Pipeline design

concrete for life

CPM Concrete Drainage Systems

Pipeline Design
CPM Concrete Drainage Systems

Pipeline design - hydraulic

Graph showing relative velocity and discharge in a circular pipe for any depth of flow

1.0

0.9

0.8

0.7
Proportional depth of flow

0.6
E
A RG
0.5
IS CH
LD
NA
TIO
0.4
P OR
P RO

0.3

ITY
0.2 L OC
VE
AL
T IO N
OR
0.1 OP
PR

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

Proportional velocity and discharge in pipes flowing part full

For calculating transitional flow, using the Colebrook-White equation, a roughness factor of Ks = 0.3mm is
recommended as a realistic figure for newly installed concrete pipelines. However, research has indicated that for
mature foul sewers of any material the Ks value may rise well above this figure and the Water Services Association
publication Sewers for Adoption 5th Edition recommend the following:

Foul and combined sewers Ks = 1.5mm (minimum velocity should be 0.75m/ see at one third design flow)
Surface water sewers Ks = 0.6mm (minimum velocity should be 1m/sec at full pipe flow)

Hydraulic flow charts have therefore been included for the three roughness coefficients Ks of 0.3, 0.6 and 1.5mm.
CPM Concrete Drainage Systems

Pipeline design - hydraulic

Example on use of flow charts

Design of surface water sewer

Pipeline length 200m

Difference in level between inlet and outlet 1m
Design discharge 4 cubic metres/sec
(4,000 litres/sec)

to determine the size of pipe when:

a. flowing full
b. the proportional depth of flow is 0.6 (i.e. 60% full)

Solution

Hydraulic gradient 1 in 200 (or 0.005)

Ks for surface water sewer 0.6mm

a. Pipe flowing full:

Refer to Hydraulic Flow Chart for Ks = 0.6mm.
The intersection of the horizontal discharge line of 4 cubic metres per second with the vertical hydraulic gradient
line of 1 in 200 gives:

Pipe diameter 1350mm

Average velocity 2.8 metres/sec

b. Pipe flowing 60% full:

Refer to the graph showing Relative.
Velocity and Discharge in a Circular pipe for any Depth of Flow.

The intersection of the horizontal proportional depth line of 0.6 with the proportional discharge and velocity curves
gives:

Proportional discharge 0.67

Proportional velocity 1.07

Therefore

Actual discharge 0.67 x 4 2.68 cubic metres/sec

Average velocity 1.07 x 2.8 3.0 metres/sec
CPM Concrete Drainage Systems

Pipeline design - hydraulic

Hydraulic flow charts

For Pipes Flowing Full Ks = 0.3mm (Colebrook-White) Water 150C

CPM Concrete Drainage Systems

Pipeline design – hydraulic

Hydraulic flow charts

For Pipes Flowing Full Ks = 0.6mm (Colebrook-White) Water at 15°C

CPM Concrete Drainage Systems

Hydraulic flow charts

For Pipes Flowing Full Ks = 1.5mm (Colebrook-White) Water at 15°C

CPM Concrete Drainage Systems

Pipeline design – structural design

Introduction

This section is based on BS EN 1295-1: 1998 Structural Design of Buried Pipelines Under Various Conditions of
Loading. This standard gives guidance on the nationally established methods of design. For the UK this is detailed
in ‘A Guide to Design Loadings for Buried Rigid Pipes’ published by HMSO 1987 and ‘Simplified Tables of External
Loads on Buried Pipelines’ published by HMSO 1992.

The charts give the maximum depth of cover for single pipelines laid in a narrow trench where there will be relief of
load due to friction at the fill/trench wall interface and where the pipe is laid in wide trench conditions.

Where special conditions apply, e.g. multiple pipelines in a single trench, pipelines supported on piles, trench
backfilled with lean concrete and delayed removal of trench sheeting, the charts may not be applicable and advice
should be sought from our Technical Department or reference made to the full publication.

