TRANSPORT FOR NSW (TfNSW)

QA SPECIFICATION R16
PRECAST REINFORCED CONCRETE BOX CULVERTS

NOTICE
This document is a Transport for NSW QA Specification. It has been developed for use with
roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not
suitable for any other purpose and must not be used for any other purpose or in any other context.
Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev Clause Authorised

Description of Revision Date
Number Number By
Ed 1/Rev 2 R7.3 Discretion by Superintendent regarding GM, CEC 03.07.92
blinding layer. (R. Neal)
Compaction adjacent to walls.
Pay Item Payment includes blinding layer and invert
R7P1 slab.
Ed 1/Rev 3 Clause numbers and lists restructured to suit GM, CEC 27.03.95
the new format. per JW
(MCQS)
2 Hold point removed and Supplier Quality
System introduced.
Ed 1/Rev 4 Specification Number changed from R7 to GM, RNIC; 03 Jan 97
R16. (J Woodward)
Converted to MS Word 6.0c.
References to RTA Specifications changed.
1 - 4, Annex Clauses renumbered
R16/1
1 Rewritten
2, 3 AS 3902 changed to ISO 9002.
4 Methods required to be in PROJECT
QUALITY PLAN
Ed 2/Rev 0 Completely rewritten. GM, RNIC 03.08.98
Ed 2/Rev 1 Annexure New schedule listing Identified Records GM, RNIC 23.05.00
R16/3
Ed 3/Rev 0 Various Text revised to direct imperative style GM, RNIC 05.10.05
”Contractor” replaced by “you”
”Superintendent” replaced by “Principal”
Reformatting and minor editing
“Shall” replaced by “must”.

Edition 3 / Revision 2 TRANSPORT FOR NSW

June 2020
 Ed/Rev Clause Authorised
Description of Revision Date
Number Number By
Ed 3/Rev 0 Foreword New clause after the Table of Contents
(cont’d) 1.2 New clause, references transferred to
Annexure R16/M
1.4 Transferred to Clause 1.2.1
1.5 Transferred to Annexure R16/D
R16/1, R16/2 Renumbered R16/A, R16/E, respectively
R16/3 Renumbered R16/C
Ed 3/Rev 1 Guide Notes Guide Notes deleted. GM, IC 17.09.10
Ed 3/Rev 2 Global References to “Roads and Maritime DCS 22.06.20
Services” or “RMS” changed to “Transport
for NSW” or “TfNSW” respectively.

ii
 QA S PECIFICATION R16

PRECAST REINFORCED CONCRETE

BOX CULVERTS
Copyright – Transport for NSW
IC-QA-R16

VERSION FOR:
DATE:

Edition 3 / Revision 2 TRANSPORT FOR NSW

June 2020
Precast Reinforced Concrete Box Culverts R16

CONTENTS
CLAUSE PAGE
FOREWORD ...............................................................................................................................................II
TfNSW Copyright and Use of this Document ...............................................................................ii
Revisions to Previous Version .......................................................................................................ii
Project Specific Changes ...............................................................................................................ii

1 GENERAL ........................................................................................................................................ 1
1.1 Scope .............................................................................................................................. 1
1.2 Structure of the Specification ......................................................................................... 1
1.3 Definitions ...................................................................................................................... 2
1.4 Basic Requirements ........................................................................................................ 2

2 DESIGN REQUIREMENTS AND PROCEDURES .................................................................................. 2

3 DESIGN BASED ON LOAD TESTING ................................................................................................ 2

4 CONCRETE WORK .......................................................................................................................... 3

5 ROUTINE SAMPLING AND TESTING ................................................................................................ 3

6 CERTIFICATION BY THE CONTRACTOR .......................................................................................... 3

7 DELIVERY TO SITE ......................................................................................................................... 3

ANNEXURE R16/A – PROJECT SPECIFIC REQUIREMENTS ........................................................................ 4

A1 General Information ....................................................................................................... 4
A2 Delivery Information ...................................................................................................... 4
A3 Class And Quantity Information..................................................................................... 4

ANNEXURE R16/B – (NOT USED)............................................................................................................. 4

ANNEXURE R16/C – SCHEDULES OF HOLD POINTS, WITNESS POINTS AND IDENTIFIED RECORDS ........ 5
C1 Schedule of Hold Points and Witness Points.................................................................. 5
C2 Schedule of Identified Records....................................................................................... 5

ANNEXURE R16/D – PLANNING DOCUMENTS ......................................................................................... 5

ANNEXURE R16/E – BASIC AND SERVICEABILITY TEST LOADS FOR SMALL CULVERT UNITS AND LINK
SLABS ............................................................................................................................................. 6

ANNEXURES R16/F TO R16/L – (NOT USED) ........................................................................................... 7

ANNEXURE R16/M – REFERENCED DOCUMENTS .................................................................................... 7

LAST PAGE OF THIS DOCUMENT IS ............................................................................................................ 7

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R16 Precast Reinforced Concrete Box Culverts

FOREWORD

TFNSW COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Transport for NSW.

