A box culvert assembly and method of forming a box culvert assembly is provided. The boxes forming the assembly comprise portions configured to allow pivoted assembly of one box into another, while reducing the likelihood of high stress or fracture. The box assembly further allows for a generally tight seal between the boxes.

CLAIM OF PRIORITY 
       [0001]    This application claims benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/338,248, filed Feb. 16, 2010, which is incorporated in its entirety by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This application relates to improved box culverts, box culvert assemblies, and methods of using box culverts. 
         [0004]    2. Description of the Related Art 
         [0005]    Box culverts are commonly used in the construction and/or road maintenance industry to form culverts. Typically, box culverts comprise box-like concrete structures with openings extending entirely through their central portions. Two or more boxes are generally arranged under the roadway in abutted, linear fashion, with the openings facing one another so as to form one long opening under the roadway. The boxes are typically pushed, or abutted up against one another, until a line of boxes has been formed with an opening extending through them. 
         [0006]    Once assembled, the boxes can be used for directing water, mud, debris, etc. from one side of the road to another, thereby inhibiting the accumulation of water, mud, or debris on the roadway itself. The boxes are generally pushed tight enough together so as to form a sealed line of boxes which inhibit leakage of water or debris outside of the culvert. 
       SUMMARY OF THE INVENTION 
       [0007]    An aspect of at least one of the embodiments disclosed herein includes the realization that during assembly of two or more boxes, it is desired to place each box in close and/or sealed contact with another box, without allowing excess mud, debris, or other material to come between the two boxes. Pushing one box culvert along the ground until it contacts and/or seals against a second box can often lead to ineffective sealing between the two boxes due for example to the dirt which is disturbed by pushing the box culvert along the ground. It would be advantageous to have a box culvert assembly which generally does not require the boxes to slide along the ground or soil, but also creates a strong contact and/or seal between the boxes. 
         [0008]    Thus, in accordance with an embodiment, a box culvert assembly can comprise first and second four-sided concrete boxes coupled to one another, the first and second boxes having first ends, second ends, and openings extending between the first and second ends. The first box can comprise a protruding ledge, the protruding ledge comprising a first portion, a second portion, and a third portion in between the first and second portions, the first and second portions having a greater thickness than the third portion. The second box can comprise a recessed ledge having surfaces for contacting and supporting the first and second portions; and wherein a gap exists between the third portion and the recessed ledge. 
         [0009]    In accordance with another embodiment, a method of constructing a box culvert can comprise providing a first box culvert, the first box culvert having a first end comprising a platform having two receiving surfaces located adjacent two corners of the box, the two receiving surfaces being elevated lower than a third surface extending between the two receiving surfaces. The method can further comprise providing a second box culvert, the second box culvert having a second end comprising a protruding lip having first and second lip ends, the first and second lip ends having a greater thickness than that of a remainder of the lip. The method can further comprise lowering the second end of the second box culvert onto the first end of the first box culvert at an angle such that the first and second lip ends contact the two receiving surfaces, and the two receiving surfaces support the second box culvert, and pivoting the second box culvert about the receiving surfaces, such that the first and second ends are joined together. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    These and other features and advantages of the present embodiments will become more apparent upon reading the following detailed description and with reference to the accompanying drawings of the embodiments, in which: 
           [0011]      FIG. 1  is a perspective view of two boxes that form a box culvert assembly; 
           [0012]      FIG. 2A  is a front elevational view of either of the boxes from  FIG. 1 ; 
           [0013]      FIG. 2B  is a back side elevational view of either of the boxes from  FIG. 1 ; 
           [0014]      FIG. 3  is a partial cross-sectional view of the box of  FIG. 2A , illustrating a thin protruding ledge: 
