REINFORCED CONCRETE PIPESMCP... · 3 | REINFORCED CONCRETE PIPES – INSTALLATION MANUAL 1 Introduction 1.1 Products Maddington Concrete Products (MCP) is a …

1 | R E I N F O R C E D C O N C R E T E P I P E S – I N S T A L L A T I O N M A N U A L

MADDINGTONCONCRETEPRODUCTSPtyLtd.MADDINGTONCONCRETEPRODUCTSPtyLtd.

AUGUST 2015

REINFORCEDCONCRETEPIPES

INSTALLATIONMANUAL


Contents1 Introduction......................................................................................................................................................................31.1 Products....................................................................................................................................................................31.2 ManufacturingSizes............................................................................................................................................31.3 LoadClasses............................................................................................................................................................41.4 Durability.................................................................................................................................................................4

2 PerformanceTesting.....................................................................................................................................................43 Applications......................................................................................................................................................................53.1 Culvert.......................................................................................................................................................................53.1.1 Overview.........................................................................................................................................................53.1.2 Hydraulics......................................................................................................................................................5

3.2 Drainage...................................................................................................................................................................53.2.1 Overview.........................................................................................................................................................53.2.2 Hydraulics......................................................................................................................................................5

4 SystemDesign..................................................................................................................................................................64.1 Loading&Clear‐Coverage.................................................................................................................................64.2 MultiplePipesConditions.................................................................................................................................7

5 Transportation................................................................................................................................................................76 GroundSupport...............................................................................................................................................................87 InstallationProcedure..................................................................................................................................................97.1 TrenchDigging.......................................................................................................................................................97.1.1 Overview.........................................................................................................................................................97.1.2 Preparation&Specifications..................................................................................................................97.1.3 Stability...........................................................................................................................................................97.1.4 Groundwater..............................................................................................................................................10

7.2 PipeSupportMaterial......................................................................................................................................107.2.1 Overview......................................................................................................................................................107.2.2 Bed&HaunchLayer...............................................................................................................................107.2.3 SideLayer....................................................................................................................................................117.2.4 OverlayLayer.............................................................................................................................................117.2.5 BackfillLayer.............................................................................................................................................11

7.3 GroundCompaction..........................................................................................................................................117.4 PipeLaying...........................................................................................................................................................127.4.1 PipePlacing................................................................................................................................................127.4.2 PipeJoining.................................................................................................................................................12

8 ReferenceMaterial......................................................................................................................................................138.1 ConversionTable...............................................................................................................................................138.2 Nomographs–InletControl..........................................................................................................................148.3 Nomographs–OutletControl.......................................................................................................................158.4 LoadCarryingCapacityGraphs...................................................................................................................16


1 Introduction

1.1 Products

Maddington Concrete Products (MCP) is afamily‐ownedandoperatedWesternAustralianbusinesswhichhasbeensupplyinghighqualityprecast steel reinforced (SR)concretepipes forindustrial, commercial and domesticapplications formore than40 years. Builtwiththe best dry‐mix concrete techniques in theindustry, MCP products have developed areputation in the industry. Designed to specificusers’ requirements, they are now one of thebest options in culvert and drainageapplications.

This manual outlines the specifics of MCPmanufacturedpipesaswellasabasicguidelineto their installation in a range of conditions.Please refer to the general contents page fordirections.

Figure 1.1: The production facility’s storage yard inMaddington,WesternAustralia

1.2 ManufacturingSizes

MCP manufactures concrete pipes for a widerangeofdiameters.Table1.1outlinestherangeofdiametersavailable.RefertoFigure1.2ontheright hand side in order to better understand aconcretepipe’spropertyvariables.

