CONCRETE PIPES - NICBM
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NIC ProductsHDPELimeStoneReady MixTiles & InterlockDry MortarCeramicsWhite BlocksConcrete PipesPaintsCladdingPlasticsBenches & Bowls
introductionThe National Industries Companys Concrete Pipe Factory is one of the largestmodern pipe factories in the Middle East. The Production capacity of the plantis approx. 250 metric Km per year.Its technology and comprehensive qulity control programme makes it apioneer in the field. Pipes are produced using semi-dry concrete mixes ina vertical cast method with the latest vibration technique. Fresh concretepipes are cured in heated kilns using thermal oil in a moist atmosphere.Raw materials for the production are procured and tested according toBritish standard specifications. Only tested raw materials shall be used forproduction. Aggregates and sand are washed in the factory before usage.1
The concrete pipe factoryproduces the followingPipes / Fittings1. Precast Non reinforced & Reinforced concrete pipes for open trench.2. Ancillary Products such as: Manhole rings. Road side Gulley & Shaft.3. HDPE / PVC / GRP lined concrete pipes for open trench.4. Precast Jacking / Micro tunneling concrete pipes.5. HDPE / PVC / GRP lined Jacking / Micro tunneling concrete pipes.6. Precast concrete box culvert / Barriers / Dolos / U-Shape Channel /Covers. etc.7. Intermediate Concrete Jacking pipes.USAGEConcrete pipes are used for: Storm drains. Sanitary sewers Irrigation distribution systems. low pressure sewer force mains. Treatment plant piping Jacked or tunneled systems. Ground water recharge systems.DIAMETERPipes are available in the following diameters:DN. 250, 300, 350, 400, 450, 500, 600, 700, 800, MM.DN. 900, 1000, 1200, 1400, 1600, 1800 & 2000 MM.Larger and other special diameters can be produced.LENGTHPipe DN 250 & 300 mm shall have a length of 1.250 meters.All other diameters from DN 350 to 2000 mm shall be in 2 meters.Pipes can be cut to any shorter length.2
APPLICABLE STANDARDS1. BS EN 1916:2002 & BS 5911-1:20022. ASTM C 76 specification for reinforced sewer and storm drain pipes.(Only on special requests)INTERNATIONAL & LOCAL APPROVALS ISO 9001 registered firm. M.P.W ApprovalQUALITY ASSURANCE Concrete pipe factory has an independent quality control department witha well equipped laboratory, aided by experienced staff to give thenecessary backup for the quality assurance program. Ministry of Public Work’s staff monitor all matters pertaining to the qualityof the products. A certificate of compliance is issued for each production.REINFORCEMENT Storm drainage pipes DN 250 to 600 mm are not reinforced as perB.S. standard. DN 700 mm and above are reinforced.JOINTS Joints of normal concrete pipes are of spigot and socket type with anelastomers ring. GRP / HDPE lined sewer drainage pipes have in wall flexible joints with anelastomeric ring.LAYINGRefer to concrete pipes laying instruction manual.3
GRP/HDPE LINEDCONCRETE,SEWER PIPE ANDMANHOLESGlass fibre reinforced plastic pipe(GRP) / high density polyethylene(HDPE) are durable and resistanceto acid, alkaline and salts.GRP / HDPE proved to be the mostsuccessful method to protect concretefrom the corrosive effects of sanitaryand industrial wastes. Continuity ofthe lining is assured by having in-wallflexible joints.When GRP / HDPE lines are installedin aggressive soils, external corrosionis avoided by coating the outer sideof the pipe with 400 micron of coaltar epoxy. Two types of sewer pipesare produced. One for open trenchlaying and the other for microtunelling/ jacking process4
