Culvert Design
Culvert Design
Culvert Design
Hydraulic Reports
The PEO shall collect field data and perform an engineering analysis as described in
Sections 3-2.2 and 3-2.3, respectively. Culverts in this size range shall be referred to on
the contract plan sheets as “Schedule Culv. Pipe in. Diam.” The PEO is
responsible for listing all acceptable pipe alternatives based on site conditions. The
decision regarding which type of pipe material is to be installed at a location will be left
to the contractor unless a specific material type is called out in the plans and justification
is provided in the hydraulic report. See Chapter 8 for a discussion on schedule pipe and
acceptable alternatives.
Culverts larger than 48 inches in diameter or span will be included as part of a specialty
report and are required to be designed by either the State Hydraulics Office or a
licensed engineer approved by the State Hydraulics Office, as outlined in Chapter 1.
In addition to standard culvert design, the State Hydraulics Office can assist in the
design of any unique culvert installation. The requirements for these structures will vary,
and the State Hydraulics Office shall be contacted early in the design phase to
determine what information will be necessary to complete the engineering analysis.
• Topographic map showing the contours and the outline of the drainage area
• Description of drainage area ground cover
• Fish passage requirement, if applicable; see Chapter 7
• Soils investigation per WSDOT’s Design Manual
• Proposed roadway profile and alignment in the vicinity of the culvert
• Proposed roadway cross section at the culvert
• Corrosion zone location, pH, and resistivity of the site
• Investigate a sufficient distance upstream and downstream and any other unique
features that can affect design, such as low-lying structures that could be affected
by excessive headwater debris and anticipated sediment transport
• Other considerations discussed in Section 3-5
If an existing culvert does not have a history of problems and only needs to be extended
or replaced, it is not necessary to gather all the information listed above to determine if
it is adequately sized for the flows it receives. Attaining the history of problems at an
existing culvert site may be sufficient to complete the analysis. Table 3-1 is a general
outline showing the information and field data requirements for a hydraulic report and
specialty report.
For culverts with spans between 4 and 20 feet, use the culvert design in this chapter. If
the crossing requires fish-bearing design criteria and/or the span is greater than 20 feet,
refer to Chapter 7 for further guidance.
Table 3-1 Field Data Requirements for Hydraulic Reports and Specialty Reports
Engineering Analysis
Collected field data will be used to perform an engineering analysis. The intent of the
engineering analysis is to ensure that the PEO considers several issues, including flow
capacity requirements, foundation conditions, embankment construction, runoff
conditions, soil characteristics, stream characteristics, potential construction problems,
estimated cost, environmental concerns, and any other factors that may be involved and
pertinent to the design. Additional analysis may be required, if a culvert is installed for
flood equalization, to verify that the difference between the floodwater levels is less
than 1 inch on either side of the culvert. The PEO should contact the State Hydraulics
Office for further guidance on flood equalization. Other miscellaneous design
considerations for culverts are discussed in Section 3-5.
Once the engineering analysis is completed, it will be part of the hydraulic report and
shall include the following information:
1. Culvert hydrology and hydraulic calculations, as described in Section 3-3 and Table
3-2.
2. Proposed roadway stationing of the culvert location.
3. Culvert length.
4. Culvert diameter. The minimum diameter of culvert pipes under a main roadway
shall be 18 inches. Culvert pipe under roadway approaches (i.e., driveway) shall have
a minimum diameter of 12 inches.
5. Culvert material.
6. Headwater depths, WSELs, and flow rates (Q) for the design flow event (generally
the 25-year event and the 100-year flow event).
7. Proposed roadway cross section and roadway profile, demonstrating the maximum
and minimum height of fill over the culvert.
This section includes excerpts from FHWA’s Hydraulic Design Series (HDS) 5, Hydraulic
Design of Highway Culverts. The PEO should refer to the Hydraulics Manual for detailed
information on the theory of culvert flow or reference an appropriate hydraulics
textbook for unusual situations. The State Hydraulics Office is also available to provide
design guidance.
The general procedure to follow when designing a culvert for a span width of less than
20 feet measured along the centerline of the roadway is summarized in the steps below.
Culvert spans more than 20 feet wide measured along the centerline of the roadway are
considered bridges and any hydraulic design for bridges is the responsibility of the State
Hydraulics Office; see Section 3-3.1.2 for further guidance.
