EUROPEAN STANDARD EN 641 NORME EUROPEENNE EUROPAISCHE NORM October 1994 cs 23,040.30; 23.040..50 Descriptors: Water pipelines, pressure pipes, potable water, water pipes, concrete tubes, reinforced concrete, armatures, meta plates, specifications, computation, equipment specifications, dimensions, tests English version Reinforced concrete pressure pipes, cylinder type, including joints and fittings Tuyaux pression en béton armé A ine en t61 Stahlbetondruckrohre mit Blechaante! Joints et pitens spéciales compris. CinschIteBl ch Rohrverbindungen und Forms tucks This European Standard was approved by CEN on 1994-10-25. CEN panbers are bound to comply with the CEN/CENELEC Internal Hegulatione cch et iputate tho conditions for oiving this European Standard the sta of « ations] standard witha Up-to-date Tists and bibliographical references concerateg such nattonal standards may be obtained on application to the Central Secretariat or to any CEN mearber. The European Standards exist 1a three official versions (English, French, Garman). A varston in any other Tangvage ade by ‘cranslation under. the responsibility of a CEN manbar into tts own language and notifies to the Cantral Secretariat has the same status as the official versions. CEN monbers are the nattonal standards bodies of Austria, Belgiun, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Laxenbourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom. CEN Eurapean Constttee for Standardization Contes Europhen de Normalisation Euranitsches Komitee fur Nonmung Central Secretariat: rue de Stassart,26 8-1050 Brussels © 1936 Copyright reserved to CEN monbers o ae Ref. No. EN 641:1994 Epage 2 EN 641:1994 CONTENTS LIST Foreword Introduction Scope Materials Design and fabrication of pipe 1 General requirements 1.1. General 1.2 Wall thickness 2 Design ot pipe 2.1 Reinorced concrete pe. steel cywncer type, not oF 2.2 Reinforced concrete mp2, steel cylincer type, pretensioned Reinforcement 1 Circumteremtal reinforcement 2 Longitudinal remtorcement 3. Positionning and cover 0 Concrete and monar 1 Mix design 2 Concrete sirengtn sensionea 21 Factory testing 1 Concrete test 2 Pipe test Annexes Annex A (Informative) > Typical Design Procedure exciuaing pretensionea type pipe Annex 8 (Intormative) : Typical Design Procedure tor pretensiones type pipePage 3 EN 641:1994 FOREWORD :ropean Standard lor concrete o19es is a stanaard which was prepared by WG § “Concrete pipes” and aisinoution of water inlended for human consumption 2 MATERIALS tatenals are specilied in clause 5 of EN 636 ‘Common Requirements). An aagitiona: requirement 1s specitied as lollows The maximum size of the aggregate snall no: exceed cne third of the concrele wall thickness cm eltner siae of ine steel cynaer a DESIGN AND FABRICATION OF PIPE 3.1 General requirements 2.4.1 Generar The pipe shall have the following principal atures + A welded steel cylinaer win steel joint nngs welded to each end, + A reiniorcing cage or cages, in tne form of 3 continuous helix of sieel wire weiseo on to longitucinal bars, concentric steel hoops welded on 10 longitudinal bars, or weiged sie! taone, The cage can also be inthe form of a steel roa wrapped directly on to the steel cylincer or on 10 a lest concrete layer covenng ine steel cylinder + A wall of dense concrete covering the steel cylinder and reintorcing cage or cages botn inside ano outsiae. + joint so designed nat it will be watenight unger all conditions of service, esther using an zlastomenc sealing ring or witn the steel end ings welded together on site. 3.1.2 Walt tnickness Table 1 shows the minimum design thickness of pipe wall and the minimum design thickness of concrete lining for each type of pipe, Actual design loading conatiions may require an increase in wall thickness, At tne spigot section of the pipe. tne snape of the steel end ring may require the Inickness of Ihe lining to be less than that specttied in Table 1, The Internat diameter shall be maintained within the tolerance specified by the Common ReauirementsTable 1 : Minimum design thickness tmiq Minimun design thickness of the concrete lining Ninn including the thickness of the cylinder Amin Aina pretensioned OND cylinder pipe (mm) (mm) (mm) 250 1s 50 40 300 15 50 40 400 15 50 40 500 | 20 55 45 00 | 20 60 35 zoo | 20 65 45 soo | 20 70 45 300 | 20 75 45 too | 20 80 23 a0 | 25 85 56 1200 | 25 95 56 3250 | 25 300 50 1400 | 25 410 50 1500 | 25 15 i600 | 25 125 1800 | 30 140 2000 | 40 155 2100 40 165 2200 40 170 2400 | 45 185 2500 | 43 195 i 2600 | «3 200 ! 