IS t 784- 1979

( Reaffirmed 1991 )
Indian Standard
SPECIFICATION FOR
PRESTRESSED CONCRETE PIPES
( INCLUDING FITTINGS )

( First Revision )

Fourth Reprint MARCH 1992

lJ!X 621.643.4L666.982.41

@ Copyright 1979

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARQ
NEW DELHI 110002

Gr 6 March 1979
 IS 8784.1978

Indian Standard
SPECIFICATlON FOR
PRESTRESSED CONCRETE PIPES
( INCLUDING FITTINGS )

( First Revision )

Cement and Concrete Sectional Committee, BDC 2

Chairman Reprcsenf ing

DnH.C. VISVESVARAYA Cement Research Institute of India, New Delhi

A~JXTIONAL DIRECTOR, ST.~ND- Research, Designs & Standards Organization

ARDS ( B & S ) ( Ministry of Railways )
DEPUTY DIRECTOR, STAND-
ARDS ( B & S ) ( Alternafe )
Sam K.C.ACQAB~AL Hindustan Prefab I.td, New Delhi
Sultr c. L. K~s~.lrrfa~ ( Alternate )
SHRI B. C. BANERJEP Cement Corporation of India Ltd, New Delhi
SHRI A. U. KIJHSXNQHANI ( Alternate )
SKI~I K. P. BANERJEE Larsen & Toubrk Limited, Bombay
Snss HARISH N. MALONE ( Altcrnalc )
SRRI R. N. BANSAL Beas Designs Organization, Nangal Township
SHKI T. C. Gana ( Alternat* )
DR N. S. BRAL Struct;tr~e~gineering Research Centre ( CSIR ),

SHRr R. v. CHALlPATHI RAO- Geological Survey of India, Calcutta

SHRI S. ROY ( Alternate )
CHIEF ENGINEER ( PROJECTS ) Irrigation Department, Government of Punjab,
Chnndigarh
DIRECTOR. IPRI ( Alternate )
DIRECTOR ( CSMRS ) Central Water Commission, New Delhi
DEPUTY DIRECTOR ( CSMRS )
( Alternate )
ENOINEER-IN-CHIEF Central Public Works Department, New Delhi
S~JPERINTENDINQ ENQINEER
f DELHI CENTRAL CIROLE
No. 2 ) ( Alternate )
SHRI A~IITABHA GHOSH National Test House, Calcutta
SIiRI E. K. RAMACIIANDBAN ( Altcrnutc) ‘,
:3
( Coxtiaurd on pugs 2 )

@ Copyright 1979
BUREAU OF INDIAN STANDARDS
This publication is protected under the Indian Copyright Act ( XIV ,of 1957 ) and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
 I$ : 781 - 1978

( Continued frown page 1 )

Mm hers Reprcscnfing

DR R. Ii. GI-iossr Cent;;afl$xd Research Institutr ( CSIR ), New

SIlRI Y. 11. PJlUL’L ( nhrna66 1 )
S;ukr M. UIN.~KARAN ( Alrernotc II )
Da 11. I<. G~os~l ‘Indian Roads Congress, New Delhi
SHI<I B. R. Govr~u Engineer-in-Chief’s Branch, Army Headquarters
SJfHI G. R. kfIIICIIA?I’DANI ( &ernafe )
SIil%I A. I-c. GGPTA Hyder;lbad Asbestos Cemrnt Products Ltd,
Hyderabad
DR R. R, HATTraNGlDI The Associated Cement Companies Ltd, Bombay
’ !hlrr P. J: j&R ( ~hV,nlc )
I~R IQIIAL iII.1 Eygineering Research Laborntorirs, Hvderahad
Sanr M. T. KAN~E DIrectorate Gcncral of Supplies & Disposals,
New Delhi
SRRT S. R. i<ULKARNl M. IV. Dastur & Co ( Pvt ) Ltd, Calcutta
SFRI s. I<. J.*ns The Institution of Engineers ( India ), Calcutta
SCIRI B. T. UXWALLA ( Alfcrnafc )
DIG MOHAN Rar Central Building Research Institute ( CSIR ),
Roorkee
Dx S. Y. RERW ( &tirnnte )
Snltr I<. K. NhhIT3IAR In personal capacity ( RamonalaJa, II First (;te:cenJ i
Park Road. Gandhinagar, Adyar, Madras )
DJL A. V. Ii. RAO National Buildings Organization, IXew Dclh’i
SHRI K. S. SR~NIVASAN ( Alternate )
rm
SURI I. N. !;. Rno Gammon India Ltd, Bombay
SlfJ%IS. R. PIN IIEIRO (. &kYIde )
SHXETAHY Central Board of Irrigation and Power, New Delhi
DEPUTY SECJ~ETARY ( Altemate )
srin1 N. Sm Roads Wing ( Ministry of Shippitlg and Transport )
S?IKX i. R. K. hlSAD ( Alternate j
Saw K. X. SUHR~~MANIAX ’ The India Cements Lrd, Madras
SFWK P. S. KAMACHANDRAN ( Allwnale )
SCPERINTENPINCI E N G I N E E R Public Works Department, Government of Tam3
( DEsrcss ) Nadu
ExWxJ~rlvli: ENCJINREIZ
( SM &: R DIVISION) ( Alfcmak )
SRRI L. SwaKooP Dalmia Cement ( Bhnrat ) Ltd, New Delhi
S~ltr A. V. RAMANA ( Alternate )
SHRI B. T. ZJNWAT.LA The Concrete Association of India, Bombay
SJIRI T. M. h~swoN ( Alternate)
Sntrr D. AJITHA SIMI~A, Director General, IS1 ( Ex-ofJirio lZlcmbrr )
Director ( Civ Engg )

