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ICS 23.040.10
© BIS 2020
FOREWORD
This Indian Standard (First Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Cement Matrix Products Sectional Committee, had been approved by the Civil Engineering Division
Council.
The manufacture and use of bar/wire wrapped steel cylinder pipes with mortar lining and coating had started in
the country during 1998. This standard was published in 2002 to provide guidance in the manufacture and quality
control of these pipes, which have to be designed for the internal pressure, external loads and bedding conditions
as specified by the purchaser. Typical applications of these pipes include water transmission mains, distribution
feeder mains, sewer pumping mains, water intake and discharge lines and plant piping.
This revision has been brought out with a view to incorporating the modifications found necessary as a result of
experience gained over years and to bring this standard in line with the present good practices being followed in
the country and abroad.
This first revision incorporates number of modifications, the most significant of them being:
a) Pipe diameter ranges have been extended further up to 1 900 mm diameter;
b) Pipe joint dimensions and field pipe joint details have been elaborated; and
c) Additional tests on pipe coating have been included.
In the formulation of this standard, assistance has been drawn from the following publications:
a) AWWA Manual M9 ‘Concrete pressure pipe’; American Water Works Association.
b) AWWA C303-08 Concrete Pressure Pipes, Bar Wrapped, Steel Cylinder Type; American Water Works
Association.
c) EN641 : 1994 ‘Reinforced concrete pressure pipes, cylinder type, including joints and fittings’; European
Committee for Standardization.
The composition of the Committee responsible for the formulation of this standard is given in Annex D.
For the purpose of deciding whether a particular requirement of this standard is complied with the final value,
observed or calculated, expressing the result of a test or analysis shall be rounded off in accordance with
IS 2 : 1960 ‘Rules for rounding off numerical values ( revised ). The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.
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IS 15155 : 2020
Indian Standard
BAR / WIRE WRAPPED STEEL CYLINDER PIPES
WITH MORTAR LINING AND COATING
( INCLUDING SPECIALS ) — SPECIFICATION
( First Revision )
3 TERMINOLOGY 4 MATERIALS
For the purpose of this standard, the following 4.1 Cement
definitions shall apply.
The cement used in the manufacture of bar/wire
3.1 Bar/Wire Wrapped Steel Cylinder Pipe — A wrapped steel cylinder pipes and specials shall be one
welded steel sheet cylinder, which may be with steel of the following:
socket and spigot rings welded to its ends for rubber a) Ordinary Portland cement conforming to IS 269;
ring joints or with steel rings welded to its ends for
welded joints, lined with cement mortar centrifugally b) Rapid hardening Portland cement conforming to
applied within the steel cylinder and spigot ring, with IS 8041;
reinforcement consisting of continuous steel bar/wire c) Portland slag cement conforming to IS 455 with
helically wound around the outside of the cylinder and not more than 50 percent slag;
securely fastened by welding to the steel socket and d) Supersulphated cement conforming to IS 6909;
spigot joint rings, and subsequently coated with dense e) Portland pozzolana cement conforming to IS1489
cement mortar covering the steel cylinder and bar/wires (Part 1) or IS 1489 (Part 2); and
except for necessarily exposed socket and spigot joints
rings. f) Sulphate resisting Portland cement conforming to
IS 12330.
3.2 Specials — All items in the pipeline other than NOTE — Sulphate resisting Portland cement shall be used
straight pipes of standard length, such as bends, where sulphate is predominant.
air valves and scour valve tees, etc, are classified as
4.2 Aggregates
specials.
The aggregates shall conform to IS 383. The
3.3 Working Pressure — The maximum sustained requirements of 6 (Grading) of IS 383 shall not apply.
internal pressure excluding surge to which each portion Manufacturer shall furnish the grading curve for fine
of the pipe line may be subjected when installed. aggregates which he proposes to use. The variation
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in fineness modulus during manufacture shall not be be permitted. All sealing rings shall be protected from
more than ± 5 percent. Silt content in Natural Sand direct rays of the sun and stored in dry place.
aggregates shall be less than 3 percent and in case of
crushed sdand, it shall be less than 10 percent. The 4.8 Bitumen Epoxy Paint or Other Protective Coating
fineness modulus of the aggregates for coating shall be The purchaser may specify the application of an
between 2.6 and 3.2. external or internal bituminous epoxy paint or other
approved coating to be applied. When the pipes are
4.3 Water to be used for carrying potable water, the inside lining
Water used for cement mortar preparation and for shall not contain any constituents soluble in such water
curing the pipes shall conform to the requirements or any ingredient which could impart any taste or odour
given in 5.4 of IS 456. to the potable water.
