Reinforced Concrete Pipe Your Name www concretepipe org
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Reinforced Concrete Pipe Your Name www. concrete-pipe. org Date Attributes
2 Our Industry’s Story & Product Attributes • • Historical perspective Important product attributes National standards & specifications Resources § Our company § Our people § Our industry association - ACPA www. concrete-pipe. org
3 Historical Perspective • Proven history = § Continued improvement of product and production methods § Long term knowledge & understanding by all stakeholders § Verifiable durability www. concrete-pipe. org
4 Continued Improvement • Early to mid XX 00’s = demand for more UG Piping to accommodate sewerage and storm water run-off § Oldest recorded RCP installation – xxxx in xxxxxx, NY § Still some RCP installations from late 1800’s in service today! www. concrete-pipe. org
5 Continued Improvement • Mid 1800’s to Early 1900’s § Prediction of runoff quantities better understood by engineers § XXXXX university developed methods for estimating XXXXX on pipe and methods to calculate supporting strength provided by XXXXX pipe culverts § Early 1900’s XXXX became a forum for improved quality of piping products § As US transportation needs - demand for RCP grew (50, 000 autos in 1905 grew to X million autos in US by 1918) § By 1930 all states using concrete pipe in their roadway systems! In 1930 approx. X million tons of RCP were produced www. concrete-pipe. org
6 Continued Improvement…Post 1930 • After great depression & WWII 4 million tons of RCP produced in 1950 • Advancement from 1930 -1970 § § Performance surveys verify durability of RCP Increased acceptance of RCP by specifiers Advancements in research & technology Production techniques & improved finish product quality • 10 million tons RCP produced annually by xxxx www. concrete-pipe. org
7 Continued Improvement…Post 1970 • 1970’s - XXX enters sanitary market • 1980’s – beginning of industry consolidation • 1980’s – XXXX begins push into storm drain market • 1990’s – RCP industry continues improvement of production methods and production machinery • See concrete pipe handbook to “read more about product & industry history” www. concrete-pipe. org
8 No better teacher than HISTORY & EXPERIENCE! Over a century of continued improvements in production & QC process provides best RCP ever produced www. concrete-pipe. org
9 Attributes of Concrete Pipe • Materials and manufacturing methods • Strength • Design & installation flexibility • Hydraulic efficiency • Durability www. concrete-pipe. org
Materials & Manufacturing Methods www. concrete-pipe. org
11 Materials Used to Make RCP • • • Portland cement (ASTM C XXX) XXXXX reinforcement Aggregates (XXXX & course) Water Typically materials combined to produce a mix with a very low xxxxx-cement ratio. Usually considered a “dry-mix” that produces a “x” slump. www. concrete-pipe. org
12 Basic Production Steps: • Storage of materials • Materials handling • Reinforcement cage production § Cage machines or wire rollers • Batching and mixing concrete • Pipe forming § Pipe forming methods – dry cast or xxxxx most common • Curing § Steam, water mist common methods used to control xxxx and moisture • Yarding and storage • See a plant tour! www. concrete-pipe. org
13 Pipe Forming Methods • Wet Cast • Dry Cast www. concrete-pipe. org
14 Vibratory Sources § Internal Hydraulic § External Pneumatic Electric Hydraulic www. concrete-pipe. org
15 Dry Cast 84”x 16’ www. concrete-pipe. org
16 Wire cage production by cage machine www. concrete-pipe. org
17 Computer controlled batching and manufacturing is common! See for yourself…. www. concrete-pipe. org
Structural Considerations www. concrete-pipe. org
19 A Buried Pipe Must Perform Two Critical Functions? XXXXXXX Buried Pipe XXXXX www. concrete-pipe. org
20 Structure Provided by Pipe Wall • RCP is designed, manufactured, tested, and installed as a rigid structure with a minimal portion of the loads present supported by the surrounding soil. The majority of the load is distributed too and supported by the pipe. • RCP installation structural strength = pipe wall strength + support from bedding • RCP wall can provide 95% of system strength! • Engineer/designer has flexibility to select how much support provided by pipe vs. bedding installation • Structure is tested at plant to confirm required structural strength! www. concrete-pipe. org
21 Strength Testing • A common method used to determine structural strength is to conduct a three-edge bearing test. • The load per linear foot which a pipe will support under this condition is termed the three-edge bearing strength. • This test is the most severe loading to which any pipe will be subjected. • There is no lateral support for the pipe, as provided under actual buried conditions, and the applied forces in the test are virtually point loads. • Specification reference: ASTM C 497 M - 96 www. concrete-pipe. org