BELL ODIDODCONCRETE PIPES FOR OPEN TRENCH LAYINGWITH SPIGOT & BELLEffective LengthPipe LengthNon-Reniforced Concrete 34042612501340spigot & bell1403005040049612501340spigot & bell1953506548058520002090spigot & bell4504007054066520002090spigot & bell5554507560074520002090spigot & bell6855008567082520002090spigot & bell85060010581093320002110spigot & bell1210Reniforced Concrete Weightkg6007575085820002110spigot & bellsingle9007008587098820002110spigot & bellsingle11208001001000112820002110spigot & bellsingle15009001101120128220002126spigot & bellsingle190010001151230141020002126spigot & bellsingle230012001301360170220002126spigot & belldouble320014001501700196220002126spigot & belldouble42505
IDODCONCRETE PIPES FOR OPEN TRENCH LAYINGWITHOUT BELLEffective LengthPipe LengthReniforced Concrete 4020002126spigot & socket in walldouble46501800190218020002126spigot & socket in walldouble58002000220244020002126spigot & socket in walldouble7700JointType
CONCRETE JACKING /MICRO TUNNELING PIPESLength 2000 mm55 651760mm65 55Inner DiameterOuter Diameter120240Reniforced Concrete mPipeLengthmm5001307606001258007
INTERMEDIATE CONCRETE JACKING PIPEIDOD2 LubricatingInserts at 180º3 Insterts at 120º2505516550 506570 80280LengthReniforced Concrete engthmm1600170194024003003000
CONCRETE MANHOLE RINGSIDIDOD640OD340300600Reniforced Concrete eelRingsNo.Weightkgspigot & socket in wall2300spigot & socket in wall3600JointType9
ROAD SIDE D SHAPE WERTICAL GULLEYA1150Reniforced Concrete GulleyLength: 1840 mm240Width: 1150 mmHeight: 450 mmWeight: 1070 kg1807307301801820REINFORCED CONCRETE SHAFT1030100010Pipe Diameter800 mmWall Thickness110 mmOuter Diameter1020 mmEffective Hight1000 mmTotal Hight1030 mmJointspigot & socket in wallSteel Rings8 ringsWeight700 kg
Joint:The Seal is a compression seal which is rolled into place.The G-ring as a roll jointStarting positionPipe material and design :Spigot-and-socket concrete pipe.A typical joint design is shown below.The pipes are pushed together.The G-ring rolls over half a turnFinished joint11
GRP INTEGRAL CONCRETE PIPES FOR OPEN TRENCH LAYINGWITH SPIGOT & BELLPipe Length130GRP LinerODIDBell ODSealingRubberEffective LengthNon-Reniforced Concrete 67082520002090spigot & bell85060010581093320002110spigot & bell1210Reniforced Concrete peWeightkg6007575085820002110spigot & bellsingle9007008587098820002110spigot & bellsingle11208001001000112820002110spigot & bellsingle15009001101120128220002126spigot & bellsingle190010001151230141020002126spigot & bellsingle230012001301360170220002126spigot & belldouble320014001501700196220002126spigot & belldouble4250
GRP INTEGRAL CONCRETE PIPES FOR OPEN TRENCH LAYINGWITHOUT BELL2126 mmSealingRingGRP LinerOuter DiameterInternal Diameter2000 mmReniforced Concrete 020002126spigot & socket in walldouble46501800190218020002126spigot & socket in walldouble58002000220244020002126spigot & socket in walldouble7700JointType13
HDPE INTEGRAL CONCRETE PIPES FOR OPEN TRENCH LAYINGWITH SPIGOT & BELLSteel CageConcreteSealingRubber2000mPipe ODPipe IDBell ODHDPE LinerPipe LengthNon-Reniforced Concrete 67082520002090spigot & bell85060010581093320002110spigot & bell1210Reniforced Concrete peWeightkg6007575085820002110spigot & bellsingle9007008587098820002110spigot & bellsingle11208001001000112820002110spigot & bellsingle15009001101120128220002126spigot & bellsingle190010001151230141020002126spigot & bellsingle230012001301360170220002126spigot & belldouble320014001501700196220002126spigot & belldouble4250
HDPE INTEGRAL CONCRETE PIPES FOR OPEN TRENCH LAYINGWITHOUT BELL2126 mmRubber RingHDPE PipeOuter DiameterInternal Diameter2000 mmReniforced Concrete 020002126spigot & socket in walldouble46501800190218020002126spigot & socket in walldouble58002000220244020002126spigot & socket in walldouble7700JointType15
GRP INTEGRAL CONCRETE JACKING /MICRO TUNNELING PIPES65655555140Effective Length 2000mm1760 mmGRP LinerOuter DiameterInner DiameterSealing Rubber240GRP Sleeve& Sealing RubberPacking RingReniforced Concrete erDiammPipeLengthmm500130760600125800** Outer joint with collar, Inner joint & bell type16
