t

t = PD/2S

Section Two

Steel Pipe Design

American SpiralWeld Pipe Company, LLC (ASWP), with our state of the art equipment and facility, located in Columbia, South Carolina, offers customers the highest quality spiral-welded pipe available (see Section 1 Introduction for more detail). ASWP steel pipe has many attributes that are directly related to the uniqueness of our 290,000 square-foot facility and, more importantly, the inherent properties of the steel from which pipe is formed. It is important that the designer understands these properties and how they affect the design of steel pipe.

Steel - Mechanical Properties

Modern steel making processes have resulted in excellent grain structure and control of the mechanical properties including: minimum yield strengths, minimum tensile strengths, elongation (measure of ductility), impact strength, and hardness. ASWP has the capability of forming spiral-welded steel pipe utilizing steel with a maximum yield strength up to 70,000 psi. However, for typical water and wastewater applications minimum yield strengths of between 35,000 psi and 52,000 psi are more common. This flexibility offers ASWP customers an ability to optimize pressure and structural capabilities.

Steel Benefits
Some of the benefits of steel pipe include: material properties; adaptability to different applications (e.g.: water and wastewater transmission; pump station and treatment plant piping; circulating water lines for power industry; penstocks; intakes and outfalls; aerial crossings; aqueducts; and trenchless); flexibility of flow and pressures by varying sizes and wall thicknesses; and the ability to provide a simple basis for design. Essentially, there are four basic criteria for the design of a steel pipe: Internal pressure External loads Handling Buckling (external pressure)

For many projects, the wall thickness recommended to allow reasonable handling of the pipe suffices for the remaining design conditions. AWWA M11, Steel Pipe A Guide for Design and Installation, and AISI Volume 3, Welded Steel Pipe Manual, provide excellent information for the design professional.

General Principles
Typically, water pipe should be designed based on the service conditions to which the pipe will be subjected for the projected life of the pipeline. In addition to evaluating service conditions including internal operating and transient or surge pressures; external operating and transient or live load, and vacuum pressures adequate stiffness should be provided for ease of handling of pipe both in the manufacturing facility and in the field. The following guidelines focus on the design and calculation of the required pipe wall thickness based on these service conditions. Most plate and sheet manufacturers today produce a very high quality steel using the continuous casting process. This process yields a fine grain, killed (de-oxidized) steel that is metallurgically homogeneous and exhibits excellent ductility. Steel pipe is typically manufactured from one of several steels available in varying strengths as listed in Table 2.1. Typically, higher strength steel has a marginally higher cost. For applications where the operating or design pressure exceeds 200 psi (1.2 MPa), an analysis should be performed to evaluate the potential cost or other advantages of using steel with yield strength in excess of 42 ksi (290 MPa). For the same pressure requirements, the increase in cost for using a higher strength material may be less than the costs associated with the increase in the required pipe wall thickness for a lesser strength steel. The use of higher strength steel normally has little benefit, though, for lower pressure, buried applications. In low-pressure designs, handling or other considerations, rather than internal pressure, will most often govern the selection of the pipe wall thickness.

Table 2.1
ASTM Material Designation Grade Minimum Yield Strength ksi (MPa) Minimum Tensile Strength ksi (MPa)

Steel Sheet (Coil or Flat) A139 B C D E 35 42 46 52 (242) (290) (315) (360) 60 60 60 66 (415) (415) (415) (455)

Steel Plate A36/A36M A516/A516M 55 60 65 70 36 30 32 35 38 (248) (205) (220) (240) (260) 58 55 60 65 70 (400) (380) (415) (450) (485)

When designing a steel pipe, the main design consideration is the pipes ability to withstand internal pressure. After a wall thickness has been determined based on internal pressure, including both operating and transient or surge pressures, that thickness must be checked to determine its adequacy for resisting external loads and the minimum thickness required for handling. External loads include: loads due to backfill material and potential live loads, and external pressure resulting from buckling forces. As required, the composite wall thickness for non-buried pipe (steel thickness plus cement lining thickness, when applicable) can be increased, or, for buried steel pipe, the stiffness of the pipe/backfill system can be increased to resist the external loads. The most common and most cost effective method used to increase the pipe/backfill system stiffness is to improve the quality of the backfill material and/or the level of backfill compaction. Included in this section are Tables 2.4, 2.5, and 2.6, listing allowable depths of cover for various pipe sizes, pressure classes, and values of E. The values in these tables were derived from the Barlow hoop stress and the Iowa deflection formulae, as presented in the American Water Works Association (AWWA) Manual M11, Steel Pipe A Guide for Design and Installation.

Internal Pressure
Design for internal pressure requires a two-part stress analysis. Each part of the analysis is governed by the application of the Barlow hoop stress formula, as follows:

t
Where: t

= PD/2S

P D S

= minimum, nominal specified wall thickness, in (mm) = pressure, psi (MPa) = steel cylinder outside diameter*, in (mm) = allowable design stress psi, (MPa)

*Note: ASWP standard steel cylinder outside diameters are listed in Table 2.6.

