1. Reinforced Concrete Pipe Attributes
Your Name Date
Reinforced Concrete Pipe Attributes

2. Our Industry’s Story & Product Attributes2
Our Industry’s Story & Product Attributes
Historical perspective
Important product attributes
National standards & specifications
Resources
Our company
Our people
Our industry association - ACPA

3. Historical Perspective
Proven history =
Continued improvement of product and production methods
Long term knowledge & understanding by all stakeholders
Verifiable durability

4. 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!

5. 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

6. Continued Improvement…Post 1930
After great depression & WWII 4 million tons of RCP produced in 1950
Advancement from
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

7. 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”

8. No better teacher than HISTORY & EXPERIENCE!
Over a century of continued improvements in production & QC process provides best RCP ever produced

9. Attributes of Concrete Pipe
Materials and manufacturing methods
Strength
Design & installation flexibility
Hydraulic efficiency
Durability

10. Materials & Manufacturing Methods

11. 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.

12. 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!

13. Pipe Forming Methods
Wet Cast
Dry Cast

14. Vibratory Sources Internal Hydraulic
External Pneumatic Electric Hydraulic

15. Dry Cast 84”x 16’

16. Wire cage production by cage machine

17. Computer controlled batching and manufacturing is common
Computer controlled batching and manufacturing is common! See for yourself….

18. Structural Considerations

19. XXXXXXX Buried Pipe XXXXXXXXX
A Buried Pipe Must Perform Two Critical Functions?
Buried Pipe
XXXXXXXXX

20. 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!

21. 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

22. 3EB Test

23. 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

24. 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

25. 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

26. 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!

27. Structure Conduit Concrete Pipe

28. 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!

29. Design & Installation

30. 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

31. 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

32. Installation Methods Positive Projecting Trench Negative Projecting

33. TRENCH Positive Projecting Embankment Negative Projecting Embankment

34. 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

35. Loads on Pipe
Earth
xxxx
Construction
Other

36. R1 R2 Rigid Pipe Traffic Load Earth Load Final Backfill Haunching
Initial Backfill
Bedding R2
Foundation
Rigid Pipe

37. Installation Flexibility w/RCP37
Installation Flexibility w/RCP
Type I – IV SIDD Installations
Well defined structural backfill materials and compaction
Pressure distribution understood and conservative

38. 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

39. AASHTO Section 27 – Concrete Culverts39
AASHTO Section 27 – Concrete Culverts
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

40. Key Components Of Structural Backfill Of RCP40
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

41. 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

42. Steps for Determining the Required Pipe Strength Class42
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

43. Resources for Finding Required Pipe Strength43
Resources for Finding Required Pipe Strength
Plug & chug - blue book
Fill height tables
Computer software - PipePac 2000

44. Hydraulics SEWERS CULVERTS Initial & Long Term Full Flow Conditions
Inlet Control
Outlet Control

45. 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

46. 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

47. Culvert Hydraulic CharacteristicsSo
“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)

48. 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.

49. 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 = 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

50. Concrete Pipe Design Manual

51. 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
HDPE ????
CMP

52. DURABILITY

53. 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!

54. 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?

55. 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

56. 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

57. Factors that Influence Durability of RCP
Materials properties
Concrete compressive strength
Xxxxxx
Absorption/permeability
Cement type
Admix enhancements

58. 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!

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

60. 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

61. 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

62. 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

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