GOVERNMENT OF ANDHRA PRADESH

OFFICE OF THE DEPUTY EXECUTIVE ENGINEER

(PR) Vig & QC SUB-DIVISION, NALGONDA.

Circular No. AEE/RCC Culverts/VQC Nlg/2013. Dated: 11.12.2013.

Sub:- CD Works-Construction of RCC Pipe Culverts in Rural Roads– Certain

guidelines communicated for proper execution of this Minor CD Works on
Rural Roads -- Reg.

* * *

It is observed during the inspection of the various roads by the QC Wing

in the district that the many of the Field Engineers are constructing the Pipe
Culverts at their whims and fancies not based on codal provisions and warrants
of the site requirement. The following common defects are observed in
construction of minor CD Works in rural roads.
1) Improper selection of type of CD Works between Piped Culvert, RCC Slab
Culvert, Road Dam, Box culvert.
2) Insufficient cushion over piped culvert.
3) Length of Body walls & Parapets.
4) Wrong alignment with respect to flow channel in case skewed crossings.
And Line of body walls gushing into embankment.
5) Inadequate U/S & D/S protection measures in case of high velocity flows
and CD ‘s located in Jungle areas.
6) Line & Plumb for body walls not followed.
7) CC Bed under pipes, Bodywall depth under pipes etc., defective.
8) Parapets not matching in length & level. Outer distance does not stick on
to 7.5m standard road width.
9) Painting, Numbering etc not followed.

In view of the above, the guidelines for Construction of RCC Pipe Culverts
in rural roads as stipulated in IRC codes & other materials are re iterated for
guidance of field engineers for adoption and better construction practices. The
piped culverts are taken up now as this type of culvert is most important and
major item in all estimates than the other CD structures.
 The self-drawn typical RCC Piped culvert and IRC Codes covering CD
Works are here with communicated to all field engineers for guidance, adoption
& further discussions.

(1) Reference Manuals::

(i) IRC-Sp-20-2004-Rural Roads Manual
(ii) IRC-Sp-13-2004-Design of Small Bridges & Culverts
(iii) IS-458-2003- Specifications for Precast Concrete Pipes
(iv) IS-783-2005- Code of Practice for Laying of Concrete Pipes.

(2) Preamble ::
Reinforcement Concrete Cement Pipes are popularly known as
Hume Pipes or Spun Pipes. These are used for culverts, sewer lines etc.,

(3) Culverts ::
A small bridge structure of less than 6 meter span between faces of
abutment is called a culvert. A Culvert is a cross drainage structure & the
function is to convey storm runoff and or other discharges from one side of the
roadway to the other side expeditiously and effectively.
3.1. Types of Culvert
The following types of culverts are generally provided across the country:
(a) RCC Pipe Culvert
(b) RCC Slab Culvert
(c) RCC Box Types Culvert
(d) Arch Culvert
(e) Cut Stone Slab Culvert
The first two types of culverts are most popular across this state. RCC
Slab culverts shall be adopted where the founding strata is rocky or of better
bearing capacity. In case where adequate cushion is not available for locating
pipe culvert RCC slab culvert should be adopted. (IRC SP13-2004). Pipe culvert
may prove to be economical where foundation of culvert is likely to be deeper
or in predominantly black cotton soil area; and where foundations are required to
be taken to more than 2.5 m below the bed level. For catchment areas upto 20
hectares pipe culverts will be economical in comparison to slab culverts on all
types of roads. For catchment area more than 60 hectares, RCC slab culvert
offers an economical and convenient proposal. Alternatively box culverts, single
or multiple cell span be used.

(4) Construction of Piped Culvert Design aspects:

4.1 General:
The required formation width for rural roads [Other District Road (ODR)
and Village Road (VR)] is 7.5m. The design life for all culvert types is 100 years.

4.2 Codes
The pipes shall be conform to IS:458-1989 (Specification for concrete
pipes) and shall be laid as per relevant IS:783-1985 (laying of concrete pipes).

