SECTION 02645

PRECAST CONCRETE BOX AND

THREE-SIDED CULVERT STRUCTURES
PART 1
1.1

SECTION INCLUDES
A.

1.2

1.3

GENERAL

Material and procedures for fabricating and installing single-cell precast

concrete box culverts, multi-cell precast concrete box culverts, precast
conventionally reinforced concrete three-sided culvert structures, and
secondary elements such as cutoff walls, aprons, footings, floor slabs,
headwalls, and wingwalls.

RELATED SECTIONS
A.

Section 02056: Embankment, Borrow, and Backfill

B.

Section 02317: Structural Excavation

C.

Section 03055: Portland Cement Concrete

D.

Section 03211: Reinforcing Steel and Welded Wire

E.

Section 03310: Structural Concrete

F.

Section 03390: Concrete Curing

G.

Section 03575: Flowable Fill

H.

Section 07105: Waterproofing Membrane

REFERENCES
A.

AASHTO M 111: Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products

B.

AASHTO T 106: Compressive Strength of Hydraulic Cement Mortars

(Using 2-in. Cube Specimens)

C.

AASHTO T 160: Length Change of Hardened Hydraulic Cement Mortar

and Concrete

D.

AASHTO T 161: Resistance of Concrete to Rapid Freezing and Thawing

Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 1 of 12
January 1, 2012

1.4

E.

AASHTO LRFD Bridge Design Specifications

F.

AASHTO Manual for Bridge Evaluation

G.

ASTM C 877: External Sealing Bands for Concrete Pipe, Manholes, and
Precast Box Sections

H.

ASTM C 882: Bond Strength of Epoxy-Resin Systems Used With

Concrete By Slant Shear

I.

ASTM C 928: Packaged, Dry, Rapid-Hardening Cementitious Materials

for Concrete Repairs

J.

ASTM C 990: Joints for Concrete Pipe, Manholes, and Precast Box
Sections Using Preformed Flexible Joint Sealants

K.

ASTM C 1504: Manufacture of Precast Reinforced Concrete Three-Sided

Structures for Culverts and Storm Drains

L.

ASTM C 1577: Precast Reinforced Concrete Monolithic Box Sections for

Culverts, Storm Drains, and Sewers Designed According to AASHTO
LRFD

M.

Precast/Prestressed Concrete Institute (PCI) Design Handbook

N.

UDOT Quality Control/Quality Assurance (QC/QA) Procedures

O.

UDOT Quality Management Plan

P.

UDOT Structures Design Memoranda

DEFINITIONS
A.

Working Drawings Drawings produced by the Contractor that

supplement the contract drawings to provide information not included in
the contract documents but required to fabricate, erect, transport, or
temporarily support the structure or structural elements in the completion
of the work.
1.
Working drawings do not supersede the contract drawings.

B.

Approval of Working Drawings Acceptance by the Department for use on

the project. The Department will review working drawings for general
conformance with the design concept and compliance with the contract
documents. Review and approval do not relieve the Contractor from
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 2 of 12
January 1, 2012

responsibility for errors, correctness of details, conformance to the

contract, and the successful completion of the work.
1.5

SUBMITTALS
A.

Working Drawings
1.
Detailed fabrication and installation drawings for approval of all
fabricated materials and cast-in-place elements that are included in
this item of work and are not detailed in the contract plans.
a.
Include all details not provided in the contract documents for
the construction and erection of the members included in this
item of work.
b.
Detail all phases of construction including layout, joint
details, lifting devices, casting methods, construction
placement, and details of any cast-in-place elements
included in this item of work.
c.
Note proposed transportation methods.
d.
Include inventory and operating load ratings in a table on the
first sheet of the drawings for structures with spans greater
than 20 ft. Refer to this Section, article 2.9 for requirements.
e.
Provide the seal of a Professional Engineer (PE) or
Professional Structural Engineer (SE) licensed in the State
of Utah and include supporting engineering calculations for
the following:
1)
Special designs of precast concrete box culverts for
sizes and loads other than those shown in Table 1 of
ASTM C 1577.
2)
Precast three-sided culvert structures.
3)
Lifting devices.
4)
Structural members and ancillary appurtenances
designed by the fabricator.
5)
Connections between precast and cast-in-place
members and appurtenances.
6)
Load ratings.
7)
Any other means and methods that require an
engineers design.
f.
Do not begin work before receiving approval of the shop
detail drawings. The Department rejects units fabricated
before shop drawing approval.
2.
Prepare drawings according to the following:
a.
Submit drawings electronically in PDF format. Use 11 x 17
inch sheets with a 1 inch blank margin on the left edge.
Place the following information in the title block in the lower
right corner of each sheet:
1)
State Project Designation
2)
State Project Name
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 3 of 12
January 1, 2012

