DECAST-CPP-Installation-Manual-2016.02.10.pdf

7/25/2019 DECAST-CPP-Installation-Manual-2016.02.10.pdf

1/60

Pressure PipeInstallation Manual


2/60

02

03

04

06

08

09

1316

22

23

23

24

25

27

28

30

ContactInformation

General

Pipe

Information

TheSteelBellandSpigotJoint

Shipping

Weights

and

Dimensions

Laying

Length

PipeMarkings

Pipe

Dimensions

for

Lined

and

Embedded

Cylinder

Pipe

JointDeflection

Bevel

Adaptors

Field

Installation

HealthandSafety

Unloading

the

Pipe

DiggingtheTrenchandPreparingtheBedding

Handling

the

Pipe

Preparing

the

Pipe

Ends

QuantitiesofLubricant&GroutforJoints

TABLE OF CONTENTS


3/60

31

3234

36

37

38

39

40

4142

46

48

50

51

54

55

56

57

Making

the

Joints

Installing

FittingsChecking

the

Gaskets

Grade

and

Line

Changes

Protecting

the

Joints

Backfilling

InstallingwithaTrenchBox

Testing

Restrained

Joints

Snap

Ring

Restrained

Joint

Welded

Restrained

Joint

HarnessClampRestrainedJoint

Closures

Emergency

Closures

Pressure

Tapping

Wall

Pieces

Pipe

OrientationField

Services


4/60

DECAST Ltd.8807 County Road 56

Utopia, ON L0M 1T0

1.800.461.5632

705.734.2892

Engineering Fax: 705.734.2270

Shipping Fax:

705.734.9373

WEB

www.decastltd.com

0

l

4

416.605.7374Rob Micieli

Vice President, Sales

647.500.3789Mauro DeFranco, P.Eng.Technical Sales Engineer

416.520.2779

905.302.1062

705.796.8868

Benoit Tanguay, ing, P.Eng. 514.209.318(Eastern Canada)

Martin Fischer

Sales

John Pozzobon, C.E.T.

Sales

Frank Mazza, C.E.T.Sales

[email protected]

ENGINEERING

[email protected]

CONTACT INFORMATION

% John Siervogel 705.623.726Field Services

CONTACTS!


5/60

GENERAL PIPE

INFORMATION

DECAST concrete pressure pipe and fittingsare manufactured to ANSI/AWWA C301standards in sizes from 400 mm to 3600mm with working pressures to 1720KPa and higher

For specialized applications DECAST canalso manufacture concrete pressure

pipe to ANSI/AWWA C300 and C302specifications.

DECAST concrete pressure pipe isrugged, durable and long-lasting. Thepipe has self-centering steel joint rings andrubber gaskets that ensure water-tightness and joint flexibility.

Concrete pressure pipe can be installedeasily, rapidly and economically because itssteel bell and spigot joint, which ismanufactured to close tolerances,permits a quickly-made watertightconnection.DECAST provides pipelinelayout drawings that show thesequence of installation for all pipe and

fittings it manufactures.

This installation manual providesinstructions for laying, joining andbackfilling pipe. It is provided as a guideonly. DECAST assumes no responsibilityor liability by reason of supplying thismanual.


6/60

THE STEEL BELL

AND SPIGOT JOINT

The bell and spigot joint consists of a steel spigot on which a rubber gasket is placed. During installation, the spend is pushed into the steel bell to form a watertight joint.

Prestressed Lined Cylinder Pipe Ready for Joining Prestressed Embedded Cylinder Pipe Ready for J


7/60

The following diagrams show the completed joint for a prestressed lined cylinder pipe and a completed jointfor a prestressed embedded cylinder pipe.

Completed Joint for a Prestressed Lined Cylinder Pipe Completed Joint for a Prestressed Embedded Cy


8/60

SHIPPING WEIGHTS AND

DIMENSIONS

TABLE 1: SHIPPING WEIGHTS AND DIMENSIONS OF

LCPAND ECP

DECAST supplies lined cylinder pipe (LCP)and embedded cylinder pipe (ECP) in thefollowing diameters.

Nominal Pipe

Diameter(mm)

Bell

O.D.(mm)

Barrel

O.D.(mm)

Approx.

