www.cpaa.asn.auConcrete Pipe Associationof Australasia

(C) 1978 STANDARDS COUNCIL

Declared on 28 April 1978 by the Standards Council to be a standard specification pursuant to the provisions of section 23 of the Standards Act 1965.

First published Reprinted

April 1978 July 1979

The following SANZ references relate to this standard:

Project No. P 3107

Draft for comment No. DZ 3107

Printing code: O.5M - 1979/7005/1821

AMENDMENTS

No. Date of iS8ue Description Entered by, and date

.

NZS 3107:1978

NEW ZEALAND STANDARD

Specification for

PRECAST CONCRETE DRAINAGE AND PRESSURE PIPES

© COPYR IGHT

The copyright of this document is the property of the Standards Council. No part of it may be reproduced by photocopying or by any other means without the prior written permission of the Director of the Stan· dards Association of New Zealand unless the circumstances are covered by the exemption sections (19 and 21) of the Copyright Act 1962.

Superseding NZS 2238

STANDARDS ASSOCIATION OF NEW ZEALAND WORLD TRADE CENTER, 15-23 STURDEE STREET, WELLINGTON 1 Postal address: Private Bag, Wellington April 1978

CONTENTS

Committee representation Related documents Foreword

GENERAL

Section

1 Scope 2 Materials 3 Reinforcement in pipes 4 Joints 5 Effective length 6 Workmanship and finish

3

7 Permissible variations in dimensions 8 Concrete cover and protection of reinforcement 9 Absorption test requirements

10 Sampling for testing •. 11 Acceptance and rejection .. 12 Testing facilities 13 Specials made from cut pipes 14 Ordering requirements

PART 1 DRAINAGE PIPES

101 Test loads 102 Ultimate load 103 Hydrostatic test 104 Marking

PART 2 PRESSURE PIPES

201 Design stresses in pressure pipes 202 Proof load 203 Hydrostatic test 204 Marking

TabZe

1 Permissible variations in diameter 2 Permissible variations in wall thickness 3 Permissible variations in length •. 4 Minimum cover over reinforcement •• 5 Test loads for classes C, S, X, Y, Z pipes

Part 1 Metric pipe sizes Part 2 Metric equivalents of imperial pipe sizes

6 Test loads for pressure pipes 7 Actual internal diameters of pipes as manufactured

Part 1 Metric pipe sizes Part 2 Metric equivalents of imperial pipe sizes

NZS 3107:1978

PAGE

5 6 7

8 8 9 9

10 10 10 12 13 13 14 14 15 15

16 16 16 17

20 21 21 21

11 11 11 12

18 19 23

33 34 & 35

NZS 3107:1978 4

Figure

1 2 3 4

Illustrating effective length "E" of pipes Crack-measuring gauge Three-edge bearing method load testing of pipes Two-edge bearing method for load testing of pipes

Appendix

A B C D

E

Method for the absorption testing of pipes Methods for the load testing of pipes Method for hydrostatic testing of drainage pipes Method for the hydrostatic pressure testing of pressure pipes __ Internal diameters of pipes as manufactured

PAGE

10 27 27 29

24 26 30

31 32

5 NZS 3107:1978

COMMITTEE REPRESENTATION

This standard was prepared under the supervision of the Concrete Industry sectional committee (31/-) for the standards Council, established under the Standards Act 1965. The committee consisted of representatives of the following:

Council of the Building Industry

Department of Scientific and Industrial Research

Harbours Association of New Zealand

*Ministry of Works and Development

*Municipal Association of New Zealand

New Zealand Concrete Masonry Association

*New Zealand Counties Association

New Zealand Master Builders Federation

New Zealand Portland Cement Association

New Zealand Ready Mixed Concrete Association

Prestressed Concrete Institute of New Zealand

The Concrete pipes Committee (31/2) was responsible for the preparation of the standard, and consisted of representatives of the organizations marked with an asterisk (*) above in addition to the following:

Hutt Valley Drainage Board

New Zealand Institution of Engineers

New Zealand Manufacturers Federation

NZS 3107:1978 6

RELATED DOCUMENTS

Reference is made in this document to the following: Clause reference

herein

NEW ZEALAND STANDARDS

*NZS 3113:0000

NZS 3121: 19 74

NZS 3122:1974

NZS 3123:1974

NZS 34 02P:1973

NZS 3421 :1972

NZS 3422:1972

MP 3801: 1972

BRITISH STANDARD

BS 2494: 1976

AUSTRALIAN STANDARD

AS 1392 :1974

Chemical admixtures for concrete 2.2

Water and aggregate for concrete 2.1

Portland cement (ordinary, rapid hardening and modified) 2.1

Portland pozzolan cement 2.1

Hot rolled steel bars for concrete reinforcement 2.1

Hard dra~n mild steel hlire for concrete reinforcement 2.1

Welded fabric of dra~n steel hlire for concrete reinforcement 2.1

A guide to the adoption of the model building byla~ (NZS 1900) by local authorities using the standard adoption and annual updating procedures. 1.2

Materials for elastomeric joint rings for pipe~ork and pipelines 2.1

Precast concrete pressure pipes 201.1

* In course of preparation

7 NZS 3107:1978

FOREWORD

This standard is a revision of NZS 2238:1968 Precast concrete drainage and pressure pipes with all dimensions shown in the International System (SI) units.

Because of the need for manufacturers to continue using existing equipment for some time, the standard provides for both a "soft" conversion of imperial dimensions involving no change in pipe size and a "hard" conversion resulting in a new range of pipe sizes more suitable for present conditions. As equipment is replaced, the "soft" conversion dimensions will become obsolete.

The format has been changed in the new standard to cover the distinctive features of drainage pipes and pressure pipes in two separate sections, preceded by a general section which includes .all provisions common to both types of pipe.

Whereas NZS 2238 had been generally written round experience with spun concrete pipes, the revised standard provides for pipes made by processes other than spinning.

The scope of the standard has been widened to provide for larger diameter pipes.