3.

4.

5.

3)
State Structure Number
4)
Contractor, Fabricator, or Erector Name
5)
Contractor, Fabricator, or Erector Drawing Number
6)
Contractor, Fabricator, or Erector Sheet Number
b.
Revise and resubmit drawings when directed by the
Engineer.
c.
Provide the seal of a PE or SE licensed in the State of Utah
when required in the contract. Place the seal in the lower
left corner of each sheet.
Prepare engineering calculations according to the following:
a.
Submit calculations electronically in PDF format. Use 8 x
11 inch sheets with a 1 inch blank margin on the left edge or
11 x 17 inch sheets with a 1 inch blank margin on the left
edge. Title block location is at the top of 8 x 11 inch sheets
or the lower right corner of 11 x 17 inch sheets. Place the
following information in the title block:
1)
State Project Designation
2)
State Project Name
3)
State Structure Number
4)
Contractor, Fabricator, or Erector Name
5)
Contractor, Fabricator, or Erector Drawing Number
6)
Contractor, Fabricator, or Erector Sheet Number
b.
Provide the seal of a PE or SE licensed in the State of Utah
on all engineering calculations. Place the seal on the
calculation cover sheet.
c.
Certify that engineering calculations have been checked
according to the Department QC/QA Procedures.
Allow the Engineer 14 calendar days to review and approve
working drawings and supporting calculations.
a.
The Engineer may grant an increase in the number of
working days for the project when that time is exceeded.
b.
This review period applies each time the drawings are
submitted.
Do not deviate from the approved drawings unless authorized in
writing. Assume the responsibility for costs incurred due to faulty
detailing or fabrication.

B.

Mix Design
1.
To the Engineer for approval. Refer to this Section, article 2.1
paragraph B.

C.

Structural Non-Shrink Grout

1.
Certificate of Compliance.
2.
The proposed method for forming grout voids and installing the
non-shrink grout including the sequence and equipment for the
grouting operation for review at least 14 days before work begins.
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 4 of 12
January 1, 2012

Obtain approval before beginning placement of structural nonshrink grout.

1.6

ACCEPTANCE
A.

Precast concrete box culverts and precast concrete three-sided culvert

structures may be accepted at a reduced price when the concrete strength
is below that specified.
1.
Price adjustment pay factor according to Section 03055.

B.

The Department rejects any elements fabricated before receiving written

approval or any elements that deviate from the approved drawings. The
Contractor is responsible for costs incurred due to faulty detailing or
fabrication.

PART 2
2.1

CONCRETE
A.

Wet Cast Concrete Class AA(AE). Refer to Section 03055.

B.

Dry Cast Concrete

1.
Minimum cement content
2.
Maximum water/cement ratio

C.
2.2

2.4

470 lb/yd3 of concrete

0.40

Flowable Bedding Concrete Use flowable fill according to Section

03575.

REINFORCING STEEL AND WELDED WIRE

A.

2.3

PRODUCTS

Coated Refer to Section 03211.

JOINT SEALANT
A.

Refer to ASTM C 990.

B.

Use a flexible butyl rubber material with a minimum cross-section of x

1 inches as a joint sealant for box culverts.

JOINT WRAP
A.

Refer to ASTM C 877.

Precast Concrete Box and Three-Sided Culvert Structures

02645 Page 5 of 12
January 1, 2012

2.5

WATERPROOFING MEMBRANE
A.