Secretory

SHRI M. N. NEELAHANDH.AX
Assistant Director ( Civ Engg ), IS1

( Continued on pa@ Zf )
 IS : i84 - 1978

Indian Standard
SPECIFICATION FOR
PRESTRESSED CONCRETE PIPES
( INCLUDING FITTINGS )
( First Revision )

0. FOKEWOKD

0.X This Indian Standard ( First Revision ) was adopted by the Indjnn
Standards Institution on 28 December 1978, after the draft finalized by
the Cement and Concrete Sectional Committee had been approved by
the Civil Engineering Division Council.
0.2 This standard was first published in 1959. The present revision ~sas
taken up with a view to bringing it in line with the latest trends in the
related technology and to incorporating the modifications found necessary
as a result of use of the earlier version of this specification.
0.3 This standard lays down the requirements of prestressed concrete
pipes primarily used for the conveyance of water and sewerage and
fittings for use with them. Two types of prestressed concrete pipes are
covered by this specification, namely, prestressed concrete cylinder pipes
and prestressed concrete non-cylinder pipes.

0.4 The present revision incorporates a number of modifications, the

most significant of them being:
a) introduction of prestressed concrete cylinder pipes,
b) inclusion of requirements of fittings, and
c) provision of more details on design criteria for the pipes.

0.5 In the formulation of this standard, due weightage has ‘been given to
international co-ordination among the standards and practices prevailing
in different countries in addition to relating it to the practices in the
field in the country.
0.6 For the purpose of deciding whether a particular requirement of this
st;tr&rd is complied with, the final value, observed or calculated,
r?rnrtGug thtl result of a test or analysis, shall be rounded off in
tlLY~wLiilll\x~ \vitfl IS : Z-1960*. The number of significant ~I:VZCS
~.~*t;~intx~irl the* rounded off value should be the same as that of the spcci-
rir,i v~lu<* itI this standard.
 -
IS : 784 - 1978

1. SCOPE

1.1 This standard covers the requirements of prestressed concrete cylinder

and non-cylinder pipes ( including fittings ) with nominal internal
diameter in the range of 80 mm to 1800 mm, in which permanent inter-
nal stresses are deliberately introduced by tensioned steel to counteract
the stresses caused in the pipe under service to the d+sired degree,

2. TERMINOLOGY

2.0 For the purpose of this standard, the following definitions shall
“PPlY*
2.1 Prestressed Concrete Cylinder Pipe - A welded sheet steel
cylinder with steel socket and spigot rings welded to its ends, lined with
concrete suitably compacted and circumferentially prestressed to with-
stand internal pressure and external design loads and subsequently coated
with cement mortar to protect the steel cylinder and prestressing wires.
2.2 Prestressed Concrete Non-cylinder Pipe -A suitably compacted
concrete core longitudinally prestressed with pre-tensioned high tensile
steel wire embedded in the concrete, circumferentially prestressed to
withstand internal pressure and external design loads and subsequently
coated with cement mortar/concrete to protect the circumferential
prestressing wire.
2.3 Fittings - All items other than straight pipes of standard length;
branch and bevel pipes ( spigot set at an angle) are also classified as
fittings.
2.3.1 Fittings may be fabricated by welding steel tube or plate, or be
formed frqm a prestressed concrete pipe by including additional steel
plate or tube where required ( see 7 ).

2.4 Working Pressure - It is the maximum sustained internal pressure

excluding abnormal conditions such as surge (water hammer), to which
the pipeline may be subjected when installed.

2.5 Site Test Pressure- It is the pressure to be applied to the pipeline

or sections, thereof, after laying, to test its strength and watertightness.
NUTE - The site test pressure to be imposed will have to be determined when
placing orders for pipes and fittings. In general, this pressure should not be less
than the maximum pipeline operating pressure plus the surge pressure, calculated
taking into account also the effect of surge-relieving devices if provided, but in no
case should exceed the hydrostatic proof test pressure.

2.6 Hydrostatic Proof Test Pressure - It is the maximum pressure

which the pipe can withstand without any leakage when tested for
hydrostatic pressure in accordance with 10.3.

4
 IS : 784 - 1978

2.7 Surge ( Water-Hammer ) Pressure - It is the pressure which is

produced by a change of velocity of the moving steam and becomes
maximum when there is a sudden stoppage which may be caused by the
closing of a valve or by shuttering down a pump station.

3. MATERIALS
3.1 Cement - The cement used in the manufacture of prestressed
concrete pipes shall be one of the following:

4 OTdinary Portland cement conforming to IS : 269-1976’;

b) Rapid hardening Portland cement conforming to IS : 8041-1978t;

4 Slag cement conforming to IS : 455-1976: with not more than

50 percent of slag; and

4 Supersulphated cement conforming to IS : 6909-1973s.

3.2 Aggregates - The coarse and fine aggregates shall conform to

IS : 383-197011.

3.3 Water - The water used in the preparation of the concrete mix
shall conform to the requirements of mixing water given in IS : 456-
19781.
3.4 Admixtures - Under no circumstances shall calcium chloride be
used in the concrete or mortar coating. NO other admixture which
causes deterioration of concrete or mortar or corrosion of steel shall be,
used in the manufacture of pipes.

