Tarik Nagadi Preformed Concrete Factory
Concrete Pipes

Reinforced Concrete pipes are produced in accordance with ASTM C 76 / BS 5911 Standards, using sulfate resistant (type V) cement. RC pipes from 300 up to1200 mm diameter are produced with bell & Spigot joints having a standard length of 2.50 meter up to 3 meter, with short pipes produced according to the customer’s requirements. Sizes over 1300mm up to 3600mm diameter are produced with tongue and groove joints, with a standard length of 2.50 up to 3 meter length. These pipes are widely used for sewerage / storm drainage system culverts and various irrigation purposes.

 

Reinforcement and concrete strength along with the product specification is provided in the technical section for reference. These pipes are produced in various classes according to the project requirement such as ASTM C 76 / Class III, Class IV and Class V, BS 5911 / Class H, M, I. The pipes are produced with modern Technology and using our fully automatic machineries.

Testing: Samples from the concrete batch is taken on daily basis, and the compressive strength tests are carried out in our laboratory as per the applicable standard specification to assure the concrete strength and to maintain the quality requirments. These samples are also sent to the independent laboratory, periodically, to confirm the internal tested results and also to satisfy the project specification, based on customer’s request. During the production process, maintaining the ISO 9001-2008 standards, different stages of tests are being carried out from the receipt of raw materials till the finished products are ready for delivery.

Before delivery of pipes various tests and inspections are performed to ensure the product meets the applicable standards. All pipes are visually inspected for flaws or damage. Concrete strength is confirmed by compressive cubes / cylinders and any products made from a concrete batch which does not achieve the required strength are quarantined until full concrete strength has been achieved. Sample pipes as per ASTM requirements are tested by the 3 Edge Bearing test method to confirm that the lot meets strength classification parameters. Gasket pipe are tested by differential load and/or hydrostatic test methods to confirm water tight jointing can be achieved in field installation.

PRODUCTS SPECIFICATION
Concrete strength: As ASTM C-76 / BS 5911 – 102 : 120

Reinforcement: Deformed steel bars (non coated) grade 60 as per ASTM A 615. Cages are prepared in a fully automatic cage welding machine using German Technology.

MANUFACTURING PROCESS
REINFORCING STEEL CAGE FABRICATION

An electrostatic welding machine well designed to fabricate suitable cages for circular pipes and manholes. Reinforcement steel prefabricated through cold drawn process and be ready in coils and straight bars, with different diameters suitable for a variety of designs. The welding impulse is electronically released. Both the welding intensity and welding time are accurately adjustable through an electronic control panel. The circular bars and bell end formed without interruption to the welding process. The diameter increased by expanding the slide dies. The longitudinal bars feed speed is adjusted separately.

The design parameters of the steel cages are programmable.

BATCHING OF CONCRETE

With the available fully computerized batching plants, the concrete is batched according to a well prepared mix design. Each batching report will be produced promptly by the system. The approved quality of raw material supplied, like sand, aggregate and cement, conform to the requirement of ASTM C-33 and C-150 respectively. The water used of potable quality. The scales and meters used in the batching are maintained in a good working condition and are subject to semi-annual calibration bases. The concrete mix is cast following 2 different processes :

DRY CAST PROCESS

Reinforced concrete pipes and circular manholes, of standard sizes, are manufactured in a dry cast process. Concrete mix, with minimum water/cement ratio is conveyed by rolling belt systems with end rotating and filling the moulds. The moulds are mechanically vibrated to consolidate concrete.The profile ring press and rotate to form the spigot shape. Then outer mould and concrete pipe are removed to the steam curing area where the outer mould removed for the next pipe production. Manhole elements are following a similar process, with a tilting facility allowing monolithic concrete cast for manhole bases.

WET CAST PROCESS

The wet cast process is used for the concrete units of sizes unsuitable to be mounted on the current machining production facilities, such as large sizes of telecommunication chambers, Fence walls and the like. The concrete with water cement ratio 0.45 is fed to moulds mounted on vibration tables or vertically with wall mounted vibrators.

UNLINED REINFORCED CONCRETE PIPE DETAILS


UNLINED REINFORCED CONCRETE PIPE DETAILS

PIPIE I.D. T E.L. T.L. JOINT PROFILE
300 50 2500 2600 BELL & SPIGOT
400 55 2500 2600 BELL & SPIGOT
500 65 2500 2600 BELL & SPIGOT
600 75 2500 2600 BELL & SPIGOT
700 85 2500 2600 BELL & SPIGOT
800 92 2500 2632 BELL & SPIGOT
900 100 2500 2640 BELL & SPIGOT
1000 110 2500 2640 BELL & SPIGOT
1100 120 2500 2640 BELL & SPIGOT
1200 125 2500 2640 BELL & SPIGOT
1500 150 2500 2600 BELL & SPIGOT
1400 169 2500 2640 SOCKET & SPIGOT
1500 173 3000 3140 SOCKET & SPIGOT
1600 178 2500 2640 SOCKET & SPIGOT
1800 190 2500 2640 SOCKET & SPIGOT
1800 180 3000 3140 SOCKET & SPIGOT
2000 200 2500 2630 SOCKET & SPIGOT
2000 225 3000 3150 SOCKET & SPIGOT
2200 228 2500 2640 SOCKET & SPIGOT
2500 250 3000 3150 SOCKET & SPIGOT
3000 300 2500 2640 SOCKET & SPIGOT
3500 350 3000 3150 SOCKET & SPIGOT

Notes:
1. All the measurement given above are in millimeters.
2. Other Sizes are available upon request.