The wall thickness should first be calculated based on the maximum sustained internal operating pressure, and then calculated based on the larger of the maximum anticipated operating plus transient/surge or field-test pressure. As noted in the AWWA Manual M11, when calculating thickness due to the operating pressure, the design stress should be limited to 50% of the minimum specified yield strength of the steel. In addition, when calculating thickness due to the operating plus transient/surge or test pressure, the design stress should be limited to 75% of the minimum specified yield strength of the steel.

Handling
For handling shop applied cement mortar lined pipe the minimum required wall thickness should be limited by a D/t (outside diameter/thickness) ratio of 240. For handling pipe with a spray-applied flexible lining or no lining at all, that is also hydrostatically tested, the minimum required wall thickness should be limited by a D/t ratio of 288. Cement mortar lined pipe: Sprayed-applied flexible lined or bare pipe: D/t = 240

D/t = 288

External Loading
For buried pipe, resistance to external loading is a function of pipe stiffness and passive soil resistance under and adjacent to the pipe. These two factors work in unison to create a pipe/backfill system whose stiffness resists the earth and live loads to which the pipe is subjected. The estimated horizontal deflection of a buried pipe can be calculated by the Iowa deflection formula, as follows:

x=

DlKWr3 EI + 0.061Er3

Where:

x
Dl K W

r EI

E
Total load = W

horizontal deflection of pipe, in (mm) deflection lag factor bedding constant external load per unit length of pipe (WE + WL), lb/in (N/mm) Where: WE = earth load (dead load) WL = live load = mean radius of pipe shell, in (mm) = pipe wall stiffness, in - lb (mm-N) Where: E = modulus of elasticity [30x106 psi (207x103 MPa) for steel and 4x106 psi (27.6x103 MPa) for cement mortar] I = transverse moment of inertia per unit length of pipe wall, in3 (mm3)* = modulus of soil reaction, lb/in2 (N/mm2) * Under load, the individual components of the pipe wall (steel, mortar lining and when applicable, mortar coating) act together as laminated rings. The combined action of these elements increases the overall moment of inertia of the pipe, over that of the steel cylinder alone. The total stiffness, EI, is equal to the sum of all individual values: EsIs + ElIl + EcIc.

= = = =

r= rad

x 2

100

ius

x 2

As noted above, the pipe/backfill system pipe stiffness and passive soil resistance of the backfill plays the key role in predicting deflection. The system is the denominator of the Iowa deflection equation, where pipe stiffness is the EI term and passive soil resistance of the backfill is the 0.061Er3 term. History has shown that, in general, the most effective improvement in the systems ability to resist loading comes from increasing the passive soil resistance of the backfill and not the pipe stiffness. When the calculated deflection exceeds the allowable, improvement of the backfill material or level of compaction should be the prime consideration versus an increase in the steel wall thickness. Following are explanations of the terms used in the equation above.

Predicted Deflection Because steel pipe is designed as a flexible conduit, significant deflection can occur without damaging the product. Common practice has limited the calculated deflection to 5%, although larger deflections may not affect pipe performance. Deflection limitations are a function of the rigidity of the specific lining and coating being used. For spray-applied flexible linings and flexible coatings, AWWA M11 recommends a maximum allowable deflection of 5%. The AWWA recommendation for cement mortar lined pipe, with a flexible coating is 3%. To limit coating cracks in a cement mortar lined and cement mortar coated pipe, AWWA recommends limiting deflection to 2%. A deflection limitation of 2% is also generally recommended for a field applied cement mortar lining due to lining equipment limitations. In summary: Cement Mortar Lining x Cement Mortar Coating = 2% of pipe diameter Cement Mortar Lining x Flexible Coating = 3% of pipe diameter Flexible Lining x Flexible Coating = 5% of pipe diameter Dl, Deflection Lag Factor The deflection lag factor is a subjective multiplier used to define the projected long-term deflection of a pipe as a function of the calculated deflection at time of installation. With a wellcompacted backfill around the pipe cylinder, it is common practice to use a factor of 1.0. This is especially true for a pressurized pipe, as the internal pressure will tend to round the pipe while in service. As a result, additional settling of the backfill over time will improve the material consolidation around a circular cylinder. This improvement in consolidation will increase, not decrease, the systems capacity to resist external load. K, Bedding Constant The bedding constant is a reflection of the influence of the bedding angle on the pipes resistance to external load. With improved bedding below the springline (50% of pipe outside diameter), support to the pipe is improved resulting in decreased deflection. The range of K is from 0.110 for pipe laid on a flat trench bottom (no bedding) to 0.083 for the pipe bedded to the springline. For typical conditions encountered with the installation of steel pipe, a conservative design value of K is 0.10. 7

