Design of Box Culvert

Page 1 of 21
LIST OF REFERENCES FOLLOWED
Sl.No.
1
Code
IRC SP:192001
IRC 5-1998
IRC 6-2010
IRC 21-2000
IRC 78-2000
IRC SP:542000
Topic
Manual for Survey, Investigation and Preparation of Road Projects
(Second Revision)
Standard Specifications and Code of Practice for Road Bridges,
Section I General Features of Design (Seventh Revision)
Section II Loads and Stresses (Fifth Revision)
Section III Cement Concrete (Plain and Reinforced) (Third
Revision)
Section VII Foundations and Substructure (Second Revision)
Project Preparation Manual for Bridges
Page 2 of 21
DESIGN OF BOX CULVERT

PROJECT INTRODUCTION:This bridge is designed as a RCC rigid frame box culvert.
DESIGN DATA :The following design data is given below:
Length of bridge = 42m

Total width of the bridge = 6.5m (including 2 no.s of sidewalks, each 700mm wide)
Loading IRC Class A-A
Velocity of water = 1.8 m/s
Discharge of water = 5000 cusec
High Flood Level ( HFL ) = 5m
Bearing Capacity of Soil = 7 t/m2
Unit weight of soil = 1900 kg f/m3
Type of Concrete = M25
Type of steel = Fe415
LOADING CONDITIONS :
a)
b)
c)
d)
e)
f)
Concentrated vertical wheel loads due to class A-A wheeled vehicles ( From IRC- 6)
Uniform vertical load due to dead load of wearing course & deck slab
Dead Load of weight of walls
Pressure from contained water
Load due to earth pressure
Load due to cantilever footpath
Page 3 of 21
DESIGN CONSTANTS :Grade of concrete used = M25

Grade of steel used = Fe415
From IS 456:2000, we have the followingscbc = permissible stress in bending compression

= 8.5 N/mm2
[ Ref. Tab 21 of IS 456:2000 ]
sst = permissible stress in steel in tension

= 230 N/mm2
[ Ref. Tab 22 of IS 456:2000 ]
Modular ratio, m = 280 / ( 3 * scbc )

= 10.98
k = ( m * scbc ) / ( m * scbc + sst )

= 0.29
J = 1 k/3
= 0.903
Q = 0.5 * scbc * k * j
= 1.11 N/mm2
Page 4 of 21
H = 7.1 + 0.3 * 2 = 7.7 m

L = 7.6 + 0.3 * 2 = 8.2 m
MOMENT COEFFICIENTS AT VARIOUS SECTIONS :Section

L/H
a
(wL)
B-1
A-2
A-3
E-4
D-5
D-6
C-7
+0.182
-0.068
-0.068
-0.032
-0.036
-0.036
+0.088
LOAD CALCULATIONS :-
Loading condition coefficients

b
c
d
2
(wL )
(wL)
(pH2)
Factor for moment
+0.083
+0.021
+0.019
-0.042
+0.021
+0.019
-0.042
+0.021
+0.019
-0.042
-0.042
+0.043
-0.042
-0.004
+0.023
-0.042
-0.004
+0.023
+0.083
+0.146
+0.023
e
(pH2)
-0.019
-0.019
-0.019
+0.043
-0.023
+0.023
-0.023
Page 5 of 21
a) Calculation for Class A-A Wheel Loading:

As per IRC Class A-A loading,
Maximum load, Pu = 6.25 t
Impact Factor = 25 %
[ Ref. IRC 6-2010, Sec II ]

[ Ref. Cl. 208.3- a-2 of IRC 6-2014]
Assuming dispersion of load is within a zone of 1 meter