In the clause dealing with cover, additional provisions are included to guard against voids, while aggressive ground conditions, aggressive fluids or abrasive detritus may be cause for additional requirements agreed to between purchaser and manufacturer.

The new standard also includes a much improved hydrostatic pressure test applied to an assembled pipeline, and a modified water absorption test.

For the engineering design of pipelines incorporating concrete pipes complying with the requirements of this standard, regard should be had to the procedures laid down in NZS 4451:1974 Loads on buried rigid pipes.

Care should be taken in using concrete pipes where they are likely to be exposed to conditions of extreme frost, solar radiation, and heat due to contents.

The Notes included in this document are not a mandatory part of the standard.

NZS 3107:1978

NEW ZEALAND STANDARD

Specification for

PRECAST CONCRETE DRAINAGE AND PRESSURE P4:PES

GENERAL

1 SCOPE

8

1.1 This standard applies to the following classes of precast unreinforced and reinforced circular pipes manufactured from portland cement concrete and intended for the conveyance of water, sewage and other liquid wastes: (a) Drainage pipes

Class C Unreinforced Class S Standard reinforced Class X Extra strength reinforced Class Y Special strength reinforced Class Z Special strength reinforced

(b) Pressure pipes

Class P Pressure pipes reinforced to withstand specified hydrostatic test head

1.2 Where any other standard named in this standard has been declared or endorsed in terms of the Standards Act 1965, then -

(a) Reference to the named standard shall be taken to include any current amendments declared or endorsed in terms of the Standards Act 1965; or

(b) Reference to the named standard shall be read as reference to any standard currently declared or endorsed in terms of the Standards Act 1965 as superseding the named standard, including any current amendments to the superseding standard declared or endorsed in terms of the Standards Act 1965.

NOl'E - The date at which amenanents or superseding standards are regarcEd as "current" is a matter of law depending upon the particular method by which this standard becomes legally en forO:! able in the case concerned. In general, if this is by contract the relevant date is the date on which the contract is created, but if it is by Act, regulation, or bylaw then the relevant date is that on which the Act, regulation, or bylaw is promulgated, for bylaws, promulgation includes updating by the procedure set out in MP 380 1 *.

2 MATERIJI..LS

2.1 The materials used in the manufacture of pipes shall comply with the following requirements:

(a) Portland cement shall conform to NZS 3122*. (b) Portland pozzolan cement shall conform to NZS 3123*. (c) Steel reinforcement:

(1) Rolled steel bars shall conform to NZS 3402P* and hard

* See list of related documents

..

9 NZS 3107:1978

drawn steel wire to NZS 3421*. (2) Steel fabric shall conform to NZS 3422*.

(d) Aggregates shall conform to the appropriate provisions of NZS 3121*.

(e) Water shall conform to the appropriate provisions of NZS 3121*. (f) Rubber used in flexible joint rings shall conform to the

appropriate provisions of BS 2494*.

2.2 Additives used in the manufacture of concrete pipes shall comply with NZS 3113*.

2.3 Pipes shall not contain material other than as provided for in clauses 2.1 and 2.2 without the approval of the purchaser.

3 REINFORCEMENT IN PIPES

3.1 The reinforcement 1n a reinforced pipe shall extend through­out the pipe, and with socketed pipes the reinforcement shall extend into the socket. The reinforcement shall be so designed that it can be readily placed and held in the desired position in the pipe mould during the moulding of the pipe, and shall be so located in the pipe wall that it will resist the tensile stresses induced by the test load appropriate to the size and class of the pipe.

3.2 When it is necessary to splice the reinforcement this shall be done by lapping the reinforcement not fewer than 50 diameters, or by welding in a manner which will ensure that the full working strength of the reinforcement is developed in the splice.

3.3 Reinforcement in elliptically reinforced pipes shall be located nearer the inner surface of the pipe on the vertical axis, and nearer the outer surface on the horizontal axis.

3.4 All steel reinforcement shall be in an "as new" condition and at the time of placing shall be free from loose rust, loose mill scale, oil, grease, and any other coating liable to impair bonding with concrete.

4 JOINTS

4.1 The type of joints shall be specified by the purchaser.

4.2 The joints shall be such that the pipes can be laid and jointed to form a continuous conduit with a smooth and uniform bore and when jointed in a straight line, the joint gap, measured on the inside of the barrel of the pipe, shall not exceed 3 mm, plus 3 rom for each 300 rom of internal pipe diameter, or 15 rom, whichever is the less.

4.3 Flexible joints shall be watertight under the hydrostatic test head specified for the pipes when the deflection angle is 0.5 0

per joint, or at any other greater deflection angle as agreed to between the manufacturer and the purchaser.

* See list of related documents

I I

NZS 3107:1978 10

4.4 If required, the manufacturer shall submit the design of the joint to the purchaser for approval.

5 EFFECTIVE LENGTH

5.1 Unless otherwise arranged between the purchaser and the manufacturer, the effective length E of each pipe, measured as indicated in fig. 1, shall be the length specified by the purchaser with a minimum of 600 mm.

Fig. 1

~m I. E .1

IT,: ~:M ::".":: .1

I. E .1 ILLUSTRATING EFFECTIVE LENGTH "E" OF PIPES

6 WORKMANSHIP AND FINISH

6.1 The interior and exterior surfaces of the pipes including joint surfaces shall be smooth, dense, and hard. They shall not be coated with cement wash or any other preparation unless this is agreed to by the purchaser.

6.2 Pipes shall be free from fractures, and from cracks wider than 0.1 rom and from other defects.

6.3 Dents not exceeding 3 rom in depth and bulges not exceeding 3 mm in height shall be permitted provided they are not contained in surfaces forming an essential part of the joint or do not extend in any other direction for a distance greater than twice the wall thickness of the pipe. .

7 PERMISSIBLE VARIATIONS IN DIMENSIONS

7.1 Any variation from the designated or specified dimensions, straightness, and squareness of ends of pipes shall not exceed the limits set out in clauses 7.1.1 to 7.1.5.