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Table 1 Nominal Internal Diameter, Nominal All Diameters Socket Ring Spigot Ring
Wall Thickness (t), Minimum Thickness +8.5 , -1.5 -1.5 , + 8.5
of the Cement Mortar Lining including
thickness of the Cylinder (ti), etc
5.2.5 Out-of-Roundness of Socket and Spigot
( Clauses 1, 5.1.1 and 7.5 ) Rings
All dimensions in millimetres. The tolerances (in mm) on the out-of-roundness of the
internal surface of the socket ring and the outer surface
Sl Nominal t ti Minimum Thickness of the spigot shall be stated below:
No. Internal Nominal of Joint
Diameter Cylinder Rings
of Pipe Thickness All Diameters Socket Ring Spigot Ring
(1) (2) (3) (4) (5) (6) + 7, -3 -3, + 7
i) 250 40 15 1.6 5.0
ii) 300 40 15 1.6 5.0 6 JOINTS
iii) 400 40 15 1.6 5.0
Joint dimensions with tolerances for socket and spigot
iv) 500 45 20 1.6 5.0
diameters shall be furnished by the manufacturer for
v) 600 45 20 2.0 5.0 inspection.
vi) 700 45 20 2.0 5.0
vii) 800 45 20 2.0 5.0 6.1 Joint Dimension
viii) 900 45 20 2.5 5.0 Joint between pipes shall be of the steel spigot and
ix) 1 000 45 20 2.5 7.0 socket joint rings for site welded joint or steel spigot
and socket joint rings with rubber ring.
x) 1 100 50 22 3.0 8.0
xi) 1 200 50 22 3.0 8.0 Width of steel spigot and socket joint ring shall not be
xii) 1 300 50 22 4.0 8.0
less than 125 mm for site welded joint and 100 mm for
rubber ring joint.
xiii) 1 400 50 22 4.0 8.0
xiv) 1 500 50 22 4.0 8.0 The joint rings shall be expanded beyond their elastic
xv) 1 600 50 22 4.0 8.0
limit so as to achieve accurate dimensions and shape.
The joint shall be self-centering and water tight under
xvi) 1 700 50 22 4.0 8.0
all service conditions. Socket of the pipes may be
xvii) 1 800 50 22 4.0 8.0 projecting or flush with the barrel.
xviii) 1 900 50 22 4.0 8.0
In case of pipe with rubber ring joints, 2 to 3 pipes shall
NOTE — Pipes with internal diameters other than those be installed in factory and site pressure test shall be
mentioned in this table and pipes for working pressure conducted, to prove and finalize pipe and joint design
higher than 28 kg/cm2 can be supplied by mutual and joint dimension tolerances, etc. For one diameter
agreement between the purchaser and the manufacturer. and different pressure, only the test for highest pressure
shall be done.
Table 2 Tolerance on Internal Diameter In case of welded joints, for internal diameters less
( Clause 5.2.1 ) than 800 mm, the steel joint rings will be site welded
externally and for internal diameters above 800 mm,
Sl Internal Diameter Tolerances the steel joint rings will be site welded externally or
No. internally.
In areas within Over Rest of
600 mm of an the Pipe
end of the Pipe 7 DESIGN
(1) (2) (3) (4)
7.1 Information to be supplied by purchaser is given in
i) Up to 900 mm ±6 ±9
Annex B.
ii) Over 900 mm and ±9 ± 12
Up to 1 600 mm 7.2 All pipes shall be designed to withstand the
iii) Over 1 600 mm and ± 10 ± 14
combined effect of internal water pressure and external
loads.
Up to 1 900 mm
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the cylinder under a tensile stress of between 50 and with a hammer having a head weight of not more than
70 MPa. Methods and equipment for wrapping the 0.5 kg. Any hollows or drumming areas detected by
bar/wire shall be such that bar/wire shall be sounding shall be repaired by approved methods.
wound around the cylinder in a helical form at
the predetermined design spacing and capable of 9 SPECIALS
controlling the tension. As the circumferential bar/
wire reinforcement is wound, a cement slurry shall 9.1 Fabrication
be applied to the cylinder just ahead of the bar/wire The steel for fabricated steel plate specials, is cut,
at a rate of not less than 0.5 1itre/m2. The slurry shall shaped and welded so that the finished special has the
consist of 1.2 kg of cement to 1 litre of water. required shape and internal dimensions.
8.4 Cement Mortar Coating Adjacent segments are jointed by butt welding. Before
lining and coating, the welding of specials shall be
After the lined cylinder has been wrapped with tested by use of hot oil or dye penetrant by use of hot
reinforcement bar/wire, the steel cylinder and oil or dye penetrant according to IS 3658 and defects,
reinforcement bar/wire shall be protected with a layer if any shall be rectified. The steel plate thickness for
of rich cement mortar. Cement mortar coating shall specials shall be as given in IS 7322.
be applied by rotary brushes or by other approved
methods and shall preferably be applied within In die penetration test, a white wash is applied over the
16 h after the bar/wire is wound. The cement, sand weld on one side of the cylinder; on other side when
and water shall be thoroughly mixed before being fed coloured paraffin or similar product is applied over the
into the cover coating machine. Minimum cement weld, no coloured spot shall appear on the white wash
content in coating mortar shall be 540 kg/m3. Water- before 4 h. If any coloured spots appear before 4 h,
cement ratio in the mix shall not be less than 0.27. weld shall be repaired and retested.