Now,
Weight, W = 6.25 + 6.25 * 0.25
7.8 t
Dimensions of Box Culvert

L = 8.2m, H = 7.7m
Moment, MWHEEL = WL = 7.8 * 8.2 = 63.96 tm
= 63960 kg-m
Section
[1]
B-1
A-2
A-3
E-4
D-5
D-6
C-7
M wheel (kg-m)
[2]
63960
Coefficient
[3]
+0.182
-0.068
-0.068
-0.032
-0.036
-0.036
+0.088
b) Calculation for Uniform Vertical Dead Load:

Thickness of wearing course = 0.075 m
Thickness of slab = 0.6 m
Total thickness = 0.675 m
Unit weight of concrete = 2500 kg/m3

Uniform load, w = 2500 * 0.675 * 1
1700 kg/m
Moment, MUDL = wL2 = 1700 * (8.2)2

= 114308 kg-m
Final Moment (kg-m)

[4] = [2 x 3 ]
+ 11640.7
- 4349.3
- 4349.3
-2046.7
-2302.6
-2302.6
5628.5
Page 6 of 21
Section
[1]
B-1
A-2
A-3
E-4
D-5
D-6
C-7
MUDL (kg-m)
[2]
114308
Coefficient
[3]
+0.083
-0.042
-0.042
-0.042
-0.042
-0.042
+0.083
Final Moment (kg-m)

[4]= [2 x 3]
+ 9487.6
- 4800.9
- 4800.9
- 4800.9
- 4800.9
- 4800.9
+ 9487.6
Coefficient
[3]
+0.021
+0.021
+0.021
-0.042
-0.004
-0.004
+0.146
Final Moment (kg-m)

[4]= [2 x 3]
+ 1833.9
+ 1833.9
+ 1833.9
- 3667.9
- 349.3
- 349.3
+ 12750.2
c) Calculation for weight of walls:

Weight, W = 2500 x 0.6 x 7.1 x 1
= 10650 kg
Moment, MWALL = 10650 * 8.2
= 87330 kg-m
Section
[1]
B-1
A-2
A-3
E-4
D-5
D-6
C-7
MWALL (kg-m)
[2]
87330
d) Calculation of water pressure:

p = x Hint = 1000 * 7.1 * 1
= 7100 kg/m
MWATER = p x H2 = 7100 * (7.7)2
= 420959 kg-m
Section
[1]
B-1
A-2
A-3
E-4
D-5
D-6
C-7
MWATER (kg-m)
[2]
420959
( = density of water = 1000 kg/m3 )
Coefficient
[3]
+0.019
+0.019
+0.019
+0.043
+0.023
+0.023
+0.023
Final Moment (kg-m)

[4]= [2 x 3]
+ 7998.2
+ 7998.2
+ 7998.2
+ 18101.2
+ 9682.1
+ 9682.1
+ 9682.1
Page 7 of 21
e) Calculation of load due to earth pressure:
Ka = (1 sin )/ (1 + sin )
= 1/3
p = Ka x x H = (1/3) x 1900 x 7.7
4877 kg/m
Moment, M = p x H2 = 4877 x (7.7)2

= 289157.33 kg-m
Section
[1]
B-1
A-2
A-3
E-4
D-5
D-6
C-7
MEP (kg-m)
[2]
289157.33
Coefficient
[3]
-0.019
-0.019
-0.019
+0.043
-0.023
+0.023
-0.023
Final Moment (kg-m)

[4]= [2 x 3]
- 5494.0
- 5494.0
- 5494.0
+ 12433.8
- 6650.6
+ 6650.6
- 6650.6
Page 8 of 21
Design for section at B-1 :

Total Momenta)
b)
c)
d)
e)
Due to wheel load = + 11640.7 kg-m

Due to deck slab and wearing course = + 9487.6 kg-m
Due to weight of walls = + 1833.9 kg-m
Due to water pressure = + 7998.2 kg-m
Due to earth pressure = - 5494.0 kg-m
MB-1 = 25466.4 kg-m
(
Required depth,
Using
M
)
(QB)
d=
M = 25466.4 * 9.81
249825.4 N-m
B=1m
Q = 1.11 N/mm2
We get,
Overall depth,
475 mm
D = 475 + 25/2 + 60 = 547.5 mm
So providing 600mm overall depth is satisfactory.
Calculation of reinforcement:
MAIN BARS Ast = M / ( sst * j * d )