7.1.1 shall not more than

Internal diameter. The actual internal diameter of a pipe differ from the diameter designated by the manufacturer by the amount shown in table 1.

7.1.2 Wall thickness. The actual wall thickness of a pipe shall not differ from the thickness designated by the manufacturer by more than the amount shown in table 2, except that an increase in wall thickness to provide a flat base for pipes shall be permitted.

7.1.3 Straightness. When tested by means of a straight-edge laid along the inside of the barrel of the pipe, the deviation from straightness shall not exceed 3 rom per 1 m of effective length.

11 NZS 3107:1978

7.1.4 Length. Unless otherwise specified by the purchaser, the actual effective length of each pipe shall not differ from the designated length by more than the amount shown in table 3.

7.1.5 Squareness of ends. When measured by means of a try square the ends of a pipe shall be square with the walls of the pipe within 1.5 rnm per 300 mm of designated diameter, or 3.0 mm whichever is the greater.

Table I

PERMISSIBLE VARIATIONS IN DIAMETER

Designated internal diameter

Up to but not including 400 mID

400 mm up to but not including 600 mm

600 DIll up to but not including 1200 DIll

1200 DIll and over

Table 2

Permissible variation in diameter

+ 3 UDD

+ 5 mm

+ 7 DIll

+ 10 UDD

PERMISSIBLE VARIATIONS IN WALL THICKNESS

Designated wall thickness

Up to but not including 25 mm

25 mm up to but not including 50 mm

50 mm and over

Table 3

Permissible variation in wall thickness

+ 2 mm

+ 3 mm

+ (3 DIll plus 1 mm for each 15 mm or part thereof of wall thick­ness) •

PERMISSIBLE VARIATIONS IN LENGTH

Designated length

Under 2 m

2 m and over

I Permissible variations in length

+ 10 DIll

+ 15 DIll

NZS 3107:1978 12

Table 4

MINIMUM COVER OVER REINFORCEMENT

Wall thickness

Up to but not including 25 mm

25 mm and over

Minimum clear cover

6mm

10 mm

8 CONCRETE COVER AND PROTECTION OF REINFORCEMENT

8.1 Where concrete embedment alone is the means of corrosion protection of steel reinforcement, the following shall apply:

(a) The minimum clear cover over the reinforcement in any pipe shall be as shown in table 4, appropriate to the wall thickness of the pipe.

(b) As voids in the concrete at the surface of steel reinforcement are undesirable, the manufacturing methods and procedures adopted shall be such as to secure close contact between concrete and steel in the finished pipes.

NOTE - Where the pipes will be subject to ground conditions aggressive to concrete or to steel reinforcement, or used to convey aggressive fluids or abrasive detritus, the purchaser is advised that additional requirements may be necessary to obtain a satisfactory service life. Any such additional require­ments shall be as agreed between purchaser and manufacturer.

Because of the di versi ty of circumstances that could apply each case will need to be treated on its merits. Treatments which may be applicable include the following - inert coatings or membrane linings, coatings on reinforcement or surface passivation by integral inhibitors in the concrete, IIlOre dense concrete, lower absorptive concrete, increased concrete thickness (sacrificial), wear­resistant concrete (for example, incorporating iron or steel stampings, punchings or grit), special pozzolan cement, and special aggregates (for example dolomitic or calcareous, or both) .

8.2 When so required by the purchaser, the manufacturer shall have chases cut in the pipes, as directed, to permit examination of the reinforcement with respect to positio

1n, net thickness of concrete

cover, and the presence of adjacent voids The width of any chase shall not exceed 25 mID, the length shallot exceed 100 rom and the depth shall not exceed the depth to the reinforcement. Alternatively examination may be by means of cores cut to any depth specified up to the full thickness of wall. The diameter of cores shall not exceed 125 mID (5 in) without agreement between purchaser and manufacture. Not more than one chase or core shall be cut in every 20 or part of 20 pipes of the same class and nominal internal diameter in an order. The chases and core holes sh~ll be repaired by the manufacturer to the satisfaction of the purchaser.

13 NZS 3107:1978

8.3 Alternatively, when agreed between the purchaser and the manufacturer, the cover over the reinforcement may be determined by a non-destructive method. In the event of disagreement, the cover shall be determined by the cutting of chases or cores as described above.

9 ABSORPTION TEST REQUIREMENTS

9.1 If absorption tests are required, test specimens shall be taken from the pipes nominated by the purchaser.

Note - Water absorption does not provide a reliable indication of pipe durability as it may be affected by the repeated wetting and drying of the pipe from which the specimen is taken.

It is arguable whether the water absorption test provides direct information on ei ther the ftmctional adequacy or potential durability of concrete pipes, but the test may be useful to a manufacturer in providing some indication of the uniformity of concrete mix and the degree of compaction achieved.

The tests. good by

manufacturer may Pipes from which the manufacturer

at his ' own discretion carry out absorption test specimens have been taken shall be made to the satisfaction of the purchaser.

9.2 Absorption tests shall be carried out by the method described ~n Appendix A.

9.3 Unless otherwise agreed between the manufacturer and the purchaser, the absorption test shall not be used for determining compliance with the standard. The following percentages may be taken as acceptable maximum values for absorption expressed as a percentage of the dry weight of the specimen:

(a) 6.5 percent for pipes specifically ordered as sewer or pressure pipes.

(b) 8 percent for other pipes.

10 SAMPLING FOR TESTING

10.1 For the purpose of sampling pipes and specials a consignment shall be divided into batches of the same class and nominal diameter.

10.2 For the purposes of checking compliance with clauses 101.1, 101.2, and 202.1, two specimens shall be drawn by a random selection process out of every 100 pipes or specials or part of 100 pipes or specials of the same class and nominal internal diameter in a batch.

10.3 Alternatively, when agreed between the purchaser and the manufacturer, a different sampling procedure may be appropriate to numerically small batches of pipes or specials, or to a slow rate of manufacture.

