Precast Culverts Project
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About the Project
Pan Gulf Technologies Limited delivered precision-engineered precast culverts designed for highway infrastructure in the United Kingdom. The solution involved structural design, generation of general arrangement and shop drawings, and performance analysis under realistic loading conditions—including thermal and fatigue effects.
Client Overview
The client required robust precast culvert solutions capable of withstanding heavy highway loadings (LM1, LM2, LM3), environmental stress, and operational safety demands. The project required adherence to UK construction codes and coordination with multiple engineering stakeholders.
Scope of Work
Developed precast culverts compliant with highway loadings (LM1, LM2, LM3), following Eurocodes and UK National Annexure, specifically PD 6694. Conducted performance checks for deflections under service loads and sliding under vehicle impact at parapets. Designed lifting and demoulding inserts, factoring in crane-lifting angles, dynamic loads, and mold specifications. Closely coordinated with geotechnical engineers, precast manufacturers, reviewing authorities, and contractors.
Key Challenges
Ensuring structural integrity under multiple load cases, thermal expansion, and fatigue conditions. Designing lifting inserts to manage dynamic forces safely and efficiently. Keeping coordination tight across multiple stakeholders to align the design with site constraints and construction sequencing.
Solutions Delivered
Pan Gulf Technologies executed comprehensive structural simulations using STAAD Connect software. We designed robust culverts and inserts aligned with manufacturing and erection demands, while maintaining continuous communication with all parties to guarantee a buildable and site-ready solution.
Software Used
STAAD Connect: Structural modeling and analysis under multiple highway loading scenarios.
MasterSeries Retaining Wall Software: Enhanced analysis of structural stability, sliding, and bearing capacities.
Results Achieved
Delivered fully compliant precast culvert design under Eurocodes and PD 6694. Provided detailed GA and shop drawings that supported accurate fabrication and installation. Successfully designed lifting inserts and matched design intent to sequencing constraints, ensuring project efficiency and constructability.
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