Private Box Culvert


Project Gallery

These pictures show various stages of the construction of a new box culvert that was constructed to take the place of an old steel and wood structure.  The existing steel and wood structure was torn down in the first phase of the operation.  The structure was placed over an existing concrete spillway, so no excavation was required and only a small flow of approximately one inch of water was involved.  When properly planned and executed, it should be possible to complete all of the work on a box culvert from the ground and without need for a crane.  The structural portion is simply a slab, some walls, and a cover slab.  The remaining parts of the work are regular road construction processes: grading, crushed stone base, paving, guardrail, and landscaping.  Often there is a small flow of water that must be maintained through and across the work.  This is usually handled by temporarily diverting water around the current work area, and then over the new foundation, as walls and cover slab are placed.  All of the work on this simple structure was performed with a handful of workers and the support of a track excavator.    

First the road was closed to traffic and forming materials were delivered to the site. Concrete foundation was placed and then wall forms were erected. Forming work was performed from the ground as about an inch of water flow was maintained through the work area.    
As forms were removed and the interior walls were visible, the forms for the end walls were set in place. Looking upstream at the completed interior walls of the 4-barrel box With end walls in place, the cover slab was formed from below with workers on the ground.  The end walls are ready for back-fill.    
Backfill was placed and the concrete to complete the cover slab was placed.  After the concrete was cured it was time for paving the approaches and installing guardrail. View of completed roadway looking across the structure View of completed structure from upstream side