4.3 Hydraulic & Field Data

 The following data needs to be collected for the design of a culvert
after detailed survey and from field visit:
(i) Catchment area of the stream in hectares.
(ii) Traverse the stream 100M either side of culvert to ascertain the actual
flow details like velocity, width & depth of flow in the clear banking
reaches.
(iii) Any meandering of the stream or skew requirement shall be
ascertained.
(iv) Average Bed Level (BL), High flood level (HFL) & Road top level (RTL).
(v) Other details i/c soils data, inlet and outlet erosion issues and possible
sediment / debris issues, any culvert skew requirements
The road top level at culvert should be fixed in advance.

4.4 Location of Culverts

A culvert should be located to fit the natural channel in line and
grade as far as is practical and aligned to give the stream a direct
entrance and a direct exit.
The culverts should line up the natural skew in a channel as far as
possible, as a culvert on a different skew could cause progressive
bank erosion & protection of banks become costly. If possible, a culvert
should have the same alignment as its channel.

4.5. Selection of Type of Pipe, Dia & No.of rows

The number of pipes, length and pipe dia should be selected based
on the study of catchment area, stream width & depth of water, stream
alignment, inlet & outlet conditions. Since the catchment area varies
widely, it is suggested to estimate discharge of a natural stream by direct
measurement. If it is not possible to measure, some of the empirical
formulae (like, Dicken's and Inglis ) listed in IRC:SP:13 may be referred to
fix the discharge.
The sample design on low profile is as follows….
i) Approximate catchment area of the stream-“M” Acres
ii) Using Dickens formula, Max. Discharge Q = C(M) ¾ ( Where C=11-
14 , where annual rain fall is 60-120 Cms).
iii) Assume Velocity of Flow based on slope conditions= V m/sec
iv) Arrive Ventage area A=Q/V sqm.
v) Assume dia. of pipes and No. of rows based on site condition and
check for ventage provided.

4.5.1 Diameter of pipe :

The cost of slab culvert is less if the hard strata for foundation is within 2m
from the bed level, otherwise, pipe culvert is chosen. The main advantage in pipe
culverts is the speed of construction and good quality of factory produced pipes.
Although use of 450 mm, 600 mm diameter pipes in CD works was more
popular in low to moderate rainfall regions, from inspection and maintenance
point of view, a minimum of 900 mm (internal) diameter is recommended.
However, taking into consideration the low embankment heights, pipes of
lesser dia, viz, 600 mm or 750 mm may also be used substantiating with
reasons.
RCC pipes of 300 and 450 mm dia, used for irrigation/ agriculture are to be
considered as mere buried conduits and not as culverts.

4.5.2 Class of Pipes::

 RCC NP3 Class non pressure pipes are generally used for culvert constructions.
Previously RCC NP2 pipes on rural roads are extensively used but due less shell
thickness there are damaged early due to the Class A loading with impact generated
by modern vehicular movements. The pipes for culverts shall to IS:458-1989 The
shell thickness is as follows.
NP3 Pipes Dia. Shell thickness
300MM 40mm
600MM 85mm
900MM 100mm
1000MM 115mm
1200MM 125mm

4.5.3 Selecting the Diameter of Pipes

(As per IRC-SP 20-2002)
Catchment Area (Hectares) Diameter of Pipe (mm)
Up to 10 1000 single row
10 to 20 1200 single row
20 to 50 1000 or 1200 (2 to 3 rows)

4.6 Earthwork Excavation:

The width of the pipe trench shall be sufficient to permit satisfactory
jointing of the pipe, but it shall not be less than the external diameter of
the pipe plus 8 inches on each side. The depth below pipes shall be
executed at least (0.2Dia. + Thickness of concrete bedding), below the bed level
of the watercourse. For headwalls the depth of excavation shall be taken upto
hard soils.

4.7 Bedding below Pipes::

The structural design of pipe culvert requires calculations of probable
maximum load on the pipe, inherent strength of pipe and selection of bedding for
the pipe. It is desirable to use Type A, i.e., concrete cradle bedding for pipes of
l000 mm diameter and above and those with fills higher than 4 m. The width of
the cradle is not less than the external diameter of the
pipe plus 200 mm. The minimum compressive strength of concrete should be
15MPa(M15). The Type B bedding is adopted for height of fill between 0.60 m and
4.0 m. It consists of a continuous layer of compacted sand or moorum, with
minimum thickness of 75 mm below the pipe. In case where foundation
conditions are unusual, low available cushion, the pipes shall be encased with
150mm thick cement concrete 1:5:10 or compacted sand or gravel all-
around in.

