ASTM B864/B864M-00(2007)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: B 864/B 864M – 00 (Reapproved 2007)
Standard Specification for
Corrugated Aluminum Box Culverts
This standard is issued under the fixed designation B 864/B 864M; 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 (e) indicates an editorial change since the last revision or reapproval.
1. Scope 2. Referenced Documents
1.1 This specification covers material, geometric, and wall 2.1 ASTM Standards:
section properties of aluminum box culverts manufactured A 36/A 36M Specification for Carbon Structural Steel
from corrugated plate or sheet, with attached rib stiffeners, for A 123/A 123M Specification for Zinc (Hot-Dip Galva-
field assembly. Appropriate fasteners and optional materials, nized) Coatings on Iron and Steel Products
such as aluminum invert plates and headwalls, are also A 153/A 153M Specification for Zinc Coating (Hot-Dip) on
described. Applications for aluminum box culverts include Iron and Steel Hardware
conduits for gravity flow drainage of surface water, such as A 307 Specification for Carbon Steel Bolts and Studs, 60
culverts and storm drains, as well as for small bridges and 000 PSI Tensile Strength
grade separation structures such as pedestrian or vehicular A 563 Specification for Carbons and Alloy Steel Nuts
underpasses, and utility tunnels. A 563M Specification for Carbon and Alloy Steel Nuts
1.2 This specification does not include requirements for [Metric]
foundations,backfill,ortherelationshipbetweenearthcoveror B 221/B 221M Specification forAluminum andAluminum-
live loads and strength requirements. These important design Alloy Extruded Bars, Rods, Wire, Shapes and Tubes.
considerations are described in the AASHTO Standard Speci- B 746/B 746M Specification for Corrugated Aluminum Al-
fications for Highway Bridges. loy Structural Plate for Field-Bolted Pipe, Pipe-Arches,
1.3 This specification does not include requirements for the and Arches
hydraulic design of these structures. Hydraulic design, place- B 790/B 790M Practice for Structural Design of Corrugated
ment of footings or inverts, and end treatments to resist scour Aluminum Pipe, Pipe-Arches, and Arches for Culverts,
are described in FHWA HDS No. 5. Storm Sewers, and Other Buried Conduits
1.4 Appendix X1 lists nominal dimensions of box culvert 2.2 AASHTO Standard:
sizes commonly available. Also listed are cross-sectional area Standard Specifications for Highway Bridges
and hydraulic design parameters for these sizes. 2.3 FHWA Standard:
1.5 Appendix X2 lists manufacturer’s suggested design HDS No. 5, Hydraulic Design of Highway Culverts, Report
properties for the rib stiffener types, spacing classes, and No. FHWA-IP-85-15
material thicknesses described in this specification.
3. Terminology
1.6 The values stated in either inch-pound units or SI units
3.1 Definitions of Terms Specific to This Standard:
are to be regarded separately as standard. Within the text, the
SI units are shown in brackets. The values stated in each 3.1.1 box culvert—a generally rectangular conduit having a
cross section symmetric about a vertical axis, with a long
system are not exact equivalents; therefore, each system shall
be used independently of the other. Combining values from the radius crown segment, short radius haunch segments, and
straight side segments, with rib stiffeners (see Fig. 1).
two systems may result in nonconformance with the specifi-
cation. 3.1.2 crown—the long radius top arc segment of a box
culvert cross section (see Fig. 1).
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.
1 3
This specification is under the jurisdiction of ASTM Committee B07 on Light Available from American Association of State Highway and Transportation
Metals and Alloys and is under the direct responsibility of B07.08 on Aluminum Officials (AASHTO), 444 N. Capitol St., NW, Suite 249, Washington, DC 20001,
Culvert. http://www.transportation.org.
