Hkkjrh; ekud IS 784 : 2019

Indian Standard

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Prestressed Concrete Pipes

( Including Specials ) —
Specification
( Third Revision )

ICS 23, 040.50; 91.100.30

© BIS 2019

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BUREAU OF INDIAN STANDARDS
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MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI-110002
www.bis.org.in www.standardsbis.in

March 2019 Price Group 12

Cement Matrix Products Sectional Committee, CED 53

FOREWORD
This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by
the Cement Matrix Products Sectional Committee had been approved by the Civil Engineering Division Council.
This standard was first published in 1959 and subsequently revised in 1978 and 2001. In the first revision in 1978,
the major modifications included introduction of prestressed concrete cylinder pipes, requirements of fittings,
provision of more details on design criteria for the pipes, etc. In the second revision in 2001, the changes incorporated
included modification in design and other aspects, inclusion of typical worked out example of design, inclusion of
detailed inspection procedure, and inclusion of additional tests on pipes.
This standard lays down the requirements of prestressed concrete pipes primarily used for the conveyance of
water and sewerage and specials for use with them. Two types of prestressed concrete pipes are covered by this
specification, namely, prestressed concrete cylinder pipes and prestressed concrete non-cylinder pipes.
While reviewing this standard, in the light of experience gained since its last revision, the Committee decided to
revise it also considering the present practices being followed by concrete pressure pipe industry. The Committee
further decided to update the standard considering the tests on finished product followed in other countries/
internationally.
This revision incorporates number of modifications, the most significant of them being:
a) Modification in design and other related aspects,
b) Inclusion of detailed specifications of cylinder type pipe,
c) Inclusion of typical worked out example of design of cylinder type pipe, and
d) Inclusion of additional tests on pipes.
In the formulation of this standard, assistance has been derived for EN 642 : 1994 ‘Prestressed concrete pressure
pipes, cylinder and non-cylinder’, European Committee for Standardization (CEN).
The composition of the Committee responsible for formulation of this standard is given at Annex M.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960
‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the rounded off
value should be the same as that of the specified value in this standard.
 IS 784 : 2019

Indian Standard
PRESTRESSED CONCRETE PIPES
(INCLUDING SPECIALS) — SPECIFICATION
( Third Revision )
1 SCOPE within 25 percent of pump head in case of pumping
This standard covers the requirements of prestressed main).
concrete pipes (including specials) with nominal 3.6 Factory Test Pressure
internal diameter in the range of 200 mm to 2 500 mm
( see Table 1, Notes ), in which permanent internal a) Site test pressure + 0.1 N/mm2, for working
stresses are deliberately introduced by tensioned steel pressure up to 1 N/mm2, and
to the desired degree to counteract the stresses caused b) Site test pressure + 0.2 N/mm2, for working
in pipe under service. pressure above 1 N/mm2.

2 REFERENCES 3.7 Surge (Water Hammer) Pressure — It is a pressure

which is produced by a change of velocity of the moving
The standards listed in Annex A contain provisions stream and becomes maximum when there is sudden
which through reference in this text constitute stoppage which may be caused by the closing of valve
provisions of this standard. At the time of publication, or by shutting down a pump station. Surge pressure may
the editions indicated were valid. All standards are be controlled within 25 percent of pump head.
subject to revision and parties to agreement based on
this standard are encouraged to investigate the 4 MATERIALS
possibility of applying the most recent edition of the
4.1 Cement
standards indicated in Annex A.
The cement used in the manufacture of prestressed
3 TERMINOLOGY concrete pipes and specials shall be one of the
For the purpose of this standard, the following following:
definitions shall apply. a) Ordinary Portland cement conforming to IS 269,
3.1 Prestressed Concrete Cylinder Pipe — A welded b) Portland slag cement conforming to IS 455
sheet steel cylinder with steel socket and spigot rings with slag not more than 50 percent,
welded to its ends for rubber ring joints or site welded c) Sulphate resisting Portland cement
joints, lined with concrete suitably compacted and conforming to IS 12330,
circumferentially prestressed to withstand internal d) Portland pozzolana cement conforming to
pressure and external design loads and subsequently IS 1489 (Part 1) with fly ash contents not more
coated with cement mortar or concrete to protect the than 25 percent, and
steel cylinder and prestressing wires. e) Rapid hardening Portland cement coforming
to IS 8041.
3.2 Prestressed Concrete Non-Cylinder Pipe — A NOTE — Sulphate resisting Portland cement shall be used,
suitably compacted concrete core longitudinally where sulphate is predominant.
prestressed with pretensioned high tensile steel wire
embedded in the concrete, circumferentially prestressed 4.2 Aggregates
and coated with cement mortar or concrete to protect The aggregates shall conform to IS 383. The provision
the circumferential prestressing wire, to withstand of 6 (Grading) of IS 383 shall not apply. The
internal pressure and external design loads. manufacturer shall furnish the grading curve for coarse
3.3 Specials — All items in the pipeline other than and fine aggregates which he proposes to use. The
straight pipes of standard length, such as bends, air valves variation in fineness modulus during manufacture shall
and scour valve tees, etc, are classified as specials. not be more than ± 5 percent. Silt content in natural sand
shall be less than 3 percent and in case of crushed sand,
3.4 Working Pressure — The maximum sustained
it shall be less than 10 percent. The fineness modulus of
internal pressure excluding surge to which each portion
the aggregates for coating shall be between 2.6 and 3.2.
of the pipeline may be subjected when installed.
3.5 Site Test Pressure — 1.5 times working pressure 4.3 Water
pertaining to the section or 1.1 times static pressure, Water used for mixing of concrete and curing of pipes
whichever is more (surge pressure is to be controlled shall conform to 5.4 of IS 456.