x,

WE, Earth Load (Dead Load) When buried in an embankment or wide trench, the settlement ratio for a flexible conduit such as steel pipe is assumed to be zero. As such, the prism of soil directly over the pipe is used as the resultant earth load. The prism dimensions are represented as a width equal to the pipe outside diameter, a height equal to the depth of cover over the top of the pipe, and a unit length of one-inch. This method is conservative as no consideration is given to potential arching action of the backfill material relative to the adjacent native soil. A conservative density of the backfill material, E, is typically taken as 120 lb/ft3 for determination of the earth load. WL, Live Load Live loads are typically a result of vehicle wheels, equipment wheels or tracks, or railroad car wheels. The accepted values for vehicle and railroad induced live loads are listed in Table 2.2. If present, live loads resulting from movement of heavy equipment over pipelines must be given special consideration. For extreme loading conditions reference: Spangler, M.G. & Handy, R.L., Soil Engineering, Harper & Row, Publishers, New York, NY (4th ed., 1982), or contact ASWP. EI, Pipe Stiffness As noted previously, the pipe stiffness EI is equal to the sum of all individual stiffness values for each of the laminar rings of the pipe structure; that is EsIs plus ElIl plus EcIc, for the cylinder, cement mortar lining, and cement mortar coating respectively. The stiffness of each of the rings is calculated using the modulus of elasticity of the component, in psi, and the moment of inertia as a per unit length value, defined as t3/12. E, Modulus of Soil Reaction The modulus of soil reaction is an empirical measurement of a given compacted soils resistance to movement. Modification of the value of E, accomplished by improving the backfill material and/or improving the level of compaction, is the most common and most cost effective way to improve the stiffness of the pipe/backfill system. In recent years, designers have taken note of the inherent increase in the E value relative to increased depth of cover. Most notably, James D. Hartley and James M. Duncan of the University of California, Berkeley, published Evaluation Of The Modulus Of Soil Reaction E, And Its Variation With Depth. Their research defined E as a function of soil type, degree of compaction, and depth of cover. Their results are listed in Table 2.3.

Table 2.2 Highway HS-20 Loading Height of Cover ft 1 2 3 4 5 6 7 8 Load psi 12.5 5.6 4.2 2.8 1.7 1.4 1.2 0.7 Railroad E-80 Loading Height of Cover ft 2 5 8 10 12 15 20 30 Load psi 26.4 16.7 11.1 7.6 5.6 4.2 2.1 0.7

For extreme loading conditions reference: Spangler, M.G. & Handy, R.L., Soil Engineering, Harper & Row, Publishers, New York, NY (4th ed., 1982). Table 2.3 E, Modulus of Soil Reaction psi
Type of Soil Depth of Cover (ft)
Standard AASHTO Relative Compaction

85%

90%

95%

100%

Fine-grain soils with less than 25% sand content (CL, ML, CL-ML) Coarse-grained soil with fines (SM, SC) Coarse-grained soil with little or no fines (SP, SW, GP, GW) Crushed stone*

0-5 5-10 10-15 15-20 0-5 5-10 10-15 15-20 0-5 5-10 10-15 15-20 na

500 600 700 800 600 900 1,100 1,300 700 1,000 1,050 1,100 3,000

700 1,000 1,200 1,300 1,000 1,400 1,700 2,000 1,000 1,500 1,600 1,700 3,000

1,000 1,400 1,600 1,800 1,200 1,800 2,300 2,700 1,600 2,200 2,400 2,500 3,000

1,500 2,000 2,300 2,600 1,900 2,700 3,300 3,800 2,500 3,300 3,600 3,800 3,000

*Crushed stone not included in Hartley-Duncan, E of 3,000 psi minimum as determined by U.S. Bureau of Reclamation. This value is extremely conservative as values from 7,000 to 16,000 psi have been witnessed in practice.

As compaction of the backfill material is the single most important factor in developing resistance to external loads for the pipe, a minimum AASHTO Standard relative compaction of 85% is recommended for all steel pipe installations. Results of evaluation of allowable cover by varying pressure class (in effect, varying wall thickness), versus evaluation of allowable cover by varying E (constant wall thickness) are shown in Table 2.4 and Table 2.5. 9

Table 2.4 Allowable Fill Heights* for Various Pressure Classes, E = 1,000-psi
Nominal Pipe ID 24-in 30-in 36-in 42-in 48-in 54-in 60-in 64-in 66-in 72-in 78-in 84-in 90-in 96-in 102-in 108-in 114-in 120-in Class 150 25-ft 23-ft 23-ft 23-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft Class 200 25-ft 23-ft 23-ft 23-ft 23-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft 22-ft Class 250 25-ft 24-ft 23-ft 24-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft 23-ft

Table 2.5 Allowable Fill Heights* for Various E Values

Nominal Pipe ID 24-in 30-in 36-in 42-in 48-in 54-in 60-in 64-in 66-in 72-in 78-in 84-in 90-in 96-in 102-in 108-in 114-in 120-in E = 1,500-psi 35-ft 34-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft 33-ft E = 2,000-psi 46-ft 44-ft 44-ft 44-ft 44-ft 44-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft 43-ft E = 2,500-psi 56-ft 55-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft 54-ft E = 3,000-psi 67-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft 65-ft

* For both allowable fill height (H) tables, Table 2.4 and Table 2.5, calculations were based on the following: ASTM A139, Grade C steel with a D/t of 240 (0.135-in min.) minimum yield (Sy) of 42 ksi, allowable deflection (x) of 3.00%, deflection lag factor (Dl) of 1.0, bedding constant (K) of 0.10, and a soil density (E) of 120 lb/ft3. The composite EI of the steel cylinder and the cement mortar lining was used in all deflection calculations.

