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REINFORCED
CONCRETE
BOX CULVERT
MANUAL
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ARIZONA
DEPARTMENT OF TRANSPORTATION
HIGHWAYS DIVISION
BRIDGE GROUP
31-019
1 99 Ll Pg. 30
$[, 00
 ------- - - - -10101194- - _ _ _.
ReinforcooToncrefeBox Culvert Manual

TABLE OF CONTENTS
Page
INTRODUCTION ii

GENERAL INFORMATION:
1.1 Definitions 1
1.2 Box Culvert Stationing 2
1.3 Proper Description of a Box Culvert 3
1.4 Selection of Barrel Sections 3
1.5 Wingwall and Apron Selection 4
1.6 Placement of New Culverts and Headwalls 5
1.7 Placement of Reinforcing Steel 5
1.8 Construction Joints 6
1.9 Culverts in Dual Roadways 6
1.10 Curb Rise 7
1.11 Extension of Existing Culverts 7
1.12 Removal of Existing Headwall 7

SHEET PREPARATION:
2.1 Roadway Plan Sheets 8
2.2 Bridge Sheets 10
2.3 Reinforced CBC Summary Sheet 11
CBC Extension Summary Sheet
2.4 Drafting Guidelines 14

LIST OF ILLUSTRATIONS:
A. Overstressed and Understressed Areas 15
B. Roadway Oearance 16
C. Reinforcing Steel Placement 17
D. Construction Joints 18
E. Location Plan - New Box Culvert 19
F. Section on Centerline Culvert - with Special Section 20
G. Special Section - Box Culvert 21
H. Section on Centerline Culvert - Dual Roadways 22
I. Location Plan - Existing Box Culvert with
Extensions and Additions 23
J. Section on Centerline Culvert - Existing Box
Culvert with Extensions 24
K. Dowels Required for Culvert Extension 25
L. Reinforced Concrete Box Culvert Summary Sheet 26
M. Concrete Box Culvert Extension Summary Sheet 27

i
- Reinforced-Concrete-Box-Culvert-Manual- - - - ·-------

INTRODUCTION

This manual has been prepared to establish a uniform procedure to be followed

in laying-out and detailing reinforced concrete box culverts for the State and
Interstate Highway System. It is to be used with the "Structures Section
Standard Drawings" for reinforced concrete box culverts. The manual not only
pertains to the standard box culverts but special designs as well.

The manual is presented in outline form to provide the designer a guideline in

the preparation to the "Roadway Plan Sheets", the "Reinforced Concrete Box
Culvert Summary Sheet'' and the "Concrete Box Culvert Extension Summary
Sheet". Unless special design is required, these sheets will provide sufficient
information necessary for the contract drawings. Sample plans and illustrations
are included to aid the designer in interpreting the general rules and criteria and
in preparing plan and detail sheets for special designs. It is the intent of this
manual to cover most of the general cases encountered; however, the general
rules and criteria may be altered to meet special conditions.

This manual supersedes the manual entitled "Reinforced Concrete Box Culvert
Manual" dated March 1981.

ii
-- -- - -Reinforced~eoncrete~Box-euivert~Manua - . 010119~

GENERAL INFORMATION

1.1 Definitions:

A. Section on Centerline of Culvert: A section projected on a plane normal

to roadway centerline rotated about the skew angle looking in the
direction of increasing stationing (ahead).

B. Culvert Cross-Section: A section normal to the culvert centerline.

C. Barrel Section: A portion of the box culvert with uniform cross-section.

D. Length of a Barrel Section: The length of each barrel section along its
centerline.

E. Length of a Culvert Total length of all barrel sections, measured along

the centerline of culvert

F. Special Sections: A special designed culvert cross-section not included

in the box culvert standards.

G. Clear Span of a Culvert: The distance measured along the construction

centerline between the inside faces of the exterior walls.

H. Skew Angle: The acute angle measured from a line normal to the
construction centerline to centerline of culvert. Clockwise is skew right
and counter clockwise is skew left.

I
 -~ ----- --- --rO/ffl 79 ➔ -- -

1.2 Box Culvert Stationing:

A. For structures 20 feet clear span or less, show station at centerline of box
culvert on the construction centerline.

B. For structures over 20 feet clear span, show beginning station and
ending station along the construction centerline.

Sta.
Culvert t~
I

/ I '
'
I
'
I
'
I I I

along Constr. <t.

Cu I vert ~ 20'-0
( A)

('Begin Sta.

