Pete Wilson

MnDOT Bridge Office - Inspection Unit

Structure Inventory

Coding
Load Ratings - Form 90
Inspection Procedures
NBI Condition Ratings
Structural Element
Condition Ratings
Culvert Maintenance &
Repairs

Hydraulic - a drainage structure beneath an

embankment (typically designed to take
advantage of inlet submergence to increase
hydraulic capacity)

Structural - a structure covered by embankment

material, designed to support soil load and live
loads. Usually composed of structural material
around the entire perimeter - some are supported
on footings with the streambed serving as the
culvert bottom.

Space between
barrels must be
less than the
width of the
smallest opening

Span length is
measured along
the centerline of
the roadway

11,400 culvert structures on MnDOT inventory

5,460 are NBIS structures (20 ft. or longer)
95% fall into 4 structure types

Precast Concrete Box..3,483

Precast Concrete Pipe-Arch3,242
Cast-in-Place Concrete Box2,935
Steel Pipe-Arch..1,014
All Other Culvert Types729

 Main

Span

Type
Main Span
Detail
Definition
Culvert Type
Barrel Length
Culvert Fill
Depth

Culvert Material Type

Culvert Design Type

1 - Concrete (CIP)
3 - Steel
5 - Precast Concrete*
7 - Timber
8 - Masonry
0 - Other
A - Aluminum

08 - Rigid Frame**
12 - Arch**
13 - Box Culvert
14 - Pipe Culvert (Round)
15 - Pipe Arch Culvert
16 - Long Span or
Elliptical Culvert

*This code is used for

precast concrete culverts

**These design types could be

bridges or culverts

Main Span Type:

112 - Concrete Arch
Main Span Detail:
Open Spandrel Arch

Main Span Type:

112 - Concrete Arch
Main Span Detail:
Arch Culvert

Provides interior
dimensions of the
culvert barrel
Unit format varies
with the culvert type
For concrete box
culverts, indicates
design (Type W,
Type C, or Precast)
and number of
barrels
12 character limit

Culvert Description

Example Code

Precast box culvert with 2 barrels

(8 ft. wide & 6 ft. high)

PCST 86D

1920s CIP culvert with 3 barrels

(10 ft. wide & 8 ft. high)

W108T

Precast pipe-arch with two barrels (102

span & 62 rise)

102x62

Steel pipe arch with two barrels

(14-2 span & 9-10 rise)

142x910

Steel pipe culvert with 3 barrels

(7-6 Diameter)

7.5 DIA.

Timber culvert with 2 barrels

(8 ft. span & 6 ft. high)

W86DTIM

Precast arch culvert

(24 ft. span & 12 ft. rise)

PCST 24x12

(12 character limit)

For new culverts, the plan

dimension will be entered
Fill depth may change if the
culvert is extended or the
roadway grade is raised
If the fill depth item is left
blank or is listed as less
than 2 ft., the culvert will not
be eligible for a 48-month
inspection cycle

Revised December 2013

If the NBI culvert rating is

4 (Poor Condition) or less,
you cannot use Form 90

Use the Inventory &

Operating Ratings from
table that correspond with
your culvert type

The MnDOT Bridge Office

does not review Form 90

Steel Pipe-Arch culvert

constructed in 1977 NBI
Rating is 5 (Fair Condition)

Precast Concrete Box

culvert constructed in 2013
(LRFD HL93 Design)

Inventory Load Rating?

Inventory Load Rating?

Operating Load Rating?

Operating Load Rating?

Precast concrete box

culvert constructed in
2004 (HS 25 Design)

Inventory Load
Rating?

Operating Load
Rating?

0% to 100% Scale
(S1 + S2 + S3 - S4)
S1 (55%)
Structural Adequacy &
Safety
S2 (30%)
Serviceability & Functional
Obsolescence
S3 (15%)
Essentiality for Public Use
S4 (13%)
Special Reductions

S1 - Structural Adequacy & Safety

(55% Maximum Reduction)

Item 62: NBI Culvert Rating

Condition 5 (Fair).10% reduction
Condition 4 (Poor)...25% reduction
Condition 3 (Serious)..40% reduction
Condition 2 (Critical)....55% reduction