           [0015]      FIG. 4  is a partial cross-sectional view of the box of  FIG. 2A , illustrating a lip that extends around at least a portion of the box: 
           [0016]      FIG. 5  is a partial cross-sectional view of the box of  FIG. 2A , illustrating a thick protruding ledge: 
           [0017]      FIG. 6  is a partial cross-sectional view of the box of  FIG. 2B , illustrating a recessed ledge and further including some sealant type material along a surface; 
           [0018]      FIG. 7  is a partial cross-sectional view of the box of  FIG. 2B , illustrating a recessed area extending around at least a portion of the box; 
           [0019]      FIG. 8  is a partial cross-sectional view of the box of  FIG. 2B , illustrating recessed ledges for receiving a protruding ledge from another box, as well as sealing pads; 
           [0020]      FIG. 9  is a side elevational view of a method of lowering a first box onto a second box and pivoting the first box into place about the second box; 
           [0021]      FIG. 10  is a schematic illustration of two boxes connected to one another, including padding and a sealed gap area formed between the two boxes. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0022]    An improved box culvert assembly  10  is disclosed herein. The embodiments disclosed herein are described in the context of a concrete box culvert assembly comprised of a plurality of concrete boxes for placement under a road because the embodiments disclosed herein have particular utility in this context. However, the embodiments and inventions herein can also be applied to types of boxes, culverts, and/or structures configured for other types of environments, and comprised of materials other than concrete. 
         [0023]    With reference to  FIG. 1 , a box culvert assembly  10  can comprise at least two boxes  12 . Each of the boxes  12  can be formed from concrete or other suitable material, and can have a first wall  14 , a second wall  16 , a third wall  18 , and a fourth wall  20 , with the first, second, third, and fourth walls surrounding an opening  22  extending through the box  12 . The box  12  can further comprise a front face  24  on one end of the box  12 , and a back face  26  on the other end of the box  12 , with each of the faces  24 ,  26  extending generally around the opening  22 . 
         [0024]    Each box  12  can further comprise a first front side attachment feature  28 . The first front side attachment feature  28  can be formed as part of the front face  22 . The first front side attachment feature  28  can be used to connect and/or attach a first box  12  to a second box  12  during assembly of a culvert. For example, and as described further herein, the first front side attachment feature  28  can be used to lower and pivot a first box  12  onto a second box  12 . In some embodiments, the first front side attachment feature  28  can comprise a protruding ledge (e.g. a tongue) extending generally along an edge of wall  14 . The first front side attachment feature  28  can be configured to rest upon and/or seal against at least a portion of a first back side attachment feature  30  of a second box  12 . 
         [0025]    With continued reference to  FIG. 1 , the first back side attachment feature  30  can also be used to connect and/or attach a first box  12  to a second box  12  during assembly of a culvert. For example, the first back side attachment feature  30  can be used to lower and pivot a first box  12  onto a second box  12 . In a preferred arrangement, the first back side attachment feature  30  can receive and support at least a portion of the first front side attachment feature. The first back side attachment feature  30  can comprise, for example, a recessed ledge, such as for example a groove, formed as part of the back face  26  of box  12  and extending generally along an edge of wall  14 . 
         [0026]    With continued reference to  FIG. 1 , the front face  24  can further comprise a second front side attachment feature  32 . The second front side attachment feature  32  can be used to connect and/or attach one box  12  to another box  12  during assembly of a culvert. For example, the second front side attachment feature  32  can comprise a peripheral lip protruding from the front face  24  and extending generally along an edge of walls  18 ,  20 , and  16 . 
         [0027]    The back face  26  can comprise a second back side attachment feature  34 . The second back side attachment feature  34  can be used to connect and/or attach one box  12  to another box  12  during assembly of a culvert. For example, the second back side attachment feature  34  can comprise a recessed area  34  extending generally along an edge of walls  18 ,  20 , and  16  for receiving the second front side attachment feature  32 . 