Rebound or droppings not exceeding one-fourth of 9.2 Lining and Coating
the total mass of mix may be used but the resulting
mix proportions shall not be leaner than original Steel plate specials are lined and coated with concrete,
design mix. Rebound not used within 1 h, shall cement mortar or other approved materials, as agreed
be discarded. The minimum 28 days compressive to between the manufacturer and the purchaser. The
strength of cement mortar shall be obtained from proportion of cement to total aggregate shall not be
cubes having area of 50 cm2 and shall not less than leaner than 1 : 3 by mass.
35 N/mm2. Pneumatic process in which mixing of
9.3 Reinforcement
ingredients is carried out at the nozzle or gun, shall
not be permitted. For cement mortar coating, reinforcement shall be
suitably tack welded to the shell. The reinforcement
The cement mortar coating shall have a minimum
shall be spirals, wire mesh or wire fabric which shall
thickness as per 5.1.2 over all steel, except at end face
conform to IS 1566. The reinforcement shall be a
and the spigot portion going inside socket, where it
minimum 3 percent by mass of the quantity of the steel
will be not less than 15 mm. To achieve adequate bond
cylinder.
between core and coat, approved bonding agent shall
be applied, at ends of pipe for a width of 100 mm, along 9.4 Jointing Between Special and Pipe
the circumference to prevent separation between steel
The specials shall be jointed to the pipe by weld joint
and cement mortar coating at ends.
or by rubber ring joint as the case may be for pipe
Concurrently with the cement mortar coating a cement joint.
slurry shall be applied on to the core at a rate of not
less than 0.5 litre/m2 just ahead of the cement mortar
10 WORKMANSHIP AND FINISH
coating. The slurry shall consist of 1.5 kg of cement to
1.0 litre of water. 10.1 Deviation from the Straightness
The thickness shall be checked for every pipe as soon When measured by means of a one metre straight edge
as, coating is done and to be corrected, if required. the deviation from straight per meter length shall not
The cement mortar coating shall be cured either by exceed 5 mm.
steam or by water or by a combination of steam and
water, or by use of approved curing compounds. If 10.2 Finish
water curing is used for coating, it shall be kept moist Pipe shall be free from local depressions or bulges
for a period of at least 7 days. greater than 5 mm extending over a length, in any
After the cement mortar coating is cured and prior to direction, greater than twice the thickness of barrel.
transport, the coating on each pipe shall be checked The external surface of the pipe may be sand faced,
for delamination and hollows by tapping the exterior, when coating of cement mortar is applied.
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11 TESTS all pipes from that lot may be tested individually and
only those with satisfactory results shall be accepted.
11.1 Hydrostatic Test for Steel Cylinder of Pipe No additional treatment of any type shall be allowed on
Each steel cylinder, with joint rings welded to its ends, the pipe before permeability test is taken.
shall be tested by the manufacturer to a hydrostatic The criteria for acceptance are the final permeability.
pressure not less than that determined by the following The measurement to be taken immediately after factory
formula: test. In case this is taken later, then the pipe has to be
2 St y kept wet for 48 h prior to test
P=
Dyi 11.4 Repair of Lining and Coating
Imperfection in manufacture or damages during
where handling may be treated/repaired and shall be accepted
P = minimum hydrostatic test pressure, in N/mm2; if they satisfy the tests. The curing of the repaired
S = stress in pipe wall during hydrostatic test, mortar may be done using curing compound.
in N/mm2, which shall be 0.75 times the 11.5 Boiling Absorption Test on Coating Mortar
specified minimum yield stress of the steel
used, or as specified by the purchaser; Coating mortar samples shall be drawn and tested for
boiling absorption test according to method described
ty = cylinder thickness, in mm; and in IS 3597.
Dyi = inside diameter of steel cylinder, in mm.
Test value shall consist of the average of a minimum
The test pressure shall be held for 1 min. to observe the of three samples taken on same day from the same
weld seams. There shall be no leaks. Any leaks in the working shift. The average absorption shall not exceed
welded seam, shall be repaired, after which the pipe 9 percent and no individual sample shall have an
section shall be re-tested hydrostatically. If on re-test a absorption exceeding 11 percent.
section shows any leaks in the welded seams, it shall be Testing shall be performed on a weekly basis.
repaired and re-tested.
11.6 Pressure Permeability Test on Coating
11.2 Pipe Test at Factory
The test is to determine the water permeability of the
The finished pipe shall be subjected to factory pressure mortar cover coat on the finished pipe under a constant
test. The pipe shall be tested in accordance with IS 3597. pressure on water column by non-destructive means.
One in 50 pipes shall be subjected to an internal Test is to be conducted as per procedure specified in
hydrostatic test. Should a pipe fail the test, then a further IS 3597.
two pipes from the same batch of 50 shall be tested.
The ratio of cumulative absorption per hour to area
If both pipes pass then the batch shall be accepted. If
of cup orifice in contact with the pipe surface is to be
one or both pipes fail then (the batch shall be rejected
calculated. The ratio shall not exceed 0.15 per hour for
or) each pipe in the batch shall be tested for individual
the period between 121 and 180 min into the test.
approval.