Weight(Kg/m)

Core

Length(m)

LCP 400 572 508 230 6.096

450 629 565 270 6.096

500 686 622 300 6.096

600 800 737 380 6.096

750 972 908 560 6.096

900 1143 1080 710 6.096

1050 1302 1251 970 6.096

1200 1473 1422 1230 6.096

1350 1667 1594 1460 6.096

1500 1838 1765 1640 6.096


9/60

ECP 1050 - 1295 1120 6.096

1200 - 1473 1340 6.096

1350 - 1626 1490 6.096

1500 - 1803 1680 6.096

1650 - 1981 2240 6.096

1800 - 2159 2650 6.096

1950 - 2337 3070 6.096

2100 - 2518 3560 6.096

2250 - 2670 3780 6.096

2400 - 2822 4020 6.096

2550 - 2975 4320 6.096

2700 - 3140 4690 6.096

2850 - 3311 5140 6.096

3000 - 3483 6030 4.877

3150 - 3686 6260 4.877

3300 - 3826 6780 4.877

3550 - 3997 7370 4.877

3600 - 4169 7970 4.877


10/60

LAYING LENGTH

TABLE

2:

LAYING

LENGTHThe

nominal

lay

length

of

a

standardlengthpipeis6.106mor

4.887m. Thenominallaylengthis

basedona10mmjointgap.Actual

laylengthcanvaryasshowninthe

followingtable:

Nominal PipeDiameter

(mm)

Min. LayingLength

(m)

AverageLaying Length

(m)

Max. LLen

(m

LCP 400 through to 1200 6.096 6.106 6.1

1350 6.096 6.106 6.1

1500 6.096 6.106 6.1

ECP 1050 & 1200 6.096 6.106 6.1

1350 6.096 6.106 6.1

1500 6.096 6.106 6.1

1650 6.096 6.106 6.1

1800 6.096 6.106 6.1

1950 6.096 6.106 6.1

2100 6.096 6.106 6.1

2250 & 2400 6.096 6.106 6.1

2550 through to 2850 6.096 6.106 6.1

3000 through to 3600 4.877 4.887 4.9


11/60

PIPE MARKINGS

The bell end inner concrete lining of thepipe surface is stenciled with:

DECAST

Date of manufacturing

Mark No.

Cylinder gauge, if other than 16 Gauge

Job No.

Serial No.CSA / NSF 61

AWWA Designation

Inspector's stamp

Concrete pressure pipe is an engineeredproduct. Prior to repositioning any pipe orfitting contact the Engineering Department atDECAST


12/60

PIPE MARKINGS

Pipe Size(in)


(mm)

Pipe Size(in)

NominaDiam

(m

16 400 78 19

18 450 84 21

20 500 90 22

24 600 96 24

30 750 102 25

36 900 108 27

42 1050 114 28

48 1200 120 30

54 1350 126 31

60 1500 132 33

66 1650 138 34

72 1800 144 36

Cylinder gauge (if other than 16 Ga)

Restrained joint (A) Snap Ring Bell, (W)

welded joint

Class of pipe (CL 12)

Pipe size, see Table 3

Lined (L), Embedded (E)

L 48 - 12 A - 14G TABLE

3:

PIPE

MARKING


13/60

A pipe that differs from a standard pipe ismarked with a coloured stripe.

A Y LLOWSTRIP indicates that the pipe has arestrained bell end.

A PINK STRIP indicates that the pipe has a

threaded or flanged outlet and is painted atthe outlet.

A LU STRIP indicates that the pipe has abevelled spigot.

Pipe Markings


14/60

PIPE MARKINGS

TABLE 4:

SPIGOT

COLOUR

CODPipe

with

cylinder

thickness

greater

than

16

Gauge

are

speciallymarkedbyaddingapaintpatchonthespigot

end. The colour code system is according to the

followingchart: U.S GaugeNumber

Steel Sheet Thickness MaCo

(mm) (in)

16 1.52 0.0598 N

14 1.90 0.0747 O

12 2.66 0.1046

10 3.42 0.1345 G

8 4.18 0.1644 Y

6 4.94 0.1943 P

N/A 6.35 0.2500

N/A 7.37 0.2900 Blue/

N/A 7.62 0.3000 Blu

N/A 7.94 0.3125 Blu

N/A 12.7 0.5000 Blue

N/A 15.88 0.6250 Red


15/60

PIPE DIMENSIONS FOR LINED AND

EMBEDDED CYLINDER PIPE

LinedCylinderPipe EmbeddedCylinderPipe


16/60

PIPE DIMENSIONS FOR LINED AND

EMBEDDED CYLINDER PIPE

TABLE

5:

LINED

CYLINDER

PIPE

DIMENSIONS


(mm)

PipeI.D.

(mm)

CoreThickness

(mm)

Std. JointDepth(mm)

JointDiameter

(mm)

BellO.D.

(mm)

BarrelO.D.