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IS 784 : 2019

4.4 Admixtures Table 1 Nominal Internal Diameter and Minimum

Admixtures may be used with the approval of the Core Thickness of Pipes
purchaser. However, use of any admixture containing (Clause 5.1)
chlorides in any form shall be prohibited. The admixtures Sl Nominal Internal Minimum Core
shall conform to IS 9103. No. Diameter of Pipe Thickness
mm mm
4.5 Steel for Reinforcement (1) (2) (3)
4.5.1 Prestressing Steel i) 200 35

Prestressing steel wire shall conform to IS 1785 (Part 1) ii) 250 35

or IS 1785 (Part 2) or IS 6003 or IS 6006. For iii) 300 35
longitudinal prestressing, wire having tensile strength, iv) 350 35
less up to 15 percent of ultimate tensile strength, may v) 400 35
be used, if required. This is to avoid excessive wear of vi) 450 35
rollers for threading, or cracking of wire during button
vii) 500 35
heading for end anchors.
viii) 600 40
4.5.2 Untensioned Reinforcement
ix) 700 40
Untensioned reinforcement may consist of mild steel x) 800 45
conforming to IS 432 (Part 1) or IS 432 (Part 2) or xi) 900 55
high strength deformed bars conforming to IS 1786 or
xii) 1 000 60
plain hard drawn steel wire conforming to IS 1785
xiii) 1 100 65
(Part 1) and IS 1785 (Part 2) or welded wire fabric
conforming to IS 1566. xiv) 1 200 70
xv) 1 300 75
4.6 Steel for Cylinder, Joint Rings and Specials
xvi) 1 400 75
Steel plates for cylinders, joint rings and specials shall xvii) 1 500 80
conform to IS 2062 or its equivalent with a minimum xviii) 1 600 85
yield stress of 250 N/mm2.
xix) 1 700 90
4.7 Rubber Sealing Rings xx) 1 800 95

4.7.1 Rubber sealing rings shall comply with IS 5382. xxi) 1 900 100
The manufacturer of pipe shall examine each sealing xxii) 2 000 105
ring visually for defects, particularly at the joints. xxiii) 2 100 110
4.7.2 Every sealing ring shall be clearly marked. The xxiv) 2 200 115
marking shall indicate the chord diameter, internal xxv) 2 300 120
diameter of the ring and name of the manufacturer of xxvi) 2 400 125
rubber sealing rings. xxvii) 2 500 130
4.7.3 In case of splices, each splice shall be thoroughly NOTES
visually checked by twisting the ring through 360°. 1 The internal diameter of pipes other than those mentioned in
Splices showing visible separation or cracks shall be this table may be supplied by mutual agreement between the
purchaser and the manufacturer. For higher pressure, the core
rejected. Not more than two splices in each ring shall thicknesses have to be increased. In such cases,
be permitted. All sealing rings shall be protected from a) the diameter will be correspondingly reduced (this is to
direct rays of the sun and stored in dry place. enable use of same moulds); and
b) multiple layers of circumferential prestressing wire shall
4.8 Bitumen or Other Protective Coating be adopted.
2 This standard includes provision up to 2 500 mm diameter pipes.
The purchaser may specify the application of an external Pipes of diameter beyond 2 500 mm may be supplied in special
or internal bituminous epoxy or other approved coating cases by mutual agreement between the purchaser and the
manufacturer subject to additional precautions taken in design,
to be applied. When the pipes are to be used for carrying manufacture, testing and construction of the pipe.
potable water, the inside coating shall not contain any 3 For internal diameter of pipes in between those mentioned
constituents soluble in such water or any ingredient which above, minimum core thickness shall be arrived at by linear
could impart any taste or odour to the potable water. interpolation.

5 DIMENSIONS AND TOLERANCES 5.2 Length

5.1 Nominal internal diameter of the pipes and minimum Effective length of non-cylinder pipes shall be up to 6 m,
core thickness shall be as given in Table 1. and effective length of cylinder pipes shall be up to 7 m.

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 IS 784 : 2019

However, for pipes of diameter up to and including 300 7.4.1 Longitudinal Prestressing Requirements
mm, the effective length shall not exceed 3 m.
The permissible stresses for various load combinations
5.3 Tolerance shall be as follows:
5.3.1 Length Sl Description of Permissible Stresses
Tolerance on length for non-cylinder pipe shall be ±1 No. Loading
percent of the specified length. For cylinder pipe Combination
tolerances on length shall be ± 2.5 percent of the Tension Compression
specified length. N/mm2 N/mm2
5.3.2 Internal Diameter (1) (2) (3) (4)
5.3.2.1 Pipes of length up to 3 m i) Longitudinal — Minimum residual
prestress compression of 2.5
The tolerance on diameter shall be ±5 mm (over entire (after losses) in N/mm2 for upto and
length) for diameter up to 300 mm. For diameter above barrel including pipe dia
300 mm, the tolerance shall be ±10 mm (over entire length). 600 mm and 1.0
5.3.2.2 Pipes of length above 3 m N/mm2 for dia above
For pipes of length above 3 m, the tolerance on 600 mm
0.5
diameter shall be as given below: ii) Longitudinal 0.56 fp 0.5 fp
prestress During
Internal Diameter Tolerances circumferential
In Areas Within Over Rest of prestressing
600 mm from the Pipe (temporary)
End of the Pipe
mm mm iii) Longitudinal 0.34 fck0.5 0 . 5 fck
Up to 900 mm ± 6 ± 9 prestress after
losses plus beam
Over 900 mm and ± 9 ± 12
action
up to 1 600 mm
iv) Handling 0.67 0.5 fp
Over 1 600 mm ± 12 ± 12
v) Transport and 0.56 fck0.5 0.5 fck
5.3.3 Core Thickness unloading
The core thickness shall not be less than the design where
thickness by more than 5 percent. The manufacturer fp = characteristic compressive strength of concrete
shall declare the core thickness and the above tolerance at p days in N/mm2, and
shall be applicable to that core thickness. fck = characteristic compressive design strength of
concrete in N/mm2.
6 JOINT DIMENSIONS NOTES
1 Longitudinal stresses induced in the core during circumferential
Joint dimensions with tolerances for socket and spigot prestressing shall be treated as temporary and shall be equal to 0.284
diameters shall be furnished by the manufacturer for times initial compressive stress induced in core.
inspection. The indicative dimensions of socket and 2 For longitudinal stress due to beam action, a pipe shall be assumed
to span its full length and support a total load per metre in Newtons
spigot are given in Annex B. equal to the self weight, the weight of the water in the pipe and earth
load equivalent to 2.2 times the outside diameter of pipe (in mm).
7 DESIGN 3 For calculation of number of longitudinals for transport and
7.1 Information to be supplied by the purchaser is given unloading conditions; following bending moment shall be considered
in Annex C. for effective length of pipes up to 5 m and diameter up to 600 mm:
Dia Bending Moment
7.2 All pipes shall be designed to withstand the combined mm N mm
effects of internal water pressure and external loads. 200 3.04 × 107
250 3.78× 107
7.3 The design of the prestressed concrete pipes shall cover 300 4.59 × 107
all such stages, which may induce stresses in any section 350 5.45 × 107
400 6.37 × 107
of the pipe. For investigation of these design stages, the 450 7.36 × 107
likely extreme conditions of stresses shall be considered 500 8.44 × 107
in the order of their occurrence, during the process of 600 11.08 × 107
manufacture, handling, erection and under service. For pipes having effective length more than 5 m, the bending moment
shall be multiplied by a factor (L/5)2, where L is the effective length of
7.4 Design Criteria for Non-Cylinder Pressure Pipes pipe. For pipes above 600 mm diameter, no special consideration is
necessary. The minimum number of longitudinals for 4 m and 5 m
The pipes shall be designed to meet the requirements long pipes shall be 12 and 16, respectively.
given in subsequent clauses.
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IS 784 : 2019