3.5 Concrete
3.5.1 Concrete Mix and Strength - The mix shall be so proportioned that
pipes and fittings satisfy ail the requirements of this standard. Only
design mix concrete shall be used and the mix shall conform to the
requirements laid down for design mix concrete in IS : 1343-1960**.
3.5.2 Concrete Qidality Control - Sufficient quality control of the concrete
shall be exercised in accordance with IS : 456-19787. Records of all
stages of quality control, shall be maintained and shall be available for
a period of 5 years from the date.of manufacture.

lSpecification for ordinary and low heat Portland cement ( fhird revision ).
tSpecification for rapid hardening Portland cement.
SSpecification for Portland slag cement ( third rruision ).
@pecification for supcrsulphatcd cement.
l\Spcciiication for coarse and fine aggregates from natural sources for concrete .
( rrcond reuirion ) .
~Code of practice foi plain and reinforced concrete ( third rwision ).
**Code of practice for prestrcssed concrete.

5
IS : 784 - 1978

3.6 Steel for Cylinders and Fittings - Steel plates for steel cylinder
and fittings shall conform to IS : 226-1975+.

3.7 Steel for Reinforcement

3.7.1 PrcJtrtssing Stttl - The longitudinal prestressing wire shall be of

1.5 mm to 7 mm diameter and the circumferential prestressing wire
shall be of 1.5 mm to 5 mm diameter the wires conforming to
IS : 1785 (Part I)-1966f and IS: 1785 ( Part II )-1967$. It shall be as far
as possible continuous over the entire length of the core. If a joint is
provided between two wires, its strength shall be at least equal to indi-
vidual strength of the wire; welding shall not be allowed for jointing of
wires.

$7.2 Unttnsioned Rtinforctmtnt - Untensioned reinforcement may consist

of mild steel conforming to IS : 432 (Part I )-1966$ and IS : 432 ( Part II )-
1966ll or high yield strength deformed bars conforming to IS: 1139-
1966f[ or welded wire fabric conforming to IS: 1566-1967**. The
methods of bending, fixing and placing the steel shall be as specified
in IS : 2502-1963tt.

3.8 Rubber Gaskets- Rubber gaskets shall normally comply with

IS:5382-1969$:. The manufacturer of the pipe shall test each gasket
by stretching it 334 percent in excess of its original length and examining
it visually for defects, particularly at any joint.

3.8.1 Gaskets shall be clearly labelled in bundles. The label shall

indicate the type of gasket, the type of joint and the diameter of the
pipe with which they are to be used, and that they have been tested.

3.9 Bitumen or Other Protective Coating-The purchaser *may

specify the application of an external or internal bituminous or epoxy or

*Specification for structural steel ( standard quality ) (~5th r&ion ).

tSpecilication for plain hard drawn steel wire for prestressed concrete: Part I Cold-
drawn strcrs-relieved wire ( rsvisrd ).
SSptcification for plain hard drawn steel wire for prestrased concrete: Part XI As-
drawn wire.
gSpecification for mild steel and medium tensile steel ban and hard-drawn steel wire
for concrete reinforcement: Part I Mild steel and medium tensile steel bars (second
rcL&ion ).
llspccification for mild steel and medium tensile steel bara and hard-drawn steel wire
for concrete reinforcement: Part II Hard drawn steel wire ( second rrvision ).
qsoecification for hot rolled mild steel. medium tensile steel and hinh w vield
,
str&$h i&e1 deformed barr for concrete reinfkement ( rrrised ) .
**Specification for hard-drawn steel wire fabric for concrete reinforcement (JFrsr
revision i.
mde of practice for bending and fixing of bars for concrete reinforcement.
@pecification for rubber sealing rings for gas mains, water mains and sewers.

6
 IS : 784 - 1978

other approved coating to be applieo. When the pipes are to be used for
carrying potable water, the inside coating shall not contain any consti-
tuent soluble in such water or any ingredient which could impart any
taste or odour whatsoever to the potable water after sterilization and
suitable washing out of the pipeline.

4. DIMENSION8 AND TOLERANCES

4.1 Dimensions
4.1.1 The internal diameter and the length of pipes shall be as speci-
fied in Table 1.

TABLE ! INTERNAL DIAMETER AND LENGTH OF PIPES

INTEBNAL DIAMETER OF PIPE LENGTH OF PIPE

mm m
and 400
80,10~,125,150,250,300,350 2, 2.5,4,5 or 6
450,560,6oC,
700,800,900,
1000,1 100, 2'5,4,
5 or6
1200,l400,1600and 1800

4.1.2 Lengths other than those in Table 1 may be supplied by agree-

ment between the purchaser and the manufacturer.
4.2 Tolerances
4.2.1 Length-The overall length of the pipe shall not vary by more
than f 1 percent of specified length.
4.2.2 Internal Diameter
4.2.2.1 For pipes of length less than 4 m, the tolerance shall be
f 5 mm for diameter up to 300 mm and f 10 mm for diameter exceed-
ing 300 mm and up to 800 mm.
4.2.2.2 For pipes of length 4 m and above the tolerance shall be as
below:
Internal Diameter Tolerance
r------ A-----,, 7
In areas within Over rest
600 mm of an end of the pipe
of the pipe
mm mm
Up to 90 mm &6 f9
Over 900 mm, f9 &I2
up to 1600 mm
Over 1600 mm *12 fl2
7
IS : 784 - I978

4.2.3 Thickness - The tolerance on the wall thickness of the pipe shall
be as below:

Wall Thickness Toterents

mm

Up to 25 mm fl.5

Over 25 mm, up to f2.0

35 mm

Over 35 mm, up to f3.0

50 mm

Over 50 mm f(3 mm+1 mm for

every 15 mm or part
thereof over 50 mm,
limited to maximum
of5mm)

5. DESIGN
5.1 General - All pipes shall be designed to withstand the combined
effects of internal water pressure and the external loads as determined
from the information supplied by the purchaser ( see Appendix A ). The
design of prestressed concrete pipes shall be in accordance with the basic
assumptions and general requirements stipulated in IS : 1343-1960*, When
prestressed concrete pipes are used to carry highly acidic sewage or
industritil wastes, necessary precautions against chemical attack and
corrosion shall be taken.

