Modular Box Culvert: Leveraging Versatility and Efficiency for Profitability

Modular Box Culvert: Leveraging Versatility and Efficiency for Profitability Box culverts are some of the most versatile structures in construction and civil engineering today. However, manufacturing box culverts of varying dimensions with consistency and accuracy is still a labour and time intensive process. Process and product variability are some of the biggest problems faced by concrete product manufacturers.

At GCI Pipe Products Inc., we specialize in production technology that serves the concrete pipe and precast industries, and is now presenting an automated, labourefficient and time-saving production system to all players in the global market.

GCI’s Modular Box Culvert can produce a wide range of sizes for both dry and wet cast processes, using rigid and robust steel panels for production of dimensionally accurate box products. GCI’s design covers every adjustable feature and fits all requirements – with variable rises, spans and wall thicknesses. A core collapsing mechanism can be provided as a strip feature for wet cast boxes.

Design Methodology GCI’s modular box culvert consists of four corner pieces of the core, jacket, pallet and header, combined to form the smallest desired size. The box size can be adjusted by attaching extension panels in between corner pieces to independently increase the rise and span. The wall thickness can be altered through pallet design.

In case of a dry cast process, external vibrators are used for uniform concrete compaction throughout the product. A control panel is provided to regulate the process and the vibration imparted. A vertical press head system eliminates the use of dead weights.

The wet cast box design utilizes a collapsible core mechanism to facilitate easy stripping of the product, enhancing repeatability and enabling quicker turnarounds.

“Quick locks” are provided to assemble corners and extensions in a quicker fashion, thereby, reducing cycle time.

Key benefits · Automatic filling: A PLC automatic control is used to alter the volumetric feed rate based on the box’s dimensions, enabling reduced labour and enhanced production. · Efficient vibrator technology: Uniform compaction and reduced wear: After performing analyses, the vibrator force has been reduced by 75% at 60Hz. A variable frequency drive is used to allow vibrators to work between 70% to 100% of their rated capacity, depending on the wall thickness of the box. · ‘Plug and Run’: Our ‘Plug and run’ system enables all vibrators to be connected to a common cable which prevents individual connections to a single socket. This reduces non-value added time.

· Exact products: Process and product variability are one of the biggest problems faced by manufacturers. Our solution reduces variability through automation, precision mould quality and a vertical press head system