Using
M = 249825.4 N-m
sst = 230 N/mm2 for Fe415 bars
j = 0.903
d = 475 mm
We get Ast = 2532.4 mm2

Providing 25 bars,
Required spacing = ( 1000 * A ) / Ast
Now,
for 25 bars, A = (/4) * 252
= 490.9 mm2
required spacing = ( 1000 * 490.9 ) / 2532.4
193 mm
Let us provide 25 bars @ 180 mm c/c as main bars in bottom.
DISTRIBUTION BARS -
Page 9 of 21
Moment,
M = 0.2 * ( Moment due to DL ) + 0.3 * ( Moment due to LL )

= 0.2 * 9487.6 + 0.3 * 11640.7
= 5389.7 kg-m
= 52873.0 N-m
Ast = M / ( sst * j * d )
Using
M =52873.0 N-m
j = 0.903
d = 475 mm
We get
Ast = 536.0 mm2
Providing 12 bars,
Now,
for 12 bars, A = (/4) * 122
= 113.1 mm2
required spacing
= ( 1000 * 113.1 ) / 536.0
= 211 mm
Let us provide 12 bars @ 200 mm c/c as distribution bars in bottom.
Page 10 of 21
Design for section at A-2 :

Total Momenta)
b)
c)
d)
e)
Due to vertical load = - 4349.0 kg-m

Due to deck slab and wearing course = - 4800.9 kg-m
MA-2 = - 4812.1 kg-m
Cantilever Design of sidewalk
Now moment due to side walk should be added

We have the following
i.
Total available width = 6500
ii.
Width of road = 4500 mm
iii.
Height of raised kerb = 300 mm
iv.
Width of sidewalk = 0.5 * { 6500 (4500 + 2 * 300 )} = 700 mm
Maximum dead load = 0.3 * 2500 = 750 kg/m2
Maximum Live Load = 750 kg/m2
Total Load = 750 + 750 = 1500 kg/m2

Providing 4 no.s of beams for the total length,
Uniform Load, w = 1500 * 8.2 / 4 = 3075 kg/m
[ 300 mm raised kerb ]

[ Ref. IRC 6:2014 - Sec II ]
Page 11 of 21
Maximum moment, Mmax = w * LSIDEWALK2 / 2
= 3075 * 0.72 / 2 = 753.4 kg-m
M
)
QB
d=
(
Required depth,
Using
M = 753.375 * 9.81
7390.9 N-m
B = 250 mm (Assumed )
Q = 1.11 N/mm2
We get d = 164 mm
Let us provide 250m mm depth at the ends and 300 mm depth at connection
Calculation of reinforcement
MAIN STEEL BARS

Ast = M / ( sst * j * d )
Using
M = 7390.9 N-m
j = 0.903
d = 164 mm
We get Ast = 217 mm2

Providing 12 bars,
A = (/4) * 122
= 113.1 mm2
No. of bars required,
= 217 / 113.1
= 1.92 mm
Let us provide 3 No.s of 12 bars as main bars in the beam.
Design of slab for combined moment on top of abutment Combined Moment, M = - 4812.1 753.4 = - 5565.5 kg-m
M
)
QB
d=
(
Required depth,
Using
M = 5565.6 * 9.81 = 54597.6 N-m

B=1m
Q = 1.11 N/mm2
We get d = 222 mm
Page 12 of 21
But overall depth should be such that we have ( L/D )
12
Hence,
We get Drequired = L/12 = 7100/12
592 mm
So let us provide an overall depth of 600 mm
Effective depth provided, d = 600 (16/2) 60 = 532 mm