7.4.2 Typical calculation for the design of longitudinal type pipe, with winding by process of counter weight/
for pipe diameter 600 mm and below is given in break is given in Annex G.
Annex D.
7.7 Typical design of prestressed concrete pipe for
7.4.3 Circumferential Prestressing Requirements drainage, sewerage and culverts is given in Annex J.
The permissible stresses for various loading
7.8 Design Criteria for Cylinder Pipes
combinations shall be as given below:
The pipes shall be designed to meet the following
Sl Description of Loading Permissible Stresses condition:
No. Combination
Sl Description of Loading Permissible Stresses
Tension Compression No. Combination
N/mm2 N/mm2 Tension Compression
(1) (2) (3) (4) N/mm2 N/mm2
i) Circumferential 0 0.55 fp (1) (2) (3) (4)
prestressing condition i) Circumferential 0 0.55fp
(Self weight + Initial Prestressing condition
prestress) (Self weight + Initial
ii) Site test condition 0.13 fck().67 0.45 fck prestress)
(Site test pressure + ii) Site test condition 0.38 fck 0.67 0.45 fck
Self weight + Weight (Site test pressure +
of water + Earth fill+ Self weight + Weight of
Final prestress) water + Earth fill +
iii) Factory test condition 0.13 fck0.67 0.45 fck Final prestress)
(Factory test pressure + iii) Operating condition 0 0.45 fck
Self weight + Weight (Working pressure +
of water + Prestress at
Self weight + Weight
factory test)
of water + Earth fill +
iv) Operating condition 0 0.45 fck Final prestress)
(Working pressure +
Self weight + iv) Operating conditions + 0.38 fck0.67 0.45fck
Weight of water + Live load (with impact)
Earth fill + where
Final prestress) fp = characteristic compressive strength of
v) Operating condition + 0.13 fck0.67. 0.45 fck concrete at p days, in N/mm2.
Live load (with fck = characteristic compressive design strength
impact) of concrete, in N/mm2.
Where
fp = characteristic compressive strength of concrete at 7.8.1 Typical design of prestressed concrete cylinder
p days, in N/mm2. pipe with winding by process of counter weight/ break
fck = characteristic compressive design strength of is given in Annex H.
concrete, in N/mm2.
NOTES 8 MANUFACTURE
1 The total tensile stress in the core shall be considered as the sum of
the hoop stress and flexural stresses, without the application of any
reduction factor. 8.1 Core
2 When calculating hoop stress, only core thickness should be
considered. When calculating ovalization flexural stress, the sum of 8.1.1 Moulds
the core and coating thickness should be considered.
3 For calculating bending moments and thrusts for external loads, The moulds and method of manufacture of pipe shall
Olander's coefficients are to be used. The values for bedding angles from be such that the form and dimensions of the finished
30° to 180° are given in Annex E. pipe conform to the requirements given in 5 and 12
4 When submitted to factory test, the mortar or concrete coated pipe
shall not have cracks in the coating wider than 0.1 mm for more than and the surface and edges are clean and true.
300 mm length.
8.1.2 Concrete Mix
7.5 Loss of prestress in circumferential and longitudinal
The proportions of cement, fine aggregate, coarse
wires shall be calculated as per Annex F.
aggregate and water used in concrete for pipe core shall
7.6 Typical design of prestressed concrete non-cylinder be determined and controlled as the work proceeds to

4
 IS 784 : 2019

obtain homogeneous, dense, workable, durable including the socket, by means of high tensile steel wires
concrete of specified strength in the pipe, and minimum or strands, which shall be provided with permanent
defects on the surface of the pipe. The proportions shall anchorages embedded in the concrete, within the joint
be those that will give the best overall results with the portion at each end. The centreline spacing between the
particular materials and the methods of placing used longitudinal wires measured along the barrel shall not
for the work. A minimum of 450 kg/m3 of cement shall exceed twice the core thickness or 150 mm, whichever
be used for concrete. The water cement ratio shall be is greater, subject to the provision of 7.4.1, Sl No. (iii).
such, as to ensure that the concrete will meet the strength
The clear cover of concrete over all steel reinforcement
requirements, but in no case it shall exceed 0.45. The
including the ends of the longitudinal prestressing wires,
soluble chloride ion content of the concrete or mortar
shall be such that in any finished pipe it is nowhere less
mix, expressed as a percentage of the mass of cement
than 12 mm.
shall not exceed 0.20 percent. For spun concrete, initial
water cement ratio at the time of mixing is high for 8.3.1 The longitudinal wires shall be stressed to the
workability and final water cement ratio after designed tension, taking into account the loss of stress
compaction is lower than initial water cement ratio. in wire. The tension shall be maintained by positive
Hence, the requirements for concrete given in 9.2.1 of means till detensioning.
IS 456 which are for constant water cement ratio are
8.3.2 The tensioned wires shall not be released until
not applicable. However, manufacturer has to do the
the concrete in the core has attained a compressive
mix design for designed strength.
strength of at least two times the initial longitudinal
Unless the design calls for higher concrete strength, prestress or 15 N/mm2, whichever is greater.
the minimum compressive strength of concrete in the
8.3.3 Wire diameter for longitudinal prestressing shall
core shall not be less than 40 N/mm2 at 28 days.
not be less 4 mm.
8.1.3 Placing of Concrete
8.4 Circumferential Prestressing
The concrete in the cores may be placed either by the
centrifugal method, vertical casting method, or by other 8.4.1 Circumferential prestressing shall not take place
approved methods. For centrifugal spinning method, until the concrete in the core has reached a minimum
concrete shall be deposited in the mould and the speed of compressive strength of 25 N/mm2, or as per the design
rotation during placing shall be such, that concrete will requirements, whichever is greater.
be evenly distributed. The same is sufficiently compacted 8.4.2 The initial stress in the wire during circumferential
at the specified thickness throughout the length of the pipe. winding shall not be more than 75 percent of the
After the concrete has been deposited, the rotation shall minimum ultimate tensile strength of wire, when
be continued at an increased speed, for a length of time counter-weight or break system is used for developing
sufficient to provide the specified strength, sufficient tension.
compaction and bond; to permit handling of the mould
from the spinning machine, without damage to the pipe 8.4.3 The initial compressive stress induced in the core
core. Excess water and laitance shall be removed from concrete shall not exceed 55 percent of the compressive
the interior surface of the pipe in anapproved manner so strength of the concrete in the pipe at the time of
that the surface is solid, straight and true. transfer.
8.4.4 Methods and equipments for wrapping the wire
8.2 Curing of Core and Cover Coat shall be such that wire shall be wound around the core
The curing of the concrete core and that of cover coat in a helical form at the predetermined design spacing
shall be in two separate operations. The curing for core and capable of controlling the tension. Wire splicing
shall be for a period, till it attains the required strength. shall be capable of withstanding a force equal to the
full strength of wire. At the ends of core pipe, the wire
Curing shall be either by steam or by water or by a shall continue for at least one extra circumferential turn
combination of steam and water, or by use of approved before being anchored.
curing compounds. Coating shall be cured for a
minimum period of 7 days, if water curing is used. If 8.4.5 The clear spacing between the successive turns
steam curing is used for coating, after that it should be of the circumferential prestressing wires shall be not
water cured for at least 3 days. less than 6 mm, except at ends or at joints and shall be
not more than 50 mm.
8.3 Pretensioning and Release of Longitudinal Wires
8.4.6 Wire diameter for circumferential winding shall
The concrete core shall be longitudinally prestressed, not be less than 4 mm.

