Box Culverts Structural Precast Concrete Solutions and System Overview 4 Products for Civil Engineering, Commercial Benefits 5 and Domestic Applications

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Box Culverts Structural Precast Concrete Solutions and System Overview 4 Products for Civil Engineering, Commercial Benefits 5 and Domestic Applications Hanson Building Products Structural Precast Products FOR THE CIVIL ENGINEERING SECTOR Structural Precast Products FORTHE CIVILENGINEERING SECTOR Hanson Building Products provides Box Culverts structural precast concrete solutions and System overview 4 products for civil engineering, commercial Benefits 5 and domestic applications. Design and specification 6-7 Technical data 8-9 In addition to our dedicated Installation guide 10-11 flooring products the Omnia Bridge Deck company designs, System overview 12 manufactures and supplies Benefits 13 non-standard structural Product details 14 precast components to Manufacture 15 clients’ specifications. Delivery, offloading 16-17 and erection Hanson Quickbuild™ Quickbuild™ walls Wall System Systems overview 18 Escape shafts Benefits 19 Bespoke Products Expertise and 20-21 capabilities Retaining walls and flood defence Nationwide service 22 2 Specialist structure precast concrete components can be incorporated into a wide range of applications. Specialist stair flights Digester tanks and other large bespoke structures Omnia Bridgedeck By taking an active involvement in the design work to offer value engineered solutions, Hanson Building Products is able to offer a competent and economic service, to provide quality assured units to a wide range of bespoke precast concrete structures. These include : Box culverts and channel sections Omnia Bridgedeck Bridge parapets Beams Columns Columns and beams Wall and floor panels Sandwich panels Box culverts and Bespoke units to a maximum channel sections handling capacity of 24 tonnes. 3 Box Culverts PRODUCT OVERVIEW Easy to install, suitable for very shallow or deep fill, ideal for use in a wide variety of civil engineering applications Hanson Building Products is the Whilst offering increased flexibility conditions and are efficiently produced largest producer of box culverts in Hanson Box Culverts retain all their in standard sizes. the UK, and are members of the original advantages. As these advantages have become Box Culvert Association. They are easy to install and can be widely recognised their range of Since its introduction over 45 years made to suit very shallow or deep fill. applications has increased making them ago the range of box culverts we offer They also offer economy by being ideal in a wide variety of civil has continued to expand. uniquely designed for particular loading engineering applications. 4 Box Culverts benefits Flexibility of range to accommodate Civil engineering almost any size requirement applications Availability of multi-cell sections Culverting Watercourses Use with shaped invert for dry weather flow situations Attenuation Tanks eg. sloping vee and half round Road Crossings Ease of installation Multi-cell Construction Can be laid as singles or in multiple runs Pipe Replacement Pedestrian and Accommodation of high Vehicle Subways storage volumes Sea Outfalls Escape Tunnels Box culvert design specific Shafts to client requirement Service Tunnels Qualified technical department with CAD facilities, Pumping Stations available to assist at all stages with design specification Channels and contract development Portals Quality Service Guaranteed Basements Solutions Available nationwide on a supply only basis CSO Chambers Complies with all relevant standards and manufactured in accordance with ISO 9001 and 14001 Hanson Box Culverts are available in Unlike pipes and corrugated steel a range of 144 standard sizes from assemblies, box culverts can be 1000mm x 600mm to 6000mm to designed to carry vertical load without 3600mm. Non-standard sizes and the relieving effect of side pressure. internal profiles can also be readily provided including shaped inverts, Therefore, when culverts are used in dwf channels, and units with cross multiple sections, they can be laid side over channels. by side with only a nominal gap between them. Reference to our table of standard sizes will give the size necessary to By comparison with arched or circular meet any conditions which may be sections no flow area is lost through required in terms of storage volume, either excessive spacing apart or flow capacity etc. For larger culvert curved profiles. widths, twin or multiple sections may also be considered. 