2e00 | 43 215 } 3000 | 5 220 | 3200 45 230 { 3500 | 50 250 | 4000 55 290 3.2 Design of pipe 3.2.1 Reinforced concrete pipe. siee! cylincer type, not pretensioned The reinforcement of the pipe shall consist of 2 welded steel cylinder surrounded by one or more cages fabricated {rom concentnc steel wire hoops. welded steel fabric or helically wound steel wire properly spaced and supported with longitudinal Feintorcing or direcily wrapped on 10 a lirst concrete layer covering the cylinger The cages can be either circular or elliptical. In pipes designed lor a maximum design pressure of more than 200 KPa, the cage shall be circular when the reinforcement consists of one cage Page 5 EN 641:1994 only, and the extemal cage shall be circular when. the reinforcement consists of 2 cages or more The minimum thickness of the steel cylinder shatt be 1.5 mm. The maximum centreline spacing of circumterentials shall be 100 mm, The pipes shail be designed to resist the flexural and hoop stresses, resulting trom each of the following conditions. + a combination of maximum design pressure and dead loads ; + a combination of design pressure, dead loads and ive loads, Under these given conditions, the tensile stresses of the stee! calculated as indicated in the typical Gesign procedure shown in Informative Annex A. shall not be greater than two thirds of the yield strength of the steel 3.2.2 Reinforced concrete pipe, steel cylinder type, pretensioned The reinforcement of the pipe shall consist of 2 welded steel cylinder on which a steel wire 1s, cirectly wrapped under low tension, he pipe steel content and disposition shall be such that the pipe shall withstand the hydrostatic pressure in both service and transient conditions the thickness of the steel cylinder, plus tne size and pitch of the helixes shall be such that the stress in steel shall not exceed haif of the yield strength of steel when the pipe Is subjected to the design pressure + Iwo thirds of the yield strength of steel wher the pipe is subjected to the maximum desicn pressure The yield strength considered shall be the lowes value of the steel cylinder and the spirals. The increase of the diameter of the pipe at ne sonngline due to external loads is calculated anc checked in companson with a maximum allowable value A x= 9.8 10802-2.2 1090; Where Oj and A x are given in mm, 0; being he design internal diameter of the pipe.Page 6 EN 641:1994 Informative Annex B gives a typical design procedure for calculating stresses under pressure and deformations of pipe when subjected 10 extemal loading, 3.3 Reintorcement 3.3.1 Circumferential reinlorcement The circumterential reinforcement shall consist of steel wire hoops with joints bull or lap welded steel wire formed in a continuous helix wiln joints bull or lap welded or welded fabne shaped and lap welded. To ensure quality of joinis representative specimens shail be tensile tesed dung which the strength of the weld shall exceed the strength of the parent steel The clear space between circumferential wires. shall be not less than 1,25 times the maximum size of the coarse aggregate or 12 mm, whichever 1s, he greater For pretensioned concrete pressure pipe the circumferential reintorcement shall consist of a steel wire directly wound on to the steel cylinder The wrapping tension shall be not less than 5OMPa, and not greater than 70 MPa. The tensile stress shall be checked during the winding operation. For the pretensioned pipe, a cement slurry shall be projected on to the steel cylinder prior 10 