(mm)

CoreLength

(m)

400 406 25 114 470 572 508 6.096

450 457 29 114 527 629 565 6.096

500 508 32 114 584 686 622 6.096

600 610 38 114 699 800 737 6.096

750 762 48 114 870 972 908 6.096

900 914 57 114 1041 1143 1080 6.096

1050 1067 67 114 1200 1302 1251 6.096

1200 1219 76 114 1372 1473 1422 6.096

1350 1372 86 121 1565 1667 1594 6.096

1500 1524 95 124 1738 1838 1765 6.096


17/60


(mm)

PipeI.D.

(mm)

CoreThickness

(mm)

Std. JointDepth(mm)

JointDiameter

(mm)

BarrelO.D.

(mm)

CoreLength

(m)

1050 1067 89 114 1143 1295 6.096

1200 1219 102 114 1302 1473 6.096

1350 1372 102 130 1467 1626 6.096

1500 1524 114 133 1622 1803 6.096

1650 1676 127 137 1781 1981 6.096

1800 1829 140 114 1944 2159 6.096

1950 1981 152 143 2095 2337 6.096

2100 2134 165 114 2255 2518 6.096

2250 2286 165 149 2410 2670 6.096

2400 2438 165 149 2569 2822 6.096

2550 2591 165 152 2715 2975 6.096

2700 2743 171 152 2873 3140 6.096

2850 2896 181 152 3064 3311 6.096

3000 3048 190 152 3216 3483 4.877

3150 3200 200 152 3369 3686 4.877

3300 3353 210 152 3521 3826 4.877

3450 3505 219 152 3673 3997 4.877

3600 3658 229 152 3826 4169 4.877

TABLE 6: EMBEDDED CYLINDER PIPE DIMENSIONS


18/60

JOINT DEFLECTION

After

the

joint

is

in

place,

the

pipe

can

be

deflected within the tolerable limits that are

shownintheTables7,8,9and10.

DeflectionofStandardPipe


19/60

TABLE 7: JOINT DEFLECTION OF LINED CYLINDER PIPE


(mm)

Max. JointOpening

(mm)

AverageLaid

Length(m)

Max.Deflection

Angle

Max. Offsetfor Std.Length(mm)

Min. CurveRadius for

Std. Length(m)

JointDepth

(mm)

JointDiameter

(mm)

400 44 6.106 5 - 24 ' 574 64 114 470

450 44 6.106 4 - 49 ' 512 72 114 527

500 44 6.106 4 - 21 ' 462 80 114 584

600 44 6.106 3 - 38 ' 387 95 114 699

750 44 6.106 2 - 55 ' 311 119 114 870

900 44 6.106 2 - 26 ' 259 142 114 1041

1050 44 6.106 2 - 7 ' 225 164 114 1200

1200 44 6.106 1 - 51 ' 197 188 114 1372

1350 41 6.106 1 - 30 ' 160 231 121 1565

1500 44 6.106 1 - 27 ' 155 238 124 1738


20/60

JOINT DEFLECTION


(mm)

Max. JointOpening

(mm)

AverageLaid

Length(m)

Max.Deflection

Angle



Length(m)

JointDepth

(mm)

JointDiamete

(mm)

400 13 6.106 1 - 32 ' 164 225 114 470

450 13 6.106 1 - 22 ' 146 253 114 527

500 13 6.106 1 - 14 ' 132 280 114 584

600 13 6.106 1 - 2 ' 110 335 114 699

750 13 6.106 0 - 50 ' 88 417 114 870

900 13 6.106 0 - 41 ' 74 499 114 1041

1050 13 6.106 0 - 36 ' 64 576 114 1200

1200 13 6.106 0 - 31 ' 56 658 114 1372

1350 13 6.106 0 - 27 ' 49 751 121 1565

1500 13 6.106 0 - 25 ' 44 833 124 1738

TABLE 8: JOINT DEFLECTION OF LINED CYLINDER PIPE WITH MECHANICAL RESTRAINED JOINTS


21/60

TABLE 9: JOINT DEFLECTION OF EMBEDDED CYLINDER PIPE


(mm)

Max. JointOpening

(mm)

AverageLaid

Length(m)

Max.Deflection

Angle

Max. Offsetfor StdLength(mm)


Std. Length(m)

JointDepth

(mm)

JointDiamete

(mm)

