www bzfxw com BRITISH STANDARD BS EN 640 1995 Reinforced concrete pressure pipes and distributed reinforcement concrete pressure pipes (non cylinder type), including joints and fittings The European S[.]
BRITISH STANDARD Reinforced concrete pressure pipes and distributed reinforcement concrete pressure pipes (non-cylinder type), including joints and fittings The European Standard EN 640:1994 has the status of a British Standard BS EN 640:1995 BS EN 640:1995 Committees responsible for this British Standard The preparation of this British Standard was entrusted to Technical Committee B/504, Water supply, upon which the following bodies were represented: Association of Consulting Engineers Association of Manufacturers of Domestic Unvented Supply Systems Equipment (MODUSSE) British Bathroom Council British Foundry Association British Non-Ferrous Metals Federation British Plastics Federation British Plumbing Manufacturers’ Association Department of the Environment Department of the Environment (Drinking Water Inspectorate) Fibre Cement Manufacturers’ Association Limited Institute of Plumbing Institution of Water and Environmental Management Local Authority Organizations Scottish Association of Directors of Water and Sewerage Services Water Companies Association Water Research Centre Water Services Association of England and Wales The following bodies were also represented in the drafting of this standard, through subcommittees and panels: Association of Metropolitan Authorities British Precast Concrete Federation Ltd Concrete Pipe Association Concrete Society Department of Transport Federation of Civil Engineering Contractors Institution of Civil Engineers Institution of Highways and Transportation This British Standard, having been prepared under the direction of the Sector Board for Building and Civil Engineering, was published under the authority of the Standards Board and comes into effect on 15 May 1995 © BSI 07-1999 The following BSI references relate to the work on this standard: Committee reference B/504 Draft for comment 92/12537 DC ISBN 580 24112 Amendments issued since publication Amd No Date Comments BS EN 640:1995 Contents Committees responsible National foreword Foreword Text of EN 640 © BSI 07-1999 Page Inside front cover ii i BS EN 640:1995 National foreword This British Standard has been prepared by Technical Committee B/504 and is the English language version of EN 640:1994 Reinforced concrete pressure pipes and distributed reinforcement concrete pressure pipes (non-cylinder type), including joints and fittings, published by the European Committee for Standardization (CEN) EN 640 was published as a result of international discussion in which the UK took an active part A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, the EN title page, pages to 12 and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover ii © BSI 07-1999 EUROPEAN STANDARD EN 640 NORME EUROPÉENNE October 1994 EUROPÄISCHE NORM ICS 23.040.10;23.040.40 Descriptors: Water pipelines, pressure pipes, potable water, water pipes, concrete tubes, reinforced concrete, armatures, specifications, design, equipment specifications, dimensions, tests English version Reinforced concrete pressure pipes and distributed reinforcement concrete pressure pipes (non-cylinder type), including joints and fittings Tuyaux pression en béton armé et tuyaux pression armature diffuse (sans âme en tôle), y compris joints et pièces spéciales Stahlbetondruckrohre und Betondruckrohre mit verteilter Bewehrung (ohne Blechmantel) einschliesslich Rohrverbindungen und Formstücken ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ This European Standard was approved by CEN on 1994-10-26 CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CEN member This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official versions CEN members are the national standards bodies of Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom CEN European Committee for Standardization Comité Européen de Normalisation Europäisches Komitee für Normung Central Secretariat: rue de Stassart 36, B-1050 Brussels © 1994 Copyright reserved to CEN members Ref No EN 640:1994 E EN 640:1994 Foreword Contents This European Standard for concrete pipes is a standard which was prepared by WG 5, Concrete pipes, of the Technical Committee CEN/TC 164, Water supply, the Secretariat of which is held by AFNOR During preparation of this standard the provisional results already available of CEN/TC 164/WG 1, General requirements for external systems and components, and of CEN/TC 164/165/JWG 1, Structural design, were considered This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by April 1995, and conflicting national standards shall be withdrawn at the latest by April 1995 In accordance with the common CEN/CENELEC Internal Regulations, the following countries are bound to implement this European Standard: Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom Page Foreword Introduction Scope Materials 2.1 Aggregates 2.2 