wrapping of the steel rod reiniorcement. This slurry shall consist of 1,2 kg ol cement to 1 itre of water, and shall be applied at a rate of nol less than 1 le per 2 square meires, 3.3.2 Longiuainal reintoreement The circumferential reintorcement in cages shall be accurately spaced and ngidly assembled by Mears of longitudinal bars or wires securely, attached so that the cage is maintained in proper shape and position during ine casting of the pipe Reinlorcement cages tormed by steel wire wrapped directly on to the steel cylinder or on 0 a concrete layer external to the cylinder do noi require longiudinal bars. 3.3.3 Posiienniag ana cover > steel! Reinforcement cages may be circular, ellipuical or 2 combination of both. The minimum cover to steel shall be one times the maximum size of aggregate or + 15 mm for pipe less than 800 OND 20 mm for pipe equal to or greater than 800 ond whichever s tre greater 3.4 Concrete and mortar 3.4.1 Mix aesign The minimum cement content shall be 300 kg per cubic metre of concrete or monar. The water cement ratio of the concrete or monar shail be suitable for the method of placement anc shall nol exceed 0,45 atter compaction. For pipes below 1000 ON/ID, a water cement ratic of 0.5 is allowed provided the minimum cemen: comtent is 385 kg per cubic meire ot concrete. 342 Concrete strength The minimum 28-day compressive sirength of the concrete shall be 35 MPa (see 4.1) 4 FACTORY TESTING Factory testing is specified in sudclause 5.3 of £1 639 (Common Requirements| Additiona’ requirements are specified as follows 4.1 Concrete test A minimum quantity of three cylinders or cubes per week of manulaciure and per mux type of concrete shail be tested for the 28 day compressive stwength (see 3.4.2) 4.2 Pipe test One in 250 pipes shall be subjected to an interna hydrostatic test. Should a pipe tail ine tasi, then & turtner two pipes [rom the same baich of 250 sna: be tesied. If bath pipes pass then the batch shat be accepted. it one or both pipes tail then the batch shall be rejected or each pipe in the batch shall be tested lar individual approval The lished pipe shall be subjected to a pressur: test at + Maximum Design Pressure + 200 kPa or 1.2 times the Maximum Design Pressure whichever is ine greater, for ON'IO less or equa to 1200Page 7 EN 641:1994 + Maximum Design Pressure + 100 kPa or 1.2 times the Maximum Design Pressure, whichever is the greater, for DNV/ID above 1200. ‘The pipe is restrained within a hydrostatic test rig and pressure tested for a period of 5 minutes. During the test the pipe shall be absolutely watertight and show no leaks, weeping or defects considered detrimental to the pipe’s performance. No crack in the external surtace shall be wider than 0,5 mm on a length exceeding 300 mm in accordance with 6.4.11 of EN 639.Page 8 EN 641:1994 ANNEX A (INFORMATIVE) TYPICAL DESIGN PROCEDURE EXCLUDING PRETENSIONED TYPE PIPE A. GENERAL The following guidelines for structural analysis show a typical metnod tor the design of reinlorced Concrete cylinder pipe. These guidelines apply to all general cases The pipe should be designed tor the conditions given in 3.2.1 s9 thar the tensile stress in the steel Goes not exceed the allowable siress as specitied in 3.2.4 A.2 NOTATION 0 pipe internal diameter t pipe wall thickness Ise steel cylinder thickness Ase: ctoss sectional area of steel cylinder per unit length As cross sectional area of spirals per unit length Ast: total cross sectional area of steel per unit length Es elastic modulus of stee! Ee elastic modulus o! concrete My bending moment per unit lengin in a longitudinal secon of ine pipe Ny Aormal force per unit length created in the longitudinal section c* the pipe by the internal pressure Mo longitudinal bending moment of a span. pipe No longitudinal force due to pipe end- foaaing by the internal pressure lee tensile siress in steel cylinger ‘sce’ yield strength : the steel cylinder 5 tensile sires in ine spirals te compressive stress in concrete fen pipe mean radius Ay area of steel in tension, per