When this document forms part of a contract

This document should be read with all the documents forming the Contract.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy
controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW
Internet website: http://www.rms.nsw.gov.au/business-industry/partners-
suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification TfNSW R16 Edition 3 Revision 1.

All revisions to the previous version (other than minor editorial and project specific changes) are
indicated by a vertical line in the margin as shown here, except when it is a new edition and the text
has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are indicated in the following manner:

(a) Text which is additional to the base document and which is included in the Specification is
shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the
Specification is shown struck out e.g. Deleted Text.

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TfNSW QA SPECIFICATION R16

PRECAST REINFORCED CONCRETE BOX CULVERTS

1 GENERAL

1.1 SCOPE
This Specification sets out requirements for the design, testing, manufacture and delivery of precast
reinforced concrete rectangular box culverts covering:
(a) small precast culvert units, up to 1200 mm span and 1200 mm height, and associated link slabs;
and
(b) large precast culvert units from 1500 mm span and up to 4200 mm span and 4200 mm height,
and associated link slabs.

This Specification does not cover installation requirements. Installation must be in accordance with
Specification TfNSW R11, Stormwater Drainage.

1.2 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 Details of Work

Project specific requirements consistent with Appendix A of AS 1597.2 for culvert units and link slabs
are given in Annexure R16/A.

1.2.2 Schedules of HOLD POINTS, WITNESS POINTS and Identified Records

The schedules in Annexure R16/C list the HOLD POINTS and WITNESS POINTS that must be
observed. Refer to Specification TfNSW Q for the definitions of HOLD POINTS and WITNESS
POINTS.

The records listed in Annexure R16/C are Identified Records for the purposes of TfNSW Q
Annexure Q/E.

1.2.3 Planning Documents

The PROJECT QUALITY PLAN must include each of the documents and requirements listed in
Annexure R16/D and must be implemented.

1.2.4 Referenced Documents

Unless specified otherwise or is specifically supplied by the Principal, the applicable issue of a
referenced document, other than a TfNSW Specification, is the issue current at the date one week
before the closing date for tenders or, where no issue is current at that date, the most recent issue.

Standards, specifications and test methods are referred to in abbreviated form (eg AS 1597). For
convenience, the full titles are given in Annexure R16/M.

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R16 Precast Reinforced Concrete Box Culverts

1.3 DEFINITIONS
The definitions of AS 1597.2 apply. The following interpretations apply to terms used in this
Specification:

Small Culvert Unit: Culvert unit with a span up to 1200 mm and a height up to 1200 mm

Large Culvert Unit: Culvert unit with a span from 1500 mm and up to 4200 mm and a
height up to 4200 mm

1.4 BASIC REQUIREMENTS

Design, test, manufacture and deliver all culverts and link slabs in accordance with AS 1597.2 and the
additional requirements of this Specification.

2 DESIGN REQUIREMENTS AND PROCEDURES

Design requirements and procedures of AS 1597.2 must apply.

Design assurance and verification must comply with the requirements of Clause 7.3 of ISO 9001.

Include in the design records, the calculations produced during both the design and verification
processes.

Provide certification demonstrating that the design complies with all the requirements of this
Specification.

HOLD POINT
Process Held: Delivery to site of culverts.

Submission Details: Design output and certification of compliance at least 5 working days prior
to commencement of delivery to site.

Release of Hold Point: The Principal will consider the submitted documents for compliance with the
Specification, prior to authorising the release of the Hold Point.

3 DESIGN BASED ON LOAD TESTING

Where a design based on load testing is adopted, provide certification, supported by testing and
calculation records, demonstrating that the design complies with the requirements of AS 1597.2 for
each different culvert / load combination.

Tables of basic test loads for standard small culvert units and link slabs are given in Annexure R16/E.

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Precast Reinforced Concrete Box Culverts R16

HOLD POINT
Process Held: Delivery to site of culverts.

Submission Details: Testing and calculation records and certification of compliance at least 5
working days prior to commencement of delivery to site.

Release of Hold Point: The Principal will consider the submitted documents, prior to authorising the
release of the Hold Point.

4 CONCRETE WORK
Concrete, reinforcement and embedments must comply with TfNSW B80.

5 ROUTINE SAMPLING AND TESTING

Routinely sample and test for each quality parameter, except concrete strength, in accordance with AS
1597.2. Sample and test for concrete strength in accordance with TfNSW B80.

Tables for serviceability test loads for standard small culvert units and link slabs are given in
Annexure R16/E.

WITNESS POINT
Process Witnessed: Each crack serviceability test.

Submission Details: At least 2 working days’ notice of intention to carry out the test.
Prior to the proposed commencement of testing, make available a certificate
of compliance in respect of test loads and other relevant details supported by
verification checklists.

6 CERTIFICATION BY THE CONTRACTOR

Prior to units being incorporated into the Works, submit to the Principal a certificate for each culvert
unit or link slab, or batch of culvert units and slabs, which states that the units conform to the
Specification and that all nonconformities have been rectified.

7 DELIVERY TO SITE
Do not transport any unit to site until at least seven days after casting and until the concrete has
reached the specified 28 day strength.