5.1.1 The design of the prestressed concrete pipes shall cover all such
stages which may induce stresses in any section of the pipe. For
investigation of these design stages, the likely extreme conditions of
stresses shall be considered in the order of their occurrence, during the
process of manufacture, handling, erection and under service, giving
due regard to the worst accompanying conditions.
NOTE - In the case of pipes manufactured by special processes where the outer
cover coating also will be in induced compression and guarantees monolithic action,
the total thickness of the pipe including that of the cover may be taken for purposes
of checking the stresses.

*Code of practice for prestressed concrete.

 IS : 784 - 1978

5.2 Design Criteria for Cylinder Pipes - The pipes shall be

designed to meet the following conditions:
Design Load Design Criteria

a) Fill load plus working There shall be no tension in the

pressure core
b) Fill load plus working Tension in the core shall not be
pressure plus surge greater than 0.70 dy& N/mma
c) Hydrostatic proof test Tension in the core shzll not be
pressure greater than O-56 d fck N/mm8
d) Fill load plus transient Tension in the core shall not bc
load plus working greater than 0’70 dfrk N/mm’
pressure
NOTE- fck is the characteristic compressive strength of concrete at 21i days in
N/mm*,as defined in IS : 456-1978*.

5.3 Design Criteria for Non-cylinder Pipes-The pipes shall be

designed to meet the following conditions:
Loading ~Description of Permissible
Combi- Loading Combination Stresses
nation r--_-_h---___
Tension Compressic,
N/mms N/mm”
a) Circumferential Stress

1A Operating conditions ( self 0’0 0.33 fck

weight + weight of water +
earth fill load + working
pressure + final prestress )
2A Operating conditions plus 0’56 dsk O-4 fck
surge or water hammer
pressure
3A Operating conditions plus 0.56 dzk 04 fck
live load ( with impact)
4A Hydrostatic proof test pres- 0’56 dxk 0’4 fck
sure + self weight +
weight of water + final
prestress
5A Self weight + initial pre- 0.0 0’5fP
stress

*Code of practice for plain and reinforced concrete ( third rcr&Jn ).

9
IS:7840 1978

b) Longitudinal Stress

1B Longitudinal prestress after - Residual corn

losses pression of 1.0

2B Initial prestress less the loss 0.56 dTP 0.5fP

of longitudinal prestress
at the time of wire
wrapping

313 Longitudinal prestress after 0’34 JTp 0’5fP

losses plus beam action
4B Handling 0.67 0.5 fp

While computing longitudinal bending stresses for combination 2 B,,

non-uniformity in the thickness of the core shall be considered and
longitudinal elements of the core shall be analysed as beams on elastic
foundations. The circumferential wrap shall be treated as a uniform
partial load on the element which gradually increases in length corres-
ponding to the manner in which the pipe is wrapped. Stresses that
remain in the core after wrapping is completed, shall be treated as
steady stresses. Stresses induced in the core during the time of wrapping
shall be classed as temporary and tensile stresses for such cases shall not
exceed O-56 c N/mms. To these, shall be added stresses induced
d
by hydraulic pressure or by the pressure from the rubber gasket or those
due to lifting and handling the pipes or stresses that may be induced due
to uneven bearing of the pipe in the trench. To determine the latter
tyie of steady stress, a pipe shall be assumed to span its full length and
support a total load equal to the self weight of the pipe, the weight of
the water in the pipe and an earth load equal to 2’2 times OD
(where OD is the outside diameter of the pipe in metres ) kN per
linear metre. The above steady stresses or combination thereof shall
not exceed 0.34 f,, N/mm2. .

NOTE-Jc, is the characteristic compressive strength of concrete at 28 days and fp

is strength of 15 cm concrete cubes in compression at p days.

6. MANUFACTURE

6.1 Moulds - The moulds and method of manufacture shall be such

that the form and dimensions of the finished work conform to the
requirements in 4 and 9 and the surface and edges are clean and true.

10
 IS : 784 - 1979

6.2 Curing
6.2.1 Water Curing - Pipes manufactured in compliance with this
standard shall be cured by immersion in water or by automatic
sprinklers for a period of not less than 7 days. The curing of, the
concrete core and that of the cbver shall be done in two separate
operations.

6.2.2 Steam Curing - Non-pressure steam curing may be permitted.

NOTE 1 - Prestress loss due to steam curing shall be considered while designing
pipes intended ta be steam-cured.

NOTE 2 - Adequate precautions shall be taken, if supersulphated cement is used

for the manufacture of the pipes.

6.3 Additional Requirements for Cylinder Pipes

6.3.0 The prestressed concrete cylinder pipes shall be manufactured

to comply with the following additional requirements.