10.4 The purchaser or his representative shall be permitted to make the selection in the presence of the manufacturer, or his agent. The specimens so selected shall be identified with the batch they represent.

NZS 3107:1978 14

11 ACCEPTANCE AND REJECTION

11.1 All material, processes of manufacture, and finished pipes shall be subject to approval by the purchaser. Any pipe which does not comply with the requirements of sections 6, 7 and 8 may be rejected by the purchaser.

11.2 If all specimens in the sample comply with the requirements of the tests specified in clauses 101.1, 101.2, and 202.1 as appropriate, the batch so represented shall be deemed to comply with the relevant requirements of the standard.

11.3 If two or more specimens fail the tests specified in clauses 101.1, 101.2, and 202.1 the batch so represented may be rejected.

11.4 Should anyone specimen fail to meet the requirements specified for a particular test (other than absorption test) except where every pipe is required to be tested, two further specimens of the same class and nominal internal diameter shall be selected for each specimen that fails and shall be tested in the same manner.

11.5 If all the specimens in the second sample are found to comply with the requirements of the test, the batch represented thereby shall be deemed to comply with the relevant requirements of the standard.

11.6 If one or more specimens of the second sample are found not to comply with the requirements of the tests, the batch represented thereby may be rejected. Alternatively, except in the case of the ultimate load test, the manufacturer may elect to test every pipe in order to determine the pipes which comply with the standard.

11.7 Requirements for the acceptance and rejection of batches represented by pipes submitted to the Hydrostatic Test shall be as set out in clause 103.2.

11.8 Subject to clause 11.1 all pipes and specials represented by test specimens which meet all the specified requirements, and all the test specimens except those subjected to the ultimate load test, shall be deemed to comply with the standard.

12 TESTING FACILITIES

12.1 Unless,otherwise arranged between manufacturer and purchaser when the order is being placed, the manufacturer shall supply all facilities for testing the pipes, and shall bear the expenses of carrying out the tests.

12.2 The manufacturer shall notify the purchaser of his intention to carry out tests at stated times, allowing sufficient notice for the purchaser or his representative to be present during the testing.

12.3 A sufficient number of quality control tests specifip.d in sections 101 and 202 based on the total production of pipes and fittings shall be made consistently by the manufacturer to ensure that his products comply with the requirements of the specifications and

15 NZS 3107:1978

certified records of all such tests shall be kept for inspection by the purchaser.

13 SPECIALS MADE FROM CUT PIPES

13.1 Where agreed between manufacturer and purchaser, specials, including Ys and Ts may be made by cutting and rejoining sections of pipe using a suitable adhesive.

13.2 Where specials are so made without providing continuous steel reinforcement across the joints, they shall be regarded as being partially non-reinforced. Such specials shall not be subjected to shocks or excessive loads during handling and installation. Extra care shall be taken when such specials are used for pressure pipe application.

14 ORDERING REQUIREMENTS

14.1 The purchaser shall specify the following:

(a) Internal diameter of pipe.

(b) Total length of pipe.

(c) Class of pipe.

(d) Test pressure for pressure pipes.

(e) Type of joints.

14.2 The purchaser may specify any of the following optional requirements:

(a) Additional protective requirements for adverse conditions (refer to Note to clause 8.1).

(b) Whether chases or core holes are required to permit examination of the cover over the reinforcement (refer to clause 8.2). Alternatively, whether the purchaser will agree to the use of a non-destructive method (refer to clause 8.3).

(c) Number of pipes to be subjected to the proof load test. A minimum of two test pipes is recommended unless certificates of recent tests on other pipes are available (refer to clauses 101.1 and 101. 2) •

(d) Whether the ultimate load test is required (refer to section 102) •

(e) Whether the hydrostatic test is required for drainage pipes (refer to clause 103).

(f) Whether the absorption test is required (refer to section 9).

(g) Whether lifting holes are required in large diameter pipes (refer to clause 104.2).

(h) Whether the hydrostatic test line is to be deflected (refer to clause 103.3).

NO'm - The prCXlf load test is also considered to be a useful indicator of concrete quali ty which in turn is a function of mix design, compaction and effiCiency of curing. The ability of a reinforced concrete pipe to carry a significantly higher load than the prCXlf load before collapsing, is influenced by

NZS 3107:1978 16

the efficiency of steel-concrete bond, by the amount and location of the steel and quality of the concrete. It is however debatable whether a test of ultimate load is necessary to,assess the combined effect of these factors; also, the test is always destructive as the pipes are usually too badly damaged to be used.

The hydrostatic test for drainage pipes provides both a quantitative measure of pipe permeability and an assessment of the efficiency of the jointed pipeline. The test is considered to be a realistic method of indicating potential pipeline durability.

PART 1 DRAINAGE PIPES

101 TEST LOADS

101.1 Class C pi pes

101.1.1 When subjected to the appropriate proof load given in table 5 by one of the methods described in Appendix B, the pipe shall not crack or show other signs of distress.

101.2 Classes S, X, X and Z pi p e s

101.2.1 When subjected to the appropriate proof load given in table 5 by one of the methods described in Appendix B, the pipe shall not develop a clearly visible crack (see clause 101.2.2), and on removal of the load any minor crack caused by the load shall not be wider than 0.1 mm.

101.2.2 A clearly visible crack means a crack into which the point of a crack-measuring gauge, complying with the details given in fig. 2, may be inserted at close intervals over a length of at least 300 mm. A minor crack means a crack of smaller size than a "clearly visible crack".

102 ULTIMATE LOAD

102.1 When so specified by the purchaser, pipes shall be subjected to the appropriate ultimate load given in table 5 by one of the methods described in Appendix B. When so tested a pipe may crack extensively but shall not distort more than 10 percent of the nominal diameter.

103 HYDROSTATIC TEST

103.1 A minimum of four pipes shall be drawn by a random selection process out of every batch for assembling into a factory test pipeline using the jointing method and materials for which the pipes are designed except as specified in clause 103.4. The test shall be performed by the method set out in Appendix C.