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R16 Precast Reinforced Concrete Box Culverts

ANNEXURE R16/A – PROJECT SPECIFIC REQUIREMENTS

A1 GENERAL INFORMATION

List of Available
Item Job Specific Parameters
Parameters
Concrete Exposure
B1 / B2 / C / U
Classification
Type of Joint Butt joint / Other
Construction Loads Standard / Other

A2 DELIVERY INFORMATION

Place of Delivery
Rate of Delivery
Place of Acceptance

A3 CLASS AND QUANTITY INFORMATION

Type Class Quantity

ANNEXURE R16/B – (NOT USED)

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Precast Reinforced Concrete Box Culverts R16

ANNEXURE R16/C – SCHEDULES OF HOLD POINTS, WITNESS

POINTS AND IDENTIFIED RECORDS
Refer to Clause 1.2.2.

C1 SCHEDULE OF HOLD POINTS AND WITNESS POINTS

Clause Type Description

2 Hold Submission of design output and certification of compliance
3 Hold Submission of testing and calculation records and certification
5 Witness Notice of intention to carry out each crack serviceability test.

C2 SCHEDULE OF IDENTIFIED RECORDS

The records listed below are Identified Records for the purposes of TfNSW Q Annexure Q/E.

Clause Description of Identified Record

2 Design output and certification of compliance
3 Testing and calculation records and certification of compliance
6 Certificate which states that the items conform to the Specification and all
nonconformities have been rectified

ANNEXURE R16/D – PLANNING DOCUMENTS

Refer to Clause 1.2.3.

The following documents are a summary of documents that must be included in the PROJECT
QUALITY PLAN. The requirements of this Specification and others included in the Contract must be
reviewed to determine additional documentation requirements.

The information to be supplied as part of the PROJECT QUALITY PLAN must include the
following:-
(a) Drawings showing the culvert unit/link slab type and class, complete dimensions including
tolerances, concrete exposure classification, and construction loading capability;
(b) Provisions for lifting of culverts and link slabs;
(c) The method of culvert unit and link slab manufacture and testing; and
(d) Sampling and testing plans and procedures (refer to Clause 6).

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ANNEXURE R16/E – BASIC AND SERVICEABILITY TEST LOADS FOR

SMALL CULVERT UNITS AND LINK SLABS
(a) General

The tables in Clauses (b) and (c) of this annexure must be used in conjunction with the requirements of
AS 1597.2 for design based on load testing and for serviceability load testing, respectively.

The size and load class used in the tables must be in accordance with Clause 1.8 of AS 1597.2. Loads
for culvert units and link slabs of 1200 mm span apply to culvert units and link slabs with spans less
than 1200 mm.

(b) Basic Test Loads

Basic test loads for link slabs and culvert units are given in Tables R16/E.1 and R16/E.2 respectively.

Table R16/E.1 – Link Slabs - Basic Test Loads

Load per metre width (kN/m)

Class Class 2-A Class 3-A Class 4-A Class 5-A
Size V2 V2 V2 V2
1200 or
205 110 137 165
less

Table R16/E.2 – Culvert Units - Basic Test Loads

Size/Class 1206/2-A 1206/3-A 1206/4-A 1206/5-A

Loading Load per metre width Load per metre width Load per metre width Load per metre width
Type H1 H3 V2 H1 H3 V2 H1 H3 V2 H1 H3 V2
U1 205 110 137 165
U4 15 15 205 17 17 110 19 19 137 23 23 165

Size/Class 1209/2-A 1209/3-A 1209/4-A 1209/5-A

Loading Load per metre width Load per metre width Load per metre width Load per metre width
Type H1 H3 V2 H1 H3 V2 H1 H3 V2 H1 H3 V2
U1 205 110 137 165
U4 30 30 205 34 34 110 37 37 137 44 44 165

Size/Class 1212/2-A 1212/3-A 1212/4-A 1212/5-A

Loading Load per metre width Load per metre width Load per metre width Load per metre width
Type H1 H3 V2 H1 H3 V2 H1 H3 V2 H1 H3 V2
U1 205 110 137 165
U4 42 42 205 45 45 110 48 48 137 59 59 165

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Precast Reinforced Concrete Box Culverts R16

(c) Serviceability Test Loads

Serviceability test loads for link slabs and culvert units are given in Table R16/E.3 and R16/E.4,
respectively.

Table R16/E.3 Link Slabs – Crack Test Loads

Size Load per metre width (kN/m)

Class Class 2-A Class 3-A Class 4-A Class 5-A
1200 or less 75 55 70 85

Table R16/E.4 Culvert Units – Crack Test Loads

Size Load per metre width (kN/m)

Class Class 2-A Class 3-A Class 4-A Class 5-A
1206, 1209,
75 50 60 75
and 1212

ANNEXURES R16/F TO R16/L – (NOT USED)

ANNEXURE R16/M – REFERENCED DOCUMENTS

Refer to Clause 1.2.4.

TfNSW Specifications

TfNSW B80 Concrete Work For Bridges

TfNSW Q Quality Management System
TfNSW R11 Stormwater Drainage

Australian Standards

AS 1597.2 Precast reinforced concrete box culverts – Large culverts

ISO 9001 AS/NZS ISO 9001 Quality management systems – Requirements

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