RC Pipe

Concrete Pipes
Reference Manual
January 2009 *
Build Build our on

on our
expertise
Contents
1. Introduction ..................................................... 2 2. Test Load Data ................................................ 8 3. Pipes for Culvert Applications ........................ 9 Flush Joint Pipes ......................................... 15 4. Pipes for Drainage Applications .................. 16 Rubber Ring Joint (Belled Socket) Pipes ..... 17 Rubber Ring Joint (In-wall ) Pipes .............. 18 5. Pipes for Sewerage Applications ................... 21 6. Pipes for Pressure Applications .................... 27 Standard Pressure Pipe Class Range .......... 29 7. Pipes for Irrigation Applications ................... 35 8. Jacking Pipes ................................................ 38 9. Handling and Installation ............................. 43 10. Reference Material ..........................................51
10.1. Approx. Critical Depth Relationships for Circular Pipe 10.2. Relative Discharge & velocity for part-full pipe flow .. 10.3. Flow relationships for Inlet Control in Culverts .......... 10.4. Energy Head relationships for pipes flowing full ........ 10.5. Colebrook White Nomograph, ks = 0.06 ................... (applicable to concrete culverts carrying stormwater)
51 51 52 53 54
10.6. Colebrook White Nomograph, ks = 0.15 ................... 55 (applicable to concrete rising mains carrying clean water) 10.7. Colebrook White Nomograph, ks = 0.6 ..................... (applicable to concrete pipes carrying stormwater) 10.8. Colebrook White Nomograph, ks = 1.5 ..................... (applicable to concrete pipes carrying sewerage) 10.9. Minimum pipe cover required for various compactors 10.10. Metric and Empirical Equivalency Table ...................
56 57 58 60
Index ..................................................................61 Pipe Quotation Request Sheet ............................ 62
The information in this publication is for guidance only. Expert advice must be obtained on the suitability of any product and on its installation in the particular circumstances in which it is proposed to be used. Further, a check should be made, at www.humes.com.au, for the current version of this document, and also as to the availability of any particular product.
1
1. Introduction
General 1. Introduction
Humes is the leading manufacturer of steel reinforced concrete pipes (SRCP) and associated precast products in Australia. Available in a wide range of diameters, lengths and with varying strengths, Humes concrete pipes have a proven track record and are custom designed for user applications including drainage, sewage, water supply and irrigation. This publication provides the information necessary to specify Humes concrete pipes for all of these applications. Specification of Humes concrete pipes has also been simplified with the inclusion of a Pipe Design Request Sheet on page 62 of Concrete Pipes. Please copy the sheet and complete the necessary information, then fax or mail to your nearest Humes office for the fastest possible service.
Joint Types
Humes concrete pipes are manufactured with two basic joint types - Flush Joint and Rubber Ring Joint. Flush Joint pipes provide an interlocking joint which allows for a small degree of flexibility in the pipeline alignment. Rubber Ring Joint pipes, either belled-socket or in-wall joint depending on the diameter of the pipe and its application, are designed to accommodate change in pipeline alignment and settlement in a pipeline whilst still maintaining a watertight joint. Further information on the joints specific to the pipe application types is provided in sections 3,4,5,6,7 and 8 of this manual.
Durability
For most common installations, the service life of concrete pipe is virtually unlimited. The longevity of steel reinforced concrete pipe provides Asset Managers with a resource requiring low in-service maintenance and the ability to be recycled into other projects if exhumed. Some of the Roman aqueducts are still in use after 2000 years and samples from the first known concrete pipes in the US, laid in 1842, were in excellent condition after more than 140 years service. Of the 350 million kilometres plus of reinforced concrete pipe that has been laid in Australia, the number of pipelines which have suffered from durability problems has been extremely small and confined mainly to unprotected pipe in highly aggressive conditions. Advances in concrete, process and product technologies such as the use of Humes Plastiline for sewer pipe lines together with our stringent quality control and assurance programs ensures that our pipes and associated products will be fit for their purpose.
Manufacturing
Humes steel reinforced concrete pipes are made from coarse and fine aggregates, cement and hard drawn deformed steel reinforcement. They are manufactured and factory tested for quality to AS/NZS 4058: 2007 "Precast concrete pipes (pressure and non-pressure)". Pipes can also be custom made and tested to meet specific customer requirements. Generally Humes concrete pipes up to 2100mm nominal diameter (DN2100) are centrifugally cast using the Humespun process invented in 1910 in Australia by Walter Hume. In use throughout the world, the Humespun process of centrifugal casting produces strong and durable concrete pipes. Humes concrete pipes larger than DN2100 are vertically cast in steel moulds using high frequency vibration which produces concrete pipes with characteristics compatible with those of centrifugally spun pipes. High abrasion resistance and impermeability of spun concrete makes SRCP the most appropriate selection for handling peak flows. A range of natural characteristics further enhance performance, including an indefinite increase in strength in the presence of moisture and autogenous healing of cracks.
80 year old Humes pipes reused for new culvert!
Pipes manufactured in 1920 at Loveday S.A. have been exhumed and reused in a culvert at the Gurra Road Project in S.A. in 2000. The manufacture of centrifugally spun pipes.
Size Class (DN)

Humes standard range of concrete pipes are available in sizes DN300 - DN2100. (DN = nominal diameter) Diameters outside the standard range and up to DN3600 are also available. Special project pipes are also available for all sizes when required or specified. Humes concrete pipes are typically manufactured in nominal 2.44m lengths to optimise transport and handling. Other lengths, longer or shorter can be manufactured on request. Comprehensive tables listing the availability of Size Classes (DN) are provided in each section.
consulting the "Australian/New Zealand Standard AS/NZS 3725: 2007 Design for Installation of buried concrete pipes" which provides methods for determining the installed load on concrete pipes from the earth fill over the pipes as well as any induced live (vehicle) load effects.
For the majority of pipe installations, Humes Standard-Strength (Class 2-4) concrete pipes, used in conjunction with type H2 or type HS2 Bedding Support, are suitable (see Figure 1.1). The letter 'H' in the terminology indicates haunch support only. 'HS' indicates both haunch and side support. The numerals after 'H' and 'HS' indicate the level of support in the material used. Design Tables 1.1 & 1.2 (page 5) for Bedding Type H2 and HS2 are provided for ease of specifying concrete pipes within a limited range of stated conditions. Figure 1.2 (page 4) compares the results for a sample pipe installation using both Type H and Type HS Bedding Supports. Similarly, for embankment installation, Table 1.5 (page 7) is provided.
Load Class
Humes steel reinforced concrete pipes are available in StandardStrength (Class 2-4) and Super-Strength (Class 6-10) Load Classes. The numeric classification system adopted to identify the load carrying capacity of concrete pipes is based on the rationale that any particular pipe class is able to carry approximately the same proportionate height of fill. For example, a Class 10 pipe can carry five times the height of fill of a Class 2 pipe, under the same installation conditions. See Section 2: Test Load Data, for further information on test loads for each size class. The required strength of a concrete pipe depends on both the load to be carried by the installed pipe, and the supporting ground installation conditions. The load transmitted onto the pipe depends on the height and type of fill material. Also, when installed in a trench, the width of the trench at the top of the pipe is important. Generally the wider the trench, the greater the load for any height of fill over the pipe. The load class for concrete pipes can be determined by
Finished surface lc D/6 or 150mm, whichever is greater*
Hydraulics
To establish the flow rates for the various types of concrete pipes, Manning's formula should be used for short run culvert and drainage applications, while the Colebrook-White formula should be used for long run drainage, gravity sewer lines and all pressure pipe applications. The Concrete Pipe Association of Australasia (CPAA) publication "Hydraulics of Precast Concrete Conduits" is recommended as a reference. Comprehensive details on the hydraulics for the different pipe types are provided in each section.
Natural ground surface or compacted fill
lc D/6 or 150mm, whichever is greater*
Backfill
Embankment fill
150mm min. overlay
150mm min. overlay Compacted ordinary fill D Compacted select fill D Compacted select fill
150mm min.
Haunch Bed
Haunch Bed
Compacted
D/3 Compacted
Compacted
D/3 Compacted
Trench
* Refer AS/NZS 3725: 2007 for cement stabilised soil
Embankment
Figure 1.1 - Type H1 and Type H2 Supports
1. Introduction
The standard also provides a range of recommended Bedding Support Type options. The range varies from no support, to haunch support, to haunch and side support.
Finished surface lc D/6 or 150mm, whichever is greater * Natural ground surface or compacted fill lc D/6 or 150mm, whichever is greater *
1. Introduction
Backfill
Embankment fill
150mm min. overlay
150mm min. overlay Compacted ordinary fill D Compacted select fill Compacted select fill 0.5 D D 0.5 D
150mm (min. width)
Side Haunch Bed
Side Haunch Bed
Compacted
D/3 Compacted
Compacted
D/3 Compacted
Trench
* Refer AS/NZS 3725: 2007 for cement stabilised fill
Embankment
Figure 1.2 - Type HS Support
Ground surface
Note: Economies may be achieved by modifying bedding type as opposed to increasing pipe class
Figure 1.3 Indicative depth of fill for various bedding installation types
Indicative depth of fill
Table 1.1 Material Quantities - H1 & HS1 Support Types

Min Trench Size Class Width (DN) (m) 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 600 650 750 850 900 1000 1100 1150 1250 1400 1650 1850 2050 2300 2500 2700 2900 3200 Material Quantities (m3/lin.m) Bedding Zone 0.066 0.072 0.083 0.094 0.099 0.110 0.121 0.127 0.138 0.154 0.182 0.204 0.338 0.380 0.413 0.446 0.479 0.528 Haunch Zone 0.015 0.020 0.028 0.037 0.044 0.055 0.067 0.076 0.090 0.112 0.155 0.195 0.239 0.302 0.357 0.418 0.483 0.584 H1 Overlay Zone Trench 0.201 0.234 0.292 0.356 0.386 0.457 0.532 0.562 0.644 0.786 1.046 1.276 1.528 1.875 2.178 2.494 2.836 3.421 Embank 0.161 0.197 0.237 0.281 0.316 0.362 0.408 0.444 0.503 0.594 0.771 0.935 1.080 1.296 1.482 1.658 1.856 2.242 HS1 Side Zone 0.044 0.053 0.070 0.089 0.097 0.118 0.142 0.148 0.174 0.221 0.309 0.388 0.475 0.597 0.704 0.815 0.973 1.154 HS1 Overlay Zone 0.157 0.181 0.222 0.267 0.289 0.338 0.390 0.414 0.470 0.564 0.736 0.888 1.053 1.278 1.474 1.679 1.959 2.267 0.117 0.144 0.167 0.192 0.219 0.243 0.267 0.296 0.329 0.372 0.461 0.547 0.605 0.699 0.778 0.843 0.949 1.088
Note: Volume quantities are approximate & based on an assumed 10% bulking See figures 1.1 (page 3) and 1.2 (page 4) for zone descriptions
Table 1.2 Material Quantities - H2, HS2 & HS3 Support Types
Min Trench Size Class Width (DN) (mm) 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 600 650 750 850 900 1000 1100 1150 1250 1400 1650 1850 2050 2300 2500 2700 2900 3200 Material Quantities (m3/lin.m) Bedding Zone 0.066 0.072 0.083 0.094 0.099 0.110 0.121 0.127 0.138 0.154 0.182 0.204 0.338 0.380 0.413 0.446 0.479 0.528 Haunch Zone 0.042 0.053 0.072 0.095 0.108 0.133 0.161 0.176 0.208 0.261 0.363 0.456 0.560 0.705 0.833 0.971 1.120 1.364 H2 & HS3 Overlay Zone Trench 0.174 0.200 0.247 0.299 0.323 0.379 0.438 0.461 0.526 0.636 0.837 1.014 1.207 1.472 1.702 1.941 2.200 2.641 Embank 0.134 0.164 0.192 0.224 0.253 0.283 0.314 0.344 0.384 0.444 0.563 0.674 0.759 0.893 1.006 1.105 1.219 1.462 HS2 & HS3 Side Zone 0.017 0.020 0.026 0.032 0.033 0.040 0.048 0.048 0.056 0.072 0.101 0.126 0.155 0.194 0.228 0.262 0.313 0.374 HS2 & HS3 Overlay Zone Trench 0.157 0.181 0.222 0.267 0.289 0.338 0.390 0.414 0.470 0.564 0.736 0.888 1.053 1.278 1.474 1.679 1.959 2.267 Embank 0.117 0.144 0.167 0.192 0.219 0.243 0.267 0.296 0.329 0.372 0.461 0.547 0.605 0.699 0.778 0.843 0.949 1.088
Note: Volume quantities based on assumed 10% bulking See figures 1.1 (page 3) and 1.2 (page 4) for zone descriptions
1. Introduction
Trench
Embank
Table 1.3 Max. Fill Heights - Trench Installation, H2 Bedding

Fill height Max. (m)
1. Introduction
Size Class (DN) 2 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 5.8 4.9 4.8 4.4 4.5 4.2 4.4 3.9 3.7 3.5 3.4 3.1 3 2.9 2.3 2.2 12.1 12.7 8.7 7.3 6.1 6.1 5.4 5.2 4.8 3.9 3.7 3
Pipe Load Class 4 6 8 10
>25 metre height
19.7 10.7 10.7 8.7 8 7.2 5.9 5.6 21.9 15.7 11.7 10.9 21.7 Size Class (DN) 2 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 10.7 7.5 7.7 6.6 6.8 5.7 5.2 4.8 4.6 4.2 4 3.8 3 2.9 13.5 10 9.3 7.7 7 6.5 5.3 5.1 14.5 12.3 10.5 8.4 7.9 20.8 17.8 >25 metre height
Table 1.4 Max. Fill Heights - Trench Installation, HS2 Bedding

Fill height Max. (m) Pipe Load Class 3 4 6 8
Notes: Assumed minimum trench width & Clayey Sand Soil Internal weight of water is considered for > DN180
In onerous fill situations, a combination of StandardStrength concrete pipes and Type HS3 Bedding Support* can provide the most appropriate solution. Table 1.6 provides details for such an installation. *Type HS3 Bedding Support is similar to that required for a flexible pipe installation.
Notes: Assumed minimum trench width & Clayey Sand Soil. Internal weight of water is considered for > DN1800.
Table 1.5 Max. Fill Heights - Embankment Installation, H2 (& HS2)

Fill height Max. (m) Size Class (DN) H2 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 3.2 2.7 2.5 2.4 2.5 2.5 2.6 2.6 2.6 2.5 2.6 2.6 2.7 2.7 2.7 2.7 2.3 2.2 Pipe Load Class 2 HS2 4.6 3.9 3.5 3.4 3.5 3.5 3.6 3.6 3.6 3.5 3.5 3.4 3.4 3.3 3.2 3.2 2.9 2.8 H2 4.9 4.2 3.8 3.7 3.8 3.7 3.9 3.8 3.9 3.8 3.7 3.6 3.7 3.7 3.7 3.7 3.4 3.4 3 HS2 6.8 5.9 5.4 5.2 5.4 5.3 5.5 5.4 5.5 5.3 5.2 5.0 5.1 4.9 4.8 4.8 4.2 4.2 H2 6.5 5.5 5.0 4.9 5.0 5.0 5.2 5.1 5.2 5.0 5.0 4.8 4.8 4.7 4.6 4.6 4.4 4.4 4 HS2 9.2 7.7 7.0 6.9 7.1 7.0 7.3 7.2 7.2 7.0 7.0 6.7 6.8 6.5 6.4 6.3 5.8 5.6 H2 6 HS2 H2 8 HS2 H2 13.6 12.5 12.2 12.6 12.4 12.9 12.8 12.9 12.3 12.3 11.8 12.0 11.5 11.4 11.2 10.6 10.4 10 HS2 19.3 17.5 17.2 17.7 17.4 18.2 18.0 18.2 17.3 17.3 16.7 16.9 16.5 16.0 15.7 14.9 14.7
8.1 11.6 7.5 10.6 7.3 10.3 7.5 10.6 7.5 10.5 7.7 10.9 7.7 10.8 7.7 10.9 7.4 10.6 7.4 10.0 7.1 10.4 7.2 10.1 7.0 6.9 6.8 6.3 6.2 9.7 9.6 9.5 8.8 8.7
10.9 15.4 10.0 14.0 9.7 9.9 13.8 14.0 10.1 14.2 10.3 14.5 10.2 14.4 10.3 14.5 9.9 9.9 9.5 9.6 9.2 9.1 9.0 8.4 8.3 13.9 13.9 13.6 13.5 13.0 12.8 12.6 11.9 11.7
Notes: Assumed Clayey Sand Soil (p=0.7 for H2 & p=0.3 for HS2). Internal weight of water is considered for > DN1800
Table 1.6 Max. Fill Heights - Embankment Installation, HS3

Fill height Max. (m) Size Class (DN) 2 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 7.4 6.2 5.6 5.5 5.6 5.6 5.8 5.8 5.8 5.6 5.6 5.3 5.4 5.2 5.2 5.1 4.5 4.4 Pipe Load Class 3 11.0 9.4 8.6 8.3 8.6 8.4 8.7 8.6 8.7 8.4 8.3 8.0 8.1 7.8 7.7 7.6 7.0 6.8 4 14.7 12.3 11.3 11.0 11.4 11.2 11.6 11.5 11.6 11.2 11.1 10.7 10.8 10.4 10.3 10.1 9.4 9.3 6 18.5 16.9 16.5 17.1 16.9 17.4 17.3 17.4 16.7 16.7 16.0 16.2 15.6 15.4 15.1 14.3 14.1
Notes: Assumed Clayey Sand Soil with p=0.3. Internal weight of water is considered for > DN1800
1. Introduction
2. Test Load Data

Commonly supplied size classes: DN300 - DN2100 Note: Intermediate strength classes are specified by linear interpolation between values and Humes can advise on individual applications.
Steel Reinforced Concrete Pipes are manufactured and proof tested to Australian Standards requirements. The Australian/NewZealand Standard, AS/NZS 4058: 2007 - Precast concrete pipes (pressure and non-pressure) provides levels of proof test loads for concrete pipes and sample pipes taken for routine quality assurance during normal production which ensures the pipes' strength. Test load requirements for all Humes concrete pipes are given below.
Table 2.1 - Test Loads in kilonewtons/metre length