10

An obvious conclusion that can be observed by using these tables is that there is no economical justification for increasing the steel thickness to enable the pipe/backfill system to accept additional cover. The appropriate approach is to increase the quality of the soil bedding envelope.

External Pressure or Vacuum

ABOVE GROUND OR SUBAQUEOUS UNBURIED INSTALLATION When pipelines are installed above ground, and the pipe is subject to vacuum, the wall thickness must be designed to withstand collapse due to the vacuum. Analysis should be based on the pipe functioning in the open atmosphere, absent of support from any backfill material. The collapsing pressure should be determined as follows:

Pc = 2Es(ts/dn)3/(1-vs2) + 2El(tl/dn)3/(1-vl2) + 2Ec(tc/dn)3/(1-vc2)

Where: Pc ts tl tc dn Es El & Ec vs vl & vc = = = = = = = = = collapsing pressure, psi (MPa) steel cylinder wall thickness, in (mm) cement lining thickness, in (mm) cement coating thickness, in (mm) diameter to neutral axis of shell, in (mm) modulus of elasticity for steel, 30x106 psi (207x103 MPa) modulus of elasticity for cement mortar, 4x106 psi (27.6x103 MPa) Poissons ratio for steel 0.30 Poissons ratio for cement mortar 0.25

BURIED INSTALLATION History has shown that buried pipelines supported by a well-compacted, granular backfill will not buckle due to vacuum. When confirmation of this stability is desired, analysis of the external loads relative to the pipe stiffness can be performed. The sum of external loads should be less than or equal to the pipes allowable buckling pressure, qa, which is determined by the following:

qa = (1/FS)(32RwBE(EI/D3))1/2

11

qa = (1/FS)(32RwBE(EI/D3))1/2
Where: qa FS Rw allowable buckling pressure, psi design factor = 2.0 water buoyancy factor 1-0.33(hw/H), 0<hw<H, but not <.67 where H = height of fill over pipe, ft hw = height of water over pipe, ft = empirical coefficient of elastic support, dimensionless = 1 1 + 4e(-.065H) = modulus of soil reaction, psi = pipe wall stiffness, in - lb where E = modulus of elasticity (30x106 psi for steel and 4x106 psi for cement mortar) I* = transverse moment of inertia per unit length of pipe wall, in3 = outside diameter, in = = = =

E EI

*Under load, the individual components of the pipe wall (steel, mortar lining and, when applicable, mortar coating) act together as laminated rings. The combined action of these elements increases the overall moment of inertia of the pipe, over that of the steel cylinder alone. The total stiffness, EI, is equal to the sum of all individual values : EsIs + ElIl + EcIc.

To determine the external loads on a pipe, the following equation applies:

whw + RwWc/D + Pv < qa

Where: qa

hw Rw Wc D Pv

= = = = = = =

allowable buckling pressure, psi specific weight of water (0.0361 lb/in3) height of water above pipe, in water buoyancy factor vertical soil load on pipe per unit length, lb/in outside diameter, in internal vacuum pressure, psi

At times, live loads may need to be addressed when analyzing potential buckling. Simultaneous application of both live loads and internal vacuum are not normally considered. When addressing live loads, the following equation applies:

whw + RwWc/D + WL/D < qa

Where: WL = live load on pipe per unit length, lb/in

12

Table 2.2, is a reconfiguration of standard HS-20 highway and E-80 railroad loading, which will simplify determination of the live load. In either of the above cases, when the qa is not adequate to resist the buckling loads, the soil envelope should first be investigated to increase the allowable E.

Trench Configuration
An accepted industry standard suggests that the minimum trench width be no less than the outside diameter of the pipe plus 24-inches (OD + 24-in). This recommended trench width provides the minimum, practical space on each side of the pipe to compact the bedding and backfill material as required to obtain the necessary degree of relative compaction. For installation in areas with extremely poor native soil (frequently taken as less than 4 blows per foot), the suggested total trench width should be equal to approximately twice the pipes outside diameter (OD x 2). This trench width will have the net affect of reducing the lateral pressure of the embedment material against the poor native soil trench walls. Placement of compacted bedding and backfill material to a height equivalent to 0.7 times the pipe outside diameter (0.7D) should be adequate for structural support of the pipe.

SELECT

BEDDING

MIN.

MIN.

