Precast RCC box culverts are essential structures used in infrastructure projects for efficient water drainage and management. This post contains the essential steps to install a box culvert. Their pre-fabricated nature ensures uniform quality and expedited installation, making them a popular choice for engineers and contractors.
Trilok Infratech, a trusted manufacturer of precast concrete products, offers high-quality box culverts engineered for strength, durability, and easy installation. Below is the recommended step-by-step procedure for installing box culverts on-site.
Steps to Install a Box Culvert
Site Survey & Analysis
Before installing Trilok Infratech’s Box Culverts, a detailed survey is essential.
- Verify design drawings (invert levels, gradients, culvert sizes).
- Confirm utilities, site accessibility, and safety measures.
- Establish permanent benchmarks to guide the installation.
This ensures Trilok Infratech culverts are placed at the right alignment and levels.
Excavation (Extra 300 mm Clearance)
Excavate the site with at least 300 mm additional clearance on each side of the Box Culvert.
- Ensure safe slope protection or shoring.
- Remove soft spots and replace them with stable material.
This gives enough working space for accurate placement of Trilok Infratech Box Culverts and proper compaction.
Crushed Stone Layer
Depending on soil conditions, provide a layer of crushed stone at the base.
- Thickness usually ranges between 100–300 mm.
- Compact in layers to 95% MDD for stability.
This acts as a strong, uniform foundation for Trilok Infratech products.
PCC (Plain Cement Concrete) Bed
Lay PCC (M10/M15 grade) over the stone base as required.
- Provides a rigid and clean surface.
- Typical thickness is 75–150 mm.
A well-laid PCC ensures the durability and stability of Trilok Infratech Box Culverts.
Dry Bedding Mortar (1:6 Cement : Sand)
Apply a dry bedding mortar (Cement : Sand = 1:6).
- Spread evenly (20–30 mm).
- Ensures full-surface contact with no voids.
This bedding allows Trilok Infratech Box Culverts to sit firmly without rocking.
Product Lifting
Trilok Infratech supplies precast Box Culverts with lifting anchors for safe handling.
- Use cranes/spreader beams as per weight capacity.
- Employ tag lines to guide the unit.
- Inspect for cracks or damage before lowering.
Always follow Trilok Infratech’s lifting guidelines to avoid product damage.
Installation in Proper Line & Level
Position the culverts carefully:
- Use laser levels/total stations for alignment.
- Place the first Trilok Infratech unit as the reference.
- Maintain the correct inverse slope for water flow.
Correct placement ensures that the Trilok Infratech culverts perform as designed for load-bearing and drainage.
Jointing Process
Rubber Gasket & Nut-Bolting
- Trilok Infratech Box Culverts come with rubber gaskets for watertight sealing.
- Secure with galvanized nuts and bolts tightened in a diagonal pattern.
Groove Filling with Non-Shrink Grout
- Fill grooves with approved non-shrink grout for permanent sealing.
- Prevents leakage and strengthens the joints.
Nut-Bolt Groove Filling
- Cover nut-bolt recesses with non-shrink grout for durability.
This three-step jointing process makes Trilok Infratech Box Culverts leak-proof and long-lasting.
After Installation
Once all units are installed and joints are sealed:
- Backfill with selected material in 200–300 mm layers.
- Compact evenly on both sides.
- Construct wing walls/headwalls as per design.
- Complete embankment and road pavement.
Following these steps ensures the optimum performance of Trilok Infratech’s precast Box Culverts in highways, railways, and irrigation projects.
Why Choose Trilok Infratech Box Culverts?
- Precision-engineered for quick installation.
- Durable precast concrete, designed for heavy loads.
- Watertight joints with gasket + grout system.
- Trusted by government projects across highways, bridges, and irrigation works.
With Trilok Infratech, you get quality, reliability, and long service life in every Box Culvert installation.
Tools Required for Box Culvert Installation
After understanding how to install the box culvert, let’s learn which tools are required to install it.
Crane or Hydra
- Heavy lifting equipment is used to safely handle and place Trilok Infratech Box Culverts.
- Ensures smooth lifting, shifting, and lowering into position without damaging the product.
Auto Level & Spirit Level
- Auto Level: A surveying instrument used to check the correct slope, alignment, and level of the culvert during installation.
- Spirit Level: A hand tool with a bubble tube, used to quickly check the flatness of surfaces.
These ensure that Trilok Infratech Box Culverts are placed in perfect line and level.
Line Dori (String Line)
- A strong thread/cord used to mark and maintain straight alignment during installation.
It helps workers to keep all culvert units in a straight line along the designed centerline.
Tommy Bar (2 Nos.)
- Steel bars are used as levers while tightening or adjusting bolts.
Essential for nut-bolt fixing in Trilok Infratech’s jointing process.
Non-Shrink Grout Material
- A special cementitious material that does not shrink after setting.
- Used for filling grooves, nut-bolt recesses, and joints in Trilok Infratech Box Culverts.
It ensures watertight and long-lasting joints.
Lifting Tools (D-Shackle & Deha Lifting Clutch)
- D-Shackle: U-shaped metal piece with a pin, used to connect lifting hooks and slings.
- Deha Lifting Clutch: A specialized tool designed for safely lifting precast concrete units with embedded anchors.
These ensure safe and secure lifting of Trilok Infratech Box Culverts without cracks or damage.
Jointing Tools (Rubber Gasket & Nut-Bolt)
- Rubber Gasket: Provides watertight sealing between culvert joints.
- Nut-Bolt Set: Holds culvert units together securely during and after installation.
Together, they make the jointing system of Trilok Infratech culverts durable and leak-proof.
Glossary of Technical Terms – Trilok Infratech
PCC (Plain Cement Concrete)
A simple mix of cement, sand, and aggregate without reinforcement.
M10 / M15 (Concrete Mix Grades)
These refer to the strength of concrete.
- M10 – Can handle 10 MPa load (suitable for leveling).
- M15 – Can handle 15 MPa load (suitable for base concrete).
MDD (Maximum Dry Density)
The highest density a soil can achieve after proper compaction in lab tests.
SSD (Saturated Surface Dry)
A condition of concrete or stone when pores are filled with water, but no free water on the surface.
QA (Quality Assurance)
A process of systematic checks and inspections to ensure product performance.
ITP (Inspection & Test Plan)
A formal checklist of tests and inspections at every stage of construction.
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