Using
M = 54597.6 N-m
j = 0.903
d = 532 mm

Providing 16 bars,
Now,
for 16 bars, A = (/4) * 162
= 201.1 mm2
= 407 mm
But maximum spacing allowed as main bars = 300mm
Let us provide 16 bars @ 300 mm c/c as main bars.
DISTRIBUTION BARS
Let us provide 12 bars @ 300 mm c/c as distribution bars.
Page 13 of 21
Design for section at E-4

Total Momenta)
b)
c)
d)
e)
Due to wheel load = - 2046.7 kg-m

Due to deck slab and wearing course = - 4800.9 kg-m
Due to weight of walls = -3667.9 kg-m
Due to earth pressure = + 12433.8 kg-m
ME-4 = + 20019.5 kg-m
M
)
QB
d=
(
Required depth,
Using
M = 20019.5 * 9.81 = 196391.3 N-m

B=1m
Q = 1.11 N/mm2
We get
421 mm
12
Hence,
We get
D = L/12 = 7100/12
592 mm
Effective depth provided, d = 600 (25/2) 60 = 527.5 mm

Using
M = 196391.3 N-m
j = 0.903
d = 527.5 mm

Providing 25 bars,
Now,
for 25 bars, A = (/4) * 252
= 490.9 mm2

= 273 mm
Page 14 of 21
DISTRIBUTION BARS
Moment = 0.2 * ( Moment due to DL ) + 0.3 * ( Moment due to LL )
= - 0.2 * 4800.9 - 0.3 * 2046.7
= - 1574.2 kg-m
Ast = M / ( sst * j * d )
Using M = 1574.2 kg-m = 15442.9 N-m
j = 0.903
d = 527.5 mm
We get,
Ast
141 mm2
Providing 10 bars,
Now,
for 10 bars, A = (/4) * 102
= 78.5 mm2
required spacing = ( 1000 * 78.5 ) / 141

= 556 mm
But maximum allowable spacing of bars is 300mm.

[Ref IRC 5]
Page 15 of 21
Design for section at C-7

Total Momenta)
b)
c)
d)
e)
Due to wheel load = + 5628.5 kg-m

Due to deck slab and wearing course = + 9487.6 kg-m
MC-7 = + 30897.8 kg-m
M
)
QB
d=
(
Required depth,
Using
We get
M = 30897.8 * 9.81 = 303107.4 N-m

B=1m
Q = 1.11 N/mm2
523 mm
Calculation of reinforcements
Now,
MAIN BARS
Ast = M / ( sst * j * d )
Using
M = 303107.4 N-m
j = 0.903
d = 523 mm

Providing 25 bars,
Now,
for 25 bars, A = (/4) * 252
= 490.9 mm2

= 175 mm
DISTRIBUTION BARS
= 0.2 * 9487.6 + 0.3 * 5628.5
+ 3586.1 kg-m
Now,
[Ref IRC 5]
Page 16 of 21
Ast = M / ( sst * j * d )
Using M = 3586.1 * 9.81 = 35179.6 N-m
j = 0.903
d = 523 mm
323.9 mm2
We get Ast
Providing 12 bars,
Now,
for 12 bars, A = (/4) * 122
= 113.1 mm2

= 349 mm

Design for bending moment at Piers

This design is same as the design of abutment except the fact that there will be no earth pressure and
the water pressure on each side will neutralize each other.
Total Momenta) Due to wheel load = - 2046.7 kg-m
b) Due to deck slab and wearing course = - 4800.9 kg-m
c) Due to weight of walls = - 3667.9 kg-m
M = - 10515.5 kg-m
M
)
QB
d=
(
Required depth,
Using M = 10515.56 * 9.81 = 103157.1 N-m

B=1m
Q = 1.11 N/mm2
We get
305 mm

Hence,
We get D = L/12 = 7100/12
592 mm
12
Page 17 of 21
Effective depth provided, d = 600 (25/2) 60 = 527.5 mm
Calculations of reinforcements
Now,