Suggested Backfill for Welded Steel Pipe

13

Design Example
The following will outline a sample design for a 72 pipeline based on the criteria listed:
Given: Pipe Outside Diameter (OD) Working Pressure (Pw) Total Surge Pressure (Ps) Field Test Pressure (Pt) Vacuum Pressure Height of Cover (H) Height of Water Above Pipe (hw) Cylinder Material Allowable Stress at Pw Allowable Stress at Ps or Pt Embedment Material Compaction Pipe Lining Pipe Coating 74.250-in 160-psi 220-psi 200-psi 8-psi 4-18-ft 4-ft ASTM A139, Grade C (42 ksi minimum yield) 50% of minimum specified yield 75% of minimum specified yield Coarse-grained with fines AASHTO 90% relative compaction 0.5-in cement mortar-in accordance with AWWA C205 80 mil tape-in accordance with AWWA C214

1. DESIGN FOR INTERNAL PRESSURE The pipe must be designed for each of the three pressure conditions listed above: operating or working pressure; surge or transient pressure; and field test pressure. The largest of the three (3) calculated values for the wall thickness will govern in the design. Refer to Internal Pressure, page 4. t = PD/2S a. Thickness required at operating or working pressure: tPw = 160(74.250) = 0.283-in 2(.5)(42,000) b. Thickness required at operating plus surge or transient pressure: tPs = 220(74.250) = 0.259-in 2(.75)(42,000) 0.283-in

c. Thickness required at field test pressure: tPt = 14 200(74.250) = 0.236-in 2(.75)(42,000)

Based on the calculated values for internal pressure, condition a, Thickness required for operating or working pressure, governs. Therefore, the nominal wall thickness of the pipe should be 0.283-in to resist internal pressure. The next step in the design process is to insure that this calculated thickness will be adequate with respect to handling. 2. CHECK FOR HANDLING In this example the pipe is lined per AWWA C205 with cement mortar and coated per AWWA C214 with an 80-mil polyethylene tape. Refer to Handling, page 5. Cement mortar lined pipe: D/t = 240 74.250/t = 240 Required thickness for handling t = 0.309-in

As the thickness required for handling is greater than the thickness required for internal pressure, the minimum thickness required for handling will govern. Therefore the nominal wall thickness for the pipe should be 0.309-in. Next this thickness (0.309-in) should be used to check the adequacy of the pipe/soil system stiffness for resistance to external loads. With this thickness design (handling), this pipe will be able to withstand an operating pressure of 175-psi and a surge/ test pressure of 262-psi. 3. CHECK FOR EXTERNAL LOAD The value for the modulus of soil reaction, E, will vary with depth of cover as noted in Table 2.3, therefore, the deflection should be verified for the maximum cover for each E value. For simplicity, the following evaluation is based on the minimum cover of 4-ft and the maximum cover of 18-ft. Refer to External Loading, page 5. a. External Load at 4-ft of cover.

x =
Where:

DlKWr3
3

EI + 0.061Er

15

Deflection Lag Factor (Dl) = 1.0 Bedding Constant (K) = 0.10 Earth Load (dead load + live load): W = WE + WL

WE = 4(120)74.250/12 = 2,970-lb/ft of pipe WE = (2,970)/12 = 248-lb/in of pipe Per Table 2.2, Live Load at 4-ft is 2.8-psi, therefore WL = 2.8(OD) WL = 2.8(74.250) WL = 208-lb/in of pipe W = WE + WL W = (248) + (208) W = 456-lb/in of pipe Mean radius of pipe (r) = r = (OD tc tl)/2 r = (74.250-0.309-0.5)/2 = 36.72-in From Table 2.3, E= 1,000 psi for embedment material that is coarse-grained with fines, compacted to 90% relative compaction, at 4-ft of cover.

Pipe Stiffness (EI) EI = ESIS + ElIl = (30x106(0.309)3/12) + (4x106(0.5)3/12) = 73,759 + 41,667 = 115,426 in-lb

x = x =

DlKWr3 EI + 0.061Er3

= 1.0(0.10)(456)(36.72)3 3 115,426 + 0.061(1000)(36.72)

0.72-in

The allowable deflection for Cement Mortar Lining x Flexible Coating = 3% of the pipe diameter.

x-ALLOWABLE = x-ALLOWABLE =
True, therefore x is OK.