6.3.1 Steel Socket and Spigot Rings - Each ring shall be formed by one
piece of steel or a nuder of pieces of steel butt-welded together. The
rings shall be expanded beyond their elastic limit, so that they are
accurately shaped. The portion of the socket and spigot rings which
shall be exposed after the pipe is completed shall be smooth to prevent
cutting of the rubber gasket during jointing and shall be protected from
corrosion by a sprayed zinc coating of minimum thickness 0’05 mm
followed by one coat of bituminous paint. Other suitable protection
may be used with the approval of the purchaser.

6.3.2 Fabrication of Steel Cylinders - The cylinders shall be accurately

shaped to the size required and steel socket and spigot rings welded
thereto after being jigged square with the longitudinal axis ( except for
bevels ).

6.3.2.1 Testing - Before it is subjected to any further manufacturing

process, each steel cylinder, with steel socket and spigot rings welded
on, shall be subjected to water pressure which stresses the steel to at
least 140 N/mm2 but nbt more than 175 N/mm2. While under stress,
the assembly, especially welds, shall be inspected and any parts showing
leakage shall be repaired and the whole assembly retested.

6.3.3 Concrete Core -The interior surface shall be smooth and free from
laitance. Unless the design calls for higher strengths, the minimum
cube strength of concrete shall not be less than 35,N/mms at 28 days.

11
IS : 784 - 1978

6.3.4 Circumferential Prestrkng

6.3.4.1 Circumferential prestressing shall not take place until the
concrete in the core has reached a sufficient compressive strength, to
resist without damage the forces acting upon it, nor until the
concrete in the core has reached a minimum cube strength of half the
specified cube strength of concrete ( see 6.3.3 ).
6.3.4.2 The initial compressive stress induced in the concrete core
shall not exceed 55 percent of the compressive strength of the concrete
in the pipe at the time of transfer..
6.3.4.3 Methods and equipment for applying the wire shall be such
that wire will be wound around the core in a helical fofm at the
predetermined design spacing and capable of controlling the tension.
Splicing or jointing ( but not welding ) may be permitted and where
splicing or jointing is carried out, the splice or joint shall develop at
least the full strength of the wire.
6.3.4.4 The clear spacing between the successive turns of the
circumferential prestressing wire shall be not less than the greatest of
the following:
a) the diameter of the prestressing wire,
b) one and half times the maximum nominal size of the aggregate
used for outer coat concrete, and
c) 5 mm.
6.3.5 Outer Cover Coating - The circumferential prestressing wire on
the core pipes is protected with a layer of cement mortar, or concrete
or any pther approved material which prevents corrosion of wire due to
ingress of water. The cover coating shall be applied within 16 hours
after the prestressing wire has been wound. If cement mortar is used
for cover coating, it shall be applied by rotary brushes or belts or by
other approved methods. The sand and cement shall be thoroughly
mixed before being fed into the cover coating machine.
Pneumatic process in which mixing of all ingredients is carried out
at the nozzle or gun, shall not be permitted.
The strength of cover coating shall be sufficiently high such that the
tensile stresses in cover concrete or mortar under different loading
combinations shall not exceed its modulus of rupture. The effect of
prestress transferred to the cover concrete due to creep may be
considered in computing the tensile stresses in the coirer. The cover
coating shall have a cover of
not less than 18 mm over all steel. The
exposed position of steel socket and spigot rings which have been already
suitably protected by a sprayed zinc coating or other suitable means
( see 6.3.1 ) shall be exempted from the 18 mm cover coating.
12
 IS I 784.1978

6.4 Additional Requirements fo3 Non-cylinder Pipee

6.4.0 The prestressed concrete non-cylinder pipes shall be manufac-
tured to comply with the following additional requirements.
6.4.1 Concrete COYG - Unless the design calls for higher concrete strength,
the minimum compressive strength of concrete shall not be less than
45 N/mma tat 28 days. The clear cover of concrete over all steel
reinforcement including the ends of the longitudinal prestressing wires,
shall be such that in any finished $ipe it is nowhere less than 12 mm.
6.4.2 Pretensioning and Release of Longitudinal Wires
6.4.2.1 The concrete core shall be longitudinally prestressed through-
out its length, including the socket, by means of high tensile steel wires,
which shall be provided with permanent anchorages embedded within
the joint portion at each end.
6.4.2.2 The centre line spacing between the longitudinal wires
measured along the arc shall not exceed twice the core thickness or
150 mm, whichever is the greater. Where reinforcement is used, the
pretension stress shall be maintained. by suitable supports, during the
placing and curing, of the pipe core-until the concrete in the core has
attained a strength equal to 1.8 times the longitudinal induced
compression in the concrete.
6.4.2.3 The longitudinal wires shall be stressed to the design tension,
taking into account the yield or slip of the temporary anchorages on the
pipe moulds, and the tension shall be maintained by positive means
during the curing of the concrete.
6.4.2.4 The tensioned wires shall not be releaged until the concrete
in the core has attained a compressive strength equal to 53 percent of the
compressive strength of the concrete in compression at 28 days.

6.4.3 Circumferential Prestressing

6.4.3.1 Circumferential prestressing shall not take place until the
concrete in the cdre has reached a sufficient compressive strength to resist
without damage the force acting upon it, nor. imtil the concrete in the
core has reached A minimum cube strength of 32 N/mms. Where the
process of manufacture is such that the strength of concrete or mortar in
the pipe differs from that, given by tests on cubes, the two may be related
by a suitable conversion factor. If the purchaser requires evidence of
this factor, he shall ask for it before placing the order.
6.4.3.2 The initial ,compressive stress induced in the concrete core
shall not exceed 55 percent of the compressive strength of the concrete in
the pipe at the time of transfer.