4.8 Lowering and Laying of Pipes:

4.8.1 General
The laying and assembly of pipes shall conform to IS: 783.
The trench shall be checked for proper level, grade and alignment before
lowering the pipes.
4.8.2 Lowering of Pipes:
The pipes shall be lowered cautiously to prevent disturbance of the bed
and sides of the trench & impact on pipe & collar. The heavy pipes shall be
lowered by means of proper chain pulley blocks.
4.8.3 Laying of Pipes:
 Laying of pipes shall proceed in up-grade of slopes & to be confirmed
for required invert levels at either ends. Pipes shall be laid true to line and grade
as specified.
All pipes & collars must be new and perfectly sound, free from cracks,
cylindrically straight and of standard nominal diameter and length with even
texture.
The body of the pipe for its entire length shall rest on an even bed in the
trench and places shall be excavated to receive the Collar for the purpose of
assembly.
4.8.4 Assembly of RCC Pipes
The culvert is to be aligned with the existing watercourse channel. The
bottom of the culvert should be embedded at least 0.2D (Defined as 20% or 1/5
of the diameter of the culvert) below the bed of the watercourse at the
upstream and downstream end of the structure.

4.8.5 Joints for Pipes ( IS:783-1985)::

The ends of concrete pipes used for road culverts maybe suitable for
flush (NP3 and NP4) or collar joints (NP2) . For pipes of diameter up to 700 mm,
external flush joint and for diameters above 700 mm, internal flush joint is
recommended.

4.8.5.1 Types - The joints may be mainly of two types, a) Rigid joints, and b)
Flexible joints.
Rigid Joints - In this the water seal is effected by cement mortar or similar
material which will not allow any movement between the two pipes.
a).Socket and Spigot Joint - The annular space between socket and spigot is
filled with cement mortar (1 : 2).
b).Collar Joint - Collars of 15 to 20 cm wide cover the joint between two pipes.
A slightly damp mixtures of cement and sand is rammed with caulking tool.
c).Flush Joint- i. Internal flush joint - ii. External flush joint.

Flexible Joints - The water seal is effected because of contact pressure

between the sealing rubber rings and the pipe surface. Rubber Ring Joints
provide concrete pipes with a high degree of flexibility to accommodate ground
settlement or alignment adjustments while maintaining a watertight joint
capable of withstanding the common levels of hydraulic head occurring in a
storm water pipeline.
These are mainly two types.
a). Roll on Joint,
b). Confined Gasket Joint.

4.8.6 Jointing of pipes:

The pipes shall be joined either by flush joint or the collar joint.
In case of flush joint the ends of pipes are specially shaped to form a self-
centering joint with jointing space 13 mm wide. The jointing space shall be filled
with cement mortar (cement : sand I :2) mixed sufficiently dry to remain in
position when forced with a trowel or rammer. Care shall be taken to fill all voids
and excess mortar shall be removed & gunny bags shall be covered on each
joint after completion.
The collar shall be of RCC 150 mm to 200 mm wide having strength as
that of pipes. Caulking space shall be between 13 to 20 mm according to the
diameter of the pipe. A few skeins of spun yarn soaked in neat cement wash
shall be inserted in the groove at the end of the pipe and the two adjoining
pipes butted against each other. The collar shall than be slided over the joint
covering equally both the pipes. Spun yarn soaked in neat cement wash shall be
passed round the pipes and inserted in the joint by means of caulking tools from
both ends of the collar. Caulking material shall be a wet mix of cement and sand
in the ratio of 1:2 rammed with caulking irons.

4.8.7 Curing of Joints

The cement mortar joints shall be cured at least for seven days.

4.9 Geometric Standards for Culverts

4.9.1 Overall width of CD works:

The overall width of culvert should be equal to the formation width of the
road. In rural roads, the road way width is 7.5m in plain and rolling terrain
measured from outer to outer of parapet walls. The carriage way width of a CD
structure is generally the overall width minus the parapets or kerbs with or
without railings which should normally allow passage of two trains of IRC Class A
Loading.

4.9.2 Design Loading

Culverts and bridges of 6m, 6.4m and 7.5m overall widths on rural roads
are normally designed for two lanes of IRC Class A loading with impact.