Steel wire for distributed reinforcement pipes 3 Design and fabrication of pipe 3.1 General requirements 3.1.1 Wall thickness 3.2 Design of pipe 3.2.1 General 3.2.2 Combined load design criteria 3.3 Reinforcement 3.3.1 Circumferential reinforcement for reinforced concrete pipe 3.3.2 Circumferential reinforcement for distributed reinforcement pipe 3.3.3 Longitudinal reinforcement for reinforced concrete pipe 3.3.4 Longitudinal reinforcement for distributed reinforcement pipe 3.3.5 Longitudinal prestressing reinforcement 3.3.6 Placement and cover to steel 3.4 Concrete and mortar 3.4.1 Mix design 3.4.2 Concrete strength Factory testing 4.1 Concrete tests 4.2 Pipe tests 4.2.1 Hydrostatic pressure tests 4.2.2 Crushing test for reinforced concrete pipe 4.2.3 Combined crushing and pressure test for distributed reinforcement pipe 4.2.4 Combined bending and pressure test for distributed reinforcement pipes Annex A (informative) Typical design procedure 11 Figure — Crushing test Figure — Combined crushing and pressure test for distributed reinforcement pipe Figure — Combined bending and pressure test for distributed reinforcement pipe 10 Figure A.1 — Coefficient Fp 12 Table — Minimum wall thickness Table — Reduction factors for V shaped support ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ © BSI 07-1999 EN 640:1994 Introduction 1) The product which is in permanent or temporary contact with water, intended for human consumption, does not adversely affect the quality of the drinking water and does not contravene the CE Directives and EFTA Regulations on the quality of drinking water This standard is to be used together with EN 639 (Common requirements) When the relevant EN dealing with general requirements, such as General requirements for external systems and components (CEN/TC 164/WG 1), Materials in contact with water (CEN/TC 164/WG 3) and Structural design (CEN/TC 164/165/JWG 1) are adopted, the current standard shall be revised, where appropriate, in order to ensure that these requirements comply with the relevant ENs To the present standard, is attached: — Annex A (informative): Typical design procedure Scope For distributed reinforcement pipes, the aggregate size shall not exceed the spacing between reinforcement steel wires and in no case shall exceed mm 2.2 Steel wire for distributed reinforcement pipes The wire to be used for distributed reinforcement shall conform to subclause 5.7 of EN 639 (Common requirements) and shall have a characteristic tensile strength of not less than 800 MPa and a tolerance on the diameter of ± 0,04 mm Design and fabrication of pipe 3.1 General requirements Pipes shall have the following principal features: a reinforcing cage or cages of steel rods, bars, wire, or fabric encased in a dense concrete wall (RCP), or multiple layers of continuous thin steel wire helically wrapped and encased in a dense mortar wall (DRP) Where beam strength is required by design, the longitudinal reinforcement shall consist of steel bars or wires or layers of wire ribbon Prestressing wire may also be used Joints shall be provided with elastomeric sealing rings in accordance with 5.8 of EN 639 ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ This European Standard covers the requirements and manufacture of circumferentially reinforced concrete pressure pipe, without steel cylinder and not circumferentially prestressed, with steel reinforcement (RCP) or a homogeneously distributed reinforcement composed of multiple layers of small diameter wires (DRP) Pipes shall have diameter ranging from DN/ID 300 to DN/ID 4000 Larger sizes could be manufactured based on the concepts of this standard This type of pipe is designed for the internal pressure, external loads, and bedding conditions designated by the purchaser Maximum design pressure shall not exceed 500 kPa The above limit shall be increased to 000 kPa in case of distributed reinforcement pipes (DRP) Materials Materials are as specified in clause of EN 639 (Common requirements) Additional requirements are specified as follows 2.1 Aggregates 3.1.1 Wall thickness Table shows the minimum design wall thickness for each type of pipe 3.2 Design of pipe 3.2.1 General Steel reinforcement shall consist of one or more circular cages, or a single elliptical cage, or a combination of an elliptical cage and one or more circular cages or multiple layers of thin wire At least one of the cages shall be circular in pipe for a design pressure of more than 150 kPa or in RCP larger than DN/ID 1800 An inner circular cage and an outer circular cage shall be used and may be combined with an elliptical cage in pipe for design pressures of more than 300 kPa Circumferential and longitudinal reinforcement for DRP shall be placed in a minimum of six layers and two layers respectively The cross-sectional area of the reinforcement shall be sufficient to meet the design requirements The maximum size of the aggregate shall not exceed one third of the pipe wall thickness, but in no case shall it exceed 32 