HDPE INTEGRAL CONCRETE JACKING /MICRO TUNNELING PIPES65655555140Effective Length 2000mm1760 mmHDPE Pipe LinerGRP Sleeve& Sealing RubberPacking RingOuter DiameterInner Diameter240Sealing RubberReniforced Concrete erDiammPipeLengthmm500130760600125800** Outer joint with collar, Inner joint & bell type17
REINFORCED CONCRETE TROUGH UNITU-Shape Trough300100100 mm70mm500mm650 htU-Shape Through3000 mm650 mm400 mmConcrete Cover500 mm650 mm100 mmOther products of the Concrete Pipes Factory18 U-Shape Concrete Channel & its Cover Manhole Box Culvert & etc,650 mm450 mm3000 mm
LAYINGINSTRUCTIONMANUAL19
LAVING INSTRUCTIONSfor precast concrete pipes and fittings ace. to BS 5911.1. DeliveryReinforced concrete pipes are carefully inspected before leaving the factory.Confirm that th consignment has been duly received on the delivery note,stating any damage which might have occured during transport.1.1 Transport & StackingFig. 1. Shows the correct method for transporting the pipes.Fig. 2. Shows the correct method for Stacking the pipes.20
1.2 Rubber gaskets supplied with the pipes should be stored in a cool, dryplace under no tension.Do not bring into contact with fuels or lubricants, chemicals, solvents etc. andkeep away from strong sunlight.2. Unloading and intermediate storageUnload the pipes with suitable hoisting units (with prec1s1on hoistingmechanism) using cables or straps (especially for outside coated pipes) (Fig. 3)Avoid setting the pipes down abruptly or knocking or rolling from a truck.Deposit the pipes on a firm base of squared timber and secure with wedges toprevent from rolling. (Fig. 2).WrongWrongRightFig. 3 Hoisting the pipe3. TrenchesThe width for sloped or sheeted trenches should comply with the regulations ofthe Ministry of Public Works (Fig. 4).b trench widthd outside pipeshaft diameterFig. 4. Sloped & sheeted trenches21
4. Laying4.1 BeddingThe bedding should be designed such that an equal distribution of pressure isguaranteed. Therefore, the whole length of the pipes should rest equally on thebedding. The soil at the angle of support (see item 4.1.1 & 4.1.2) shall have atleast the same density as at the bottom range of the pipes.However, it is advisable not to increase the natural density of the beddingat the trench bottom. This means that the trench bottom is to be compactedonly slightly before installation, but a better compaction is to be cared for thesupporting parts.Pipes with bell sockets need to have sufficiently large socket holes.Linear and point beddings are not permissible (Fig. 5)linear bedding (wrong)point bedding (wrong)Fig. 5. Linear and point beddingA concrete support is recommended, in case the natural soil is not suitable for asand or sand gravel bedding or if statical or other reasons demand it.For pipes with an outside coating , sand shall be used. In case of concretecradle or encasing, measures against buoyancy are to be taken.22
4.1.1. Bedding on natural soila) Pipes with circular cross section. Shape a bearing surface in the natural soil for the shaft of the pipesin accordance with the required angle of support 2 cc M.P.W. regulations. The pipe shall lie equally on thenatural soil. The socket should not rest on the soil (Fig. 6).Fig. 6. Bedding on natural soilb) Pipes with base.If the ground is suitable, laying on natural soil or on a support out of compactable material is possible.Normally the pipes are laid on a concrete slab, but at least on blinding concrete.4.1.2 Bedding on placed sand or gravel sand-Trench.Here the pipe trench should be excavated at least 100 mm. 1/1 0 DN deeper than the bottom level of thepipe. (Fig. 7). Introduce sand and fine gravel and compact in su9h a way that the pipe when laid lies squarelyand uniformly on the bedding at the given support angle 2oc M.P.W. regulations.After laying the pipe, always remember to remove all wedges, planks or boards used for aligning in order toavoid linear and point bedding.Fig. 7. Bedding on placed sand or gravel sand23