Test Loads KN/m (length) Load Class Standard Strength Class 2 Crack 14 15 17 20 23 26 29 32 35 37 42 46 50 54 58 62 66 70 74 78 86 94 102 110 Class 3 Class 4 Class 6 Super Strength Class 8 Class 10 Crack 75 85 100 115 130 145 160 173 185 210 230 250 270 290 310 330 350 370 390 430 470 Ultimate 94 106 125 144 163 182 200 217 231 263 288 313 338 363 388 413 438 463 488 538 588 -
2. Test Load Data
Size Class (DN) 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 2250 2400 2700 3000 3300 3600
Ultimate Crack Ultimate Crack Ultimate Crack Ultimate Crack Ultimate 21 23 26 30 35 39 44 48 52 56 63 69 75 81 87 93 99 105 111 117 129 141 153 165 21 23 26 30 35 39 44 48 52 56 63 69 75 81 87 93 99 105 111 117 129 141 153 165 32 34 39 45 52 59 66 72 78 84 95 104 113 122 131 139 149 158 167 176 194 212 230 248 28 30 34 40 46 52 58 64 69 74 84 92 100 108 116 124 132 140 148 156 172 188 204 220 42 45 51 60 69 78 87 96 104 111 126 138 150 162 174 186 198 210 222 234 258 282 306 330 45 51 60 69 78 87 96 104 111 126 138 150 162 174 186 198 210 222 234 258 282 56 64 75 86 98 109 120 130 139 158 173 188 203 218 233 248 263 278 293 323 353 60 68 80 92 104 116 128 138 148 168 184 200 216 232 248 264 280 296 312 344 376 75 85 100 115 130 145 160 173 185 210 230 250 270 290 310 330 350 370 390 430 470 -
3. Pipes for culvert applications

Rubber Ring Joint (RRJ)
RRJ pipes are also suitable for culvert applications and are most effective when differential ground settlement is anticipated or if a pipeline is expected to flow full under outlet control conditions with a significant hydraulic pressure head. See Section 4, Concrete Stormwater Pipes for further details.
Culvert
Humes can provide a comprehensive range of steel reinforced concrete culvert pipes in sizes DN225 - DN3600. (commonly supplied size classes: DN300 - DN2100). They are available with two basic joint types - Flush Joint (FJ) and Rubber Ring Joint (RRJ).
Size Class (DN)

See Table 3.2 (page 15) for details of Flush Joint Pipes.
Load Class
Humes concrete culvert pipes are available in Standard-Strength (Class 2-4) and Super-Strength (Class 6-10) Load Classes. The most appropriate culvert installation can be obtained by matching both pipe Load Class and the Bedding Support Type. For the majority of installations, Standard-Strength concrete culvert pipes used in conjunction with type H2 or type HS2 Bedding Support, are suitable. For large fill situations, a combination of Super-Strength pipes and type HS3 Bedding Support can provide the most appropriate and economical solution. Further information on the Load Class of concrete pipes can be obtained by referring to Section 1: Introduction (page 3).
Flush Joint (FJ)

FJ pipes with External Bands (EB) are recommended for normal culvert conditions. They provide an interlocking joint between pipes, as shown in Figure 3.1, and give a true and positive alignment along the length of the pipeline. When EB bands are used in conjunction with FJ culvert pipes, they provide a soil-tight joint along the pipeline and prevent loss of bedding material into the pipe. Groundwater infiltration may occur however, when the groundwater level is significantly above the pipeline obvert (approx. 3m). FJ pipes fitted with EB bands allow a small degree of flexibility for the bedding-in/movement of the pipeline during natural processes of consolidation.
Hydrology
The maximum flow to be considered in storm water culverts and pipes is a function of: the hydrological data pertaining to tributary overland flows, as experienced throughout the service life of the drainage system The most commonly used formula to determine the quantity of water generated by a storm event is known as the rational formula: Q = 0.278 C I A where Q = discharge (m3/s) C = coefficient of runoff (dimensionless) I = intensity (mm/hour) A = catchment area (km2), C will most commonly vary between 0.7 and 0.9 say, for grassed surfaces and paved (sealed) areas. The magnitude of I, the intensity is a function of geographical area. By example a Brisbane storm may have an intensity of two times that of a Melbourne storm. Australian Rainfall and Runoff (ARR) is a guide to flood estimation produced by (and the subject of continuing review by) the Institution of Engineers, Australia. In addition to ARR, local and state authorities may have specific or alternative data/design requirements, such the Queensland Urban Drainage manual (QUDM).
Figure 3.1 - Flush Joint Profile
3. Culvert Applications
Inlet control
Inlet control conditions shown in Figure 3.2 exist in a pipeline where the capacity of the pipeline is limited by the ability of upstream flow to easily enter the pipeline, a common situation in coastal Australia where short culvert lengths on steep grades are used. The flow under inlet control conditions can be either inlet submerged or unsubmerged.
Outlet control
Where culverts are laid on flat grades and empty below the downstream water level, the culvert typically operates with outlet control conditions as shown in Figure 3.3.
H HW > D D TW >D
Unsubmerged
HW 1.2D
D
HW > D D
H TW = D
Submerged
HW > 1.2D
D
HW 1.2D
H D TW < D
Figure 3.2 - Inlet Control

Legend for Figure 3.2 and 3.3 HW = Head Water TW = Tail Water D = Diameter
HW< 1.2D D H TW < D
Figure 3.3 - Outlet Control When operating under outlet control conditions, the culvert pipe may flow full or part-full depending on the tailwater depth. Where the tailwater depth is greater than the pipe diameter, the pipe will typically flow full. Where the tailwater depth is less than the pipe diameter, the design tailwater depth should be taken as the greater of the actual tailwater depth or (dc + D)/2, where dc is the critical depth for the actual flow discharge (see Figure 3.4).
10
The design charts Figures 10.3 & 10.4 (pages 52, 53) for pipe culvert inlet and outlet conditions allow the designer to evaluate maximum discharge conditions at maximum headwater. For a lesser discharge, Figure 3.4 can be used to determine flow characteristics. Where inlet flow conditions exist in a culvert, the flow capacity of the pipeline is independent of the pipe surface roughness (Manning's 'n').
Installation
Humes culvert pipes above DN525 are normally supplied with elliptical grid reinforcement, unless a circular grid is specifically requested. Elliptical grid reinforced pipes must be laid with the word "TOP" at the crown (or invert) of the pipe, and within 10 each side of the vertical centreline. To simplify handling, lifting holes are generally provided in the top of all FJ pipes and FJ splays above DN 525. See Section 9 (page 43) : Handling and Installation for further details.
Figure 3.4 - Relative discharge and velocity in part-full pipe flow
1.0 .9 .8
Proportional Depth y/D
.7 .6 .5 .4 .3 .2 .1
Q/
Qf
V/
Vf
.1
.2
.3
.4
.5
.6
.7
.8
.9
1.0
1.1
1.2
Proportional Discharge Q/Qf and Proportional Velocity V/Vf Q = Part-full Velocity Qf = Full Flow Discharge V = Part-full Velocity Vf = Full Flow Discharge
Installing flush joint pipes
The pipeline flow capacity for inlet control conditions is dependent on the ratio of headwater depth to culvert diameter and the inlet geometry type. Outlet control conditions operating in a culvert determine the pipeline flow capacity by the effects of pipe surface roughness (Manning's n'), pipeline length and slope, and inlet geometry type.
Installing 3600mm diameter pipes.
11
Other Culvert Products

Humes manufactures a wide range of associated components to provide the complete culvert pipeline solution. These include: Headwalls - These are used where the hydraulic design requires improved inlet and outlet flow conditions. FJ Splay pipes - These permit curves in pipeline alignment without the usual problems of hydraulic head loss (turbulence) that can result from a rapid change in the direction of the flow at a sharp bend. Details are given for the minimum radius of curved alignment. See Table 3.1 and Figure 3.5 for minimum radius using double ended splays and recommended radius using single ended splays. EB bands can also be used with FJ Splays. For lesser radii, FJ bend pipes may be supplied. Notes: 1. The number of splay pipes required is determined from the deflection angle and the centreline radius. This information should be given when ordering splay pipes. Humes Engineers will calculate the optimum number of splay pipes required. 2. The curve "hand" is described as when looking downstream in the direction of the flow.
Precast Concrete Headwall
Table 3.1 - Minimum Radius for curved pipe alignment: Flush Joint Splays
Min CL Radius* (m) Economical (single ended) 11.5 11.8 12.2 12.4 12.6 13 13.4 13.7 14 14.4 15 15.9 16.7 Not typically supplied Absolute Min. (double ended) 4 4.3 4.6 4.9 5.2 5.8 6.4 7 7.7
Size Class (DN) 600 675 750
825 900 1050 1200 1350 1500 1650

Multiple Barrel Splay Pipes (EB Joint).
1800 1950 2100
Stan (nom dard P ipe inal leng th) L/2
C L
* Minimum radius is measured to the pipe centre line at joint
Radiu
s (R)
Splay pipes
Right hand curve looking down stream
Direction of flow
Pipeline deflection angle ()
Figure 3.5 - Minimum single-ended splay radius achieved with flush joint splays in curved pipeline alignment
12
Example 3 - Culvert Pipe

A culvert is to be laid under a proposed road embankment. From the catchment physical data and hydraulic information, the designer has determined a peak flow of 5.5 cumecs (5500 litres/sec) passing through the culvert pipeline. The roadway alignment requires an embankment height of 2.0m above existing ground surface, and the culvert is to be laid at natural ground level. To avoid flooding the roadway pavement the maximum upstream flood level is to be 300mm below roadway level. Due to downstream flow restrictions, the estimated tailwater level is 1.0m above the natural ground surface. The width of the roadway formation including embankment slope is to be 50m, over which the natural ground surface falls 500mm. The culvert is to be constructed with headwalls. Calculate appropriate culvert pipe diameter/s for these conditions. Calculate outlet velocity and check if erosion requires consideration. From the information provided: Q required = 5.5 cumecs (5500 litres/sec) Max Headwater HW = 1.70m (embankment height minus min. freeboard), Max Tailwater TW = 1.00m Pipe culvert length = 50m, Pipe culvert slope = 1 in 100 (500mm fall over 50m length) Assume square edge inlet Step 1 Assume inlet Control Conditions: 1.1 Try 1500mm diameter FJ pipe (as max headwater is 1.7m): HW/D = 1.7/1.5 = 1.13 From Figure 10.3 Flow Relationships for Inlet Control in Culverts (page 52), using scale (1) Square edge with headwall: Q = 4.1 cumecs < Q required, therefore try larger pipe diameter/culvert area. 1.2 Try twin 1050mm FJ pipe: HW/D = 1.7/1.05 = 1.62 From Figure 10.3 Flow Relationships for Inlet Control in Culverts (page 52), using scale (1) Square edge with headwall: Q = 2 x 2.4 = 4.8 cumecs < Q required, therefore try larger pipe diameter/culvert area. 1.3 Try twin 1200mm diameter FJ pipe: HW/D = 1.7/1.2 = 1.42 From Figure 10.3 Flow Relationships for Inlet Control in Culverts (page 52), using scale (1) Square edge with headwall: Q = 2 x 3.1 = 6.2 cumecs > Q required. 1.4 Establish head water height with twin 1200mm diameter FJ pipe and max. flow: Qmax. = Q required = 5.5 cumecs (5500 litres/sec) Q per pipe = 2.75 cumecs From Figure 10.3 Flow Relationships for Inlet Control in Culverts (page 52), using scale (1) Square edge with headwall: HW/D = 1.23; therefore HW (inlet control) = 1.23 x 1.2 = 1.48m (<1.7m), therefore twin 1200mm diameter FJ pipes are ok for inlet control conditions.
1.0 .8 .6 .4
Step 1.3 Q = 2 x 3.1 = 6.2 m3/s
Step 1.1 Q = 4.1 m3/s
Step 1.2 Q = 2 x 2.4 = 4.8 m3/s
Step 1.4 HW/D = 1.23
Figure 10.3 - Flow Relationships for Inlet Control in Culverts
Step 2 Check for outlet control conditions: 2.1 Determine critical flow depth (dc) Q / (g0.5 x D2.5) = 2.75/ (9.810.5 x 1.22.5 ) = 0.557 from Figure 10.1 Approx. Critical Depth Relationships for Circular Pipe (Page 51), dc/D = 0.75, therefore dc = 0.90m
Figure 10.1 - Approximate Critical Depth Relationships for Circular Pipe
.2
dc/ D
Step 2.1 dc/D = 0.75
.1 .08 .06 .04
dc
.02
Q = m3/s D=m g = m/s2
.01 .0001 .001 .01 .1 1.0
Q/(g)0.5(D)2.5
Note: For partly-full flow outlet control if (dc+D)>TW, then approx. HW can be established by using (dc+D) in Figure 10.4 Energy Head relationship for Pipes Flowing Full (page 53). 2.2 Establish HW level for outlet control conditions HW = [TW or (dc + D) / 2] + H - fall (dc + D) / 2 = (0.9 + 1.2) / 2 = 1.05m (> TW =1.0m) therefore adopt (dc + D)/2 = 1.05m in Fig. 10.4 (page 53) (in lieu of TW): From Figure 10.4 Energy Head relationship for Pipes Flowing Full (page 53): for Q = 2.75 cumecs, L =50m & ke = 0.5 (square edge head wall) then H = 0.65m HW (outlet control) = 1.05 + 0.65 0.5 = 1.20m
13
Step 3 Determine Flow Velocity: For inlet control conditions, the outlet velocity can be determined via the Colebrook-White formula (adopt k = 0.60mm) Hydraulic gradient = (HW -TW + fall)/Length = (1.51.0+0.5)/50 = 0.02 from Figure 10.7 Full Flow Conditions Colebrook-White Formula (ks = 0.6) (Page 56) with Qf = 6.2/2 = 3.1 cumecs: Vf = 4.52 m/s,
.0400 .0300
Step 2.2 H = 0.65m
Step 2.2 Q = 5.5/2 = 2.75 m3/s
.0200
45 0
7.5 m/ s 7.0 m/ s m/ s 6.0 m/ s 5.5 m/ s 5.0 m/ s 6.5 4.5
DN
30 0
DN
37 5
DN
52 5
m/
60 0
.0100
DN
4.0
m/
DN
67 5
DN
75 0
3.5
m/
Hydraulic Gradient (m/m)
82 5
DN
90 0
DN
3.0
DN
DN
.0050
DN 10 50 DN 1 DN 125 12 00 DN 12 75 DN 13 50
97 5
m/
2.5
m/
DN
.0020
.0010
m 1.9 /s m 1.8 /s m 1.7 /s m/ s 1.6 m 1.5 /s m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s
100 200 300 500 700 1000 2000 3000
18 00
DN
.0005
4000 5000
Discharge in litres per second
Figure 10.4 - Energy head relationships for pipes flowing full (n = 0.011)
Figure 10.7 - Full Flow Conditions Colebrook-White Formula ks=0.6mm
2.3 Compare HW level for inlet control and outlet control conditions: HWinlet =1.50m > HWoutlet = 1.20m, therefore inlet control governs. Use twin 1200mm diameter FJ pipes
from Figure 10.2 Relative Discharge & Velocity in Part-Full Pipe Flow (page 51), Q/Qf = 2.75/3.1 = 0.88, gives V/ Vf = 1.12 and y/D = 0.72 Therefore V = 5.1 m/s, and y = 0.86m (< dc = 0.90m) As actual flow depth (y) is less than the critical depth (dc), a hydraulic jump may occur at the culvert outlet if the downstream channel flow is not supercritical. Erosion protection at the culvert outlet may be necessary.
1.0 .9 .8
y/D Proportional Depth y/D

.7 .6 .5 .4 .3 .2 .1
Q/
Qf
V/
Vf
Q/Qf
.1
.2
.3
.4
.5
.6
.7
.8
.9
1.0
V/Vf
1.1 1.2
Proportional Discharge Q/Qf and Proportional Velocity V/Vf
Summary Use twin 1200mm diameter FJ Pipes Erosion protection at the culvert outlet may be necessary
14
19 50 21 00 DN 22 50 DN 24 00 DN 2 DN 550 2 DN 700 28 50
7000
2.0
DN
16 50
DN
.0030
15 00
DN
10000
ks = 0.6mm
Flush Joint Pipes

for culvert applications
Commonly Supplied Size Classes: DN300 - DN2100 Nominal Length: 2.44m except where denotes. Other lengths may be available on request.
Pipe length
ID
OD
Note: Pipe mass based on product density of 2600kg/m3 for spun pipe and 2500kg/m3 for vertically cast pipe. Flush Joint Pipe
Table 3.2 - Flush Joint Pipes

Actual Internal Diameter D (mm), Pipe Class, Mass (kg) and Outside Diameter (OD)
Standard Strength Load Classes Size Class (DN) 225 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 2250* Class 2
ID (mm) Mass (kg)
Super Strength Load Classes Class 4 Class 6

ID (mm) Mass (kg)
Class 3
ID (mm) Mass (kg)
Class 8
ID (mm) Mass (kg)
Class 10
ID (mm) Mass (kg)
ID (mm)
Mass (kg)
OD (mm) 279
229 300 375 450 534 610 685 762 838 915 1066 1219 1372 1524 1676 1828 1994 2160 2250
125 205 280 400 465 565 690 815 945 1090 1420 1775 2165 2405 2885 3375 4200 5215 8140
229 300 375 450 518 600 679 756 832 903 1054 1207 1360 1504 1656 1808 1982 2136 2250
125 205 285 405 545 625 735 865 1000 1200 1550 1925 2340 2710 3220 3745 4515 5655 8775
229 300 375 450 502 586 661 730 806 883 1026 1179 1332 1468 1620 1772 1944 2110 2250
130 210 290 415 625 705 850 1045 1205 1370 1830 2245 2700 3245 3820 4400 5225 6205 9165 2250 290 363 444 502 586 661 730 806 883 1026 1171 1292 1424 1576 1718 1904 2050 235 330 445 625 710 860 1055 1215 1390 1855 2355 3230 3860 4495 5295 5980 7535 280 355 438 502 570 637 714 782 851 966 1109 1242 1374 1516 1668 1834 1990 260 360 465 630 800 1005 1170 1400 1655 2430 3045 3830 4590 5450 6200 7340 8715 268 343 418 486 554 615 682 754 795 926 1059 1202 1324 1476 1628 1794 1960 295 395 545 705 885 1135 1385 1605 2085 2775 3580 4335 5230 6065 6855 8040 9335
362 445 534 616 698 781 864 946 1029 1194 1359 1524 1676 1842 2006 2198 2388 2530 2550 2718 2742
Typically project specific production only 14195 2250 15050 2250 18640
2850 2718 2742
2400*
2438
8795 2438 9640 2438 10850 2438 20620 2438 20715 2438 20855
2768 3060 3030 3060 2700 21250 2700 21340 2700 21490 3410 3410 3460 3060 32700 3060 32800 3060 32950 4010 3900 4240
2700*
2700
11460
2700
11585 2700 13115
3000*
3060
13750 3060 15835 21240 24700 3060 3300 3600 16510 21350 24820
3300 3600
3300 3600
21110 24535
3300 3600
Note: Internal diameters (ID) subject to change without notice
15
Rubber ring
4. Pipes for drainage applications

Humes provide a comprehensive range of steel reinforced concrete stormwater pipes from DN225 to DN3600 (Common Size Classes: DN300 to DN2100). Rubber Ring Joint (RRJ) pipes are recommended for stormwater drainage systems, although Flush Joint (FJ) pipes can also be used dependant on requirements of the client / asset owner. RRJ pipes up to DN1800 are supplied with a belled-socket joint, while those larger than DN1800 are supplied with an in-wall joint (see Figures 4.1 & 4.2).
Max. joint draw Witness marks Spigot Nominal laying gap Socket
Inside surface
Figure 4.1 - RRJ Pipe with Belled Socket Joint
Rubber ring