         [0028]    With continued reference to  FIG. 1 , the first front side attachment feature  28  can comprise first and second portions  36 , and a third portion  38  extending between the first and second portions  36 . As illustrated in  FIG. 1 , the first and second portions  36  can have a greater thickness than the third portion  38 . For example, the first and second portions can have a thickness (the thickness having a direction extending in a direction between walls  14  and  20 ) which is approximately twice that of the thickness of third portion  38 . In some embodiments, the first and second portions can have a thickness which is at least twice that of the thickness of the third portion. In some embodiments, the first and second portions can have a thickness which is at least three times that of the thickness of the third portion. In some embodiments, the first and second portions can have a thickness which is at least four times that of the thickness of the third portion. Other ranges are also possible. In some embodiments, the thickness of the first and second portions can be at least 2 inches. In some embodiments, the thickness of the first and second portions can be at least 3 inches. In some embodiments, the thickness of the first and second portions can be at least 4 inches. Other ranges are also possible. In some embodiments, the third portion  38  can comprise a relatively thin protruding ledge of concrete, and the first and second portions, positioned on either end of third portion  38 , can comprise relatively thick protruding portions of concrete. In some embodiments, the first, second, and third portions  36 ,  38  can have the same thickness, forming one protruding lip. In some embodiments, the first and second portions can protrude from corners of the box  12 . In some embodiments, the first and second portions can protrude over a recessed area of the front face  24  adjacent the second front side attachment feature  32 . In some embodiments, the first and second portions can be configured to support the weight of the box  12 . 
         [0029]    With continued reference to  FIG. 1 , the first back side attachment feature can comprise first and second surfaces  40 , and a third surface  42  extending between the first and second surfaces  40 . As illustrated in  FIG. 1 , the first and second surfaces  40  can have an elevation (the elevation having a direction extending between walls  14  and  20 , with wall  20  being higher than that of wall  14 ) lower than that of the third surface  42 . In other embodiments, the elevations can vary. In some embodiments, the first, second, and third surfaces all have the same elevation, forming a single platform (e.g. all the surfaces can comprise one surface). Additionally, the third surface  42  can generally form part of a relatively thin ledge extending between first and second surfaces  40 . 
         [0030]    With continued reference to  FIG. 1 , the back face  26  can further comprise fourth and fifth surfaces  44 . The fourth and fifth surfaces  44  can be located adjacent the first and second surfaces  40 , and can be elevated lower than the first and second surfaces  40 . The fourth and fifth surfaces  44  can be used to receive first and second portions  36  from another box  12 . For example, the first and second portions  36  can comprise first and second inner ledges  46  (only one of which is shown in  FIG. 1 ). The first and second inner ledges  46  can be located on either side of third portion  38 , and can be configured to rest upon and/or seal against the fourth and fifth surfaces  44  when the two boxes  12  are assembled. 
         [0031]    With reference to  FIGS. 2A and 2B , the front face  24  and back face  26  can have a substantially similar appearance when viewed directly head-on. Surfaces and portions of the front face  24  which generally protrude outwardly can have corresponding recessed areas on back face  26 , and surfaces and portions on the back face  26  which generally protrude outwardly can have corresponding recessed areas on front face  24 . Additionally, the protruding and recessed portions of front face  24  and back face  26  can be angled (e.g. inclined) so as to guide and facilitate connection of corresponding portions on the back face  26  and/or front face  24  of another box  12 . 
         [0032]    For example, and with reference to  FIGS. 2A and 3 , the third portion  38  of first front side attachment feature  28  can have an angled surface  38   a  facing generally towards the wall  20  of box  12  (e.g. facing towards the bottom of the box  12 ). With reference to  FIGS. 2B and 6 , the third surface  42  of first back side attachment feature can be angled and facing generally away from wall  20  of box  12  (e.g. facing towards the top of box  12 ). When boxes  12  are assembled, the angled surfaces  38   a  and  42  can facilitate ease of assembly. Additionally, and as explained further below, the angled surfaces  38   a  and  42  and/or overall configuration of the third portion  38  and third surface  42  can create a space (e.g. gap) between the third portion  38  and third surface  42  for insertion of sealing fluid or other material. 