Using
M = 103157.1 N-m
j = 0.903
d = 527.5 mm

Providing 16 bars,
Now,
for 16 bars, A = (/4) * 162
= 201.1 mm2

= 213.5 mm
DISTRIBUTION BARS
= - 0.2 * 4800.9 - 0.3 * 2046.7
= - 1574.2 kg-m
Ast = M / ( sst * j * d )
Using M = 1574.2 kg-m = 15442.9 N-m
j = 0.903
d = 527.5 mm
We get,
Ast
141 mm2
Providing 8 bars,
Now,
for 8 bars, A = (/4) * 82
= 50.3 mm2
required spacing = ( 1000 * 50.3 ) / 141

= 356 mm
[Ref IRC 5]
Page 18 of 21
SPECIFICATIONS OF MATERIALS
GENERAL All materials to be used in works shall conform to Indian Standards Specification as
published by Bureau of Indian Standard from time to time (and in the absence, thereof, as
approved by the Engineer-in-Charge).
Page 19 of 21
BRICKS
All bricks shall be approved quality of standard specifications made of good Brick
earth, uniform deep red, cherry or copper colour, thoroughly burnt in kiln (machine made)
without being vitrified, regular in shape and size, sound, hard homogenous in texture, true to
shape and of standard dimensions, and shall be free from cracks, chips, flaws stones or humps
of any kind shall not show appreciable signs of efflorescence either dry or subsequent to
soaking in water.
The size of brick shall be 39/4 * 15/4 * 11/4 (conventional) or 200*100*100 (modular).
The bricks should emit a clean ringing sound on being struck and have a minimum crushing
strength of 105 kg/sq.cm. All the bricks which absorb water more than 20% of their own dry
weight after 24 hours immersion in cold water shall be rejected.
COARSE AGGREGATES FOR CEMENT CONCRETE WORKS Stone chips and Stone ballast for cement concrete (plain in reinforced) shall be hard,
of uniform and fine texture, free from faults of planes of weakness and free from weathered
faces. The ballast or chips must be free from loam, clay or any surface coating, organic matter
or other impurities, and screened free of dust, stone of black and hard variety as is generally
available from quarries in pakur or pachami areas will be normally used. Stone aggregates
from other may also be used provided the same is found suitable in the opinion of the
Engineer-in-Charge. The opinion of the Engineer-in-Charge must be recorded in writing.
The ballast or chips shall be obtained by breaking from large blocks and
Must be more cubical in shape.
Gravel for use as coarse aggregates in cement concrete work must be hard, absolutely
free from surface coating and no being broken, the fractured surface must indicate a
uniform and fine texture free from laminations or planes of weakness. It shall be
thoroughly washed and free from foreign elements.

Jhama chips for cement concrete work shall be obtained by breaking good quality
jhama bats, must not be spongy or with any coating of foreign materials and
homogenous in the chips shall be more or less cubical in shape. All coarse aggregates
for concrete work shall be well graded. These shall be cleaned for removal of dust,
and if so necessary in the opinion of the Engineer-in-Charge, shall be washed at the
cost and expense of the contractor.
Page 20 of 21
SAND All sand shall be clean, sharp and free from clay, loam, organic, or any other foreign matter
and the same shall be obtained from approved source. The contractor shall get the sample of
and to be used in different kind of works approved by Engineer-in-Charge before using the
same in work. Sand which in the opinion of the Engineer-in-Charge of his representative, is
dirty, and must be washed to his satisfaction at the cost and expenses of the contractor.
Sand for all cement concrete work must be coarse. The sand shall pass through a
mesh, 4.75 mm. square measured in the clear. Sand shall not be used in the concrete
works if contains more than 10% of the fine grains passing through a 76 mesh sieve
as used for cement test, nor should be fineness modulus be less than 2.00 unless
specific permission is obtained from the Engineer-in-Charge.