0.03(72) 2.16-in

x < x-ALLOWABLE = 0.72-in (1%) < 2.16-in (3%),

The pipe design for 4-ft of cover is satisfactory for the defined conditions.

b. External Load at 18-ft of cover.

x =
Where:

DlKWr3 EI + 0.061Er3

1.0 0.10 13,365-lb/ft of pipe 1,114-lb/in of pipe than 8-ft, WL = 0

Deflection Lag Factor (Dl) = Bedding Constant (K) = Earth Load (dead load): W = WE + *WL W = 18(120)74.250/12 = W = (13,365)/12 = *Note: Depth of cover is greater

Mean radius of pipe (r) = 36.72-in r = (OD tc tl)/2 r = (74.250-0.309-0.5)/2 = 36.72-in From Table 2.3, E= 2,000 psi for embedment material that is coarse-grained with fines, compacted to 90% relative compaction, at 18-ft of cover. Pipe Stiffness (EI) EI = ESIS + ElIl = (30x106(0.309)3/12) + (4x106(0.5)3/12) = 73,759 + 41,667 = 115,426 in-lb

x =

x = __1.0(0.10)(1114)(36.72)3
115,426 + 0.061(2000)(36.72)

DlKWr3 EI + 0.061Er3

=
3

0.90-in

The allowable deflection for Cement Mortar Lining x Flexible Coating = 3% of the pipe diameter.

x-ALLOWABLE = x-ALLOWABLE =

0.03(72) 2.16-in

x < x-ALLOWABLE = 0.90-in < 2.16-in, True, therefore x is OK.

The pipe design for 18-ft of cover is satisfactory for the conditions defined.

4. CHECK FOR BUCKLING In this example, confirmation of resistance to buckling will include an analysis of the external loads relative to the pipe stiffness. The sum of external loads must be less than or equal to the pipes allowable buckling pressure, qa, which for this example is determined as follows: a. Buckling design for 4-ft of cover.

qa = (1/FS)(32RwBE(EI/D3))1/2
Where: qa FS Rw = allowable buckling pressure, psi = 2.0 = 1-0.33(hw/H) = 1-0.33(4)/(4) = 0.67 B B B E = = 1 1 + 4e(-.065H) 1
(-.065)(4)
.

1 + 4e = 0.2448 = 1000 psi

Pipe Stiffness (EI) EI = ESIS + ElIl = (30x106(0.309)3/12) + (4x106(0.5)3/12) = 73,759 + 41,667 =115,426 in - lb D qa = 74.250-in

= (1/FS) 32RwBE(EI/D3) = 1 2

1/2

32 (0.67)(0.2448)(1000) 115,426 409,345

1/2

= 19.24 psi External Loads are now calculated and must not exceed qa.

qa

> whw + RwWc + Pv D

18

Where: qa

w
hw Rw Wc D Pv 19.24 19.24

= 19.24 psi = 0.0361 lbs/in3 48-in 0.67 248-lbs/in 74.250-in 8.0 psi (0.0361)(48) + (0.67)(248) + 8.0 74.250 > 11.97 External Loading OK for 4-ft of cover. = = = = = >

b. Live load consideration for 4-ft of cover.

qa

w
hw Rw Wc WL D Pv 19.24 19.24

qa

= 19.24 psi

> wHw + RwWc + WL D D

= 0.0361 lbs/in3 = 48-in = 0.67 = 248 lbs/in = 208 lbs/in = 74.250-in = 8.0 psi > (0.0361)(48) + (0.67)(248) + _208_ 74.250 74.250 > 6.77 Live Loading OK for 4-ft of cover.

c. Buckling design for 18-ft of cover.

qa
Where: qa FS Rw

= (1/FS)(32RwBE(EI/D3))1/2
= allowable buckling pressure, psi = 2.0 = 1-0.33(hw/H) = 1-0.33(4)/(18) = 0.93

1 1 + 4e
(-.065H)

19

B B E

1 1 + 4e(-.065)(18) = 0.4461 = 2000 psi

Pipe Stiffness (EI) EI = ESIS + ElIl = (30x106(0.309)3/12) + (4x106(0.5)3/12) = 73,759 + 41,667 = 115,426 in- lb D = 74.250-in 1/2 qa = (1/FS) 32RwBE(EI/D ) = 1 2 qa

32 (0.93)(0.4461)(2000) 115,426 409,345

1/2

= 43.26 psi

External Loads are now calculated and must not exceed qa.

qa
qa w hw Rw Wc D Pv 43.26

> wHw + RwWc + Pv D

= 43.26 psi = 0.0361 lbs/in3 = 48-in = 0.93 = 1,114 lbs/in = 74.250-in = 8.0 psi > (0.0361)(48) + (0.93)(1,114) + 8.0 74.250 > 23.69 psi External Loading OK for 18-ft of cover.

43.26

Normal live loads at depth exceeding 8-ft are insignificant and therefore no calculation will be required at 18-ft of cover. 5. DETERMINE FACTORY TEST PRESSURE t = PD/2(.75S) or P= 2t(.75S)/D P = (2)(.309)(.75)(42,000) 74.250 20 = 262 psi 262 psi

Table 2.6

CEMENT MORTAR LINED PIPE WITH FLEXIBLE COATING

Nom. I.D. (in) Cylinder O.D. (in) Mortar Lining (in) Pressure Class (psi) Design t* (in) Pipe Weight** (lb/ft) E = 1000 psi H*** Soil wt. (ft) (lb/ft) E = 3000 psi H*** Soil wt. (ft) (lb/ft)