Item 66: Inventory Load Rating

Up to 55% reduction based upon table

S2 - Serviceability & Functional Obsolescence

(30% Maximum Reduction)
Deductions for Structures with a Deck

Item #58: Deck Condition.5% reduction

Item #68: Deck Geometry4% reduction
Width of Roadway Insufficiency.15% reduction
FHWA Item #28 (Lanes on Structure)
FHWA Item #29 (ADT)
FHWA Item #51 (Bridge Roadway Width)

Where traffic runs

directly on the top
slab of a culvert type
structure, code the
actual roadway width
This will also apply
where the fill is
minimal and
headwalls or
parapets affect the
flow of traffic
FHWA Item 68 (Deck
Geometry) would
then be calculated

S3 - Essentiality for Public Use

(15% Maximum Reduction)

Item #19: Detour Length

Item #29: ADT
Item #100: STRANET Designation

S4 - Special Reductions

(13% Maximum Reduction)

Item #19: Detour Length
Item #36 A,B,C & D: Traffic Safety Features
Item #43: Structure Type

A culvert inspection should determine the

Structural Condition
Hydraulic Performance
Safety of the Roadway above the Culvert
A complete walk-through inspection of the culvert
should be performed.
Inspect the channel running through the culvert as
well as the roadway passing above the culvert.
Examine the culvert end treatments, embankment,
guardrail & railings.

Ideally, a walk-through
inspection should be
conducted during low
water conditions

Water levels are typically

lower in the fall & winter but ice can prevent a full
inspection

Inadequate ventilation
might require confined
space entry procedures

If high water prevents a

walk-through inspection,
a follow-up inspection
should be performed

Culverts can be added

to the statewide
underwater inspection
contract
In some cases, internal
inspections are not
feasible

Note if a full walk through inspection was

performed, and who did the inspection

Take general photos of each culvert end, the

culvert barrel, and the roadway above (take
photos of significant deterioration)

If a culvert has been extended or modified,

the general notes should clearly explain
what was done (and when it was done)

Waders
Probing Rod
LED Flashlight
Camera

Tape Measure
String Line
Level
Hammer
Life Jacket

New culverts are assigned a 12-month inspection

frequency

Culverts with an NBI rating of 5 or higher qualify

for a 24-month inspection frequency

Culverts with an NBI rating of 6 or higher qualify

for a 48-month inspection frequency (there are
additional requirements)

Culverts will automatically revert to a lower

frequency as the NBI condition rating changes

NBI Culvert Rating

(Section 2.1.5)

NBI Channel Rating

(Section 2.1.4)

Culvert Structural
Elements (Section 3.6)

Other Bridge Elements

(Section 3.8)

Railing Elements
(Section 3.3.10)

Should accurately reflect

the general overall
condition of the culvert

Impacts the Bridge

Sufficiency Rating,
Deficient Status,
Inspection Frequency,
and Load Rating
Requirements

Must be consistent with

structure inventory coding
and structural element
selection

CIP Box Culvert constructed in

1947 (masonry headwalls)
Ceiling & walls have leaching
cracks
Construction joints have leaching
& rust stains
Center wall joint has 3 separation
Spalling below drain inlet
Deterioration on approximately 5%
of culvert length
NBI Culvert Rating?

Note when the NBI condition rating was last

changed, and describe why the rating was changed

240 - Steel Culvert

241 - Concrete Culvert
242 - Timber Culvert
243 - Masonry/Other Culvert
388 - Culvert End Treatment
421 - Culvert Footing
987 - Roadway Over Culvert
Railing Elements
Other Elements (Guardrail,
Drainage, Slope Protection)

312 Steel Arch

314 Steel Pipe (Round)
315 Steel Pipe-Arch
316 Steel Long Span/Elliptical

About 65 on the
Minnesota inventory most constructed from
1930-1960

Spans range from 10 ft.

to 24 ft.

Typically supported by
concrete footings some have concrete
spandrel fill

Some have masonry

headwalls & railings

About 350 on the

Minnesota inventory
(1930s to present)

MnDOT Plates 3040F &

3041D show standard
sizes up to 10 ft. diameter

Minnesota inventory diameters range from 3 ft.

to 19 ft.

Over 1,000 on the

Minnesota inventory
(1930s to present)
MnDOT Plate 3050B
(18 radius corners)
6-1 to 16-7 span
MnDOT Plate 3051B
(31 radius corners)
13-3 to 20-7 span
Long span pipe arches
have spans up to 30-4
(47 radius corners)

Includes box, elliptical, low

profile arch, high profile arch,
underpass, pear shape, and
pipe-arch (47 corner)

Standard tables include

spans from 20 ft. to 40 ft.