Medium sand may be used for cement mortar for masonry, plaster etc. and also for
bituminous works of road, fineness modulus should be between 2 to 1.8.

Sand filling in plinth or foundation where specified may be done with local sand.
CEMENT No cement excepting those supplied by the department shall be normally be used in
work or bought to the site by contractor. Cement bags should be stored in a water tight shed
having wooden floor or platforms raised atleast 45 cm. as approved by the Engineer-inCharge. Cement which is partially set or which is lumpy or caked is to be treated as damaged
and shall be removed from site immediately.
STEEL All steel shall be clean and free from loose mill scales, dust, loose rust and coats of
paints, oil or other coating. Any scale or loose rust shall be removed before use even though
the same may be applied by the department, without any claim any extra charge for the same.
Page 21 of 21
No steel excepting those supplied by the department shall be used normally in work or
brought to the site by the contractor.

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Page 1 of 21

LIST OF REFERENCES FOLLOWED

DESIGN OF BOX CULVERT

DESIGN DATA :The following design data is given below:

Length of bridge = 42m

DESIGN CONSTANTS :Grade of concrete used = M25

From IS 456:2000, we have the followingscbc = permissible stress in bending compression

[ Ref. Tab 21 of IS 456:2000 ]

sst = permissible stress in steel in tension

[ Ref. Tab 22 of IS 456:2000 ]

Modular ratio, m = 280 / ( 3 * scbc )

k = ( m * scbc ) / ( m * scbc + sst )

H = 7.1 + 0.3 * 2 = 7.7 m

MOMENT COEFFICIENTS AT VARIOUS SECTIONS :Section

Loading condition coefficients

a) Calculation for Class A-A Wheel Loading:

[ Ref. IRC 6-2010, Sec II ]

Assuming dispersion of load is within a zone of 1 meter

Dimensions of Box Culvert

b) Calculation for Uniform Vertical Dead Load:

Total thickness = 0.675 m

Unit weight of concrete = 2500 kg/m3

Moment, MUDL = wL2 = 1700 * (8.2)2

Final Moment (kg-m)

Final Moment (kg-m)

Final Moment (kg-m)

c) Calculation for weight of walls:

d) Calculation of water pressure:

( = density of water = 1000 kg/m3 )

Final Moment (kg-m)

Moment, M = p x H2 = 4877 x (7.7)2

Final Moment (kg-m)

Design for section at B-1 :

Due to wheel load = + 11640.7 kg-m

D = 475 + 25/2 + 60 = 547.5 mm

So providing 600mm overall depth is satisfactory.

MAIN BARS Ast = M / ( sst * j * d )

We get Ast = 2532.4 mm2

required spacing = ( 1000 * 490.9 ) / 2532.4

M = 0.2 * ( Moment due to DL ) + 0.3 * ( Moment due to LL )

Ast = 536.0 mm2

= ( 1000 * 113.1 ) / 536.0

Design for section at A-2 :

Due to vertical load = - 4349.0 kg-m

Cantilever Design of sidewalk

Now moment due to side walk should be added

Total Load = 750 + 750 = 1500 kg/m2

[ 300 mm raised kerb ]

MAIN STEEL BARS

We get Ast = 217 mm2

M = 5565.6 * 9.81 = 54597.6 N-m

But overall depth should be such that we have ( L/D )

So let us provide an overall depth of 600 mm

Effective depth provided, d = 600 (16/2) 60 = 532 mm

MAIN BARS Ast = M / ( sst * j * d )

We get Ast = 494.1 mm2

required spacing = ( 1000 * 201.1 ) / 494.1

Design for section at E-4

Due to wheel load = - 2046.7 kg-m

M = 20019.5 * 9.81 = 196391.3 N-m

But overall depth should be such that we have ( L/D )

So let us provide an overall depth of 600 mm

Effective depth provided, d = 600 (25/2) 60 = 527.5 mm

MAIN BARS Ast = M / ( sst * j * d )