13
 IS : 784 - 1978

6.4.3.3 Methods and equipment for applying the wire shall be such
that wire shall be wound around the core in a helical form at the
predetermined design spacing and capable of controlling the tension.
Splicing or jointing (but not welding) may be permitted and where
splicing or jointing is carried out the splice or joint shall develop the full
strength of the wire.
6.4.3.4 The clear spacing between the succestive turns of the
circumferential presfressing wire shall conform to 6.3.4.4.
6.4.4 Cement Mortar Cover Coating -Y The requirements of cement mortar
cover coating shall c6nform to 6.3.5. However, the minimum thickness
of cover coating may be reduced to 15 mm in case 6f pipes manufactured
by processes wherein the outer coating also will be in induced
coqpression.

7. FITTINGS
7.1 Steel Plate - The steel for fabricated steel plate fitting is cut,
shaped and welded so that the finished fitting has the required shape and
interior dimensions. Adjacent segments are jointed by lap or but tweld-
.
. Manufacturer’s standard fittings shall be hydrostatically tested
ktfore lining and coating. The hydrostatic proof test pressure is ond and
a hailf times the maximum working pressure, unless otherwise arranged
at the time of order. Wherever feasible, other fittings shall be hydrostati-
’ tally tested at the works. However, where this is not practicable, then
by agreement between the purchaser and the supplier, testing may be
carried out by the application of a penetrant oil or other means.
7.2 Wire Mesh Reinforcing - Wire mesh is applied to the interior
and exterior surfaces of the steel plate fittings where they are to be lined
and coated with ‘concrete. It is positioned at a suitable distance from
the surfaces of the steel plate to permit adequate bonding of the lining
and coating and provide adequate cover for the mesh reinforcement.

7.3 Lining and Coating - Steel plate fittings are lined and coated
with concrete or cement mortar or other approved mategials, as agreed
between the manufticturer and the purchaser.

8. JOINTS
8.1 Unless specified otherwise, joints on pipes and fittings shall be of
the spigot and socket type, so manufactured that, when fitted with the
correct rubber gasket, the joint shall be self-centring and flexible.
8.2 The gasket and pipe dimensions shall be in accordance with the
manufacturer’s standard diinensions and tolerances. The gasket shall
be of suchi size that when jointed, in accordance with the manufacturer’s

14
 IS : 784 - 1978

instructions, it shall provide a positive seal within the manufacturer’s

recommended range of maximum joint deflection and withdrawal under
all combinations of joint and gasket dimensional tolerance.

9. WORKMANSHIP AND FINXSH

9.1 Deviation from the Straight-The maximum permissible
deviation from the smaight on internal surfaces of any pipe throughout
its length, tested by means of a rigid straight edge parallel to the
longitudinal axis of the pipe, shall not exceed 3 mm for every metre
length for all pipe diameters.

9.1.1 Unless otherwise specified, the ends of the pipe shall be square
with their longitudinal axis SO that, when placed in a straight line in
the trench, any gap between the two faces required to be in contact
shall not exceed 5 mm in pipes up to 600 mm dia or less, and 10 mm in
pipes larger than 600 mm diameter.

9.2 Finish - Pipes shall be free from local depressions 6r bulges greater
than 5 mm in depth and extending over a length, in any direction,
greater than twice the thickness of barrel. The external surface of the
pipe shall be sand-faced due to cement mortar coating applied under
high velocity.

10. TESTS
10.1 Visual Inspection - The pipe selected in accordance with 11
shall be checked for conformity to the requirements in 9.2.

10.2, Dimensipnal Characteristics - The pipes selected in accordance

with 11 shall be checked for conformity to the dimensional requirements
in 4.

10.3 Hydrostatic Proof Test

19.3.1 Atter circumferential prestressing/out coating, each pipe sha]]

withstand a hydrostatic proof test’ pressure applied in accordance with
the procedure described in Appendix B. Socket and spigot pipes shall
have the hyd.rostatic pressure applied to the whole pipe, including that
port& of the socket which is subjected to pressure in the ‘ as laid ’
condition. There shall be no leakage, or other signs of distress.
19.3.2 The hydrostatic proof test pressure shall’ he one and a half
times the working pressure. as defined in 2.4, except where the strength
of the pipe has to be increased. to take care of surge or water hammer.
In these cases the hydrostatic proof test pressure shall be the working
pressure, p!us allowance for surge, or one.and a half times the working
pressure, whichever is the greater.

15
IS : 784 - 1978

ID.4 Permeability Test - .For the specimens of pipes selected in

accordance with 11 the drop of water level in the stand pipe when
tested for permeability of core and coat as specified in Appendix C,
shall not exceed 1 ems in half an hour taken over a period of 2 hours.
10.5 Additional Test for Non-cylinder Pipes

10.5.1 Three-Edge Bearing Test -The specimens of pipes selected in

accordance with 11 when subjected to the three-edge bearing test as
described in IS : 3597-1966* shall meet the minimum load requirements
specified in Table 2.
TABLE 2 MINIMUM LOAD REQUIREMENTS FOR PRESTRESSED
CdNCRETE NON-CYLINDER PIPES WHEN SUBJECTED
TO THREE-EDGE BEA’RING TEST
( Clauses 105.1 and 11.3.2.1 )

DIAMETER OF PIPES THREE EDGE BEARING TEST

r__-____h-____-__~
Load to Produce Ultimate
0.25 mm Wide Load
Crack
(1) (2) (3)
mm N/m N/m
80 10 000 16 000
IO0 10 000 16 000
125 10000 16 000
150 10 000 16 000
250 10 000 17 000
300 12000 18 000
350 13 000 20 000
400 14 000 21 000
450 25 000 23 000
500 17000 26 000
600 19 000 29 000
700 21 000 31 ooo
800 24 000 36 000
900 25 000 38 000
1 000 27 000 40 000
1 loo 28 000 41 000
1200 29 000 44000
1400 30 000 45 000
1600 30 000 45 000
1 800 30 000 45 OW

*Methods of test for concrete pipes.

