REINFORCED CONCRETE PIPES

REINFORCED CONCRETE PIPES

INSTALLATION MANUAL

MADDINGTON CONCRETE PRODUCTS Pty Ltd.

MADDINGTON CONCRETE PRODUCTS Pty Ltd.

1| REINFORCED CONCRETE PIPES ? INSTALLATION MANUAL

AUGUST 2015

Contents

1 Introduction...................................................................................................................................................................... 3 1.1 Products.................................................................................................................................................................... 3 1.2 Manufacturing Sizes ............................................................................................................................................ 3 1.3 Load Classes ............................................................................................................................................................ 4 1.4 Durability ................................................................................................................................................................. 4

2 Performance Testing..................................................................................................................................................... 4 3 Applications ...................................................................................................................................................................... 5

3.1 Culvert ....................................................................................................................................................................... 5 3.1.1 Overview......................................................................................................................................................... 5 3.1.2 Hydraulics ...................................................................................................................................................... 5

3.2 Drainage ................................................................................................................................................................... 5 3.2.1 Overview......................................................................................................................................................... 5 3.2.2 Hydraulics ...................................................................................................................................................... 5

4 System Design.................................................................................................................................................................. 6 4.1 Loading & Clear-Coverage................................................................................................................................. 6 4.2 Multiple Pipes Conditions ................................................................................................................................. 7

5 Transportation ................................................................................................................................................................ 7 6 Ground Support............................................................................................................................................................... 8 7 Installation Procedure.................................................................................................................................................. 9

7.1 Trench Digging....................................................................................................................................................... 9 7.1.1 Overview......................................................................................................................................................... 9 7.1.2 Preparation & Specifications.................................................................................................................. 9 7.1.3 Stability ........................................................................................................................................................... 9 7.1.4 Groundwater.............................................................................................................................................. 10

7.2 Pipe Support Material ...................................................................................................................................... 10 7.2.1 Overview...................................................................................................................................................... 10 7.2.2 Bed & Haunch Layer ............................................................................................................................... 10 7.2.3 Side Layer .................................................................................................................................................... 11 7.2.4 Overlay Layer............................................................................................................................................. 11 7.2.5 Backfill Layer ............................................................................................................................................. 11

7.3 Ground Compaction.......................................................................................................................................... 11 7.4 Pipe Laying ........................................................................................................................................................... 12

7.4.1 Pipe Placing ................................................................................................................................................ 12 7.4.2 Pipe Joining................................................................................................................................................. 12 8 Reference Material...................................................................................................................................................... 13 8.1 Conversion Table ............................................................................................................................................... 13 8.2 Nomographs ? Inlet Control .......................................................................................................................... 14 8.3 Nomographs ? Outlet Control....................................................................................................................... 15 8.4 Load Carrying Capacity Graphs ................................................................................................................... 16

2| REINFORCED CONCRETE PIPES ? INSTALLATION MANUAL

1 Introduction

1.1 Products

Maddington Concrete Products (MCP) is a family-owned and operated Western Australian business which has been supplying high quality precast steel reinforced (SR) concrete pipes for industrial, commercial and domestic applications for more than 40 years. Built with the best dry-mix concrete techniques in the industry, MCP products have developed a reputation in the industry. Designed to specific users' requirements, they are now one of the best options in culvert and drainage applications.

This manual outlines the specifics of MCP manufactured pipes as well as a basic guideline to their installation in a range of conditions. Please refer to the general contents page for directions.

1.2 Manufacturing Sizes

MCP manufactures concrete pipes for a wide range of diameters. Table 1.1 outlines the range of diameters available. Refer to Figure 1.2 on the right hand side in order to better understand a concrete pipe's property variables.

Figure 1.1: The production facility's storage yard in Maddington, Western Australia

WALL THICKNESS

EFFECTIVE LENGTH

INTERNAL DIAMETER

OUTER DIAMETER

OVERALL LENGTH

SOCKET END JOINT

SPIGOT END JOINT

Figure 1.2: The variable properties of a concrete pipe

DIAMETER SIZE [mm] 300 375 450

600 750 900 1200

PRODUCT CODE

P01 P02 P03 P04 P05 P06 P07

OVERALL LENGTH

[mm] 2440 2440 2440

2440 2440 2440 2440

EFFECTIVE LENGTH [mm] 2340 2340 2340

2340 2340 2340 2340

Table 1.1: Range of SR concrete pipes available in stock or to order

WALL THICKNESS

[mm] 45 45 48

55 68 85 100

WEIGHT [kg]

310 390 470 690 1130 1700 2600

3| REINFORCED CONCRETE PIPES ? INSTALLATION MANUAL

1.3 Load Classes

The Australian Standard Code for precast concrete pipes (pressure and non-pressure), also referred to as AS/NZS-4058:2007, has classified SR concrete pipes in load classes ranging from 2 to 10, 10 being the products able to withstand the greatest applied loads.