/ /
'

I
..,
c I ear
S an of Cu I vert >20'-0
Measured along Constr. t

( 8)

2
- - - - - - ~ -Reinforced Concrete-Box CulvertManuaI-- - - - -1-0101-J94- - -

1.3 Proper Description of a Box Culvert:

A. When describing a culvert give information in the following order:

1. Number of barrels.

2. Span of the barrel.

3. Height of the barrel opening.

4. The total length of the culvert.

5. The degree and direction of the skew, if any.

B. Examples:

1. Three barrels 10 x 8 box culvert 100 feet long can be described

as: New 3-10x8x100' -0'' CBC

2. Same as Example 1 with 30 degrees skew to the right

New 3-10x8x115'-6" CBC Sk 30° Rt

1.4 Selection of Barrel Sections:

A. Each barrel section shall be selected according to the depth of fill along
the centerline of the culvert.

For 0 to 10' fill Use Table I

over 10' to 15' fill Use Table II
over 15' to 20' fill Use Table ill
over 20' to 25' fill Use Table IV
over 25' to 30' fill UseTableV

For fills greater than 30 feet, special sections must be designed.

B. The desirable minimum length of each barrel section is 15 feet. If any

barrel section except Table I is less than the minimum length, continue
using the cross-section of the higher fill for another barrel section.

3
-- - - - - - -Reinforced-eoncrete-Box-eulvert Man~~+- - - - - - - - - - - 010119

C. Culvert barrel sections adjacent to headwalls should always be Table

I (0-10' fill) and preferably be used with no more than two other barrel
sections.

D. The joint between the barrel sections should be made parallel to the
main transverse reinforcement. For skewed culverts requiring phased
construction and a joint skewed to the main reinforcement, a special
edge beam must be designed and detailed.

Special attention should be given to culverts with large skew angles,

high fills and multiple spans. The use of the following standard culverts
under high fills should be avoided.

4 barrels: 12' spans with skews greater than 35 degrees.

5 barrels: 10' spans with skews greater than 35 degrees.

12' spans with skews greater than 35 degrees.

6 barrels: 8' spans with skews greater than 35 degrees.

10' spans with skews greater than 35 degrees.
12' spans with skews greater than 20 degrees.

E. For skewed culverts, a portion of the barrel section will be overstressed

while other portions will be understressed since the joints between
barrel sections are not parallel to the construction centerline. Refer to
Figure A, page 15. Generally, the slight overstress is acceptable if the fill
at culvert centerline is within the designed maximum and the increase in
height is less than 3 feet. If the increase in height is greater than 3 feet or
the box skew angle greater than 45 degrees the stress due to the overload
must be checked.

1.5 Wingwall and Apron Selection:

A. Use wings that correspond to the embankment slopes. Refer to

Standards B-04.10, B-04.20, B-04.30, B-04.40, B-04.50, B-04.60, B-04.70
and B-04.80. For embankment slopes different than that shown on the
standards, use the wing with the flatter slope.

B. Use outlet aprons corresponding to the wings selected. Refer to

Standards B-06.10, B-06.20, B-06.30 and B-06.40.

4
- - - - - - --wReinforced-€oncrete-Box-eulvert-Manual- - - - - - - - - - - - - - - - - ----. otfJ1194- - - -

1.6 Placement of New Culverts and Headwalls:

A. The top of the deck of box culverts should not penetrate into the
pavement structure (surface and base) except when used as the traffic
riding surface.

B. Curbs of box culverts should be located outside the recovery area from
the edge of the traffic lane when guardrail or other means of protection
is not provided. The minimum distance from the edge of paved
shoulder to the face of the curb shall be 4' -0" when guardrail is installed.
Refer to Figure B, page 16. Table I of the Standard Box Culverts has
been designed structurally for use as a riding surface.

C. For culverts located at or near subgrade elevation, in which case the

headwalls would normally be within the recovery area from the traffic
lanes, a determination must be made as to whether to place the CBC
headwalls outside the recovery area or to install guardrail or other
protective barriers.

1.7 Placement of Reinforcing Steel:

A. Transverse Bars: Main transverse bars have been designed to be placed

normal to the culvert centerline. For the case of a short extension, bars
may be placed on the skew provided a special design is made.
Extensions less than half the width of the box culvert with skews 30
degrees and greater are considered short extensions.

B. Longitudinal Bars: Longitudinal bars shall be placed parallel to the

culvert centerline. Bars shall project through the construction joint a
minimum length of 1' -6".

C. Bars·at the End Barrel Sections: For skewed culverts, bars located at the
end barrel sections may be fabricated to exact lengths or field cut All
bars cut may be used for reinforcement at other portions of the box. This
applies to both transverse and longitudinal bars. Refer to Figure C,
page 17.