Current edition approved Sept. 1, 2007. Published September 2007. Originally Available from National Technical Information Service (NTIS), 5285 Port
approved in 1995. Last previous edition approved in 2000 as B 864/B 864M-00. Royal Rd., Springfield, VA 22161, http://www.ntis.gov.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
B 864/B 864M – 00 (2007)
FIG. 1 Box Culvert Geometry
3.1.3 haunch—the short radius segments at the upper cor- 4.2.4 Class C Spacing, consisting of either Type 1 or Type
ners of a box culvert cross section, making the transition 2 external rib stiffeners spaced at 18 in. [457 mm] center-to-
between the long radius crown segment and the straight side center.
segments (see Fig. 1). 4.2.5 Class D Spacing, consisting of either Type 1 or Type
3.1.4 rib stiffeners—spaced extruded aluminum structural 2 external rib stiffeners spaced at 9 in. [229 mm] center-to-
members, curved to the shape of the transverse cross section of center.
box culverts and attached by field-bolting to the corrugated
plate shell (see Fig. 1). 5. Ordering Information
3.1.5 rise—the clear inside vertical dimension from the
5.1 Orders for products specified herein shall include the
bottom of the straight side segments of a box culvert to the
following information required as necessary to adequately
crown, measured at the axis of symmetry (see Fig. 1).
describe the desired product characteristics:
3.1.6 shell—the continuous, structural enclosure of the box
5.1.1 Name of product (corrugated aluminum box culvert),
culvert consisting of modular, field-assembled, and bolted
5.1.2 ASTM designation and year of issue, as B XXX-____
corrugated aluminum plate members forming the crown,
for inch-pound units or B XXXM-____ for SI units,
haunch, and side segments (see Fig. 1).
5.1.3 Number of structures,
3.1.7 span—the clear inside horizontal dimension of a box
5.1.4 Nominal dimensions of each structure including the
culvert, measured at the bottom of the straight side segments
rise, span, length (measured along the bottom centerline), and
(see Fig. 1).
cross sectional area required,
NOTE 1—The nominal length increment is 2.25 ft [0.68 m]. Special
4. Classification
lengths can be provided.
4.1 Aluminum box culverts consist ofa9by2 ⁄2 in. [229 by
5.1.5 Minimum and maximum cover height over structure
64 mm] corrugated aluminum plate shell in combination with
topcenterline(measuredfromtheinsidecrestofthecorrugated
extruded aluminum stiffening ribs. The plate thickness, stiff-
plate to the finished surface of the traveled way),
enertype,andspacingclassatthecrownandhaunchofthebox
culvert may differ, provided they satisfy the ordering informa-
NOTE 2—The minimum and maximum cover height is assumed to
tion and the design properties (see 5.1 and 6.1). The plate
apply to the entire length of the structure unless the purchaser specifies
otherwise. The design specifications limit cover height to a range of
thickness and stiffener type and spacing class may be varied
between 1.4 ft and 5.0 ft [0.43 m and 1.52 m]. Small deviations in the
along the length of the box culvert in accordance with cover
height of cover can make a significant difference in the design. It is
and loading requirements, as agreed upon between the pur-
recommended that the purchaser specify minimum and maximum cover
chaser and the fabricator.
heights to the nearest 0.1 ft [30 mm].
4.2 Rib Stiffener Type and Spacing Class:
5.1.6 Dead load unit weight, if different than 120 lb/ft
4.2.1 Rib stiffeners consist of either Type 1 or Type 2 at the
3[1920 kg/m ],
option of the fabricator. Geometry, section, and mechanical
5.1.7 Structure live load vehicle configuration, if different
properties must conform to the requirements of Fig. 2. Rib
than AASHTO HS 20-44 (see AASHTO Standard Specifica-
stiffener spacing classes shall be as defined in 4.2.2-4.2.5 and
tions for Highway Bridges),
illustrated in Fig. 3.
5.1.8 Corrugated footing pads or full invert plates, if re-
4.2.2 Class A Spacing, consisting of either Type 1 or Type 2
quired. For box culverts not supported on concrete footings,
external rib stiffeners spaced at 54 in. [1372 mm] center-to-
allowable foundation bearing capacity, if different than 2
center.