5
IS 784 : 2019

8.4.7 Test Cube Conversion Factors 8.5.8 Mortar Soundness

The core concrete compressive strength shall be taken on After the mortar coating is cured and prior to transport,
cubes of 150 mm × 150 mm × 150 mm. Where the process the coating on each pipe shall be checked for
of manufacture is such that the strength of concrete in the delamination and hollows by tapping the exterior with
pipe differs from that given by tests on vibrated cubes, the a hammer having a head mass of not more than 0.5 kg.
two may be related by suitable conversion factors. If the Any hollows or drumming areas detected by sounding
purchaser requires evidence of these factors, he shall ask shall be repaired by approved methods.
for it, before placing the order. The core concrete strength 8.5.9 All cement coming in contact with each other shall
shall be obtained by multiplying the cube strength with be of same type and composition and shall be from the
the conversion factor and shall be used for design purpose.
same cement works.
In the absence of any data, the compressive strength
for spun concrete at 28 days may be obtained by 9 ADDITIONAL REQUIREMENTS FOR
multiplying the cube compressive strength with a CYLINDER PIPES
conversion factor of 1.25. 9.1 The prestressed concrete cylinder pipes shall be
manufactured to comply with the following additional
8.5 Cover Coating
requirements.
8.5.1 The circumferential prestressing wires on the core
9.1.1 Steel Socket and Spigot Joint Rings
pipes shall be protected with a layer of rich cement
mortar or concrete or any other approved material Each ring shall be formed by one piece of steel or a
which prevents corrosion of wire. number of pieces of steel butt welded together. The
rings shall be expanded beyond their elastic limit so as
8.5.2 If cement mortar is used for cover coating, it shall
be applied by rotary brushes or by other approved to maintain accurate shape and dimensions. Joint rings
methods and shall preferably be applied within 16 h after shall be protected from corrosion.
the prestressing wire is wound. The cement, sand and The minimum thickness of steel joint ring suitable for
water shall be thoroughly mixed, before being fed into site welded joint shall be as given below:
the cover coating machine. Minimum cement content in Nominal Internal Nominal Wall
coating mortar shall be 540 kg/m3 and that for concrete Diameter Thickness of Joint Rings
500 kg/m3. Water cement ratio in the mix shall not be mm mm
less than 0.27, if cement mortar is used for coating. 200 5.0
Rebound or droppings not exceeding one fourth of the 250 5.0
total mass of mix, may be used but the resulting mix 300 5.0
proportions shall not be, leaner than original design mix. 350 5.0
Rebound not used within one hour, shall be discarded. 400 5.0
8.5.3 Pneumatic process in which mixing of ingredients 450 5.0
is carried out at the nozzle or gunshall not be permitted. 500 5.0
8.5.4 The compressive strength of the cover coating 600 5.0
mortar shall be obtained from cubes having area of face 700 5.0
50 cm2 or the compressive strength of the cover coating 800 5.0
concrete shall be obtained from cube having area of 900 6.0
face 100 cm2 and shall not be less than 35 N/mm2 at the 1 000 7.0
time of factory testing of pipe. 1 100 7.0
8.5.5 The mortar coating shall have a minimum cover of 1 200 8.0
18 mm and concrete coating shall have a minimum cover 1 300 8.0
of 25 mm, over all steel, except at end face and the spigot 1 400 8.0
portion going inside socket, where it will be not less than 1 500 8.0
15 mm. To achieve adequate bond between core and 1 600 10.0
coat, approved bonding agent shall be applied, at ends 1 700 10.0
of pipe for a width of 50 mm, along the circumference
1 800 10.0
to prevent separation between core and coat, at ends.
1 900 12.0
8.5.6 Concurrently with the mortar coating, cement slurry 2 000 12.0
shall be applied on to the core at a rate of not less than 2 100 12.0
0.5 litre/m2 just ahead of the mortar coating. The slurry
2 200 12.0
shall consist of 1.2 kg of cement to per litre of water.
2 300 14.0
8.5.7 The thickness shall be checked for every pipe as 2 400 14.0
soon as, coating is done. 2 500 14.0

6
 IS 784 : 2019

9.1.2 Fabrication of Steel Cylinders with steel joint rings embedded at ends for site welding.
In case of pipes for culverts, joints may be spigot and
The cylinder shall be accurately shaped to the size
socket, roll on gasket joint, confined gasket joint or
required and steel socket and spigot rings welded
flush joint. The joint shall be designed such that it will
thereto after being jigged square with the longitudinal
be water tight under all service conditions. Joint design
axis (except for bevel). The minimum wall thickness of
shall be furnished by manufacturer before undertaking
steel cylinders shall be 1.6 mm.
manufacture. The rubber ring joint design, shall take
9.1.2.1 Testing into consideration the tolerance for rubber cord,
tolerance for socket and spigot diameters, allowable
Before it is subjected to any further manufacturing
deflection at joint and permanent set in the rubber ring.
process, each steel cylinder with steel socket and spigot
rings welded on it, shall be subjected to water pressure 11.2 The sealing rings shall be of such size that when
which stresses the steel to at least 140 N/mm2, but not jointed, in accordance with the manufacturer’s
more than 175 N/mm2. The test pressure shall be held instructions, it shall provide a positive seal within the
for 1 min. While under stress, the assembly especially manufacturer’s recommended range of maximum joint
welds, shall be inspected and any parts showing leakage deflection. Not more than two splices in each ring shall
shall be repaired and the whole assembly retested. be permitted.