24

30

36

42

48

25.375 25.375 25.375 25.375 25.375 25.375 31.375 31.375 31.375 31.375 31.375 31.375 37.500 37.500 37.500 37.500 37.500 37.500 37.500 43.750 43.750 43.750 43.750 43.750 43.750 43.750 49.750 49.750 49.750 49.750 49.750 49.750 49.750

0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.375 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500

150 200 250 300 400 500 150 200 250 300 400 500 150 175 200 250 300 400 500 150 175 200 250 300 400 500 150 175 200 250 300 400 500

0.135 0.135 0.151 0.181 0.242 0.302 0.135 0.149 0.187 0.224 0.299 0.374 0.156 0.156 0.179 0.223 0.268 0.357 0.446 0.182 0.182 0.208 0.260 0.313 0.417 0.521 0.207 0.207 0.237 0.296 0.355 0.474 0.592

70.3 70.3 74.6 82.6 98.5 114.4 87.1 91.8 104.1 116.4 140.8 165.1 112.5 112.5 121.6 138.9 156.6 191.4 226.1 163.0 163.0 175.0 198.9 222.7 270.3 317.6 198.6 198.6 214.1 245.1 275.9 337.5 398.7

25.0 25.0 25.4 26.4 29.7 35.2 23.3 23.5 24.2 25.2 28.5 34.0 22.7 22.7 23.0 23.6 24.6 27.9 33.4 23.1 23.1 23.3 24.0 25.0 28.3 33.8 22.7 22.7 23.0 23.6 24.2 28.0 33.5

6344 6344 6445 6699 7536 8932 7310 7373 7593 7907 8942 10668 8513 8513 8625 8850 9225 10463 12525 10106 10106 10194 10500 10938 12381 14788 11293 11293 11443 11741 12040 13930 16666

67.2 67.2 67.5 68.4 71.5 76.7 65.8 66.0 66.5 67.4 70.5 75.9 65.4 65.4 65.6 66.1 67.0 70.2 75.4 65.7 65.7 65.8 66.4 67.3 70.4 75.7 65.4 65.4 65.6 66.1 66.7 70.2 75.4

17052 17052 17128 17357 18143 19463 20645 20708 20864 21147 22119 23814 24525 24525 24600 24788 25125 26325 28275 28744 28744 28788 29050 29444 30800 33119 32537 32537 32636 32885 33183 34925 37512

23

21

Table 2.6

CEMENT MORTAR LINED PIPE WITH FLEXIBLE COATING

Nom. I.D. (in) Cylinder O.D. (in) Mortar Lining (in) Pressure Class (psi) Design t* (in) Pipe Weight** (lb/ft) E = 1000 psi H*** Soil wt. (ft) (lb/ft) E = 3000 psi H*** Soil wt. (ft) (lb/ft)

54

60

64

66

72

55.750 55.750 55.750 55.750 55.750 55.750 55.750 61.750 61.750 61.750 61.750 61.750 61.750 61.750 65.875 65.875 65.875 65.875 65.875 65.875 65.875 67.875 67.875 67.875 67.875 67.875 67.875 67.875 74.250 74.250 74.250 74.250 74.250 74.250

0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500

150 175 200 250 300 400 500 150 175 200 250 300 400 500 150 175 200 250 300 350 400 150 175 200 250 300 350 400 150 175 200 250 300 350

0.232 0.232 0.265 0.332 0.398 0.531 0.664 0.257 0.257 0.294 0.368 0.441 0.588 0.735 0.274 0.274 0.314 0.392 0.471 0.549 0.627 0.283 0.283 0.323 0.404 0.485 0.566 0.646 0.309 0.309 0.354 0.442 0.530 0.619

237.4 237.4 256.9 295.8 334.6 411.9 488.8 279.4 279.4 303.3 351.0 398.7 493.6 588.0 310.1 310.1 337.3 391.7 445.9 500.0 554.0 325.5 325.5 354.4 412.2 469.7 527.2 584.5 377.1 377.1 411.7 480.8 549.7 618.5

22.5 22.5 22.7 23.4 24.4 27.8 33.3 22.4 22.4 22.6 23.3 24.3 27.6 33.2 22.3 22.3 22.5 23.2 24.2 25.7 27.6 22.3 22.3 22.5 23.2 24.2 25.6 27.5 22.2 22.2 22.5 23.1 24.1 25.6

12544 12544 12655 13046 13603 15499 18565 13832 13832 13956 14338 15005 17043 20501 14690 14690 14822 15283 15942 16930 18182 15136 15136 15272 15747 16426 17376 18666 16484 16484 16706 17152 17894 19008

65.3 65.3 65.4 66.0 66.9 70.1 75.4 65.2 65.2 65.4 66.0 66.9 70.0 75.3 65.2 65.2 65.4 65.9 66.8 68.2 70.0 65.2 65.2 65.4 65.9 66.8 68.2 70.0 65.2 65.2 65.4 65.9 66.8 68.2

36405 36405 36461 36795 37297 39081 42036 40261 40261 40385 40755 41311 43225 46498 42951 42951 43082 43412 44005 44927 46113 44255 44255 44390 44730 45341 46291 47513 48411 48411 48560 48931 49599 50639