5
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Reinforced Concrete Box Culvert Manual- - - - --- - - - - - -10101194- - -

1.8 Construction Joints:

A. Construction joints shall be provided and spaced not more than 38' -6"
apart in the top slab and walls except as noted in Section 1.8 (B) below.
Construction joints in the floor slab are optional. Joints shall be made
parallel to the main transverse steel.

B. For end barrel sections of skewed culverts, the construction joint shall be
located at a minimum distance of 2' -0" from the end of barrel, but not
more than 30' -0" from the end of barrel measured along the culvert
centerline. Refer to Figure D, page 18.

C. For highly skewed multiple barrel culverts, a joint terminating at the

edge beam (curb) over a wall support will be required. Refer to Figure
D, page 18.

1.9 Culverts in Dual Roadways:

A. The culverts should be continuous through the median, unless wide

medians indicate separate culverts should be used.

B. Where culverts are extended through the median, the exposed portion
of the barrel should be covered by an earth berm. The berm shall not be
less than 9 inches in depth over the box culvert and shall have a 10:1
slope away from the box in a direction parallel to the median centerline.

C. The median may be drained with a pipe culvert under one of the
roadways or, if possible backflow is not objectionable, a pipe may be
placed through the sidewall of the box culvert. However, the energy
grade line shall not exceed the allowable headwater in the median.

6
Re iiiforceaToncreteBoxTillvert Manual - --- -- ----------- - - - - - - - - - - -- -10101194- -

1.10 Curb Rise:

A. Culverts located in roadways with steep grades, or skewed culverts

with a steep slope, need a curb rise when the elevations at which the
gradeline meets the curb line from beginning to end of box differs 6
inches or more. The curb rise is needed to prevent fill from spilling
over the curb and/ or wings.

B. Height of stirrups in a varying height curb should be increased in 3

inch increments. Length of vertical bars in raised wing should be
adjusted from the length shown on the Culvert Standards. Horizontal
bars in raised wings to be added if required.

1.11 Extension of Existing Culverts:

A. Box culvert extensions shall be consistent with the established scope and
intent of the project as defined in the appropriate scoping document
(Project Assessment, Design Concept Report, etc.).

B. Placement of extended culvert headwalls may be established as that for

new culvert design or may fall under other established ADOT design
criteria as established in the scoping document.

1.12 Removal of Existing Headwall:

A. Existing headwall is to be removed if required for new construction.

The projecting steel should be incorporated in new concrete for bond.

B. Existing curb is to be removed if its top elevation will be within one foot
of the new finished grade. Refer to Standard B-01.10.

C. Remove headwall to inside face of curb if top slab is less than 8 inches
thick. H removal of headwall to the inside face of curb is not required,
dowels should be placed in the top slab joining the two structures.
Refer to Standard B-01.11.

D. If portions of wings are to be removed, payment for removal of

structural concrete shall be as shown per Standard B-01.11.

7
Reinforced
= = =Concrete-Box
~==~ Culvert
~~ Manual
~ ~ = ~ - - - - - - - - - - - - - - - - ~ 010-1194-
~~ --:._

SHEET PREPARATION

2.1 Roadway Plan Sheets:

A. New Culverts:

1. Prepare a Reinforced Concrete Box Culvert Summary Sheet. Refer to

Figure L, page 26 and Section 2.3, page 11.

2. Prepare a detail sheet in accordance with the requirments of the

current edition of the Roadway Drafting Guides For Use in Office
and Field.

3. General Data to be shown:

a. CBC stationing. Refer to Section 1.2, page 2.

b. Size of culvert and skew.

c. Invert elevations at the top of the floor slab.

d. Distance to left and right end of culvert from construction

centerline measured along the centerline of culvert.

e. Percent slope of culvert and direction of flow.

f. Headwall and apron details, if required.

g. Bank Protection: Type, location and quantity.

h. Channel Changes: Location, size and excavation quantity.

i. Drainage Data: Flows and highwater elevations as required in

Article 602.4 of the Roadway Design Guidelines.

B. Revision of Existing Culvert:

1. Prepare a Concrete Box Culvert Extension Summary Sheet. Refer to

Figure M, page 27 and Section 2.3, page 11.

2. Prepare a detail sheet in accordance with the requirements of the

current edition of the Roadway Drafting Guides For Use in Office
and Field.