10 SPECIALS 12 WORKMANSHIP AND FINISH

10.1 Fabrication 12.1 Deviation from the Straightness

The steel for fabricated steel plate specials is cut, shaped When measured by means of a 1 m straight edge the
and welded so that the finished special has the required deviation from straight per metre length shall not exceed
shape and internal dimensions. Adjacent segments are 5 mm.
joined by butt welding. Before lining and coating, the 12.2 Finish
welding of specials shall be tested by use of hot oil or dye
penetrate according to IS 3658 and defects, if any shall Pipe shall be free from local depressions or bulges
be rectified. The steel plate thickness for specials shall be greater than 5 mm extending over a length, in any
as given in IS 1916. In die penetration test, a white wash direction, greater than twice the thickness of barrel.
is applied over the weld on one side of the cylinder; on The external surface of the pipe may be sand faced,
other side when colored paraffin or similar product is when coating of cement mortar is applied.
applied over the weld, no colored spot shall appear on the 13 TEST
white wash before 4 h. If any coloured spots appear before
4 h, weld shall be repaired and retested. 13.1 Design Proving and Manufacturing Process
Approval Test in Factory
10.2 LINING AND COATING
This test is applicable for pipes with rubber ring joint
Steel plate specials are lined and coated with concrete only. As soon as 4 to 5 pipes are made, at least 2 to 3
or cement mortar or other approved materials, as agreed pipes shall be installed and site pressure test shall be
to between the manufacturer and the purchaser. The conducted, to prove and finalize pipe and joint design
proportion of cement to total aggregate shall not be and joint dimension tolerances, etc. For one diameter
leaner than 1:3 by mass. and different pressure, only the test for highest pressure
shall be done. For this test no external load should be
10.3 Reinforcement
applied. See the typical sketch as shown in Annex L.
For concrete or cement mortar coating, reinforcement
shall be suitably tack welded to the shell. The 13.2 Hydrostatic Factory Test
reinforcement shall be wire rods and spirals or wire mesh 13.2.1 Non-Cylinder Pipes
or wire fabric. The pipe shall be tested in accordance with IS 3597.
10.4 Jointing Between Special and Pipe The pipe shall not show leakage. Damp or wet patches
shall be accepted. If the pipe fails to pass the test, it
The specials shall be jointed to the pipe by rubber ring can be cured or repaired to improve its water tightness
joint or by welding or by caulking as the case may before and then retested. In case the pipe does not stand the
pipe joints only. rated internal pressure, it shall be accepted for lower
pressure, purchaser at his own discretion may accept
11 JOINTS
the pipes for lower pressure to which it withstands,
11.1 Unless otherwise specified, joints between pipes provided all other requirements are conforming to this
shall be of spigot and socket type with rubber ring or standard.

7
IS 784 : 2019

13.2.2 Cylinder Pipes requirement of final permeability. The final

permeability shall not exceed 0.3 cm3.
The pipe shall be tested in accordance with IS 3597.
The pipe shall not show leakage. Cylinder pipe when When a higher result is obtained, the test shall be
subjected to hydrostatic test pressure at factory, the repeated on twice the number of pipes originally tested
mortar coating shall not have the crack wider than and the lot shall be accepted, if all pipes pass the test.
0.1 mm for 300 mm length. Damp patches appearing Where the retest is not satisfactory, all pipes from that
on the surface of the cylinder pipe shall not be allowed. lot may be tested individually, and only those with
satisfactory results shall be accepted.
In case the non-cylinder pipes or cylinder pipes used
NOTE — It is recommended that initial absorption should
for drainage, sewerage and culverts as non-pressure not exceed 2.0 cm 3 and the difference in any two
pipes of NP2/NP3/NP4 class loading, the pipes shall consecutivereadings during initial absorption should not be
be tested for 0.14 N/mm2. more than 0.8 cm3.

NOTE — For explanation of NP2, NP3 and NP4, see IS 458. 13.4 Three Edge Bearing Test (for Pipes for
Drainage, Sewerage and Culverts)
13.3 Permeability Test on Coating
Pipes designed for drainage, sewerage and culverts when
The permeability test when conducted in accordance subjected to three edge bearing test in accordance with
with the method described in IS 3597 shall meet the IS 3597 shall meet the requirement as given in Table 2.

Table 2 Three Edge Bearing Test Loads for Pipes for Drainage, Sewerage and Culverts
( Clause13.4 )
Sl Nominal Internal NP2 Class NP3 Class NP4 Class
No. Dia of Pipe Load to Produce Maximum Load to Produce Maximum Load to Produce Maximum
mm 0.25 mm Crack 0.25 mm Crack 0.25 mm Crack
kN/m kN/m kN/ m

(1) (2) (3) (4) (5)

i) 200 11.77 14.50 24.60
ii) 250 12.55 15.00 25.50
iii) 300 13.48 15.50 26.40
iv) 350 14.46 16.77 29.80
v) 400 15.45 19.16 33.90
vi) 450 16.18 21.56 36.90
vii) 500 17.16 23.95 40.00
viii) 600 18.88 28.74 46.30
ix) 700 20.35 33.53 52.20
x) 800 21.57 38.32 59.30
xi) 900 22.80 43.11 66.30
xii) 1 000 24.27 47.90 72.60
xiii) 1 100 25.50 52.69 80.40
xiv) 1 200 26.97 57.48 88.30
xv) 1 300 28.20 62.30 96.20
xvi) 1 400 29.42 67.06 104.20
xvii 1 500 30.77 71.85 111.90
xviii) 1 600 32.12 76.64 119.60
xix) 1 700 33.59 81.40 127.40
xx) 1 800 35.06 86.22 135.30
xxi) 1 900 36.41 91.00 135.30
xxii) 2 000 37.76 95.80 135.30
xxiii) 2 100 38.99 100.60 138.70
xxiv) 2 200 40.21 105.38 142.20
xxv) 2 300 — 110.00 148.60
xxvi) 2 400 — 114.96 155.00
xxvii) 2 500 — 119.70 160.80
NOTE — Pipes with other three-edge bearing test requirements may be supplied by agreement between the purchaser
and the manufacturer.