16
11. SAMPIJNG AND CRITERIA FOR ACGEPTANCE
11.1 Lot - ,411items of the same type and size manufactured under
relatively similar conditions in respect of raw materials and pr~~Gng
operations shall be grouped together to constitute the lot.
11.2 Each lot shall be taken up separately for sampling and evaluation
for comformity to the requirements of the specification. The sanrples
from the lot shall be taken at random.

11.3 Criteria for Acceptance - A lot shall be considered as con-

forming to the requirements of this specification if the conditions
mentioned in 10.3, 11.3.1, 11.3.2, and 11.3.2.1 are satisfied; otherwise
it shall be considered as not conforming to the requirements of this
specification.

11.3.1 The scale of sampling shall be as given in Table 3. The

number of samples to be tested for three-edge bearing test shall be taken
from those found satisfactory in respect of requirements given in 10.1
and 10.2.
11.3.2 The number of defective pipes shall not be more than the
permissible number given in Table 3 when tested for the requirements
given in 10.1, 10.2, 10.4 and 10.5.

TABLE 3 SCALE OF SAMPLING AND NuMBEEl OF ACCEPTABLE

DEFECTIVES

( Cluu~cs 11.3.1 and 11.32 )

NO.OFITEMS ,VISTJAL INSPECTION DIMENSIONAL LOADBEARIIWTEET

INTHE LOT p---Aw-_~ AND PERME- ----h-__y
N.o. of No. of ABILITY No. of No. ofAc-
Samples Accept- TESTS Samplea ceptable
able De- r---_~ Defectives
fectives No. of No. of
Samp- Accept-
les able De-
fectives

(1) (2) (3) (4) (5) W (7)

20 to 50 20 1 3 0 2 0
51 ,, 100 32 2 5 0 2 0
9,
0 4
125 1
101 300 125
2: z: zz
1: 0 z3 I MU11.3.2.1
200
200 80
125 5f 71
*J

17
 11.3.2.1 In respect of three-edge bearing test, when number of
items in a lot exceeds 100, the average ( E ) and the range ( R = maximum
observaU!on - minimum observation ) shall be calculated for all samples
tested from the lot. The lot shall be considered satisfactory, if the value
of(Z - 0.5 R ) is greater than the minimum load requirements specified
in Table 2.

12. MANUFACTURER’S CERTIFICATE

X2.X The manufacturer shall, if required by the purchaser, furnish a

certificate confirming that the products suppEed against his order comply
in all respects with the requirements of this standard.

13. INSPECTION

13.1 The purchaser or his representative shall at reasonabIe times have

free access: to the place of manufacture for the purpose of examining,
and for witnes&ng the testing and marking of the pipes and fittings.

14. MARKING

14.1 The folio-&n information shall be clearly marked on each pipe.

and fitting:
a) Hydrostatic proof testpressure,
bj Dare of’ manufacture, and
c) X\r:amL-of’ manufacturer or his registered trade-mark or both.

14.1.1 Each pipe may also be marked with the ISI Certification
Mark.
NDTY- Tine U.Wof the ISI Certification Mark is governed by the provhions of
the Indian Standards Institution ( thtifiCZltiOD Marks and the Rules and
) AC:
~quhtto~s mack thereunder. The ISI Mark OKI products covered by an Indian
Standard convcy~ the assurance that they have been produced to comply with the
reqtti~mcnrs of that standard under a well-defined system of inspection, tating and
u&i control which is devised and supervised by IS1 and operated by the
4prv~dJ cr. IST rrrarkcd products are alao continuously checked by IS1 for conformity
In Qat standard 6s a further wfcguard. Details of conditions under which a licence
Ivr &C USC oi the IS1 ‘Certification Mark may be granted to manufacturen or
praccssoru, .*nay be obtained from the Indian Standards Iostitutiou.

I8
 IS : 784 - 1978

APPENDIX A,
( Clause 5.1 )
INFbRMATlON TO BE SUPPLIED WITH AN ENQUIRY
OR ORDER FOR CYLINDER AND NON-CYLINDER PIPES

A-l. The following information shall be supplied:

a) The type of cement to be used in the core and the cover coat
( see 3.1, 6.3.3, 6.3.5 and 6.4.4 );

b) Whether or not a bituminous or other approved coating is

required internally and externally ( see 3.9 );

c) The maximum working pressure ( see 2.4 j;

d) The mnxitnum site test pressure ( see 2.5 );

e) Hydrostatic proof test pressure (see 2.6);

i
f) Pressure in addition to (c) which will be encountered due to
surge, if any; and

g) The purchaser shall specify either the external crushing test

load or give the following information:

1) The maximum and minimum depths of cover over the crown

of the pipe.

2) The width of the trench at the crown of the pipe ( normally

outside diameter of pipe plus 600 mm ). If the pipe is not
to be laid in a trench, full details should be supplied.

