Precast Bridge Solutions

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OTEC 2008, DML

Products Available
Elliptical Pipe
Box Culvert
Three Sided Flat Top/3-S
Hanson Arch

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OTEC 2008, DML

Elliptical Pipe

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OTEC 2008, DML

Advantages
Use when:

Height or width restrictions exist

Greater capacity is required at shallow depths of flow (Horizontal
Elliptical).
Higher flushing velocities are required at low flows (Vertical Elliptical).
Very high fills (Vertical Elliptical)
Intended for storm sewer applications

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OTEC 2008, DML

Elliptical Pipe
Specifications

ASTM C-507
AASHTO M207
Joints

Tongue and Groove

Mastic Joint Compound
Preformed Butyl Sealants
Some locations rubber joint

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OTEC 2008, DML

Available Sizes

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OTEC 2008, DML

Fill Height Tables

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OTEC 2008, DML

Box Culverts

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OTEC 2008, DML

Advantages
Maximize Hydraulic Capacity
Minimize Cover Option
Substitute for cast in place and
metal arches or multiple
barrel applications

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OTEC 2008, DML

Specifications Governing Design

Box (> 2 fill) Spec - Retired

Box (< 2 fill) Spec - Retired

ASTM C-789
ASTM C-850

ASTM C-1433 Box Culvert (all fills) (2004)

ASTM C-1577 Box Culvers (LRFD)

AASHTO
ASCE

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OTEC 2008, DML

17th edition sec 16.7

Standard 26-97

42 sizes between
3x2 and 12x12
x4(min) fill heights each
= 168 Designs

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OTEC 2008, DML

Reinforcing

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OTEC 2008, DML

Design

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OTEC 2008, DML

Design

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OTEC 2008, DML

Three Sided Flat

Top

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OTEC 2008, DML

Three Sided Flat Top

Per AASHTO 17th Ed. (Standard LFD)

Section 16.8 Precast Reinforced Concrete 3 Sided Structures
ASTM C-1504
Three Sided Structure
ODOT 706.051 Precast Reinforced Concrete Three-Sided Flat Topped Culverts
Spans 12 - 42 feet
Rises to 10 feet* (min 3ft depends on Span)

(prefer 1 ft. increments)

8 or 5 foot standard section length

Skews to 45 degrees (limits maximum span)

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OTEC 2008, DML

Longitudinal Section

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OTEC 2008, DML

Joint Details

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OTEC 2008, DML

The Design

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OTEC 2008, DML

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OTEC 2008, DML

As7

Cut off length for As1

Handling steel #4
bars @ 12 OC.
Not required for
structural design.

As2

As5

As6

As1
As4

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OTEC 2008, DML

Reinforcing Detail
No Scale

Construction

Shipped as installed
Removed from trucks utilizing crane

Pick points

Placed in keyway/footing
Keyway grouted

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OTEC 2008, DML

6x6x3/8 masonite shim

(2 to 4 per section)

Elevated Footing/Stem wall to

increase effective rise dimension
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OTEC 2008, DML

EASY AS ONE
TWO

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OTEC 2008, DML

THREE

Joints sealed with external wrapper

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OTEC 2008, DML

W. 130th

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OTEC 2008, DML

W 130th

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OTEC 2008, DML

W 130th

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OTEC 2008, DML

Arch

Per AASHTO ( LFD or LRFD)

ASTM C-1504
Three Sided Structure
ODOT 706.052 Precast Reinforced Concrete Three-Sided Arched Topped Culverts
Spans 12,14,16,20,24,28,32,36,42 and 48 feet
Rises to 12 feet* (min 4ft depends on Span)
8 foot standard section length

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Precast Components

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Arch Typical Section

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OTEC 2008, DML

Design Info

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OTEC 2008, DML

Loading analysis is done

in CandeCAD.

Design Info

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OTEC 2008, DML

Output is used as input for a

MathCAD steel design template.

Reinforcing Details
Structure & Headwall

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OTEC 2008, DML

Reinforcing Details
Wingwall & Footing

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Delivery

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Installation

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Skew with Beveled

Ends

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Parapet walls can be monolithic on the end units or

precast separate and placed at the site.

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OTEC 2008, DML

Detached parapet walls have a precast collar behind them

and are mounted with stainless steel hardware

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Manufacturing

Reinforcing Setup

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Set Forms

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Yard the Product

For Shipping

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Wingwalls

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OTEC 2008, DML

Wingwalls Flat Top and Box Culverts

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Arch Wingwalls And Headwalls

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Precast wing walls sit on a foundation that is common with the barrel
foundation.
Prevents differential settlement.
Makes walls easier to place.

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OTEC 2008, DML

When everything is set the joints are wrapped.

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Precast or Cast-In-Place

Cast-In-Place or Precast
What are the differences?
Similar designs?

Specifications?
Installation & construction issues?
Concerns include:

Tolerances
Joints
Strength
Testing
And more

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Precast
National Specifications
Controlled Production Environment

Installation Efficiency
Economical

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National Specifications

ASTM

C1433 (C789 & C850)

C1577
AASHTO (Materials & Testing)

M273 & M259

AASHTO (Bridge Design)

Sections 3,6,8,17,26
ASCE

26-97
28-00

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OTEC 2008, DML

ASTM C1433/1577
Product specification
Covers all aspects of the precast box culvert

It is for monolithic boxes only. For other RCB (3-sided) refer to

ASTM C1504 & AASHTO

Specific material standards
Steel
Cementitious
Aggregates
Specific design

Design Tables
Modified & Special Design
Specific manufacture

Mixture & Curing

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OTEC 2008, DML

ASTM C1433/1577
Specific physical requirements

Cylinders & Cores

Specific permissible variations

Internal, Slab & Wall Thickness, Lgth of Opposite Surfaces, Lgth of

Section, Position & Area of Reinf., Haunch Dimen.

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Controlled Production
Environment
Concrete batching

Forms
Steel placement
Concrete placement

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Installation Efficiency
Speed
Structural performance/design verified prior to delivery

Versatility

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Economics

Time is money
Total Installed Cost (Not Unit Price)

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Cast-In-Place
No ASTM or AASHTO Standards
Multiple Field Related Variables

Time Dependant

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National Standards

None specific to Cast-In-Place

Designs based on general AASHTO Bridge Standards & ACI
Concrete strength:3000 4000 psi

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Field Related Variables

Weather
Forms

Steel placement
Concrete consistency (truck to truck variability)
Curing

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OTEC 2008, DML

Time Dependent
Form removal, backfill, design load application all based on

concrete strength
Forms:
Designed by P.E.
Placing Concrete:

Weather sensitive (wind, humidity, temperature)

Need approval for working in the rain
Temperature limits
Time in Truck limits
Walls- 1-2 hour set before placing top slab

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OTEC 2008, DML

Cast-In-Place
Curing Concrete:

Minimum cure is weather dependent

Water curing
Wet mat curing
Water spray curing
Ponding curing
Membrane Curing

What is a curing day?

Form Removal:

2500 psi for slabs

2 day or more cure for culvert footings
Vertical surfaces 12 hrs after pre-set
Inside forms 1800 psi

Full design strength must be obtained before construction or full

traffic loads are allowed

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OTEC 2008, DML

Cast-In-Place
If acceptance test cylinders fail:

Cores < design but average determined to be structurally adequate,

payment to be adjusted
Concrete not structurally adequate to be removed

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