If this requirement has not been attained in the above
The pipe shall be tested for a period of 3 min. During the
stipulated period, the test is to be continued for further
test the pipe shall be absolutely water-tight and show no
periods 240, 300, 360, 420 or 480 min until the
leaks, weeping or defects considered detrimental to the
requirement is met. If the requirement has not been met
pipe’s performance. No crack in the external surface
at 480 min, the pipe has failed to the test, and in such
shall be wider than 0.5 mm on a length exceeding
case further 2 pipes from the batch shall be tested. If both
300 mm using a feeler gauge.
pipes passed for the test the batch shall be accepted. The
Pipe may be dispatched to the laying site if compressive test shall be applied to one pipe in batch up to 500 pipes.
strength of coating mortar criteria specified in 8.4 of
this specification is fulfilled. 12 SAMPLING AND CRITERIA FOR
ACCEPTANCE
11.3 Permeability Test on Coating
The drop of water level, in the specimens of pipes 12.1 Pressure Pipes for Water Supply and Sewerage
selected; when tested according to method described in All the pipes manufactured under relatively similar
IS 3597 shall not exceed 2 cm3 at the end of 2 h and conditions in respect of raw materials and processing
the final permeability between fourth and third hours operation shall be grouped together to constitute a lot.
shall not exceed 0.3 cm3. When a higher result is
obtained, the test shall be repeated on twice the number Each lot shall be taken separately for sampling
of pipes originally tested and the lot shall be accepted, if evaluation, for conformity to the requirements of this
all pipes pass the test. Where re-test is not satisfactory, standard. Scale of sampling is as given in Table 3.
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Sl No. of Pipes Joint Rings Hydrostatic Testing Coating Hydrostatic Test Dimensional Permeability
No. in Lot of Cylinder Thickness of Pipe at Factory Test1) Test
* ** * ** * ** * ** * ** * **
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
i) Up to 50 ALL NIL ALL NIL 3 NIL 1 NIL 3 NIL 3 NIL
ii) 51 - 100 ALL NIL ALL NIL 5 NIL 1 NIL 5 NIL 5 NIL
iii) 101 - 300 ALL NIL ALL NIL 8 NIL 2 NIL 8 NIL 8 NIL
iv) 300 - 500 ALL NIL ALL NIL 10 NIL 2 NIL 10 NIL 10 NIL
v) 500 - 1 000 ALL NIL ALL NIL 14 1 4 NIL 14 1 14 1
1)
Includes socket and spigot dimensions for pipes with rubber ring joints.
* Number of samples.
** Number of defectives acceptable.
12.2 After the lot is accepted, each pipe shall be marked 13.1.2 Wall Thickness
with a colour band at ends. Different colours to be used
for different pressure heads. Measurement of outside circumference of the pipe shall
be made at three positions and average outside diameter
13 PROCEDURE FOR INSPECTION of the pipe shall be calculated. The inside diameter
shall be measured at three positions and average shall
13.1 Dimensional Checks be calculated. The wall thickness shall be calculated as
follows:
13.1.1 Internal Diameter
Average outside Average inside
diameter – diameter
The internal diameter shall be measured at each end of =
the pipe at approximately 50 mm from the ends. Two 2
measurements of the internal diameter at 90° to each
At the spigot section of the pipe, the shape of the steel
other shall be made at each end and centre.
joint ring may require thickness of the lining to be
To accomplish this, ‘Go’ and ‘No Go’ gauges of the less than that specified. The internal diameter shall be
stiff rod with hardened rounded ends are used. The maintained within the tolerance specified.
length of gauges and colour are given below:
13.1.3 Internal Barrel Length
Length Colour The length shall be measured on four longitudinals at
Gauges for ends 90° intervals. The average reading shall be internal
barrel length.
‘Go’ 1 mm less than – ve tolerance Green
‘No Go’ 1 mm more than +ve Orange 13.1.4 Socket and Spigot Diameters
tolerance
The inside circumference of the socket ring and outside
circumference of the spigot ring shall be checked by the
Gauges for centre measurement.
‘Go’ 1 mm less than – ve tolerance Green with
white bands 13.1.5 Straightness
‘No Go’ 1 mm more than +ve Orange with The straightness shall be measured by a 1 m long
tolerance white bands gauge. The deviation from straight line taken between
two points 1 m apart, along the pipe barrel shall not
Example: exceed 5 mm (see Fig. 2).
Suppose theoretical diameter of pipe is 1 200 mm and length of Any deviation from straightness of the bore of pipe
pipe 5 m.
shall be assessed by the use of a gauge as shown in
Tolerance Length of Gauge
Fig. 2. When edge Y is used and both ends are not in
Ends ± 9 ‘Go’ 1 200 - 10 = 1 190 mm contact with the pipe bore, it shall be deemed not to
‘No Go’ 1 200 + 10 = 1 210 mm comply with this standard. When edge × is used and
Centre ± 12 ‘Go’ 1 200 - 13 = 1 187 mm both end of gauge are in contact with the pipe bore, it
‘No Go’ 1 200 + 13 = 1 213 mm shall be deemed not to satisfy the requirement of the
standard.
