CONCRETE PIPE AND PORTAL CULVERT HANDBOOK
CONCRETE PIPE ANDPORTAL CULVERT HANDBOOKP.I.P.E.SPipes, Infrastructural Products andEngineering Solutions Division5th Edition 2009
PREFACEConcrete pipes and portal culverts are the most frequently used and accepted products for stormwater drainage,culverts, outfall sewers and many other applications. To meet these needs South Africa’s concrete pipe industry hasgrown tremendously over the past eighty years.Modern technology and the acceptance of SABS standards ensure that products with consistently high quality areproduced. Provided sound design and installation methods are followed, these products will give the desired hydraulicand structural performance over a long service life.This handbook is intended to cover all aspects of concrete pipe and portal culvert selection, specification, and testing.As a handbook it does not attempt to replace textbooks or codes, but rather to complement them by providing theinformation needed for quick site decisions and guidance for designers to ensure that all aspects of product use areconsidered. A companion publication ‘The Concrete Pipe and Portal Culvert Installation Manual‘ deals with productinstallation.Publications by the American Concrete Pipe Association have been used freely and acknowledgement is hereby madeto this organisation.The Pipes, Infrastructural Products and Engineering Solutions (PIPES) Division of the Concrete Manufacturers Associationhas had this handbook prepared for the guidance of specifying bodies, consultants and contracting organisationsusing concrete pipes and portal culverts manufactured in accordance with the relevant SABS standards. The Divisionexpresses appreciation to A.R. Dutton & Partners for the preparation of the original Concrete Pipe Handbook to whichadditions and amendments have been made to produce this publication.Published byConcrete Manufacturers AssociationBlock D, Lone Creek, Waterfall Office Park,Bekker Road, MidrandTelephone: 27 11 805 6742Fax: 27 86 524 9216Email: main.cma@gmail.comWebsite: www.cma.org.zaFifth Edition 20095th Edition 2009Revised by A. GoynsPIPES ccP O Box 12519Clubview0014
CONTENTSINTRODUCTION8.2.FLOATATION BEFORE BACKFILLING341.1.OBJECTIVE28.3.FLOATATION AFTER BACKFILLING341.2.SCOPE29.SEWER CORROSION2.PRODUCT CLASSIFICATION9.1.CORROSION MECHANISM2.1.STANDARDS29.2.CORROSION PREDICTION2.2.CONCRETE PIPES2AND CONTROL352.3.PORTAL CULVERTS49.3.DEVELOPMENTS IN SOUTH AFRICA362.4.MANHOLES69.4.DESIGN AND T CLASSIFICATION63.2.HYDRAULIC LENGTH73.3.PRESSURE PIPELINES73.4.SEWERS ANDSTORMWATER OUTFALLS3.5.3.6.8PIPE MATERIAL CHOICEFOR SEWERS9.6.ALLOWABLE CRACK WIDTHS10.41PORTAL CULVERT STRENGTHS10.1. GENERALSTORMWATER CULVERTS10.2. DETERMINING PORTAL939SACRIFICIAL THICKNESS ANDHYDRAULICS OFPOROUS PIPES3841CULVERT STRENGTHS4210.3. PORTAL BASE SLABS44154.LOADS ON BURIED PIPELINES4.1.INTRODUCTION1611.4.2.EARTH LOADS1711.1. WATER TEST444.3.TRAFFIC LOADING2111.2. AIR TESTING4511.3.455.CONCRETE PIPE STRENGTHS5.1.EXTERNAL LOADS235.2.INTERNAL PRESSURE245.3.SAFETY FACTORS255.4.SELECTION OF THECONCRETE PIPE CLASS6.BEDDING6.1.GENERAL6.2.TRENCH AND NEGATIVEPROJECTION INSTALLATIONS6.3.FIELD TESTINGSOIL DENSITY TESTBIBLIOGRAPHY47252627POSITIVE PROJECTIONINSTALLATIONS306.4.SOILCRETE BEDDING316.5.JACKING CONDITIONS327.PIPE JOINTING7.1.JOINT TYPES7.2.BUTT AND INTERLOCKING32JOINT PIPES337.3.SPIGOT AND SOCKET JOINTS337.4.IN-THE-WALL JOINTS338.FLOATATION8.1.GENERAL1345th Edition 2009
as South African National Standards (SANS) and willretain their numbers. This document uses the latter.1. INTRODUCTION1.1.OBJECTIVEThe purpose of this handbook is to give the users,designers, specifiers and installers of precast concretepipe and portal culverts the basic guidelines for thecorrect use, selection and specification of theseproducts. A companion publication “The Concrete Pipeand Portal Culvert Installation Manual” gives details ofhow these products should be installed.1.2.SCOPEThe content of this handbook covers the pre-constructionactivities associated with precast concrete pipe andportal culverts, namely those undertaken by the designerof the project. Descriptions are given of the basic theoryneeded for determining: product sizeproduct strengthproduct durabilityspecial product featuresThe basic formulae, diagrams and tables support this. Thisinformation is adequate for most product applications.However, the