Joints John Kallemeyn

Good Joint (note gasket compression) Rigid Rugged Resilient

Bad Joint (note lack of compression) Rigid Rugged Resilient

Ugly Joint (note rolled gasket cracked bell) Rigid Rugged Resilient

Good Trust Relationships Reputation Profits Rigid Rugged Resilient

Bad-Ugly Back Charges Poor Reputation Loss of Market Share Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Rigid Rugged Resilient

What Does the Customer Want? Rigid Rugged Resilient

Rigid Rugged Resilient

It is important to understand the specification prior to bidding Rigid Rugged Resilient

The Product that is Quoted should be capable of meeting the owners expectations Rigid Rugged Resilient

Rigid Rugged Resilient

Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Standards For Joint Design Rigid Rugged Resilient

Common Standards ASTM C 361 Standard Specification for Reinforced Concrete Low-Head Pressure Pipe ASTM C 443 Standard Specification for Joints for Concrete Pipe and Manholes Using Rubber Gaskets ASTM C 1619 Standard Specification for Elastomeric Seals for Joining Concrete Structures ASTM C 1628 Standard Specification for Joints for Concrete Gravity Flow Sewer Pipe Using Rubber Gaskets ACPA QCAST ACPA Plant certification manual Bureau of Reclamation M1 Standard Specifications for Reinforced Concrete Pressure Pipe (R4 Joint) Rigid Rugged Resilient

Critical Joint Criteria Specification C361 C443 C1628 ACPA Bureau of Rec M1 R4 Joint Taper Yes No Bell Thickness Tongue Thickness Gasket Location Confined Joints Allowed Single Offset Joints Allowed (<25 ft Head) Joint /Gasket design Rigid Rugged Resilient

Joint Taper C 361 C 443 C 1628 ACPA Bureau of Rec M1 R4 8.4.7 Not more than 2o Not more than 3.5o except tapers up to 5o are not prohibited if proven adequate 6.1.5 Not more than 2o except tapers up to 3o are not prohibited if proven adequate NA Rigid Rugged Resilient

Compression and Stretch Specification C 361 11 C 443 11 C 1628 11 ACPA Bureau of Rec M1 R4 Min Compression 15% NS (2) 15 Max Compression 50% NS 50 (3)(4) 40 (6)(7) 40 (9) Max Stretch 20% (1) 30 30 (5) 20 (8) 20 (10) (1) 30% for gasket with design pack greater than 75% (2) Specification reads that the Annular Space of centered joint must be less than 75% of the thickness of the uncompressed gasket (3) 60% for non-circular joint designs (4) 55% for joints that have offsets on both bell and spigot (5) 35% for pipe over 96" with class E gaskets (6) 50% for gasket pack greater than 75% (7) 60% for all non-circular gaskets (8) 30% for gasket with design pack greater than 75% (9) 50% for gasket with design pack greater than 75% (10) 30% for gasket with design pack greater than 75% Alternative designs are acceptable if approved in writing by the owner Rigid Rugged Resilient

Gasket Sealing Location Parallel sealing surfaces of joint shall extend not less than 3/4“ away from the edge of the gasket C 1628 Joint shall be designed to provide a minimum distance from the edge of the gasket to the entrance chamfer on the bell of a closed joint ½” for 12-27” ¾” for 30” and larger Pipe Bureau of Reclamation R4 3/4” Distance A Rigid Rugged Resilient

Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Headers and Pallets Concrete joints are mirror images of headers and pallets A quality vendor for purchasing headers and pallets is must Inspection and re-inspection are critical Take steps to prevent production related damage to headers and pallet Rigid Rugged Resilient

Header and Pallet Inspection Incoming Inspection Check all rings when purchased Recheck inspection As needed to ensure proper dimensions QCAST requires annual inspection of header and pallets used for the production of sanitary sewer pipe and manholes Rigid Rugged Resilient

Rigid Rugged Resilient

Rigid Rugged Resilient

Why Re-check Rings? Rigid Rugged Resilient

Rigid Rugged Resilient

Rigid Rugged Resilient

Rigid Rugged Resilient

Keep headers and pallets free of concrete buildup Advantages Joint surfaces are smoother and more defined Release agent is more effective Rings easier to remove Less damage to rings Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Gasket Tolerances: O-Ring Diameter ASTM C 361 and C 1628 Larger of ±1/64” or ±1.5% ASTM C 443 ±6.0% Volume ASTM C 361 & ASTM C 1628 ±3% for gaskets up to and including ½” in diameter, and ± 1% for gaskets of 1” diameter and larger. For gasket diameters between ½” and 1” the tolerance shall vary linearly from ± 3% to ± 1%.

