Transcript RCP attributes - American Concrete Pipe Association

Your Name
Date
Reinforced Concrete Pipe
Attributes
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Our Industry’s Story & Product
Attributes
•
•
•
•
Historical perspective
Important product attributes
National standards & specifications
Resources
 Our company
 Our people
 Our industry association - ACPA
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Historical Perspective
• Proven history =
 Continued improvement of product
and production methods
 Long term knowledge &
understanding by all stakeholders
 Verifiable durability
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Continued Improvement
• Early to mid XX00’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!
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Continued Improvement
• Mid 1800’s to Early 1900’s
 Prediction of runoff quantities better
understood by engineers
 XXXX 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
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Continued Improvement…Post
1930
• After great depression & WWII 4 million tons
of RCP produced in 1950
• Advancement from 1930-1970
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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
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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”
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No better teacher than HISTORY & EXPERIENCE!
Over a century of continued improvements in
production & QC process provides best RCP ever
produced
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Attributes of Concrete Pipe
• Materials and manufacturing
methods
• Strength
• Design & installation flexibility
• Hydraulic efficiency
• Durability
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Materials &
Manufacturing
Methods
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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.
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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 xxxxxxxxx most
common
• Curing
 Steam, water mist common methods used to control
xxxx and moisture
• Yarding and storage
• See a plant tour!
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Pipe Forming Methods
• Wet Cast
• Dry Cast
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Vibratory Sources
 Internal Hydraulic
 External Pneumatic
Electric Hydraulic
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Dry Cast
84”x 16’
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Wire cage
production by cage
machine
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Computer
controlled
batching and
manufacturing
is common!
See for
yourself….
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Structural Considerations
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A Buried Pipe Must
Perform Two Critical
Functions?
XXXXXXX
Buried Pipe
XXXXXXXXX
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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!
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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
C497M - 96
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3EB Test
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D-Load
Supporting strength of a pipe
loaded under xxxxxx-xxxx
xxxxxxx (xxx) test conditions,
expressed in pounds per
linear foot per foot of inside
diameter or horizontal span
when tested according to
ASTM Cxxx.
D0.01 = load (psf) to produce
0.01” crack, 12” long
DULT = load (psf) to cause
structural failure
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Pipe Classification
ASTM
C-76
CLASS I
D0.01
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
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Example
Class IV 60” Pipe
D0.01 = 2,000
Dult
= 3,000
Load0.01
= 5’ x 2,000 lbs/ft/ft x 8’ =
80,000 lbs.
the .01 Design Crack
LoadBefore
ult
= 5’ x 3,000 lbs/ft/ft x 8’ =
120,000 lbs.
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Structure Confirmed before
Shipment
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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!
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Structure
Conduit
Concrete Pipe
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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!
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Design & Installation
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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
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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 -xxxxxxxx
• 6 - Specify the class
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Installation Methods
Trench
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Negative Projecting
Positive
Projecting
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Positive Projecting
Embankment
Negative Projecting Embankment
TRENCH
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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
xxxxxxxxx installation for designs
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Loads on Pipe
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•
•
•
Earth
xxxx
Construction
Other
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Traffic Load
R1
Earth Load
Final Backfill
Haunching
Initial Backfill
Bedding
Foundation
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R2
Rigid Pipe
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Installation Flexibility w/RCP
• Type I – IV SIDD Installations
• Well defined structural backfill
materials and compaction
• Pressure distribution understood
and conservative
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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.
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Middle Bedding loosely
placed uncompacted
bedding except
for Type 4
AASHTO Section 27 –
Concrete Culverts
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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 xxxx ONLY
Type 1 = Most Supporting structural strength
Type 4 = Requires 95% of structural strength to be provided by
Pipe Wall
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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
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Gravity Pipe Classes
AASHTO M170
ASTM C76
Class
I
D-Load .01
800
D-Load Ult.
1200
II
1000
1500
III
1350
2000
IV
2000
3000
V
3000
3750
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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
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Resources for Finding Required
Pipe Strength
•Plug & chug - blue
book
•Fill height tables
•Computer software PipePac 2000
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Hydraulics
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SEWERS
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Initial & Long Term
Full Flow Conditions
CULVERTS
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Inlet Control
Outlet Control
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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
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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
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Culvert Hydraulic Characteristics
Inlet Control (inlet
geometry only)
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Outlet Control(everything else)
H
Hw
“n”
Inlet
Geometry
D =
Hw =
Tw =
Diameter
Headwater depth
Tailwater depth
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T
w
So
L
L =
n =
So =
Culvert Length
Mannings roughness
Slope
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Basic’s- Our Hydraulic Advantage
• The xxxxxxxx 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. xxxxxxxx = 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.
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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
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Concrete Pipe Design Manual
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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
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Installed
.010-.011
.012-.020????
.021-.029
DURABILITY
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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!
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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?
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Research & Historic Performance
Proves RCP Durability
State
Highway Departments
Federal
Highway Administration
Corp
of Engineers
U.S.
Bureau of Reclamation
Soil
Conservation Service
Local
Government Agencies
Universities
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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
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Factors that Influence Durability
of RCP
• Materials properties
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Concrete compressive strength
Xxxxxx
Absorption/permeability
Cement type
Admix enhancements
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Factors that Influence Durability
of RCP….Cont.
• Chemical & Physical Factors
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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!
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National Standards &
Specifications
• Overview
• RCP - national standards of
importance
 Materials, manufacturing,
complimentary components,
installation, test methods
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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
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Specs & Standards of Note..
• Materials for RCP – XXX, 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
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Let us be your Resource!
• XXXX Company name and
contact info
• xxxxxxxxx.com Company website
• We can provide:

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


Presentations
Proper installation of RCP
Structural design of RCP
Competitive product comparisons
Plant tours
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Other Resources!
• ACPA Resources at
www.xxxxxxxx-xxxx.org




Research
Tech. resources and information
Education
Design aid software
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