17 NZS 3107 :1978

103.2 The acceptable rate of water loss shall not exceed 0.6 ml/mm diameter/metre length/hour; when subjected to a test pressure of 10 m of water, provided that, if the test line fails to meet this requirement the following shall apply:

(a) If the rate of water loss does not exceed double the acceptable rate, a second test shall be allowed on another randomly selected set of four (or more) pipes from the same batch. If the water loss for this second test does not exceed 0.6 ml/mm diameter/metre length/hour, the lot represented (including the pipes of the first test) shall be deemed to comply.

(b) If the first test line loses water at a rate in excess of double the acceptable rate, or in the case of a second test line as provided in clause l03.2(a) the loss exceeds the acceptable rate, the whole of the batch represented shall be deemed not to comply.

103.3 Notwithstanding an acceptable rate of water loss, if it is apparent that the loss is caused by a defective joint, or other obvious manufacturing defects, the purchaser may reject one or more pipes under test.

103.4 When so specified by the purchaser, the test line shall be deflected one-half degree, or such other deflection as may be agreed between the manufacturer and the purchaser at one or more of the joints in the pipeline. When so deflected the test line shall meet the requirements of clause 103.2.

103.5 When so specified by the purchaser, plain ended and flush jointed drainage pipes shall be tested generally in accordance with the procedure described in Appendix D except that the test pressure shall be 10 m head of water. When so tested, the rate of water loss shall not exceed the amount specified in clause 103.2.

103.6 For the test pipeline the foregoing retesting provisions of 103.2 shall be in lieu of the provisions of section 11.

104 MARKING

104.1 Unless otherwise arranged between the purchaser and manufacturer, the following information shall be clearly and durably marked on each drainage pipe at the time of manufacture:

(a) One of the following letters, as appropriate, to indicate the class of pipe:

C Unrein forced S standard reinforced X Extra strength reinforced Y Special strength reinforced Z Special strength reinforced

(b) The nominal internal diameter.

(c ) Manufacturer's name or registered trade mark.

(d) Date of manufacture.

TA

BLE

5

Nom

inaZ in

tern

al

dia

meter

Class

C

(rrm)

Pro

of

100 19

150 19

200 19

300 22

400 28

500

600

700

800

900

1000

1200

1400

1600

1800

2000

2200

2400

'!ES

T

LOA

DS

FOR

C

LA

SS

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C

, S

, X

, Y

AN

D

Z

PIP

ES

PA

RT

1

ME

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IC

PIP

E

SIZ

ES

Test

Zoads in

kN/m

Cla

ss S C

lass X

C

lass Y

P!,o

OfJ

UZ

timate

Pro

of

I Ul-tim

ate P

roo

f I

Ultim

ate

10 15

12 19

19 28

10 15

12 19

19 28

11 16

13 19

19 28

12 18

15 22

22 33

14 20

18 27

27 40

16 24

21 32

32 48

18 27

25 37

37 56

20 30

29 44

44 65

23 34

33 49

49 74

24 36

36 55

55 82

26 39

40 58

60

91

29 44

47 70

70 105

31 46

52 78

78 117

33 50

57 86

86 128

35 53

62 9

3

93

140

37 55

66 99

99 149

39 58

72 109

110

41 61

77

115

115

Pro

of

25

25

26

29

36

42

50

58

66

73

81

93

104

114

124

131

144

153

Cla

ss Z

I Ultim

ate

38

38

38

44

53

64

74

88

99

109

121

140

155

172

186

197

Z

t-1 en IN

..... o ..... ..... \0

..... co

..... co

TA

BLE

5

Nom

inal inte1'lU

ll diam

eter C

las8 C

(in)

(rrm)

Pro

of

Pro

of

4 100

19 10

6 150

19 10

9 225

19 11

12 300

22 12

15 375

26 13

18 450

29 15

21 525

17

24 600

18

30 750

21

36 9

00

24

42 1050

27

46 1200

29

54 1350

30

60 1500

32

66 1650

34

72 1800

35

60 2000

37

84 2100

38

90 2250

40

96 2400

41

TE

ST

LOA

DS

FOR

C

LASSES

C,

S,

X.

Y AND

Z P

IPE

S

PAR

T 2

METR

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EQU

IVA

LENTS

OF

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PIP

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SIZ

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loa

ds

in kN

/m

Clas8

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Za8S X

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laS8 Y

I UZ

timate

Pro

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r!oof I

UZ

timate

15 12

19 19

26

15 12

19 19

26

16 13

19 20

26

18 15

22 22

33

20 17

26 26

39

22 20

29 29

44

25 22

33 33

50

27

25

37 37

56

32 31

47 47

70

36 36

55 55

62

41 42

64 63

96

44

4

7

70 70

105

45 50

76 76

114

46 55

62 82

123

50 58

88 8

8

131

53 62

93 9

3

140

55 66

99 9

9

149

57 70

105 105

158

59 74

112 112

61 7

7

115 115

Clas8

Z

Pro

of

I U

Ztim

ate --

--

--

--

25 36

25 38

26 36

29 44

34 50

39 59

44 66

50 74

I-' \0

6

3

94

73 109

85 127

93

140

101 151

109 164

117 175

124 186

131 197

Z

e<l en

139 208

w

146 I-' 0 ....,

153 .. I-' \0

...., Q

)

NZS 3107:1978 20

104.2 All elliptically reinforced pipes shall be clearly and indelibly marked with the word "top" on both inside and outside to indicate their correct laying positions with regard to the direction of loading. A lifting hole shall be provided in each pipe unless its omission is agreed to, or required by, the purchaser.

NOTE - Compliance with this standard may be claimed in two ways:

(1) '!he expression "NZS 3107" appearing on a product is a claim by the manu­facturer that it complies with the requirements of this standard. This is the manufacturer's responsibility, and carries the usual obligations under the Sale of Goods Act 1908 and the Consumer Information Act 1969, as well as others under the Standards Act 1965.