Figure1.2:Thevariablepropertiesofaconcretepipe

DIAMETERSIZE[mm]

PRODUCTCODE

OVERALLLENGTH[mm]

EFFECTIVELENGTH[mm]

WALLTHICKNESS

[mm]

WEIGHT[kg]

300 P01 2440 2340 45 310375 P02 2440 2340 45 390450 P03 2440 2340 48 470600 P04 2440 2340 55 690750 P05 2440 2340 68 1130900 P06 2440 2340 85 17001200 P07 2440 2340 100 2600

Table1.1:RangeofSRconcretepipesavailableinstockortoorder

WALLTHICKNESS

INTERNALDIAMETEROUTERDIAMETEREFFECTIVELENGTH

OVERALLLENGTH

SOCKETENDJOINT SPIGOTENDJOINT


1.3 LoadClasses

The Australian Standard Code for precastconcrete pipes (pressure and non‐pressure),also referred to as AS/NZS‐4058:2007, hasclassified SR concrete pipes in load classesrangingfrom2to10,10beingtheproductsabletowithstandthegreatestappliedloads.

MCPmanufacturesalloftheirconcretepipesforstandardstrength(LoadingClass4)accordingtoAS/NZ‐4058:2007specifics.

It is important to remind theuser that the testload to determine the loading class for aparticular application should be determined in

accordance with the Australian Standard Codefor design for installation of buried concretepipes,alsoreferredtoasAS/NZS‐3725:2007.

1.4 Durability

AllSRconcretepipesmanufacturedatMCParedesignedtocomplywithAS/NZ‐4058:2007,andare therefore expected to have a service life of100 years if installed following the properprocedure.

2 PerformanceTestingIn order to comply with the latest version ofAS/NZ‐4058:2007, routine performance testsarecarriedoutonalldiametersizesproducedatMCP.Pipesaretested,usingappropriatetestingequipment (see Figure 2.1), to withstand bothproofloading(cracking)andultimateloading.

Proof loading is the indicated loadappliedonaSR concrete pipe without the formation ofcracks greater than the test cracks specified inaccordance with AS/NZ‐4058:2007. Ultimateloadingiscalculatedas1.5theproofloadingforstandard strength classes, and 1.25 the proofloadingforsuperstrengthclasses.Itrepresentsthemaximumdesignedloadwhichthepipecanwithstandbeforereachingstructuralfailure.

Figure 2.1: The load testing facility in Maddington,WesternAustralia

The specifics for loading classes to which allpipesmanufacturedatMCPhavetocomplywithcanbefoundinTable2.1.

DIAMETERSIZE[mm]

STANDARDSTRENGTH [kN/m] SUPERSTRENGTH1[kN/m]CLASS2 CLASS4 CLASS6 CLASS8

PROOF ULT PROOF ULT PROOF ULT PROOF ULT300 15 23 30 45 45 56 60 75375 17 26 34 51 ‐ ‐ ‐ ‐450 20 30 40 60 ‐ ‐ ‐ ‐600 26 39 52 78 ‐ ‐ ‐ ‐750 32 48 64 96 ‐ ‐ ‐ ‐900 37 56 74 111 ‐ ‐ ‐ ‐1200 46 69 92 138 ‐ ‐ ‐ ‐

Table2.1:TestloadsforvariousclassesofSRconcretepipesaccordingtoAS/NZ‐4058:2007

1–UponrequestMCPcandesignandmanufacturepipestomeetthesuperstrengthclass


3 Applications

3.1 Culvert

3.1.1 Overview

Culverts are short conduits used to passwaterunder roadways. They are constructed incircular, rectangular, andoval shapes. Concretepipes manufactured by MCP can be used inculvert applications. The hydraulic analysis ofculvertsiscomplicatedbecausetheflowregimeis variable. Section 3.1.2 outlines the basics inculverthydraulics.

3.1.2 Hydraulics

There are 2 types of flow control for culverts:inletcontrolandoutletcontrol.Generally if theculvert is operating on a steep slope, inletcontrolconditionscanbeassumed(Figure3.1);if it is operatingon amild slope, outlet controlconditionscanbeassumed(Figure3.2).

The flow rate through a culvert (Q) can bedetermined by multiplying the intensity of astormbythecatchmentareathetributaryfeedsoff from multiplied again by the coefficient ofrunoff. By combining this information withother geometrical and hydraulic variables,headwater levels can be determined usingappropriate nomographs. Each form of flowcontrol requires different inputs in order todetermineasolution.Usingthesetools,awaterengineerwillbeabletocorrectlyselectthemostsuitable pipe size to fulfill all regulationsregardingwaterdischarge.