theory given is by no means rigorous. Thereader is advised to consult the relevant textbooks orcodes, should a detailed analysis be required. A list ofuseful publications is given at the end of this handbook.2. PRODUCTCLASSIFICATION2.1.Codes of practice that detail how product size,strength and durability should be selected.Product standards that prescribe what productrequirements have to be met.prescribehowThe South African Bureau of Standards (SABS) has beenrestructured. The division dealing with the production ofstandards is Standards South Africa (StanSA). All thepreviously designated SABS standards are to be renamed5th Edition 2009ScopeNormative referencesDefinitionsMaterials usedRequirements to be metSampling and complianceInspection and test methodsMarkingNormative and informative annexures.Most factories operated by the PIPES Division membercompanies have approved quality management systemsto ensure that products comply with the relevant SANSspecifications. In addition to this GCS, does frequentaudits to check that standards are being maintained.These standards are periodically reviewed to ensurethat marketplace requirements are met.2.2.CONCRETE PIPES2.2.1.StandardsSANS 676 - Reinforced concrete pressure pipesSANS 677 - Concrete non-pressure pipesThere are three groups of standards which are applicableto precast concrete pipe and portal culverts, namely:2 Currently there are two South African national standardsapplicable to concrete pipe:STANDARDSConstruction standards thatproducts should be installed.The division dealing with the issuing of manufacturingpermits and the auditing pf production facilities is GlobalConformity Services (GCS). The products covered by thispublication comply with the requirements of relevant(SANS) document. These are performance specificationsthat detail the properties of the finished products needed toensure that they are suitable for their required application.All these standards have the same basic layout, namely:The code of practice for the selection of pipe strength is:SANS 10102 - Part 1: Selection of pipes for buriedpipelines: General provisions- Part 2: Selection of pipes for buriedpipelines: Rigid pipesThere are no standards for determining the size ordurability of concrete pipe. If the reader requires moredetail than given in this publication, reference should bemade to the appropriate literature, some of which isdetailed at the end of this publication.The standards for the installation of concrete pipe areincluded as sections in SANS 1200 standardized specificationfor civil engineering construction. These sections are:
2.2.DB - Earthworks (pipe trenches)L - Medium pressure pipe linesLB - Bedding (pipes)LD - SewersLE - Storm water drainageLG - Pipe jackingTABLE 1: STANDARD D-LOAD CLASSIFICATION FORCONCRETE PIPESPipe ClassD-LoadPipe classesNon-pressure pipePipes are classified in terms of their crushing strengthwhen subjected to a vertical knife-edge test-load. Thetwo alternative crushing load test configurations areshown in Figure 1 (a) & (b).Figure 1: Crushing load test configurations forconcrete pipe(a) Two edgebearing test(b) Three edgebearing testThe three edge-bearing test is preferred as thepipe is firmly held in place by the bottom twobearers before and during the test. With the twoedge bearing test there is the danger that the pipecould slip out of the testing apparatus or might notbe perfectly square when tested.The proof load is defined as the line load that a pipecan sustain without the development of cracks of widthexceeding 0.25 mm or more over a distance exceeding300 mm, in a two or three edge bearing test. Nonreinforced pipes are not permitted to crack under theirproof load.Proof loadkN/mUltimate 100D100xD125.00xDExample:For a 1050 mm diameter 75D pipe proof load 1.05x 75 78.75 kN/m ultimate load 1.05 x 93.75 98.44 kN/mPipes made in accordance to SANS 677 are dividedinto two types, SC pipes for stormwater and culvert applicationsSI pipes for sewer and irrigation applications.SC pipes are used in applications where there is no internalpressure. A small sample ( 2%) of pipes is subjected tothe crushing strength test to prove that they meet thestrength required. SI Pipes, on the other hand, are usedin applications where there could be internal pressureunder certain conditions (as when blockages occur). Toensure that the pipes will meet this possible conditionand