(2) The Standard Certification Mark appearing on a product C8rt:ifies compliance wi th the standard through a system of supervision, control, and testing which has been established by the manufacturer to the satisfaction of the Standards Council. In addi tion, periodical inspections are made at the manufacturer's works, and testing to the standard at agreed intervals is carried out by independent testing authorities. '!he Standard Certification Mark is registered as a certification trade mark under the Trade Marks Act 1953, and may be used only (a) in terms of a licence issued by the Standards Association of New Zealand and also (b) in conjunction with the licence number and the relevant New Zealand standard number.

Further particulars of the conditions of licensing may be obtained from the Director, Standards Association of New Zealand, Private Bag, Wellington.

vl'OVEO ~

"~~ <"~ t-~ 4(AND s"'

THE STANDARD CERTIFICATION MARK

PART 2 PRESSURE PIPES

201 DESIGN STRESSES IN PRESSURE PIPES

201.1 Unless another basis of design is agreed upon between the purchaser and the manufacturer, the calculations for the wall thickness of the pressure pipe and the area of the circumferential steel reinforcement shall be based on the internal hydrostatic test pressure specified by the purchaser and on the external load appropriate to the diameter of the pipe as shown in table 6, acting together, or such other value of load as may be specified by the purchaser.

NOTE - Al teD1atively, the design of pressure pipes should be based on the method given in AS 1392*.

*See list of related documents

21 NZS 3107:1978

202 PROOF LOAD

202.1 When subjected to the appropriate proof load given in table 6 by one of the methods described in Appendix B, the pipe shall not develop a clearly visible crack as defined in clause 101.2.2.

203 HYDROSTATIC TEST

203.1 The appropriate hydrostatic test pressure specified by the purchaser shall be applied to every pressure pipe in accordance with the procedure described in Appendix D.

203.2 During the test, moisture appearing on the surface of the pipe in the form of damp patches shall not be considered to be leakage.

203.3 If, during the test, beads of water appear on the surface of the pipe, the pressure shall be maintained on the pipe for an additional period equal to the initial period required for the test, and the pipe shall be accepted if the beads do not grow or run.

203.4 When so tested, no pipe shall crack, show any other sign of distress, or leak (subject to the requirements of clauses 203.1 to 203.3).

NOTE - Where pressure pipes are likely to be subjected to external loads then special consideration may be necessary.

204 MARKING

204.1 Unless otherwise arranged between the purchaser and the manufacturer, the following details shall be clearly and durably marked on each pressure pipe:

(a) The words "PRESSURE TESTED TO" followed by the value of the hydrostatic test pressure in kilopascals.

(b) The nominal internal diameter.

(c) The manufacturer's name or registered trade mark.

(d) Date of manufacture.

NOTE - CO!Dpliance with this standard may be claimed in two ways:

(l) The expression "NZS 3107" appearing on a product is a c"Urim by the manufacturer that it complies with the requirements of this standard. 'Ibis is the manufacturer's responsibility, and carries the usual obligations under the Sale of Goods Act 1908 and the Consumer Information Act 1969, as well as others under the Standards Act 1965.

*See list of related documents

~----- - - - - - - ----

NZS 3107:1978 22

(2) '!he Standard Certification Mark appearing on a product certifies compliance wi th the standard through a sys tem of supervision, con trol, and tes ting which has been established by the manufacturer to the satisfaction of the Standards Council. In addition periodical inspections are made at the manufacturer's works, and testing to the standard at agreed intervals is carried out by independent testing authorities. The Standard Certification Mark is regist­ered as a certification trade mark under the Trade Marks Act 1953, and may be used onLy (a) in terms of a licence issued by the Standards Association of New Zealand and also (b) in conjunction with the licence number and the relevant New Zealand standard number.

Further particulars of the conditions of licensing may be obtained from the Director, Standards Association of New Zealand, Private Bag, Wellington.

i~~ ~PJ!

~"'(ANO ~t'

THE STANDARD CERTIFICATION MARK

23 NZS 3107:1978

Table 6

TEST LOADS FOR PRESSURE PIPES

Nominal, internal, Proof Zoad diameter

mm kN/m

100 10

150 10

200 11

225 11

300 12

375 13

400 14

450 15

500 16

525 17

600 18

700 20

750 21

800 22

900 24

1000 26

1050 27

1200 29

1350 30

1400 31

1500 32

1600 33

1650 34

1800 35

2000 37

2100 38

2200 39

2250 40

2400 41

NZS 3107:1978 24

APPENDIX A

METHOD FOR THE ABSORPTION TESTING OF PIPES

Al Apparatus.

Al.l The following apparatus is required :

(a) A ventilated drying oven of appropriate size.

(b) A balance of suitable capacity and readable to 0.05 percent of the mass of the sample and accurate to ± 0.05 percent of the mass of the sample.

A2 Preparation of test pieces.

A2.l From each pipe selected for testing., a test piece shall be taken which is -

(a)

(b)

A core made with a diamond drill and of diameter not smalle~ than 50 rom; or

2 A piece cut and ground to an area of not less than 10 000 rom measured on one surface.

The thickness of the piece shall be the full wall thickness of the pipe. Each piece shall be free from cracks other than craze cracks.

A3 Test procedure

A3.l The test piece shall be dried at a temperature of 110 ± 5 °e for a period of four days. The drying shall then be continued until two successive weighings at intervals of not less than 2 h and not more than 24 h show an increment of loss not greater than 0.1 percent of the original mass of the piece.

A3.2 The dried piece (mass WI) shall be placed in a suitable receptacle, covered with clean potable water, brought to boiling point, and boiled for 5 h. At the end of this time the piece shal] be cooled in water to a final temperature of from 15 to 20 °e.

A3.3 When cool, the piece shall be allowed to drain for not more than 1 min, the superficial water shall be removed by means of absorbent paper or a cloth, and the piece immediately weighed (W2).

A4 Calculation and report

A4.1 The absorption of each test piece shall be reported separately and shall be calculated from the following formula:

Percentage absorption = x 100

but subject to the provision of clause A4.2.