Rubber Ring Joints provide concrete pipes with a high degree of flexibility to accommodate ground settlement or alignment adjustments. The RRJ profile is designed for ease of installation, and allows curved alignment adjustments while maintaining a watertight joint capable of withstanding the common levels of hydraulic head occurring in a storm water pipeline. Table 4.1 presents the minimum radius for curves in the pipeline for the standard range of pipes. Details on other sizes can be obtained by contacting Humes.
Socket Spigot
Max. joint draw Inside surface Nominal laying gap
Figure 4.2 - RRJ Pipe with In-wall (Skid) Joint
Size Class (DN)

See Tables 4.2 & 4.3 (pages 17, 18) for details.
Table 4.1 - Maximum Joint Deflection: RRJ - Drainage Applications

Size Class (DN) 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 Max Max CL deflection Min CL Deviation angle at joint Radius* per pipe /N (m) (mm) (degrees) 81 81 55 43 38 34 26 21 34 26 21 21 26 21 68 26 34 1.9 1.9 1.3 1.0 0.9 0.8 0.6 0.5 0.8 0.6 0.5 0.5 0.6 0.5 1.6 0.6 0.8 45 50 55 60 70 70 80 85 90 95 95 100 125 130 80 80 80
4. Drainage Applications
R = where:
L 2 (tan 1/2 /N)
Figure 4.3 - Curved Alignment using Deflected Straight Pipe
R = Radius of curvature, feet L = Average laid length of pipe sections measured along the centerline, feet = Total deflection angle of curve, degrees N = Number of pipes with pulled joints /N = Total deflection of each pipe, degrees
* Minimum radius is measured to the pipe mid point
16
Nominal Pipe length
Rubber Ring Joint (Belled Socket) Pipes

for culvert, drainage and sewerage applications
Commonly Supplied Size Classes: DN300 - DN1800 Pipe Length (nom): 2.44m Pipes available in most areas indicated by bold type. Other lengths may be available on request. Additional sizes have restricted availability and designers should consult Humes to confirm their supply status.
ID OD
G H
Rubber Ring Joint (Belled Socket) Pipe
Note: Pipe mass based on product density of 2600kg/m3 for spun pipe and 2500kg/m3 for vertically cast pipe.
Table 4.2 - Rubber Ring Joints (Belled Socket)

Actual Internal Diameter (ID), Socket Dimensions (A,G & H), Outside Diameter (OD) and Pipe Mass.
Standard Strength Load Classes Load Class Class 2 Class 3 Class 4 Super Strength Load Classes Class 6 Class 8 Class 10 Socket Dimensions Socket Dimensions (A,G & H) Load Class G (mm) 89 108 114 114 76 114 114 80 114 121 114 147 133 133 133 140 133 133 143 133 176 196 143 196 143 143 146 196 171 152 215 178 171 215 178 171 215 210 171 230 194 194 194 H (mm) 83 95 114 114 89 114 114 95 114 133 114 116 190 133 133 133 133 133 152 133 113 146 152 118 152 152 146 128 149 152 138 259 149 151 259 149 165 215 149 170 292 292 203 Pipe OD (mm) 279 293 305 311 362 381 400 445 457 496 534 560 597 616 636 666 698 724 762 781 784 820 864 860 890 914 946 950 978 1042 1040 1093 1220 1190 1244 1372 1350 1420 1524 1514 1714 1866 2032
Size Class ID (mm) Mass (kg) ID (mm) Mass (kg) ID (mm) Mass (kg) ID (mm) Mass (kg) ID (mm) Mass (kg) ID (mm) Mass (kg) A (mm) (DN) 225 225 300 229 229 229 229 300 304 300 375 381 380 450 450 457 534 534 530 610 610 610 685 680 680 760 750 762 762 838 830 838 910 900 915 1070 1050 1066 1220 1200 1200 1370 1350 1524 1676 1828 110 135 220 240 220 280 370 305 340 545 435 605 800 515 650 880 625 815 1130 760 845 1175 940 955 1145 1380 1050 1200 1410 1415 1425 2030 1895 1790 2335 2175 2190 3275 2460 2690 3550 3890 4450 229 229 229 229 300 304 300 375 381 380 50 450 457 518 534 530 598 610 610 673 680 680 744 750 762 762 818 830 838 910 900 915 1070 1050 1066 1220 1200 1200 1370 1350 1524 1676 1828 110 140 220 240 220 280 375 310 345 545 440 610 805 595 650 880 685 820 1135 805 855 1180 985 1000 1150 1385 1105 1210 1420 1425 1435 2035 1910 1800 2345 2195 2210 3290 2610 2715 3575 3925 4495 229 229 229 229 300 304 300 375 381 380 450 450 457 518 534 530 598 610 610 673 680 680 744 750 762 762 818 830 838 910 900 915 1058 1050 1066 1200 1194 1200 1330 1344 1504 1636 1788 110 140 220 240 240 280 375 315 345 545 450 615 805 675 655 880 765 820 1135 920 860 1185 1170 1010 1160 1390 1305 1215 1425 1535 1445 2040 2115 1820 2355 2555 2300 3300 2995 2810 3905 4470 5085 Not typically supplied 362 368 394 406 451 470 508 540 546 622 622 694 749 711 762 822 797 851 932 886 915 988 997 996 1033 1084 1064 1098 1149 1197 1190 1302 1391 1364 1454 1543 1540 1670 1695 1710 1937 2089 2267
375
450
525
600
675
750
825
900
1050
1200
1350 1500 1650 1800
288 304 300 355 375 380 438 450 457 502 534 530 586 610 610 653 670 680 728 734 762 762 798 814 838 878 884 915 1022 1018 1066 1156 1160 1200 1294 1286 1460 1596 1744
250 285 375 345 370 545 480 615 805 680 665 890 770 830 1140 930 930 1190 1125 1125 1170 1395 1320 1350 1445 1555 1595 2055 2250 2140 2380 2695 2685 3325 3400 3555 4515 5065 5900
280 298 300 351 361 380 438 450 457 502 524 530 570 600 610 645 648 680 712 710 738 762 782 782 814 862 852 915 990 960 1010 1120 1090 1160 1240 1230 1404 1546 1668
280 305 380 395 425 545 500 615 810 685 715 895 860 895 1145 1030 1070 1200 1290 1295 1340 1405 1500 1590 1635 1850 1855 2075 2725 2695 2930 3360 3435 3775 4115 4210 5335 6045 7285
268 284 300 343 357 380 418 444 457 486 510 530 554 578 610 615 616 656 680 680 706 762 748 750 782 800 790 851 950 920 966 1070 1040 1110 1200 1190 1354 1486 1608
310 340 380 420 430 550 580 640 810 755 785 895 945 1015 1150 1205 1255 1350 1500 1485 1560 1630 1745 1825 1875 2335 2335 2600 3075 3035 3340 3905 3970 4345 4630 4720 5990 6915 8220
Note: Internal diameters (ID) subject to change without notice
17
Rubber Ring Joint (In-wall) Pipes

for culvert, drainage and sewerage applications
Commonly Supplied Size Classes: DN1200 - DN3600 Nominal Pipe Length: 3.0m (*denotes 2.44m) Other lengths are available.
Effective Pipe length
ID
OD
Rubber Ring In-wall Joint Pipe Note: Pipe mass based on product density of 2600kg/m3 for spun pipe and 2500kg/m3 for vertically cast pipe.
Table 4.3 - Rubber Ring Joints (In-wall)

Actual Internal Diameter (ID), Outside Diameter (OD) and Pipe Mass.
Standard Strength Load Classes Size Class (DN) 1200* 1950* 2100* 2250 Class 2 ID (mm) 1280 1950 2100 2250 Mass (kg) 2985 5515 6340 8795 Class 3 ID (mm) 1280 1950 2100 2250 Mass (kg) 3005 5540 6370 8880 2250 11925 2250 15050 2250 2400 2438 9575 2438 9660 2438 10895 2438 2700 2700 11505 2700 11590 2700 13175 2700 3000 3060 13795 3060 15875 3060 16585 3060 3300* 3600* 3300 3600 21110 20165 3300 3600 21240 20220 3300 3600 21350 20320 32700 3060 32800 3060 32950 21250 2700 21340 2700 21490 20620 2438 20715 2438 20855 18640 Class 4 ID (mm) 1280 1950 2100 Mass (kg) 3025 5580 6415 Class 6 ID (mm) 1260 1894 2068 2250 Mass (kg) 3285 6715 7265 12120 Super Strength Load Classes Class 8 ID (mm) 1240 1830 2000 Mass (kg) 3545 7850 8585 Class 10 ID (mm) 1200 1780 1920 Mass (kg) 4015 8760 10055 OD (mm)
1500 2220 2388 2550 2650 2742 2850 2742 2768 3060 3030 3060 3410 3410 3460 4010 3900 4130
= Not typically supplied
18
Hydraulics
Generally, a stormwater pipeline system is designed so that the hydraulic gradeline is at or below the level of the line joining the upstream and downstream manhole surface levels as shown in Figure 4.3 (page16).
1 Horizontal Reference V2/2g 2 2 Hfriction V2/2g
Installation
All Humes RRJ belled socket pipes are supplied with laying witness marks indicated in the RRJ profile for easy control of the deflected joint. (See Fig. 4.1, pg 16 or Fig. 9.8, pg 45) Note: Humes concrete stormwater pipes are normally supplied with elliptical grid reinforcement, unless a circular grid is specifically requested. Elliptical grid reinforced pipes must be laid with the word "TOP" at the crown (or invert) of the pipe and within 10 each side of the vertical centreline. To simplify handling, lifting anchors can be provided if requested in heavy large size RRJ pipes, and for RRJ pipes DN1800 and over, Humes provides a special rubber ring lubricant to assist joining. See Section 9: Handling and Installation for further details.
Total Energ y Line Free Water Surface Flow Pipe Invert Slope
Base Level H1 + V2/2g = H2 V2/2g + Hfriction
H1
H2
Figure 4.4 - Uniform Flow Conditions The loss of energy head in the pipeline is the aggregate of elevation, exit velocity and friction head losses. Of these, normally only elevation and friction head losses are major considerations. The flow of water in a stormwater pipeline operating full or with minor energy head is determined from the hydraulic gradient in the pipeline. For determining head loss in a stormwater pipeline, the Colebrook-White formula is recommended as is a roughness height (ks) of 0.6mm. Figure 4.4 gives the capacity and flow velocity of a pipeline flowing with an established hydraulic grade. Alternatively, available energy head can be used to determine the required pipe size for a given flow discharge. Figure 3.4 - Relative discharge and velocity in part-full pipe flow (page 11), can be used to determine part-flow depth, velocity and discharge in a pipeline. Although a value of ks = 0.6mm is recommended, where the stormwater system is located in a fully developed urban environment, this reasonably conservative value, which is determined from the combined effects of pipe surface and solid material carried in the flow, may be reduced to 0.15mm, considerably increasing the flow capacity where appropriate (see Figure 10.5, page 54).
Large diameter Rubber Ring Joint (In-wall)Pipe installation
Other Stormwater Products

Humes supplies a wide range of associated components to provide the complete stormwater drainage system. These include precast access chambers and maintenance shafts, drop inlets, side entry pits, bends, tees and junctions, as well as stormwater pits. With the ever increasing need to responsibly manage a healthy environment, Humes have developed a technically advanced portfolio of stormwater quality management products. Humeceptor non-scouring sediment and oil interceptor targets priority fine sediments, which transport nutrients and toxicants, close to where they are generated, protecting local creeks, wetland habitats and wildlife as well as downstream rivers, bays and oceans. Humeceptor is proven to capture as much as 90% of ALL sediment (including the material less than 100 microns which is of most concern), 97.8% of free oils and significant quantities of other materials lighter than water (eg. cigarette butts, polyester beads, plastic food wrappers etc) Humegard in-line gross pollutant traps are designed to trap a range of gross pollutants including plastics, aluminum, waxed packaging, drink containers, cigarette buttts, syringes, polystyrene, paper and coarser-grained sediment (150 microns+). Laboratory and field testing has proven capture rates up to 100% for gross pollutants prior to by-pass and up to 85% on an annualised basis, allowing for periods of high flow by-pass.
Load Class
Humes concrete stormwater pipes are available in StandardStrength (Class 2-4) and Super-Strength (Class 6-10) Load Classes. The most appropriate stormwater pipe installation can be obtained by matching both pipe Load Class and the Bedding Support Type. For the majority of installations, StandardStrength concrete stormwater pipes used in conjunction with Type H2 or Type HS2 Bedding Support, are suitable. For large fill situations, a combination of Super-Strength pipes and Type HS3 Bedding Support can provide the most appropriate and economical solution. Further information on the Load Class of concrete pipes can be obtained by referring to Section 1. Introduction (page 3).
19
Example 4 Stormwater Pipe

A stormwater drainage pipeline is proposed to service a new industrial development in Sydney. The new line is to connect into an existing system at an existing downstream manhole. The total catchment area of 4 hectares (0.04km2) is to be paved/sealed, resulting in an estimated coefficient of run = 0.9. The estimated time for the total catchment to be contributing to the outflow discharge is 30 minutes. The 1:50 year rain fall intensity has been calculated as 100mm/hr (for the 30 minute duration), and the new line length is 80 metres. A minimum 600mm dia pipe is specified for maintenance purposes, and the asset owner requires a maximum velocity of 8 m/s and design life of 100 years. An estimation of the system confirms the total energy head at the downstream (Hd/s) pit to be 0.5m. Calculate the peak flow rate Check suitability of DN600 pipe with respect to maximum velocity & energy head: Step 1 Calculate Peak Flow: Peak flow rate formula: Q = 0.278 CIA Therefore Q = 0.278 x 0.9 x 100 x 0.04 = 1.0 cumec (m3/s) Step 2 Check suitability of DN600 From Figure 10.7 Full Flow Conditions Colebrook-White Formula (ks=0.6mm) (page 56), with 600mm dia pipe: Hydraulic Gradient = 0.21 m/m and v = 3.55m/sec (<8m/s therefore velocity ok) Energy Loss (Hf) of pipe = .021m/m x 80m = 1.68m Velocity Head (Hv) = v2 / 2g = 0.64m Total energy head at upstream end of new pipeline is: Hu/s = Hf + Hv + Hd/s = 1.68 + 0.64 + 0.5 = 2.82m Therefore for a DN600 pipe the upstream invert level must be 2.82m below finished surface level.
.0400 .0300
.0200
45
7.5 m/ s 7.0 m/ s m/ s 6.0 m/ s 5.5 m/ s 5.0 m/ s 6.5 4.5

52 5 DN 0
DN
30
DN
37
DN
m/
DN
60
.0100
4.0
5
m/
DN
3.5
82 5
67
DN
75
m/
DN
90
3.0
97 5 DN 1 DN 125 12 00 DN 1 DN 275 13 50 10 50
DN
.0050
DN
m/
DN
2.5
15
m/
DN
DN
.0010
.0005
100
200
300
500
700
1000
2000
3000
4000 5000
7000
Discharge in litres per second ks = 0.6mm
Step 3 Check suitability of DN750 Try 750mm dia pipe to reduce depth of invert (using Q = 1.0 cumecs) From Figure 4.4 Full Flow Conditions Colebrook-White Formula (ks=0.6mm) (page 56), with 750mm dia pipe: Hydraulic Gradient = 0.0068 m/m and v=2.3 m/s (<8m/s therefore velocity ok) Hf = 0.0068 x 80 = 0.54m Hv = 2.32 / 2g At upstream end of new pipeline Hu/s = 0.54 + 0.27 + 0.5 = 1.31m Invert for DN750 need only be 1.31m below finished surface (use DN750 if possible as less excavation is required) Note: The existing system should be analysed to determine the hydraulic effect due to pipeline addition. A longitudinal profile of the total stormwater system's hydraulic effects is recommended.
20
DN 2 DN 250 2 DN 400 2 DN 550 2 DN 700 28 50

10000
DN
21
.0020
2.0 m 1.9 /s m 1.8 /s m 1.7 /s m 1.6 /s m 1.5 /s m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s
16 DN
50 18 DN 00 19 50 00
.0030
00
5. Pipes for sewerage applications

Humes provide a comprehensive range of steel reinforced concrete sewerage pipes in diameters from 225mm to 3600mm (DN300 - DN2100 Common Size Class Range). Rubber Ring Joint (RRJ) pipes are recommended for sewerage applications. RRJ pipes up to DN1800 are supplied with a belled socket joint, while those larger than DN1800 are supplied with an in-wall joint (see Figures 4.1 & 4.2, page 16).
Outside face
Standard cover Extra cover (up to 25mm)
Outside face
Sewerage Pipes
In conjunction with sewerage system designers, Humes engineers have developed a range of concrete sewerage pipes to economically minimise or eliminate corrosive gas effects which can exist in sewer pipeline systems. Humes has available proven design methods which can assist the systems designer to investigate the possibility of sulphide build-up in the system. Where the system design cannot avoid sulphide generation, Humes manufactures a number of sewerage pipes incorporating special features. These include: Thermoplastic lining Plastiline sheeting A chemically inert plasticised PVC material, developed by Humes research scientists, is mechanically fixed to the pipes internal surface during the manufacturing process, as shown in Figure 5.1, to give complete protection against chemical attack on the pipe surface. Humes AKS PE lining A high density polyethelyne sheet providing high resistance to abrassives and aggresives. Thermoplastic sheeting need only be applied to the pipe's internal surface above the low flow level during normal operating conditions. Calcareous aggregate - This provides added protection by inhibiting the progress of chemical attack, and is used in either the concrete cover to reinforcement or sacrificial layer. Humes internal engineering design services group (TDS) can provide guidance of increased service life that is achievable. Sacrificial layer concrete - An internal surface layer of concrete additional to the nominal 10mm cover to reinforcement in spun concrete pipe, as shown in Figure 5.1. The sacrificial layer is designed to gradually chemically corrode during the life of the pipe. Humes' Engineers can determine the required thickness by analysis of the system. The corrosion process leaves the pipe structurally sound at the end of its design life, making it possible for the service life of the pipeline to be reassessed and possibly extended. Additional cover to reinforcement - The extra cover gives added protection where the systems designer has little or no information to carry out a detailed pipe-system analysis. A summary of these various treatments is presented following, along with a set of general guidelines. When in doubt, the designer should contact Humes for a specific analysis of the pipeline's operating conditions.
2250mm diameter Plastiline Pipes
Standard cover Sacrificial Layer
Outside face
Standard cover
Calcereous aggregate concrete Outside face
Standard cover
Corrosion protection liner (Plastiline or AKS PE lining)
Figure 5.1 - High Durability Sewer Pipe Solutions
21
5. Sewerage Applications
Summary of Sewerage Pipeline Solutions

Humes have developed a range of solutions to maximise durability, and even eliminate the potential adverse effects of sewerage aggressives (eg sulphuric acid attack).