- Embankment:Only possible when compaction of embedding is done on natural soil.Fig. 8. EmbankmentIn case of bedding on hard subground, e.g. rock or strongly compacted gravel,the thickness of support is to be increased to 100 mm 1/4 DN. See (Fig. 9).Fig. 9. Avoid linear and point bedding24
4.1.3 Bedding on concrete cradle supportIf M.P.W. regulations required, for example for very compact subground or rock,the concrete support at the bottom level shall be 50 mm 1/4 DN, but at least100 mm thick (Fig. 10).The concrete support is made out of concrete K 100, or, K150 if reinforcementis required.Fig. 10. Concrete cradle support with monolithic bottom slab25
4.1.4 Concrete encasingConcrete encasing is made to increase bearing capacity of the pipe. It mightbecome reasonable to subdivide the encasing at proper distances at the pipejoints by gaps.Fig. 11. Partial encasingFig. 12. Complete encasing4.2 Pipe joint4.2.1 Rubber gasket ringsOnly the rubber rings delivered together with pipes may be used. Beforeinstallation they are to be thoroughly cleaned and wipped off. The pipe sealingsurface at the bell and spigot is also cleaned and wipped off ( ). (Fig. 13)The gasket ismounted on thespigot, ensuringthat it is not twistedand is underuniform tension.Fig. 13. Cleaning & Wipping offFig. 14. Installing Rubber Gasket Rings26
4.2.2 Jointing of pipesThe pipe, hanging horizontally on the hoisting unit (with precision hoistingmechanism), is pulled towards the already laid pipe until the rubber ring isequally situated at the bevelled side of the socket.Fig. 15. Jointing of Pipes-Centric introduction into the socket in the straight elongation of thepreviously laid pipe.-Equal and slow contraction with pulling unit or other equipment. The pipeshould hang freely.-As a standard value for the force is equal to the pipe weight.-During the contraction the straight position of the pipe towards the laid pipeis to be guaranteed.After the contraction, the position of the pipe concerning the inclination andthe direction should be checked and corrected (the pipe is still hanging on thehoisting unit). Minor deflections of the socket are now possible. The positionedpipe is fastened with wedges and finally underfilled.27
4.2.3. Pipe Joints-Roll-on gasket (Fig. 16)The rubber ring is mounted on the notch at the spigot end. Do not useLUBRICANTS for roll-on gaskets. During contraction, the rubber ring should rollin equally.If the rubber ring rolls in unevenly or it slides (when contacted with moisture)the socket might burst. The pipe has to be drawn out and inserted a newrubber ring.Fig. 16. Roll-on gasket28
4.2.4 Gap width and pipe deflectionThe gap width between the ends of the pipes shall be at least 5 mm, but onaverage, depending on the pipe diameter, 1 0 to 20 mm, as spacers wedgesmay be used and removed later. After the centering of the pipes and before theconstruction of the pipe support a deflection can be made in the permissiblesize, if necessary.The maximum permissible deflections are:DN250- mThe maximum permissible gap width depends on the pipe diameter and theshape of the socket (consult pipe factory).29
5. Testing of Watertightness of PipelinesBefore embedding, it is to be assured that the pipeline is in the correct position.5.1 Testing of pipelinesThe test for watertightness of the pipeline out of concrete and reinforcedconcrete pipes may be made with the complete pipeline, sections of the pipeline(Fig. 17)The pipeline shall be tested before backfilling. In order to prevent buoyancy orthe sliding of the pipeline, it may be covered partially. The pipe joints need toremain free. Close the pipeline at the ends of the section to be tested as wellas all inlets and branches with adequate cover slabs. At the cover slabs, bends,branches and other fittings where forces might occur during tests, have to besecured thoroughly, i.e. supported against firm abutments.In order to avoid