A4.2 Concrete using absorptive aggregate, that is, vesicular. Where vesicular aggregate* is used, the test result shall be expressed as the net absorption of the piece according to the following formula:

25 NZS 3107:1978

Net absorption

Ws Dry mass of test piece.

Wa = Dry mass of vesicular aggregate in test piece.

As = Percentage absorption of test piece.

Aa = Percentage water absorption of vesicular aggregates.

* NO'lE - The acceptability or otherwise of the vesicular aggregate will depend on its effect on pipe strength and permeability.

NZS 3107:1978 26

APPENDIX ·B

METHODS FOR THE LOAD TESTING OF PIPES

Bl General

Bl.l The load test shall be applied in accordance with either the three-edge bearing method or the two-edge bearing method described in clauses B2 and B3.

B2 THREE-EDGE BEARING METHOD

B2.l Apparatus. The following apparatus is required for the three-edge bearing method:

(a) Testing machine. A testing machine so substantial and rigid tha 4

the distribution of the test load along the length of the barrel of the pipe will not be appreciably affected by the deformation or yielding of any part of the machine during the application of the load.

(b) Bearing blocks. Three softwood bearing blocks of the shape indicated in fig. 3, and of a length not less than the length of the pipe to be tested, exclusive of the socket. The portions of the blocks which will be in contact with the pipe shall be protected by rubber packing not less than 12 mm and not more than 25 rom in thickness.

(c) Crack-measuring gauge. Dimensions of a suitable crack-measuring gauge are shown in fig. 2.

B2.2 Positioning of pipe in tes t in g machine. The bearing blocks and the pipe shall be set up in the testing machine in such a manner tha t a longi tudinal plane through a vertical diameter of the pipe, and a vertical plane containing the line passing through the centre of t ­upper bearing block and a point midway between the two lower bearing blocks, coincide as shown in fig. 3. Elliptically reinforced pipes shall be so placed in the machine that the word TOP is in the vertical plane containing the axis of the pipe.

B2.3 Application of load. The load shall be applied vertically along the centre line of the pipe, through the upper bearing block, in a manner that will ensure a uniform distribution of the load throughout the length of the barrel of the pipe. The resultant point of application of the applied load(s) shall coincide with the mid­point of the total length of the pipe including the socket, if any. The load shall be increased at a continuous rate in the range 150 to 500 N/m per second until the specified test load is applied. The test load shall be maintained on the pipe for no longer than is necessary to observe and record the load, and to examine the pipe.

B2.4 Test load to be applied. The total applied load shall be the appropriate test load per linear metre specified in table 5 or table 6 whichever is applicable for that class and size of pipe or otherwise specified, multiplied by the effective length of the pipe in metres.

E E

27

~ E

NLI~ _____ in_4_ta_p~~

r O'125mm thick steel

Fig. 2 CRACK - MEASURING GAUGE

NZS 3107:1978

Bearing block packing

15mm

Fig. 3

Spacing:: ~2 or 25 mm

whichever is the greater

-""",,~~,~~_ Rubber pocking

,ll.~LkJlL.L..p::,:-- Bearing block

I

~

THREE - EDGE BEARING METHOD FOR LOAD TESTING OF PIPES

NZS 3107 :1978 28

B3 TWO-EDGE BEARING METHOD

B3.l Apparatus. The following apparatus is required for the two­edge bearing method:

(a) Testing machine. A testing machine so substantial and rigid that the distribution of the test load along the length of the barrel of the pipe will not be appreciably affected by the deformation or yielding of any part of the machine during the application of the load.

(b) Bearing blocks. Two hard unyielding bearing blocks (a top block and a bottom block) 150 rom in width and of a length not less than the length of the pipe, exclusive of the socket. The bearing faces of the blocks shall be protected by rubber packing 25 rom in thickness.

(c) Crack-measuring gauge. One suitable form of crack-measuring gauge is shown in fig. 2.

B3.2 Positioning of pipe in testing machine. The bearing blocks and the pipe shall be set up in the testing machine in such a manner that the longitudinal plane through a vertical diameter of the pipe and the vertical plane containing a line passing through the mid­points of the blocks coincide as shown in fig. 4.

Elliptically reinforced pipes shall be so placed in the machine that the word "TOP" is in the vertical plane containing the axis of the pipe.

B3.3 Application of load. The load shall be applied vertically along the centre line of the pipe, through the upper and lower bearing block, in a manner that will ensure a uniform distribution of the load throughout the length of the pipe. The resultant point of application of the applied load(s) shall coincide with the mid­point of the total length of the pipe including the socket, if any. The load shall be increased at a continuous rate in the range 150 to 500 N/m per second until the specified test load is applied. The test load shall be maintained on the pipe for no longer than is necessary to observe and record the load, and to examine the pipe.

B3.4 Test load to be applied. The total applied load shall be the appropriate test load per linear metre specified in table 5 or table 6, whichever is applicable for that class and size of pipe or otherwise specified, multiplied by the effective length of the pipe in metres.

Bearing

Bearing

Fig. 4

29 NZS 3107:1978

packing

packing

--l I ~150mm

TWO - EDGE BEARING METHOD FOR LOAD TESTING OF PIPES

NZS 3107:1978 30

APPENDIX C

METHOD FOR HYDROSTATIC TESTING OF DRAINAGE PIPES

Cl Appara tus

Cl.l The test apparatus shall comprise:

(al Bulkheads which are sealed to the test pipeline ends and anchored to ensure that significant movement (creep) does not occur during the period of measurement of water loss from the pipeline;

(b) Means of filling the pipeline with water and of maintaining a substantially constant pressure for the duration of the test (s ee clause C2.S);

(cl Means of venting air from the pipeline; and

(d) Means of accurately measuring the water loss during the test period.

C2 Te s t pipe li ne

C2.l The test pipeline comprises four (or more) test pipes assembled with the joint sealing method and materials designed for the pipes; the pipeline ends are to be closed with bulkheads as described in clause Cl.l (a).