Humes RRJ pipes are designed to provide a watertight seal against infiltration in to the system and exfiltration of sewerage into groundwater. The joint seal is designed against a minimum 9m head (90KPa), internal and external, and the joint configuration allows for watertightness to be maintained even when normal settlements cause joint deflections in the pipeline. Pipeline installers can also use this joint flexibility to maintain line and level of the pipeline. See Table 4.1 (page 16) for details of the minimum radius for RRJ pipelines. Humes RRJ pipes used in sewerage pipelines are supplied with natural rubber rings with root inhibitor, which prevents vegetation roots from entering the system.
Type 1: Standard Sewer Pipe

With a minimum cementitious content in excess of 400 kg/m3, standard sewer pipes are adequate for most properly designed sewer systems.
Type 2: Extra cover to reinforcement

The cover to reinforcement can be increased from a nominal standard to up to 25mm. Commonly specified for sewer systems with insufficient data on future flow characteristics.
Lengthens life by up to 2 times.
Type 3: Sacrificial layer

An increased wall (cover) thickness provided at the internal diameter. It is acceptable for this layer to corrode (in lieu of the structural pipe profile) over the specified service life of the pipeline. Based on client supplied project data Humes engineers can assist in determining the requisite thickness of sacrificial layer, using either siliceous or calcareous aggregates. Lengthens life by up to 3 times.
Size Class (DN)

Where corrosion protection is added to the pipe in the form of a sacrificial layer or extra cover, the internal bore of the pipe is reduced and designers need to include this reduction in the waterway area in their hydraulic design. RRJ pipes with corrosion protection linings are readily available in sizes of DN750 and above. The diameter reduction is generally 20mm to 40mm, depending on the system and its design life requirements. See Tables 4.2 & 4.3 (page 17, 18) for details of Size Class (DN) availability.
Type 4: Calcareous aggregate

Concrete pipes manufactured from suitable calcium rich aggregate, such as limestone, provide added resistance to acidic corrosion, by inhibiting the progress of the chemical attack. Its use will further augment durability performance when incorporated as a sacrificial layer. Lengthens life by up to 2 times.
Load Class
Humes concrete sewerage pipes are available in StandardStrength (Class 2-4) and Super-Strength (Class 6-10) Load Classes. The most appropriate/economical pipeline installation can be obtained by matching both pipe Load Class and the Bedding Support Type. For the majority of installations, Standard-Strength concrete sewerage pipes used in conjunction with Type H2 or Type HS2 Bedding Support, are suitable. For large fill situations, a combination of Super-Strength pipes and Type HS3 Bedding Support can provide the most appropriate and economical solution. Further information on the Load Class of concrete pipes can be obtained by referring to Section 1 - Introduction (page 3).
Type 5: Corrosion Protection Linings (CPL)

Corrosion Protection Linings provide the ultimate protection against chemical attack in a sewerage environment. Plastiline A tried and true PVC liner with over 45 years inservice use in Australia: Black - ultimate UV protection Ease of welding AKS Humes concrete pipe lined with High Density Polyethylene sheet (HDPE) provides maximum: Abrasion resistance, and pull off strength. This material is available in pale colours, which are favoured by installers and beneficial for visual inspection.
Up to 120 year service life.
22
Hydraulics
The hydraulic design for each section of the sewage pipeline system requires investigation of both peak and minimum flows. Peak flows in the system determine the pipe size class which should then be checked to ensure that at minimum flows the sewage flow velocity does not fall below the selfcleansing velocity. Gravity flows in a sewage pipeline between manholes are designed hydraulically by considering pipe friction losses and any flow disturbance losses at inlets, outlets, bends and junctions in the pipeline. Losses due to flow disturbances should be minimal since the designer should eliminate these as part of the campaign against hydrogen sulphide generation. Frictional losses along the pipeline are based on the Colebrook-White formula, using a recommended roughness height ks value of 1.5mm (see Figure 10.8, page 57). This chart also indicates minimum velocities for slime control and the self-cleansing velocities. The flow discharge and velocity given is for the pipeline running full. The values can be adjusted for a pipeline running part-full by referring to Figure 3.4 (page 11) for part-full flow conditions.
Installation
Humes RRJ bell-socket pipes have laying witness marks indicated at the outside face for easy control of the deflected joint.(see Fig. 4.1, pg16 or Fig. 9.8, pg45). Humes concrete sewerage pipes are typically supplied with elliptical grid reinforcement, unless a circular grid is specifically requested. Elliptical grid reinforced pipes must be laid with the word "TOP" at the crown (or invert) of the pipe, within 10 each side of the vertical centreline. Lifting anchors can be provided to simplify lifting/handling. Humes provides a special rubber ring lubricant to assist jointing. See Section 9, Handling and Installation, for further details.
Class 4 Pipes with Sacrificial Layer.
Plastiline sewer pipe installation.
Pipe with AKS lining
23
Associated Sewerage Products

Humes manufacture a comprehensive range of products associated with reticulation and trunk sewer systems. From experience, a collaborative approach with designers and authorities will often provide the most cost effective solution, and Humes are equipped to supply project specific products. Standard products for this range are summarised below. For further information refer to product specific brochures and details available at www.humes.com.au Access Chambers Humes superior quality precast chambers have a nominal shaft diameter of 1050 1100mm, dependent on region and asset owner requirements. These are configured with RRJ and mastic joints to suit authority specifications and standards. The system is complete from benched chamber bases, (Superbowl eliminates the need for benching) to finished surface level, in either trafficked or non trafficked applications. Shafts outside the standard diameter range may be made to order.
QuickTee base
Maintenance Shafts (QuickTee) DN600 vertical shafts with DN300 non-person entry lid, that provide access to the sewerage system to introduce inspection (CCTV) and maintenance equipment. The shaped base ensures optimum flow in the system. As for the access chambers QuickTee is a complete system from base to finished surface level: DN600 shaft enables equipment manoeuvrability. DN600 shaft provides emergency storage Sloping trafficable top matches finished surface level falls up to 1 in 7. HumeSeal is a patented watertight elastomeric seal to connect service pipes to chambers (Access Chambers and Maintenance Shaft) .The standard size range is DN100 to DN225 and other sizes may be made to order. The HumeSeal can accommodate up to 17 degrees deflection without losing watertight connection between service pipe and shafts.
Cover and surround completing a QuickTee installation
Access Chamber base
HumeSeal at chamber / shaft base
24
Pump Wells Humes supply chambers up to DN3600 which may be specifically designed to customer requirements. (See Table 5.1 below for capacities) Storage Tanks The size range is the same as for pump wells. These units are configured with end walls and fittings to meet project specific requirements. (See Table 5.1 below for capacities) Both pump wells and storage tanks can be provided with corrosion protection liners (CPLs).
A precast pump well.
A precast storage tank.
Table 5.1 -Indicative Storage Capacity (Litres) based on Flush Joint Pipe, Load Class 2.
DN (mm) 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 Length of Pipe (metres) 0.2 15 23 33 45 59 74 91 110 131 179 234 295 365 441 525 617 715 0.4 29 47 66 90 117 147 182 221 263 358 467 591 730 883 1051 1233 1430 0.6 44 68 98 134 175 221 274 331 394 536 701 887 1094 1324 1576 1850 2145 0.8 58 91 131 179 234 295 365 441 525 715 934 1182 1459 1766 2101 2466 2860 1.0 73 114 164 224 292 369 456 552 657 894 1168 1478 1824 2207 2627 3083 3575 1.2 87 137 197 269 351 442 547 662 788 1073 1401 1773 2189 2649 3152 3699 4290 1.22 89 139 200 273 357 450 556 673 801 1090 1425 1803 2225 2693 3205 3761 4362 1.4 102 160 230 314 409 516 639 772 919 1251 1635 2069 2554 3090 3677 4317 5005 1.6 116 182 262 358 468 590 730 883 1050 1430 1869 2364 2919 3532 4203 4933 5721 1.8 131 205 295 403 526 663 821 993 1182 1608 2102 2660 3283 3973 4728 5549 6436 1.83 133 209 300 410 535 676 835 1009 1202 1636 2137 2704 3338 4039 4807 5632 6543 2.0 145 228 328 448 585 737 912 1103 1313 1788 2336 2955 3648 4414 5254 6166 7151 2.2 160 251 361 493 643 811 1003 1213 1445 1966 2569 3251 4013 4856 5779 6782 7866 2.4 174 274 394 538 701 885 1095 1324 1576 2145 2802 3546 4378 5297 6304 7399 8581 2.44 177 278 400 547 713 899 1113 1346 1602 2180 2849
4451 5386 6409 7522 8724
This table is included to assist designers with determining volumes of pipes when they are used in other than conduit applications such as holding or storage tanks and pump wells. Note: Internal diameters (ID) and hence, volume storage, is subject to change without notice.
25
3605
Example 5 Sewerage Pipe

A gravity sewer main is proposed to serve a new residential development. The development is for medium density population over an area of 500 ha. Adopting an average dry weather flow rate of 0.2 l/s/ha for the medium density residential development, we get an: Average dry weather flow = 0.2 l/s/ha x 500ha = 100 l/s
.0400 .0300
DN 30 0
Ma
DN 37 5
x. V
elo
city
The
rmo
DN 45 0
.0200
pla
stic
Lin
er
4.0
DN 52 5
4.5 m/
m/
DN 60 0
DN 75 0
.0100
DN 67 5
Slim
.0030
eC
ont
rol
Therefore: Peak dry weather flow = (100 x 2.5) + (0.6 x 500) = 550 l/s As only a low density population will exist during the developmental stage of the new estate, adopt a low density flow of 0.13 l/s/ha for this period, Therefore: Minimum short-term dry weather flow = 0.13 x 500 = 65 l/s Summarising design parameters: Minimum average dry weather flow 65 l/s Average dry weather flow 100 l/s Peak wet weather flow 550 l/s Step 1 Nominate appropriate pipe diameter For concrete pipe with sewage flows ks = 1.5 mm is typically recommended. 1.1 Try DN525 pipe
.0020
Mi
n. V
elo
city
Sel
fC
lea
nsi
ng
.0010
2.0 m 1.9 /s m 1.8 /s m/ s 1.7 m 1.6 /s m 1.5 /s m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s 0.9 m/ s
.0005
50
100
300
500
700
1000
2000
Discharge (Q) in litres per second ks = 1.5mm
Figure 10.8 - Full Flow Conditions Colebrook-White Formula ks = 1.5mm
From Figure 10.8 Full Flow Conditions Colebrook-White Formula ks=1.5mm (page 57), with peak wet weather flow of 550 l/s: Hydraulic gradient (s) = 0.0155 (approx 1:64), and full flow velocity (Vf) = 2.5m/s 1.2 Establish minimum allowable velocities for slime control & self cleansing CPAAs Hydraulics of Precast Conduits recommends: For slime control sD = 0.002m, therefore with D = 0.525m: s = 0.0038 & vmin = 1.22m/s For self cleansing sD = 0.0008m, therefore with D = 0.525m: s = 0.0015 & vmin = 0.78m/s Step 2 Confirm appropriate minimum pipe grade 2.1 Nominate pipe grade for DN525 as being less than 1:64 (s = 0.0155) Try 1 in 75 (s= 0.013) 2.2 Check average dry weather flow velocity Q/Qf = 100/550 = 0.18 From Figure 3.4 Relative Discharge & Velocity in Part-full Pipe Flow (page 11), V/Vf = 0.75: therefore V = 1.88m/sec (which is greater than minimum velocity slime control therefore ok) 2.3 Check minimum average dry weather flow velocity Q/Qf = 65/550 = 0.12 From Figure 3.4 Relative Discharge & Velocity in Part-full Pipe Flow (page 11), V/Vf = 0.68: V = 1.70m/sec (which is also greater than minimum velocity slime control therefore ok) Therefore adopt DN525 on grade 1 in 75
26
DN 15 00 DN 16 50 DN 18 00 DN 19 50 DN 21 00
The CPAAs Hydraulics of Precast Conduits recommends multiplying average dry weather flow by a factor of 2.5, to get peak dry weather flow. Also, for a new residential development, consider an allowance of 0.4 to 0.8 (say 0.6) l/s/ha for infiltration.
3.5 3.0 m/
DN 82 5 DN 90 0 DN 97 5 DN 10 50 DN 1 DN 125 12 00 DN 1 DN 275 13 50
m/
.0050
Ma
x. V
2.5
m/
elo
city
4000
6000 8000
Humes provide a comprehensive range of steel reinforced concrete pressure pipes in diameters from 225mm to 3600mm (standard range DN300-DN1800). Rubber Ring Joint (RRJ) pipes are recommended for all concrete pressure pipe applications. RRJ pipes up to DN1800 diameter are supplied with a belled socket joint, while those larger than DN1800 are supplied with an in-wall joint (see Figures 4.1 and 4.2 , page 16).
Size Class (DN)
Max CL Max Internal Wall Min CL Deviation deflection Dia thickness Radius* per pipe angle at joint (ID) (mm) (m) (mm) (degrees) 304 300 367 38 50 34 38 58 36 42 55 70 41 51 68 44 57 76 48 52 70 52 55 64 76 54 60 70 66 65 89 70 75 89 75 110 77 82 95 95 102 72 68 72 64 55 51 55 68 60 43 34 55 38 34 34 34 51 51 26 51 30 30 21 51 30 34 51 30 47 26 26 43 43 21 38 26 21 68 1.7 1.6 1.7 1.5 1.3 1.2 1.3 1.6 1.4 1 0.8 1.3 0.9 0.8 0.8 0.8 1.2 1.2 0.6 1.2 0.7 0.7 0.5 1.2 0.7 0.8 1.2 0.7 1.1 0.6 0.6 1 1 0.5 0.9 0.6 0.5 1.6 83 88 83 94 108 117 108 88 100 140 175 108 156 175 175 175 117 117 234 117 200 200 280 117 200 175 117 200 128 234 234 140 140 280 156 234 280 88
300
375
381 380
Joint Type
Rubber Ring Joints provide concrete pipes with a high degree of flexibility to accommodate ground settlement or deflections. The RRJ profile is designed for ease of installation, and allows curved alignments or alignment adjustments while maintaining a pressure tight joint seal. Table 6.1 presents the maximum joint deflections possible for the standard range of pressure pipes. See also Figure 6.1. Witness marks are provided to indicate both nominal laying gap and maximum joint deflection. Where fittings are included in the pipe system, thrust blocks should be provided to prevent lateral or longitudinal movement and separation in the adjacent pipe joint. The magnitude of the thrust force is dependent on the pressure in the pipeline and the deflected angle or restriction to flow. The design of reinforced concrete pressure pipe systems as described in the Concrete Pipe Association of Australasia publication, "Hydraulics of Precast Concrete Conduits", is recommended to specifiers and designers.
450
446 450 450 457 534 525 534 530 610 600 610 610 685 675 680 680 760 750 750 762 762 838 825 830 838 Positive overlap 910 900 900 915 1050 1050 1070 1066
Maximum Deviation
Zero Gap
1200
1200 1200 1370 1350 1524 1676 1828
1350 1500
Figure 6.1 - Deflected Joint Details
1650 1800
Note: Commonly available sizes indicated in bold IDs and walls thickness subject to change without notice * Minimum radius is measured to the mid point of the centre line (as opposed to centreline intersection at joint)
27
6. Pressure Applications
6. Pipes for Pressure Applications
Table 6.1 - Maximum Joint Deflection: RRJ - Pressure Pipe (and Sewerage) Applications
Size Class (DN)

The size class for reinforced concrete pressure pipes will depend on hydraulic calculations for pressure and discharge. Commonly supplied size classes for reinforced concrete pressure pipes are from DN300 to DN1800 diameter (see Table 6.2). Pipe can also be supplied below DN300 and, for these diameters, reduced lengths of 1.22 metres are normally provided. Pipe diameters above DN1800 can be supplied where required for special projects.
Load/Pressure Class
Reinforced concrete pressure pipes are designed for the combined effects of external load and internal (in-service) pressure. Australian/New Zealand Standard, AS/NZS 4058: 2007 - Precast concrete pipes (pressure and non-pressure) gives a minimum requirement for factory test pressure of 120% of working pressure in the pipeline. Working pressure when specified should include all effects as well as any dynamic surge pressures in the pipeline. To simulate the combined effects of load and pressure, the corresponding test load for a pressure pipe, with a minimum factory test pressure of 120% working pressure, is increased above the normal calculated non-pressure value by as much as 182% by the application of the formula:
Pressure pipe installation
T=W F
Pt Pt-Pw
1/
T = test load W/F = calculated test load Pt = test pressure Pw = working pressure
The combination of test pressure and test load can be most economically achieved when a balanced condition of their effects is considered in the design. The table for the balanced conditions of maximum allowable fill height for maximum test pressure is given in Table 6.3 (page 30) for stated design and installation conditions. For the majority of installations, concrete pressure pipes can be installed using Type H2 Bedding Support. See Section 1: Introduction, for further information on the design and installation of concrete pipes.
28
Table 6.2 - Pressure Pipe Class Range

Size Class (DN)
200
300
400
500
700
Internal Diameter (mm) x Wall Thickness (mm) 300 304 x 38 304 x 38 304 x 38 304 x 38 300 x 50 367 x 34 375 367 x 34 367 x 34 381 x 38 367 x 34 381 x 38 380 x 58 446 x 36 450 446 x 36 446 x 36 450 x 42 450 x 55 457 x 70 534 x 41 525 534 x 41 534 x 41 534 x 51 530 x 68 610 x 44 600 610 x 44 610 x 44 610 x 57 600 x 81 685 x 48 675 685 x 48 680 x 52 680 x 70 760 x 52 750 760 x 52 762 x 64 762 x 76 838 x 54 825 838 x 54 830 x 60 826 x 76 900 910 x 66 910 x 66 910 x 66 899 x 97 1050 x 70 1050 1050 x 70 1050 x 85 1050 x 97 1200 1200 x 75 1200 x 75 1200 x 110 1370 x 77 1370 x 77 1326 x 94 1524 x 95 1524 x 95 1500 x 107 1676 x 95 1828 x 102 1676 x 95 1828 x 102 1200 x 110
285 390 300 355 565 385 450 625 840 530 680 930 645 915 1250 780 880 1225 960 1195 1290 1075 1295 1580 1470 2255 1840 2180 2610 2260 3435 2540 3130 3655 4070 4020 4600
1350
1500 1650 1800
= Not typically supplied Sizes commonly available indicated by bold type. Other Pressure Classes may also be available. Note: Pipe mass based on product density of 2600 kg/m3 for spun pipe and 2500kg/m3 for vertically cast pipe. Internal diameters subject to change without notice.
29
Pressure Class (kPa)
Pipe Mass 2.44m long (kg)
Table 6.3 - Pressure Pipe Actual Size and Maximum Test Pressures
Pressure Pipes Size Class (DN) Actual Size ID x wall (mm) 304 x 38 300 298 x 41 300 x 50 294 x 53 367 x 34 357 x 39 375 381 x 38 375 x 41 380 x 58 370 x 63 446 x 36 436 x 41 450 450 x 42 450 x 55 430 x 65 457 x 70 534 x 41 518 x 49 525 534 x 51 514 x 61 530 x 68 514 x 76 610 x 44 594 x 52 600 610 x 57 598 x 63 610 x 76 598 x 82 685 x 48 673 x 54 675 680 x 52 656 x 64 680 x 70 660 x 80 760 x 52 750 736 x 64 750 x 55 Maximum Test Pressure (kPa) 650 700 975 1050 550 575 525 550 900 975 450 475 450 700 875 900 450 550 525 700 750 800 425 475 550 625 725 800 400 475 425 575 600 700 350 500 400 1800 1650 1500 1350 1200 1050 900 825 750 (cont.) Size Class (DN) Pressure Pipes Actual Size ID x wall (mm) 730 x 65 726 x 64 750 x 70 762 x 76 750 x 82 838 x 54 832 x 57 830 x 60 806 x 72 838 x 70 814 x 82 910 x 66 898 x 72 900 x 65 880 x 75 915 x 89 1050 x 70 1018 x 86 1070 x 75 1058 x 81 1066 x 89 1050 x 97 1200 x 75 1168 x 91 1200 x 110 1180 x 120 1370 x 77 1360 x 82 1350 x 82 1326 x 94 1524 x 95 1508 x 103 1676 x 95 1652 x 107 1828 x 102 1812 x 110 Maximum Test Pressure (kPa) 525 475 550 575 625 350 400 425 525 475 600 425 475 425 500 575 375 500 400 450 475 525 350 450 525 600 325 350 350 400 350 400 325 375 325 350
Note: Commonly available sizes indicated in bold Hydrostatic test pressure = 1.2 working pressure. Internal diameters subject to change without notice.
30
Hydraulics 6. Pressure Applications