Figure 3.3:The principle of conservation of energy asoutlinedbyBernoulli

Figure 3.1: A culvert with inlet control operatingconditions

Figure 3.2: A culvert with outlet control operatingconditions

3.2 Drainage

3.2.1 Overview

SRconcretepipesmanufacturedbyMCPcanbeemployed in the channeling and discharge ofstormwater. Concrete pipes manufactured byMCPcanbeusedinculvertapplications.Rubberringjoints(RRJ)areemployedintheconnectionof various pipe segments. For more details onthedesignofpipejointsconsultSection4.1.

3.2.2 Hydraulics

Drainage application systems of pipes can bedealtwith using the Bernoulli Principle. Figure3.3outlineshowtheprincipleofconservationofenergycanbeused toassignanumericalvaluetounknownparameters.Usingthistool,awaterengineerwillbeabletocorrectlyselectthemostsuitable pipe size to fulfill the drainagerequirements.

DIAMETER

DIAMETER

ROADSURFACE

ROADSURFACE

HEAD

TAILWATER

HEADWATER FLOW

FLOW

HEADWATER

FLOW

H2

V22/2G

HF

H1

V12/2G

REFERENCEPOINT1

REFERENCEPOINT2

FRICTION

ENERGYLINE

WATERSURFACE

UPPERREFERENCELINE

LOWERREFERENCELINE

H1+V12/2G=H2+V22/2G+HFCONSERVATIONPRINCIPLE


4 SystemDesign

4.1 Loading&Clear‐Coverage

AspreviouslydiscussedinSection2,reinforcedconcretepipesarebuilttobeabletowithstandultimateloadingsinaccordancetospecificationswhichcanbefoundinAS/NZ‐4058:2007.

The soil material making up the stratum ofclear‐cover on the top of a pipe allows for anylive loads (axle loads coming from vehiclemovement on the surface) to be distributedalong the trench/embankment. The degree towhich these loads aredistributed is verymuchreliant on geotechnical properties of the soilsuchasfrictionangle,unitweightofthematerialandlevelofsaturation.

Thedeeperundergroundthepipeispositioned,thelessconcentratedtheliveloadsare,reducingthe stress on the concrete. AS/NZS‐3725:2007outlinesaminimumof150mmofclear‐coverinorder to protect the concrete pipe fromvibrationsandotherconstructionrelatedissueswhich might arise. This value is often notsufficient in order to guarantee that thepositionedpipe isnot subject todirect stresseswhich could be greater than the ultimate loadstowhichthepipehasbeentestedtowithstand.

Fordifferentdiameterpipes,differentdesirableclear‐covers apply. These values are a functionofthepossibleliveloadswhichcouldbeappliedon the top surface (vehicles applying pressureon the backfill). These pressures can berepresented in number and intensity of axlerepetitionsonasurfacearea.TheDepartmentofMain Roads in Western Australia classifiesvehicleloadsin5axlecategories:

Single‐AxleStandardTyres(SAST) Single‐AxleDualTyres(SADT) Tandem‐AxleSingleTyres(TAST) Tandem‐AxleDualTyres(TADT) Tri‐AxleDualTyres(TRDT)

Eachcategorypresentslimitationsregardingtheloadingpressurewhichcanbeexertedonaroadsurface (and everything lying underneath).AUSRoadshaveproduced these limitations andareenforcedonWesternAustralianroads.

Table 4.1 outlines the desired minimum clear‐coverswhichwillnotcompromisethestructuralsoundness for all the pipes manufactured atMCP.

DIAMETERSIZE[mm]

CLEAR‐COVER 1

[mm]SAST SADT TAST TADT TRDT

300 150 225 250 N/A N/A375 150 250 260 N/A N/A450 150 260 280 N/A N/A600 150 150 150 4702 N/A750 150 150 150 480 N/A900 150 150 150 500 N/A1200 150 150 150 150 8002