4.9.3 Minimum span :

From the consideration of maintenance of culverts, it is preferable that
the clear waterway of pipe culvert is 1000 mm (900 mm internal Φ). Culverts of
small span or diameter get choked due to silt. It is not possible to enter the pipe
and carry out inspection and repairs. Irrigation pipes do not come under the
purview of pipe culverts.

4.9.4 Headwall:
The Headwalls are raised up to top of the crust level of the road. The
length of headwall is equal to four times the diameter of pipe for retaining
the slope of earthen bank within 1(Vertical) to 1.5(Horizontal). Longer head walls
are provided for wider streams as per site requirements. Suitably designed RCC
face wall (150mm thick) can also be used for single row pipe culverts.

Rough calculation of length of Body walls.

Length of the body wall L =2H+(nD+(n-1)D/2)+0.60
Where H=Ht. of the Body wall from the Bed Level, N=No.of vents, D= Dia.
Of Pipes in Mtrs.
It shall be ensured that the invert of the pipe is placed 150mm below the
average bed level.
4.9.5. Parapet wall and railing :
For culverts, where parapet walls are provided they shall be of plain
concrete M15 grade or store masonry with size 0.30x0.30M or 0.30x0.45M or
0.45x 0.45M over Head walls. The standard road width of 7.50M shall be
maintained measured from outer to outer of parapet walls at all points. In case
of small pipe culverts with low banking height, no parapet walls are needed and
guard stones would be adequate. Guard stones provided shall be of size
200x200x600 mm. (IRC SP-13-2004).
If considered necessary either pipe railing or guard stones of
200x200mm section projecting 300mm above kerb and spaced at
1200mm c/c may be fixed. At the end of parapets and returns,
400x400x600mm RCC blocks are provided at four comers at the mid of
returns. Numbering of culverts and direction of flow can be marked on
these pillars.

4.9.6 Line, Grade & Plumb:;

Line and grade should be checked as the pipe are installed on the bedding
and further the head walls shall be checked against Line & Plumb, any uneven
surface noticed shall be immediately rectified on the day of removal of
shutterings.

4.9.7 Grade of Concrete:

As per IRC: 21, the M15 is the minimum grade for plain concrete and M20
for design mix. Where the quantum of concrete work is small like CD works of
rural roads, it is suggested to use nominal mix based on volumetric proportion of
cements and aggregate with a water cement ratio upto 0.45. The minimum
quantity of cement shall be 310kg/m3. The nominal mix adapted in small works
and their corresponding strength for different works using 43 grade cement is
given in Table for guidance (IRC-SP-20-2002). The Super plasticizers could be
used to improve workability. It is advisable to use plasticisers and reduce w/c
ratio to 0.4 to achieve higher strength of concrete.
TABLE :: GRADES of CONCRETE
Grade Nominal Mix Usage
M10 1:4:8 Lean concrete as leveling course
M15 1:3:6 Bed Concrete, PCC Pier/Abutments
1:2.5:5 Abutment, Wing/Return Walls, Foundation for
RCC works
M20 1:2:4 RCC Pier, Abutment Caps, Raft foundations, Dirt walls
M25 1:1.5:3 RCC Superstructure

Note: Mix proportions are by weight

The Power driven mixers and vibrators must be used for concrete works of
CD Works to achieve required compaction & strength.

4.9.8 Number of culverts per kilometer (IRC-Sp-20-2002)::

 It is recommended to provide about 2-3 culverts per km length of road
depending on the topography. Culverts are provided at the rate of one per 500
m length of road to avoid water logging.

4.9.9 Height of Culvert:

The minimum height of the formation level of the road from the bed level
required in case of pipe culvert is 1.75m ( for 900mm pipe) ( IRC Sp-20-2002)

4.9.10 Cushion over Pipes :

The cushion between the top of the pipe and the road top level shall not be
less than 600 mm. (IRC SP13-2004) and preferably 1.0M (IRC_SP-20-2002).

4.9.11 Clear Distance between Pipes :

The Clear Distance between Pipes may be adopted as 500mm for pipes
dia. less than 1000mm and 600mm for the pipes above 1200mm. (IRC_SP-20-
2002).