1050 44 6.106 2 - 13 ' 236 156 114 11431200 44 6.106 1 - 57 ' 208 178 114 1302

1350 48 6.106 1 - 51 ' 197 187 130 1467

1500 51 6.106 1 - 47 ' 190 194 133 1622

1650 54 6.106 1 - 44 ' 184 201 137 1781

1800 31 6.106 0 - 56 ' 99 373 114 1944

1950 60 6.106 1 - 38 ' 175 211 143 2095

2100 31 6.106 0 - 48 ' 85 432 114 2255

2250 67 6.106 1 - 35 ' 168 220 149 2410

2400 67 6.106 1 - 29 ' 158 234 149 2569

2550 63 6.106 1 - 20 ' 142 260 152 2715

2700 63 6.106 1 - 15 ' 134 275 152 2873

2850 63 6.106 1 - 11 ' 126 294 152 3064

3000 63 4.887 1 - 7 ' 96 247 152 3216

3150 63 4.887 1 - 4 ' 91 258 152 3369

3300 63 4.887 1 - 1 ' 87 270 152 3521

3450 63 4.887 0 - 59 ' 84 282 152 3673

3600 63 4.887 0 - 57 ' 80 293 152 3826


22/60

JOINT DEFLECTION

TABLE 10: JOINT DEFLECTION OF EMBEDDED CYLINDER PIPE WITH MECHANICAL RESTRAINED JOINTS


(mm)

Max. JointOpening

(mm)

AverageLaid

Length(m)

Max.Deflection

Angle



Std. Length(m)

JointDepth

(mm)

JoiDiam

(m

1050 13 6.106 0 - 38 ' 67 548 114 11

1200 13 6.106 0 - 33 ' 59 624 114 13

1350 13 6.106 0 - 29 ' 52 704 130 14

1500 13 6.106 0 - 26 ' 47 778 133 16

1650 13 6.106 0 - 24 ' 43 854 137 17

1800 13 6.106 0 - 22 ' 39 932 114 19

1950 13 6.106 0 - 20 ' 36 1005 143 20

2100 13 6.106 0 - 19 ' 34 1082 114 22


23/60

2250 13 6.106 0 - 18 ' 32 1156 149 24

2400 13 6.106 0 - 16 ' 30 1232 149 25

2550 13 6.106 0 - 16 ' 28 1303 152 27

2700 13 6.106 0 - 15 ' 26 1379 152 28

2850 13 6.106 0 - 14 ' 25 1470 152 30

3000 13 4.887 0 - 13 ' 19 1235 152 32

3150 13 4.887 0 - 12 ' 18 1293 152 33

3300 13 4.887 0 - 12 ' 17 1352 152 32

3450 13 4.887 0 - 11 ' 16 1410 152 36

3600 13 4.887 0 - 11 ' 16 1469 152 38


24/60

BEVEL ADAPTORS

BevelAdaptor

Bevel

adaptors

may

be

used

to

make

minor

grade or line changes that are beyond the

normaljointdeflection.


25/60

FIELD INSTALLATION &

HEALTH AND SAFETY

HEALTH AND SAFETY

All installation procedures and operations

must be performed in accordance with local

Occupational Health and Safety Act (OHSA)

regulationsandcodes.

FIELD

INSTALLATION

The most common way to lay prestressed

concrete pipe is with a backhoe, although

other methods can be used depending on the

conditions and the size of the pipe

beinginstalled.


26/60

UNLOADING THE PIPE

All DECAST pipe is inspected at ourfacilities before shipping. However, thepipe should always be checked for anydamage that may have occurred duringtransit. Note any damage on the packingslip before accepting the pipe.

Before unloading the pipe, the truck andthe trailer must be parked on a level, stable

surface with brakes applied and, ifnecessary, wheels blocked. Whenunloading multi-tiered shipments, the crosstimbers must be secured to the trailer siderail on the side that is being unloaded toprevent the timbers from kicking up-wardsand dropping the rear pipe off the backside of the trailer.

When pipes are unloaded using a forklift,forks must be cushioned using rubber orwood to prevent damaging the pipe.

Pipe may also be unloaded using abackhoe or crane fitted with a cable orsling, with safe lifting capacity, that hasbeen centered on the pipe at thebalancing point. The cable or sling mustbe short enough to control themovement of the pipe. Multiple slingsmay be needed if the pipe or fittingsare large. Chains are not recommended.

Gaskets should be stored in a cool placeaway from heat, sunlight, gasolineor other materials that can damagerubber. Joint lubricants should be storedaccording to the manufacturer'sinstructions. If freezing conditions areexpected, the pipe must be set onwooden skids off the ground.

Unloadingpipeusinforklift


27/60

DIGGING THE TRENCH AND

PREPARING THE BEDDING

The typical trench geometry should allowfor sufficient clearance to properly installthe pipe. Pipe designs are affected by thetrench geometry, and hence the trenchgeometry should not be changed from thecontract specifications without consultingthe supervising engineer and DECAST.

