ASTM B864/B864M-19

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: B864/B864M − 13 (Reapproved 2018) B864/B864M − 19
Standard Specification for
Corrugated Aluminum Box Culverts
This standard is issued under the fixed designation B864/B864M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope*
1.1 This specification covers material, geometric, and wall section properties of aluminum box culverts manufactured from
corrugated plate or sheet, with attached rib stiffeners, for field assembly. Appropriate fasteners and optional materials, such as
aluminum invert plates and headwalls, are also described. Applications for aluminum box culverts include conduits for gravity flow
drainage of surface water, such as culverts and storm drains, as well as for small bridges and grade separation structures such as
pedestrian or vehicular underpasses, and utility tunnels.
1.2 This specification does not include requirements for foundations, backfill, or the relationship between earth cover or live
loads and strength requirements. These important design considerations are described in the AASHTO LRFD Bridge De-
sign Specifications and the LRFD Bridge Construction Specifications.
1.3 This specification does not include requirements for the hydraulic design of these structures. Hydraulic design, placement
of footings or inverts, and end treatments to resist scour are described in FHWA HDS No. 5.
1.4 Appendix X1 lists nominal dimensions of box culvert sizes commonly available. Also listed are cross-sectional area and
hydraulic design parameters for these sizes.
1.5 Appendix X2 lists manufacturer’s suggested design properties for the rib stiffener types, spacing classes, and material
thicknesses described in this specification.
1.6 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each
system may not be exact equivalents; therefore, each system shall be used independently of the other. Combining values from the
two systems may result in non-conformance with the standard.
1.7 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 ASTM Standards:
A36/A36M Specification for Carbon Structural Steel
A123/A123M Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A153/A153M Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
A307 Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength
A563 Specification for Carbon and Alloy Steel Nuts
A563M Specification for Carbon and Alloy Steel Nuts (Metric)
B221 Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
B746/B746M Specification for Corrugated Aluminum Alloy Structural Plate for Field-Bolted Pipe, Pipe-Arches, and Arches
B790/B790M Practice for Structural Design of Corrugated Aluminum Pipe, Pipe-Arches, and Arches for Culverts, Storm
Sewers, and Other Buried Conduits
This specification is under the jurisdiction of ASTM Committee B07 on Light Metals and Alloys and is under the direct responsibility of B07.08 on Corrugated Aluminum
Pipe and Corrugated Aluminum Structural Plate.
Current edition approved Nov. 1, 2018May 1, 2019. Published November 2018May 2019. Originally approved in 1995. Last previous edition approved in 20132018 as
B864/B864M – 13.B864/B864M – 13 (2018). DOI: 10.1520/B0864_B0864M-18.10.1520/B0864_B0864M-19.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
B864/B864M − 19
2.2 AASHTO Standard:Standards:
LRFD Bridge Design Specifications
LRFD Bridge Construction Specifications
2.3 FHWA Standard:
HDS No. 5, Hydraulic Design of Highway Culverts, Third Edition. FHWA publication number HIF–12–02 (2012).
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 box culvert—a generally rectangular conduit having a cross section symmetric about a vertical axis, with a long radius
crown segment, short radius haunch segments, and straight side segments, with rib stiffeners (see Fig. 1).
3.1.2 crown—the long radius top arc segment of a box culvert cross section (see Fig. 1).
3.1.3 haunch—the short radius segments at the upper corners of a box culvert cross section, making the transition between the
long radius crown segment and the straight side segments (see Fig. 1).
3.1.4 rib stiffeners—spaced extruded aluminum structural members, curved to the shape of the transverse cross section of box
culverts and attached by field-bolting to the corrugated plate shell (see Fig. 1).
3.1.5 rise—the clear inside vertical dimension from the bottom of the straight side segments of a box culvert to the crown,
measured at the axis of symmetry (see Fig. 1).