Whilst the normal recommendation in the UK is to have a minimum of 1.2m cover (measured from the top of the
pipe barrel to the finished road surface) under roads and 0.9m elsewhere, it is sometimes necessary to lay pipes at
less cover and the charts have been prepared with a minimum cover of 0.6m in Roads and Fields, etc. However,
special precautions should be taken to minimise the risk of mechanical damage during future excavations and
reinstatement of other services, agricultural machinery, etc.

The charts are based on the loadings likely to be encountered when installation, including reinstatement, is
complete and care must be taken to ensure that the concentrated load due to construction traffic does not exceed
the design surcharge loads given.

For a full structural analysis contact our Technical Department who can provide detailed calculations and
recommendations on bedding design.

Bd Bd Bd
H

min
300mm

Bc Bc Bc
CPM Concrete Drainage Systems

Pipeline design – structural design

Bedding class and factors

The load-bearing capacity of a concrete pipeline is dependent both on the strength of the manufactured pipe and
on the support provided by the bedding. The bedding factor (Fm) is the ratio of the strength of the laid pipe to its
laboratory crushing test strength.
The higher the bedding factor the greater is the load carrying capacity of a given pipeline.

The methods of bedding normally used with concrete pipes are:

Bc
Bc Bc

300 300
300
Y

DN

Y Y
45° 180° Y

Bedding class F B S
o o o
Description 45 granular bed 180 granular bed 360 granular bed
Bedding factor 1.5 1.9 2.2
1¼ Bc 1¼ Bc
Bc+200min Bc+200min

300 300

120° 120°
¼Bc ¼Bc
¼DN min ¼DN min

Bedding class A unreinforced A reinforced

o o
Description 120 unreinforced concrete cradle 120 reinforced concrete cradle
Bedding factor 2.6 3.4
Notes
1. Concrete cradles may extend to sides of trench.
2. Transverse steel to be 0.4% min of section at x-x (Fm 3.4).
2
3. Minimum strength concrete of 20N/mm .
4. Allow concrete to gain sufficient strength prior to trafficking.
5. Maintain pipeline flexibility by leaving gaps at pipe joints filled with compressible material.
6. Bedding beneath and at sides of pipe to be well compacted.
7. Bedding/backfill directly above pipe to be lightly compacted.
8. Dimension Y: minimum of 1/6Bc or 100mm under barrels, and 50mm minimum under sockets whichever is
greater (400mm maximum). In rock etc. use 1/4Bc and 150mm minimum under sockets.

Key Granular bedding Selected backfill In-situ

material material concrete

Nominal size of pipe Pipe bedding requirement

DN mm
225 to 525 10, 14 or 20 nominal single size or 14 to 5 graded or 20 to 5 graded
600 and above 10, 14, 20 or 40 nominal size crushed rock or 14 to 5 graded or 20 to 5 graded or 40 to 5 graded
CPM Concrete Drainage Systems

Pipeline design – structural design

Crushing test loads

Crushing test loads in kilonewtons per metre of effective length for concrete pipes.

EN 1916 / BS 5911-1:2002
Nominal Size Minimum crushing load
DN (Fn)
kN/m
225 27
300 36
375* 45
400 48
450* 54
500 60
525* 63
600 72
675* 81
700 84
750* 90
800 96
825* 99
900 108
1000 120
1050* 126
1125+ 135
1200 144
1350* 162
1400 168
1500* 180
1600 192
1800 216
2000 240
2100* 252
2200 264
2400* 288
2500 300
2800 336
3000 360

* Denotes classic size.

+
Not kitemarked.

Notes:

1. Pipes of higher crushing strengths than those above can be manufactured in certain diameters. Details of required
strengths should be sent to the Sales Office at Mells.