2.6

Refer to Section 07105.

STRUCTURAL NON-SHRINK GROUT

A.

Use gray, non-shrink grout containing no calcium chloride or admixture

containing calcium chloride or other ingredient in sufficient quantity to
cause corrosion to steel reinforcement.

B.

Use quick-setting, rapid strength gain, non-shrink, and high-bond strength

grout.

C.

Meet all the requirements of AASHTO T 160 with the exception that the
Contractor-supplied cube molds will remain intact with a top firmly
attached throughout the curing period.

D.

Mix structural non-shrink grout just before use according to the

manufacturers instructions.

E.

Refer to Table 1 for additional structural non-shrink grout requirements.

Table 1
Structural Non-Shrink Grout
Requirements

*Properties
Accelerated Weathering:
Tested Medium
Accepted Weight Loss
Compressive Strength
Accepted Bond Strength

<3% White Utah Road Salt

<15% @ 300 Cycles
>3,000 psi @ 24 hours
>5,000 psi @ 7 days
>1,000 psi @ 24 Hours

ASTM

AASHTO
T 161
T 106

C 882 as
modified by
C 928 8.5

Length Change
No expansion after 7 days
T 160
* Certified test results from a private AASHTO accredited testing laboratory are
acceptable.
2.7

LIFTING DEVICES
A.

Use lifting devices that can support the required vertical and horizontal
forces with the applicable safety factors as specified in the Component
Handling and Erection Bracing requirements of the PCI Design Handbook.

B.

Galvanize according to AASHTO M 111.

Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 6 of 12
January 1, 2012

2.8

GROUTED SPLICE COUPLERS

A.

2.9

Refer to Section 03211.

MANUFACTURE
A.

Use a Department Certified Concrete Precaster or a pre-qualified project

site caster for precast concrete box and three-sided culverts according to
the Department Quality Management Plan: Precast-Prestressed Concrete
Structures.

B.

Precast Concrete Box Culverts

1.
Refer to ASTM C 1577.
2.
Special designs for sizes and loads other than those shown in
Table 1 of ASTM C 1577 require approval by the Engineer.
3.
Prepare special designs according to AASHTO LRFD Bridge
Design Specifications, Section 12.
4.
Provide 1 inch minimum concrete cover to reinforcing steel bars.
5.
Provide minimum concrete cover to reinforcement where welded
wire fabric is used, equal to the greater of three times the diameter
of the wire or 1 inch.
6.
Provide 2 inch minimum concrete cover to the reinforcing steel in
the top of the top slab of box sections covered with less than 2 ft of
fill for all types of reinforcement.
7.
Provide tongue and groove ends or equivalent to transfer shear
between sections at all joints.
8.
Design and form section ends so that the sections can be laid
together to make a continuous line of box sections compatible with
the permissible variations in Section 11 of ASTM C 1577.

C.

Precast Concrete Three-Sided Structures

1.
Refer to ASTM C 1504 with the following exceptions:
a.
Design the structure according to AASHTO LRFD Bridge
Design Specifications, Section 12.
b.
Design for HL-93 live loading.
2.
Provide a maximum longitudinal wire spacing of 8 inches for
welded wire. Provide a circumferential wire spacing not greater
than 4 inches or less than 2 inches.
3.
Provide minimum concrete cover to welded wire fabric equal to the
greater of three times the diameter of the wire or 1 inch.
4.
Provide 2 inch minimum concrete cover to all reinforcing steel in the
top of the top slab for three-sided structures covered by less than 2
ft of fill.

Precast Concrete Box and Three-Sided Culvert Structures

02645 Page 7 of 12
January 1, 2012

2.10

D.

Do not locate horizontal and vertical changes in alignment greater than 10

degrees at a joint between precast segments of a precast concrete box
culvert unless otherwise approved by the Engineer.

E.

Permanently mark each precast unit with date of casting and supplier
identification.

F.

Cast the Department structure number into the top and exposed faces of
the headwall at each end of the structure as shown in the plans.

G.

