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
611.03.03 Shop Drawings. Precast box sizes outside the depth or size range of ASTM
C 1577 will require shop drawings with structural steel calculation by an engineer licensed in Kentucky. Precast box dimensions and fill depth within KYHL-93 or KY Table 1 will not require shop drawings or calculations unless requested by the engineer. Precast wing walls and headwalls will require shop drawings and stamped calculations by an engineer licensed in Kentucky for all precast structures. Submit shop drawings for review according to Subsection 105.02, except do not include original tracings. Include on the shop drawings details of joint configuration, the size of rubber gaskets or butyl rubber sealants when used, the area of steel reinforcement, lift holes, and the size and location of reinforcement.
611.03.04 Excavation. Perform structure excavation according to Section 603, except
as modified in this subsection.
611.03.05 Bedding. Perform bedding as specified in the Plans or Standard Drawings.
Level the compacted bedding with a template or straightedge to ensure uniform support throughout the entire width and length of the structure. When desired, substitute crushed aggregate up to 3/4 inch maximum size for sand as bedding material. Do not use DGA or gravel base for this substitution. Substitute measure for measure. The Engineer will require a vertical trench from the bottom of the excavation to the top of the culvert or original ground, whichever is lower, as specified in the Plans or Standard Drawings.
611.03.06 Laying Sections. Do not lay any unit until the Engineer approves the
proposed location. Take soundings for foundation design at the inlet and outlet of each culvert and at intervals no greater than 20 feet along the grade line of the bottom of the culvert, to a depth of 3 feet. Perform soundings on the centerline and at each edge of the culvert. Where ledge rock, gravel, hardpan, or other unyielding material is encountered or known to exist within the limits stated, prepare the foundation as specified in the Plans or Standard Drawings. Camber the box culvert sections as the Engine er directs. Begin placing sections at the outlet end of the pipe with the bell or groove end being laid upgrade. Fully extend successive spigot ends into each adjoining hub. Provide a “come-along” or other mechanical device to pull each section firmly into the previously placed section, tightly meshing the joints. Do not push sections together with a tractor-mounted blade. After installing the sections, seal lift holes by inserting a tapered precast concrete plug and coating the top of the joint around the plug with asphalt mastic material. When the Plans require the volume between side-by-side installations to be filled with grout, use grout consisting of one part cement to 6 parts mortar sand or concrete sand, with sufficient water to provide a consistency suitable for job conditions. Provide drainage with 4-inch weepholes as specified in Subsections 610.03.03 and
603.03.05 respectively, except that for side-by-side installations separated by grout, place weepholes in the extreme outside walls only.
Grout formed openings between the precast se ctions and any side entry of pipes or top entry of manholes to form a watertight joint. When manholes are to be placed directly on the top slab of the precast sections, provide sufficient additional steel reinforcement in the top slab to compensate for the section removed.
611.03.07 Joints. Use either rubber gaskets, butyl rubber sealants, or asphalt mastic
joint sealing compound in joints between the precast box sections. Use the same material throughout each individual structure.
A.Rubber Gaskets. Use a cement and lubricant to facilitate joining the sections that is recommended by the manufacturer of the rubber gaskets. Install the rubber gaskets in a manner to snugly fit in the beveled surface of the tongue and groove ends of the section to form a flexible water-tight seal under all conditions of 611-2 service.
B.Butyl Rubber Sealants. Use a primer; rate and method of primer application; and width and method of application of the butyl rubber sealant recommended by the manufacturer. Provide the Engineer with the manufacturer’s literature for installation procedures.
C.Asphalt Mastic Joints. Prime and seal asphalt mastic joints according to Subsection 701.03.05.
D.Joint Fit. Regardless of the type of sealant to be used, ensure proper meshing of the joints. Do not allow sand or foreign materials to intrude into joints. If sand or foreign material is present within the joint upon joining the sections, thoroughly clean until no sand or foreign material is present, and reseal the joint. If the joint is not entirely filled with sealant after connecting the culvert sections fill all exposed unsealed areas, both inside and outside the culvert, with asphalt mastic or other approved material. If using plastic gaskets, use an additional sealant compatible with the plastic and recommended by the gasket manufacturer. Fill the exterior joint gap on the top of precast reinforced concrete boxes with mortar. Cover the exterior joint with a minimum of a 15-inch double layer geotextile fabric joint wrap. Before applying the wrap, ensure that the surface is free from dirt and foreign substance. Use one continuous roll of double layered joint wrap to cover the joint on the top of the box and to extend completely down the sides to the bottom of the box. During backfilling, keep the joint wrap in the proper location over the joint. Apply the joint wrap to all joint sections.