3) Whether more than one pipeline is to he laid in the trench,

and if so, what will be the trench width at the crown of
the pipe.
DeratIs of the backfill material, that is, sand, gravel, etc,
and its density.

5) Type of bedding intended, and

6) Anticipated loading superimposed on ground surface.

IS ; 78&p 1978

APPENDIX B
( czause10.3.1 )
IIYIIR~STATN: PRRssu3RE PROOF TEST #

B-1. Internal pressure shall be applied to a pipe or fitting at a rate not

exceeding O-2 N/mm’ in 5 seconds. Full pressure shall be maintained
for at least one minute or as Tong as may be required to inspect
each pipe.
B-2. Care shall be taken to remove all air from the pipe or fitting before
the pressure is applied.
R-9. During the test, the moisture appearing on the surface of the pipe
in the form of damp patches shall not be considered leakage. If during
the test, beads of water appear on tb@‘surface of the pipe, the pressure
shall be maintained on the pipe for an additional period equal to the
initial period required for the test and the pipe shall be accepted if the
beads do not grow or run.

APPENDIX C
( Clause JO.4 )
PERMEARILITY TEST

0-I. Water at 300 mm head is applied over a surface of 3 000 mm2 by

means of an apparatus consisting of a small steel cup and stand pipe,
attached to the prestressed pipe with adhesive. The drop of water level
in the stand pipe is observed over half-hour period. On each pipe, three
tests shall be done immediately after curing is completed. The average
of these three tests shall not exceed 1 cm8 in half an hour taken over
a period of 2 hours.

20
 IS t 784 - 1978

-Concrete Pipes and Poles Shcommittee, BDC 2 : 6.

Ayt;‘r) Ip- EN~XREXR Research Da&s & Standards Organknrion

( Ministry of Railways )
Sanr S. N. Beau Dir~~ra~~~cnctal of Supplies k Disposals,
:cw *
SHRIT. N. OBOVEJA ( d&m& 1
SHRI BRAOWA~ SINO% Conpez P&&nufacturcrs Association of India,
I
SBRI 1. !% SOD ( Aihnak )
SxarP. C. CSW-RRJEE Orissa Cement Ltd. Rajgangpur
_~
Saix U. N. I~ATH ( Aknutr )
Cmxr ENGINEER ( WSP ) Municipal Corporation of Greater Bombay
HYDRAULIC ENIXNEXB ( Allrmmfr )
DIRXCT~R ( RE ) Central Electricity Authority, New Delhi
DEPUTY DIRECTOR ( RF. ) ( Ahnou )
Drtuxmm OF TELICGRAPHS ( L ) Ports and Telegraph Dcparrmcot
DIVISIONAL ENCUXEE~ TZLE-
ORAPRE (C) ( Ahmolr )
SZKRI P. C. JAXN Engineer-in-Chief% Branch, Army Hcadquarten
SERI 0. P. BEATIA ( Alkmdr )
Stiax R. D. JAIN Rural Electrification Corporation Ltd, New Delhi
SHRI P. -0 ( Rlrrrnulr )
SRRI N. G. Josar Indian Humc Pipe Co Ltd, Bombay
SHBI K. K. KAYATH The I;crala Prcmo Pipe Factory Ltd, Quiton
SERI N. M. NWIYXKAN National Environmental Engineering Rcsclrcb
Institute ( CSIR ), Nagpur
SRRt S. R. Prt?RuRO Gammon India Ltd. Bombay
SRRr K. G. SAL%‘1 Hindustan Prefab Ltd, New Delhi
Sasx G. 8. SINOH ( Ahmtr)
STJ~ZEIXTXXD~NO SURVXYOR or Central Public Woltr Dcpartmcnt, New Delhi
WORK0 ND2 )
SaIft v. d. TALATX Spu~p~x&Construction Co (Bar& ) Pvt Ltd,

SERX A. V. TAL~TTI( AL&m& )

Soar B. T. UNWALLA The Concrctc Association of India, Bombay
Sxttr T. M. MENON ( Alfemafr )
DB H. C. VISV~~VARAYA Cement Racarch Institute of India, Xcw Delhi
SHRX S. SUBRAY~INIAN ( Alfrmntc )
SHRI ZACH~RXA GEOBOS Stntc~w8l~rxEngincering Racarch Ccntrc ( CSXR

DE B. vXLNIA’IX8WA=u ( dl@nafr )

21

,
 BUREAU OF INDIAN STANDARDS
Headquarters:
Manak Bhavan. 9 Bahadur Shah Zafar Marg, NEW DELHI 110002
Telephones: 331 01 31, 331 13 76 Telegrams: Manaksanstha
( Common to all Offices )
Regional Offices: Telephone
Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg, 331 01 31
NEW DELHI 110002 331 1375
I
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Branch Offices:
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I
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*Sales Office in Calcutta is at B Chowringhre Approach, P. 0. Princep 27 68 00

Street. Calcutta 7GOO72
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Bombay 400007
ZSales Office in Bangalore is at Unity’Building, Narasimharajs Square, 22 36 71
Bangalore 560002
Reprography Unit, BIS, New Delhi, India
 AHEFIDMENT NO. 1 MARCH 1985
TO
IS:78401978 SPECIFICATION FOR PRESTRESSED
CONCRETE PIPES (INCLUDING FITTINGS)

(First Revision)

(Page 7, Informat tabte below otauee

4.2.2.2) -
Substitute 'Up to 900 mm’for
'Up to 90 mm'.

(BDC 2)

Reprography Unit, BIS, New Delhi, India