22 3 EB Test www. concrete-pipe. org
23 D-Load Supporting strength of a pipe loaded under xxxxxx-xxxxxxx (xxx) test conditions, expressed in pounds per linear foot per foot of inside diameter or horizontal span when tested according to ASTM Cxxx. D 0. 01 = load (psf) to produce 0. 01” crack, 12” long DULT = load (psf) to cause structural failure www. concrete-pipe. org
24 Pipe Classification ASTM C-76 CLASS I D 0. 01 Dult 800 1, 200 CLASS II 1, 000 1, 500 CLASS III 1, 350 2, 000 CLASS IV 2, 000 3, 000 CLASS V 3, 000 3, 750 www. concrete-pipe. org
Example Class IV 60” Pipe D 0. 01 = 2, 000 Dult = 3, 000 Load 0. 01 = 5’ x 2, 000 lbs/ft/ft x 8’ = 80, 000 lbs. the. 01 Design Crack Load. Before ult = 5’ x 3, 000 lbs/ft/ft x 8’ = 120, 000 lbs. www. concrete-pipe. org 25
Structure Confirmed before Shipment 26 60” RCP is tested before it leaves the point of manufacture to prove it can carry the load of a loaded Tractor and trailer with no lateral support! www. concrete-pipe. org
27 Structure Conduit Concrete Pipe www. concrete-pipe. org
28 Facts of Structural Strength Component • Structural Strength Proven for over Century • No Other Storm Drain Pipe supports xxxx like RCP Pipe Wall does • Engineer has flexibility to depend more on Plant Tested xxx Vs Installation • STUCTURE IS TESTED & CONFIRMED ON FINISHED PRODUCT! www. concrete-pipe. org
29 Design & Installation www. concrete-pipe. org
30 Structural Design = Foundation of all Pipe System • • • Pipe” must be considered as a “bridge” Determine live and dead loading conditions How will pipe be installed Bedding support to be provided Predict the “Pipe” performance/Select pipe strength class www. concrete-pipe. org
31 Steps for Indirect Pipe Design (Determining Required Pipe Strength Class) • 1 - Select the method of installation (trench, embankment, etc. ) • 2 -xxxxx • 3 - Determine the live load • 4 - Determine the bedding factor (installation type: 1 – 4) • 5 -xxxx • 6 - Specify the class www. concrete-pipe. org
32 Installation Methods Trench www. concrete-pipe. org Negative Projecting Positive Projecting
33 Positive Projecting Embankment Negative Projecting Embankment TRENCH www. concrete-pipe. org
34 Installation Type Makes a Difference! • Xxxxxx Installation helps support load through frictional forces between trench wall and backfill. • Negative projection partial trench wall helps support similar to trench installation. • Positive projection embankment does not provide any resistance to loads • Conservative approach is to use xxxxx installation for designs www. concrete-pipe. org
35 Loads on Pipe • • Earth xxxx Construction Other www. concrete-pipe. org
36 Traffic Load R 1 Earth Load Final Backfill Haunching Initial Backfill Bedding Foundation www. concrete-pipe. org R 2 Rigid Pipe
37 Installation Flexibility w/RCP • Type I – IV SIDD Installations • Well defined structural backfill materials and compaction • Pressure distribution understood and conservative www. concrete-pipe. org
38 AASHTO- RCP Standard Installation (SIDD) Overfill H SW, ML, or CL Do/6 (MIN) Do Do (MIN) Excavation Line as required Haunch - see table Bedding see table Di Do/3 Outer Bedding Materials Foundation and compaction each side, same requirements as haunch. www. concrete-pipe. org Middle Bedding loosely placed uncompacted bedding except for Type 4
AASHTO Section 27 – Concrete Culverts 39 27. 5. 2. 2 -1. Structural Backfill §Type 1: Highest quality installation using select granular soils with high compaction requirements for haunching and bedding. §Type 2: Allows silty granular soils with less compaction required for haunching and bedding. §Type 3: Allows use of soils with less stringent compaction requirements for haunching and bedding. §Type 4: Allows use of onsite native material for haunching and bedding with no compaction required. (6” of Bedding is required if rock foundation) §All Backfill Requirements above to xxxxxx ONLY §Type 1 = Most Supporting structural strength §Type 4 = Requires 95% of structural strength to be provided by Pipe Wall www. concrete-pipe. org
40 Key Components Of Structural Backfill Of RCP §No compaction under invert. §Haunch Support: §compaction of material to spring line only §Assumes voids are present §adding additional safety factors §Rigid pipe does not require compaction of the overfill www. concrete-pipe. org
41 Gravity Pipe Classes AASHTO M 170 ASTM C 76 Class I D-Load. 01 800 D-Load Ult. 1200 II 1000 1500 III 1350 2000 IV 2000 3000 V 3000 3750 www. concrete-pipe. org
42 Steps for Determining the Required Pipe Strength Class • 1 - Select the method of installation (trench, embankment, etc. ) • 2 - Determine the earth load • 3 - Determine the live load • 4 - Determine the bedding factor (installation type: 1 – 4) • 5 - Calculate the required D-Load • 6 - Specify the class www. concrete-pipe. org