ensure that the joints are watertight, a small sampleof pipes is hydrostatically tested to a pressure of 140kilopascals in addition to the crushing strength test.Table 2 gives proof loads of the preferred nominaldiameters given in SANS 676 and 677.TABLE 2: PREFERRED CONCRETE PIPE DIAMETERSAND PROOF LOADS IN- KN/MD Loads in Kilonewtons/mNominal PipeDiameter-mm he ultimate load is defined as the maximum lineload that the pipe will support in a two or three edgebearing test and shall be at least 1.25 times theproof 41.362.082.590022.545.067.590.0The standard crushing load strength designation isthe D-load (diameter load). This is the proof load inkilonewtons per metre of pipe length, per metre ofnominal pipe diameter. The standard D-load classeswith their proof and ultimate loads are given inTable 1.1 05026.352.578.8105.01 20030.060.090.0120.01 35033.867.5101.3135.01 50037.575.0112.5150.01 80045.090.0135.0180.05th Edition 20093
Notes1) Pipes with diameters smaller than 300 mm, or largerthan 1 800 mm are made at some factories.2.3.PORTAL CULVERTS2.3.1.Standards2) Strengths greater than 100D can be producedto order.The standard for precast concrete culverts is SANS986, precast reinforced concrete culverts.3) Most pipes are made in moulds with fixed outsidediameters. The designer should check minimumthe internal diameters to ensure that requirementsare met.There is no National code of practice for theselection of portal culvert size or strength. However,the biggest single group of users, the national andprovincial road authorities, require that portal culvertsunder their roads meet the structural requirementsof TMH7, the Code of Practice for the Design ofHighway Bridges and Culverts in South Africa. Thelocal authorities generally adhere to the requirementsof this code. This document also gives guidelines forproduct durability.Pressure pipePressure pipes are classified in terms of their hydraulicstrength when subject to an internal pressure testunder factory conditions.Hydraulic strength is defined as the internalpressure in bar that the pipe can withstand for atleast 2 minutes without showing any sign of leakage.The standard hydraulic strength designation is thetest (T) pressure. The SANS 676 pressure classesare given in Table 3.The standards for the installation of precast portalculverts are included in sections 1200DB and 1200LEof the SANS 1200 series.TABLE 3: STANDARD PRESSURECLASSES FOR PIPEPipe class4Test pressureBarsIf more detail than provided in this document isrequired, reference should be made to the appropriateliterature, some of which is listed at the end ofthis 101 0002.3.2.Portal Culvert ClassesPrecast portal culverts are classified in termsof their crushing strength, when subjected to acombination of loading cases involving verticaland horizontal knife-edge test-loads under factoryconditions. The proof and ultimate loads are definedin the same way as for pipes with the ultimate loadsbeing 1.25 times the proof loads for the particularloading configurations.Special-purpose pipeMany pressure pipelines are installed at a nominal filland where they are not subject to traffic loads. Underthese circumstances the hydraulic strength designation,given in Table 3, is adequate.The standard crushing strength designation used isthe S-load. (Span-crushing load) This is the verticalcomponent of the proof load in kilonewtons that a1metre length of culvert will withstand, divided by thenominal span of the portal culvert in metres.However, when a pipeline is subject to the simultaneousapplication of internal pressure and external load, thepipes will need to sustain a higher hydraulic pressureand crushing strength than when service loads areapplied separately.There are three different loading configurations that areapplied to precast portal culverts to model the installedconditions, namely:Under these conditions the pipes will be classified asspecial-purpose pipes and the required hydraulic testpressure and crushing strength to meet the requiredinstalled conditions will have to be calculated. Thesepipes must be specified in terms of both their D-loadand T-pressure values.5th Edition 2009 Deck bending moment and swayDeck shearInner leg bending moment and shearThese configurations are shown respectively inFigure 2(a), (b) and (c) below and the standard S-loadclasses with their proof load requirements are givenin Table 4.