damages of the pipes, the line shall be filled without pressurefrom a water tank or a water truck. The pipeline to be tested must not haveany connection with a pressure pipeline. The pipeline must be filled by enoughtime before testing. The pipelines are tested with an internal pressure of max0.15 bar for 15 minutes or If necessary, water can be added continuously. Thepipeline is watertight, whenever the added amount of water during the testingperiod of 15 minutes does not exceed the values listed in (table 1) and when thepipe joints remain tight.Fig. 17 Pipeline Test Procedure30
Inside diameterInside surfaceWater additionmm2m 00.63Table 1. Permissible addition of water for concrete and reinforcedconcrete pipes.5.2 Testing of single pipe jointsFor pipes with diameters exceeding1000 mm the single pipe joints canbe tested with certain socket testinginsturments. (Fig. 18). Tne pipes ofthe section to be tested should besecured against lateral shifting.A classification with water additionvalues is not possible for single pipejoints. The tightness is proven whenno water is leaking out of the pipejoints.A slow decrease of pressure ispermissible.Fig 18 Testing device for thesingle joints31
6. Embedding and Backfilling6.1 Pipe support and emb
ASTM C 76 specification for reinforced sewer and storm drain pipes. (Only on special requests) inTernaTional & local approVals ISO 9001 registered firm. M.P.W Approval QualiTy assurance Concrete pipe factory has an independent quality control department with a well equipped laboratory, aided by experienced staff to give the necessary backup for the quality assurance program .
HDPE pipes with shut off valves or butter fly valves. "NIC HDPE" corrugated pipes with circular corrugation have integral built-in bell for pipe sizes 200mm & above. For pipe size 100 to 150mm, a special coupler is fixed on one end of pipe. Pipes are supplied with factory installed rubber gasket at spigot end.
the welding equipment. There is no 4G position for pipes. 5G position -For pipes only, both pipes are horizontal. The pipe cannot be turned or rolled while welding. 6G position -F or pipes only, both pipes are on an inclined axis (45 5 ) and the pipes cannot be turned or rolled.
Types of coupling connections Table A2 A2.4 A2.5 A2.3 for connecting threated pipes to FibreFlex pipes for connecting welded steel pipes to FibreFlex pipes for the straight connection of two FibreFlex pipes FibreFlex Pro Press Thread Adaptor FibreFlex Pro Press Weld Adaptor FibreFlex Pro Press Coupler FibreFlex Pro Press Coupler A2.5 FibreFlex Pro
special piping materials such as glass or lined pipe 3.2 Concrete and Ceramic Pipes Pipes may be made from concrete or ceramic materials. These pipes are usually used for low pressure applications such as gravity flow or drainage underground. Concrete
Concrete Beams 9 Lecture 21 Elements of Architectural Structures ARCH 614 S2007abn Reinforced Concrete - stress/strain Concrete Beams 10 Lecture 21 Elements of Architectural Structures ARCH 614 S2007abn Reinforced Concrete Analysis for stress calculations steel is transformed to concrete concrete is in compression above n.a. and
Redi-Mix Concrete, LLC 10K11521 . While EPDs can be used to compare concrete mixtures, the data cannot be used to compare between construction products or concrete mixtures used in different concrete products unless the data is integrated into a comprehensive LCA. For example, precast concrete, concrete masonry units and site cast concrete all .
HDPE HDPE y Since 2002 HDPE r ge ter System HDPE or Cold ter y & tion HDPE or ble Duct HDPE or Sea ter e HDPE or Gas tion et ps Manholes. NIC Products HDPE LimeStone Ready Mix Dry Mortar . "NIC HDPE" drainage & sewage pipes are produced as per international standard EN 1519, DIN 19535 & DIN 19537. It can be used inside building for .
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