         [0033]    With reference to  FIGS. 2A and 4 , the wall  18  can comprise the second front side attachment feature  32 , such as for example a lip. The second front side attachment feature  32  can comprise an angled surface  32   a  facing generally away from wall  16  (e.g. facing away from the inside of the box  12 ). As described above, the second front side attachment feature  32  can extend around walls  18 ,  20 , and  16 . With reference to  FIGS. 2B and 7 , the wall  16  can comprise a recessed area  34 . The recessed area  34  can comprise an angled surface  34   a  facing generally towards wall  18  (e.g. facing towards the inside of box  12 ). When boxes  12  are assembled, the angled surfaces  32   a  and  34   a  can facilitate ease of assembly. 
         [0034]    With reference to  FIGS. 2A and 5 , the first and second portions  36  can comprise angled surfaces  36   a  facing generally towards the wall  20  of box  12  (e.g. facing towards the bottom of the box  12 ). With reference to  FIGS. 2B and 8 , the first and second surfaces  40  can be angled (e.g. inclined), and can generally face away from wall  20  (e.g. face away from the inside of box  12 ). The fourth and fifth surfaces  44  can also, or alternatively, be angled, and can generally face away from wall  20  (e.g. face away from the inside of box  12 ). Thus, when boxes  12  are assembled, the angled surfaces  36   a ,  40 , and/or  44  can facilitate ease of assembly. 
         [0035]    While the angles (e.g. inclinations) of the surfaces  38   a ,  32   a ,  36   a ,  42 ,  34   a ,  40 , and  44  illustrated in  FIGS. 3-8  are shown as being approximately 5 degrees with respect to first wall  14 , other angles can also be used, including but not limited to angles greater than or less than 5 degrees. Additionally, the angles can vary from surface to surface. For example, the angle (e.g. inclination) of surface  38   a  can be different from that of surface  42 . The angle of surface  38   a  can additionally, or alternatively, be different from that of surface  34   a.    
         [0036]    With reference to  FIGS. 9 and 10 , a method for assembling the boxes  12  is shown. As illustrated in  FIG. 9 , to assemble two of the boxes  12 , one of the boxes  12  can first be resting flat on the ground (e.g. the box on the right in  FIG. 9 ). The other box  12  can then be lowered from above, usually by a mechanical device such as a crane, such that portions of the other box  12  contact and pivot about portions of the box  12  already on the ground. 
         [0037]    For example, a box  12  can be lowered until the first and second portions  36  of the box  12  are resting upon the first and second surfaces  40  of the box  12  already on the ground. The crane can be supporting a portion of the weight of the box  12  as it is lowered into place and placed into contact with the box  12  already on the ground. Once contact is made, the lowered box  12  can swing into the box  12  already on the ground, such that the second front side attachment feature  32  fits into the recessed area  34 , and the second inner ledges  46  rest on the fourth and fifth surfaces  44 . In some embodiments, the first and third portions  36 ,  38  can support at least ⅓ of the weight of the box  12  as it is being lowered into place on first and second surfaces  40 . In some embodiments, the first and third portions  36 ,  38  can support at least ½ of the weight of box  12  as it is being lowered into place on first and second surfaces  40 . In some embodiments, the first and third portions  36 ,  38  can support at least ⅓ of the weight of the box  12  as it is being lowered into place on both the first and second surfaces  40  and the fourth and fifth surfaces  44 . In some embodiments, the first and third portions  36 ,  38  can support at least ½ of the weight of box  12  as it is being lowered into place on both the first and second surfaces  40  and the fourth and fifth surfaces  44 . Other ranges of weight support are also possible. 