22

24

Table 2.6

CEMENT MORTAR LINED PIPE WITH FLEXIBLE COATING

Nom. I.D. (in) Cylinder O.D. (in) Mortar Lining (in) Pressure Class (psi) Design t* (in) Pipe Weight** (lb/ft) E = 1000 psi H*** Soil wt. (ft) (lb/ft) E = 3000 psi H*** Soil wt. (ft) (lb/ft)

78

84

90

96

102

80.250 80.250 80.250 80.250 80.250 80.250 86.500 86.500 86.500 86.500 86.500 86.500 92.000 92.000 92.000 92.000 92.000 92.000 98.250 98.250 98.250 98.250 98.250 98.250 104.500 104.500 104.500 104.500 104.500 104.500

0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500

150 175 200 250 300 350 150 175 200 250 300 350 150 175 200 250 300 350 150 175 200 250 300 350 150 175 200 250 300 350

0.334 0.334 0.382 0.478 0.573 0.669 0.360 0.360 0.412 0.515 0.618 0.721 0.383 0.383 0.438 0.548 0.657 0.767 0.409 0.409 0.468 0.585 0.702 0.819 0.435 0.435 0.498 0.622 0.746 0.871

428.9 428.9 469.4 550.1 630.7 711.0 486.3 486.3 533.3 627.2 720.8 814.2 539.7 539.7 592.9 699.1 805.0 910.6 603.6 603.6 664.3 785.4 906.2 1026.8 671.0 671.0 739.6 876.7 1013.4 1149.8

22.2 22.2 22.4 23.1 24.1 25.5 22.2 22.2 22.4 23.1 24.1 25.5 22.1 22.1 22.4 23.0 24.1 25.5 22.1 22.1 22.4 23.0 24.1 25.5 22.1 22.1 22.4 23.0 24.0 25.5

17816 17816 17976 18538 19340 20464 19203 19203 19376 19982 20847 22058 20332 20332 20608 21160 22172 23460 21713 21713 22008 22598 23678 25054 23095 23095 23408 24035 25080 26648

65.2 65.2 65.4 65.9 66.8 68.2 65.2 65.2 65.4 65.9 66.9 68.2 65.2 65.2 65.4 66.0 66.9 68.2 65.2 65.2 65.4 66.0 66.9 68.2 65.3 65.3 65.4 66.0 66.9 68.3

52323 52323 52484 52885 53607 54731 56398 56398 56571 57064 57869 58993 59984 59984 60168 60720 61548 62744 64059 64059 64256 64845 65729 67007 68239 68239 68343 68970 69911 71374

25

23

Table 2.6

CEMENT MORTAR LINED PIPE WITH FLEXIBLE COATING

Nom. I.D. (in) Cylinder O.D. (in) Mortar Lining (in) Pressure Class (psi) Design t* (in) Pipe Weight** (lb/ft) E = 1000 psi H*** Soil wt. (ft) (lb/ft) E = 3000 psi H*** Soil wt. (ft) (lb/ft)

108

114

120

110.500 110.500 110.500 110.500 110.500 110.500 116.500 116.500 116.500 116.500 116.500 116.500 122.625 122.625 122.625 122.625 122.625 122.625

0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500

150 175 200 250 300 350 150 175 200 250 300 350 150 175 200 250 300 340

0.460 0.460 0.526 0.658 0.789 0.921 0.485 0.485 0.555 0.693 0.832 0.971 0.511 0.511 0.584 0.730 0.876 0.993

738.9 738.9 815.7 968.9 1121.9 1274.4 810.0 810.0 895.4 1065.8 1235.8 1405.3 885.9 885.9 980.5 1169.3 1357.7 1508.0

22.1 22.1 22.4 23.0 24.0 25.5 22.1 22.1 22.4 23.0 24.0 25.5 22.1 22.1 22.3 23.0 24.0 25.2

24421 24421 24752 25415 26520 28178 25747 25747 26096 26795 27960 29708 27100 27100 27345 28204 29430 30902

65.3 65.3 65.4 66.0 66.9 68.3 65.3 65.3 65.5 66.0 66.9 68.3 65.3 65.3 65.5 66.1 67.0 68.0

72157 72157 72267 72930 73925 75472 76075 76075 76308 76890 77939 79570 80074 80074 80319 81055 82159 83385

*t is based on 42 ksi minimum yield strength steel and .135 or D/240 minimum thickness. **Based on steel cylinder and cement lining thickness noted. ***Based on 120 lb/ft3 soil density and a 3% allowable deflection in a wide trench or embankment condition. Note: This table represents external loading conditions only and does not include any buckling evaluation.

24

A Subsidiary of ACIPCO P.O. Box 2727, Birmingham, AL 35202 Customer Service: 1-866-442-ASWP (2797) Email: rcarpenter@acipco.com Internet: www.acipco.com/aswp

10/03-5M