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ANNEX A
( Clause 2 )
269 : 2015 Specification for ordinary 1852 Rolling and cutting tolerances for
Portland cement (sixth revision) hot rolled steel products
383 : 2016 Specification for coarse and fine 2062 : 2011 Steel for general structural
aggregates from natural sources purpose (fourth revision)
for concrete (second revision) 3597 : 1998 Methods of test for concrete
432 Specification for mild steel pipes (second revision)
and medium tensile steel bar/ 3658 : 1999 Code of practice for liquid
wires hard-drawn steel wire for penetrant flaw detection (second
concrete reinforcement revision)
(Part 1) : 1982 Mild steel and medium tensile 5382 : 1985 Rubber sealing rings for gas
steel bar/wires (third revision) mains, water mains and sewers
(Part 1) : 1982 Hard-drawn steel wire (third (first revision)
revision) 5822 : 1994 Code of practice for laying of
455 : 2015 Specification for Portland slag electrically welded steel pipes
cement (fourth revision) for water supply (second
revision)
456 : 2000 Code of practice for plain and
reinforced concrete (fourth 6909 : 1990 Specification for supersulphated
revision) cement
783 : 1985 Code of practice for laying of 7322 : 1985 Specification for specials for
concrete pipes (first revision) steel cylinder reinforced concrete
pipes (first revision)
1489 Specification for Portland
pozzolana cement 8041 : 1990 Specification for rapid hardening
Portland cement (second
(Part 1) : 2015 Fly ash based (third revision) revision)
(Part 2) : 2015 Calcined clay based (third 9103 : 1999 Specification for admixtures for
revision) concrete (first revision)
1566 : 1982 Specification for hard-drawn 12330 : 1988 Specification for sulphate
steel wire fabric for concrete resisting Portland cement
reinforcement (second revision)
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ANNEX B
( Clause 7.1 )
B-1 The following information shall be supplied: 2) The width of the trench at the crown of
a) The type of cement to be used for the lining and the pipe (normally outside diameter of pipe
the cover coat (see 4.1); + 600 mm) If the pipes are to laid above
ground/partial trench, full details including
b) Whether or not a bituminous or other approved L-section should be supplied,
coating is required internally and externally
(see 4.8); 3) Whether more than one pipeline is to be laid
in the trench and if so, what will be the trench
c) The maximum working pressure (see 3.3); width at the crown of the pipe,
d) The maximum site test pressure (see 3.4); 4) Details of the backfill material, that is, sand
e) Factory test pressure (see 3.5); gravel etc,
f) Pressure in addition to (c) to which the pipeline 5) Density of filling material,
will be subjected due to surge (water hammer), 6) Type of bedding intended, and
if any;
7) Anticipated superimposed loading on ground
g) Soil investigation and soil data; surface.
h) Following pipe installation details:
1) The maximum and minimum depths of cover
over the crown of the pipe,
ANNEX C
( Clause 7.6 )
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C-3.1 Calculation of Total Steel Area (Ast) C-3.3 Area of Bar/wire Reinforcement (Ab)
a) Required total steel area considering factory test Total steel area ( Ast ) = Cylinder steel area (Ay) + Area
pressure: of bar/wire reinforcement ( Ab)
Pf × Dyi Ab = Ast – Ay
Ast =
2 × f st = 3 700 – 2 500 = 1 200 mm2/m …… (4)
For factory test pressure Pf , fst ≤ 0.75 × fsce or As per clause 7.4 minimum area of bar reinforcement
187 N/mm2 that is, fst ≤ 0.75 × 250 or 187 N/mm2 Ab =0.83 × D or 487 mm2/m
Average circumferential stress in steel cylinder for Ab = 0.83 × 1 000 = 830 mm2/m …… (5)
factory test pressure,
or
fst = 187 N/mm2
Ab = 487 mm2/m …… (6)
1.2768 × 1 035 Provide area of bar/wire reinforcement greater of (4),
Ast = = 3.533 mm2/mm
2 × 187 (5) and (6)
=3533 mm2/m ...... (1)
Therefore, provide Ab = 1 200 mm2 /m
b) Required total steel area considering site test
pressure: C-3.3.1 Center to Center Spacing of Bar/Wire
Ps × Dyi Reinforcement
Ast =
2 × f st Bar/wire diameter db = 6 mm
For site test pressure Ps, fss ≤ 0.66 × fsce or 165 N/mm2 Cross-sectional area of bar/wire Adb = π / 4 × db2
that is fss ≤ 0.66 × 250 or 165 N/mm2 = 0.7854 × 62 = 28.27 mm2
Average circumferential stress in steel cylinder for site 1 000 × Adb
Centre to centre spacing = Ast =
test pressure, fst = 165 N/mm2 Ab
For working pressure Pw, fsw ≤ 0.5 × fsce or 125 N/mm² . Since, clear spacing 17.56 > Bar/wire diameter and
centre to centre spacing 23.56 < 50 mm
that is fsw ≤ 0.5 × 250 or 125 N/mm² Hence, 6.0 mm dia bar/wire is acceptable.