3-3.1.1 Flow
The first step in designing a culvert is to determine the design flows to be used. The flow
from the basin contributing to the culvert can be calculated using the methods described
in Chapter 2. Generally, culverts will be designed to meet criteria for two flows: the 25-
year event and the 100-year event. If fish passage is a requirement at a culvert location,
contact the State Hydraulics Office (see Chapter 7). Guidelines for temporary culverts
are described further in Section 3-3.1.9. The PEO will be required to analyze each
culvert at each of the design flows, ensuring that the appropriate criteria are met.
rock excavation, it may be more feasible to alter the culvert profile or change the
channel alignment upstream or downstream of the culvert. This is best evaluated on a
case-by-case basis, with potential environmental and stream stability impacts being
balanced with construction and function ability issues.
• Culvert pipe connections for dissimilar materials must follow Standard Plan B-60.20-
02 of WSDOT’s Standard Plans.
• For cast-in-place box culvert connections, contact the Bridge Design Office for rebar
size and embedment.
• Precast box culvert connections must follow American Society for Testing and
Materials (ASTM) C 1433, AASHTO M 259, M 273, and Standard Specification 6-
02.3(28).
3-3.1.7 Minimum Culvert Diameter
The minimum diameter of a culvert under a main roadway must be 18 inches. Culvert
pipe under roadway approaches must have a minimum diameter of 12 inches. If
replacing an existing culvert, the new culvert shall have at least the same diameter as the
existing culvert even if the hydraulic analysis shows that a smaller-diameter culvert
would meet hydraulic design requirements in that location.
For design-build projects, the design and flow rate are determined by the design-builder
based on the requirements of project permits.
For design-bid-build projects on fish-bearing streams, the State Hydraulics Office
calculates the flow rates necessary for temporary diversions and that value is part of the
contract documents. A conceptual-level plan is required for permits, but no plans for the
temporary diversion system should be put into the final plan set and should not be
documented in the specialty report, unless otherwise approved.
Temporary diversions for fish-bearing streams shall be designed for the following storm
events:
• Single season: For a temporary diversion expected to be in place for a single fish
window, the design flow rate shall be, at a minimum, equal to the expected 50
percent exceedance flow rate during the window when the temporary diversion is in
place with a contingency plan that shall be in place within 2 hours or less to bring the
system to meet the expected 10 percent exceedance flow rate during the window
when the temporary diversion is in place. The expected flow rates during the
window when the temporary diversion is in place can be determined through stream
gage data (if available) or through an MGSFlood seasonal flow analysis (western
Washington only). The flows can also be measured in the previous fish window years
to get a base flow followed by an analysis for a 2-year storm based on rainfall for
that fish window. If there are no data to calculate the flows during the construction
window, then the expected 2-year flow rate shall be used for the design flow
(contingency not necessary in this case) unless the PEO can justify a different flow if
approved by the State Hydraulics Office.
• Multiple season: A gravity bypass is required if the stream diversion is expected to
remain in place over the winter; pump bypasses will not be allowed. The culvert shall
be the lesser of the size required to pass the 25-year flow event or that required to
meet the existing culvert capacity. The length of the stream bypass contained within
a culvert shall not be longer than the existing culvert unless otherwise approved by
the State Hydraulics Office. Fish passage shall not be decreased from the existing
conditions as evaluated by the Fish Passage Inventory, Assessment, and Prioritization
Manual.
The design flood for temporary structures over water bodies shall be determined on a
case-by-case basis by the State Hydraulics Office.
Allowable Headwater
This section presents hydraulic design criteria for allowable headwater for circular and
box culverts and pipe arches and for bottomless culverts.
3-3.2.1 General
The depth of water that exists at the culvert entrance at a given design flow is referred
to as the headwater. Headwater depth is measured from the invert of the culvert to the
water surface, as shown in Figure 3-1. See the glossary for definitions.
Limiting the amount of headwater during a design flow can be beneficial for several
reasons. The potential for debris clogging reduces as the culvert size is increased.
Maintenance is virtually impossible to perform on a culvert during a flood event if the
inlet is submerged more than a few feet. Also, increasing the allowable headwater can
adversely impact upstream property owners by increasing flood elevations. These
factors must be taken into consideration and balanced with the cost-effectiveness of
providing larger or smaller culvert openings.