31
Reinforced concrete pressure pipes are designed for the maximum operating discharge rate in the pipeline. There are two design types of pressure pipelines, the gravity pressure pipeline and the pumped pressure pipeline. Gravity pressure pipelines utilise the static head over the length of the pipeline to provide discharge and the pipes used are designed to a minimum factory test pressure of 120% working pressure, or working pressure plus 15 metres head, whichever is greater. Gravity pressure mains are an hydraulically 'soft' system, rarely incurring the effects of waterhammer. Pumped pressure pipelines are susceptible to water-hammer effects if the system is not designed and operated to eliminate its occurrence, possibly leading to an hydraulically 'hard' system. Water-hammer effects and their analysis require a detailed knowledge of the operating conditions within the system and its geometry. Water-hammer in a pressure pipe system, which can be as high as 100 times the flow velocity head at shutdown in the pipeline, is typically caused by either rapid valve closure or uncontrolled pump operation, either at start-up or breakdown.
AS/NZS 4058: 2007 Clause 4.5 nominates minimum test requirements for pressure pipes: Performance test pressure of pipe and joint (Pt) = Min. 1.2 times the working pressure of pipe and joint. Ultimate test pressure (Pu) being the lesser of: (i) 1.5 times the allowable working pressure (Pw) (ii) 1.2 times the allowable working pressure (Pw) plus 75kPa
A reinforced concrete pipe, overloaded with passing pressure surges, will expand and some minor cracks may result. So long as the concrete is not fractured or blown out, the pipe will likely return to its original state of servicability after the pressure surge passes, with visible cracking reducing over time. The cracks will re-seal under the natural action of the concrete's autogenous healing process. During this time it may be necessary to reduce the pipeline working pressure. The working pressure in a pipe to provide the specified discharge is determined from the sum of the elevation (static lift) between pipeline inlet and outlet and head (pressure) losses along the pipeline caused by pipe and fluid friction effects and exit velocity head loss. The Concrete Pipe Association of Australasia document "Hydraulics of Precast Conduits" (available for free download at www.concpipe.asn.au) is an excellent reference for quantifying the magnitude of these losses where considered appropriate. Establishing the magnitude of friction head losses along the pipeline is carried out by using the Colebrook-White equation, adopting recommended values for pipe surface roughness height (ks) depending on the fluid type. For clean water in a water supply pipeline, a value of pipe surface roughness (ks) 0.06mm is appropriate. However, where in doubt, or where a significant number of fittings are in the pipeline, a more conservative value of (ks) 0.15mm is recommended. Design charts (Figure 10.5 & 10.6, page 54, 55) based on the surface roughness values of 0.06mm and 0.15mm are provided in section 10. For sewer rising mains, a value of 0.6mm is recommended and the appropriate chart (Figure 10.7, page 56) is provided in section 10 The Colebrook-White charts provide the slope of the hydraulic gradient for a required discharge flow rate in the pipeline, and friction head losses in the pipeline can then be determined by applying this value over the line's entire length. Where a pressure pipeline has a change in horizontal or vertical alignment, or where bends, reducers, tees or valves are fitted within the pipe system, unbalanced forces at the change in flow direction need to be resisted by fitting thrust blocks along the pipeline. The magnitude of the thrust force is determined by geometrics and the size of the thrust block is found by adopting a value for the passive resistance of the soil in the trench walls. (A minimum soil bearing capacity of 100kPa is often adopted). Table 6.4 provides typical values of thrust block sizes based on stated conditions.
Deflection angle Concrete Thrust Block
However, in a reinforced concrete pipeline subjected to unforeseen operations, the pipes are ductile in nature and any surges in the line which could result in cracked pipes will not cause the system to become unserviceable. Table 6.4 - Pressure Pipe Thrust Block Size for Horizontal Bends
Width per 10m head 15o deflection (mm) Soil Bearing Pressure 100kPa 100 100 125 150 175 185 200 200 250 275 300 325 350 375 425 200kPa 50 50 75 75 100 100 100 100 125 150 150
W idt
Size Class (DN) 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800
Minimum OD+300
150 175 175 200
Section
Figure 6.2 Thrust Block Detail

Note: Minimum Concrete strength 25 MPa
Other Pressure Pipe Products 6. Pressure Applications

Reinforced concrete pressure pipes can be manufactured with bends, reducers and cast-in mild steel, cast iron or plastic fittings, where required by the system designer. Typical arrangements are shown below.
Single mitre bend.
Cement lined mild steel off takes.
Socket to spigot reducer.
Mild steel adaptor for 2100mm diameter skid ring joint pipe.
Air valve on 2700mm diameter skid ring joint pipe.
32
Field Hydrostatic Testing 6. Pressure Applications

33
Before delivery to site, every Humes pressure pipe is hydrostatically tested to the specified test pressure. Consequently, field pressure testing should not be specified for the purpose of reassessing individual pipe performance. However, the manner in which the pipes have been handled on site, and the conditions to which they have been subjected prior to and during laying, may require that the test be applied to "prove" the pipeline installation. The purpose of specifying a field hydrostatic test is solely to reveal the existence of inadequate laying procedures. It is strongly recommended that the specified site test pressure be no greater than the sustained working pressure to which the pipeline will be subjected in service. When a field test is to be applied, preconditioning of the pipeline is essential to give meaningful results. The pipeline should be allowed to stand under 50 kPa hydrostatic pressure at the highest point in the line for such time as is necessary to allow natural absorption of water into the concrete. The time taken for this to occur will depend on the moisture condition of the pipes, as well as the ambient site conditions. Some lines will need no more than 24 hours, others may need weeks. Subsequently, pressurisation should be carried out slowly, initially at 50 kPa increments per hour. Once the test pressure has been reached, and providing no major faults have appeared, the loss of water should be measured at hourly intervals over a period of three hours. If measurements show a steadily decreasing loss rate, equilibrium has not been achieved and it may be necessary to allow a further period of preconditioning before attempting further measurements. A test result is considered satisfactory when the amount of water lost in one hour does not exceed the amount defined by the equation: 1 QL = N.D.(TP) /2 / 70 QL: N: D: TP: leakage in litres per hour number of joints in the section of line under test diameter of pipe in metres specified site test pressure in kiloPascals
Remember, correct laying procedures and proper supervision during installation are a better solution to providing evidence of good installation. See Section 9, Handling & Installation (page 43). The Concrete Pipe Association of Australasia, CPAA, publication, Field Testing of Concrete Pipelines and Joints", comprehensively details all aspects of this procedure. This document is available for free download at www.concpipe.asn.au
Field testing of pipes.
Routine Hydrostatic testing of pipes.
Example 6 Pressure Pipe

A pressure pipeline is to be designed for transferring raw sewage from a central collection pump station, located within a built up city area, to a proposed treatment plant at the city boundary. The length of the pipeline is to be 5km and the pipeline route is to include five 90 horizontal bends and three 60 horizontal bends. The elevation difference between the pump station and the treatment plant is a rise of 5 metres. An estimated maximum discharge rate (based on pump characteristics) is 500 l/s. The system is to be designed for an estimated 15 metres of water-hammer, and a maximum velocity of 2.0m/s. The pipeline is to follow natural surface with a nominal 1.0 metre cover to top of the pipe. Specify an appropriate steel reinforced concrete pipe for the system.
.0005 100 200 300 500 700 1000 .0400 .0300
0
.0200
45
7.5 m/ s 7.0 m/ s m/ s 6.0 m/ s 5.5 m/ s 5.0 m/ s 6.5 4.5

52 5 DN 0
DN
30
DN
37
DN
m/
DN
60
.0100
4.0
5
m/
DN
3.5
82 5
67
DN
75
m/
DN
90
3.0
97 5 DN 1 DN 125 12 00 DN 12 75 DN 13 50 10 50
DN
.0050
DN
m/
DN
2.5
15
m/
DN
DN
.0010
2000
3000
4000 5000
7000
DN
21
.0020
2.0 m 1.9 /s m 1.8 /s m/ s 1.7 m 1.6 /s m 1.5 /s m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s
16 DN
50 18 DN 00 19 50 00 DN 2 DN 250 2 DN 400 2 DN 550 2 DN 700 28 50
.0030
00
10000
The CPAA publication, Hydraulics of Precast Conduits recommends adopting a roughness coefficient (ks) = 0.6mm for pumped sewerage flows.
Step 1 Nominate suitable pipe diameter From Figure 10.7 Full Flow Conditions Colebrook-White Formula ks=0.6mm (page 56), with Q = 500l/s & vmax = 2m/s: Minimum size class = DN600 Step 2 Calculate friction head From Figure 10.7 (page 56): with Q = 500l/s & DN600: Hydraulic gradient = 0.0055 & Friction head loss = 0.0055 x 5000 (elevation difference) = 27.5m Step 3 Estimate velocity head From Figure 10.7 (page 56): with Q = 500l/s & DN600: Vf = 1.8m/s Therefore exit velocity head of straight pipe = 1.82/2g = 0.165m For 90 and 60 bends adopt velocity head coefficients (kb) for sharp bends of = 1.27 and 0.68 respectively (refer section 1 of CPAA Hydraulics of Precast Concrete Conduits) Head loss at bends: Hb = kb x v2 / 2g for 5 No. 90 bends and 3 No. 60 horizontal bends: (5 x 1.27 x 0.165) + (3 x 0.68 x 0.165) = 1.384m Step 4 Estimate total head Total Head = Static lift + Friction head + Velocity head + Bends = 5 + 27.5 + 0.165 + 1.38 = 34m Include specified allowance for water-hammer (15m) Allowable working pressure head in pipeline = 34 + 15 = 49m Step 5 Calculate test & ultimate pressures Allowable working pressure (Pw) = gravity x pressure head = 9.81 x 49 = 481 kPa Per AS/NZS 4058: 2007, clause 4.5 (b): Ultimate test pressure (Pu) is the lesser of: 1. 1.5 times allowable working pressure (= 721 kPa) 2. 1.2 times allowable, plus 75kPa (= 556kPa) Pu = 556 kPa Using the Concrete Pipe Association of Australasia free design software Pipe Class , a Load Class 2 pipe is adequate for 1 metre cover with type H2 installation. Specify a DN600 reinforced concrete pressure pipe class 2/556
34
7. Pipes for Irrigation applications

Humes provide a range of steel reinforced concrete irrigation pipes in diameters from DN300 to DN750. Rubber Ring Joint (RRJ) pipes are recommended for irrigation applications where a pressure tight joint seal is required.
Positive overlap
Applications
Humes range of small diameter reinforced concrete irrigation pipes are easily transported and laid using farm machinery equipment and can be relocated around the property to meet changing irrigation requirements without the need for special pipelaying skills. Concrete irrigation pipe systems have reduced maintenance requirements and enhance property values.
Joint Type
Rubber Ring Joints (RRJ) are designed to provide a joint seal capable of resisting pressures far in excess of those normally operating in most irrigation systems. Maximum deviations in alignment are given in Table 7.1 (refer also to Figure 7.1). Deflections may be the result of pipeline settlements or included during laying to provide a change in pipeline alignment. Witness marks are provided to indicate both nominal laying gap and maximum joint deflection (see Fig. 4.1, pg16 or Fig.
Table 7.1 - Maximum Joint Deflection: RRJ - Irrigation Pipe Applications Size Class (DN) 300 375 450 525 600 675 750 Max CL Max Deviation deflection per pipe angle at joint (mm) (degrees) 63 72 51 46 40 36 29 1.4 1.6 1.1 1.0 0.9 0.8 0.6 Min CL Radius* (m) 100 88 128 140 156 175 234
9.8, pg45).
DN375 and DN450 pipe joints may be compatible with some cast iron fittings. Check applicable dimensions with relevant suppliers to confirm. Custom fittings are normally specified for larger diameters.
Size Class (DN)

Reinforced concrete irrigation pipes are manufactured in diameters from DN300 to DN750 as shown in Table 7.2 (refer Figure 7.2). Beyond this range, Humes reinforced pressure pipes as detailed in Section 6, Pressure Applications can be used to give an increased choice to the pipeline designer. The size class of pipe required is determined from the irrigation supply requirements of the planned farm crop yield.
Table 7.2 - Pipe Dimensions (mm) and Masses (kg) Note: Pipe mass based on product density of 2600 kg/m3
Size (DN) Outside Diameter Diameter (ID) (OD) 300 367 446 534 610 685 760 362 435 518 616 698 781 864 Socket Dimensions A 451 516 603 711 797 886 997 G 107 106 127 147 147 147 143 H 89 70 74 133 133 133 152 Mass per 2.44m length (kg) 220 300 385 530 645 780 960
Effective Pipe length
300 375 450 525 600 675 750
ID OD
Figure 7.2 - Pipe Dimensions
35
7. Irrigation Applications
Maximum Deviation
Zero Gap
Load/Pressure Class
The Load Class of a reinforced concrete irrigation pipe is normally Class 2, since most pressure pipelines follow the ground's natural surface and are laid at a maximum depth of around 1 metre. The Pressure Class of irrigation pipes is determined from the irrigation requirements and is usually up to a maximum of 500 kPa Pressure Class (415 kPa working). Most commonly, a reinforced concrete irrigation pipe Pressure Class 200 kPa is required. Table 7.3 presents Standard Pressure Classes as a guide. Other intermediate Pressure Classes are also available when required.
Table 7.3 - Standard Pressure Classes

Size Class (DN) 300 375 450 525 600 675 200 300 x 31 367 x 34 446 x 36 534 x 41 610 x 44 685 x 48 760 x 52 Pressure Class (kPa) 300 367 x 34 446 x 36 534 x 41 610 x 44 685 x 48 760 x 52 500 367 x 34 440 x 39 534 x 41
Internal diameter (mm) x Wall Thickness (mm)
Hydraulics
The hydraulic flow requirements of the reinforced concrete irrigation system is used to determine the Size Class required. The hydraulic pressure to provide the required flow discharge in the pipeline is determined from the sum of the elevation difference between the supply point and receiving discharge point, and frictional losses along the pipeline caused by flows along the pipe's surface. Table 7.4 presents Head Loss based on the surface texture common to concrete pipe for irrigation water (ks = 0.15mm).
750
Table 7.4 - Head Loss in metres per 10m Length of Pipeline