Average circumferential stress in steel cylinder for C-3.4 Calculation of Stress in Steel Considering
working pressure, Total Steel Area Provided
fsw = 125 N/mm2 Actual total steel area, Ast
0.7845 × 1 035 Ast = Ay + Ab = 2 500 + 1 200 = 3 700 mm2/ m
Ast = = 3.248 mm2/mm
2 × 125 =3.700 mm2/mm.
=3248 mm2/m ...... (3)
As per 7.3.1 stress in steel shall not exceed.
Total steel area Ast = Greater of (1), (2) and (3) a) 187 N/ mm2 or 75 percent of the yield strength of
= 3 691 mm2/m say, 3 700 mm2/m steel when the pipe is subjected to the factory test
pressure.
C-3.2 Cylinder Steel Area, Ay b) 165 N/ mm2 or 66 percent of the yield strength
of steel when the pipe is subjected to the site test
Ay = ty × 1 000 = 2.5 × 1 000 = 2 500 mm2/m.
pressure.
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c) 125 N/ mm2 or 50 percent of the yield strength Dyi = Inside diameter of steel cylinder (in mm).
of steel when the pipe is subjected to the working = 1 035 mm.
pressure.
Therefore, Hydrostatic test pressure for steel cylinder
C-3.4.1 Calculation of Stress in Steel (Fa)
2 × 250 × 0.75 × 2.5
P × Dy P= = 0.905 8 N/mm 2
Fa = 1 035
2 × Ast
C-3.6 Check for Horizontal Deflection of Pipe
a) For factory test pressure, P = 1.276 8 N/mm2
1.276 8 × 1 035 C-3.6.1 Calculation of Allowable Deflection of Pipe
Fa = = 178.58 N/mm 2
2 × 3.700 As per 7.3.2, allowable deflection of pipe should not be
Yield strength of steel cylinder, fsce = 250 N/mm 2 more than D2 / ( 1.02 × 10 5 ) .
1 0002
Allowable stress in steel ≤ 0.75 × 250 or 187 N/mm2 Allowable deflection = P = = 9.80 mm
Therefore allowable stress in steel = 187 N/mm2 (1.02 ×105 )
As the actual stress is steel (178.58) is less than C-3.6.2 Calculation of Actual Deflection of Pipe
allowable stress in steel (187), satisfies the criteria.
Actual horizontal deflection of pipe is calculated by
b) For site test pressure, P = 1.176 8 N/mm2 using the Spangler formula for deflection:
1.776 8 × 1 035
Fa = = 164.59 N/mm 2
2 × 3.700 D1 × K b × W × rm 3
∆x =
E1 + 0.061 4 × E ′ × rm 3
Yield strength of steel cylinder, fsce = 250 N/mm2
Allowable stress in steel ≤ 0.66 × 250 or 165 N/mm2 where
Therefore allowable stress in steel = 165 N/mm2 ∆x = increase of diameter at the springline,
As the actual stress is steel (164.59) is less than Dl = deflection lag factor,
allowable stress in steel (165), satisfies the criteria.
Kb = bedding coefficient,
c) For working pressure, Pw = 0.784 5 N/mm2 W = vertical load on pipe,
0.784 5 × 1 035 El = flexural rigidity of pipe wall (computed wall
Fa = = 1099.72 N/mm 2
2 × 3.700 stiffness),
E' = modulus of soil reaction, and
Yield strength of steel cylinder, fsce = 250 N/mm2
rm = pipe mean radius.
Allowable stress in steel ≤ 0.5 × 250 or 125 N/mm2
Therefore allowable stress in steel = 125 N/mm2 The computed wall stiffness should be one-fourth of
As the actual stress is steel (109.72) is less than the value derived from the composite wall section of
allowable stress in steel (125), satisfies the criteria. pipe.
C-3.5 Calculation of Hydrostatic Test Pressure of C-3.6.2.1 Calculation of vertical Load on top of pipe
Cylinder due to backfill ( W ).