T- PIPE

Draining flow to pipe lines. T-pipes can be
manufactured to different pipe sizes.

PIPE DEFLECTED JOINT DETAILS


PIPE I.D MAX. PULL(mm) ALLOW.DEF.ANGLE(deg)
300 20 2° 52’
400 20 2° 12’
500 20 1° 48’
600 20 1° 31’
700 25 1° 43’
800 25 1° 09’
900 25 1° 02’
1000 20 1° 24’
1100 20 1° 16’
1200 20 1°11’
1400 30 1° 05’
1500 30 0° 57’
1600 30 0° 52’
1800 30 0° 48’
2000 30 0° 42’
2200 30 0° 42’
2500 35 0° 40’
3000 35 0° 40’
3500 35 0° 40’

Notes:
1. All the measurement given above are in millimeters.
2. Other Sizes are available upon request

REINFORCED CONCRETE LINED PIPES SECTION
Reinforced Concrete pipes are lined with (PVC / HDPE & GRP) produced in accordance with ASTM C76/ BS 5911 Standards, using type V cement. RC pipe of diameters ranging from 800 up to 3500 mm are produced with standard lengths, either of 2.5 meter or 3 meters, These pipes are widely used for sewerage system, to prevent chemical attack from the sewage water and to prevent damages arising out of such contamination.

PVC/HDPE LINED PIPES SUMMARY DETAILS


PVC/HDPE LINED PIPES DETAILS

PVC/HDPE LINED PIPES DETAILS

PIPIE I.D. T E.L. T.L. JOINT PROFILE
800 92 2500 2632 BELL & SPIGOT
900 100 2500 2640 BELL & SPIGOT
1000 110 2500 2640 BELL & SPIGOT
1100 120 2500 2640 BELL & SPIGOT
1200 125 2500 2640 BELL & SPIGOT
1400 169 2500 2640 SOCKET & SPIGOT
1500 173 3000 3140 SOCKET & SPIGOT
1600 178 2500 2640 SOCKET & SPIGOT
1800 190 2500 2640 SOCKET & SPIGOT
1800 180 3000 3140 SOCKET & SPIGOT
2000 200 2500 2630 SOCKET & SPIGOT
2000 225 3000 3150 SOCKET & SPIGOT
2200 228 2500 2640 SOCKET & SPIGOT
2500 250 3000 3150 SOCKET & SPIGOT
3000 300 2500 2640 SOCKET & SPIGOT
3500 350 3000 3150 SOCKET & SPIGOT

Notes:
1. All the measurement given above are in millimeters.
2. Other Sizes are available upon request.

Specifications
Jacking and Tunneling

In all of jacking and tunneling operations, directions and distances are carefully established prior to beginning the operation. The first step is the excavation of jacking pits or shafts at each end of the proposed line. The pit must be of sufficient size to provide ample working space for the jacking head, jacks, jacking frame, reaction blocks, spoil removal and one or two sections of pipe. Provisions are made for the erection of guide rails in the bottom of the pit. For large pipe it is desirable to set the rails in a concrete slab. If drainage is to be discharged from the jacking pit, a collection sump and drainage pump are required. The number and capacity of jacks depend on the type of soil, size of the pipe and jacking distance. The jacks are placed on both sides of the pipe so the resultant jacking force is slightly below the springline. Use of a lubricant, such as bentonite, to coat the outside of the pipe is helpful in reducing frictional resistance and preventing the pipe from setting when forward movement is interrupted. Because of the tendency of soil friction to increase with time, it is usually desirable to continue jacking operations without interruptions until completion. Correct alignment of the guide frame, jacks and backstop is necessary for uniform distribution of the axial jacking force around the periphery of the pipe. By assuring that the pipe ends are parallel, and the jacking force properly distributed through the jacking frame to the pipe and parallel with the axis of the pipe, localized stress concentrations are avoided.

 

 

A jacking head is often used to transfer the force from the jacks or jacking frame to the pipe. In addition to protecting the end of the pipe, a jacking head helps keep the pipe on proper line by maintaining equal force around the circumference of the pipe. Use of a cushion material, such as MDF packer, between adjacent pipe sections provides uniform load distribution.