8
- - -- - --ueinforced Concrete-Box Culver1-Manua1- - - - - - - - - - -- - - -- - ------+01011911--- - -

3. General Data to be shown:

a. CBC stationing. Refer to Section 1.2, page 2.

b. Size of culvert and skew.

c. Size of new culvert to be added, if any.

d. Extension of existing culvert, if any, must specify length,

direction and slope of extension.

e. Invert elevations at the top of the floor slab for new and existing
structures.

f. Headwall and apron details, if required.

g. Bank Protection: Type, location and quantity.

h. Channel Changes: Location, size and excavation quantity.

i. Drainage Data: Flows and highwater elevations as required in

Article 602.4 of the Roadway Design Guidelines when available.

9
- -- - -Reinforced ConcreteBox CulverfManual - - - - - - - ~ - - - - - - - - - - - - t0/01194- - - ·

2.2 Bridge Sheets:

A. New Culverts:

For standard culvert sizes, no bridge sheet is required. All

information shall be provided on the Reinforced Concrete Box
Culvert Summary Sheet and the Roadway Plan Sheet.

B. Revisions of Existing Culverts:

For standard culvert sizes, no bridge sheet is required. All

information shall be provided on the Concrete Box Culvert
Extension Summary Sheet and the Roadway Plan Sheet

C. Standard Size Culverts with Special Sections (fill heights greater than 30
feet) and non-standard size culverts:

1. Location Plan. Refer to Figures E and I, pages 19 and 23.

2. Section on Centerline of Culvert Refer to Figures F, H, and J,

pages 20, 22 and 24.

3. Part Plan when needed to show reinforcing steel.

4. Special barrel section. Refer to Figure G, page 21.

5. Special headwall, if required.

6. Special apron, if required.

7. General Notes.

8. Refer to Reinforced Concrete Box Culvert Summary Sheet and

the Concrete Box Culvert Extension Summary Sheet for all other
data.

10
- =R=einfi=o=rc=oo=---=C=on=c=re=re~B=o=~~euI=-v~e=rt=M=a=n=M=·-------------------'~0~70~~~79~4 - - -

2.3 Reinforced Concrete Box Culvert Summary Sheet and

Concrete Box Culvert Extension Summary Sheet:

A. Span:

1. Culverts are classified into two groups:

a. 20 feet clear span or less.

b. Over 20 feet clear span.

Entry must be made on the Summary Sheet accordingly. Refer to

Figures L and M, pages 26 and 27.

B. Description:

1. Give Stations according to Section 1.2, page 2.

2. For dual roadway systems, identify roadway: i.e. EB or WB etc.

3. Indicate structure number for structures over 20 feet clear span.

4. Give barrel description according to Section 1.3, page 3.

5. List wings and/ or apron used.

C. Standard Drawings:

1. Give standard numbers from Structures Section Standard

Drawings for the corresponding sections used.

D. Length of Barrel or Barrel Extension:

1. The Roman Numerals on the Summary Sheet correspond to the

table numbers in the Standard Drawings.

2. Give length of barrel sections for both left and right of the
construction centerline. Refer to Figures L and M, pages 26 and
27.

3. For special sections, length of barrel section(s) to be given on the

bridge sheet.

11
- - -- -----ileinforced Concrete-Box Eulvert Manual ----- - - - ----1-,010119- - --

E. Approximate Quantities:

1. Structural Excavation:

Limits of structural excavation payment can be found in

Standard B-19.50.

Quantities should be rounded to the nearest 1 cubic yard.

Minimum value shown should be 5 cubic yards.

2. Structure Backfill:

Refer to Standard B-19.50 for placement and measurement

of structure backfill.

Quantity should be rounded to the nearest 1 cubic yard.

Minimum value shown should be 5 cubic yards.

3. Concrete and Reinforcing Steel Quantities:

a. Quantities for barrels:

All standard quantities have been calculated for a

section with barrel length of one foot. The quantities per
linear foot of barrel can be found in Standard B-02.10 and
B-02.70.

Multiply the length of each barrel section by the

corresponding volume per linear foot for concrete and
by the weight per linear foot for reinforcing steel.

Total barrel quantities is the sum of all barrel sections.

b. Quantities for headwalls:

Headwall quantity includes wings, curb and cut-off wall

quantities. All headwall quantities can be found in
Standard B-05.10, B-05.20 and B-05.30.

Quantities can be obtained directly off the standards for

single barrel headwalls. For two or more barrels, simply
add .& c or .& s for each additional barrel to the single barrel
headwall quantity.

12
- - Reinforced Concrete Box Culvert Manual- - --10101/94

For level wings, quantities can be found on Standards

B-08.10 and B-08.20. For length of wing equal to height
of box opening plus two feet (H+2), quantities can be
obtained directly; otherwise, additional quantities per
foot of wing are given for lengths greater than H+2.

c. Quantities for outlet apron:

Quantities can be found on Standard B-06.20, B-06.30

and B-06.40.