Only about 50 in Minnesota constructed from 1965-1985

Elliptical shapes are by far

the most common

 Barrel

Distortion
Longitudinal Deflection
Corrosion and Section Loss
Bolted Seams (Loose or Missing
Bolts, Cracking, Cusped Seams)
Leakage (Infiltration or Exfiltration)

Flexible Culverts

Depend upon soil

pressure to
provide lateral
support

Some change in
the original crosssection is
expected

If the backfill is
unstable, the
barrel will continue
to distort

Barrel cross-section should be smoothly curved and

symmetrical

Compare field measurements to design dimensions look for continued or excessive distortion

Look for evidence of uneven settlement (negative

camber) along the length of the culvert barrel

Galvanized coatings will degrade over time

The most significant corrosion typically occurs at
the waterline (due to water and abrasion)

Condition State 1: Little or no deterioration. No deflection or distortion. Protective

coating is sound. Minor staining or surface corrosion (no section loss). Seams and
joints are sound - no distress or leakage.
Condition State 2: Minor to moderate deterioration. Slight deflection or distortion.
Protective coating may have moderate deterioration. Moderate surface corrosion or
minor section loss (surface pitting). Bolted seams may have minor distress, but all bolts
are secure (no cracking around bolt holes). Minor joint leakage (no backfill infiltration).
Condition State 3: Extensive deterioration. Function or structural capacity has not
been significantly impaired. Measurable deflection or distortion. Protective coating may
have failed. Extensive surface corrosion or measurable section loss. Bolted seams may
have obvious distress. Bolts may be loose or misaligned - cracks may have formed
around bolt holes. Moderate joint leakage (minor backfill infiltration).
Condition State 4: Severe or critical deterioration. Function or structural capacity has
been severely impacted - immediate repairs or structural analysis may be required.
Severe barrel deflection or distortion (sagging, buckling, or crown reversal). Advanced
corrosion & severe section loss (large sections rusted through). Bolted seams may
have failed. Severe joint leakage or separation (significant backfill infiltration).

Surface corrosion along

the waterline (full length)
Condition State 2

Flaking rust (with minor

section loss) along the
waterline
Condition State 3

Cracks have formed

along a bolted seam
Condition State 3

Failure of a bolted
seam
Condition State 4

108 CIP Concrete Rigid Frame

112 CIP Concrete Arch
113 CIP Concrete Box
508 Precast Concrete Rigid Frame
512 Precast Concrete Arch
513 Precast Concrete Box
514 Precast Concrete Pipe (Round)
515 Precast Concrete Pipe-Arch

About 40 on the
Minnesota inventory most constructed from
1900-1960

Spans typically range

from 10 ft. to 30 ft.

Typically supported by
concrete footings

Most have concrete

headwalls & wingwalls

76 on the MnDOT
inventory, constructed
from 1920 to present

MnDOT Standard Plate

3000L - RCP diameters
range from 4 ft. to 11 ft.

Precast segments are

typically 6 ft. long

MnDOT Standard Plate

3100G (flared end
treatments)

3,200 on the MnDOT

inventory, constructed from
1950 to present
MnDOT Standard Plate
3014J - RCPA spans range
from 51 to 169
Precast segments are
typically 6 ft. long and are
connected with steel tie rods
MnDOT Standard Plates
3110G & 3114H (end
treatments)

About 70 on the MnDOT

Inventory

Rapid construction and a

natural streambed

Bebo arches introduced

in 1966 - now available in
spans up to 102 ft.

First Bebo arch in the

U.S. was constructed in
1981 (Br. #27652 in
Edina)

MnDOT has 6
standard arch sizes
(24 ft. to 44 ft.
spans)
Fixed radius shape
Segments are 6 ft.
or 8 ft. wide
Footings are castin-place - the arch
sections rest on an
elastomeric pad

108 - CIP Concrete Rigid Frame

508 - Precast 3-Sided Structures

Flat top sections spans up to 30 ft.

Arch top sections spans up to 48 ft.

Footing supported

Smaller flat top

versions are
commonly used for
pedestrian
underpasses

Over 2,900 on the MnDOT inventory

Type W constructed prior to 1945, Type C
constructed after 1945 (more steel reinforcement)

Introduced in 1970s,
now nearly 3,500 on
the MnDOT Inventory

MnDOT Standard
Plans 5-395.100a-e

Spans from 6-16 ft.