Jacking Concrete Pipe
Concrete pipe is frequently installed by tunneling and jacking where deep installations are necessary or where conventional open excavation and backfill methods may not be feasible. Concrete pipelines were first jacked in place by the Northern Pacific Railroad between 1896 and 1900. In more recent years, this technique has been applied to sewer construction with intermediate shafts along the line of the sewer as jacking stations. The feasibility and planning of tunneling and jacking projects should be coordinated with local concrete pipe manufactures and jacking contractors.

Axial Loads
The axial or thrust loads are transmitted from one concrete pipe section to another through the joint surfaces. To prevent localized stress concentrations, it is necessary to provide relatively uniform distribution of the axial loads around the periphery of the pipe. This is accomplished by assuring that the pipe ends are parallel within the tolerances prescribed by applicable standards, using a cushion material, plywood, between the pipe sections, and care on the part of the contractor to insure that the jacking force is properly distributed through the jacking frame and perpendicular to the pipe axis. The cross-sectional area of a standard concrete pipe wall is more than adequate to resist stresses encountered in normal jacking operations. For projects where extreme jacking pressures are anticipated due to long jacking distances or excessive unit frictional forces, intermediate jacking stations may be used, and greater care taken to avoid bearing stress concentrations.

Earth Loads
The major factors influencing the vertical earth load on pipe installed by jacking are:
1. Weight of the prism of earth directly above the bore.
2. Upward shearing of frictional forces between prism of earth above bore and adjacent earth.
3. Cohesion of the soil.

Live Loads
Jacked installations are generally constructed at such depths of cover that effects of live loads are negligible. Highway and aircraft loads are considered insignificant at depths greater than 10 feet, however, railroad loads are considered up to 3 feet of cover.

Reinforced concrete pipe as small as 500mm inner diameter and as large as 3500mm inner diameter are being used for jacking. Since conventional jacking procedures require access by workmen through the pipe to the heading, 500 mm diameter pipe is generally the smallest practical size for most jacking operations. When jacking smaller size pipe, earth removal is accomplished by mechanical means such as augers and boring equipment. How ever size less than 500mm jacking pipe also available on request based our certaing site conditions.

Concrete pipe is ideally suited for tunneling and jacking. The pipe can be pushed forward immediately after the soil is excavated, providing a complete tunnel liner for protection of workers and equipment. Because of technological advances and increasing experience, many pipelines are now being jacked.

Jacking Procedure

The usual construction sequence for tunneling and jacking concrete pipe is: Excavate jacking pits or shafts, construct jacking abutments or thrust blocks, and install jacks, jacking frame and guide rails. - Begin tunnel excavation by machine, or hand, depending on conditions. - Lower first section of pipe, position jacks and jacking frame, and jack pipe forward. - Continue excavation, remove soil through pipe, insert seceding sections of pipe between the lead pipe and jacks and jack forward. - Repeat sequence, excavation, soil removal, pipe insertion and jacking, until the operation is complete.

Excavation should not proceed the jacking operation more than necessary. Material is trimmed so the tunnel bore slightly exceeds the outside diameter of the pipe. Such a procedure results in minimal disturbance to the adjacent soils. The lead pipe is generally contained within a shield projecting from the mining machine or equipped with a cutter or shoe to protect the pipe when excavating by hand. Jacked pipe tends to set or freeze when forward movement is interrupted, resulting in significantly increased frictional resistance, therefore, continuous operation is desirable. Occasionally a lubricant, such as bentonite slurry, is pumped into the space between the tunnel bore and the outside of the pipe to reduce frictional resistance. After the jacked pipe have reached their final position, grout is frequently pumped into this same space to insure continuous bearing with the surrounding soil.

When increased resistance develops due to soil conditions or length of run, intermediate jacking stations may be inserted at periodic intervals. The intermediate jacking station pushes only the several lengths ahead while bearing on the pipe behind. The use of intermediate jacking stations reduces axial loads on the pipe and required jacking capacity.

The number and capacity of the jacks primarily depends upon the size and length of the pipe to be jacked and the type of soil encountered. Abutments for the jacks must be strong enough and large enough to distribute the maximum capacity of the jacks to the soil behind the backstops.

UNLINED REINFORCED CONCRETE JACKING PIPE DETAILS

Notes:
1. All the measurement given above are in millimeters.
2. Other Sizes are available upon request

PVC/HDPE LINED REINFORCED CONCRETE JACKING PIPE DETAILS

Notes:
1. All the measurement given above are in millimeters.
2. Other Sizes are available upon request

GRP LINKED REINFORCED CONCRETE JACKING PIPE DETAILS

Notes:
1. All the measurement given above are in millimeters.
2. Other Sizes are available upon request

JACKING PIPE PRODUCTION

SPARK TESTING FOR LINER JOINT

PIPE D-LOAD TEST REQUIREMENTS
AS PER ASTM C - 76M SPECIFICATIONS

 
Copyright © 2014 Nagadi. All Rights Reserved.
site by ain technologies