Pipeline design

concrete for life

CPM Concrete Drainage Systems

Pipeline Design

CPM Concrete Drainage Systems

Pipeline design - hydraulic
Graph showing relative velocity and discharge in a circular pipe for any depth of flow

1.0
0.9
0.8

Proportional depth of flow

0.7
0.6
0.5

0.4
P

P
RO

OR

NA
TIO

LD

IS

A
CH

RG

0.3
0.2

0.1

PR

OP

T
OR

IO N

AL

L
VE

OC

ITY

0
0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

Proportional velocity and discharge in pipes flowing part full

For calculating transitional flow, using the Colebrook-White equation, a roughness factor of Ks = 0.3mm is
recommended as a realistic figure for newly installed concrete pipelines. However, research has indicated that for
mature foul sewers of any material the Ks value may rise well above this figure and the Water Services Association
publication Sewers for Adoption 5th Edition recommend the following:
Foul and combined sewers Ks = 1.5mm (minimum velocity should be 0.75m/ see at one third design flow)
Surface water sewers Ks = 0.6mm (minimum velocity should be 1m/sec at full pipe flow)
Hydraulic flow charts have therefore been included for the three roughness coefficients Ks of 0.3, 0.6 and 1.5mm.

CPM Concrete Drainage Systems

Pipeline design - hydraulic
Example on use of flow charts
Design of surface water sewer
Pipeline length
Difference in level between inlet and outlet
Design discharge

200m
1m
4 cubic metres/sec
(4,000 litres/sec)

to determine the size of pipe when:

a. flowing full
b. the proportional depth of flow is 0.6 (i.e. 60% full)
Solution
Hydraulic gradient
Ks for surface water sewer

1 in 200 (or 0.005)

0.6mm

a. Pipe flowing full:

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

1350mm
2.8 metres/sec

b. Pipe flowing 60% full:

Refer to the graph showing Relative.
Velocity and Discharge in a Circular pipe for any Depth of Flow.
The intersection of the horizontal proportional depth line of 0.6 with the proportional discharge and velocity curves
gives:
Proportional discharge
Proportional velocity

0.67
1.07

Therefore
Actual discharge
Average velocity

0.67 x 4
1.07 x 2.8

2.68 cubic metres/sec

3.0 metres/sec

CPM Concrete Drainage Systems

Pipeline design - hydraulic
Hydraulic flow charts
For Pipes Flowing Full Ks = 0.3mm (Colebrook-White) Water 150C

CPM Concrete Drainage Systems

Pipeline design hydraulic
Hydraulic flow charts
For Pipes Flowing Full Ks = 0.6mm (Colebrook-White) Water at 15C

CPM Concrete Drainage Systems

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

CPM Concrete Drainage Systems

Pipeline design structural design
Introduction
This section is based on BS EN 1295-1: 1998 Structural Design of Buried Pipelines Under Various Conditions of
Loading. This standard gives guidance on the nationally established methods of design. For the UK this is detailed
in A Guide to Design Loadings for Buried Rigid Pipes published by HMSO 1987 and Simplified Tables of External
Loads on Buried Pipelines published by HMSO 1992.
The charts give the maximum depth of cover for single pipelines laid in a narrow trench where there will be relief of
load due to friction at the fill/trench wall interface and where the pipe is laid in wide trench conditions.
Where special conditions apply, e.g. multiple pipelines in a single trench, pipelines supported on piles, trench
backfilled with lean concrete and delayed removal of trench sheeting, the charts may not be applicable and advice
should be sought from our Technical Department or reference made to the full publication.
Whilst the normal recommendation in the UK is to have a minimum of 1.2m cover (measured from the top of the
pipe barrel to the finished road surface) under roads and 0.9m elsewhere, it is sometimes necessary to lay pipes at
less cover and the charts have been prepared with a minimum cover of 0.6m in Roads and Fields, etc. However,
special precautions should be taken to minimise the risk of mechanical damage during future excavations and
reinstatement of other services, agricultural machinery, etc.
The charts are based on the loadings likely to be encountered when installation, including reinstatement, is
complete and care must be taken to ensure that the concentrated load due to construction traffic does not exceed
the design surcharge loads given.
For a full structural analysis contact our Technical Department who can provide detailed calculations and
recommendations on bedding design.