Provide the number and type of lifting devices required to support the
vertical and horizontal forces with the applicable safety factors as
specified in the Component Handling and Erection Bracing requirements
of the PCI Design Handbook.
1.
Use a maximum diameter of 3 inches when lifting holes are used.
Locate holes to avoid interference with the reinforcing steel.

H.

Load rate all precast concrete box culverts and precast concrete threesided structures with spans greater than 20 ft according to the AASHTO
Manual for Bridge Evaluation and Department Structures Design
Memoranda.
1.
Measure span length along roadway centerline.

I.

Concrete Curing Refer to Section 03390.

QUALITY ASSURANCE
A.

Precast Elements
1.
Prevent cracking or damage of precast elements during shipping,
handling, and storage.
2.
Replace defects and breakage of precast elements.
a.
Members that sustain damage or surface defects during
fabrication, handling, storage, hauling, or erection are
subject to review or rejection.
b.
Obtain approval before performing repairs.
c.
Repair work must reestablish the elements structural
integrity, durability, and aesthetics to the satisfaction of the
Engineer.
d.
Determine the cause when damage occurs and take
corrective action.
e.
Failure to take corrective action, leading to similar repetitive
damage, can be cause for rejection of the damaged element.
f.
Cracks that extend to the nearest reinforcement plane and
fine surface cracks that do not extend to the nearest
reinforcement plane but are numerous or extensive are
subject to review and rejection.
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 8 of 12
January 1, 2012

g.
3.

PART 3
3.1

3.2

Full depth cracking and breakage greater than 1 ft are cause

for rejection.
Document all test results. The quality control file will contain at
least the following information:
a.
Element identification
b.
Date and time of cast
c.
Concrete cylinder test results
d.
Quantity of used concrete and the batch printout
e.
Form-stripping date and repairs if applicable
f.
Location/number of blockouts and lifting inserts
g.
Temperature and moisture of curing period
h.
Lifting device details, requirements, and inserts

EXECUTION

PREPARATION
A.

Excavating, Trenching, Bedding, and Backfill

1.
Refer to Section 02317.

B.

Scarify moisture condition and compact the top 8 inches of the excavated
ground surface to at least 90 percent of the maximum laboratory density.

BEDDING AND BACKFILL

A.

Over excavate the material under the box location according to Section
02317 to a minimum depth of 6 inches.
1.
Replace over excavated material with granular backfill borrow or
free draining granular backfill as specified in Section 02056.
2.
Provide a minimum bedding of 6 inches of granular backfill borrow
or free draining granular backfill.
3.
Limit the soil gradation for granular backfill borrow used as bedding
under precast members to 100 percent passing the inch sieve.
4.
Modify the soil gradation for free draining granular backfill used as
bedding under precast members to 100 percent passing the inch
sieve and no more than 10 percent passing the No. 4 sieve.

B.

Level and compact bedding material to provide uniform support of the

structure along its entire supported width and length.

C.

Backfill structure with granular backfill borrow as specified in Section

02056 and as shown in the plans.

D.

Refer to project plans for excavation, bedding, and backfill requirements

where a three-sided culvert structure is placed on a footing.
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 9 of 12
January 1, 2012

E.
3.3

Backfill the gap between multiple single cell culverts with flowable fill.

INSTALLATION
A.

Inspect precast elements for defects before lowering into trench.

B.

Repair or replace any defective, damaged, or unsound precast elements.

C.

Use a trench width adequate to place and compact bedding material.

Minimum outside width of trench is the outside width of structure plus 2 ft
each side.

D.

Lay precast elements starting at the downstream end.

E.

Carefully lower precast elements into the trench with suitable equipment to
prevent damage.

F.

Remove all dirt and foreign material from joints. Prevent dirt and material
from re-entering joints.

G.

Apply joint sealant furnished by culvert manufacturer to box culvert.

1.
Place the joint material on the bottom half of the groove (bell) of the
box last placed.
2.
Place the balance of the joint material on the top half of the tongue
(spigot) of the box to be set.
3.
Place the material about 1 inch from the leading edge of the groove
and tongue.
4.
Maintain the joint material at 70 degrees F or greater during
placement.