C2.2 The test pipeline axis shall be substantially horizontal.

C2.3 The test pipeline should be filled with clean potable water and kept filled for a period not exceeding three days, prior to commencement of the test. At no time, however, shall the internal pressure be allowed to exceed the specified test pressure (namely 10 m head of water above pipeline invert).

C2.4 The pipeline may be shielded from the direct rays of the sun and draped with sacking kept continuously wet throughout the test.

C2.S Water pressure shall be applied in the pipeline gradually until the specified test pressure head, as measured at the pipeline invert, is reached. The test pressure shall be maintained substan­tially constant, within a variation of ± 500 mm head of water, for the duration of the specified test period.

C2.6 For measurement of rate of water loss, the test pressure shall be equal to 10 m head of water measured above the pipeline invert, and the test period shall be at least one hour, or such longer period or aggregate of period as agreed between purchaser and manufacturer.

31 NZS 3107:1978

APPENDIX D

METHOD FOR THE HYDROSTATIC PRESSURE TESTING OF PRESSURE PIPES

Dl Apparatus

Dl.l The following apparatus is required:

(a) Pressure equipment. Equipment capable of applying and sustaining the necessary hydrostatic test pressure to the inside surface of the pipe.

(b) Test-ends. Test-ends and rubber jointing rings capable of reproducing the conditions of jointing to be used in the pipeline and capable of closing the ends of the pipe tightly. The test­ends shall incorporate a connection through which hydrostatic pressure can be applied to the inside of the pipe, and a release for the escape of air from within the pipe.

(c) Pressure gauge. A gauge of suitable pressure range and accurate to within ± 2 percent, fitted to the pipeline. Means shall also be provided for attaching the purchaser's gauge.

D2 Application of hydrostatic pressure

D2.1 The pipe shall be surface dry at the time of testing. It shall be supported so that the longitudinal axis is approximately horizontal, in order that the exterior surface, (except at the supports) can be readily examined.

D2.2 The ends of the pipe shall be closed by means of test-ends and rubber jointing rings specified in clause Dl.l(b), in a manner that will ensure no leakage occurs through or past the closure during the test. The pipe shall then be filled with water and the air expelled.

D2.3 Pressure shall be applied gradually to the inside of the pipe until the specified test pressure, measured at the lowest point of the pipe, is reached. The test pressure shall be maintained on the pipe for a period equal to 1 min, plus 30 s for each 12.5 rnrn or part thereof of wall thickness of the pipe.

D2.4 While the pipe is under the test pressure it shall be tapped repeatedly with a wooden mallet weighing approximately 0.5 kg and having a handle approximately 250 rnrn in length.

NZS 3107:1978 32

APPENDIX E

INTERNAL DIAMETERS OF PIPES AS MANUFACTURED

El For information purposes the nominal internal diameters and the range of actual internal diameters of pipes, as manufactured at the date of publication of the standard, are listed in parts 1 and 2 of table 7.

For pressure pipes the diameter designated by the manufacturer may be less than the nominal diameter, and may be subject to negotiation between purchaser and manufacturer at the time of ordering.

Table 7

Norrrinal dia .

150

300

400

500

600

700

800

900

1000

1200

1400

1600

1800

33

ACTUAL INTERNAL DIAME'lERS OF PIPES AS MANUFACTURED

Class S

152

310

410

510

620

720

820

920

1030

1240

1450

1680

1880

Part 1 METRIC PIPE SIZES

(All dimensions in millimetresl

Actua l interna l diameters

Class X ClassY

152 152

310 310

410 400

510 510

620 610

720 710

820 810

920 910

1030 1020

1240 1220

1450 1420

1680 1630

1880 1830

NZS 3107:1978

Class Z

152

300

400

500

600

700

800

900

1000

1200

1400

1600

1800

NZS 3107:1978 34

Table 7 - continued

ACTUAL INTERNAL DIAME'lERS OF PIPES AS MANUFACTURED

Part 2 METRIC EQUIVALENTS OF IMPERIAL PIPE SIZES

NominaZ internaZ Class C CZassS CZassX dicoreter of pipe

mm in TT1TI in mm in mm in

100 4 102 4 102 4 102 4

150 6 152 6 152 6 152 6

225 9 229 9 229 9 229 9

300 12 305 12 305 12 305 12

375 15 381 15 381 15 381 15

450 18 457 18 457 18 457 18

525 21 533 21 533 21

600 24 610 24 610 24

750 30 762 30 762 30

900 36 914 36.5 914 36.5 , 1050 42 1067 42 1067 42

1200 48 1219 48 1219 48

1350 54 1372 54 1372 54

1500 60 1524 60 1524 60

1650 66 1676 66 1676 66

1800 72 1829 72 1829 72

2000 80 2032 80 2032 80

2100 84 2134 84 2108 83

2250 90 2311 91 2286 90

2400 96 2438 96 2438 96

35 NZS 3107 :1978

Table 7 - oontinued

AcrUAL INTERNAL DIAME'lERS OF PIPES AS MANUFACTURED

Part 2 METRIC EQUIVALENTS OF IMPERIAL PIPE SIZES

Nominal internal Class Y Class Z diameter of pipe

mm in mm in mm 1,.n

100 4 102 4 102 4

150 6 152 6 152 6

225 9 229 9 229 9

300 12 305 12 305 12

375 15 381 15 375 14.75

450 18 457 18 451 17.75

525 21 533 21 521 20.50

600 24 603 23.75 590 23.25

750 30 756 29.75 730 28.75

900 36 902 35.50 883 34.75

1050 42 1054 41.50 1022 40.25

1200 48 1207 47.50 1175 46.25

1350 54 1359 53.50 1327 52.25

1500 60 1505 59.25 1467 57.75

1650 66 1657 65.25 1619 6~. 75

1800 72 1810 71.25 1 772 69.75

2000 80 2019 79.50 1981 78

2100 84 2108 83 2096 82.50

2250 90 2286 90 2273 89.50

2400 96