Reinforced Concrete Pipe Attributes Your Name Date Reinforced Concrete Pipe Attributes www.concrete-pipe.org

Our Industry’s Story & Product 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

Historical Perspective Proven history = Continued improvement of product and production methods Long term knowledge & understanding by all stakeholders Verifiable durability www.concrete-pipe.org

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! www.concrete-pipe.org

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 www.concrete-pipe.org

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

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

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

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

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

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! www.concrete-pipe.org

Pipe Forming Methods Wet Cast Dry Cast www.concrete-pipe.org

Vibratory Sources Internal Hydraulic External Pneumatic Electric Hydraulic www.concrete-pipe.org

Dry Cast 84”x 16’ www.concrete-pipe.org

Wire cage production by cage machine www.concrete-pipe.org

Computer controlled batching and manufacturing is common Computer controlled batching and manufacturing is common! See for yourself…. www.concrete-pipe.org

Structural Considerations www.concrete-pipe.org

XXXXXXX Buried Pipe XXXXXXXXX A Buried Pipe Must Perform Two Critical Functions? Buried Pipe XXXXXXXXX www.concrete-pipe.org

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

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 www.concrete-pipe.org

3EB Test www.concrete-pipe.org

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 www.concrete-pipe.org

Pipe Classification 1,350 3,750 3,000 CLASS V 2,000 1,500 1,000 CLASS IV 1,350 CLASS III 1,500 1,000 CLASS II 1,200 800 CLASS I Dult D0.01 ASTM C-76 www.concrete-pipe.org

Example Class IV 60” Pipe Load0.01 Dult = 3,000 Load0.01 = 5’ x 2,000 lbs/ft/ft x 8’ = 80,000 lbs. Loadult = 5’ x 3,000 lbs/ft/ft x 8’ = 120,000 lbs. Before the .01 Design Crack www.concrete-pipe.org

Structure Confirmed before Shipment 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

Structure Conduit Concrete Pipe www.concrete-pipe.org

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

Design & Installation www.concrete-pipe.org

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

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 www.concrete-pipe.org

Installation Methods Positive Projecting Trench Negative Projecting www.concrete-pipe.org

TRENCH Positive Projecting Embankment Negative Projecting Embankment www.concrete-pipe.org

Installation Type Makes a Difference! 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 xxxxxxxxx installation for designs www.concrete-pipe.org

Loads on Pipe Earth xxxx Construction Other www.concrete-pipe.org

R1 R2 Rigid Pipe Traffic Load Earth Load Final Backfill Haunching Initial Backfill Bedding R2 Foundation Rigid Pipe www.concrete-pipe.org

Installation Flexibility w/RCP 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

AASHTO- RCP Standard Installation (SIDD) Overfill SW,ML, or CL H Do/6 (MIN) Do Do (MIN) Excavation Line as required Haunch - see table Bedding see table Di Do/3 Outer Bedding Materials and compaction each side, same requirements as haunch. Middle Bedding loosely placed uncompacted bedding except for Type 4 Foundation www.concrete-pipe.org

AASHTO Section 27 – Concrete Culverts 39 AASHTO Section 27 – Concrete Culverts 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 www.concrete-pipe.org

Key Components Of Structural Backfill Of RCP 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

Gravity Pipe Classes AASHTO M170 ASTM C76 Class D-Load .01 D-Load Ult. 41 Gravity Pipe Classes AASHTO M170 ASTM C76 Class D-Load .01 D-Load Ult. I 800 1200 II 1000 1500 III 1350 2000 IV 3000 V 3750 www.concrete-pipe.org

Steps for Determining the Required Pipe Strength Class 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

Resources for Finding Required Pipe Strength 43 Resources for Finding Required Pipe Strength Plug & chug - blue book Fill height tables Computer software - PipePac 2000 www.concrete-pipe.org

Hydraulics SEWERS CULVERTS Initial & Long Term Full Flow Conditions Inlet Control Outlet Control www.concrete-pipe.org

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

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 So “n” D Hw H Tw Inlet Geometry D = Diameter L = Culvert Length Hw = Headwater depth n = Mannings roughness Tw = Tailwater depth So = Slope Inlet Control (inlet geometry only) Outlet Control(everything else) www.concrete-pipe.org

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. www.concrete-pipe.org

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

Concrete Pipe Design Manual www.concrete-pipe.org

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 Installed RCP .008-.010 .012 .010-.011 HDPE .009-.015 .010 .012-.020???? CMP .012-.030 .012-.026 .021-.029 www.concrete-pipe.org

DURABILITY www.concrete-pipe.org

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

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

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 www.concrete-pipe.org

Service Life- Corp of Engineers Report RCP-xx-xxx yr. CONFIRMED HDPE - Unknown No more than xx yrs. Corrugated steel with coatings or aluminum – no greater than xx years www.concrete-pipe.org

Factors that Influence Durability of RCP Materials properties Concrete compressive strength Xxxxxx Absorption/permeability Cement type Admix enhancements www.concrete-pipe.org

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

National Standards & Specifications Overview RCP - national standards of importance Materials, manufacturing, complimentary components, installation, test methods www.concrete-pipe.org

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

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 www.concrete-pipe.org

Let us be your Resource! XXXX Company name and contact info xxxxxxxxx.com Company website We can provide: Presentations Proper installation of RCP Structural design of RCP Competitive product comparisons Plant tours www.concrete-pipe.org

Other Resources! ACPA Resources at www.xxxxxxxx-xxxx.org Research Tech. resources and information Education Design aid software www.concrete-pipe.org