H.

Disassemble joint, check position of joint sealant, repair alignment, and reinstall when adjoining elements cannot be pulled together to meet
minimum joint requirements.

I.

Pull box culvert sections together to inch joint gap spacing measured
face to face of adjoining concrete surfaces with the joint gap being uniform
on all sides of the box culvert.
1.
Use appropriate pulling devices to avoid misalignment and damage
to box sections.
2.
The Engineer may approve up to a inch joint gap spacing in
cases where it is necessary to adjust the total length of a box
culvert run.
3.
Reject box sections when the installation tolerance cannot be met
due to casting variations.
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 10 of 12
January 1, 2012

4.

3.4

Prevent soil from being forced into the joint as the box sections are
placed.

J.

Do not disturb previously completed joints during laying operation.

K.

Do not lay precast elements when water is in the trench.

L.

Place three-sided structure sections against previous sections as tightly as

possible while maintaining alignment.
1.
Follow manufacturers installation recommendations.
2.
Do not exceed joint tolerances in the stamped drawings.

M.

Apply joint wrap to the top slab and side walls at all joints.
1.
Clean top and sides of concrete surface at joints before placing
joint wrap.
2.
Use a minimum width of 2 ft centered on the joint.

N.

Install precast cutoff walls, aprons, wingwalls, and headwalls, as follows:

1.
Establish working points, working lines, and benchmark elevations
before placing elements.
2.
Clean bonding surfaces between elements of debris, dust, and rust
before connecting elements to achieve the required bonding
between protruding bars and elements.
3.
Place cut-off wall and apron elements as shown in the plans.
a.
Adjust the final location of the cut-off wall or apron elements
if actual joint gaps cause the final location to vary.
b.
Adjust the height of each apron element by means of
leveling devices or shims.
4.
Lift apron segments using lifting devices as shown on the approved
fabrication and installation working drawings.
5.
Set elements in the proper horizontal location. Check for proper
alignment and grade within specified tolerances.
6.
Adjust vertical leveling devices before full release of the apron from
the crane to reduce the amount of torque required to turn the bolts
in the leveling devices. Check for proper grade within specified
tolerances.
7.
Place or pump bedding concrete or grout into voids and pockets as
shown in the plans.

STEEL REINFORCEMENT
A.

Refer to Section 03211.

Precast Concrete Box and Three-Sided Culvert Structures

02645 Page 11 of 12
January 1, 2012

3.5

3.6

JOINTS
A.

Mechanically connect the exterior sections of three-sided precast concrete

structures at all top joints within a minimum length of 12 ft from each end
of the structure.
1.
Use at least four mechanical connections per joint with a maximum
spacing of 10 ft.
2.
Galvanize all plates, shapes, and hardware.

B.

Connect three-sided precast concrete structures to the footing, pedestal,

or slab 2 ft from the outermost exterior edge of the structure at all four
corners of the structure with a galvanized rigid mechanical connection.
1.
Locate the connection on the interior face of the segment to allow
for future inspection.

LIFTING HOLES AND DEVICES

A.

3.7

3.8

3.9

CAST-IN-PLACE CONCRETE
A.

Refer to Section 03310.

B.

Project the reinforcing steel at least 12 inches out of the precast box
section and square off the concrete face where precast box sections join
cast-in-place concrete.

REPAIRS
A.

Box sections may be repaired as allowed in the referenced specification

only when approved in advance by the Engineer.

B.

Repairs made before approval will be cause for rejection.

MINIMUM LENGTH
A.

3.10

Plug lifting holes and lifting device recesses with structural non-shrink
grout. Finish flush with all concrete surfaces.

Do not use precast segments less than 5 ft in lay length.

WATERPROOFING MEMBRANE
A.

Apply a waterproofing membrane to the top slab and side walls of all
concrete box culverts and three-sided structures for the full length of the
structures. Refer to Section 07105.
END OF SECTION
Precast Concrete Box and Three-Sided Culvert Structures
02645 Page 12 of 12
January 1, 2012