Diggingatrenchforalengthofpipe


28/60

DIGGING THE TRENCH AND

PREPARING THE BEDDING

COVER MATERIAOVER MATERIANATIVE MATERIAATIVE MATERIA

Typical Trench Bedding

A space along the width of the pipeapproximately 200 mm deep and 400 mmlong should be made at the place where thepipe will be joined. This space allowsroom for the installation of the diaperaround the joint. To allow removal of thecable after the pipe has been laid, a spacecan also be made at the point where thesling is located.

After digging the trench, the contractormust follow the specifications that areappropriate for the type of bedding. Forany change to the specifications, thesupervising engineers should be consulted.


29/60

HANDLING THE PIPE

Slip

the

steel

cable

sling

under

the

pipe.

Hookoneendoftheslingonthehookofthebucket.

When you find the balancing point on the

lengthofpipe,markthebalancingpointsonthe

otherlengthsofpipe.

To achieve the best possible control over the

joining,slowlymovethebackhoetotheendof

thetrench,ascloselyasissafe.

Backhoewithsteelslingmovingpipe


30/60

PREPARING THE PIPE ENDS

For proper installation of the gasket priorto joining the pipe the following stepsshould be adhered to:

Clean the spigot groove and the insideof the bell. Apply lubricant on thespigot groove and the inside of the bell.See Table 11 for recommended amounts.

Apply lubricant to the rubber gasket witha clean cloth. Caution: Use only thelubricant supplied by DECAST Petroleumbased lubricants should not be usedbecause they will damage the rubbergasket.

3 Place the lubricated gasket in thegasket groove of the entire spigot ring.

When the gasket is in place, insert asmooth rod or a screwdriver between thegasket and spigot

ring and run the screwdriver/rod around the entire circumferenceof the spigot ring to ensure that thegasket is stretched evenly aroundthe spigot. This usually takes 2 to 3rotations to accomplish.

4

Coat the gasket with lubricant.

5

Do not pre-install gaskets in pipestrung out ahead of theinstallation crew because the jointlube under the gasket can dry fromthe heat of the sun or be diluted byrain water. In both of thesesituations, the gaskets ability toslide within the groove duringinstallation will be inhibited.


31/60

Cleanspigotgrooveandinsideofbell Applying lubricant to the spigotgroove

Applying

lubricant

to

the

gasket

with

a

cleanclothUsing

a

screwdriver

to

ensure

that

thegasket is stretched evenly around the

spigot

Applyinglubricanttotheinsidbell

Coating

the

gasket

with

lubric


32/60

QUANTITIES OF LUBRICANT

& G ROU T F O R JO I NT S

Quantities of lubricant shownare based on applying 1.5 mmthick layer of lubricant to thegasket, spigot groove and theinside of bell.

The amount of grout shownare based on grouting the outside

joint opening of a standard joint.

TABLE

11:

APPROXIMATEQUANTITIES

OF

JOINT

LUBR ICANT&

GROUTFOR

EXTER NALSTANDARDJO


(mm)

Approx. No.of Joints per10 Kg Pail of

Lubricant

Approx.Amount

of Grout perJoint

(cu. meter)


(mm)

Approx. No.of Joints per10 Kg Pail of

Lubricant

ApAm

of GrJ

(cu.

400 34 0.0142 1950 5 0.

450 31 0.0159 2100 4 0.

500 28 0.0176 2250 3 0.600 23 0.0211 2400 3 0.

750 18 0.0263 2550 3 0.

900 15 0.0315 2700 3 0.

1050 11 0.0363 2850 2 0.

1200 9 0.0414 3000 2 0.

1350 8 0.0473 3150 2 0.

1500 7 0.0525 3300 2 0.

1650 6 0.0650 3450 2 0.1800 6 0.0709 3600 1 0.


33/60

MAKING THE JOINTS

Carefully

maneuver

the

pipe

to

align

the

spigotend toward the existing bell end so that the

spigotwillenterthebellendsquarely. Ifthepipe

is properly aligned, the pipe will slide in

smoothly. If any dirt touches the lubricated

spigot ring of the pipe already in position, the

spigot ring must be cleaned and lubricated

again.

PipeJoining

PipeJoiningOptions

The following diagram shows three methods of majoints.


34/60

INSTALLING FITTINGS

Fitting

joints

slide

together

in

the

same

way

asjoints for straight pipe. Aswith straight pipe,

hydraulicpullersandcome-alongscanbeused

tojointhefittings.

The long and short sides of the elbow are

stenciledonthefaceofthespigot.Additionally,

fittingsaregivenatopmarkatthespigotorbell

endasrequired.

Long,ShortandTopMark

Come-alongs or hydraulic pullers canbe used to


35/60

Elbowmovedintopositiononthepipe

g y p

pull thejoint home while thebackhoe supports

the elbow from above.