5 Box Culverts DESIGN & SPECIFICATION Hydraulic design Discharge rates for box culverts in the Thus, for a 2400 x 1200 section laid Hanson standard range are calculated at a gradient of 1 in 500 and with an for a gradient of 1 in 1000 in assumed roughness coefficient of accordance with the Colebrook-White 0.6mm, the discharge rate is given by equation assuming the culvert running 4.29 x 1.4 x 0.93 = 5.59m3/s. full under uniform flow conditions. Comparable discharge rates for The flow capacity of a culvert is circular pipes are given in the Table 2 determined by a number of different (overleaf). factors. In addition to the gradient and roughness coefficient, the geometry For any gradient between 1 in 1000 of the inlet and outlet and the and 1 in 250, the gradient multiplier tailwater level can affect the mode of (Table 3 overleaf) should be applied. flow and may prevent the culvert from running full or under uniform flow A value of 0.3mm has been assumed conditions. for roughness coefficient, ks, which depends upon the accuracy of laying In such cases the flow capacity will be and jointing in addition to the quality lower than the full discharge rate. of the culvert surface. Where a different value is required, the discharge rate at the appropriate gradient should be adjusted by the use of the roughness multiplier (Table 4 overleaf). Platform units 6 Design and Surface loading detailing and fill depth Box culverts are generally designed Loading applied at the ground surface and detailed in accordance with the and weight of fill material produce a Box Culvert Association Standard combination of vertical and horizontal Specification which covers materials, forces on the box culvert. manufacturing tolerances, external loading design and detailing standards. Surface loading may be specified as a standard loading type, equivalent Box culverts carrying highway loading uniform loading or individual wheel or railway loading are designed to loads. The critical load on a culvert can current standards and specification as occur at minimum or maximum fill. Cast on end walls stipulated by the client. Each enquiry for a culvert should state The lowest grade of concrete used is the minimum and maximum fill depth C45/55 with a 20mm maximum size and the amount or type of surface of aggregate. The nominal cover to loading. reinforcement complying with the exposure requirements of BS8500. It is recommended that the minimum fill depth should be not less than An experienced team of engineers and 200mm or one fifteenth of the internal technicians backed by CAD facilities width of the culvert if this is greater. provide a flexible and comprehensive design and detailing service enabling the clients design and specification criteria to be satisfied. Access units D.W.F channels Animal crossing ledges Twin cell construction (solid or cantilever) 7 Box Culverts TECHNICAL DATA Please size by span x height. All dimensions are internal Table No.1 Dimensions, flow area and discharge rate Internal 1000 1200 1500 1800 2100 2400 2700 3000 3300 height 600 0.53 0.65 0.83 1.01 1.19 mm 0.50 0.64 0.86 1.07 1.29 800 0.73 0.89 1.13 1.37 1.61 1.85 2.09 2.33 mm 0.77 0.99 1.33 1.67 2.01 2.36 2.71 3.06 1000 0.93 1.13 1.43 1.73 2.03 2.33 2.63 2.93 3.23 mm 1.07 1.37 1.84 2.32 2.80 3.29 3.79 4.29 4.79 1200 1.37 1.73 2.09 2.45 2.81 3.17 3.53 3.89 mm 1.76 2.37 3.00 3.64 4.29 4.95 5.61 6.28 1500 2.18 2.63 3.08 3.53 3.98 4.43 4.88 mm 3.21 4.08 4.98 5.89 6.81 7.74 8.68 1800 3.17 3.71 4.25 4.79 5.33 5.87 mm 5.21 6.38 7.57 8.78 10.00 11.24 2100 4.34 4.97 5.60 6.23 6.86 mm 7.83 9.31 10.82 12.36 13.92 2400 5.69 6.41 7.13 7.85 mm 11.11 12.94 14.81 16.70 2700 7.22 8.03 8.84 mm 15.11 17.32 19.56 3000 8.93 9.83 mm 19.88 22.49 3300 10.82 mm 25.48 3600 1 mm Notes 1. The standard range of box culverts generally have flat inverts and 190mm corner splays up to 4800mm span and 225mm splays from 5100mm to 6000mm span and a maximum length of 2m. 2. Sizes other than those stated can be manufactured to suit customer requirements. 3. Special internal profiles, shaped inverts and dry weather flow channels can be produced and are available on request. 8 Table No.2 Table No.3 Table No.4 Circular pipe discharge rates for Gradient multiplier Roughness multiplier comparison with standard culverts Diameter Flow area Discharge Roughness DN m2 rate m3/s Gradient Multiplier coefficient ks Multiplier 0.06 1.11 900 0.64 0.67 1 in 1000 1.0 0.15 1.05 1050 0.87 1.00 1 in 800 1.1 0.30 1.00 1 in 700 1.2 0.60 0.93 1200 1.13 1.42 1 in 600 1.3 1.50 0.85 1 in 500 1.4 1350 1.43 1.93 1 in 400 1.6 1500 1.77 2.54 1 in 300 1.8 1650 2.14 3.25 1 in 250 2.0 1800 2.54 4.08 Width mm (internal span) Flow area m2 Discharge rate m3/s 3600 3900 4200 4500 4800 5100 5400 5700 6000 m m 3.53 3.83 4.13 4.43 4.73 m 5.29 5.80 6.30 6.81 7.32 4.25 4.61 4.97 5.33 5.69 6.02 6.38 6.74 7.09 6.95 7.62 8.29 8.97 9.64 10.28 10.96 11.64 12.32 5.33 5.78 6.23 6.68 7.13 7.55 8.00 8.45 8.90 9.62 10.57 11.52 12.48 13.44 14.37 15.33 16.30 17.27 6.41 6.95 7.49 8.03 8.57 9.08 9.62 10.16 10.70 12.48 13.74 15.00 16.26 17.54 18.79 20.07 21.35 22.64 7.49 8.12 8.75 9.38 10.01 10.61 11.24 11.87 12.50 15.49 17.07 18.67 20.27 21.88 23.48 25.11 26.74 28.37 8.57 9.29 10.01 10.73 11.45 12.14 12.86 13.58 14.30 18.61 20.55 22.50 24.46 26.43 28.40 30.40 32.40 34.41 9.65 10.46 11.27 12.08 12.89 13.67 14.48 15.29 16.10 21.84 24.14 26.46 28.80 31.15 33.52 35.90 38.29 40.70 10.73 11.63 12.53 13.43 14.33 15.20 16.10 17.00 17.90 25.14 27.82 30.53 33.27 36.02 38.80 41.59 44.40 47.22 11.81 12.80 13.79 14.78 15.77 16.73 17.72 18.71 19.70 28.52 31.59 34.71 37.85 41.02 44.22 47.44 50.68 53.93 12.89 13.97 15.05 16.13 17.21 18.26 19.34 20.42 21.50 31.95 35.43 38.96 42.53 46.13 49.77 53.43 57.11 60.81 4.
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