4.10. Numbering of Culverts:

4.10.1. The number of culvert is indicated in each km. For instance number 21/8
represent the 8th CD structure in kilometre 21.
The information regarding (1) the number of spans (2) clear span length in
m, and (3) the type of decking or culverts, is indicated below:
Number of spans, clear span in m, type of culvert/small bridges are given,
e.g. 1 x 2 x S , means 1 span of 2 m with RCC solid slab. For various types of
culverts and small bridges use the symbol as RCC Solid slab – S, Pipe culvert – P,
Arch – A, Box Type – B, Stone Slab – ST.
The number of the structure shall be inscribed near the top of the left hand side
parapet wall as seen by traffic in the end elevation when approaching the
structure from each direction.

4.10.2. The methodology for inscribing numbers on parapets, RCC posts has
been given, in IRC:7 'Recommended Practice for Numbering of Bridges and
Culverts. The size of letter shall not be less than 100mm high and shall conform
to IRC:30' Standard Letters and Numerals of Different Heights for Use on
Highway Signs'.

5.0. Protection works:

When the mean velocity of flow is more than 2.6m/sec protection of
entry and exit end is desirable. Otherwise, stone pitching of bed would be
adequate (IRC_SP-20). High outlet velocities can cause erosion for a
significant distance downstream of an outlet & appropriate dissipation
measures will be required.
5.1 Aprons
If high headwater depths are to be encountered, or if the approach
velocity of the channel is high or special soil conditions, such as alluvial soils will
cause scour, a short channel flexible boulder apron at U/S & D/S of culvert is
necessary. This apron should extend at least one pipe diameter upstream from
the entrance and 1.5 times the diameter of pipe downstream with the top of the
apron should not protrude above the normal streambed elevation. The size of
stone for flexible boulder apron shall be large as possible. In no case any
fragment shall weigh less than 40 kg and size not less than 300mm. A toe wall all
along the apron with 600mm x 600mm size filled with the same stones is
desirable. The surface on which the stone apron is to be laid shall be leveled,
compacted and prepared for the length and width. The cement concrete
grouting shall be undertaken at the discretion of the engineer in charge as
per prevailing site condition.

5.2 Revetment to Banks::

Where the formation height of embankment is quite high, a quadrilateral
revetment on four sides with RR Stones not less than 225mm thick with 150mm
gravel backing shall be provided to safe guard the embankment against scour.

5.3 Debris Control

Accumulation of debris / jungle trash at a culvert inlet can result in the
culvert not performing as designed. The consequences may be damages from
inundation of the road and upstream property. The designer has three options for
coping with the debris problem:
(i) Debris Racks are iron jolly structures placed across the stream
channel to collect the debris before it reaches the culvert entrance.
(ii) Jungle Trap : 200mm dia. 1.0 to 1.50M high RCC Guard posts at
0.60m c/c in Zigzag manner installed on U/S to prevent Tree
trunks/branches etc from entering into the culvert vents.

6.0. Culvert maintenance

Since the waterway is usually small they tend to get clogged due to
accumulation of silt and debris. In addition, the growth of vegetation should be
checked lest the life of CD works would be curtailed. Culverts will not last the
expected life unless inspected and repaired twice in a year.
The maintenance covers the following aspects:
(i) Choking of Vents
(ii) Wash out of Approaches
(iii) Dislodgement of Cushion
iv) Scour on D/S
v) Silting/Debris on U/S
The bed of the stream should be suitably protected to prevent erosion
or scour. The sinking of approaches is quite common in rural areas. This is
primarily due to improper compaction of the earth fill. Occurrence of potholes
due to undermining is also common phenomenon.

The QC Inspections will be focused on this aspect of proper constructions

of piped culverts and defective construction will be recommended for rejection
and the amount can be recovered from the field officers in charge of the works
hence forth.
 Yours faithfully,

( Neelakanteshwar Yedla)
neelakantyedla@gmail.com
Dy. Executive
Engineer,
(PR) Vig & QC Sub-Division,
Nalgonda.

Encl:-
1) Typical 1V & 2V Pipe culvert drawing.
2) Relevant IRC Codes.

To,

The Executive Engineer (PR) PIU Divn Nalgonda, EE PRI Divn Nalgonda & EE PRI
Miryalaguda with a request to communicate the same all field Engineers under
their control.
Copy to all DyEE’s /AEE’s through EE’s concerned.
C/S to the Executive Engineer (PR) Vig & QC Divn.Hyderabad for favour of
information.