Table4.1:Minimumclear‐coversforvariousdiameterpipes

1–Theclear‐coveralreadyincludestheminimum150mmrequiredbyAS/NZS‐3725:20072 – These values are critical and represent the minimal values for clear‐cover. Maximum values should not exceed minimal +10 mm. SeeReferenceMaterialinSection8.4formoredetailedinformationIt is important tohighlighthowaxlecategoriesrepresent lawenforced limitations,and thereforerepresent theworsepossiblescenarios foreachcase.Theseaxlecategories’limitationsareavailableontheDepartmentofMainRoads’websiteandshouldneverbeinfringed.SimplechartshavebeendevelopedbyMCPtoquicklydeterminetheultimateloadcarryingcapacityatvaryingcoverdepthsforthedifferentClass4pipesizes‐refertoSection8.4


4.2 MultiplePipesConditions

Multiplepipescanbepositionedparalleltoeachother in the same trench (see Figure 4.2).AS/NZS‐3725:2007 outlines the minimumvalues for distances (LC) between the pipe’soutside wall and either the trench wall or theoutersurfaceofthepiperunningparallelnexttoit.LCisdirectlyrelatedtothepipe’sdiameterasoutlinedinTable4.2.

DIAMETERRANGE[mm]

LC[mm]

≤600 150>600,≤1200 200

Table4.2:GradinglimitsforselectfillinbedandhaunchzonesaccordingtoAS/NZ‐3725:2007

Figure7.3:Thecomponentsforpipesupportmaterials

5 TransportationThe transportation of steel reinforced concretepipes is a delicate task which requires correctequipment in order to ensure the safe deliveryoftheproductpurchasedwithoutcompromisingitsstructuralabilities(nocracks).

A platform semitrailer is required fortransportation of the product from theproduction site to the client’s site. Platformsemitrailers allow the forklifts easy access toload up the cargo from the sides withoutincurring in logistical problems. Semitrailerswithsignificantlateralconfinementswillnotbeloadedwiththepurchasedorderofpipes.

The stacking process requires the pipes to bestoredon “crates”whichcanbepositionedoneontopoftheotherinrows.Strapsorchainscanbeutilizedtosecurethecargotothesemitrailer.Theminimumrequirementistohavetwostrapsoneachendofthestackofpipes.Twoadditionalstraps can be employed to better secure thebottomrowstothedeckforadditionalsupport.Safetyandconservingthestructuralintegrityofthepipesisthemainaimofsuchprocess.

BACKFILLLAYER

OVERLAYLAYER

HAUNCHLAYER

BEDLAYER

OUTERDIAMETER SIDELAYER

EXISTINGGROUNDSUPPORT

OUTERDIAMETER

OUTERDIAMETER

150mmMINIMUM

LcLc Lc Lc

PIPE’SCLEARCOVERAGE

FINISHEDSURFACE


6 GroundSupport

Theconcretepipesreadyforinstallationhavetobe able to withstand the loads to which theyhave been designed to resist. In order tomakesure the soil around the pipe is not subject toany movement which might compromise theshort‐term and long‐term stability andfunctionalityof thepipesystem,propergroundsupportneedstobeinplace.

It is up to the design engineer’s discretion todecide which technique of ground support toutilize in the final design. All specified designguidelines regarding depth of the embedment,widthof the trench,haunch typeand thicknessandmanyotherrequiredvariablescanbefoundby consulting the Australia Standard AS/NZ‐3725:2007. This guideline outlines 3 majortechniquesofgroundsupportforpipes:

Unsupported (Type U): No bed, haunchorsidesupportforthepipe.Thisdesignprovidestheleastsupportforthepipe;itishowever thecheapestand least time‐consuming technique to install aconcretepipe.RefertoFigure6.1forthecross‐sectionalviewofthepipesupport.

D

Figure6.1:UnsupportedTypeUsupport

HaunchSupport(TypeH):Bedlayerandhaunchsupportforthepipeareinplace.This design provides medium supportfor the pipe. Refer to Figure 6.2 for thecross‐sectionalviewofthepipesupport.

Figure6.2:HaunchTypeHsupport

Haunch& Side Support (TypeHS): Bedlayer,haunchtogetherwithsidesupportfor the pipe are in place. This designprovidesthehighestlevelofsupportforthe pipe; it is however the most costlysolution. Refer to Figure 6.3 for thecross‐sectionalviewofthepipesupport.

