Project Overview
Luck Stone’s Bealeton quarry faced a critical infrastructure challenge when a quad run of 15×9 corrugated metal arch pipes (CMP) beneath their railroad crossing and entrance roadway began failing. To ensure long-term stability and safety, the solution called for replacing the aging CMP with a robust precast concrete box culvert system.
Challenges
Virginia Construction Company (VCC), based in Fredericksburg, VA, was tasked with completing the entire installation within an aggressive eight-day window while keeping the quarry operational. The project also required maintaining continuous water flow from Craig Run, which necessitated a live bypass pipe during the first phase of installation. Compounding the challenge, the team faced rain throughout the installation, adding pressure to meet the tight timeline.
Solutions
Concrete Pipe & Precast (CP&P) supplied a custom-engineered 12’x9’ precast box culvert designed to ASTM C1577 LRFD and VDOT specifications (HL-93, E80-RR, LL for 4-5′ of fill). The system included:
- 79 standard quad-run box culvert pieces
- 8 skewed end sections
- 4 wing walls
- Parapet and bull nosing pieces
Each box featured a 1’-2” thick top slab, 10” walls, and a 1’ thick base slab. The heaviest section weighed 59,200 lbs. Installation was sequenced in two phases, enabling traffic to shift onto the completed half while the remaining CMP was removed and the installation finalized; an installation duration of eight business days.
Outcome
Despite site constraints and adverse weather, CP&P and VCC collaborated closely to complete the project on schedule. The new box culvert now provides a durable, long-term solution for Luck Stone’s critical quarry entrance and railroad crossing. To learn more about CP&P’s precast box culvert solutions, contact us at info@concretepandp.com
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