8
 IS 784 : 2019

13.5 Dimensional Characteristic periods either 240, 300, 360, 420 or 480 min until the
requirement is met.
The pipe selected shall be checked for conformity to
the dimensional requirements as given below: If the requirement has not been met at 480 min, the
pipe has failed to the test, and in such case further 2
a) Socket and spigot diameters of the pipes as pipes from the batch shall be tested. If both pipes
given by manufacturer. passed for the test, the batch shall be accepted.
b) Dimensional requirements as given in 5.
The test shall be applied to one pipe in batch up to 500
13.6 Repair of Core and Coat pipes.
Pipes not satisfying any of the tests, which may be 14 SAMPLING AND CRITERIA FOR
arising due to occasional imperfection in manufacture ACCEPTANCE
or damages during handling may be treated/repaired
and shall be accepted, if they satisfy the tests. The curing 14.1 Pressure Pipes for Water Supply and Sewerage
of the repaired concrete or mortar may be done using Basic requirement, unless the design proving and
curing compound. manufacturing process test given in 13.1 is satisfactorily
carried out, no acceptance tests shall be undertaken.
13.7 Boiling Absorption Test on Coating Mortar
This has to be done for every new diameter of pipe and
Coating mortar samples shall be drawn and tested for for one pressure.
boiling absorption test according to method described All the pipes manufactured under relatively similar
in IS 3597. Test value shall consist of the average of a conditions in respect of raw-materials and processing
minimum of three samples taken on same day from the operation shall be grouped together to constitute a lot.
same working shift. The average absorption shall not
exceed 9 percent and no individual sample shall have Each lot shall be taken separately for sampling and
an absorption exceeding 11 percent. Testing shall be evaluation, for conformity to the requirements of this
performed on a weekly basis. standard, if the conditions mentioned in 5.1, 5.2, 5.3,
11.1, 11.2 and 12.2 are satisfied (even after repairs).
13.8 Pressure Permeability Test on Coating Scale of sampling shall be as given in Table 3.
The test is to determine the water permeability of the 14.2 For non-pressure pipes for drainage, sewerage and
mortar cover coat on the finished pipe under a constant culvert, only permeability test from Table 3 besides
pressure on water column by non destructive means. dimensions and three edge load bearing test is necessary.
Test is to be conducted as per procedure specified in 14.3 After the lot is accepted, each pipe shall be marked
IS 3597. with a colour band at ends. Different colours to be used
The ratio of cumulative absorption per hour to area of for different pressure heads.
cup orifice in contact with the pipe surface is to be 15 PROCEDURES FOR INSPECTION
calculated. The ratio shall not exceed 0.15 per hour for
the period between 121 and 180 min into the test. 15.1 Dimensional Checks
If this requirement has not been attained in the above 15.1.1 Internal Diameter
stipulated period, the test is to be continued for further The internal diameter shall be measured at each end

Table 3 Scale of Sampling and Number of Acceptable Defective Samples

(Clause14.1)
Sl Number Hydrostratic Socket and Permeability Coating Dimensional Three Edge
No. of Pipes Test Spigot Thickness Test Bearing Test
in Lot Dimension Drainage,
Sewerage,Culvert
Pipes
* ** * ** * ** * ** * ** * **
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
i) 20-50 All Nil All Nil 3 Nil 3 Nil 3 Nil 2 Nil
ii) 51-100 All Nil All Nil 5 Nil 5 Nil 5 Nil 2 Nil
iii) 101-300 All Nil All Nil 8 Nil 8 Nil 8 Nil 3 Nil
iv) 301-500 All Nil All Nil 10 Nil 10 Nil 10 Nil 4 Nil
v) 501-1 000 All Nil All Nil 14 1 14 1 14 1 5 Nil

*Number of samples.
**Number of defective acceptable.

9
IS 784 : 2019

of the pipe at approximately 50 mm from the ends Example:

and also at centre (for internal diameter above
Suppose the theoretical diameter of socket, D = 1 383 mm
700 mm). Two measurements of internal diameter
at 90 ° to each other shall be made at each end and 2
Permissible variation –0.05 mm
at centre.
The maximum diameter, D1 = 1 385 mm
To accomplish this, ‘Go’ and ‘No Go’ gauges of a
stiff rod with hardened rounded ends shall be used. The minimum diameter, D2 = 1 382.5 mm
The length of gauges and colour shall be as given
The sway, S = 2 × [h×(D1×h )]0.5
below:
Assume, h = 5 mm (see Fig. 1)
Length Colour
Gauges for ends: Sway, S = 2 × [5 × (1 385 × 5)]0.5
‘Go’ 1 mm less than Green
= 2 × 83
diameter after applying
= 166 mm
- ve tolerance
L2 = (S / 2)2 + ( D1 ×h)2
‘No Go’ 1 mm more than the Orange
diameter after applying = (166/2)2 + (1 385 × 5)2
+ve tolerance = 6 889 + 1 904 400
Gauges for centre (for internal diameter of pipes above
L = 1 382.5 mm
700 mm):
This should not be more than the minimum permissible
‘Go’ 1 mm less than the Green with
inside diameter.
diameter after applying white bands
- ve tolerance Therefore, in this case
‘No Go’ 1 mm more than the Orange with Length of gauge, L = 1 382.5 mm
diameter after applying white bands
Maximum permissible sway = 166 mm.
+ve tolerance
Example:
Suppose theoretical diameter of pipe = 1 200 mm and
length of pipe 5 m.
Tolerance Length of gauge
Ends +9 ‘Go’ 1 200 – 9 – 1 = 1 190 mm
‘No Go’ 1 200 + 9 + 1 = 1 210 mm
Centre ± 12 ‘Go’ 1 200 – 12 – 1 = 1 187 mm
‘No Go’ 1 200 + 12 + 1 = 1 213 mm
15.1.2 Core Thickness Gauge for Measuring Sway
FIG . 1ARRANGMENT FOR M EASURING SWAY
Measurement of outer circumference of core shall be
made at three barrel positions and average outer 15.1.3.2 Spigot diameter
diameter of core shall be calculated. The inside diameter
The gauge as shown in Fig. 2 shall be used.
shall be measured at three barrel positions and average
is calculated. The core thickness shall be calculated as Example:
follows:
Suppose the theoretical outside diameter of spigot =
Average outside diameter  Average inside diameter 1 200 mm
=
2 Permissible variation = + 1 mm
15.1.3 Socket and Spigot Diameters The maximum diameter = 1 201 mm
15.1.3.1 Socket diameter (jointing surface) The minimum diameter = 1 199 mm
The socket diameter shall be checked by measuring To enable gauge to pass over the spigot surface the
the sway by touching the two points B and B1, along diameter must be more by 1 mm than the maximum
the circumference of socket (see Fig. 1); BB1 gives the spigot diameter.
sway.