Quantities can be obtained directly from the standards

for single barrel culverts. For two or more barrels,
simply add A c or A s for each additional barrel to the
single barrel apron quantity.

d. Quantities for laps at construction joints:

Since the weight of the #4 reinforcment times the 1' -6"

extension equals one pound, the number of longitudinal
bars equals the weight of steel quantity in pounds per
joint

The number of longitudinal bars shall be based on the cc

and gg bars from the smaller section.

e. Skewed culverts require edge beam reinforcing at ends.

Quantities must be calculated. Refer to Standard B-01.10
and B-01.11.

f. Quantities for special sections must be calculated.

g. Culvert extensions require dowels. Dowel reinforcing steel

weight must be calculated and included in reinforcing steel
quantity.

h. Total quantities:

Add quantities for barrels, headwalls, aprons, joints,

edge beam reinforcing, dowels, and special sections
whenever applicable.

Quantities should be rounded to the nearest cubic yard

for concrete and nearest 5 lbs for reinforcing steel.

13
- ~efnforceoToncrete Box CtUvercManual - - - -10/61194 - -

4. Removal of Existing Concrete:

Refer to Standard B-01.11 and Section 1.12, page 7 for proper

limits of payment.

Quantities should be computed to the nearest 0.1 cubic yard

and the total rounded to the nearest cubic yard.

5. Placement of Dowels:

Give the actual number of dowels to be placed. Dowel steel

weight shall be included in the total reinforcing steel
quantities. Refer to Figure K, page 25.

6. Drainage Excavation:

Drainage excavation for channel cleanout and/ or channel

changes.

Quantities should be rounded to the nearest 1 cubic yard.

Minimum value shown should be 5 cubic yards.

F. Remarks:

1. Reference details used.

2.4 Drafting Guidelines:

A. All CADD sheets shall be developed in accordance with the guidelines

published by CADD System Services.

B. For standard culverts, additional detailing guidelines, contained in the

Roadway Drafting Guides for Use in Office and Field, should be
followed.

C. When bridge details are required for non-standard applications,

additional detailing guidelines, contained in the CADD Standards
Volume III, should be followed. The standard North arrow is to be
shown on the location plan.

14
- - - -R
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=oncrctc Box Culvert Manual 070179

Under - stressed
Area

Construction
Joint

TABLE I TABLE II
Barrel Section Barrel Section

Line of equal fl I I
paral lei to Constr 'A?!11--0ver-stressed
Area

PART PLAN

Average fl I I ~
/
... ------ --- ---------- - ------ - ----------- ----I
i-- Design
fl I I height
/

I" .,

SECTION A-A

Overstressed and Understressed Areas

Figure A
15
 ----------
Reinforced Concrete Box Culvert Manual - - 10701/94 ---"

raffle Paved Shoulder •4' MI n I mum

anes Including any wl th guardra I I
Widening
Pavement

,1 ,1
V y

... ~

A-~
*Measured Normal to Construction l

TYPICAL SECTION
NOTE-On al I new structures, top of slab shal I
not exceed subgrade elevation except when
used as the traffic riding surface.

Roadway Oearance
Figure B
16
 Reinforced Concrete Box Culvert Manual

I,. spaces @ 38'-6 or I ess

Constr.
Cut bars in Joint
fleld & use
as shown by
arrows.

Cut bars in
I,;aTableMal::,-1I
'-6
Constr.
Joint field & use
as shown by
arrows.
LONGITUDINAL STEEL TRANSVERSE STEEL
PLAN

Cut bars ln.........,- 38'-6" or less

fleld & use
as shown by
arrows.

1 ... •38'-6 Max. I 38'-6 Max . .,,1

Table I •• Table I

PLAN
*Construction Joint must end at an Interior wal I.
Refer to Figure D page 18.

Reinforcing Steel Placement

Figure C
17
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End of Barrel
Constr.
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30'-0 Max.

,. 58'-0 Max. ., I.. 38'-6 Max ... 1

PART PLAN

38'-6 Max.
Curb

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58'-0 Max.
1-
PART PLAN

Construction Joints
Figure D
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22
Reinforced Concrete Box Culvert Manual

New Inlet Wings

Std. B-04. 70
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: ,,:; /New 2-1 Ox6x99'-0

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Location Plan - Existing Box Culvert with Extensions and Additions

Figure I
23
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24
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Reinforced Concrete Box c~u1vcrt Manual

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The table Indicates the number of dowels required
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Dowels Required for Culvert Extension

Figure K
25
Reinforced Concrete Box Culvert Manual 10/01/94
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