Size Class (DN) 300 375 450 Discharge* litres/second 10 50 0.016 100 0.055 250 0.36 0.15 500 0.5 0.2 750 0.45 0.15 0.075 0.045 0.025 1000 0.8 0.25 0.13 0.075 0.045
0.0053 0.019
0.0022 0.0077 0.047
Example 7 - Irrigation Pipe
525 600 675
0.001 0.0035 0.025 0.065 0.0015 0.010 0.035 0.001 0.0055 0.020 0.0030 0.012
1m
typ
ica
750
* See Page 35 for Conversions Note: Values are for clean water (ks = 0.15mm) Values to right of red line have pumped velocity > 3.0m/sec and scour may occur in the channel at the outlet.
18m
1500m
Not to scale
A pumped irrigation pipeline is proposed to supply water from the river on a farm up to a storage dam for crop irrigation. The distance from the river to the dam is 1500 metres and the river is approximately 18 metres below the dam. The dam is to be used to irrigate 1 hectare of cotton fields at a frequency of 50mm every 10 days. Due to the characteristics of the nominated pump, the most efficient and economical operation is to run the pump continuously for no less than 2 hours. Specify an appropriate size and pressure class of irrigation pipe. The quantity of water required to water the crops every 10 days is: 10,000m2 x 0.005m = 500 m3 = 500,000 litres As the pump should run continuously for more than 2 hours, then the maximum pumping rate required filling the dam prior to irrigation is 250,000 litres/hour (70 l/s).
Adopting a discharge rate of 50 l/s, the time to refill the dam = 500,000 litres /180,000litres/hour = 2 hours 50 mins. From table 7.4 of head loss (per 10m of pipeline): Head loss due to friction in the pipeline, for say DN375 diameter pipe with a discharge of 50 l/s: 0.0053 x 1500m/10m = 0.795m Working head in the pipeline is static head plus friction head losses: = 18 + 0.795 = 18.8m Working pressure in pipeline is thus: 18.8m x 9.81m/s2 = 184.4 kPa Minimum Test Pressure as nominated in AS 40582007 Precast concrete pipes pressure & non-pressure, clause 4.5(a) is 1.2 times working pressure, Therefore, Test Pressure = 1.2 x 184.4 = 221.3 kPa Specify 225 kPa test pressure ie. Class 2/225 irrigation pipe.
36
Table 7.5 - Cylindrical Capacity (Litres) based on flush joint pipe, Load Class 2.
DN mm 300 375 450 525 600 675 750 Length of Pipe (metres) 0.2 15 23 33 45 59 74 91 0.4 29 47 66 90 117 147 182 0.6 44 68 98 134 175 221 274 0.8 58 91 131 179 234 295 365 1.0 73 114 164 224 292 369 456 1.2 87 137 197 269 351 442 547 1.22 89 139 200 273 357 450 556 1.4 102 160 230 314 409 516 639 1.6 116 182 262 358 468 590 730 1.8 131 205 295 403 526 663 821 1.83 133 209 300 410 535 676 835 2.0 145 228 328 448 585 737 912 2.2 160 251 361 493 643 811 1003 2.4 174 274 394 538 701 885 1095 2.6 177 278 400 547 713
1113
37
899
8. Jacking Pipes
Humes provide a comprehensive range of steel reinforced concrete jacking pipes in diameters from DN300 to DN3600 (common size classes vary between DN300 and DN2100). Historically jacking pipes in Australia and overseas were based on a modification of pipes designed for installation by conventional trenching techniques. In 2005 Humes introduced the S and J-Series jacking pipes specifically designed for installation by pipe jacking that incorporate a steel collar cast onto one end of the pipe and an elastomeric seal (rubber ring) providing a flexible and water tight joint.
Jacking Applications
The International Society for Trenchless Technology (ISTT) defines pipe jacking as A system of directly installing pipes behind a shield machine by hydraulic jacking from a drive shaft such that the pipes form a continuous string in the ground. The term microtunnelling is also often used to describe this method of pipe installation however the definitions of microtunnelling vary around the world. There is significant variation in actual techniques now adopted; however, what is common is that the concrete jacking pipe must meet the requirements of both the pipe jacking contractor and the longterm asset owner. Pipe jacking is used to install conduits below ground for a variety of applications including:
8. Jacking Pipes
Sewerage pipelines. Stormwater pipelines. Road and rail culverts. Pressure pipelines. As a sleeve pipe into which other utility pipelines (commonly water & sewerage) or electricity and communication cables are installed.
A typical jacking pipe installlation, note air ducting and rail transport of spoil material.
Detail - Humes Intermediate Jacking Station Rubber rings Timber joint packer Lead pipe (steel can)
Trail pipe
Jacking direction Jacks
Crane to lower pipes into position
Lubrication port Standard pipe
Standard pipe Thrust ring
Jacking direction
Working face with jacking shield
Drive Shaft with hydraulic jacks
Intermediate jacking station to assist longer drives
Target Shaft
Figure 8.1 - Typical Pipe Jacking Set-Up (for pipes larger than 900 mm diameter)
38
Pipe Types
Humes can supply a range of different types of jacking pipes to suit a wide range of applications and installation methods. Butt Joint jacking pipes are available in the size range DN300 to DN3000 (standard range DN300 to DN2100). Butt Joint jacking pipes are manufactured as a modification to the standard Flush Joint drainage pipe. Butt Joint jacking pipes incorporate a single wide jacking face. External recesses at each end of the pipe allow for a rolled steel band to be located between adjacent pipes, providing the necessary shear connection (see Fig 8.2). Butt Joint jacking pipes can provide a cost effective solution for typically short length applications where only limited flexibility is required and a soil or watertight joint is not required. This pipe is most suited to sleeve pipe applications for road and rail crossings where the annulus between the utility pipeline or conduit is to be filled with grout after installation.
Steel plate
an elastomeric seal located within the steel collar and an accurately formed spigot (see Figure 8.4). In this unique design the seal is retained between the corrugations in the steel collar ensuring that it remains in place and in compression in deflected joints subject to either internal or external hydrostatic pressure. This pipe provides a pipe with high axial load transfer capacity and a flexible joint watertight tight joint. This is the ideal choice for jacking pipes for stormwater, culverts and sleeve pipe applications. Available diameters of these pipes are listed in Table 8.2 (page 41) and further details are contained in a separate brochure Humes S-Series Jacking Pipes.
Rubber ring Steel collar Water stop
Jacking direction Figure 8.4 - S-Series joint profile Jacking direction Figure 8.2 - Butt Joint Profile MDF* or softwood
MDF* or softwood
In-Wall Joint jacking pipes are available in the size range DN1200 to DN3600 (standard range DN1200 to DN2100). These pipes are manufactured as a modification to the standard Rubber Ring In-wall drainage and sewerage pipes. In-wall joint jacking pipes incorporate a concrete socket formed in the wall of the pipe, a rubber ring located on the pipe spigot and timber packers on one or both joint faces (see Fig 8.3). In-Wall Joint jacking pipes can provide a cost effective solution for typically short length applications where a flexible watertight joint is required, however, this type of joint can have limitations in jacking load transfer. J-Series pipe should be specified in these situations
Steel joint cover plate Rubber ring
The J-Series is a complete jacking pipe system incorporating standard jacking pipes, pipes with specially designed threaded fittings for injection of lubricants and grout and intermediate jacking station (interjack) pipes. The J Series range of pipes all provide high axial load transfer capacity and a flexible water tight joint including the interjack pipes. This is the ideal jacking pipe for all stormwater, sewerage (including an inert thermoplastic lining if required), culvert, sleeve pipe and jacked low pressure pipeline applications. Available diameters of these pipes are listed in Table 8.2 (pg 41) and further details are contained in a separate brochure Humes J-Series Jacking Pipes.
Steel collar Muck ring Ligature Water stop
Receiving Pit Rubber ring
MDF* or softwood Jacking direction
Inside of pipe
Figure 8.3 - In-wall Joint Profile S-Series jacking pipes are available in the size range DN300 to DN700 inclusive and are a custom designed jacking pipe incorporating a single wide jacking face including timber packers, a stainless steel corrugated collar cast onto the pipe, *Medium Density Fibreboard
Internal joint recess for secondary sealant (if required)
MDF* or softwood Jacking direction
Figure 8.5 - J-Series joint profile
39
8. Jacking Pipes
J-Series jacking pipes are available in the size range DN800 to DN2000 inclusive and are a custom designed jacking pipe incorporating a single wide jacking face including timber packers, a steel collar cast onto the pipe, an elastomeric seal and muck ring located on the pipe spigot (see Figure 8.5). In this design the elastomeric seal is retained within the accurately formed recess on the pipe spigot that will remain in place and in compression in deflected joints subject to either internal or external hydrostatic pressure. The muck ring limits the ingress of soil into the joint during jacking.
Selection of Jacking Pipes

The most basic requirements of all jacking pipes is that they must be capable of supporting the excavation (earth and traffic loads), transferring axial load, providing a shear connection between adjacent pipes and joint flexibility that allows for each pipe to follow the path excavated in front of the shield. In addition jacking pipes may need to prevent ingress of surrounding soil, groundwater, lubricants or grouts and provide a joint capable of withstanding internal pressure in stormwater, sewerage or pressure pipeline applications. As stated above the jacking pipe must meet both the needs of the pipe jacking contractor and asset owner who is usually represented by the pipeline designer. Table 8.1 provides a summary of the capabilities of each of the different types of jacking pipes for different requirements and applications.
Capability/Suitability of Humes Jacking Pipes Jacking Pipe Requirements or Application Standard Size Class Extended Diameter Range Incorporation of inert thermoplastic lining Suitability in different soil conditions Asset Owner External grouting Internal Pressure Test 4 Capability (kPa) Application of internal secondary sealants Sewerage pipelines Stormwater pipelines
1
Butt Joint DN300 - D2100 DN2250 - DN3000 N/A Not recommended in soft silts/clays or sandy 2 soils Not suitable N/A Not suitable Not suitable Limited suitability Limited suitability Limited suitability 0 - 50
8 7
In-Wall Joint DN1200 - DN2100 DN2250 - DN3600 Available All soil types
S-Series DN300 - DN700 DN800 N/A All soil types
J-Series DN800 - DN2000 > DN2000 Available All soil types
Limited suitability3 90 Limited suitability Suitable Suitable Suitable Suitable 0 - 50
Suitable for short lengths 90 N/A Limited suitability Ideally suited Ideally suited Ideally suited 0 - 150
9 6
Ideally suited 150

5
Suitable Ideally suited Ideally suited Ideally suited Ideally suited < DN1000: 0 - 150 DN1000 - DN2000: 10 no limit 250
5
8. Jacking Pipes
Road and rail culverts Sleeve pipe applications Asset Owner and Contractor Length of jacked pipeline (m)
External Pressure Test 11 Capability Jacking Force Transfer Intermediate Jacking Stations Pipes Open Face Shields Closed Face Pressure Shields Lubrication along length of pipeline
N/A Good To be provided by contractor Suitable Not Suitable Not Suitable

12
90 Moderate To be provided by contractor Suitable Limited Suitability Limited Suitability
90 Excellent N/A Suitable Ideally suited N/A
Excellent Available DN900 - DN2000 Suitable Ideally suited Ideally suited
Table 8.1 - Jacking Pipe Type Selection Guide

Notes: 1. Refer to Humes for availability 2. The joint is not water or soil tight, this could lead to ingress of soil surrounding the pipe and ultimately collapse of the ground above the pipeline. Attempts to seal the BJ with internally applied joint sealants are generally not effective in the long term life of the pipeline. 3. Grout pressures need to be carefully monitored. 4. Test to AS/NZS 4058: 2007. 5. Higher pressures are possible with certain diameters refer to Humes for advice if higher pressures are required. 6. If corrosive sewage gases are expected consider using vitrified clay jacking pipes distributed by Humes. 7. The Butt Joint jacking pipe is suitable for short length drives in certain soil conditions if the annulus between the concrete sleeve pipe and the product pipe is grouted. This grout should also flow into the annulus between the sleeve pipe and the excavated ground. 8. Lack of joint flexibility largely controls maximum length. This could be extended in certain soil conditions and if some damage to pipe joints is acceptable. 9. Intermediate jacking stations not available and length is mainly limited by installation equipment. Some pipe jacking contractors may be able to achieve longer lengths of individual drives in certain soil conditions. Refer to jacking pipe contractor for advice for longer drives. 10. The maximum length will be controlled by installation equipment rather than pipe capability. 11. There is no published test method for external joint testing of reinforced concrete pipes. External pressures due to lubrication or grouting can be well in excess of ground water pressures. 12. For lubrication to be effective, the annulus between the external diameter of the pipe and the excavated soil needs to be filled. The Butt Joint pipe will not provide an effective sealed joint.
40
Contractor
Size Class
The internal diameter (ID) of the jacking pipe will be determined by the in-service requirements of the pipeline. The external diameter (OD) in turn must be compatible with the shield machine used by the pipe jacking contractor. Table 8.2 contains details of internal and external diameters for Humes standard range of Class 4 jacking pipes. The external diameters of the S and J Series are typically compatible with overseas pipe jacking equipment. The nominal diameters of some S and J Series pipes correspond to nominal diameters adopted in European standards and differ to current Australian Standards.
Load Class
Jacking pipes are subject to substantial installation loads and permanent soil and live loads as for any buried pipe. These permanent loads are usually much less than those which may act on the pipe during installation. As such a minimum Class 4 pipe is usually recommended although in some short length drives a Class 3 may be suitable. The Class 4 pipe to Australian Standard AS/NZS 4058: 2007 has very similar strength requirements to load classes specified for jacking pipes in European and Japanese Standards. AS/NZS 4058: 2007 gives the method for determining the permanent vertical loads acting on pipes installed using pipe jacking. The jacking pipe is installed underground into undisturbed
natural ground where the soils natural cohesion contributes to arching over the pipe. Where the calculation includes the effects of arching due to soil cohesion extensive soil investigations should be carried out to determine the appropriate design soil properties. The jacking installation results in a recommended bedding factor between 2 and 3 that is used to determine the minimum suitable pipe class required due to permanent loads. The higher value is recommended when the annulus between the pipe and ground is grouted. Grouting of this annulus with a suitable cementitious grout is recommended in most installations as any voids could create a drainage path external to the pipeline which in turn could lead to soil erosion, lowering of ground water tables and, in aggressive soil conditions, an increased risk of corrosion of pipe materials. The axial loading from the pipe jacking is not directly included in the selection of the pipe load class. Timber packers are placed between the jacking faces of the concrete pipes to avoid high stresses that could result from direct concrete to concrete contact. The axial load capacity of the concrete pipe is determined based on the minimum pipe wall thickness, concrete strength, properties of the timber packers and the deflections that can be expected at pipe joints during installation. The allowable jacking forces and associated maximum joint deflections are calculated in accordance with the Concrete Pipe Association of Australasias publication Jacking Design Guidelines.
Table 8.2 - Jacking Pipe Diameter Selection Chart (Standard range is equivalent to load class 4 pipes)
Nominal Diameter DN300 DN350 DN375 DN400 DN450 DN475 DN500 DN525 DN600 DN675 DN700 DN750 DN800 DN825 DN900 DN975 DN1000 DN1050 DN1100 DN1200 DN1350 DN1500 DN1650 DN1800 DN1950 DN2000 DN2100 2088 2388 2096 2388 Note: Alternative internal diameters (and external diameters) may be available to suit project specific requirements, please refer to Humes for advice. 1920 2220 1200 1500 1163 1324 1452 1596 1756 1930 1359 1524 1676 1842 2006 2198 2000 2420 1026 1194 1100 1200 1350 1500 1650 1800 1332 1450 1626 1800 1974 2150 790 875 951 946 1029 1111 1000 1220 900 1110 730 864 800 1000 518 586 653 616 698 781 700 876 600 774 438 534 500 672 363 445 400 450 540 606 In-Wall Joint ID OD ID 280 Butt Joint OD 362 ID 300 350 S Series OD 430 480 ID J Series OD
41
8. Jacking Pipes
Hydraulics
Whether the jacking pipes are used in culvert, stormwater, sewerage or pressure applications, the same hydraulic design methods used for trenched pipe apply. The relevant information is provided in each of these respective sections: Section 3 - Pipes for culvert applications Section 4 - Pipes for stormwater applications Section 5 - Pipes for sewerage applications Section 6 - Pipes for pressure applications
Installation
Humes S and J-Series jacking pipes are provided with cast in lifting anchors as standard. These anchors can also be provided in some sizes in the butt and in-wall joint pipes. Threaded steel fittings can be included in all man-entry sized jacking pipes for injection of both lubricating fluid and cementitious grout into the annulus external to the pipe. These fittings are usually located midway along the pipe length at the four quarter points of the pipe circumference starting at 45 degrees from the top of the pipe. The actual details of the fittings and the number of pipes with these fittings are usually advised by the pipe jacking contractor prior to manufacture. Timber packers are attached to one end of the jacking pipe using a suitable adhesive well in advance of jacking. It is essential that the correct sized packers are placed in the correct position to ensure satisfactory load transfer between pipes.
Humes Interjack station.
8. Jacking Pipes
Jacking forces and joint deflections must be monitored during installation to ensure that the pipe is not overstressed during installation. If maximum jacking forces and associated joint deflections are exceeded spalling of the concrete in the pipe joint may occur. This spalling often occurs on the external surfaces of the joint that may not be visible from inside the pipeline. Further installation instructions are contained in the separate S-Series and J-Series product brochures for these pipes.
Starting shaft showing exit opening and jacking station.
42
9. Handling and Installation

Placing Your Order
When ordering Pipeline Systems products, the following basic information helps us quickly meet your requirements. Give the details of the delivery address and unloading requirements, the specific pipe details, diameter, type, class, quantities and delivery schedules. Any other particular pipe or delivery requirements. List any other requirements ie. fittings or associated products. If necessary specification type or application type details if you require verification of product suitability. Also include any testing or special inspection requirements. Written instructions are usually the best instructions. The Pipe Design Request Sheet on the inside back cover of this publication should be used when giving written instructions for ordering the pipe. Alternatively AS/NZS 4058: 2007 also includes an ordering checklist.
Concrete pipes loaded onto truck for delivery to site.
Arriving at the Site

The Concrete Pipe Association of Australasia (CPAA) publication,"A Foremans Laying Guide is available as a PDF from the web site or in hard copy for site use. The content covers a broad range of the issues which may be encountered on site. In addition, the CPAA has a DVD covering the installation practices for SRCP. When stacking on site, pipes should always be placed with the "Top" mark facing upwards. Take extra care when pipes are double stacked. If pipes are to be stored on the job for a period of months, orientating them east to west, when possible, will reduce the sun's effects on the barrel of the pipes. This, although not essential, will help to ensure integrity until installed below ground level.
Rubber rings and EB bands should be fitted to the pipe's spigot at the ground surface before lowering the pipe into the trench. The rubber ring is fitted into the groove on the spigot as shown in Figure 9.1 and should be checked to ensure that the ring has no twists around its circumference. This guarantees uniform rolling when jointing. If the pipes are joined and excessive "springback" is experienced in the joint, then the joint should be pulled open and the rubber ring again fitted onto the spigot, ensuring that no twists occur around its circumference. It's a good idea to stack pipes on timber bearers at one-third points along the barrel for easy access when fitting lifting equipment. All pipes should be chocked to prevent movement when stacked. RRJ pipes can be supplied with lifting devices if requested for handling and laying, however, more commonly suitable lifting straps or chains are used for handling the pipes. Where chains are used, take care to minimise damage to the pipe and bedding when removing the chains after placing the pipe.
Handling On-Site
When installing Rubber Ring Joint (RRJ) pipes, minimise the rubber rings' exposure to direct sunlight. Rubber rings are best stored inside the pipe barrel and left in plastic or hessian bags when supplied. EB bands as available for Flush Joint (FJ) pipes should also be stored inside the pipe. Rolling rubber rings do not need lubrication as they rely on the natural effects of rubber on concrete to roll. Ensure the spigot end (male end) of the pipe is clean and dry.
Ensure no twists in ring
Apply lubricant to front face of ring and spigot surface in front of Rubber Ring after fitting Pipe Spigot Rolling Rubber Ring Note: Do not lubricate
Ring sits in Groove Ensure ring sits against Spigot Step Pipe Spigot Apply lubricant to socket lead-in
Pipe Socket
Pipe Spigot Inside surface
Skid Ring
Note: Do not apply lubrication to underside of skid ring
Figure 9.1 - Fitting Rubber Ring
Figure 9.2, Skid Joint Lubrication
43
9.Handling and Installation
Humes Rubber Ring Lubricant is supplied with all skid ring joint pipes. The lubricant is a special mix of soft soap solution (see Figure 9.2). NEVER use petroleum products, (e.g. grease) as a substitute lubricant.
Flush joint (FJ) pipes are generally supplied with lifting holes and plugs are provided which should be secured after laying. Lifting equipment (certified for the pipe load) should be sized so as not to damage the pipe (see Figure 9.3).
150mm
Batter excavation above top of pipe as required to suit ground stability
Lift Load Spreader Bar
Note: Lifting equipment to suit pipe mass as stencilled on pipe Lifting hole
Pipe OD
Figure 9.4 - Trench Profile

250 up to 1050 size 500 above 1050 size D
Figure 9.3 - Lifting Equipment
Where a pipe is to be laid at natural surface level, the more severe loading from an embankment condition results in a higher pipe class requirement. A trench load condition can be simulated by placing and compacting fill material to 95% Modified Maximum Dry Density up to the level of the top of pipe, and then excavating the trench into the placed fill as shown in Figure 9.5.
Height of pipe
Compacted embankment Natural ground surface Step 1 - Place embankment fill to level of top of pipe.
Height of pipe Step 2 - Excavate trench into the placed fill, lay pipe.
Figure 9.5 - Stages for creating trench conditions at embankment installations.
The Pipeline Foundation

The foundation for a pipeline at the trench invert under the pipes, provides stability and uniformity along the pipeline. Hard or soft spots in the foundation under the pipeline should be removed and replaced with compacted granular material to give uniform support to the pipe (see Figure 9.6).
Trench installation of RRJ pipe, note battered excavation
Digging the Trench

Remember, all trenches, deep or shallow, can be dangerous environments. Excavated material should be placed far enough from the top of the trench to allow sufficient clearance for installation operations, and to minimise the danger of rocks or lumps rolling back into the trench. The design engineer has specified the pipe strength class based on a maximum trench width at the top of the pipe. The width of the trench nominated by the specifier should not be exceeded without first checking with the pipeline designer. Trench walls may be battered or benched above the top of pipe without affecting the pipe design strength class (see Figure 9.4).
Finished surface
Rock broken away for min. 300mm and compacted fill placed between rock and pipe
Soft spot removed and refilled with compact fill
Figure 9.6 - Trench Foundation Conditions
44
Placing the Bed