If a culvert is to be placed in a stream that has been identified in a FEMA flood insurance
study, the floodway and floodplain requirements for that municipality may govern the
allowable amount of headwater. In this situation, the PEO shall contact the State
Hydraulics Office for additional guidance.
3-3.2.2 Allowable Headwater for Circular and Box Culverts and Pipe Arches
Circular culverts, box culverts, and pipe arches shall be designed such that the ratio of
the headwater (HW) to diameter (D) during the 25-year flow event is less than or equal
to 1.25 (HW/D <1.25). HW/D ratios larger than 1.25 are permitted, provided that
existing site conditions dictate or warrant a larger ratio. An example of this might be an
area with high roadway fills, little stream debris, and no impacted upstream property
owners. The justification for exceeding the HW/D ratio of 1.25 must be discussed with
the State Hydraulics Office and, if approved by the RHE, included as a narrative in the
hydraulic report.
The headwater that occurs during the 100-year flow event must also be investigated.
Two sets of criteria exist for the allowable headwater during the 100-year flow event,
depending on the type of roadway over the culvert:
1. If the culvert is under an interstate or major state route that must be kept open
during major flood events, the culvert must be designed such that the 100-year flow
event can be passed without overtopping the roadway.
2. If the culvert is under a minor state route or other roadway, the culvert shall be
designed such that there is no roadway overtopping during the 100-year flow event.
However, there may be situations where it is more cost-effective to design the
roadway embankment to withstand overtopping rather than provide a structure or
group of structures capable of passing the design flow. An example of this might be a
low average daily traffic roadway with minimal vertical clearance that, if closed
because of overtopping, would not significantly inconvenience the primary users.
Overtopping of the road will begin to occur when the headwater rises to the elevation
of the road. The flow over the roadway will be similar to flow over a broad-crested weir,
as shown in Figure 3-2. A methodology is available in HDS-5 to calculate the
simultaneous flows through the culvert and over the roadway. The PEO must be mindful
that the downstream embankment slope must be protected from the erosive forces that
will occur. This can generally be accomplished with riprap reinforcement, but the State
Hydraulics Office should be contacted for further design guidance. Additionally, the PEO
should verify that the adjacent ditch does not overtop and transport runoff, causing
damage to either public or private infrastructure.
Figure 3-2 Roadway Overtopping
Tailwater Conditions
The depth of water that exists in the channel downstream of a culvert is referred to as
the tailwater and is shown in Figure 3-1 above. Tailwater is important because it can
affect the depth of headwater necessary to pass a given design flow. This is especially
true for culverts that are flowing in outlet control, as explained in HDS-5. Generally, one
of three conditions will exist downstream of the culvert and the tailwater can be
determined as described below:
• If the downstream channel is relatively undefined and depth of flow during the
design event is considerably less than the culvert diameter, the tailwater can be
ignored. An example of this might be a culvert discharging into a wide, flat area. In
this case, the downstream channel will have little or no impact on the culvert
discharge capacity or headwater.
• If the downstream channel is reasonably uniform in cross section, slope, and
roughness, the tailwater may affect the culvert discharge capacity or headwater. In
this case, the tailwater can be approximated by solving for the normal depth in the
channel using Manning’s equation as described in Chapter 4.
• If the tailwater in the downstream channel is established by downstream controls,
other means must be used to determine the tailwater elevation. Downstream
controls can include such things as natural stream constrictions, downstream
obstructions, or backwater from another stream or water body. If it is determined
that a downstream control exists, a method such as a backwater analysis, a study of
the stage-discharge relationship of another stream into which the stream in question
flows, or the securing of data on reservoir storage elevations or tidal information
may be involved in determining the tailwater elevation during the design flow. If a
field inspection reveals the likelihood of a downstream control, contact the State
Hydraulics Office for additional guidance.
Flow Type
Refer to HDS-5 for in-depth discussions of culvert flow types.
Approval from RHE is required when using HDS-5 for culvert calculation forms, charts,
and nomographs if using hand calculations for culvert design. However, the FHWA
culvert design computer program HY-8 is the preferred WSDOT design method.
Computer Programs
Once familiar with culvert design theory as presented in this chapter, the PEO shall use
one of several commercially available culvert design software programs. FHWA has
developed a culvert design program named HY-8 that uses the same general theory
presented in this chapter. HY-8 is a user-friendly, Windows-based software, and the
output from the program can be printed and incorporated directly into the hydraulic
report. HY-8 is free software distribution. It is available by contacting either the RHE or
the State Hydraulics Office at the following link.
