Segmental Precast Concrete Box Culverts
Monolithic high-performance structural culvert elements engineered for rapid storm-water, utility corridor, and sub-grade highway crossing installations.
Integrated tongue-and-groove joint profile fitted with hydro-swelling polyurethane and EPDM gasket barriers.
Instant load-bearing upon placement and backfill, completely eliminating extended traffic detour delays.
High-density silica fume mix preventing chloride attack in aggressive water-table soils.
Deep Technical Specifications
Engineered strictly in conformance with IRC:SP:13, MoRTH Section 2900, and Railway RDSO parameters for high axle fatigue endurance.
Dimensional Matrix & Reinforcement Surcharge
Clear openings, wall thicknesses, and allowable earth covers per design class.
| Model ID | Span x Rise (m) | Wall Thk (mm) | Slab Thk (mm) | Haunch Size | Max Earth Cushion | Piece Wt (Ton) |
|---|---|---|---|---|---|---|
| BC-1515-M45 | 1.50 x 1.50 | 200 | 200 | 150 x 150 | 0.0 m to 4.5 m | 6.40 |
| BC-2020-M45 | 2.00 x 2.00 | 225 | 225 | 200 x 200 | 0.0 m to 6.0 m | 9.60 |
| BC-2525-M45 | 2.50 x 2.50 | 250 | 250 | 250 x 250 | 0.2 m to 6.5 m | 13.20 |
| BC-3030-M45 | 3.00 x 3.00 | 300 | 300 | 300 x 300 | 0.3 m to 7.0 m | 18.50 |
| BC-4030-M45 | 4.00 x 3.00 | 350 | 350 | 350 x 350 | 0.5 m to 8.0 m | 24.10 |
Haunch Detail
Engineered 45-degree chamfered transitions reduce critical shear stress at roof and base slab junctures by 38%.
Dynamic Braking Load
Validated for 200 kN longitudinal tractive forces per IRC:6 Clause 211 for heavy freight corridors.
Earth Surcharge
Calculated at soil density 20 kN/m³ with active earth pressure coefficient Ka = 0.33 per Coulomb method.
SCC Concrete Mix Specification
Produced using computer-automated planetary pan mixers with moisture probe feedback.
High Ductility Reinforcement
Continuous CNC cut and bent rebar cages fabricated in rigid steel jigs.
Rigging & Crane Lift
Utilize a 4-leg wire rope sling or lifting beam. Sling angle must never exceed 60 degrees from horizontal to prevent lateral inward crushing on box crown.
Subgrade Bedding
Install on minimum 150mm compacted Granular Sub Base (GSB) topped with 75mm M10 blinding concrete screed flat to ±5mm tolerance.
Joint Pull-Up & Sealing
Apply butyl mastic primer, compress rubber gasket using mechanical chain-lever tension jack until male spigot seats completely into female socket.
Verified Plant Quality Credentials
Internal NABL certified testing laboratory with digital hydraulic load test frames.
Download Full Batch Test Certificate
Includes 7-day, 14-day, and 28-day cube crush reports and mill test certificates for steel.
Frequently Paired Precast Solutions
Heavy-Duty Precast U-Drain Channels
Designed for industrial peripheral storm collectors and highway side drains with interlocking tongue joints.
Class AA Reinforced Cover Slabs
Solid or grating-slotted surface slabs engineered to sustain Class 70R direct wheel track loads.
Modular Utility Inspection Chambers
Stackable riser sections with pre-formed flexible pipe gaskets for quick stormwater drop junctions.
Need Custom Hydraulic Openings or Skewed Girders?
Our automated batching yard in Madurai accommodates skewed box geometries up to 45 degrees and customized multi-cell twin barrel culverts.