Rise from 4-12 ft.

4 design types based

upon fill height

Precast box sections are typically 6 ft. long (4 ft. long

on larger boxes), connected with steel tie bolts

 Installation

Damage (Precast)
Cracking & Leaching
Scaling & Abrasion
Spalling & Delamination
Joint Misalignment, Separation, or
Leakage

Condition State 1: Minor cracking, scaling, leaching, or staining (no delaminations

or spalls). No joint leakage or misalignment. Connection bolts may have minor
surface corrosion.
Condition State 2: Moderate cracking, scaling, leaching, or staining. Minor
delamination or spalling (any exposure of reinforcement is minimal). Minor joint
leakage, separation, offset, or misalignment (no backfill infiltration). Connection bolts
may have corrosion.
Condition State 3: Extensive deterioration - function or structural capacity of the
culvert has not been significantly impaired. Extensive cracking, scaling, leaching or
staining. Structural cracking may be present. Delamination & spalling may be
prevalent (exposed rebar with section loss). Moderate joint leakage or misalignment
(minor backfill infiltration). Connection bolts may have severe corrosion.
Condition State 4: Severe or critical deterioration. Function or structural capacity of
the culvert has been severely impacted - immediate repairs or structural analysis
may be required. Severe structural cracking. Severe scaling or spalling (exposed
reinforcement may have significant section loss). Severe joint leakage or
misalignment (significant backfill infiltration). Connection bolts may have failed.

Minor leakage (infiltration)

on precast box culvert
Condition State 2

Crack (with extensive

leaching and rust stains)
on CIP box culvert
Condition State 3

Spalling on box culvert

ceiling
Condition State 3

Spalling on precast
round pipe culvert
Condition State 4

77 timber box
culverts on the
MnDOT inventory,
constructed from
1936 to 1987

10 ft. maximum span

(most have multiple
barrels)

Some concrete box

culverts have timber
extensions

 Barrel

Distortion or
Deflection
Timber Deterioration
(weathering, decay, fire
damage or abrasion)
Connections
(misalignment or
separation)
Leakage (infiltration or
exfiltration)

Condition State 1: No barrel distortion or deflection. Minor weathering, splitting,

cracking, or staining. No decay, fire damage, structural distress, or leakage.
Connections are secure, members are properly aligned.
Condition State 2: Slight barrel deflection or distortion. Moderate weathering,
cracking, or splitting. Minor decay, fire damage, or structural distress. Minor leakage
(no backfill infiltration). Connections may be slightly loose. Members may be slightly
warped, separated, offset or misaligned.
Condition State 3: Extensive deterioration - function or structural capacity has not
been significantly impaired. Measurable barrel deflection or distortion. Extensive
weathering, cracking, or splitting. Moderate decay, fire damage, or structural distress
(slight crushing or sagging). Moderate leakage (backfill infiltration). Loose
connections. Members may be significantly warped, separated, offset or misaligned.
Condition State 4: Severe or critical deterioration - function or structural capacity of
the culvert has been severely impacted - immediate repairs or structural analysis
may be required. Barrel may have severe deflection or distortion. Severe cracking,
fire damage, or significant crushing or sagging. Severe leakage or backfill infiltration.
Connections may have failed. Members may be broken or missing.

Moderate Weathering
Condition State 2

Barrel Deflection &

Wall Separation
Condition State 3

014 Plastic Pipe (Round) Culvert

812 Masonry Arch Culvert
A13 Aluminum Box Culvert

37 on the Minnesota inventory

Most constructed from 1880-1930

(many are historic)

Spans range from 10 ft. to 22 ft.

Condition State 1: Little or no deterioration. Masonry may have minor

weathering (mortar joints are sound). Joints have no leakage.
Condition State 2: Minor to moderate deterioration. Masonry may have
moderate weathering or cracking (mortar joints may have minor
deterioration). Joints may have minor separation, misalignment, or leakage.
Condition State 3: Extensive deterioration, but the function or structural
capacity of the culvert has not been significantly impaired. Masonry may
have weathering or cracking (mortar joints may have extensive
deterioration). Joints may have significant separation, misalignment, or
leakage (there may be evidence of backfill infiltration).
Condition State 4: Culvert has severe or critical deterioration. Function or
structural capacity of the culvert has been severely impacted - immediate
repairs or structural analysis may be required. Masonry may have severe
weathering or spalling (mortar joints may have failed). Joints may have
severe misalignment, or leakage (significant backfill infiltration).