Figure 2: Load test configurations for precast portal culvertsPPVV PPVvPPhh PPhhPPPSsS PSPPPhlh1hl Phl(a) Deck bendingmoment and sway(b) Deck shear(c) Inner leg bendingmoment and shearTABLE 4: STANDARD S-LOAD CLASSIFICATION FOR PORTAL CULVERTSProof loads - kN/m of lengthCulvert classS-LoadVerticalLeg Proof loads - kN/m of lengthHorizontalHeight S/275 x SHeight S75S75 x S300.4 x0.60 x75 x S100S100 x S300.3 x 100 x S0.50 x 100 x S125S125 x S300.2 x 125 x S0.45 x 125 x S150S150 x S300.2 x 150 x S0.43 x 150 x S175S175 x S300.2 x 175 x S0.40 x 175 x S200S200 x S300.2 x 200 x S0.40 x 200 x SNote: S is the nominal span in metres.Table 5 gives the vertical and horizontal proof loads obtained by applying the classification in Table 4 to the preferredportal culvert dimensions given in SANS 986. A table similar to Table 5 can be obtained by application of the values inTable 4 to obtain the inner leg bending moments and shears. It should be noted that there will be two different valuesof the horizontal load for each culvert span and class, i.e. when 0.5 H/S 1.0 and H/S 1.0. When H/S 0.5no horizontal leg load is required.TABLE 5: PREFERRED PORTAL CULVERT DIMENSIONS AND PROOF LOADSVertical proof loads in kN/m of lengthCulvertspan mm450Culvert 270.0----Horizontal proofload allclasses kN/mCulvert Class3055th Edition 2009
2.4.MANHOLES2.4.1.StandardsThe standard for precast concrete manhole sections,slabs, lids and frames is SANS 1294.Figure 3: Conduit flowing fullTotalTotal energyenergy linelineHydHydraulicraulic gradgradee linelinehhffvvv2–22g2gg2 2The standard manhole dimensions are hardmetric, namely: 750 mm diameter - used as shaft sections1 000 mm diameter - normally used aschamber sections1 250 mm diameter - used as chamber sections1 500 mm diameter - used as chamber sections1 750 mm diameter - used as chamber sectionsStreStreamlineamlinePipePipe invertinvertDatDatumumThese sections are available in lengths of 250 mm,500 mm, 750 mm and 1 000 mm.In the past manholes were produced in soft metricdimensions. Hence when components have to bereplaced it is essential that actual details and dimensionsbe checked before ordering replacements as old sizesare no longer available and it may be necessary toreplace the whole manhole.Currently SANS 1294 is being revised. When thisstandard is released, a detailed section on manholeswill be added to this publication.3. HYDRAULICS3.1.CONDUIT CLASSIFICATIONConduits conveying fluids are classified by variousparameters, namely, whether:They flow as open channels or closed conduitsThe flow is uniform, in which case the flow depth,velocity and discharge along the whole length ofthe conduits are constant. If not uniform, the flowis variedThe flow is steady in which case the flow past agiven point has a constant depth, velocity anddischarge. If not steady, the flow is unsteady.6A pipeline conveying potable water or other fluidsgenerally flows full and operates under pressure andthe flow is both uniform and steady. The total energyin such a system will have three components, namelyconduit height or diameter, velocity head and pressurehead as shown in Figure 3.5th Edition 2009hhppzzThe total energy at any point along a conduitoperating under pressure can be defined byBernoulli’s equation:H z d/2 hp v2/2gWherez - height of invert above datum ind -conduit height or diameter in mv - velocity in m/sg - gravitational constant in m/s/shp - pressure head in pipeline in mhf - energy loss due to friction in mAs there is pressure in such a conduit, the fluidcan be carried uphill provided the value of “hp”stays positive. Such a system is classified as apressure pipeline.On the other hand, a conduit conveyingstormwater or sewage generally flows partlyfull and the flow is frequently both varied andunsteady. There is an air/fluid interface andtherefore, no pressure component to the totalenergy as shown in Figure 4.Figures 3 and 4 show systems where the pipe invert,hydraulic grade line or water surface and the totalenergy line are all parallel. This is called uniform flowand the only energy losses are due to friction. Howeverif there are any transitions such as changes in verticalor horizontal alignment, or the crossectional shape ofthe conduit then these will also cause energy losses dueto the liquid expanding or contracting.The means of determining the hydraulic properties ofconduits flowing under pressure and those flowing partlyfull, as open channels are understandably different.A further factor that needs to be considered is thehydraulic length of the conduit.TheThe totaltotal enereneroperatingoperating undundBernoulli’sBernoulli’s eqeqHH zzWhereWhere zz -- heigheidd -- cocovv -- vevegg -- gragrhhpp -pr-prhhff -en-en
