Mingha Bluff culvert install 3

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Excavation and preparation of the box culvert bedding foundation

The successful installation of precast box culverts begins with special site preparation for the foundation, typically referred to as bedding, on which the culvert will rest. TruLine Civil is an experienced Box Culvert installation contractor who understands the importance of bedding the culvert structure properly. The excavation cut was down to 4.8m below the rails. To alleviate the problem with groundwater below the culvert bedding foundation, a drain was dug down to a half a meter beneath the culvert to drain away the the silted ground water. A settling pond was excavated for the dirty ground water to drain into. From the settling pond the water went to ground. The water was not allowed to run straight into the Bealey River. With the surface and subsurface water controlled the site preparation conditions for the bedding gravels were dry. During installation provision of dewatering methods were available on the remote Mingha Bluff site in case they needed to be used to ensure the subgrade was dry. Unsuitable, unstable materials below the plan foundation were removed. After the appropriate excavation was performed the River Bealey river-run gravels subgrade was proof compacted.

Each of the 7 x 1.5m box culvert sections was craned into position. Negotiating the overhead rail and fragile underground services without interrupting the flow of the installation takes skill and expertise.

Bedding under the box culvert beneath the railway has been designed and formed so as to be able to support the full load of the installed pre-cast box culvert, its contents, and the loading of the overburden and rail traffic above.

Detail of caulking on the compression joint between the two mating concrete sections.

The thickness of the bedding material was 15cm minimum, as required by the project specifications. The bedding comprised of medium granular crushed AP20, it was installed and compacted and precisely levelled to provide uniform support for the full length and width of each box culvert section. This granular base material was sufficiently fine to achieve a level bedding surface. The final grading for the bedding was achieved with a laser. For the final grading, the granular material was screeded. The final grading allowed an easy crane-lift installation to set the box culvert sections precisely to marked targets on the foundation. The time and care taken ensuring the box culvert bedding preparation was done correctly enabled for very swift and accurate placement and fitting of the 7 x 1.5m individual culvert segments. Next Mingha Bluff install gallery 4 post >>

6:00–8:00pm, placement of the first three culvert sections

Affixing reinforcing hoops to the two wing-wall attachment flanges.

Affixing reinforcing hoops to the two wing-wall attachment flanges.

Custom sizing of the high-tensile steel threaded re-bar to the 10.5m culvert length.

Custom sizing of the high-tensile steel threaded re-bar to the 10.5m culvert length.

Preparing the bedding or foundation gravels.

Marking out the precise culvert section placements.

The crane and support truck.

First section of culvert being lowered into position.

Micro-adjustment of culvert position.

TruLine Civil works against the clock to place a new 2.5m square culvert beneath main trunk railway on bed of the Otira River, Arthurs Pass.

Of note is the fact that the crane operating team level and square each of the 1.5m culvert sections at the point of origin to ensure seamless delivery to their planned position on the foundation.

Application of caulking to the compression joint between the two mating concrete sections.

Application of caulking.

Detail of caulking on the compression joint between the two mating concrete sections.

Detail of caulking on the compression joint.

Insertion of threaded rebar temporarily to enable light compression of the first two mating concrete sections.

Tightening locking nuts on threaded rebar cinches together the first two mating concrete sections.

“Dumpy” laser provides benchmark level for installation.

Rebar lock-nut detail.

Preparing the lock-nut

Careful fine adjustment of the culvert sections, lightly compresses the joint between the two mating concrete sections

Craning the third section of box culvert into position.at the northern end of the culvert.

Description

Project name: Tru-Line Civil Website case studies portfolio
Client (Industry): TruLine Civil (Construction/Contracting)
Discipline: Documentary photography / Corporate communications design / Infographics  / Technical writing / Web content management
Format: Website / Case Studies / Methodologies
Location: Mingha Bluff SH73, Arthurs Pass, New Zealand
Date: July 2016

Credits

Design firm: MagentaDot Brands
Photographer: Shaun Waugh
Client: Tru-Line Civil