Spalling on masonry
blocks (with extensive
joint leakage)
Condition State 3

Cracking through
masonry blocks with
some block separation &
displacement
Condition State 4

For single barrel culverts,

quantity will typically 2
(one at each end)

For multiple barrel

culverts, the quantity will
typically be 2 x the
number of barrels

Monolithic end
treatments can be rated
as a single unit

If no end treatments
exist, this element does
not need to be rated

Condition State 1: Little or no deterioration. Timber - minor splitting. Steel - minor

surface corrosion. Masonry - minor weathering . Concrete - minor cracking or scale.
Condition State 2: Minor to moderate deterioration. Timber - moderate splitting (minor
decay or fire damage). Steel - surface corrosion (minor section loss). Masonry moderate weathering (minor joint deterioration). Concrete - moderate cracking or
scaling (minor delamination or spalling). Slight settlement or misalignment.
Condition State 3: Extensive deterioration. Timber - extensive splitting, significant
decay or fire damage (slight sagging or crushing). Steel - extensive corrosion (section
loss). Masonry - extensive weathering (joints have significant deterioration). Concrete extensive cracking or scaling (delamination or spalling is prevalent). Significant
undermining, settlement or misalignment.
Condition State 4: Severe deterioration, function or structural capacity has been
severely impacted - immediate repairs or structural analysis may be required. Timber severe splitting or advanced decay (severe sagging or crushing). Steel - advanced
corrosion (severe section loss). Masonry - severe weathering (joints have failed).
Concrete - severe cracking, scaling, delamination, or spalling. Severe undermining,
settlement or misalignment.

Scaling on headwall
(exposed rebar)
Condition State 3

Timber headwall plank

loose - concrete apron
slightly undermined
Condition State 3

Precast box culvert walls on end sections

tipped & separated
Condition State 4

Culvert footings (if

visible) can be rated
separately from the
culvert barrel

Arch footings are

typically cast-in-place
concrete

Look for deterioration

as well as
undermining and
settlement

Condition State 1: Little or no deterioration. Concrete - minor cracking,

leaching, or scaling. Masonry - minor weathering (joints are sound).
Condition State 2: Minor to moderate deterioration. Concrete - moderate
cracking, scaling or leaching (minor delamination or spalling). Masonry moderate weathering (minor joint deterioration). Slight settlement or
undermining.
Condition State 3: Extensive deterioration. Concrete - extensive cracking,
scaling or leaching (delamination or spalling may be prevalent). Masonry extensive weathering (significant joint deterioration). Significant settlement or
undermining.
Condition State 4: Severe or critical deterioration. Function or structural
capacity of the culvert has been severely impacted - immediate repairs or
structural analysis may be required. Concrete - severe cracking, scaling,
delamination, or spalling. Masonry - severe weathering (failed joints or
displaced masonry blocks. Severe settlement or undermining.

#981: Signing
#982: Approach Guardrail
#984: Deck & Approach Drainage
#985: Slopes & Slope Protection
#987: Roadway over Culvert
#988: Miscellaneous Items

Railing Elements

Cracking or settlement of the

roadway may be the result of
culvert settlement, barrel
distortion, or voiding of
backfill

Note the condition of the

roadway - take a photo!

Note if (and when) the and

overlay has been added or if
the roadway has been
reconstructed or repaired

Condition State 1: Roadway over culvert is in good

condition. Paving may have minor cracking, but there
is no settlement.
Condition State 2: Roadway over culvert has
moderate cracking (or other deterioration). There
may slight settlement.
Condition State 3: Roadway over culvert has
severe cracking (or other deterioration) - there may
be significant settlement.

Joint Banding
Concrete
Reinforcement
Culvert Lining

BIRM - Chapter 14 (Inspection of Culverts)

MnDOT Bridge Inspection Manual (Section 3.6)

MnDOT LRFD Chapter 12 (Buried Structures)

MnDOT Road Design Manual 9.3 (Large Hydraulic

Structures)

FHWA Recording & Coding Guide

MnDOT Recording & Coding Guide (Coming

Soon!)