before and after the transition. For most applicationsthe use of a coefficient as shown in the formula below,is adequate:Figure 4: Conduit flowing partly fullTotal energy lineWater surfacePipe inverthf2vv22g–2g2The total energy atHanypoint k(v/2g)along a conduit flowingLpartly full can be defined by the Energy equation:2where/2g loss in metres (m)H yH L- vheadkaWhere y - depth ofcoefficient,flow in musually between 0.0 and 1.0dependentv - velocity in m/s upon transition detailsv - velocity inconstantmetres persecond (m/s)g - gravitationalin m/s/sg - the gravitational constant in metres persecond per second (m/s/s)yDat umThe total energy at any point along a conduitflowing partly full can be defined by the energyequation:H y v2/2gWhereHYDRAULIC LENGTHThe hydraulic length of a conduit is determined by therelationship between the energy losses due to frictionand those due to transitions. When the energy lossesdue to friction exceed those due to transitions then theconduit is classified as hydraulically long. When thosedue to transitions exceed those due to friction then theconduit is classified as hydraulically short. In general apipeline is hydraulically long whereas a culvert crossingis hydraulically short.The energy losses due to friction are determined usingone of the friction formulae, such as Manning, tocalculate the velocity through the conduit. Manning’sequation is given below:v 1/n(R)2/3S1/2whereTABLE 6: ENERGY LOSS COEFFICIENTSFOR PIPELINE FLOWEntrance or outlet 0Bevelled0.250.50Round
SANS 1200 DB - Earthworks (pipe trenches) SANS 1200 L - Medium pressure pipe lines SANS 1200 LB - Bedding (pipes) SANS 1200 LD - Sewers SANS 1200 LE - Storm water drainage SANS 1200 LG - Pipe jacking 2.2.2. Pipe classes Non-pressure pipe Pipes are classified in terms of their crushing strength when subjected to a vertical knife-edge test-load. The
IV. PIPE CULVERT Pipe culvert may be a single or multiple pipes; therefore, if it’s used a single culvert, then a large diameter culvert is required if the width of the water channel becomes greater than multiple pipe culvert is going to use in that place. The multiple pipe culvert i
Concrete Box Culvert and Corrugated Metal Pipe Culvert Program (Region 2 Bundle) Colorado is one of the fastest growing states in the country, and with that growth comes significant strain on aging transportation systems that has significant and tangible consequences in the form of growing safety and mobility problems. The rural highways which
1. Single W-beam guardrail with one short post midspan over culvert, 2. Nested W-beam guardrail with one short post midspan over culvert, 3. Single W-beam guardrail with Jong span across culvert, and 4. Nested W-beam guardrail with long span across culvert. The culvert was assumed to have a minimum soil cover of 18 in. (45.7 cm).
An existing SRH-2D model will be used to facilitate the setup for this tutorial. SRH-2D provides two different ways to define a culvert. The recommended method to simulate a culvert in SRH-2D is to couple the FHWA HY-8 culvert model with SRH-2D. This tutorial will demonstrate this. The second approach for simulation of a culvert involves
ASTM C76 - Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe . C. ASTM C150 - Portland Cement . D. ASTM C443 - Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets . E. . 3.2 PIPE INSTALLATION A. Inspect pipe and accessories for defects before lowering into trench. B. Replace any defective, damaged or unsound pipe. .
PRECAST CONCRETE BOX CULVERT INTRODUCTION This paper presents a suggested procedure for the proper installation of precast concrete box culvert. It is simply a guide. Procedure-wise, it is not all-inclusive and is not intended to supersede project specifications. Federal regulations covering safety for all types of construction, including sewer and
May 15, 2011 · Prior to 1970, this pipe was known as American concrete cylinder pipe or P-381. From 1970 to 1995, it was marketed as Concrete Cylinder Pipe or Pretensioned Concrete Cylinder Pipe (P-303). Since 1995, it has been marketed as Bar-Wrapped Pipe or “BWP”, Concrete Cylinder Pipe
CONCRETE CULVERT DESIGN AND DETAILING MANUAL 2003 03 14 INTRODUCTION Page 1 1 INTRODUCTION 1.1 GENERAL The Concrete Culvert Design and Detailing Manual have been prepared to facilitate the design and detailing of standard rectangular concrete culverts. 1.2 DIVISIONS This Manual is divided up into the following divisions: Division 1 Introduction