36/60

CHECKING THE GASKETS

A

feeler

gauge

is

used

to

test

the

joints

for

correctgasketplacement.

LCPPIPE

Use the external feeler gauge to check the

gasketfromtheoutside.

1 Insertthefeelerintothejoint.

2

If

you

cannot

feel

the

gasket

anywherealong the full circumference, thejointis

ACCEPTABLE.

3 Ifyoufeelthegasketanywherealongthe

circumference, remake thej oint usinga

newlubricatedgasket.

THE GASKETCANNOTBE FELT

AROUND THE FULLCIRCUMFERENCE

OF JOINT, THEREFORE, THE JOINT IS

ACCEPTABLE FEELER GAUGE

RUBBER GASKET

AcceptableLCPJoint

THE GASKET IS FELT ANYWHERE, REMAKE

JOINT WITH NEW LUBRICATED GASKET

F

RUBBER GA

UnacceptableLCPJoint

EXTERNAL

FEELER GAUGE

INTERNAL

FEELER GAUGE

23 mm

68 mm

ExternalandInternalFeelerGauge

ECPPIPE


37/60

Inspect the gaskets using the internal feeler

gauge from the inside. Insert spacers

(12mm) between the bell and spigot ends to

allowentryofthefeelergauge.

1 Insertthefeelerintothejoint.

2 Ifthefeelergaugedoesnotfitbetweenthe

bellandthespigot,thejoint isACCEPTABLE.

3 Occasionally,thejointringsmaypermitthe

feelergaugetobeinsertedoverthespigotlip

for a certain distance along the

circumference.Attheselocations,youmust

beabletofeelthegasket. Ifyoudo,thejointis

ACCEPTABLE.

4 Ifyou do not feel the gasketwhere the

feelergaugewasinserted,thegaskethas

been rolled or is cut. Remake thejoint

usinganewgasket.

THE FEELER GAUGE FITS IN BETWEEN THE SPIGOT

AND BELL, AND THE GASKET CAN BE FELT AROUND

THE FULL CIRCUMFERENCE OF THE PIPE.

THEREFORE,THE JOINTIS ACCEPTABLE

FEELER GAUGE

RUBBER GASKET

AcceptableECPJoint

THE FEELER GAUGE FITS IN BETWEEN THE

SPIGOTAND BELL, BUTCANNOT FEEL THE

GASKET. THEREFORE, REMAKE JOINT WITH NEW

LUBRICATED GASKET

FEELERGAUGE

RUBBER GASKET

UnacceptableECPJoint


38/60

GRADE AND LINE CHANGES

If joint deflections are required, they shouldbe made after the pipes have beenjoined. Restrained joints must bedeflected as described in the restrainedjoint section of this manual. Pipe positionscan be checked with a laser or transit.

A level is used to check the elevation of the bell ethe pipe.


39/60

PROTECTING THE JOINTS

To

protect

the

joints,

a

mortar

collar

is

poured

aroundthefullcircumferenceofthejoint.

1 Placethediaperaroundthefullcircumference

of thej oint so that it straddles thejoint.

Tightenthewiresorthestraps.

2 Mix 3 parts sand to1 part cementwith

enoughwater to make a free-flowing grout.

Ensure

that

the

same

cement

that

was

used

in

thepipecoatingisusedinthegrout.

Seetable11forapproximateamountof

groutperstandardjoint.

3 Pourthegroutintothediaperononeside

until the mortar appears on the other side.

Continue pouring the grout on the other

sideuntilthediaper isfull.Trowelthegapat

thetopofthediaperwithastiffermix.

4 Mortartheinsideofthej oint. Usearatioof3:1(sa

cement) and enoughwater to make a mix tha

easily

trowelled.

Point

the

inner

joint

recess

andthesurfacesmoothwiththeinsideofthepipe.

Pouringthegroutinthediaper


40/60

BACKFILLING

Bulldozerbackfillingthepipe

Follow

the

contract

specifications

for

backfilling. In general, after the pipe has been

laidtothe lineandgrade,material istampedin

uniform layers not more than 200 mm in

thickness up to the spring line of the pipe.

From the spring line of the pipe to about 300

mm above the top of the pipe, selected

material is spread uniformly and compacted.

The remainder of the trench is filledwith any

readily

available

backfill

appropriate

for

the

trafficconditions.


41/60

INSTALLING WITH

A T REN CH BO X

Soil

conditions

and

ensuring

safety

often

requires that pipe is installedwithin a trench

box.

Afteryoupull theboxahead in the trench, it is

important tocheck thepipe tomakesure that

thepipejointshavenotpulledapart.