mm 1) Should be considered as any product used for the conveyance and distribution of water intended for human consumption © BSI 07-1999 EN 640:1994 Table — Minimum wall thickness DN/ID 300 400 450 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 and larger a Minimum design wall thickness for RCP mm Minimum design wall thickness for DRP mm 60 60 60 60 65 65 70 75 85 90 100 110 115 125 135 140 150 160 165 180 185 190 200 40 40 40 40 45 45 50 55 60 65 65 70 70 75 80 a a a a a a a a a a To be supplied by manufacturer 3.2.2 Combined load design criteria The pipe shall be designed to resist the stresses due to internal pressure, external loads and, if required, beam loading resulting from each of the following conditions: — a combination of maximum design pressure and dead loads; — a combination of design pressure, dead loads, and live loads For information, see informative annex Dead and live loads, coefficients for moment and thrust calculations and bedding angle shall be calculated in accordance with the appropriate national standards transposing EN as available or, in absence of such standards, with the appropriate regulations or recognized and accepted methods at the place where the pipeline is installed 3.3 Reinforcement 3.3.1 Circumferential reinforcement for reinforced concrete pipe The circumferential reinforcement shall consist of steel bars or wire in helical or hoop form, or welded wire fabric shaped and lap welded or butt welded into cages The weld quality and welding procedures shall be assured by testing a representative sample of butt or lap welds at a stress equal to at least the original strength of the steel The elements composing the circumferential reinforcement shall be connected by longitudinal bars The diameter and number of these bars shall be sufficient to prevent the cage deforming during fabrication and shall be suitable to give the pipe the designed strength For pipes having thickness less than 80 mm, the reinforcement shall normally be a single cage For multiple cage reinforcement, the internal cage shall have at least 50 % of the circumferential steel area required by the design while the external cage shall have at least 40 % of the required area The maximum distance between two adjacent bars of the circumferential reinforcement shall not exceed 1,5 times the wall thickness but in no case greater than 150 mm ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ 3.3.2 Circumferential reinforcement for distributed reinforcement pipe For DRP the circumferential reinforcement shall consist of layers of wire with diameter not greater than mm in helical or hoop form homogeneously distributed in the pipe wall For the above pipe the specific volume of reinforcement (as ratio between volume of reinforcing wire and total volume of pipe wall) shall not be less than % In each layer, the design spacing between adjacent wires shall not be less than times the wire diameter and not more than twice the largest size of aggregate used; deviation from design spacing shall be accepted if, in a longitudinal section of the central part of the barrel, the following condition is met: — five adjacent squares, having sides equal to the wall thickness, contain a total of at least 90 % of design number of wires © BSI 07-1999 EN 640:1994 3.3.3 Longitudinal reinforcement for reinforced concrete pipe The circumferential reinforcement in cages shall be accurately spaced and rigidly assembled by means of longitudinal bars securely attached so that it is maintained in proper shape and position during the casting of the pipe Not less than four longitudinal bars shall be provided for each cage, and additional bars shall be provided as necessary so that the circumferential spacing between longitudinal bars shall not exceed 450 mm in any barrel cage 3.3.4 Longitudinal reinforcement for distributed reinforcement pipe For distributed reinforcement pipe, the longitudinal reinforcement shall be made of wire with diameter not exceeding mm, and shall be placed in layers parallel to the pipe axis and in between layers of circumferential reinforcement Contact between longitudinal and circumferential reinforcement is allowed If longitudinal reinforcement is made of short lengths of straight wire the overlap shall be not less than 80 times the wire diameter If the longitudinal reinforcement is made of ribbon composed by a zig-zag continuous wire, the overlapping sides of the helically wrapped ribbon shall not be less than 40 times the wire diameter Specific volume (as described in 3.3.2) of longitudinal reinforcement shall be not less than 0,2 % For DRP, cement shall be not less than 500 kg per cubic metre of mortar, and water-cement ratio shall not exceed 0,4 3.4.2 Concrete strength The minimum 28 day compressire strength of concrete and mortar shall be 35 MPa Factory testing 4.1 Concrete tests A quantity of three cylinders or cubes per week, per mix type, or per 100 cubic metre of concrete, whichever is the greater shall be tested for 28 day compressive