Figure6.3:HaunchandsideTypeHSsupport

150mmMINIMUM

150mmMINIMUM

150mmMINIMUM

150mmMINIMUM

BACKFILL

BACKFILL

OVERLAYMATERIAL

ORDINARYFILL

HAUNCHSUPPORT

COMPACTEDBEDLAYER

UNCOMPACTEDBEDLAYER

TRENCHWIDTH

TRENCHWIDTH

OUTERDIAMETER

OUTERDIAMETER



150mmMINIMUM

150mmMINIMUM

BACKFILL

OVERLAYMATERIAL

HAUNCHSUPPORT

COMPACTEDBEDLAYER

UNCOMPACTEDBEDLAYER

OUTERDIAMETER


TRENCHWIDTH

SIDESUPPORT

D/3

D/3


7 InstallationProcedure

7.1 TrenchDigging

7.1.1 Overview

Trenchdiggingcanbedifficultandpropersafetyprocedures must be followed in order tominimizechancesofdamageorinjuriesonsite.

A geotechnical report of the soil in which thetrench will be dug is required in order todetermine the soilprofileof the site.Referenceto AS/NZ‐3725:2007 should be taken intoaccount together with local governmentregulations and procedures when consideringthesite’sgeotechnicalconditions.

Figure7.1:Theexcavationofatrench

7.1.2 Preparation&Specifications

Various techniques for excavation of trenchesexist and depending on soil properties anddepth of excavation the most suitable oneshould be selected at discretion of the designengineer(seeSection4).

The trench foundation layer must be firm anduniform. Large inconsistent rocks must beremoved and soil voidsmust be filledwith theproper material to ensure uniform plane onwhich to lay the concrete pipe. This willguaranteebetterstabilityandloaddistribution.

The depth to which the trench must beexcavated to depends on the characteristics ofthe SR concrete pipe (loading class, outer

diameter…), the soil conditions and the load towhich itwillbesubject to.Section4.1providesan easy to follow guideline to determine thedepthoftheclear‐cover.

The width of the trench is also critical as thegreaterthewidth,themoreverticalloadtheSRconcrete pipe could possibly be subject to.Please refer to AS/NZ‐3725:2007 formore thespecifics regarding this factor as it can changeduetomanyfactors.

7.1.3 Stability

Soilmaterial excavated from the site shouldbeplaced at appropriate distance from the trenchto avoid complications during constructionprocess.

Trenchesexcavatedtoadepthofmorethan1.5meters present a significantly higher risk ofcollapse increasing the risk of injuries and/ordelays to the project. In order to avoid this,battering or benching, as seen in Figure 7.2,mightbeconsideredasanoptiontoincreasethestability of the walls. This is common practiceamongtheindustry.

The utilization of retaining walls or other soilstrengthening techniques are also a possibilitybutmaynotbeascost‐effective.

Figure7.2:Benchingandbattering techniquesused fordeep‐trenchexcavations



PIPE’SEMBEDMENT

TRENCHWIDTH

TRENCHWIDTH

BENCHINGTECHNIQUE

BATTERINGTECHNIQUE


7.1.4 Groundwater

The presence of seasonal shallow groundwatermight be a problem when digging a trenchespecially in urbanized areas. Precautionmeasures must be put in place in order tostabilize and control the water level. Ageotechnical engineer’s advice is recommendedon themost suitablepractice toemploy for thegivenscenario.

7.2 PipeSupportMaterial

7.2.1 Overview

The pipe support material is composed of thefollowingcomponents:

BedLayer HaunchLayer SideLayer OverlayLayer BackfillLayer

Each layermust conform to specific guidelinesdiscussed in the later sub‐sections. It isimportant to build these layers in sections andcompactthegroundateveryspecificintervalinordertoachievepropersupportfortheconcretepipe.Figure7.3outlines thecomponentsof thepipesupportmaterial.

Figure7.3:Thecomponentsforpipesupportmaterials

7.2.2 Bed&HaunchLayer

Laying the bed is a critical step of the pipeinstallationprocedureasitprovidestheverticalweight support for the concrete pipe. The bedmust be leveled and graded with precision sothatitfulfillsthedesigner’sspecifications.