As per 11.1, each steel cylinder, with joint rings welded C-3.6.2.1.1 Weight of Earth fill ( We ) ( see Fig. 4 of
to its ends, shall be tested by the manufacturer to a IS 783 )
hydrostatic pressure not less than that determined by H / Bt = 1.0 / 1.69 = 0.592
the following formula:
Ct = 0.5446
2 St y
P= We = Ct × Ke × Bt2
Dyi
= 0.5448 × 17650 × 1.692
Where, = 27 464 N/m
P = Minimum hydrostatic test pressure, in N/mm 2;
C-3.6.2.1.2 Live load ( Wl ) ( see Fig. 3 and 9.1 of
S = Stress in pipe wall during hydrostatic test, IS 783 )
in N/mm2;
Cp × P × α
= 0.75 × 250 = 187.50 N/mm2; W1 =
l
ty = Cylinder thickness ( in mm ) = 2.5 mm; and
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IS 15155 : 2020
Component A Y AY Ix
Total Section 1000 t 0.5 t 500 t 2 333.33 t 3
Steel Cylinder ( n – 1 ) Ay ti + 0.5 ty = Yy ( n – 1) Ay Yy ( n – 1) Ay Yy2
Steel Bar ( n – 1 ) Ab ti + ty + 0.5 db = Yb ( n – 1) Ab Yb ( n – 1 ) Ab Yb2
ΣA Σ AY Σ Ix
Y = ΣAy / ΣA I x = Ix – Y 2 × ΣA
Component A Y AY Ix
Total Section 45 000.00 22.50 1012500.00 30374696.25
Steel Cylinder 15 357.25 18.75 287948.44 5399033.20
Steel Bar 7 371.48 23.00 169544.04 3899512.92
Total 67 728.73 1469992.48 39673242.37
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C-3.6.2.4 Actual horizontal deflection of pipe is: fss = Allowable average circumferential stress in steel
cylinder for site test pressure, N/mm2
D1 × K b × W × rm 3
∆x = fst = Allowable average circumferential stress in steel
E + 0.061 4 × E ′ × rm 3
1 cylinder for factory test pressure, N/mm2
1× 0.096 × 38.04 × 522.503
∆x = fsw = Allowable average circumferential stress in steel
53 412 858 + 0.061 4 × 4.80 × 522.503 cylinder for working pressure, N/mm2
520919512.74 Fa = Calculation of stress is steel, N/mm2
∆x =
95 453 418.05
Fi = Flexural rigidity of pipe wall (computed wall
Dx = 5.46 mm stiffness)
Actual horizontal deflection of pipe (5.46 mm) is less H = Height of fill, m
than allowable deflection of pipe (9.80 mm )
Hence the design is safe for horizontal deflection. Ix = Moment of inertia of the transformed section about
it’s centre of gravity parallel to the X-axis, mm4/m
C-4 SYMBOL USED IN THE DESIGN
Kb = Bedding coefficient
a = Impact factor Ke = Density of fill material, kg/m3
A b = Area of bar/wire reinforcement, mm2/m l = Length of pipe assumed to carry concentrated load, m
Adb = Cross-sectional area of bar/wire, mm 2
n = Modular ratio
Ay = Cylinder steel area, mm /m
2
p = Axle load, N
Bc = Outside diameter of pipe, mm P = Minimum hydrostatic test pressure, N/mm2
Bt = Trench width, mm Pw = Working pressure, N/mm2
CP = Coefficient used in the calculation of vertical load Ps = Site test pressure, N/mm2
on a pipe due to concentrated superimposed load
Pf = Factory test pressure, N/mm2
Ct = Coefficient used in the calculation of vertical load
on a pipe due to fill material when the pipe is installed rm = Pipe mean radius, mm
in Trench condition.
S = Stress in pipe wall during hydrostatic test, N/mm2
D = Diameter of pipe, mm
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ANNEX D
( Foreword )
COMMITTEE COMPOSTION
Cement Matrix Products Sectional Committee, CED 53
Organization Representative(s)
National Council for Cement and Building Shri V. V Arora (Chairman)
Materials, Ballabgarh
Ambuja Cements Limited, Ahmedabad Shri J. P. Desai
Shri B. K. Jagetiya (Alternate)
Asbestos Information Centre, New Delhi Shri Durgesh C. Sharma
Shri John Nicodemus (Alternate)
Brihanmumbai Municipal Corporation, Mumbai Shri Vishal Thombare
Central Design Organization Nasik, Mumbai Representative
Central Pollution Control Board, Delhi Representative
Central Public Health & Environmental Engineering Representative
Organization, New Delhi
Central Public Works Department, New Delhi Shri Manoj Kumar Sharma
Shri Prem Pal Singh (Alternate)
CSIR-Central Building Research Institute, Roorkee Shri S. K. Singh
Shrimati M. Surya (Alternate)
CSIR-Structural Engieering Research Centre, Shri P. Srinivasan
Chennai Dr B. H. Bharat Kumar (Alternate)
Delhi Development Authority, New Delhi Representative
Directorate General of Factory Advise Services and Dr Champak Bhattacharya
Labour Institute, Mumbai
Engineers India Limited, New Delhi Shri Rajanji Srivastava
Shri Anurag Sinha (Alternate)
Everest Industries Limited, New Delhi Shri Y. Srinivasa Rao
Shri S. P. Bolar (Alternate)
Gammon Engineers and Contractors Pvt Ltd, Shri Manish Mokal
Mumbai Shri Sudeesh Rajendran (Alternate)
HIL Limited, Hyderabad Shri R Pradeep Kumar
Dr D. Satyanarayana (Alternate)
Housing & Urban Development Corporation Chairman and Managing Director
Limited, New Delhi Shri Deepak Bansal (Alternate)
Military Engineer Service, Engineer-in-Chief’s Shri V. K. Manglik
Branch, Integrated HQ of Ministry of Defence Shri P. K. Gupta (Alternate)
(Army), New Delhi
