above the flowline of the culvert. Raise box culvert weep holes to accommodate significant silting when the Engineer directs. Make adequate provisions for thorough drainage of backfill and embankment according to Subsection 603.03. Boxes less than 4 feet in height are not required to have weepholes.
610.03.04 Placing Concrete. Place concrete according to Subsection 601.03.09.
Place the base slab or footings, and allow them to cure before constructing the remainder of the structure. Construct base slabs, footings, and apron walls as monolithic units when practical. When construction joints are necessary, place them at right angles to the culvert barrel. Bond construction joints, according to Subsection 601.03.10. In constructing all box culverts having a clear height of 5 feet or more, place concrete in the side walls, and allow it to set before placing the top slab. For culverts having a clear height of less than 5 feet, if desired, pour the culvert top slab monolithically with the side walls. When using this method of construction, make all necessary construction joints vertical and at right angles to the axis of the culverts. Construct each wingwall as a monolithic unit. Place construction joints, where unavoidable and when not specified in the Plans, horizontal or vertical as appropriate.
610.03.05 Removing Forms. Remove forms according to Subsection 601.03.14.
610.03.06 Surface Finish and Placing Fill. Finish surfaces according to Subsection
601.03.18 Texture top slabs of box culverts to be used as the wearing surface for traffic
according to Subsection 609.03.10, and conform to the roadway rideability requirements of Subsection 501.03.19. Place backfill or embankment as allowed by concrete strength. Backfill according to Subsection 603.03. Construct embankment according to Subsection 206.03.
610.03.07 Extensions to Existing Culverts. Construct extensions according to the
lines and grades established and to dimensions specified in the Plans. Remove portions of the existing structure designated to be removed according to Subsection 203.03. Remove portions of the existing structure designated to be removed in a manner that provides a neat junction with the extension, and leave undamaged that portion of the existing structure that is to remain in service. For exposed joints in the finish work, the Engineer may require sawing of the existing concrete to a depth sufficient to ensure a neat joint. Repair all damage to the existi ng structure due to his activities. Remove and dispose of all silt or other debris that may have collected within the barrel of the existing structure. The Engineer will only require this silt and debris removal once, unless erosion control measures were not adequate.
610.04 Measurement.
610.04.01 Concrete. The Department will measure the quantity according to
Subsection 601.04.
610.04.02 Steel Reinforcement. The Department will measure the quantity according
to Subsection 602.04.
610.04.03 Structure Excavation. The Department will measure the quantity
according to Subsection 603.04. The Department will measure the removal and replacement of unstable material in footing excavation as Structure Excavation.
610.04.04 Removal of Existing Structure. The Department will measure the quantity
610-2 according to Subsection 203.04. The Department will not measure repair of damage to, removal of silt and debris from, and providing a neat cut for the joint on the portion of the structure designated to remain for payment and w ill consider them incidental to this item of work.
610.04.05 Headwall. The Department will measure the quantity as each.
610.05 PAYMENT. The Department will make payment for the completed and accepted
quantities under the following: Code Pay Item Pay Unit 08100, 08102-08105, 02555 Concrete See Subsection 601.05 08150 Steel Reinforcement See Subsection 602.05 ---- Structure Excavation See Subsection 603.05 02731 Remove Structure See Subsection 203.05 01200-01223 Pipe Culvert Headwall, Size Each The Department will consider payment as full compensation for all work required under this section. 610-3 SECTION 611 PRECAST REIN FORCED CONCRETE BOX CULVERT SECTIONS
611.01 DESCRIPTION. Install precast reinforced concrete box sections used as culverts,
storm drains, and sewers.
611.02 Materials.
611.02.01 Concrete. Conform to Subsections 601.02 and 601.03 and the
Precast/Prestress Concrete Manual.
611.02.02 Steel Reinforcement. Conform to Section 811.
611.02.03 Backfill Material. Conform to Subsection 206.03.01.
611.02.04 Free Draining Backfill Material. Conform to Section 805.
611.02.05 Grout. Conform to Subsection 601.02.
611.02.06 Sand. Conform to Section 804.
611.02.07 Sand for Pipe Bedding. Conform to Section 804.
611.02.08 Crushed Aggregate for Bedding. Conform to Section 805.
611.02.09 Joint Sealer for Rigid Pipe. Conform to Section 807.
611.02.10 Geotextile Fabric. Conform to Section 843.
611.03 Construction.
611.03.01 Transportation and Handling. Handle and store the precast units so that
flexural stresses are not induced until the concrete age is 7 days or attains a compressive strength of 3,000 psi. Remove and replace all sections that are not in true alignment and grade or that show undue settlement after laying, or are otherwise damaged.
611.03.02 Precast Unit Construction. Cons truct units according to ASTM C1577,
replacing Table 1 (Design Requirements for Precast Concrete Box Sections Under Earth, Dead and HL-93 Live Load Conditi ons) with KY Table 1 (Precast Culvert KYHL-93 Design Table), and Section 605 with the following exceptions and additions:
1.A water meters is not required if using dry-cast methods.
2.Mark all box culverts sections with the following information on the inside top of each section with letters no less than 2 inches high:
a.Span, rise, maximum and minimum design earth cover, and KY Table 1.
b.Date of manufacture.
c.Name and trademark of the manufacturer. For entrance and exit box sections, indent the required information. Mark interior sections by indenting or with waterproof paint.
3.Furnish precast sections at least 4 feet long.
4.Contrary to ASTM C 1577 Section 10.3, ensure the compressive strength of the cores tested is equal to or greater than the design strength. 611-1
Source: Kentucky Standard Specifications for Road and Bridge Construction, 2019 Edition. Pages 385–387 of 718.