The soil must be compacted, using properequipment before laying the pipes to avoidunexpected settlements. In order toaccommodatethesocketofthepipeatthejoints,chasesmustbeexcavatedsothattheloadoftheconcrete pipes and of the soil on top is evenlydistributed.G

F

Figure7.4:Supportmustbeuniform inorder toevenlyspreadthesupportreactiononthepipe

Boththebedandthehaunchmustbecomposedof a non‐cohesive material which does notdecompose over time. The granular propertiesto be used for these two sections must becoherentwiththegrainsizespecificationsfoundin AS/NZ‐3725:2007. Table 7.1 outlines suchspecifications.

SIEVESIZE[mm]

WEIGHTPASSING[%]

19.0 1002.36 100‐500.60 90‐200.30 60‐100.15 25‐00.075 10‐0

Table7.1:GradinglimitsforselectfillinbedandhaunchzonesaccordingtoAS/NZ‐3725:2007

BACKFILLLAYER

OVERLAYLAYER

HAUNCHLAYERBEDLAYER

OUTERDIAMETER


SIDELAYER

TRENCHWIDTH

PIPE’SEMBEDMENT


UNACCEPTABLELOADDISTRIBUTION

ACCEPTABLELOADDISTRIBUTION


7.2.3 SideLayer

The same soil properties used for the bed andhaunch layers apply for the side layer. Thegranular properties are however different; forproper grain size specifications, please refer toAppendix A in the Australian Standard AS/NZ‐3725:2007. Table 7.2 outlines suchspecifications.

SIEVESIZE[mm]

WEIGHTPASSING[%]

19.0 1002.36 100‐500.60 100‐300.30 50‐150.15 25‐0

Table 7.2: Grading limits for select fill in side zonesaccordingtoAS/NZ‐3725:2007

7.2.4 OverlayLayer

The overlay layer’s soil does not have toconform to such strict rules as the layersunderneath it. For logistical purposes, it iscommon to use the material used for the sidelayerduring thisprocedure.Thisallowshavinganoverlay free from large rockparticleswhichcouldendupdamagingtheconcretepipeduringcompaction. This layer must have at least 150millimeters thicknessat the topof theconcretepipeinordertoprovideitenoughprotection.

7.2.5 BackfillLayer

The backfilling layer consists of the remainingexposed areaof the trench.No clear guidelinesexisttowhichmaterialtouseforthebackfillingprocedure.Thechoiceislefttothediscretionofthe pipe layer which should make a decisionwiththerelevantstakeholders.

It is important to note that the choice of thebackfill material might be impacted by thefunction of the surface layer. If a road is to beconstructed then the road base, sub‐base andsub‐grade design have to be incorporated.Please consult any relevant standards orguidelinesbeforecarryingoutanywork.

7.3 GroundCompaction

Thedegreeofcompactionofthegroundaroundembracingandsupportingthepipeisthekeyinensuring the optimization of the pipe’s loadcarrying capacity. The density index (ID) forcohesion‐less soils should be determined by aprofessional geotechnical engineer inaccordance to the Australian Standard AS‐1298:1980.Table7.3outlinestherangelimitsofthe grading curve the selected fill must fallinsideof.

Groundcompactionshouldtakeplace inevenlyplaced layers of no more than 150 mm inthicknessinordertoensurenovoidsareleftinthe support material (see Figure 7.5). Propercompacting equipment should be operated inorder to achieve the desired compaction. Theweight of heavy compacting equipment shouldbetakenintoaccountwhencompactingthesoilabove the concrete pipe. A temporaryembankment should be put in place to allowsufficientclearancefortheconcentratedloadtodisperse without causing structural damage totheconcretepipeunderneath. H

Figure7.5:Supportmustbeplacedinuniformlayersinordertoincreaseitsdrydensityvalue

OUTERDIAMETER


SUPPORTMATERIAL


SUPPORTTYPE1

MINIMUMDEPTH[mm]