strength 4.2 Pipe tests 4.2.1 Hydrostatic pressure tests Hydrostatic pressure test shall be carried out on every pipe either individually or jointed The test section shall have suitable bulkheads attached to each end and shall be filled with water and allowed to gradually reach the maximum design pressure within Pipe shall be kept under such pressure for at least 15 without cracking No measurable leakage shall develop during the test period Damp spots or water drops developing on the surface of the pipe and which remain on the surface shall not be considered cause for rejection Pipes that fail may be reworked and retested at the option of the manufacturer ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ 3.3.5 Longitudinal prestressing reinforcement 4.2.2 Crushing test for reinforced concrete pipe At the choice of manufacturer, the pipe shall be longitudinally prestressed throughout its length, including the socket, by means of high tensile wires (see 5.7.2 of EN 639 Common requirements) The longitudinal prestress shall be sufficient to prevent excessive tensile stresses developing in the pipe due to beam loading The longitudinal wires shall be stressed to design tension, taking into account all losses due to creep, shrinkage, relaxation and slip The test shall be carried out on a test machine having: — a load recording facility; — a stiff loading beam the lower face of which is a bearer having an elastomeric bearing strip of thickness between 10 mm and 40 mm and hardness between 45 and 65 IRHD The maximum width of the bearing strip shall be: — DN k 400: 500 mm; — 400 < DN k 1200: 0,12 mm times DN; — DN > 1200: 150 mm; — a lower bearer on which is located a V shaped support which is either covered with or has two bearing strips of elastomeric material having the same thickness and hardness as that on the loading beam Where the angle (¶) of opening of the V is 170° or more, the crushing strength shall be as recorded Where the opening is less than 170°, a reduction factor shall be applied to the recorded strength as given in Table 3.3.6 Placement and cover to steel The minimum cover to steel for both internal and external surfaces shall be 20 mm for RCP and mm for DRP respectively or one times the largest aggregate size, whichever is the greater Maximum cover for DRP shall not exceed mm 3.4 Concrete and mortar 3.4.1 Mix design For RCP, a minimum of 300 kg of cement shall be used for each cubic metre of concrete The water-cement ratio shall be such as to ensure that the concrete will meet the strength requirements, but in no case shall it exceed 0,45 © BSI 07-1999 EN 640:1994 Table — Reduction factors for V shaped support Angle 150° k ¶ < 160° 160° k ¶ < 170° ¶ U 170° Reduction factor 0,98 0,99 1,00 The test consists of subjecting a complete pipe or pipe section not shorter than m to the action of a uniformly distributed load For instance, to achieve uniform distribution, bearers may be divided into sections The test load shall be applied symmetrically over the entire bearer length The position of the load may be adjusted to maintain horizontal stability During application of at least the final third of the specified load, the rate of increase of load shall be constant and this period of loading shall be at least 30 s Test pipe resistance qr expressed in N/m is related to the effective length of the specimen by the formula: Q test load q r = = -rinternal barrel length L bi The purpose of this test is to verify pipe behaviour at limit states of cracking and ultimate: — crack load (qc): load at which the first 0,3 mm wide crack occurs over a length of 300 mm as measured in accordance with 6.4.11 of EN 639 (Common requirements); — ultimate load (qu): maximum load that the pipe can sustain without collapse Pipe taken only to crack load and satisfactorily tested shall not be excluded from delivery 4.2.3 Combined crushing and pressure test for distributed reinforcement pipe The testing apparatus (see Figure 2), similar to the one described in 4.2.2, is fitted with a device for collecting and measuring water leakage The test shall be carried out on one pipe for each new design with the pipe filled with water, having bulkheads as described in 4.2.1 The top of the pipe shall be loaded by means of a longitudinal beam of adequate stiffness, having a minimum length equal to 0,5 times the internal barrel of the pipe The supporting edges, spaced as described in 4.2.2 shall have a minimum length equal to 0,6 times the internal barrel length of the pipe The test is carried out by raising the internal pressure to MDP, and then slowly increasing the load, until the maximum wall moment Mc is reached, as determined by the following: Mc = k · qr · rm where: — the k value is a function of load application; — rm is the pipe mean radius; — Mc is equal to 1,5 times the maximum design moment The pipe will pass the test if after the removal of the bending load the measured leakage does not exceed 0,04 litre per square metre per hour Satisfactorily tested