2. CPM Group do not make all of the sizes listed above.

CPM Concrete Drainage Systems

Pipeline design – structural design

Safe supporting strength

For a safe design the supporting strength of an installed pipeline must exceed the total external design load where
the supporting strength is the product of the pipe crushing strength and the bedding factor and the total external
load is the sum of the trench load, surcharge load and for pipes greater than DN600 the equivalent water load.
A minimum bedding factor required can be calculated from:

We x Fse
Fm >
Fn.

Where Fm = Bedding factor

We = Total external load (See BS EN 1295 – 1)
Fse = Factor or safety taken as a minimum of 1.25 (see note below)

• Unreinforced pipes (DN225-600 inclusive) = 1.25

• Reinforced pipes manufactured to BS EN 1916, the Fse increases to

1.5, However in order to maintain design continuity and to cater for schemes designed prior
to the implementation of BS EN1916, CPM will continue to test reinforced pipes to BS5911 –
100 proof loads permitting continued use of the current Fse = 1.25
CPM Concrete Drainage Systems

Pipeline design – structural design

Depth of cover charts – Class 120 Pipes under fields Fse = 1.25

DN Bc Bd Cover Depth (m)

mm mm mm 1.0 2.0 3.0 4.0 5.0 6.0 7.0
225 295 0.7
Wide
300 410 0.85
Wide
375 495 1.05
Wide
450 530 1.15
Wide
525 675 1.20
Wide
1.35
600 770
Wide

675 860 1.45

Wide
750 940 1.50
Wide
825 985 1.60
Wide
900 1100 1.90
Wide
1050 1265 2.10
Wide
1125 1345 2.20
Wide
1200 1450 2.30
Wide
1350 1620 2.50
Wide
1500 1740 2.70
Wide
1600 1920 2.81
Wide
1800 2090 3.10
Wide

DN = Nominal diameter Bc = External diameter Bd = Trench width

Class B Class S
CPM Concrete Drainage Systems

Pipeline design – structural design

Depth of cover charts – Class 120 Pipes under main roads Fse = 1.25

DN Bc Bd Cover Depth (m)

mm mm mm 1.0 2.0 3.0 4.0 5.0 6.0 7.0
225 295 0.7
Wide
300 410 0.85
Wide
375 495 1.05
Wide
450 530 1.15
Wide
525 675 1.20
Wide
1.35
600 770
Wide

675 860 1.45

Wide
750 940 1.50
Wide
825 985 1.60
Wide
900 1100 1.90
Wide
1050 1265 2.10
Wide
1125 1345 2.20
Wide
1200 1450 2.30
Wide
1350 1620 2.50
Wide
1500 1740 2.70
Wide
1600 1920 2.81
Wide
1800 2090 3.10
Wide

DN = Nominal diameter Bc = External diameter Bd = Trench width

Class B Class S
Sco t land S ales a nd Work s
CPM Group Ltd, 101 Main Street, Newmains, Wishaw,
Lanarkshire, ML2 9BG
Tel: 01698 386922 Fax: 01698 387167

Po lling to n Wo rks
CPM Group Ltd, Pollington, Goole,
East Riding of Yorkshire, DN14 0DU
Tel: 01405 860591 Fax: 01405 863606

Leek S ales a nd Wo rk s
CPM Group Ltd, Barnfields, Leek, Scotland Sales and Works
Staffordshire, ST13 5QG
Tel: 01538 380500 Fax: 01538 380510

Te chnic al Off ic es
CPM Group Ltd, CPM House, Heath Mill Road, Wombourne,
Wolverhampton, West Midlands WV5 8AP
Tel: 01902 356220 Fax: 01902 356221

Pollington Works

Leek Sales and Works

Hea d Of fi
ficce S ales and Work s
CPM Group Ltd, Mells Road, Mells, Nr Frome, Technical Offices

Somerset, BA11 3PD

Tel: 01179 812791 Fax: 01179 814511

sales@cpm-group.com Head Office Sales and Works

ww w. cp m-g ro up. co m