tons/ft [192 kPa],
4.2.3 Class B Spacing, consisting of eitherType 1 orType 2
external rib stiffeners spaced at 27 in. [686 mm] center-to-
NOTE 3—Design procedures for corrugated footing pads or full invert
center. plates are beyond the scope of this specification. However, general
B 864/B 864M – 00 (2007)
Type 1 Type 2
Alloy 6061-T6 6061-T6
Yield Strength 35 ksi [241.3 MPa] 35 ksi [241.3 MPa
Tensile Strength 38 ksi [262.0 MPa] 38 ksi [262.0 MPa]
2 2 2 2
Area 1.71 in. [1103 mm]2.27in. [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]2.68in. [43 917 mm ]
k-ft k-ft
Plastic Moment Mp = 4.97 [6.72 kN-m] Mp = 7.81 [10.60 kN-m]
FIG. 2 Extruded Aluminum Rib Stiffeners Geometry and Nominal Properties for Design
5.1.9 End treatment (bevel, skew, grade or slope correc-
tions, 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,
eachhaving0.43mminimumandmaximumcovers,assumingadeadload
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 deter-
mined for the crown and haunch segments of the box culvert in
accordance with the ordering information and AASHTO Stan-
dard Specifications for Highway Bridges.TheAASHTO speci-
fication is applicable for the range of geometric limits given in
Ribs are either Type 1 or Type 2.
Fig. 1 and Table 1.
FIG. 3 Rib Stiffener Spacing Classes
7. Materials
considerations for design of structural plate arch footings are given in
7.1 The corrugated plate material utilized for the shell shall
Practice B 790/B 790M. Also, specific design criteria for similar applica-
be fabricated from aluminum sheet or plate conforming to the
tions are available in the AASHTO Standard Specifications for Highway
Bridges. chemical, mechanical, thickness and shape requirements of
B 864/B 864M – 00 (2007)
TABLE 1 Geometric Limits of Box Culverts
members having like dimensions and curvature are inter-
A
Elements Minimum Maximum changeable. Sufficient bolt holes shall be provided in the
corrugated shell to match the arrangement, number, and
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]
spacing of bolt holes in the stiffeners. The layout of the
Radius of crown(r ) . 24.79 ft [7.56 m]
c
stiffeners relative to the corrugated shell shall be in accordance
Radius of haunch(r ) 2.50 ft [0.76 m] .
h
Haunch angle (D) 50° 70° with 4.2 for the stiffener type and spacing class required by the
Length of leg (D) 0.50 ft [0.15 m] 5.2 ft [1.59 m]
design.
B
Length of rib on leg (t) .
8.4 Rib stiffeners that are designed to be continuous around
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 the periphery of the crown and haunch, but that are not
is less.
fabricated in one piece, shall be provided with splice connec-
tions at the intermediate ends. The design of the splice shall be
adequate to develop the bending and axial loads carried by the
Specification B 746/B 746M. Section properties for the corru-
rib stiffener at the location of the splice.
gated plate are provided in Practice B 790/B 790M.
8.5 Rib stiffeners shall be provided with adequate bolted
7.2 Rib stiffeners shall be extruded shapes conforming to
connectors to resist the beam shear that develops between the
the chemical and mechanical requirements of Specification
B 221/B 221M for 6061-T6. Their dimensions and the re- stiffener and the shell due to the moment requirements de-
quired, nominal section properties developed are shown in Fig. scribed in 6.1.
2.
8.6 Corrugated footing and invert plates shall be fabricated
7.3 Corrugated aluminum footing and invert members,
in accordance with Specification B 746/B 746M.
when specified, shall conform to the same material require-
8.7 Special members for headwalls, cut-off walls, etc. and
ments as 7.1. Thickness shall be as required by the design (see
special plates forming skewed ends, beveled ends, or curved
Note 3) and shall not be less than 0.100 in. [2.5 mm].
alignment, when required, shall be accurately cut to fit the
7.4 Corrugated aluminum headwalls, when specified, shall
requirements of the ordering information. Cut edges of mem-
conform to the same material requirements as 7.1. Aluminum
bers shall not contain excessive notches, gouges, or burrs, and
walers, tie-back rods, deadman anchors, and other aluminum
shall present a workmanlike finish.
structural members shall conform to the mechanical and
chemical requirements of 7.2. Any steel tie-back rods, dead-
9. Dimensions and Permissible Variations
man anchors, or other steel structural member shall meet the
requirements of Specification A 36/A 36M. Where they are
9.1 Furnished box culvert dimensions shall not vary from
installed in contact with aluminum members steel members
the ordered sizes by more than the permissible amounts given
shall be hot-dip galvanized after fabrication in accordance with
in Table 2, except as noted in 9.2 and 9.3.
the coating requirements of Specification A 123/A 123M. The
9.2 When agreed upon between the purchaser and the
thickness, shape, and dimensions of headwall and incidental
fabricator, the span dimension furnished may exc
...