3.1.6 shell—the continuous, structural enclosure of the box culvert consisting of modular, field-assembled, and bolted
corrugated aluminum plate members forming the crown, haunch, and side segments (see Fig. 1).
3.1.7 span—the clear inside horizontal dimension of a box culvert, measured at the bottom of the straight side segments (see
Fig. 1).
4. Classification
4.1 Aluminum box culverts consist of a 9 by 2 ⁄2 in. [229 by 64 mm] corrugated aluminum plate shell in combination with
extruded aluminum stiffening ribs. The plate thickness, stiffener type, and spacing class at the crown and haunch of the box culvert
may differ, provided they satisfy the ordering information and the design properties (see 5.1 and 6.1). The plate thickness and
stiffener type and spacing class may be varied along the length of the box culvert in accordance with cover and loading
requirements, as agreed upon between the purchaser and the fabricator.
4.2 Rib Stiffener Type and Spacing Class:
4.2.1 Rib stiffeners shall consist of Type 1, Type 2, or Type 10 at the option of the fabricator. Geometry, section, and mechanical
properties must conform to the requirements of Fig. 2 or Fig. 3. Rib stiffener spacing classes shall be as defined in 4.2.2 – 4.2.5
and illustrated in Fig. 4 or Fig. 5.
4.2.2 Class A Spacing, consisting of either Type 1, Type 2, or Type 10 external rib stiffeners spaced at 54 in. [1372 mm]
center-to-center.
4.2.3 Class B Spacing, consisting of either Type 1, Type 2, or Type 10 external rib stiffeners spaced at 27 in. [686 mm]
center-to-center.
FIG. 1 Box Culvert Geometry
Available from American Association of State Highway and Transportation Officials (AASHTO), 444 N. Capitol St., NW, Suite 249, Washington, DC 20001,
http://www.transportation.org.
Available from National Technical Information Service (NTIS), 5285 Port Royal Rd., Springfield, VA 22161, http://www.ntis.gov.
B864/B864M − 19
Type 1 Rib Type 2 Rib
Alloy 6061-T6 6061-T6
Yield Strength 35 ksi [240 MPa] 35 ksi [240 MPa]
Tensile Strength 38 ksi [260 MPa] 38 ksi [260 MPa]
2 2 2 2
Area 1.71 in. [1103 mm ] 2.27 in. [1465 mm ]
Center of Area Yc = 1.02 in. [26.0 mm] Yc = 1.76 in. [44.8 mm]
3 3 3 3
Plastic Modulus 1.70 in. [27 858 mm 2.68 in. [43 917 mm ]
Plastic Moment Mp = 4.97 k-ft [6.72 kN-m] Mp = 7.81 k-ft [10.60 kN-m]
FIG. 2 Geometry and Nominal Design Properties for Types 1 and 2 Ribs
Type 10 Rib
Alloy 6061-T6
Yield Strength 35 ksi [240 MPa]
Tensile Strength 38 ksi [260 MPa]
2 2
Area 7.166 in. [4623 mm ]
Center of Area Yc = 2.228 in. [56.6 mm]
3 3
Plastic Modulus 11.074 in. = [181 465 mm ]
Plastic Moment Mp = 32.23 k-ft [43.7 kN-m]
FIG. 3 Geometry and Nominal Design Properties for Type 10 Ribs
B864/B864M − 19
FIG. 4 Rib Stiffener Spacing Classes for Type 1 and Type 2 Ribs
FIG. 5 Rib Stiffener Spacing Classes for Type 10 Ribs
B864/B864M − 19
4.2.4 Class C Spacing, consisting of either Type 1, Type 2, or Type 10 external rib stiffeners spaced at 18 in. [457 mm]
center-to-center.
4.2.5 Class D Spacing, consisting of either Type 1 or Type 2 external rib stiffeners spaced at 9 in. [229 mm] center-to-center.