In addition to being user-friendly, HY-8 is advantageous in that the headwater
elevations and outlet velocities calculated by the program tend to be more accurate than
the values calculated using the methods presented in this chapter. HY-8 computes an
actual water surface profile through a culvert using standard step-backwater
calculations. The methods in this chapter approximate this approach but make several
assumptions to simplify the design. HY-8 also analyzes an entire range of flows input by
the user. For example, the program will simultaneously evaluate the headwater created
by the Q25 and Q100 flow events, displaying all the results on one screen. This results
in a significantly simplified design procedure for multiple flow applications. The HY-8
program contains a help guide accessed internally to aid in the system’s operations.
Additional guidance will be provided in future revisions to the Hydraulics Manual.
Example
Refer to HDS-5 for example culvert calculations.
Projecting Ends
A projecting end is a treatment where the culvert is allowed to protrude out of the
embankment (see Figure 3-4). The primary advantage of this type of end treatment is
that it is the simplest and most economical of all treatments. Projecting ends also
provide excellent strength characteristics because the pipe consists of a complete ring
structure out to the culvert end.
Projecting ends have several disadvantages. For metal, the thin wall thickness does not
provide flow transition into or out of the culvert, significantly increasing head losses (the
opposite is true for concrete; the thicker wall provides a more efficient transition). From
an aesthetic standpoint, projecting ends may not be desirable in areas exposed to public
view. They should be used only when the culvert is located in the bottom of a ravine or
in rural areas.
Modern safety considerations require that no projecting ends be allowed in the
designated clear zone. (See WSDOT’s Design Manual for details on the clear zone and for
methods that allow a projecting end to be used close to the traveled roadway.)
Figure 3-4 Projecting End
Metal culverts exceeding 6 feet in diameter but less than 10 feet in diameter, and all
thermoplastic culverts, must be installed with a beveled end and a concrete headwall or
slope collar as described in Sections 3-4.2 and 3-4.4. Concrete pipe will not experience
buoyancy problems and can be projected in any diameter. However, because concrete
pipe is fabricated in relatively short 6- to 12-foot sections, the sections are susceptible
to erosion and corresponding separation at the first joint from the end.
treatment shall be provided if needed. The State Hydraulics Office can assist in the
design of special end treatments.
Figure 3-5 Beveled End Section
Headwalls
A headwall is a concrete frame poured around a beveled culvert end. It provides
structural support to the culvert, eliminates the tendency for buoyancy and provides
inlet and outlet protection. A headwall is a required end treatment for all culverts that
range in size from 4 to 10 feet. Contact the RHE for direction on headwalls required for
culverts smaller than 4 feet. Headwalls shall be used on all thermoplastic culverts, 30
inches in diameter and larger. A typical headwall is shown on Standard Plans B-75.20-03
or in Figure 3-6. When the culvert is within the clear zone, the headwall design can be
modified by adding safety bars. Standard Plans B-75.50-01 and B-75.60-00 provide the
details for attaching safety bars.
The PEO is cautioned not to use safety bars on a culvert where debris may cause
plugging of the culvert entrance even though the safety bars may have been designed to
be removed for cleaning purposes. When the channel is known to carry debris, the PEO
shall provide an alternative solution to safety bars, such as increasing the culvert size or
providing guardrail protection around the culvert end.
Figure 3-6 Headwall
Improved Inlets
When the head losses in a culvert are critical, the PEO may consider the use of a
hydraulically improved inlet. Contact the RHE for guidance when considering using a
hydraulically improved inlet. These inlets provide side transitions as well as top and
bottom transitions that have been carefully designed to maximize the culvert capacity
with the minimum amount of headwater; however, the design and form construction
costs can become quite high for hydraulically improved inlets. For this reason, their use
is not encouraged in routine culvert design. It is usually less expensive to simply increase
the culvert diameter by one or two sizes to achieve the same or greater benefit.
Certain circumstances may justify the use of an improved inlet. When complete
replacement of the culvert is too costly, an existing inlet-controlled culvert may have its
capacity increased by an improved inlet. Improved inlets may also be justified in new
construction when the length of the new culvert is long (more than 500 feet) and the
headwater is controlled by inlet conditions. Improved inlets may have some slight
advantage for barrel- or outlet-controlled culverts, but usually not enough to justify the
additional construction costs. If the PEO believes that a site might be suitable for an
improved inlet, the RHE shall be contacted. Also, HDS-5 contains a significant amount of
information related to the design of improved inlets.