Ministry of Science & Technology, New Delhi Representative
Ministry of Environment and Forest, New Delhi Representative
National Council for Cement & Building Materials, Shri P. N. Ojha
Ballabgarh Dr Varsha Liju (Alternate)
National Test House, Kolkata Shri B. R. Meena
Shri Aloke De (Alternate)
North Delhi Municipal Corporation, New Delhi Shri Pradeep Bansal
Shri M. P. Gupta (Alternate)
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Organization Representative(s)
Public works department, Government of Haryana, Shri Lalit Arora
Chandigarh
Rural Electrification Corporation Limited, New Shri G. S. Bhati
Delhi Shri Ranjit Ranjan (Alternate)
Spun Pipes Manufacturer’s Association of Shri C. Y. Gavhane
Maharashtra, Nanded Shri D. N. Joshi (Alternate)
Tamil Nadu Water Supply & Drainage Board, Shri S. Hariramasamy
Chennai
The Indian Hume Pipe Company Limited, Mumbai Shri P. R. Bhat
Shri S. J. Shah (Alternate)
In Personal Capacity, (B-806, Oberoi Exquisite Shri A. K. Jain
Oberoi Garden City, Goregaon East, Mumbai)
BIS Directorate General Shri Sanjay Pant Scientist ‘F’ and Head (Civil Engineering)
[ Representing Director General ( Ex-officio ) ]
Member Sectary
Dr Manoj Kumar Rajak
Scientist ‘D’ (Civil Engineering), BIS
SUB-COMMITTEE COMPOSTION
Concrete Pipes Subcommittee, CED 53:2
Organization Representative(s)
In personal capacity (2nd floor, Saket, 5 Manisha Shri P. D. Kelkar (Convener)
Housing Society, Karve Nagar, Pune 411052)
Ambuja Cements Ltd, Ahmedabad Shri J. P. Desai
Shri B. K. Jagetiya (Alternate)
Apollo Hawkeye Pedershaah Concrete Tech Pvt Ltd, Shri Anil Milhoutra
Distt Mehsana Shri Amit Suthar (Alternate)
Central Public Works Department, New Delhi Shri B. B. Dhar
Shri Mathura Prasad (Alternate)
CSIR-Central Building Research Institute, Roorkee Shri S. K.singh
Shrimati M. Surya (Alternate)
CSIR-National Environmental Engg. Research Dr Tapan Chakrabarti
Institute, Nagpur Dr T. Nandy (Alternate)
CSIR-Structural Engineering Research Centre, Shrimati P. S. Ambily
Chennai Shri S. Sundar Kumar (Alternate)
Delhi Jal Board, New Delhi Shri Verinder Singh Thind
Directorate General of Supplies & Disposals, Addl. Director General (QA)
Hyderabad
Essar Steel Ltd, Mumbai Representative
Federation of U.P. Pipe Manufacturers, Lucknow Shri A. S. Puri
Shri S. P. Rastogi (Alternate)
Haryana Public Works Department, Chandigarh Shri Mahesh Kumar
Shri Mahabir Singh (Alternate)
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Organization Representative(s)
Indian Water Works Association, Bhopal Shri R. N. Gupta
Larsen and Toubro Limited, Chennai Shri P. Balakumar
Shri T. S. S. Prasad (Alternate)
Maharashtra Engineering Research Institute, Nashik Shri A. S. Mahire
Millars Concrete Technologies Pvt Limited, Mumbai Shri Gunwant Galande
Shri N. B. Joshi (Alternate)
Ministry of Science and Technology, New Delhi Shri Chander Mohan
Municipal Corporation of Greater Mumbai, Mumbai Representative
National Council for Cement & Building Materials, Shri Amit Trivedi
Ballabgarh Shri Amit Prakash (Alternate)
National Highway Authority of India, New Delhi Dr J. K. Goyal
Shri Ajay Kumar Sabharwall (Alternate)
Pakona Engineers (I) Pvt Ltd, Vadodara Shri Rohit J. Shah
Shri Ashok J. Kothari (Alternate)
Public Health & Municipal Engg. Department Representative
Public Health Engineering Department Chattisgarh, Representative
Raipur
Rajasthan Public Health Engineering Department, Representative
Jaipur
Shah Technical Consultancy Pvt Ltd, Mumbai Shri Mahaveer K. Tone
Shrimati Sumedha S. Shah (Alternate)
Spun Concrete Pipe Manufacturers’ of Karnataka, Shri K. V. Sekhar Raju
Bangalore
Spun Pipe Manufacturers Association of Maharashtra, Shri C. Y. Gavhane
Nanded Shri D. N. Joshi (Alternate)
Tamil Nadu Water Supply & Drainage Board, Chennai Shri K. Nagarajan
Tata Consultancy Services, Mumbai Representative
The Indian Hume Pipe Company Limited, Mumbai Shri P. R. Bhat
Shri S. J. Shah (Alternate)
The Tata Iron and Steel Company Ltd, Mumbai Shri S. G. Joshi
Shri Ganesh P. Chaudhari (Alternate)
Waste and Land Management Institute, Aurangabad Representative
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BIS is a statutory institution established under the Bureau of Indian Standards Act, 2016 to promote harmonious
development of the activities of standardization, marking and quality certification of goods and attending to
connected matters in the country.
Copyright
BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without
the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the
standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to
copyright be addressed to the Director (Publications), BIS.
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
‘BIS Catalogue’ and ‘Standards: Monthly Additions’.
This Indian Standard has been developed from Doc No.: CED 53 (10868).