5. Ordering Information
5.1 Orders for products specified herein shall include the following information required as necessary to adequately describe
the desired product characteristics:
5.1.1 Name of product (corrugated aluminum box culvert),
5.1.2 ASTM designation and year of issue, as B XXX-____ for inch-pound units or B XXXM-____ for SI units,
5.1.3 Number of structures,
5.1.4 Nominal dimensions of each structure including the rise, span, length (measured along the bottom centerline), and cross
sectional area required,
NOTE 1—The nominal length increment is 2.25 ft [0.68 m]. Special lengths can be provided.
5.1.5 Minimum and maximum cover height over structure top centerline (measured from the inside crest of the corrugated plate
to the finished surface of the traveled way),
NOTE 2—The minimum and maximum cover height is assumed to apply to the entire length of the structure unless the purchaser specifies otherwise.
The design specifications limit cover height to a range of between 1.4 and 5.0 ft [0.43 and 1.52 m]. Small deviations in the height of cover can make
a significant difference in the design. It is recommended that the purchaser specify minimum and maximum cover heights to the nearest 0.1 ft [30 mm].
3 3
5.1.6 Dead load unit weight, if different than 120 lb/ft [1920 kg/m ],
5.1.7 Structure live load vehicle configuration, if different than AASHTO HL-93 (see AASHTO LRFD Bridge Design
Specification),
5.1.8 Corrugated footing pads or full invert plates, if required. For box culverts not supported on concrete footings, allowable
foundation bearing capacity, if different than 2 tons/ft [192 kPa],
NOTE 3—Design procedures for corrugated footing pads or full invert plates are beyond the scope of this specification. However, general considerations
for design of structural plate arch footings are given in Practice B790/B790M. Also, specific design criteria for similar applications are available in
AASHTO LRFD Bridge Design Specifications.
5.1.9 End treatment (bevel, skew, grade or slope corrections, corrugated aluminum headwalls, cut-off walls, or other special
provision), if required,
NOTE 4—End conditions involving beveled or skewed cut ends may require a structural support wall or collar. The design procedures for these end
treatments as well as for vertical headwalls are beyond the scope of this specification.
5.1.10 Other special requirements such as stubs, tap-ins, saddles, elbows, etc., if required, and
5.1.11 Material certification, if required (see 13.1).
NOTE 5—Typical ordering information may be described as: (1) One corrugated aluminum box culvert, in accordance with ASTM B XXX-____, 7 ft,
3 in. rise by 20 ft, 6 in. span by 45 ft long, having a 1.4 ft minimum cover and a 3.0 ft maximum cover, with full invert plates; or (2) Two corrugated
aluminum box culverts, in accordance with ASTM B XXXM-____, each being 1.96 m rise by 4.67 m span by 18.3 m long, each having 0.43 m minimum
and maximum covers, assuming a dead load unit weight of 2162 kg/m , having full invert plates and having ends slope adjusted for 2 % grade, including
certification.
6. Design Properties
6.1 The required plastic moment capacities shall be determined for the crown and haunch segments of the box culvert in
accordance with the ordering information and AASHTO LRFD Bridge Design Specifications. The AASHTO LRFD Bridge Design
Specifications are applicable for the range of geometric limits given in Fig. 1 and Tables 1 and 2. When agreed upon by the
purchaser and the fabricator, box culvert geometries outside the limits given in Tables 1 and 2 may be designed using other
recognized Design Specifications.
TABLE 1 Geometric Limits of Box Culverts 8 ft 9 in. to 25 ft 5 in.
[2.67 to 7.75 m]
A
Elements Minimum Maximum
Span (S) 8.75 ft [2.67 m] 25.42 ft [7.75 m]
Rise (R) 2.50 ft [0.76 m] 10.50 ft [3.20 m]
Radius of crown (r ) . . . 24.79 ft [7.56 m]
c
Radius of haunch (r ) 2.50 ft [0.76 m] . . .
h
Haunch angle (Δ) 50° 70°
Length of leg (D) 0.50 ft [0.15 m] 5.2 ft [1.59 m]
B
Length of rib on leg (t) . . .