43 Resources for Finding Required Pipe Strength • Plug & chug - blue book • Fill height tables • Computer software Pipe. Pac 2000 www. concrete-pipe. org
44 Hydraulics l SEWERS Initial & Long Term l Full Flow Conditions l l CULVERTS Inlet Control l Outlet Control l www. concrete-pipe. org
45 Concrete Pipe Design Manual • Foreword • Index of Contents § Chapter 1 : Introduction § Chapter 2 : Hydraulics of Sewers § Chapter 3 : Hydraulics of Culverts § Chapter 4 : Loads and Supporting Strengths § Chapter 5 : Supplemental Data • Tables • Figures • Appendix www. concrete-pipe. org
46 Culvert Control Conditions • Inlet Control § Water can flow through the culvert at a greater rate than water can enter it § Inlet geometry only • Outlet Control § Water can enter the culvert at a greater rate than water can flow through it § Slope, roughness, length, inlet geometry, headwater, tailwater, & diameter www. concrete-pipe. org
Culvert Hydraulic Characteristics Inlet Control (inlet geometry only) 47 Outlet Control(everything else) H Hw Inlet Geometry D = Hw = Tw = D “n” Diameter Headwater depth Tailwater depth www. concrete-pipe. org So T w L L = n = So = Culvert Length Mannings roughness Slope
48 Basic’s- Our Hydraulic Advantage • The xxxx capacity (the amount of water a pipe can convey) of all types of storm sewer pipe depends on how smooth the interior pipe wall is. xxxx = More Capacity • Smoothness of pipe represented by Manning’s Roughness Coefficient commonly called xxxxxxx’x “x” • Smaller Manning’s “n” = smoother surface = more water through pipe. www. concrete-pipe. org
49 You must understand Manning’s “n” • Manning’s Equation can be used to determine barrel capacity of any culvert or open channel. Manning’s Equation is: 2/3 1/2 Q = 1. 486 X AR S n Q = discharge, cubic feet/sec A = cross-sectional area of pipe in square feet R = hydraulic radius in feet R = A/WP WP = Wetted Perimeter in feet = circumference of pipe in full flow S = slope, or grade in ft/ft n = manning’s n, coefficient of roughness www. concrete-pipe. org
50 Concrete Pipe Design Manual www. concrete-pipe. org
51 Importance of Manning’s “n” • Note the only variable in Manning’s Equation between RCP and the other products is the Coefficient of roughness Manning’s “n”. Lab Promoted RCP. 008 -. 010. 012 HDPE. 009 -. 015. 010 CMP. 012 -. 030. 012 -. 026 www. concrete-pipe. org Installed. 010 -. 011. 012 -. 020? ? . 021 -. 029
DURABILITY www. concrete-pipe. org
53 Proven Record of RCP • No other product commercially available today can provide the proven record of durability exhibited by RCP! • Oldest recorded installation of RCP in xxxxxx, xx still in service today! www. concrete-pipe. org
54 Why Does Durability Matter • Service life of product > project design life • FHWA – pavement design life of 50 yrs, bridges should have design life of 100 yrs • Shouldn’t culverts and storm sewer systems have service life as long as pavements and bridges? www. concrete-pipe. org
55 Research & Historic Performance Proves RCP Durability l. State Highway Departments l. Federal Highway Administration l. Corp of Engineers l. U. S. Bureau of Reclamation l. Soil Conservation Service l. Local Government Agencies l. Universities www. concrete-pipe. org
56 Service Life- Corp of Engineers Report §RCP-xx-xxx yr. §HDPE - Unknown §CONFIRMED §No more than xx yrs. §Corrugated steel with coatings or aluminum – no greater than xx years www. concrete-pipe. org
57 Factors that Influence Durability of RCP • Materials properties § § § Concrete compressive strength Xxxxxx Absorption/permeability Cement type Admix enhancements www. concrete-pipe. org
58 Factors that Influence Durability of RCP…. Cont. • Chemical & Physical Factors § § § Fire – Not RCP Acids (effluents and soil side) Sulfates Chlorides Freeze-Thaw Abrasion • In the Storm Sewer & Culvert environment most of the above listed durability factors are not of concern! www. concrete-pipe. org
59 National Standards & Specifications • Overview • RCP - national standards of importance § Materials, manufacturing, complimentary components, installation, test methods www. concrete-pipe. org
60 Overview - Specifications & Standards • Development process (who, why, & how) Chapter 8 of ACPA Concrete Pipe Handbook • ASTM & AASHTO are two of the most prominent Standard Associations www. concrete-pipe. org
61 Specs & Standards of Note. . • Materials for RCP – XXX, XXX • Manufacturing process – ASTM C xx & AASHTO M xxx • Test methods – ASTM C xxx & AASHTO T xxx • Installation of RCP – ASTM xxxx & AASHTO Sect. xx www. concrete-pipe. org
62 Let us be your Resource! • XXXX Company name and contact info • xxxxx. com Company website • We can provide: § § § Presentations Proper installation of RCP Structural design of RCP Competitive product comparisons Plant tours www. concrete-pipe. org
63 Other Resources! • ACPA Resources at www. xxxx -xxxx. org § § Research Tech. resources and information Education Design aid software www. concrete-pipe. org