pipe shall not be excluded from the delivery 4.2.4 Combined bending, and pressure test for distributed reinforcement pipes The test shall be carried out on one pipe for each new design by placing the pipe between two bulkheads as described in 4.2.1 (see Figure 3) The pipe is placed on two steel self-aligning saddles of 100 mm width, with 90° beating support Rubber with Shore A durometer hardness in the range of 50 to 65 shall be placed in between each saddle and the pipe The span between the centrelines of saddles shall be equal to 0,75 times the pipe length The bending load shall be applied by means of two upper saddles, having the same sizes and the same rubber strips as the lower ones The centreline distance between the two upper saddles shall be 0,18 times the pipe length The load shall be applied through a connecting beam by an hydraulic jack, and measured by a dynamometer Testing apparatus is completed by a device collecting and measuring water leakage The test is carried out by raising internal pressure to the maximum design pressure, and then gradually increasing the applied loading until large moisture spots appear on the external surface of the pipe, and the maximum beam bending moment Mp is reached, as determined by the following: Mp = 1,25Mo ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ © BSI 07-1999 EN 640:1994 where: — Mo, equal to 0,0625qr L2bi, is the maximum design bending moment due to a uniformly distributed load equal to the earth load in combination with dead and live loads acting on a simply supported beam with a total length equal to the pipe length Lbi and a clear span equal to 0,75Lbi The pipe will pass the test if at the MDP, after removal of bending load, the leakage does not exceed 0,04 litre per square metre per hour Pipes that fail may be retested at the option of the manufacturer Satisfactorily tested pipe shall not be excluded from delivery Figure — Crushing test © BSI 07-1999 EN 640:1994 Figure — Crushing test (concluded) © BSI 07-1999 © BSI 07-1999 Figure — Combined crushing and pressure test for distributed reinforcement pipe EN 640:1994 EN 640:1994 10 Figure — Combined bending and pressure test for distributed reinforcement pipe © BSI 07-1999 EN 640:1994 Annex A (informative) Typical design procedure ( f ct and fck expressed in MPa) A.1 General The following guidelines for structural analysis show a typical method for the design of both RCP and DRP The pipe should be designed for the conditions given in 3.2.2 considering: — serviceability limit state; — ultimate limit state A.2 Notation N1 normal force in the wall M1 maximum bending moment in the wall Ach cross-sectional area of the pipe wall taking into account the reinforcement affected by the n = 15 ratio Zch section modulus of the pipe wall taking into account the reinforcement affected by the n = 15 ratio fc stress in concrete f cb allowable bending tensile stress value of concrete f ct allowable stress value in pure tension of concrete fck characteristic 28-day compressive strength of concrete fyk characteristic yield strength of steel fsd design stress for steel fcd design stress for concrete w area of steel reinforcement expressed as a percentage of total cross-sectional area — for DCP: A.3 Wall design A.3.1 Serviceability limit state The analysis can be carried out in two alternative ways A.3.1.1 Stress design The following condition should be satisfied: N1 M1 f c = + - ≤ f cb A ch Z ch In the section where M1 = 0: N1 f c = ≤ f ct A ch for < M1/N1 k t/6 linear interpolation of allowable value should be employed The allowable stress values should be taken as follows: — for RCP: f cb = 1,30f ct f ct = a + b6 + c6 + d6 f cb = 1,30 f ct where: the coefficients a, b, c, d should be supplied by the manufacturer on the basis of certified test data A.3.1.2 Limitation of cracking for RCP Limitation of cracking is checked by a single coefficient Fp from Figure A.1, depending on the stress ratio due to normal force and bending stress: N1 M1 F c = F p + - ≤ 6MPa A Z ch ch A.3.2 Ultimate limit state The analysis can be carried out in two alternative ways: — normal force and moment resistance of the wall; — stress design A.3.2.1 Normal force and moment resistance of the wall The following load factor should be used: — ¾F: 1,35 for dead loads and design pressure; — ¾F: 1,50 for live loads and surge The following strength reducing factors should be used to obtain the design stress values f ck f cd = 1,50 f yk f sd = 1,15 f sd f sdo = -1,60 (only at zero bending moment cross section) Tensile strength of concrete should be neglected A.3.2.2 Design by stress Tensile strength of concrete should be neglected Allowable stresses of concrete, mortar and reinforcing steel should be assumed in conformity to national standards transposing EN as available Only at zero bending moment cross section, allowable values, for stress in steel should be reduced by a factor of 1,6 f ct = 0,18 f ck © BSI 07-1999 11 EN 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