Installingwithatrenchbox


42/60

TESTING

All testing must be done in accordance withcontract specifications and procedures.DECAST can provide test bulkheads toaccommodate field test pressures on isolatedsections of the pipeline. Air testing is notrecommended.

TestBulkhead


43/60

RESTRAINED JOINTS

When a pipeline changes size, direction oris bulkheaded, the internal line pressurecreates a thrust condition along thepipeline. At these locations, restrainedjoints are installed to counteract thethrust. Snap Ring joints, welded jointsand Harness Clamp are the typicalrestrained joints that DECAST uses.Harness Clamp restrained joints are

normally used at the long term bulkheadlocations.


44/60

SNAP RING

RESTRAINED JOINT

This patented joint assembly providesrestraint for pipe diameters 400 mmthrough 1800 mm and is provided byDECAST. The Snap Ring joint assembly isused for applications requiring restraintdue to unbalanced forces (such as bends,tees, etc.), therefore eliminating theneed for thrust blocks.

The joint design eliminates the problemof point bearing and at the same timepermits deflection, for slight directionalchanges during installation. Followingassembly of the joint, the voids around thejoint are filled with a protective cement/sand grout. This grout helps to distributethe thrust load uniformly around the jointperimeter.

Registered trade name of Price Brothers Corporation

Snap RingJoint

At the same time, the grout willcompress under load to permit slight


45/60

compress under load to permit slightsettlement of the pipeline. The result is asuperior restrained joint with a shortinstallation time that effectivelyeliminates the chance of aninstallation error.

The Snap Ring method is a fast and easyway to make a better mechanicalrestrained joint. The joint is completely self-contained, ready to engage, and completedby tightening a 9 mm bolt. It onlyrequires one man just a few minutes tocomplete the joint using a speed wrench. Snap RingJoint Assembly


46/60

SNAP RING RESTRAINED

JOINT

DEFLECTINGASNAPRINGJOINT

ASSEMBLY

IfadeflectionoftheSnapRingisnecessary,

theinsertringmustbetightenedintwostages.

Stageone:Thejoint isassembledsquarelyand

the insert is tightened only enough to prevent

thepipefrompullingapartduringdeflection.

SingleBoltSnapRingJoint

Stagetwo:Oncethepipehasbeendeflectedthe

requiredamount,the insertcanbetightened to


47/60

SnapRingJoint

q g

the extent of the bolt travel. Hand tightening is

allthatisrequired,donotforcethebolt.


48/60

WELDED

RESTRAINED JOINT

Welded joints are another method used totransmit thrust as well as provide joint restraint.However, they are generally less economical thana mechanically restrained joint due to field weldingcosts. The rigidity of a welded joint coupled withextreme soil settlement will cause adjacent pipelengths to transform into one long rigid beam,subjected to bending and shear stresses. To thisend, welded type joints are used in special

applications to resist thrust and to increase the lay-length of a standard pipe.

If welded joints are used, DECAST recommendseither an internal welded joint or an externalwelded joint. Internal welded joints are utilized forpipelines 1200 mm and larger in diameter, wherewelding inside the pipeline is feasible.

This method requires a water-tight weld due tothe absence of the gasket.

Internal Field Weld

For pipelines 1050 mm and smallerin diameter, an external welded joint


49/60

jis recommended. This method requires afield-weld bar (rolled to joint diameter),which is wedged tightly against theassembled joint rings. The procedure iscompleted by a partial or full weld ofthe joint assembly circumference,avoiding unnecessary heat which maydamage the rubber gasket.

ExternalFieldWeld


50/60

HARNESS CLAMP

RESTRAINED JOINT

TheHarnessClampRestrainedJoint isnormally

used

at

locations

where

there

is

the

potential

for

future connection. It is also used where the

application dictates a higher pressure, for

exampleatabulkhead.

HarnessClampJoint

DEFLECTING A HARNESS

CLAMP JOINT


51/60

When deflecting a Harness Joint the two C

clamps must be assembled and tightened in

two steps:

Step one: Assemble joint tightening the two

bolts only enough to prevent the pipe frompulling apart during deflection.

Step two: Once the pipe is deflected to the

appropriate angle tighten the bolts and grout

as usual.

Harness

Clamp

Joint

CLOSURES


52/60

CLOSURES

Closure sections are used when a newpipeline is connected to an existingpipeline, or when a connection is requiredafter an isolated pressure test. Tomanufacture the closure section, DECASTrequires the exact dimensions of theclosure length.

If access to the pipe joints is available, the

closure should be measured as per thediagram to the right. If the bulkheadscannot be removed or if completeexcavation is not possible, DECASTTechnical Services can instruct the surveycrews on how to acquire the necessarydimensions. DECAST will manufacture theclosure to fit the existing opening. Theclosure may be installed with a coupling or

a split welding sleeve.