Concrete pipes are placed on a prepared flat bedding. Shaped bedding is not necessary for concrete pipe. Bed material is spread across the full trench width to the depth required, and compacted to prevent settlement of the pipeline. Bed material should be granular and fall within the specified size limits given in Table 9.1.
Sieve Size (mm) 19.0 2.36 0.60 0.30 0.15 0.075* Weight passing (%) 100 100 to 50 90 to 20 60 to 10 25 to 0 10 to 0
Laying the Pipe

EB bands when fitted to flush joint pipes are "flipped" into position across the joint after settling the pipe in place on the prepared bed. For RRJ pipes less than DN1800, a laying gap is indicated on the outside of the pipe by a series of witness marks (see Figure 9.8) which show that the joint has been pushed fully "home", thus ensuring proper jointing.
Witness Mark Locations Spigot Maximum joint draw
Witness Marks
Socket
Table 9.1 - Recommended Grading Limits for Select Fill in Bed and Haunch Zones *Low plasticity required In many instances, the pipe mass is sufficient to compact the bed under the pipe after an allowance of extra depth of loose bed material is made to accommodate settlement during natural compaction. Bed material each side of the pipe should be compacted to give a good stable support to the embedment soil profile higher up in the installation. Chases must be dugout for belled-socket joints as shown in Figure 9.7.
Maximum joint draw
Spigot
Normal laying gap
Figure 9.8 - Rubber Ring Joint Witness Marks RRJ pipes laid around a curve where the joint is to be deflected, should firstly be pushed fully home (zero laying gap) and then the pipe levered at the opposite end to produce the required deflection as shown in Figure 9.9.
Correct
Positive overlap
Incorrect
Figure 9.7 - Trench Foundation Preparation
Maximum Deviation
Zero Gap
Excavation of Socket Zone
The recommended procedure for laying pipe is to fit the spigot into the socket. In this orientation, joints are restrained from opening as a result of pipe movement during pipeline settling. Laying in this manner protects surfaces inside the pipe socket from the entry of bed material which may occur if jointed socket onto spigot. Even so, if adequate precautions are taken, there is no reason why concrete pipes cannot be jointed and laid in the reverse manner.
Preparing the bedding to accommodate the socket.
45
Jointing the Pipes

When joining RRJ pipes there is a "nominal" recommended joint laying gap and a maximum laying gap, as shown in Table 9.2 and Figure 9.10. The force required to joint RRJ pipes increases as the pipe diameter increases. Generally speaking, pipes less than DN450 can readily be pushed home without using leverage tools.
Laying Gaps* Nominal (mm) 3 3 3 3 5 5 5 5 5 8 8 8 10 10 10 10 10 10 10 10 10 10 15 15 Maximum (mm) 5 5 5 10 12 12 12 12 12 12 10 15 15 20 15 18 18 55 25 33 36 37 44 48
Pipes larger than DN450 and up to DN1200 can be pushed home using simple leverage tools combined with the slung pipe mass as shown in Figure 9.11.
Size Class Size Class (DN) (DN) 100 150 225 300 375 450 Belled Socket Joint 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 In-wall Joint 2100 2250 2400 2700 3000
Figure 9.11 - Jointing Small Diameter Pipes
Pipes larger than DN1200 require jointing by use of a come-along, or by a winch and rope to the slung pipe from the laid pipeline. The jointing load is resisted by a "dead man" timber located upstream in the pipeline as shown in Figure 9.12.
HW Timber Dead Man located 2 to 3 pipes in the layed pipeline Rubber Ring on Spigot
Wire Rope or Chain Come-along
HW Timber Bearer placed in socket
Figure 9.12 - Jointing Large Diameter Pipes
Table 9.2 - Laying Gaps (mm) * Laying gaps as viewed from pipe bore
External Witness marks
Nominal laying gap for good practice
Maximum laying gap (ensures joint overlap of spigot into socket)
Jointing of large diameter sewerage pipes.
Figure 9.10 - Rubber Ring Joint Laying Gaps Note: In-wall joint similar
46
Multiple 1350 diameter Rubber Ring Joint stormwater pipes.
Preparing the bedding at the socket end of the pipe to be joined.
Approximate jointing loads are given in Table 9.3 for standard RRJ pipes. Where lifting devices are fitted for handling, these are used to make the jointing operation quick and easy. Flush joint pipes are easily jointed without effort, but always ensure that the joints interlock is properly made.
Bedding and Backfilling the Pipe

Pipe embedment is the general name given to the soil profile around the installed pipe and includes the bed zone, where required, and overlay zone as shown in Figure 9.13. Pipe bedding refers to the bed and haunch zones which provide the underlying support to the pipe.
150mm
Table 9.3 - Table of Indicative Jointing Loads - Standard Range

Pipe Embedment Size Class (DN) 300 375 450 525 600 675 750 825 900 1050 1200 1350 1500 1650 1800 1950 2100 Indicative Jointing Load (kg)* 110-140 150-170 180-250 250-290 300-380 320-400 420-470 500-590 570-660 700-770 810-850 900-980 1000-1200 1200-1350 1600-1700 1600-1800 1700-1850
Overlay Zone
Side Zone (HS only)
Bedding
Haunch Zone Bed Zone
The four most important points when bedding and backfilling around reinforced concrete pipes are: Avoid damaging the pipes by excessive impact from heavy compaction equipment. Keep large rocks (greater than 300mm) and other such hard objects out of the fill adjacent to the pipes. Bring up the haunch and side zones on both sides of the pipe, so that the difference between the level of the material never exceeds two compaction layer thicknesses. This ensures that the pipes will not be eased slightly out of alignment. Avoid running heavy construction equipment over the pipes until a sufficient cushion of material has been placed, approximately 300mm for normal equipment. When using vibrating compaction equipment, allow a 500mm cushion of material over the pipe or alternatively turn off the vibration until this level is reached.
*Note: The lower figure is the most commonly achieved in practice.
47
Figure 9.13 - Pipe Embedment Profile
Large vibrating rollers should always be checked for their effects. Humes engineers can provide guidance. The "Haunch Zone" in both "H" and "HS" type installations is essential to support the lower portion of the pipe. Voids in the haunch zone under the pipe should not exist as they may cause instability in the embedment compaction. The "Side Zone" compaction in HS Type installations is important in supplying side support to laterally resist the load on the pipe. When installing pipes in HS type installations, it is a requirement that the trench side walls also have sufficient strength to carry the load shed from the pipe and through the side zone material. Visual inspection of the physical nature of the exposed surface is usually sufficient to determine if this condition is achievable, however, when in doubt, Humes engineers can provide guidelines and recommendations. The range of recommended concrete pipe installations varies from that which requires the least amount of work, "Type U", through to the installation containing the greatest amount of preparation and supervision, the "Type HS3" installation. "Type U" support shown in Figure 9.14 is an uncontrolled pipe installation and only requires that there should be no unevenness in support under the pipe. In many instances, the inbuilt strength of reinforced concrete pipe allows this very inexpensive method to be used. Where the pipeline is to be subjected to vehicle loads, this type of installation is not recommended.
Compacting of fill material is a critical part of the installation
Natural ground surface
Finished surface
Backfill
Embankment fill
150mm
150mm
150mm
Ordinary fill D D
Natural ground surface Soil Rock Bed (only required where foundation is rock)
Trench Figure 9.14 - Type U Support
Embankment
48
"Type H" support involves the selection and compaction, not only of the bed material, but also the haunch material as illustrated in Figure 9.15. Selection of the bed and haunch material to be used should be made to suit the grading limits described in Table 9.1 (page 45). These grading limits have been derived from experience, of both stability of the compaction after installation and ease of compaction during placement. The depth of the Haunch Zone and the degree of compaction is dependent on the type of support specified, either H1 or H2. The measurement of compaction given "Density Index", relates to the non-cohesive material specified. If a cohesive material outside the grading limits and containing significant amounts of clay and silt is to be used, then "Maximum Dry Density" for standard compaction is used to describe the degree of compaction. Table 9.4 presents a table of equivalent support stiffness. After placement of the haunch material, ordinary fill material can be used in the Overlay Zone around the pipe. This material only requires that no stones be greater than 150mm and no specific compaction level is needed.
Table 9.4 - Equivalent Compaction Stiffness

Standard Compaction* Max. Dry Density 95% 90% 85% Density Index 70% 60% 50%
*Compactive effort shall be applied at 90-100% of optimum moisture content.
Backfill
Embankment fill
150mm
150mm
150mm
D Haunch zone Bed zone 0.10 x OD (H1) 0.30 x OD (H2) Compact 50% (H1) Compact 60% (H2)
D Haunch zone Bed zone
Trench
Embankment
Figure 9.15, Type H Support
49
The third type of bedding support available is the "HS Type", which specifies both haunch and side support, as indicated in Figure 9.16. This type of installation is an extension of the haunch type support and includes a Side Zone with material meeting the requirements given in Table 9.5. Depth of placement and compaction of both this side zone material and the haunch zone material lower down in the soil profile, is dependent on the type of support specified, HS1, HS2 or HS3. Narrow trenches can cause difficulty in working and compacting the bedding to the required levels which must be achieved to give the assumed support for the pipe. This is particularly important for Type HS3 Support where significant levels of side support are assumed. Remember, if the width of the trench is increased during installation, this will cause an increase in the load on the pipe. The trench width however, may be increased by benching or battering above the level of the top of the pipe as shown in Figure 9.17.
Table 9.5 - Grading Limits for Select Fill in Side Zones

Sieve Size (mm) 75.0 9.5 2.36 0.60 0.075 Weight passing (%) 100 100 to 50 100 to 30 50 to 15 25 to 0
Backfill
Embankment fill
150mm
150mm
150mm
Side zone Haunch zone Bed zone
0.5 OD 0.10 x OD (HS1) 0.30 x OD (HS2,HS3) Compact 50% (H1) Compact 60% (H2) Compact 70% (H3)
Side zone Haunch zone Bed zone
Trench
Embankment Figure 9.16 - Type HS Support
Specified Trench Width
Specified Trench Width
150mm minimum
Bench trench walls if necessary above top of pipe
150mm minimum
Bench and batter trench walls if necessary above top of pipe
Figure 9.17 - Trench Profile Above Pipe Installation
50
10. Reference Material

The following is a compilation of informative reference material, useful for the hydraulic design and installation of steel reinforced concrete pipe.
Figure 10.1 - Approximate Critical Depth Relationships for Circular Pipe

1.0 .8 .6 .4
.2
dc /D
.1 .08 .06 .04
dc
.02
Q = m3/s D=m g = m/s2

.0001 .001 .01 .1 1.0
.01
Q/(g)0.5(D)2.5
1.0 .9 .8
Proportional Depth y/D
.7 .6 .5 .4
Q/
Qf
V/
Q = Part-full Velocity Qf = Full Flow Discharge V = Part-full Velocity Vf = Full Flow Discharge
.2 .1
.1
.2
.3
.4
.5
.6
.7
.8
.9
1.0
1.1
1.2
Proportional Discharge Q/Qf and Proportional Velocity V/Vf
51
.3
Vf
(1)
(2)
(3)
(1) Square edge with headwall (2) Socket end with headwall (3) Socket end projecting
Figure 10.3 - Flow Relationships for Inlet Control in Culverts
To use scale (2) or (3) project horizontally to scale (1), then use straight inclined line through D and Q scales, or reverse as illustrated
52
Entrance loss coefficient: ke = 0.5 for: - sq. cut pipe end - mitred precast end - headwall with sq. end ke = 0.2 for: - socket end protruding - headwall with socket end
Figure 10.4 - Energy head relationships for pipes flowing full (n = 0.011)
53
.0100 .0090 .0060 .0070 .0050
2.5
m/
.0020 .0002
DN 150
.0030
DN 300
.0001
DN 375
2.0 m 1.9 /s m/ s 1.8 m 1.7 /s m 1.6 /s m/ s 1.5 m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s
DN 225
DN 450
0.9
DN
600
.0010 .0009 .0008 .0007 .0006 .0005 .0004 .0003
m/
525
0.8 0.7 m/ m/
m/
DN
DN
675
DN
825
750
0.6
DN
DN
m/
DN 105 0 DN 112 5 DN DN 1200 127 5
0.5
975
900
DN
135
.0001
10
20
30
40
60
80 100
200
300
500
800
1000
Discharge in litres per second k s = 0.06mm
Figure 10.5 - Full Flow Conditions Colebrook-White Formula k s = 0.06mm (applicable to concrete culverts carrying stormwater)
54
DN
.0002
150
DN
.0400 .0300
.0200
DN 37
8.0 m 7.5 /s m/ s 7.0 m/ s 6.5 m/ s 6.0 m/ s 5.5 m/ s 5.0 m/ s
DN 30
.0100
DN 45
4.5
m/
DN 52
4.0
m/
DN 60
DN 67
3.5
m/
DN 75
.0050
82
DN
90 0
3.0
m/
DN
5 97
10
50
DN 11 25 DN 12 00 DN 1 DN 275 13 50
DN
.0030
2.5
DN
m/
15
00 16 DN 50 18 DN 00 19 DN 50 00 21 DN 50
.0005
100
200
300
500
700
1000
2000
3000
4000
5000
7000
10000
Discharge in litres per second

ks = 0.15mm
Figure 10.6 - Full Flow Conditions Colebrook-White Formula ks=0.15mm (applicable to concrete rising mains carrying clean water)
DN
DN
.0010
1.9 m 1.8 /s m/ s 1.7 m 1.6 /s m 1.5 /s m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s
DN
.0020
22
24
DN
27 0 28 0 50
DN
DN
25
50
00
55
.0400 .0300
.0200
DN 37
7.5 m/ s 7.0 m/ s 6.5 m/ s 6.0 m/ s 5.5 m/ s 5.0
DN 30
DN 45
m/
4.5
DN 52
m/
DN 60
.0100
4.0
m/
DN 67
3.5
DN 75
m/
DN 82
DN 90
3.0
.0050
DN 97 5 DN 10 50 DN 1 DN 125 12 00 DN 12 75 DN 13 50
m/
2.5
m/
DN
DN
.0010
.0005
100
200
300
500
700
1000
2000
3000
4000 5000
7000
DN
21
.0020
2.0 m 1.9 /s m/ s 1.8 m 1.7 /s m 1.6 /s m/ s 1.5 m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s
16 DN
50 18 DN 00 19 50 00 DN 2 DN 250 2 DN 400 25 50 DN 2 DN 700 28 50

10000
.0030
Figure 10.7 - Full Flow Conditions Colebrook-White Formula ks=0.6mm (applicable to concrete pipes carrying stormwater)
56
15
00
.0400
DN 30
.0300
Ma
DN 37 5
x. V
elo
city
The
rmo
DN 45
.0200
pla
stic
Lin
er
4.0
DN 52
4.5 m/
m/
DN 60
.0100
DN 67
75
3.5
82 5 0
DN
m/
DN
97
3.0
50 11 00 25
DN
90
DN
m/
DN
10
DN
12 7 13 5 50
12
.0050
DN
18 DN
.0030
19 DN
50 DN 21 00
ont
rol
.0020
Mi
n. V
elo
city
Sel
fC
lea
nsi
ng
.0010
2.0 m 1.9 /s m 1.8 /s m 1.7 /s m/ s 1.6 m 1.5 /s m/ s 1.4 m/ s 1.3 m/ s 1.2 m/ s 1.1 m/ s 1.0 m/ s 0.9 m/ s
2000
DN
16
Slim
DN
15
00 50
elo
city
.0005
50
100
300
500
700
1000
4000
Figure 10.8 - Full Flow Conditions Colebrook-White Formula ks = 1.5mm (applicable to concrete pipes carrying sewerage)
00
eC
DN
DN
Ma
x. V
2.5
m/
6000 8000
57
Concrete Pipe Association of Australasia
Vibratory Smooth Drum Roller (Up to 7t)
Vibratory Trench Roller (Up to 2t)
Vibratory Rammer (Up to 75kg)
Reproduced by authority of Concrete Pipe Association of Australasia
Figure 10.9 - CPAA Compaction Charts

.
58
15t Excavator and Compaction Wheel
Vibratory Smooth Drum Roller (Up to 10t)
Notes: 1. When using a pedestrian vibrating plate the minimum compacted fill is 125mm for all pipe classes and trench types. 2. The graphs and diagrams shown are for guidance only. For special applications or for applications not shown on the drawing refer to AS/NZS 3725: 2007 or use the CPAA software, PipeClass v1.2. 3. Widening of the trench beyond the minimum specified in AS/NZS 3725: 2007 will increase the load carried by the pipe and will require a review of the pipe class and trench compaction method. 4. The pipe cover shown on the graphs refers to compacted depth of fill above the pipe crown 5. To obtain sufficient compaction you may have to use shallower fills and possibly a lighter roller.
25t Excavator and Compaction Wheel
Reproduced by authority of Concrete Pipe Association of Australasia
59
10.10 - Imperial and metric equivalents

Length 1 mm 1m 1 km = 0.039370 in = 3.28084 ft = 0.621371 miles 1 in 1 ft 1 mile = 25.4 mm = 0.3048 m = 1.609344 km
Area
1 cm2 1 m2 1 ha
= 0.1550 in2 = 10.7639 ft2 = 2.47105 acres
1 in2 1 ft2 1 acre
= 6.4516 cm2 = 0.0929063 m2 = 0.404686 ha
Volume
1 m3
= 35.3147 ft3
1 ft3
= 0.0283168 m3
Liquid Measure
1 litre 1 litre 1 litre 1 megalitre
= 0.0353147 ft3 = 0.219969 imp gal = 0.2642 US gals = 0.08104 acre ft
1 ft3 1 US gal 1 acre ft
= 28.3168 litres = 3.785 litres = 1.234 megalitres
1 imp gal = 4.54609 litres
Velocity
1 m/sec 1 kph
= 3.28084 ft/sec = 0.621371 mph
1 ft/sec 1 mph
= 0.3048 m/sec = 1.609344 kph
Mass
1 gram 1 kg 1 tonne
= 0.035274 oz = 2.20462 lb = 0.984207 tons = 1.102312 US tons
1 oz 1 lb 1 ton
= 28.3495 grams = 0.45359 kg = 1.01605 tonnes
1 US ton = 0.90718 tonnes
Volumetric Flow Rate
1 litre/sec 1 litre/sec
= 13.19814 imp gal/min = 0.0353147 cusecs
1 imp gal/min = 0.075768 litre/sec 1 cusec = 0.0283168 cumecs
Force
1 kN
= 224.809 lbf = 0.100361 tonf
1 lbf 1 tonf
= 0.004448 kN = 9.96402 kN
Pressure and Stress
1 MPa 1 kPa
= 0.064749 tonf/in2 = 0.145038 lbf/in = 0.3346 ft head