Bd

Bd

Bd

min
300mm

Bc

Bc

Bc

CPM Concrete Drainage Systems

Pipeline design structural design
Bedding class and factors
The load-bearing capacity of a concrete pipeline is dependent both on the strength of the manufactured pipe and
on the support provided by the bedding. The bedding factor (Fm) is the ratio of the strength of the laid pipe to its
laboratory crushing test strength.
The higher the bedding factor the greater is the load carrying capacity of a given pipeline.
The methods of bedding normally used with concrete pipes are:
Bc

Bc

Bc

300

300

300

DN
Y

45

Bedding class

360 granular bed

1.5

1.9

2.2

1 Bc
Bc+200min

300

120

300

120

Bc
DN min

Bc
DN min

A unreinforced

A reinforced
o

120 unreinforced concrete cradle

120 reinforced concrete cradle

2.6

3.4

Bedding factor

180 granular bed

1 Bc
Bc+200min

Description

45 granular bed

Bedding factor

Bedding class

Description

180

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

Granular bedding
material

Key

Selected backfill
material

In-situ
concrete

Nominal size of pipe

DN

Pipe bedding requirement

mm

225 to 525

10, 14 or 20 nominal single size or 14 to 5 graded or 20 to 5 graded

600 and above

10, 14, 20 or 40 nominal size crushed rock or 14 to 5 graded or 20 to 5 graded or 40 to 5 graded

CPM Concrete Drainage Systems

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

Nominal Size
DN
225
300
375*
400
450*
500
525*
600
675*
700
750*
800
825*
900
1000
1050*
1125+
1200
1350*
1400
1500*
1600
1800
2000
2100*
2200
2400*
2500
2800
3000

EN 1916 / BS 5911-1:2002
Minimum crushing load
(Fn)
kN/m
27
36
45
48
54
60
63
72
81
84
90
96
99
108
120
126
135
144
162
168
180
192
216
240
252
264
288
300
336
360

* Denotes classic size.

+
Not kitemarked.
Notes:
1.

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

2.

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

CPM Concrete Drainage Systems

Pipeline design structural design

Safe supporting strength

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

Fm >
Where Fm
We
Fse

=
=
=

We x Fse
Fn.

Bedding factor
Total external load (See BS EN 1295 1)
Factor or safety taken as a minimum of 1.25 (see note below)

Unreinforced pipes (DN225-600 inclusive) = 1.25

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

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

CPM Concrete Drainage Systems

Pipeline design structural design
Depth of cover charts Class 120 Pipes under fields Fse = 1.25
DN

Bc

Bd

mm

mm

225

295

300

410

375

495

450

530

525

675

600

770

mm
0.7
Wide
0.85
Wide
1.05
Wide
1.15
Wide
1.20
Wide
1.35
Wide

675

860

750

940

825

985

900

1100

1050

1265

1125

1345

1200

1450

1350

1620

1500

1740

1600

1920

1800

2090

Cover Depth (m)

1.0

2.0

3.0

4.0

5.0

6.0

1.45
Wide
1.50
Wide
1.60
Wide
1.90
Wide
2.10
Wide
2.20
Wide
2.30
Wide
2.50
Wide
2.70
Wide
2.81
Wide
3.10
Wide

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

Class B
Class S

7.0

CPM Concrete Drainage Systems

Pipeline design structural design
Depth of cover charts Class 120 Pipes under main roads Fse = 1.25
DN

Bc

Bd

mm

mm

225

295

300

410

375

495

450

530

525

675

600

770

mm
0.7
Wide
0.85
Wide
1.05
Wide
1.15
Wide
1.20
Wide
1.35
Wide

675

860

750

940

825

985

900

1100

1050

1265

1125

1345

1200

1450

1350

1620

1500

1740

1600

1920

1800

2090

Cover Depth (m)

1.0

2.0

3.0

4.0

1.45
Wide
1.50
Wide
1.60
Wide
1.90
Wide
2.10
Wide
2.20
Wide
2.30
Wide
2.50
Wide
2.70
Wide
2.81
Wide
3.10
Wide

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

Class B
Class S

5.0

6.0

7.0

Sco t land S ales a nd Work s

CPM Group Ltd, 101 Main Street, Newmains, Wishaw,
Lanarkshire, ML2 9BG
Tel: 01698 386922 Fax: 01698 387167
Po lling to n Wo rks
CPM Group Ltd, Pollington, Goole,
East Riding of Yorkshire, DN14 0DU
Tel: 01405 860591 Fax: 01405 863606
Leek S ales a nd Wo rk s
CPM Group Ltd, Barnfields, Leek,
Staffordshire, ST13 5QG
Tel: 01538 380500 Fax: 01538 380510

Scotland Sales and Works

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

Hea d Of fi
fic
ce S ales and Work s
CPM Group Ltd, Mells Road, Mells, Nr Frome,
Somerset, BA11 3PD
Tel: 01179 812791 Fax: 01179 814511
sales@cpm-group.com

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Leek Sales and Works

Technical Offices

Head Office Sales and Works