MeasuringforaTypicalClosure:

Closures can be manufactured for restrained o

restrainedareasofthepipeline.

EMERGENCY CLOSURES


53/60

InstalledClosure Installedstandardweldsleeveclosure

DECAST can provide a full range of Emergency Closuresections available in 6.096 m and 7.315 m lengths. These

sections are designed to replace standard lengths ofpipe in restrained and non-restrained areas. The

plain ends of the closure sections are suitable fowelded sleeve or mechanical coupling. Fo

information regarding Emergency Closure please contact our Engineering department.

EMERGENCY CLOSURES

PRESSURE TAPPING


54/60

PRESSURE TAPPING

Tapping into concrete pressure pipe isa routine application. The proceduresfor tapping concrete pressure pipe whilethe pipe is under pressure are thesame as for tapping other kinds of pipe.Weld-on tapping assemblies are notrecommended for tapping concrete pipebecause deformation may occur duringwelding to the pressurized steel cylinder.

The tapping saddle configuration shouldallow for the saddle to be securely boltedto the pipe before the prestressing wire orthe reinforcing rod from the tap openingare removed.

Tapping

machine

positioned

on

pipe

DECAST can provide a full range of tappingsaddles for concrete pressure pipe andother piping products DECAST also


55/60

Installed wire anchor tapping saddle

other piping products. DECAST alsoprovides a full line of tapping services. Inlined cylinder pipe 900 mm and smaller astrapless saddle tap may be used for tapsbetween 19 mm and 38 mm. The saddleanchors directly to the prestressing wireafter the mortar coating has been carefullychipped away.

This type of tapping saddle requiresno reinforcing bands or excavation underthe pipe. Encase all exposed steel in a 3:1mortar mix after the tap has been made.

Use a strap-type saddle for larger taps.The saddle shown in the photograph belowis for a 200 mm tap in a 750 mm diameterpipe.

PRESSURE TAPPING


56/60

PRESSURE TAPPING

The reinforcing bands of the saddle must be

torqued

and

the

space

between

the

saddle

andthebarrelofthepipegroutedbeforeanyof

the prestressing wires are cut. The space

around the saddle gland can be grouted after

the pressure test is complete but must be

done prior to tapping the pipe. In all cases

tapping concrete pressure pipe should only be

done by qualified, experienced personnel.

After

tapping

is

complete

the

saddle

should

be

protected by encasement in a cement rich

concreteormortarwithaminimumcoverof25

mmoverallsteelsurfaces.Densotapeandpaste

may also be used where concrete

placementisimpractical. Strap-typesaddleusedforlargertaps

WALL PIECES


57/60

WALL PIECES

WallPiece

Wall pieces are generally provided with wall

flanges

or

thrust

collars

at

the

point

at

which

thewall is to encase the piece. Ifyour project

does not incorporate this feature, internal

bracing should be used to ensure that the

pieceremainsroundduringtheconcretepour.

Wall pieces may also be providedwithwater

stops.

These

are

not

designed

for

thrust

restraint. If thrust restraint is required, joint

restraints (mechanical or welded) must be

used. If thrust flanges are incorporated in the

wall piece the longitudinal thrust must be

transmitted from the wall piece to the

chamberorathrustblock.

PIPE ORIENTATION


58/60

PIPE ORIENTATION

Pipe

Orientation

It is common practiceto describe pipe asif it is

being viewed from the spigot end looking

toward the bell end.

FIELD SERVICES


59/60

DECAST offers the assistance of highly

trained and experienced Field ServiceTechnicians who can advise your crew oninstallation procedures and repairmethods. Please see page 2 of this manualfor contact information.


60/60

DECAST Ltd.

8807 County Road 5

Utopia, ON L0M 1T0

1.800.461.5632

705.734.2892

WEB

www.decastltd.com

0

4

Most extensive product linein the industry

PRESTRESSED CONCRETE CYLINDER PIPE AND FITTINGS

VALVE AND UTILITY CHAMBERS

STEEL PIPE AND FITTINGS

BRIDGE GIRDERS

DE-SPAN

BRIDGE SUPERSTRUCTURE AND SUBSTRUCTURE

TUNNEL SEGMENTSBOX CULVERTS

REINFORCED CONCRETE PIPE

MAINTENANCE HOLES &CATCH BASINS

INTEGRATED FRAME & COVER MH SYSTEM (IFC)

HEADWALLS

RAILWAY / SUBWAY TIES

Documents

DECAST-CPP-Installation-Manual-2016.02.10.pdf