Gasket Tolerances: Profile Diameter ASTM C 361 NA ASTM C 1628 Larger of ±1/64” or ±3% ASTM C 443 ±6.0% Cut Length ASTM C 1628 nominal cut length of ±3%

Physical Gasket Requirements ASTM C 1619 Physical Property Requirements of Elastomeric Seals Class A Class B Class C Class D Class E Formerly C361 Formerly C443   Standard Gaskets 54 psi Oil Resistant Gaskets 54 psi Standard Gaskets 13 psi Oil Resistant Gaskets 13 psi Gravity Flow Sewer 13 psi Tensile, min, psi (MPA) 2300 (15.9) 1500 (10.3) 1200 (8.3) 1800 (12.4) Elongation at break, min, % 425 350 Specified Hardness, Shore A 40-60 Oven-Age Tensile reduction, max % of original 15 20 Oven-Age Elongation reduction, max % of original 40 Oven-Age hardness increase, max - Compression Set, max % 25 Water Absorption, max % weight increase 5 10 Ozone Resistance level, 50 pphm No Cracks Liquid Immersion IRM 903 Oil. Max % volume change 80 Splice Strength Classification Class 3 Class 2

Gasket Splice Testing Splice ASTM C 1619 References D 2527 Class 1 20% of ultimate elongation Class 2 50% of ultimate elongation Class 3 100% of ultimate elongation While elongated shall be rotated 180o in each direction Subjected to the bend test 180o 270o The Rod used shall be equal to the gasket Diameter

ACPA Certification for Gasket Quality Gasket quality shall be monitored through in-house testing of all gasket shipments Frequency for in-house testing: 12” – 33” pipe minimum of 1/300 36” pipe and larger minimum of 1/100

ACPA Certification for Gasket Quality O-Ring gaskets: tested for splice strength, gasket volume, cord diameter, gasket length and gasket hardness (durometer). Profile gaskets: tested for splice strength, gasket volume, gasket hardness (durometer), gasket length and gasket height and width. Pre-lubricated gaskets: tested for splice strength, gasket hardness (durometer), gasket length and gasket height and width.

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Gauge Design Height of points is critical for gauges Gauges need to be made light enough for use but heavy to resist bending www.concrete-pipe.org

Vacuum Test Quality Control Will locate leaks through barrel and problems with joints Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Designing the Joint for Installation www.concrete-pipe.org

Steps to Create Durable Joints Even the best designed joint will leak if it is cracked or damaged www.concrete-pipe.org

Recommended Steps to Prevent Joint Failure Additional Bell Steel for Special Projects Detail Joint Epoxy coat joint sealing surface Supply quality lube www.concrete-pipe.org

Additional Bell Steel 48” B 5 Rigid Rugged Resilient

Epoxy Coating of O-ring joint Bells

Tips for lube selection: Consistency in subfreezing weather (Northern climates) Consistency at elevated ambient temperatures How long does it last on a pipe and gasket in warm conditions? Homogeneity (Does it separate?) Lubricity (Does it work?)

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Very Important People Pipe Producers (Sales, Engineers, Production, QC) Gasket Suppliers Contractors Inspectors Owners Rigid Rugged Resilient

Rigid Rugged Resilient

Important Topics: Giving the customer what they want (what they asked for) Specifications Rings Gaskets Quality Control Designing for Installation Very important people Calculations (If we have time) Rigid Rugged Resilient

Critical Joint Calculations Minimum Compression Maximum Compression Maximum Pack Design of Gauges

Minimum Compression www.concrete-pipe.org

Example Minimum Compression 36” Joint as Designed Compression is at 37% both sides www.concrete-pipe.org

Example Minimum Compression Concrete to concrete contact Min Compression is at 26% www.concrete-pipe.org

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Example Minimum Compression Concrete to concrete contact+ snap ring loose and bent inward .050” Min Compression is at 18%

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Example Minimum Compression Concrete to concrete contact + snap ring loose and bent inward .050” + header .100” small Min Compression is at 1% www.concrete-pipe.org

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Example Minimum Compression Concrete to concrete contact+ snap ring loose and bent inward .050” + header .100” small + Pallet .100” big Min Compression is at -16% www.concrete-pipe.org

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www.concrete-pipe.org

Single offsets are just as susceptible to this type of tolerance stacking. They are generally plagued by a much larger Minor annular space www.concrete-pipe.org

Single offset off centered 21% Compression with no tolerances added www.concrete-pipe.org

Calculations Maximum Compression

Calculations Maximum Compression

Example Maximum Compression Concrete to concrete contact Max Compression is at 48% www.concrete-pipe.org

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Max Pack Does the gasket fit in the area allowed for it? www.concrete-pipe.org

Max Pack Equation www.concrete-pipe.org

Design gasket is 21/32” Look what happens when we stick a 3/4” in the grove www.concrete-pipe.org

Gauges Go/No Go Gauges How do we ensure we are within our tolerances www.concrete-pipe.org

Equations The key is that gauges are designed with the same tolerances as used in the initial joint design www.concrete-pipe.org

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