2
1 tonf/in2 = 15.4443 MPa 1 lbf/in2 = 6.89476 kPa 1 ft head = 2.989 kPa

60
Index
Access Chambers . . . . . . . . . . . . . . . . . . . 24 Additional cover to reinforcement . . . . . . 21 AKS Sheeting . . . . . . . . . . . . . . . . . . . . . . 22 Bedding . . . . . . . . . . . . . . . . . . . . . . . 45, 47 Bedding Supports Type H2 & Type HS2 . . . . . . . . . . . . . . . 3 Type HS3 . . . . . . . . . . . . . . . . . . . . . . . 4 Material Quantities . . . . . . . . . . . . . . . . 5 Butt Joint jacking . . . . . . . . . . . . . . . . . . . . . . . . 39 Calcareous Aggregate . . . . . . . . . . . . 21, 22 Compaction Equivalents . . . . . . . . . . . . . 49 Comparative Fill Heights Standard strength . . . . . . . . . . . . . . . . . 4 Corrosion Protection Liners Plastiline. . . . . . . . . . . . . . . . . . . . . . . . 22 AKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Critical Depth Relationships . . . . . . . 10, 51 Culvert Pipe example . . . . . . . . . . . . . . . . . . . . . . . 13 Deflections irrigation . . . . . . . . . . . . . . . . . . . . . . . 35 jacking . . . . . . . . . . . . . . . . . . . . . 41, 42 joint details . . . . . . . . . . . . . . . . . . . . . 45 maximum joint . . . . . . . . . . . . . . . . . . 27 Durability general . . . . . . . . . . . . . . . . . . . . . . . . . 2 E.B. Band . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Embedment Profile . . . . . . . . . . . . . . . . . . 47 Field Test pressure pipe . . . . . . . . . . . . . . . . . . . . 33 Flow Relationships . . . . . . . . . . . . . . . 10, 52 Flush Joint (FJ), dimensions & masses . . . . . . . . . . . . . 15 jacking . . . . . . . . . . . . . . . . . . . . . . . . 39 lifting equipment . . . . . . . . . . . . . . . . . 44 profile . . . . . . . . . . . . . . . . . . . . . . . . . . 9 stormwater . . . . . . . . . . . . . . . . . . . . . 16 Foundation conditions . . . . . . . . . . . . . . . . . . . . . . 44 pipeline . . . . . . . . . . . . . . . . . . . . . . . . 44 preparation . . . . . . . . . . . . . . . . . . . . . 45 Full Flow ks=0.06mm . . . . . . . . . . . . . . . . . . 31, 54 ks=0.15mm . . . . . . . . . . . . . . . . 31,36, 55 ks=0.6mm . . . . . . . . . . . . . . . . 31, 34, 56 ks=1.5mm . . . . . . . . . . . . . . . . 23, 26, 57 General introduction . . . . . . . . . . . . . . . . . . . . . 2 Grading bed & haunch zones . . . . . . . . . . . . . . 45 side zone . . . . . . . . . . . . . . . . . . . . 48, 50 Handling and Installation . . . . . . . . . . . . 43 Head Loss culvert . . . . . . . . . . . . . . . . . . . . . . . . . 12 drainage . . . . . . . . . . . . . . . . . . . . . . . 34 irrigation . . . . . . . . . . . . . . . . . . . . . . . 36 pressure . . . . . . . . . . . . . . . . . . . . . . . 31 Hydraulics culverts . . . . . . . . . . . . . . . . . . . . . . . . . 9 general . . . . . . . . . . . . . . . . . . . . . . . . . 3 irrigation . . . . . . . . . . . . . . . . . . . . . . . 36 jacking . . . . . . . . . . . . . . . . . . . . . . . . 42 pressure pipe . . . . . . . . . . . . . . . . . . . . 31 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 23 stormwater . . . . . . . . . . . . . . . . . . . . . 19 Imperial and Metric Equivalents . . . . . . . 60 Induced Trench Installation bedding type HS2 . . . . . . . . . . . . . . . . . 6 Inlet Control flow relationships . . . . . . . . . . . . . 10, 52 Installation culverts . . . . . . . . . . . . . . . . . . . . . . . . 11 jacking . . . . . . . . . . . . . . . . . . . . . . . . 42 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 23 stormwater . . . . . . . . . . . . . . . . . . . . . 19 trench profile . . . . . . . . . . . . . . . . . . . 50 Irrigation applications . . . . . . . . . . . . . . . . . . . . . 35 example . . . . . . . . . . . . . . . . . . . . . . . 36 Jacking Pipes applications . . . . . . . . . . . . . . . . . . . . . 38 dimensions . . . . . . . . . . . . . . . . . . . . . 41 suitability chart . . . . . . . . . . . . . . . . . . 40 Joint Profile culvert . . . . . . . . . . . . . . . . . . . . . . . . . . 9 jacking . . . . . . . . . . . . . . . . . . . . . . . . 39 Joint Type culvert . . . . . . . . . . . . . . . . . . . . . . . . . . 9 general . . . . . . . . . . . . . . . . . . . . . . . . . 2 irrigation . . . . . . . . . . . . . . . . . . . . . . . 35 jacking . . . . . . . . . . . . . . . . . . . . . . . . 39 pressure . . . . . . . . . . . . . . . . . . . . . . . 27 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 22 stormwater . . . . . . . . . . . . . . . . . . . . . 16 Jointing Pipes large size . . . . . . . . . . . . . . . . . . . . . . . 46 small size . . . . . . . . . . . . . . . . . . . . . . . 46 loads . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Laying Gaps rubber ring joint . . . . . . . . . . . . . . . . . 46 Load Class culverts . . . . . . . . . . . . . . . . . . . . . . . . . 9 general . . . . . . . . . . . . . . . . . . . . . . . . . 3 irrigation . . . . . . . . . . . . . . . . . . . . . . . 36 jacking . . . . . . . . . . . . . . . . . . . . . . . . 41 pressure . . . . . . . . . . . . . . . . . . . . . . . 28 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 22 standard strength . . . . . . . . . . . . . . . . . 3 stormwater . . . . . . . . . . . . . . . . . . . . . 19 super strength . . . . . . . . . . . . . . . . . . . . 3 Lubrication Points handling/installation . . . . . . . . . . . . . . 43 jacking . . . . . . . . . . . . . . . . . . . . . . . . 39 Maintenance Shafts . . . . . . . . . . . . . . . . . 24 Manufacturing centrifugal cast . . . . . . . . . . . . . . . . . . . 2 Maximum Depth irrigation . . . . . . . . . . . . . . . . . . . . . . . 36 Maximum Fill Height bedding Type H2, trench . . . . . . . . . . . . 6 bedding Type HS2, trench . . . . . . . . . . . 6 bedding Type HS3, embankment . . . . . 7 bedding Type HS2, embankment . . . . . 7 bedding Type H2, embankment . . . . . . 7 Maximum Jack Force . . . . . . . . . . . . . 41, 42 Other Products pressure . . . . . . . . . . . . . . . . . . . . . . . 32 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 24 stormwater . . . . . . . . . . . . . . . . . . . . . 19 Outlet Control flow relationships . . . . . . . . . . . . . . . . 10 types . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pipe Support Type U . . . . . . . . . . . . . . . . . . . . . . . . 48 Type H . . . . . . . . . . . . . . . . . . . . . . . . 49 Type HS . . . . . . . . . . . . . . . . . . . . . . . 50 Pipe Type culvert . . . . . . . . . . . . . . . . . . . . . . . . . . 9 drainage . . . . . . . . . . . . . . . . . . . . . . . 16 irrigation . . . . . . . . . . . . . . . . . . . . . . . 35 jacking . . . . . . . . . . . . . . . . . . . . . . . . 38 pressure . . . . . . . . . . . . . . . . . . . . . . . 27 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 21 Placing an order . . . . . . . . . . . . . . . . . . . . 43 Placing the Bed . . . . . . . . . . . . . . . . . . . . 45 Plastiline Sheeting . . . . . . . . . . . . . . . 21, 22 Pressure Class irrigation . . . . . . . . . . . . . . . . . . . . . . . 36 pressure . . . . . . . . . . . . . . . . . . . . . . . 28 Pressure Pipe example . . . . . . . . . . . . . . . . . . . . . . . 34 max pressure . . . . . . . . . . . . . . . . . . . . 30 Profile trench . . . . . . . . . . . . . . . . . . . . . . . . . 44 Pump Wells . . . . . . . . . . . . . . . . . . . . . . . 25 QuickTee . . . . . . . . . . . . . . . . . . . . . . . . . 24 Radius centreline for RRJ . . . . . . . . . . . . . . . . 16 Rainfall Intensity . . . . . . . . . . . . . . . . . . . . 9 Rubber Ring In-wall, dimensions & masses . . . . . . . . . . . . . 18 Rubber Ring Joint (RRJ) belled socket dimensions . . . . . . . . . . . 17 belled socket profile . . . . . . . . . . . . . . 16 culverts . . . . . . . . . . . . . . . . . . . . . . . . . 9 dimensions & masses . . . . . . . . . . . . . 17 in-wall profile . . . . . . . . . . . . . . . . . . . 18 irrigation . . . . . . . . . . . . . . . . . . . . . . . 35 jacking, in-wall . . . . . . . . . . . . . . . . . . 39 jacking, steel band . . . . . . . . . . . . . . . 39 pressure . . . . . . . . . . . . . . . . . . . . . . . 27 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 22 stormwater . . . . . . . . . . . . . . . . . . . . . 16 Sacrificial Layer Concrete . . . . . . . . . . . . . 21 Sewerage Pipe example . . . . . . . . . . . . . . . . . . . . . . . 26 general . . . . . . . . . . . . . . . . . . . . . . . . 21 Site arrival . . . . . . . . . . . . . . . . . . . . . . . . . 43 handling . . . . . . . . . . . . . . . . . . . . . . . 43 Size Class culverts . . . . . . . . . . . . . . . . . . . . . . . . . 9 general . . . . . . . . . . . . . . . . . . . . . . . . . 3 irrigation . . . . . . . . . . . . . . . . . . . . . . . 35 jacking . . . . . . . . . . . . . . . . . . . . . . . . 41 pressure . . . . . . . . . . . . . . . . . . . . . . . 28 sewer . . . . . . . . . . . . . . . . . . . . . . . . . 22 standard range . . . . . . . . . . . . . . . . . . . 3 stormwater . . . . . . . . . . . . . . . . . . . . . 14 Skid Joint lubrication . . . . . . . . . . . . . . . . . . . . . . 43 Splays radius . . . . . . . . . . . . . . . . . . . . . . . . . 12 curved alignment . . . . . . . . . . . . . . . . 12 Standard Class Range pressure pipe . . . . . . . . . . . . . . . . . . . . 29 Standard Pressure Classes irrigation . . . . . . . . . . . . . . . . . . . . . . . 36 Storage Capacity flush joint pipe (indicative) . . . . . . . . . 25 flush joint pipe (cylindrical) . . . . . . . . . 37 Storage Tanks . . . . . . . . . . . . . . . . . . . . . 25 Stormwater Pipe example . . . . . . . . . . . . . . . . . . . . . . . 20 Test Loads standard strength . . . . . . . . . . . . . . . . . 8 super strength . . . . . . . . . . . . . . . . . . . . 8 Thrust Block pressure pipe . . . . . . . . . . . . . . . . . . . . 31 Trench digging . . . . . . . . . . . . . . . . . . . . . . . . 44 Uniform Flow stormwater . . . . . . . . . . . . . . . . . . . . . 19 Witness Marks . . . . . . . . . . . . . . . . . . 45, 46
61
Pipe Quotation Request Sheet

Refer AS 4058:2007, Section 6
Client: Project: Quotation Basis: Budget Estimate Design Standard: AS 4058-2007, or Other (list) Tender Pressure Requirements This section only applies where a pipeline is to: operate at a specified working pressure, be field tested for acceptance, where watertightness is specified. Pressure Class Working pressure in pipeline (State working pressure including dynamic & surge effects) kPa, or metres Have installation conditions been considered & included in working pressure?* No, or Yes Line is: Gravity, or Pressure Pumped
General Details: (tick as applicable) Culvert & Stormwater Application: Flush Joint Sewerage Application: Gravity Rubber Ring
Microtunnelling (Jacking Pipe) Unsealed Joint Pressure/Irrigation Other (list): Pipe Class (complete table): Size Class Load Class Total Length (m) Sealed Joint
Field acceptance test: Is the installed line to be subjected to a field acceptance test?* No, or Yes: kPa Watertightness requirements for non-pressure pipe: Is a watertightness test (90 kPa) required?* No Yes Is a project specific factory pressure test required? No, or Yes kPa
Note: Refer purchaser/specifier to AS/NZS 3725:2007 and AS/NZS 4058:2007 to confirm the nominated tests are appropriate to the installation and pipeline application.
62
HumesPipelineSystems
page 1 of 2
Pipe Quotation Request Sheet

Refer AS 4058:2007, Section 6
Special Requirements (indicate special requirements below) Cement type: Reinforcement cover: Reo. Grid Type: Circular, or Elliptical Sacrificial Layer: Yes, or No Calcareous Aggregates: Yes, or No Minimum bore diameter: _______ mm Other (list):
Quote Finalisation / Contact Details Response required (date): __________ Tender closing (date): _____________ Name: Job Title: Company: Location: Phone: Fax:
Corrosion Protection Lining Type of lining: Plastiline AKS Quantity: Pipe Diameter: No. pipes: Degree of lining: 359 330 300 270 Other:
Email: Signature: Date:
HumesPipelineSystems
page 2 of 2
National Sales: 1300 361 601

Sunshine Coast Ph: (07) 5472 9700 Fax: (07) 5472 9711 HEAD OFFICE 18 Little Cribb St Townsville QLD Milton 4064 Ph: (07) 4758 6002 Ph: (07) 3364 2800 Fax: 04193364 386 Fax: (07) 477 2963 QUEENSLAND Townsville Ph: (07) 4758 6000 Fax: (07) 4758 6001 Brisbane/Gold Coast Ph: (07) 3866 7100 Fax: (07) 3866 7101 Bundaberg Ph: (07) 4152 2644 Fax: (07) 4152 5847 Rockhampton Ph: (07) 4924 7900 Fax: (07) 4924 7901 Toowoomba Ph: (07) 4633 1420 Fax: (07) 4634 3874
Email: [email protected]
Website: www.humes.com.au
Echuca Ph: (03) 5480 2371 Fax: (03) 5482 3090 Townsville Ph: (07) 4758 6002 TASMANIA Fax: 0419 477 386 Invermay Ph: (03) 6335 6300 Fax: (03) 6335 6330 Townsville SOUTH Ph: (07) 4758 6002 AUSTRALIA Fax: 0419 477 386 Adelaide Ph: (08) 8168 4544 Fax: (08) 8168 4549 Townsville WESTERN Ph: (0 AUSTRALIA Perth/Welshpool Ph: (08) 9351 6999 Fax: (08) 9351 6977 Perth/Gnangara Ph: (08) 9302 8000 Fax: (08) 9309 1625 Townsville NORTHERN TERRITORY 6002 Ph: (07) 4758 Darwin Ph: (08) 8984 1600 Fax: (08) 8984 1614
NEW SOUTH WALES Ph: (07) 4758 6002 Grafton Ph: (02) 6644 7666 Fax: (02) 6644 7313 Kempsey Ph: (02) 6562 6755 Fax: (02) 6562 4235 Sydney Ph: (02) 9832 5555 Fax: (02) 9625 5200 Tamworth Ph: (02) 6765 7766 Fax: (02) 6765 2683
Lismore Ph: (02) 6621 3684 Fax: (02) 6622 1342 Newcastle Ph: (02) 4966 4669 Fax: (02) 4966 4914 Canberra Ph: (02) 6285 5309 Fax: (02) 6285 5334 Townsville Ph: (07) 4758 6002 VICTORIA Fax: 0419 477 386 Melbourne Ph: (03) 9360 3888 Fax: (03) 9360 3887
Copyright Humes - January 2009

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Concrete Pipes

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Index ..................................................................61 Pipe Quotation Request Sheet ............................ 62

80 year old Humes pipes reused for new culvert!

Size Class (DN)

Natural ground surface or compacted fill

lc D/6 or 150mm, whichever is greater*

150mm min. overlay

Figure 1.1 - Type H1 and Type H2 Supports

150mm min. overlay

150mm (min. width)

Side Haunch Bed

Side Haunch Bed

Figure 1.2 - Type HS Support

Indicative depth of fill

Table 1.1 Material Quantities - H1 & HS1 Support Types

Table 1.3 Max. Fill Heights - Trench Installation, H2 Bedding

Pipe Load Class 4 6 8 10

>25 metre height

Table 1.4 Max. Fill Heights - Trench Installation, HS2 Bedding

Table 1.5 Max. Fill Heights - Embankment Installation, H2 (& HS2)

Table 1.6 Max. Fill Heights - Embankment Installation, HS3

2. Test Load Data

Table 2.1 - Test Loads in kilonewtons/metre length

2. Test Load Data

3. Pipes for culvert applications

Size Class (DN)

Flush Joint (FJ)

Figure 3.1 - Flush Joint Profile

Figure 3.2 - Inlet Control

Figure 3.4 - Relative discharge and velocity in part-full pipe flow

Proportional Depth y/D

Installing flush joint pipes

Installing 3600mm diameter pipes.

Other Culvert Products

Precast Concrete Headwall

Size Class (DN) 600 675 750

825 900 1050 1200 1350 1500 1650

1800 1950 2100

Stan (nom dard P ipe inal leng th) L/2

* Minimum radius is measured to the pipe centre line at joint

Right hand curve looking down stream

Pipeline deflection angle ()

Example 3 - Culvert Pipe

Step 1.3 Q = 2 x 3.1 = 6.2 m3/s

Step 1.1 Q = 4.1 m3/s

Step 1.2 Q = 2 x 2.4 = 4.8 m3/s

Step 1.4 HW/D = 1.23

Figure 10.3 - Flow Relationships for Inlet Control in Culverts

Step 2.1 dc/D = 0.75

.1 .08 .06 .04

Q = m3/s D=m g = m/s2

.01 .0001 .001 .01 .1 1.0

Step 2.2 H = 0.65m

Step 2.2 Q = 5.5/2 = 2.75 m3/s

7.5 m/ s 7.0 m/ s m/ s 6.0 m/ s 5.5 m/ s 5.0 m/ s 6.5 4.5

Hydraulic Gradient (m/m)

Discharge in litres per second

Figure 10.7 - Full Flow Conditions Colebrook-White Formula ks=0.6mm

y/D Proportional Depth y/D

Proportional Discharge Q/Qf and Proportional Velocity V/Vf

Flush Joint Pipes

Table 3.2 - Flush Joint Pipes

Super Strength Load Classes Class 4 Class 6

2850 2718 2742

11585 2700 13115

Note: Internal diameters (ID) subject to change without notice

4. Pipes for drainage applications

Figure 4.1 - RRJ Pipe with Belled Socket Joint

Rubber Ring Joint (RRJ)

Max. joint draw Inside surface Nominal laying gap

Figure 4.2 - RRJ Pipe with In-wall (Skid) Joint

Size Class (DN)

Table 4.1 - Maximum Joint Deflection: RRJ - Drainage Applications

L 2 (tan 1/2 /N)

Figure 4.3 - Curved Alignment using Deflected Straight Pipe