MINIMUMZONECOMPACTION 2

[%]BEDZONE

HAUNCHZONE

BEDANDHAUNCHZONESID

SIDEZONESID RD3

U 75 ‐ ‐ ‐ ‐

H H1 100 0.1D 50 ‐ ‐H2 100 0.3D 60 ‐ ‐

HS

HS1 100 0.1D 50 50 85HS2 100 0.3D 60 60 90HS3 100 0.3D 70 70 95

Table7.3:MinimumdepthandzonecompactionpropertiesaccordingtoAS/NZ‐3725:2007

1 – Subcategories of support types exist for trenches designedwith haunch supports only (H1 & H2) and for the ones designedwith sidesupportsaswell(HS1,HS2&HS3).Thehigherthesubcategorynumber,thegreatercompactionrateanddepthlayerisrequired.Checkwithageotechnicalengineertodeterminewhichsubcategoryisthemostsuitablefortherequiredperformance.2–ThecompactionzoneexcludesthemiddleD/3sectionofthebeddinglayer3–Thedrydensityratio(RD)onlyappliesifusingacohesivematerialasthesupportmaterial,somethingwhichisnotreallyrecommended

7.4 PipeLaying7.4.1 PipePlacing

Concrete pipes have to be placed in theexcavated trench after the placing of the bedlayer.An excavator should assist in theplacingofthepipe.Itisimportanttorememberthatthesoilmust be compacted and to the proper lineandgradeaspreviouslyspecifiedinSection7.3.Ifthepipeplacingdoesnotfulfillthedesigner’sindications,thenthepipemustberemovedandappropriateremediationmustbecarriedouttothe bed layer. Alterations to the beddingwhilethe pipe is still in place are dangerous and notacceptable.

7.4.2 PipeJoining

AllSRconcretepipesmanufacturedatMCPuserubber ring joints. The procedure forinstallation is simple yet effective. Theelastomeric seal band is put in place and thesecond pipe (positioned at a relatively smalldistance to the one already in position) ispushed so that its spigot is pushed fully homeinto the socket of the pipe already in position.The use of a lever pulled by a worker at thesocketendofthesecondpipeisusefultogetthepipeintopositionasseeninFigure7.6.

Under no circumstances should heavymachinerysuchasexcavatorsbeoperatedaloneto push the spigot pipe home into the socket.This is highly dangerous and could result indamaging the concrete pipe ultimatelycompromising its efficiency and possibly itsfunctionality.

If a deviation in the joint is required by thedesign,theprocedureisthesameasifthepipeswere laid straight. The spigot must be pushedfully home into the socket. Only after this hashappened, it is recommended to lever the pipeinto position in order to achieve the desiredangle of deviation. For more informationregarding specific joints properties such asmaximum angle of deviation, maximum layinggapsandothersconsultwithaspecialistatMCP.F

Figure 7.6: Pushing the pipe into place using both

manualandmechanicalassistance

ELASTOMETRICSEAL

SOCKETENDJOINT

SPIGOTENDJOINT

MANUALASSISTANCE

MECHANICALASSISTANCE


8 ReferenceMaterial

8.1 ConversionTable

LENGTH 1mm1cm1m1km

= 0.0394 in=0.3937in=3.2808ft=0.6214miles

1in1in1ft

1mile

=25.4000mm=2.5400cm=0.3848m=1.6093km

AREA 1mm21cm21m21ha

= 0.0016in2=0.1550in2=10.7639ft2=2.4711acres

1in21in21ft2

1acre

=645.1600mm2

=6.4516cm2=0.0929m2=0.4047ha

VOLUME 1mm3

1cm31m3

= 0.0164in3=16.3934in3=35.3147ft3

1in31in31ft3

=61.0240mm3

=0.0610cm3=0.0283m3

LIQUIDSTORAGE 1L1L1L

1ML

= 0.0353ft3=0.2200impgal=0.2642USgal=0.0810acreft

1ft31impgal1USgal1acreft

=28.3168L=4.5461L=3.7850L=1.234ML

VELOCITY 1m/sec1km/hr

= 3.2808ft/sec=0.6214miles/hr

1ft/sec1mile/hr

=0.3848m/sec=1.6093km/hr

VOLUMETRICFLOW 1L/sec= 13.1981impgal/min 1impgal/min =0.0758L/sec

MASS 1g1kg

1tonne[1000kg]1tonne[1000kg]