         [0038]    Because the first and second portions  36  are relatively thick compared to both third portion  38  and the thin ledge comprising surface  42 , and because first and second surfaces  40  are positioned near corners of the box  12  already on the ground, the weight of other box  12  is easily supported by the two contact points or areas near the corners of the boxes  12 . If the weight of the other box  12  were to be lowered onto the surface  42 , the ledge comprising surface  42  may likely break or fracture. Similarly, the third portion  38  may break or fracture. Thus, providing relatively thick first and second portions  36 , along with recessed receiving areas  40  near the corners of the box  12 , can facilitate assembly of the two boxes  12  without undesired stress or fracture. 
         [0039]    Additionally, and with reference to  FIGS. 8 and 10 , sealing pads  48  or other similar devices can be used to facilitate assembly of the boxes  12  and/or form a seal between the boxes  12 . For example, a sealing pad  48  can be placed and/or attached onto first and second portions  36  or first and second surfaces  40 . The sealing pads  48  can be used to cushion and/or absorb the contact between the first and second portions  36  while one box  12  is being lowered and pivoted about another box  12 . The sealing pad  48  can remain, in a compressed state, between the two boxes after they have been assembled, as shown in  FIG. 10 . 
         [0040]    With continued reference to  FIGS. 9 and 10 , by using the first and second portions  36  and surfaces  40  to create initial contact and pivot points between boxes  12 , an area (e.g. gap) between the third portion  38  and surface  42  can be created and/or used. Similarly, by using sealing pads  48 , an area (e.g. gap) between the third portion  38  and surface  42  can be created and/or used. For example, and as illustrated in  FIG. 10 , a gap  50  can be created between the third portion  38  and surface  42 . Prior to assembly of the boxes, a sealant  52  (e.g. a type of adhesive, or any other type of sealant), such as shown in  FIG. 6 , can be spread across surface  42 . When the boxes are assembled, and pivoted into place on top of first and second surface  40  and sealing pads  48 , the sealant can be pressed and fill at least part of the gap  50  shown in  FIG. 10 , thereby facilitating a strong, generally leak-free attachment between the two boxes. In some embodiments, the gap  50  can be bordered at least in part by the sealing pads  48 . 
         [0041]    While the sealant  52  can be used in gap  50 , it is understood that sealant could be used elsewhere. For example, sealant could be used between the angled surfaces  32   a  and  34   a  along the walls  18 ,  20 , and  16  of the boxes  12 , and/or between the angled surfaces  36   a  and  44 . In some embodiments, no sealant can be used, and gap  50  can remain open. In some embodiments, no sealant can be used, and gap  50  does not exist. Rather, the third portion  32  can contact (e.g. but not press with significant force) against the surface  42  when the boxes  12  are assembled. 
         [0042]    In yet other embodiments, sealing pads  48  can be placed elsewhere, or not used at all. For example, in some embodiments, no sealing pads  48  can be used. Instead, the first and second portions  36  can directly contact the first and second surfaces  44 . In other embodiments, sealing pads  48  can be used on the other two corners (e.g. the bottom two corners) of the boxes in addition to or alternatively from using sealing pads  48  as shown in  FIG. 10 . 
         [0043]    In yet other embodiments, the first, second, and third surfaces  40  and  42  can all generally have the same elevation (i.e. can be coplanar). Thus, in such an embodiment, the gap  50  can be significantly larger than that shown in  FIG. 10 . Other sizes, shapes, and configurations for the gap  50  other than that shown are also possible. 
         [0044]    As described above, the assembly  10  allows the boxes to be placed together and/or sealed without sliding the boxes along the ground. This advantageously inhibits the accumulation of dirt, debris, or other matter which may cause premature deterioration or inefficient use of the culvert. 
         [0045]    Additionally, the boxes  12  can be pivoted about two points or areas which are stable, and can fully support the load of a concrete box  12 . This advantageously permits the boxes  12  to be assembled without undesired stress and/or fracture. This arrangement also advantageously allows the boxes to be sealed together, and/or formed tightly together, simply by lowering one box down next to another and allowing gravity to pivot one box into another. Such ease of assembly reduces the effort involved in assembling a large culvert. 
         [0046]    Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments can be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.