10
 IS 784 : 2019

The clearance between gauge points = Any deviation from straightness of the bore of pipe
1 200 + 1 + 1 = 1 202 mm. shall be assessed by the use of a gauge as shown in
Fig. 3. When edge Y is used and both ends are not in
For checking spigot, the gauge is held in the positionas
contact with the pipe bore, it shall be deemed not to
shown in Fig. 2. Then by keeping point ‘X’ fixed, other
comply with this standard.
end ‘Y’ of gauge is moved over thecircumference of spigot,
where the gap between spigot surface and gauge is
maximum, a strip 2.5 mm thick and 25 mm wide (straight
side) (1 201 × 1 199 = 2.0 mm) is inserted. It should not
go. Two checks shall be done at 90° to each other.

FIG. 3 ARRANGMENT FOR CHECKING STRAIGHTNESS

16 MARKING
16.1 The following information shall be clearly marked
on each pipe:
a) Source of identification of the manufacturer,
b) Size and hydrostatic factory test pressure, and
c) Date of manufacture.

16.2 BIS Certification Marking

Each pipe may also be marked with the Standard Mark.

FIG. 2 A RRANGMENT FOR CHECKING S PIGOT DIAMETER 16.2.1 The use of the Standard Mark is governed by
the provisions of the Bureau of Indian Standards Act,
15.1.4 Straightness 2016 and the Rules and Regulations made thereunder.
The details of conditions under which a licence for the
The straightness shall be measured by a 1 m long gauge. use of Standard Mark may be granted to manufacturer
The deviation from straight line taken between two and producers may be obtained from the Bureau of
points one metre apart, along the pipe barrel shall not Indian Standards.
exceed 5 mm (see Fig. 3).

ANNEX A
(Clause 2)
LIST OF REFERRED INDIAN STANDARDS
IS No. Title IS No. Title
269 : 2015 Specification for ordinary Portland (Part 1) : 1982 Mild steel and medium tensile steel
cement (sixth revision) bars (third revision)
383 : 2016 Specification for coarse and fine (Part 2) : 1982 Hard-drawn steel wire (third revision)
aggregate for concrete (third 455 : 2015 Specification for Portland slag
revision) cement (fifth revision)
432 Specification for mild steel and 456 : 2000 Code of Practice for plain and
medium tensile steel bars and hard- reinforced concrete (fourth revision)
drawn steel wire for concrete 458 : 2003 Precast concrete pipes (with and
reinforcement: without reinforcement — Specification
(fourth revision)
11
IS 784 : 2019

IS No. Title IS No. Title

783 : 1985 Code of practice for laying of 3597 : 1998 Methods of test for concrete pipes
concrete pipes (first revision) (second revision)
1489 (Part 1) : Specification for Portland pozzolana 3658 : 1999 Code of practice for liquid penetrant
2015 cement: Fly ash based (fourth flaw detection (second revision)
revision) 5382 : 1985 Specification for rubber sealing rings
1566 : 1982 Specification for hard-drawn steel for gas mains, water mains and
wire fabric for concrete reinforcement sewers (first revision)
(second revision) 5986 : 2017 Specification for hot rolled steel
1785 Specification for plain hard-drawn sheet, plate and strip for forming and
steel wire for prestressed concrete flanging purpose (fourth revision)
(Part 1) : 1983 Cold-drawn stress relieved (second 6003 : 2010 Specification for prestressed concrete
revision) (first revision)
(Part 2) : 1983 As drawn wire (first revision) 6006 : 2014 Specification for relieved strand for
1786 : 2008 Specification for high strength deformed prestressed concrete (first revision)
steel bars and wires for concrete 6240 : 2008 Specification for hot rolled steel plate
reinforcement (fourth revision) (up to 6 mm) sheet and strip for the
1916 : 1989 Specification for steel cylinder pipes liquefiable gas cylinders
with concrete lining and coating (first 8041 : 1990 Specification for rapid hardening
revision) Portland cement (second revision)
2041 : 2009 Steel plates for pressure vessels used 9103 : 1999 Specification for admixtures for
at moderate and low temperature — concrete (first revision)
Specification (third revision) 10748 : 2004 Specification for hot-rolled steel
2062 : 2011 Hot rolled medium and high tensile strips for welded tubes and pipes
structural steel — Specification 12330 : 1988 Specification for sulphate resisting
(seventh revision) Portland cement

ANNEX B
(Clause 6)
INDICATIVE DIMENSIONS OF SOCKET AND SPIGOT OF
PRESTRESSED CONCRETE NON-CYLINDER PIPE

B-1 The indicative dimensions of socket and spigot of prestressed concrete pipe are given below (see also Fig. 4):

FIG. 4 DETAILS OF J OINTS

12
 IS 784 : 2019

Nominal Dia of Roll on Joint Confined Joint

Pipe
C B C B
A
Internal Dia of External Dia of Internal Dia of External Dia of
mm
Socket Spigot Socket Spigot
mm mm mm mm
Spigot
200 308 290 308 290
250 352 334 352 334
300 404 386 404 386
350 456 438 456 438
400 518 500 518 500
450 562 544 562 544
500 612 594 612 594
600 726.5 704 726.5 704
700 826.5 804 826.5 804
800 937.5 915 937.5 915
900 1 058.5 1 036 1 058.5 1 036
1 000 1 165.5 1 141 1 165.5 1 141
1 100 1 270.5 1 246 1 270.5 1 246
1 200 1 381.5 1 357 1 381.5 1 337
1 300 1 496.5 1 472 1 496.5 1 472
1 400 1 595.5 1 571 1 595.5 1 571
1 500 1 706 1 678 1 706 1 678
1 600 1 818 1 790 1 818 1 790
1 700 1 928 1 900 1 928 1 900
1 800 2 036 2 008 2 036 2 008
1 900 2 154 2 126 2 154 2 126
2 000 2 264 2 236 2 264 2 236
2 100 2 374 2 346 2 374 2 346
2 200 2 488 2 454.5 2 488 2 431.5
2 300 2 598 2 564.5 2 598 2 564.5
2 400 2 708 2 674.5 2 708 2 674.5
2 500 2 818 2 784.5 2 818 2 784.5
FIG