611.03.08 Backfilling. Backfill according to Subsection 603.03, the Plans, and the
Standard Drawings. Place free draining backfill between side-by-side installations when required by the Plans. Compact the backfill as the Engineer directs.
611.03.09 Headwalls. Construct headwalls as specified in the approved Shop
Drawings, Plans, or Standard Drawings.
611.04 Measurement.
611.04.01 Structure Excavation. The Department will measure the quantity
according to Subsection 603.04. For necessary side-by-side installations, the Department will measure the entire excavated volume between sections when the Plans or the Engineer require excavation of this volume. The Depa rtment will measure embankment placed and subsequently excavated according to the plan requirements for bedding as structure excavation. The Department will not measur e free draining backfill or grout between side- by-side installations for payment and will cons ider them incidental to this item of work.
611.04.02 Precast Reinforced Concrete Box Sections. The Department will measure
the quantity in linear feet according to the length dimensions specified in the Plans. The Department will not measure joint materials (including the geotextile fabric wrap), shear connectors required for joining sections, and any required acceptance coring for payment and will consider them incidental to this item of work. The Department will not measure repair of sections not in true alignment and grade or that show undue settlement after laying, or otherwise damaged.
611.04.03 Headwalls. Headwalls and wingwalls may be precast or poured-in-place.
The Department will measure the quantity as each regardless of which construction method is used for construction of the headwall. 611-3
611.05 PAYMENT. The Department will make payment for the completed and accepted
quantities under the following: Code Pay Item Pay Unit ---- Structure Excavation See Subsection 603.05 03010-03038 Precast Concrete Box Sections, Size Linear Foot 01200-01221 Pipe Culvert Headwall, Size Each 08100-08105, 02555 Concrete, Class See Subsection 601.05 08150 Steel Reinforcement See Subsection 602.05 The Department will consider payment as full compensation for all work required under this section. 611-4 SECTION 612 STRUCTURAL PLATE SOIL INTERACTION STRUCTURES
612.01 DESCRIPTION. Furnish and install corrugated metal multi-plate soil interaction
structures where an equivalent inner diameter of greater than 10 feet and less than or equal to 26 feet is required for drainage or other openings. Corrugated metal multi plate soil interaction structures include pipe, pipe arches, and arches.
612.02 Materials.
612.02.01 Pipe. Conform to Section 809 for the following:
1.Corrugated Aluminum Alloy Structural Plate Pipe, Pipe Arches, and Arches.
2.Corrugate Steel Structural Plate Pipe, Pipe Arches, and Arches.
612.02.02 Concrete. Conform to Subsection 601.02 and 601.03.
612.02.03 Asphalt Material for Coating and Paving. Conform to Section 806.
612.02.04 Bedding and Backfill Materials.
A.Fine Aggregate. Conform to Section 804, Sand for Pipe Bedding.
B.Coarse Aggregate. Conform to Section 805, Structural Granular Backfill.
C.Flowable Fill. Conform to Section 601.02 and 601.03.
612.02.05 Joint Materials. Conform to Subsection 701.02.
612.03 Construction.
612.03.01 Composition. Provide structures that consist of prefabricated sections
ready to be assembled and erected at the site. Furnish prefabricated sections consisting of asphalt coated galvanized (zinc coated) corrugated steel or aluminum alloy plates that have been factory shaped and punched. The Department will allow the use of a factory assembled structure when units are available that conf orm to the requirements of the Contract for opening size, material, corrugation dimensions, metal thickness, and coating. Ensure that factory assembled steel units are asphalt coated. The Department will not extend the Contract time to accommodate the use of factor y assembled pipe or pipe arches. Ensure that field and factory assembled steel pipe and pipe arch units are asphalt coated and paved.
612.03.02 Transportation and Handling. Transport and handle according to
Subsection 701.03.04.
612.03.03 Erections Plans. Submit a pdf copy of the erection plans for each unit to
the Engineer. Include with each submitted set of erection plans a natural scale plan, an elevation view of the structure, and the design calculations. In lieu of design calculations, the Department will accept a manufacturer’s certification that the proposed structure conforms to all of the Department’s structural design requirements. The Department will return one set after review with needed corrections noted. Each time the Department requires corrections, submit a new copy of the erection plans. The Department will have 20 calendar days to review each submission. After the Department has approved the erection drawings, submit the final approved drawings in 22 inch by 36 inch Portable Document Format (PDF) that will produce near clear prints and sharp lines on both 11 inch by 17 inch and 22 inch by 36 inch prints (“PDF Prints”). The department reserves the right to require hard copy prints on a case by case basis. 612-1
Source: Kentucky Standard Specifications for Road and Bridge Construction, 2019 Edition. Pages 388–391 of 718.