A
See Fig. 1 for illustration of geometric elements.
B
Minimum 19 in. [483 mm] or length of leg (D) minus 3 in. [76 mm], whichever is
less, or within 3 in. (76 mm) top of footing.
B864/B864M − 19
TABLE 2 Geometric Limits of Box Culverts with Spans from 25 ft
6 in. to 36 ft 0 in. [7.75 to 10.97 m]
A
Elements Minimum Maximum
Span (S) 25.50 ft [7.75 m] 36.0 ft [10.97 m]
Rise (R) 5.58 ft [1.70 m] 14.00 ft [4.27 m]
Radius of crown (r ) . . . 26.33 ft [8.03 m]
c
Radius of haunch (r ) 3.64 ft [1.11 m] . . .
h
Haunch angle (Δ) 48° 68°
Length of leg (D) 0.40 ft [0.125 m] 5.92 ft [1.80 m]
B
Length of rib on leg (t) . . .
A
See Fig. 1 for illustration of geometric elements.
B
Minimum 28 in. [483mm] or length of leg (D) minus 3 in. [76 mm], whichever is
less, or within 3 in. [76 mm] top of footing.
7. Materials
7.1 The corrugated plate material utilized for the shell shall be fabricated from aluminum sheet or plate conforming to the
chemical, mechanical, thickness and shape requirements of Specification B746/B746M. Section properties for the corrugated plate
are provided in Practice B790/B790M.
7.2 Rib stiffeners shall be extruded shapes conforming to the chemical and mechanical requirements of Specification B221 for
6061-T6. Their dimensions and the required, nominal section properties developed are shown in Fig. 2 and Fig. 3.
7.3 Corrugated aluminum footing and invert members, when specified, shall conform to the same material requirements as 7.1.
Thickness shall be as required by the design (see Note 3) and shall not be less than 0.100 in. [2.5 mm].
7.4 Corrugated aluminum headwalls, when specified, shall conform to the same material requirements as 7.1. Aluminum walers,
tie-back rods, deadman anchors, and other aluminum structural members shall conform to the mechanical and chemical
requirements of 7.2. Any steel tie-back rods, deadman anchors, or other steel structural member shall meet the requirements of
Specification A36/A36M. Where they are installed in contact with aluminum members steel members shall be hot-dip galvanized
after fabrication in accordance with the coating requirements of Specification A123/A123M. The thickness, shape, and dimensions
of headwall and incidental members shall be as required by the design (see Note 4).
7.5 Aluminum cut-off walls, when specified, shall conform to the same material requirements as 7.1 and provide a nominal
thickness of 0.10 in. [2.5 mm].
7.6 Bolts and nuts required to join corrugated plates together, or to join corrugated plates to the stiffeners or other structural
members, shall conform to the requirements of Specification B746/B746M. Bolts and nuts for joining structural and other items
that are not corrugated shall conform to the requirements of Specification B746/B746M or alternatively meet or exceed the
requirements of Specification A307, Grade A and Specifications A563 and A563M. Steel bolts and nuts shall be hot-dip galvanized
in accordance with Specification A153/A153M, Class C.
8. Fabrication
8.1 The corrugated aluminum shell of the box culvert shall conform to the geometric dimensional limits specified in Table 1,
Table 2and , or when agreed upon by the purchaser and the fabricator, outside the limits in Tables 1 and 2. Box culverts shall be
subject to the manufacturing tolerances in 9.1 – 9.3.
8.2 Corrugated aluminum shell plates shall be fabricated in accordance with Specification B746/B746M.
8.3 Extruded aluminum rib stiffeners shall consist of annular rings conforming to the shape and dimensions of the structural
plate shell. The bolt holes shall be punched so that all members having like dimensions and curvature are interchangeable.
Sufficient bolt holes shall be provided in the corrugated shell to match the arrangement, number, and spacing of bolt holes in the
stiffeners. The layout of the stiffeners relative to the cor
...