MCP manufactures all of their concrete pipes for standard strength (Loading Class 4) according to AS/NZ-4058:2007 specifics.

It is important to remind the user that the test load to determine the loading class for a particular application should be determined in

accordance with the Australian Standard Code for design for installation of buried concrete pipes, also referred to as AS/NZS-3725:2007.

1.4 Durability

All SR concrete pipes manufactured at MCP are designed to comply with AS/NZ-4058:2007, and are therefore expected to have a service life of 100 years if installed following the proper procedure.

2 Performance Testing

In order to comply with the latest version of AS/NZ-4058:2007, routine performance tests are carried out on all diameter sizes produced at MCP. Pipes are tested, using appropriate testing equipment (see Figure 2.1), to withstand both proof loading (cracking) and ultimate loading.

Proof loading is the indicated load applied on a SR concrete pipe without the formation of cracks greater than the test cracks specified in accordance with AS/NZ-4058:2007. Ultimate loading is calculated as 1.5 the proof loading for standard strength classes, and 1.25 the proof loading for super strength classes. It represents the maximum designed load which the pipe can withstand before reaching structural failure.

Figure 2.1: The load testing facility in Maddington, Western Australia

The specifics for loading classes to which all pipes manufactured at MCP have to comply with can be found in Table 2.1.

DIAMETER SIZE [mm]

300 375 450 600 750 900 1200

STANDARD STRENGTH [kN/m]

CLASS 2

CLASS 4

PROOF ULT PROOF ULT

15

23

30

45

17

26

34

51

20

30

40

60

26

39

52

78

32

48

64

96

37

56

74

111

46

69

92

138

SUPER STRENGTH1 [kN/m]

CLASS 6

CLASS 8

PROOF ULT PROOF ULT

45

56

60

75

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Table 2.1: Test loads for various classes of SR concrete pipes according to AS/NZ-4058:2007

1 ? Upon request MCP can design and manufacture pipes to meet the super strength class

4| REINFORCED CONCRETE PIPES ? INSTALLATION MANUAL

3 Applications

3.1 Culvert

3.1.1 Overview

Culverts are short conduits used to pass water under roadways. They are constructed in circular, rectangular, and oval shapes. Concrete pipes manufactured by MCP can be used in culvert applications. The hydraulic analysis of culverts is complicated because the flow regime is variable. Section 3.1.2 outlines the basics in culvert hydraulics.

3.1.2 Hydraulics

There are 2 types of flow control for culverts: inlet control and outlet control. Generally if the culvert is operating on a steep slope, inlet control conditions can be assumed (Figure 3.1); if it is operating on a mild slope, outlet control conditions can be assumed (Figure 3.2).

HEAD WATER

DIAMETER

ROAD SURFACE FLOW

Figure 3.1: A culvert with inlet control operating conditions

HEAD WATER

ROAD SURFACE

DIAMETER

FLOW

HEAD

TAIL WATER

The flow rate through a culvert (Q) can be determined by multiplying the intensity of a storm by the catchment area the tributary feeds off from multiplied again by the coefficient of runoff. By combining this information with other geometrical and hydraulic variables, headwater levels can be determined using appropriate nomographs. Each form of flow control requires different inputs in order to determine a solution. Using these tools, a water engineer will be able to correctly select the most suitable pipe size to fulfill all regulations regarding water discharge.

V12/2G H1

UPPER REFERENCE LINE ENERGY LINE

WATER SURFACE

FRICTION

FLOW

HF V22/2G H2

LOWER REFERENCE LINE

REFERENCE

REFERENCE

POINT 1 H1 + V12/2G = H2 + V22/2G + HF CONSERVATION PRINCIPLE POINT 2

Figure 3.3: The principle of conservation of energy as outlined by Bernoulli

Figure 3.2: A culvert with outlet control operating conditions

3.2 Drainage

3.2.1 Overview

SR concrete pipes manufactured by MCP can be employed in the channeling and discharge of stormwater. Concrete pipes manufactured by MCP can be used in culvert applications. Rubber ring joints (RRJ) are employed in the connection of various pipe segments. For more details on the design of pipe joints consult Section 4.1.

3.2.2 Hydraulics

Drainage application systems of pipes can be dealt with using the Bernoulli Principle. Figure 3.3 outlines how the principle of conservation of energy can be used to assign a numerical value to unknown parameters. Using this tool, a water engineer will be able to correctly select the most suitable pipe size to fulfill the drainage requirements.

5| REINFORCED CONCRETE PIPES ? INSTALLATION MANUAL

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