Table of Contents

    Methodology for Box Culverts

    1. Reference Drawings of Box Culverts

    Reviewed drawings shall be referred to for casting of box culverts.

    2. Working Drawings

    Working drawings, structural drawings, and relevant details shall be submitted to the AE prior to commencement of work for approval. After approval, setting out of the structure shall be carried out at site.

    3. Scope of Work

    The work shall consist of widening of existing box culverts or reconstruction/construction of new box culverts as per reviewed drawings. The work includes:

    • Excavation
    • Foundation Preparation
    • PCC & Raft Construction
    • Wall Construction
    • Deck Slab Construction
    • Return Wall & Curtain Wall Construction
    • Apron & Protection Works

    4. Reference

    • Contract Agreement
    • IRC: SP: 84-2014
    • MoRTH Specifications (5th Revision)
    • Relevant Approved Drawings

    5. Plant & Machinery

    • Mixer Machine with Weigh Batcher / Batching Plant
    • Transit Mixer
    • Concrete Vibrator & Hand Rammer
    • Trailer / Open Body Truck
    • Water Tanker
    • Water Pump
    • Shuttering Plates & Staging Materials
    • Backhoe Loader / Excavator

    6. Materials

    Cement, mineral admixtures, chemical admixtures, fine aggregates, coarse aggregates, and water shall conform to Clause 1700 of MoRTH Specifications.

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    Reinforcement steel shall be HYSD Fe-500 grade bars conforming to IS:1786 or as shown in approved drawings.

    Concrete grade shall be as specified in reviewed drawings. Concrete shall be produced, transported, and placed as per approved mix design.

    7. Method of Construction

    1. Excavation shall be carried out manually or mechanically depending upon site conditions. Care shall be taken to avoid over-excavation. The PCC bed level shall be maintained accurately.
    2. If required, the foundation surface shall be sprinkled with water before laying PCC.
    3. Layout marking shall be carried out for raft and walls.
    4. PCC of grade M15 or as shown in approved drawings shall be laid over prepared foundation.
    5. Concrete grades for raft, walls, deck slab, return wall, and curtain wall shall be as per reviewed drawings.
    6. Reinforcement steel shall be fixed and tied as per approved BBS and drawings.
    7. Formwork for raft including haunch and kick-starter shall be erected properly.
    8. Concreting shall be carried out as per Clause 1700 of MoRTH Specifications.
    9. Post-concreting inspection shall be carried out after de-shuttering and any defects shall be rectified immediately.
    10. Proper curing arrangements shall be ensured after concreting.
    11. The same sequence shall be followed for walls, return walls, and curtain walls.
    12. Weep holes shall be provided as per approved drawings.
    13. Scaffolding and soffit formwork for top slab shall be erected properly.
    14. Deck slab reinforcement shall be tied as per approved BBS and drawings.
    15. Concreting of top slab shall be carried out after inspection approval.
    16. Boulder pitching and apron protection works shall be executed on upstream (U/S) and downstream (D/S) sides.
    17. If total wall height is less than 3 m, slab shall be cast monolithically along with walls after casting starter and haunch.
    18. Side shutters of wall and deck slab may be removed after 12 hours of concreting or as approved by the Engineer.
    19. Proper curing of deck slab and wall surfaces shall be carried out by ponding and wet hessian cloth covering.
    20. Soffit staging shall be removed after achieving required strength and as per span criteria.
    21. Floor protection works on U/S and D/S sides shall be carried out as per GFC drawings.
    22. Traffic diversion arrangements shall be made before commencement of work to ensure safe and smooth vehicular movement.

    8. Quality Control

    Sampling and testing frequency shall be carried out as per MoRTH Clause 1700 and IS:4926-2003 requirements.

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    • Concrete Cube Testing
    • Slump Test
    • Reinforcement Inspection
    • Formwork Inspection
    • Line, Level & Alignment Check
    • Cover Measurement

    9. Safety

    1. All construction vehicles and equipment such as transit mixers, JCBs, and excavators shall have functional reverse horns and safety systems.
    2. Excavated areas shall be properly barricaded using safety tapes, caution boards, and barricading arrangements.
    3. Workers shall use PPE such as helmets, safety shoes, reflective jackets, gloves, and safety belts.
    4. Proper illumination and warning signs shall be provided during night work.
    5. Traffic management and diversion arrangements shall be maintained throughout the construction period.