= 0.0353oz=2.2046lb=0.9842tons=1.1023UStons

1oz1lb1ton

1USton

=28.3495g=0.4536kg=1.0161tonnes=0.9072tonnes

FORCE 1kN1kN

= 224.8090lbforce=0.1004tonforce

1lbforce1tonforce

=0.0044kN=9.9640kN

PRESSURE 1kPa1MPa

= 0.1450psi=145.0377psi

1psi1psi

=6.8900kPa=0.0069MPa

POWER 1kW =1.3400hp 1hp =0.746kW


8.2 Nomographs–InletControl

EXAMPLE

GIVEN:Internaldiameterofthepipeis1050mm;thegivendischargeis3.4m3/sec

RESULT:Dependingontheentrancetypeoftheculvert,theheadwaterdepthdividedbythediameterofthepipecanbeobtainedtracingalinethroughthetwogivenvariablesandextendingthatlineuntilscale(1)isreached.


8.3 Nomographs–OutletControl

EXAMPLE

GIVEN:Internaldiameterofthepipeis1200mm;thegivendischargeis1.95m3/sec;thelengthofthepipeis40m;andthecoefficientofentrancelossis0.5.

RESULT:Tracealineconnectingtheinternaldiameterpointandthelengthvalueoftheculvert.Thenextstepistoconnecttheflow‐ratevaluewiththelinepreviouslydrawnatthe“turningline”.Extendthatlineuntilthe“Head”scaleisreachedrevealingtheheadlevelofthewater.


8.4 LoadCarryingCapacityGraphs

Relevant to Section 4.1, these graphs outline the results from the Excel formulated load carryingcapacitiesforatypicalPerthsandysoilassuming:

45degreesloaddispersion; Bulkunitweightof20kN/m3; Factorofsafetyof1.5

The red dashed line outlines the factored load carrying capacity for a pipe class 4 of the specifieddiameter complying with AS/NZ‐4058:2007. Any depth cover value whose axle line is situatedunderneaththecapacitylineissuitabletobeemployedasaclear‐covervalue.Allreinforcedpipeshavebeenanalyzedundervehicleloadsclassifiedunderthese5axlecategories:

53.0kNperaxle;Single‐AxleStandardTyres(SAST) 80.0kNperaxle;Single‐AxleDualTyres(SADT) 90.0kNperaxle;Tandem‐AxleSingleTyres(TAST) 135.0kNperaxle;Tandem‐AxleDualTyres(TADT) 181.0kNperaxle;Tri‐AxleDualTyres(TRDT)

Theaboveaxleloadsareworkingloadswhichareun‐factored.Toobtainthepermissiblewheelloadingfromthesechartsfortheparticulardepthcoverandaxlecategoryreadtheultimateloadinganddividethisvaluebythe1.5factorofsafety(FOS).

Permissiblewheelloading=UltimateloadingFOS

Example: 300pipeloadclass4 Depthcover=250mm Tandem‐axlewithsingletyres Ultimateloading=45kN Permissiblewheelloading=45/1.5=30kN


20

40

60

80

100

120

140

160

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

UltimateLoading[kN/m

]

DepthCover[m]

300LOADCLASS4

Single‐axlewithsingletyres

Single‐axlewithdualtyres

Tandem‐axlewithsingletyres

Tandem‐axlewithdualtyres

Tri‐axlewithdualtyres

20

40

60

80

100

120

140

160

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

Ultim

ate Loading[kN/m

]

DepthCover[m]

375LOADCLASS4







20

40

60

80

100

120

140

160

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

Ultim

ate Loading[kN/m

]

DepthCover[m]

450LOADCLASS4






20

40

60

80

100

120

140

160

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

Ultim

ate Loading[kN/m

]

DepthCover[m]

600LOADCLASS4







20

40

60

80

100

120

140

160

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

Ultim

ate Loading[kN/m

]

DepthCover[m]

750LOADCLASS4






20

40

60

80

100

120

140

160

0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

Ultim

ate Loading[kN/m

]

DepthCover[m]

900LOADCLASS4







40

60

80

100

120

140

160

180

0.15 0.25 0.35 0.45 0.55 0.65 0.75 0.85 0.95

Ultim

ate Loading[kN/m

]

DepthCover[m]

1200LOADCLASS4






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