unit length AQ area ol steel in compression. per unt Fength Ys cisiance between the steel in tension and ine extreme concrete compression ve lever arm ore in 4.3 LOADS AND FORCES Dead and tive loads, coetticients for cross-sectional bending moments and thrust calculations any bedding angle should be determined ia accordance with appropriate national standaros \ransposing EN as available, or in the absence a, Such standards, with the appropriate regulations op fecognised and accepted meinods at the place where the pipeline is installed (Normal lorces duc to external loads are normally neglected} Conventions * positive moment : a@ moment which gives tension in the insige fibre of the pipe wall + Regalive moment : a moment which gives tension in the outside fibre of the pipe wail A normal force should be considered as a negative ‘one when it induces compression in the pipe wall and positive when 1 induces tension, A.4 CALCULATION OF STRESSES Stresses are calculated in the sections where respectively the maximum positive and negative bending moments occur Each section operates under compound bending (ending moment + normal force). The normal ferce being mainly a positive force due to internal Pressure. il is advisable to use tne principle of summation “y adding the pressure stresses to the crcula: benaing stresses A.4.1 Hoop stresses due to internal pressure (P) haope Ns + BID ee Ae ia 2 Ast A.4.2 Circular stress in ste! due to bendirg moment The calculation of stress is made in two dilterent ways depending on wheiher the reinforcement is, low yield strength plain wire (normally 2+5 MPa) + high yield strengih indented wiresinormally 400 0; 500 MPa) The calculation of stresses tor each section 1s mage in accordance with current prasuce of Feinorced concrete design, on Ihe basis of thefollowing diagram, where the tensile strength of Page 9 EN 641:1994 the concrete is neglected Figure A.2a Pipe with one circular cage 1 = Steel cylinder 2 = intemal circular reinforcing cage 3 = Extemal circular reinforcing cage te compressed area Ts fay at: al AY fay A Figure A.2b Pipe with two circular cages Figure A.2c Pipe with one elliptical cage with or without circular cage Invert section S = Springline section 4 = Eliplical reinforcing cage Figure A.2 : Typical arrangements of pipe reinforcement +The section where maximum positive bending moment occurs is normally the invert where the tensioned steel is the steel cylinder (see Figure A.2a), oF a combination of steel cylinder and helixes (see Figures A.2b and A.2c) + The section where maximum negative moment occurs is normally the springline where the tensioned steel is the external cage of helixes oF a combination of the internal ellipical cage and the external cage. A421 Low yield strength steel The tensile stress in the tensioned steel (stee! cylinder or helixes, or combination of both) 1s calculated using the formula Mt ye Ay fam= A422 High yield strengin steel + In the section where the maximum negative bending moment occurs (normally spnngine)Page 10 EN 641:1994 the tensile stress in the tensioned steel (normally the helixes of the external cage) is Calculated as in A.4.2.1 In the section where the maximum positive bending moment occurs (normally the invert). the calculation is made as in A.4.2.1 when tne feintorcement consisis of one circular cage only. When the reinforcement is as shown in Figure A.2b and A.2c. the design model used tor calculation takes into account the redistribution of stresses between the steel cylinger and the Nelixes once the yield sirengtn of the steel cylinaer ‘seq iS reached, in an Lumate state approach An equivalent model of this stress redistribution is used to calculate serviceability state, where ihe allowable tensile stresses in tne steel are limited to two thirds of the yield strength The tensile force in steel due to vending is aisnbuted between the syiinse ata he weloes (oencing + pressure) shes of 2 ts . and ony in the hebres forthe pa o! his tense free when oes total esses ngner nan The calculation