Energy Dissipators
When the outlet velocities during the design-year storm event are 5 ft/s or greater, the
PEO shall use an energy dissipator. Energy dissipators can be quite simple or very
complex, depending on site conditions. Debris and maintenance problems should be
considered when designing energy dissipators.
Energy dissipators include:
• Rock-protected outlets
Rock is frequently hand placed around the outlet end of culverts to protect against
the erosive action of the water (Figure 3-8). The material size at the outlet is
dependent on the outlet velocity as determined using a full flow analysis as noted
in Table 3-3. The limits of this protection would cover an area that would be
vulnerable to scour holes. As an alternative to using Figure 3-8 and Table 3-3, the
Hydraulic Toolbox calculator, which can be downloaded from FHWA’s website,
can be used to determine the area of the scour protection and the size of the
riprap. Refer to Table 4-2 for the class of rock or riprap to be used. The calculation
results need to be included in the Hydraulic Report. (See Section 3-4.5 for details
on wing walls and aprons.)
Figure 3-8 Rock-Protected Outlet
Note: Evaluate need to extend splash pad made to suit site conditions.
Culvert Debris
Debris problems can cause even an adequately designed culvert to experience hydraulic
capacity problems. Debris may consist of anything from limbs and sticks to logs and
trees. Silt, sand, gravel, and boulders can also be classified as debris. The culvert site is a
natural place for these materials to settle and accumulate. No method is available for
accurately predicting debris problems. Examining the maintenance history of each site is
the most reliable way of determining potential problems. Sometimes, upsizing a culvert
is necessary to enable it to more effectively pass debris. Upsizing may also allow a
culvert to be more easily cleaned. The PEO must consult with the RHE for guidance on
potential culvert debris issues.
Camber
When a culvert is installed under moderate to high fills 30 to 60 feet or higher, greater
settlement of the fill may occur under the center of the roadway than at the sides. This
occurs because at the culvert ends there is little fill while the centerline of the roadway
contains the maximum fill. The difference in surcharge pressure at the elevation of the
culvert may cause differential settlement of the fill and can create a low point in the
culvert profile. To correct for the differential settlement, a culvert can be constructed
with a slight upward curve in the profile, or camber, as shown in Figure 3-9. This is
determined by the HQ geotech.
The camber is built into the culvert during installation by laying the upstream half of the
culvert on a flat grade and the downstream half on a steeper grade to obtain the design
grade after settlement. The amount of expected camber can be determined by the HQ
Materials Laboratory and must be shown on the appropriate profile sheet in the contract
plans.
Figure 3-9 Camber under High Fills
manhole can be eliminated at the angle point if debris and sedimentation have not
historically been a concern at the existing culvert.
Figure 3-10 Culvert Angle Point
Upstream Ponding
The culvert design methodology presented in Section 3-3 assumes that the headwater
required to pass a given flow through a culvert will be allowed to fully develop upstream
of the culvert inlet. Any peak flow attenuation provided by ponding upstream of the
culvert inlet is ignored. If a large enough area upstream of the inlet is available for
ponding, the design headwater will not occur, and the culvert will not pass the full
design flow. However, by ignoring any ponding effects, the culvert design is simplified,
and the final results are conservative. Most culverts should be designed using these
assumptions.
If it is determined that the ponding characteristics of the area upstream of the inlet need
to be taken into consideration, the calculation of flow becomes a flood routing problem,
which entails a more detailed study. Essentially, the area upstream of the inlet acts as a
detention pond and the culvert acts as an outlet structure. The culvert can be designed
using flood-routing concepts similar to designing a stormwater detention pond, but that
methodology is beyond the scope of the Hydraulics Manual. Because the need for this
type of culvert design is rare, the RHE shall be contacted for further assistance.
provided at both the inlet and outlet chambers. Figure 3-11 illustrates a typical twin-
barrel inverted siphon.
The following considerations from HEC-22, Chapter 6 (1) are important to the efficient
design of siphons:
Additional information related to the design of siphons is provided in HEC-22 (1) and
United States Bureau of Reclamation (USBR) Design of Small Canal Structures (6), which
includes a design example.