is made as follows My yz Ay + calculate ta 44 (similarto A.4.2.1) Wa = lang + taps? tecg «ta gy 15 the tensile bending stress in steel cylinder and in the helixes of the internal cage. the bending sires in the cylinder and in the helixes are consicered separately the bending stress in the cylinger is the benging stress in ine nelixes 1s Calculated considering the total tensile force ue to bending taken by tne cylinder ar the helixes 1s, fa ya (Ase = As) the force taken by the cylinaeris 2 Ise Ase = (2 tocq “tap I Asc the force to be taken by the nelixes is Ineretore Foe F-Face tay (Ase * As) tec la pl Ase The bending stress in the helices is tee z A.4.3 Total circular stresses in longitudinal sections of the pipe farlap+tay A.4.4 Longitudinal cross section Stresses in pipe When the pipeline is end-loaded, a longitudinal stress occurs in the cylinder ; is equal to pasboee tH Oy K Ditse flee tes = A.S CALCULATION OF STRESSES IN SPAN-PIPES A.5.1 Circular stresses They are calculated using the same formula as detailed in A.4 when applied to bending moments anc forces calculated on the basis of Annex 8 of EN 639 (Common Requirements). 4.5.2 Longitudinal stresses The bending moment induces longitudinal stresses which are distributed in the cross section, as shown in Figure A.3. PN Newval ans Eee aca a Figure A.3 Stress distbution+ Non end-loaded pipeline : ‘The position of the neutral axis is detined by angle © such as flan O02) (t=tge) = Age The tensile stress in the cylinder is given by : Ma(1+cosa)n (t= tse} fm? tan o sin? a No = 2k t t@cos of mena -(1 a) (lana) 2, fee = MK fmm (14.005) k and a being computed by solving the equations @ and @, 2e T2 (sina -acosa)+a-sina cosa Page 11 EN 641:1994 End-loaded pipeline : ‘The cross section of pipe is subjected to compound bending, under the moment Mz and the normal tensile stress No. ‘The position of the neutral axis is defined by the angle c : i M; ae ang Me. with as 0-H oO @ eo Zo Ta (sina -@ cosa)+a -sina cosa -rn(1-“2cosa)page 12 EN 641:1994 ANNEX B (INFORMATIVE) TYPICAL DESIGN PROCEDURE FOR PRETENSIONED TYPE PIPE 8.1 GENERAL The following guidelines for structural analysis show a typical method for the design of pretensioned type pipe The pipes should be designed for the conditions given in 3.2.2 50 that the tensile sires in the siee! does not exceed the allowable stress as specilied in 3.2.2 The deflection of the pipe due to external loads is checked against a maximum allowable value as specilied in 3.2.2 ‘The attention of the designer is drawn to the fact that the pipe becomes relatively less ngid tor larger diameters. It is hus more dependent on suppor trom lateral earth restraint (passive pressure) in resisting external loads. B.2 | NOTATION Same as in Inlormative Annex A B.3. CALCULATION OF MATION UNDER LOAD DEFOR- Oead and live loads and bedding angles shall be determined in accordance with appropnate national standards transposing EN as available, or in the absence of such standards, with the appropriate fequlations or recognised and accepted methods ai the place where the pipeline is installed The design is based upon an empirical formula determined from research and experimentation The increase of diameter at the springline o! pipe is calculated by using, for example. Ine Spangler formula Dik Ov tm? OE o0s1e in? ‘Ax: increase of diameter at the springing Oj: deflection tag tactor (= 1 for pressure pipes) ky: bedding coefficient (see table below) Qy* vertical load on pipe Ei: flexural rigidity of pipe wall (computed wall stiffness) E': modulus of soil reaction B> beading angie Table B.1 : Table of kp values Bree) e ° 0,110 15 0,108 225 0105 30 0,102 35 01096 60 0.080 75 0.085 30 0,083 The computed wall stiffness should be one founn of the value derived trom the composite wall section of pipe, with + Ee concrete modulus of elasticity = 28 000 MPa, + Eq Stee! modulus of elasticity = 20 0000 MPa 8.4 CALCULATION OF STRESSES IN STEEL DUE TO HYDROSTATIC PRESSURE (P) The stress in steel ta is calculated as follows POV 2 Ast