13
IS 784 : 2019

ANNEX C
(Clause 7 .1)
INFORMATION TO BE SUPPLIED BY THE PURCHASER WITH AN ENQUIRY OR ORDER
FOR PRESTRESSED CONCRETE PIPES

C-1 The following information shall be supplied: 2) The width of the trench at the crown of
the pipe (normally outside diameter of
a) The type of cement to be used in the core and
pipe + 600 mm). If the pipes are to be
the cover coat (see 4.1);
laid above ground in case of partial trench,
b) Whether or not a bituminous or other full details including L-section should be
approved coating is required internally and supplied.
externally (see 4.8);
3) Whether more than one pipeline is to be
c) The maximum working pressure (see 3.4); laid in the trench and if so, what will be
d) The maximum site test pressure (see 3.5); the trench width at the crown of the pipe.
e) Factory test pressure (see 3.6); 4) Details of the backfill material, that is,
f) Pressure in addition to (c) to which the pipeline sand, gravel, etc.
will be subjected due to surge (water hammer) 5) Density of filling material.
(see 3.7), if any; 6) Type of bedding intended.
g) Following pipe installation details: 7) Anticipated superimposed loading on
1) The maximum and minimum depths of ground surface.
cover over the crown of the pipe. h) Site soil investigation and soil data.

ANNEX D
(Clause 7.4.2)
TYPICAL CALCULATION FOR THE DESIGN OF LONGITUDINALS FOR
PIPE DIAMETER 600 mm AND BELOW

D-1 Explanation of various symbols used in subsequent Initial compressive stressinduced in core, fci
clauses is given in Annex K. = 10.657 5 N/mm2 (Assumed)
D-2 DATA D-3 CALCULATION OF STRESS IN
Diameter of pipe, D = 500 mm LONGITUDINAL DIRECTION
Effective length of pipe, L = 5 000 mm D-3.1 Centre Line Spacing Between Longitudinal
Core thickness, Tc = 35 mm Wires
Coat thickness, Tb = 22 mm
Centreline spacing between longitudinal wires shall not
Minimum compressive strength of core concrete (spun) exceed twice the core thickness or 150 mm, whichever
at various stages:
is greater ( see 8.3 )
a) Characteristic compressive design strength, fck
= 2 × Tc or 150 mm, whichever is greater
= 40 N/mm2
b) At winding (see 8.4.1), fp2 = 25 N/mm2 = 2 × 35 = 70 or 150 mm, whichever is
greater that is, 150 mm.
c) At detensioning longitudinals (see 8.3.2), fp1
= 15 N/mm2 Number of longitudinals considered in design = 16
Diameter of longitudinal wire = 4 mm Centreline spacing between longitudinal wire
Ultimate tensile strength of wire (see 4.5.1) = 3.1416 ×(D+Tc)/N
= 1 715 N/mm2
14
 IS 784 : 2019

= 3.1416 × (500 + 35)/ 16, D-3.4 Precompression in Core in Longitudinal

= 105.04 mm < 150 mm Direction
Hence, number of longitudinal considered in design is At the stage of winding:
correct.
Loss of prestress in longitudinal wire at winding
D-3.2 Initial Longitudinal Precompression in Core = Total losses × 0.9 = 212.63 × 0.9
Initial stress in longitudinal wire ( see 8.4.2), fsil = 191.37N/mm2
= 1 715 × 0.75 Stress in longitudinal wire at winding, fslw
= 1 286.25 - 191.37
= 1 286.25 N/mm2
= 1 094.88 N/mm2
Area of core concrete, Ac = 3.141 6 × 535 × 35
Precompression atwinding, fclw
= 58 826.46 mm2
16 × 12.57 × 1094.88
=
Longitudinal precompression 58 826.46
= 3.743 2 N/mm2
Longitudinal force N × Adl × fsil At site test:
= =
Ac Ac
Stress in longitudinal wire after losses, fsl
Initial precompression, fcil = 1 286.25 - 212.63
= 1 073.62 N/mm2
16 × 12.57 × 1286.25
= Final precompression, fcl
58826.46
= 4.397 5 N/mm2 16 × 12.57 × 1073.62
=
Concrete strength required at detensioning of 58 826.46
longitudinals, fpl ( see 8.3.2 ) = 3.670 5 N/mm2

= 2 ×fcil or 15 N/mm2, whichever D-3.5 Longitudinal Stress Due to Circumferential

is greater, Winding
= 2 × 4.397 5 = 8.795 0 or Maximum local longitudinal tensile stress during
15 N/mm2, winding
Adopt fpl = 15 N/mm2 = 0.284 × 10.657 5
D-3.3 Loss of Stress in Longitudinal Wires = 3.026 7 N/mm2
(see Annex F)
D-3.6 Stress Due to Beam Action
a) Relaxation of wire
Self weight of pipe, Ws = 2 295.62 N/m
= 0.08 ×fsi l = 0.08 × 1 286.25
= 102.90 N/mm2 Weight of water, Ww = 1 963.50 N/m
b) Deformation due to creep Earth load to be considered ( see 7.4.1 )
= 2.50 ×fcil = 2.50 × 4.397 5 = 2.2 × ( D + 2 ×Tc + 2 ×Tb )
= 10.99 N/mm2 = 2.2 × 614
= 1 350.80 N/m
c) Deformation due to shrinkage
Total load, W = Ws + Ww+ 1 350.80
= 0.000 1×Es= 0.0001×20.0 × 104
= 20.00 N/mm2 = 5 609.92 N/m
d) Yield due to mould shortening, wire stretchdue Modulus of circular section of pipe, Z1
to filling, vibration during spinning, etc
2 × Es 3.1416 614 4 – 500 4
= Effective length of pipe +80 mm = ×
32 614
= 12 731 728 mm3
2× 20×104
=
5000 + 80 Bending moment, BM =
WL2 5 609.92 × 5 × 5 × 1 000
=
= 78.74 N/mm2 8 8
= 17 531 000 Nmm
Total losses = 102.90 + 10.99 + 20.0 + 78.74
= 212.63 N/mm2 BM
Stress due to beam action = = ±1.376 9 N/mm 2
Z1

15
IS 784 : 2019

D-3.7 Stress Due to Self Weight of Core Stress due to transport and handling
Self weight of core, Wc = 1 411.84 N/m Bending moment 8.44 × 10 7
= = = ± 6.629 1 N/mm2
Modulus of circular section of core, Z2 Z1 12 731728
3.141 6 570 4 – 500 4 D-3.9 Summary of Stresses in Longitudinal Direction
= × = 7 416 520 mm3
32 570
B.M. due to mass of core, BM Stress Due to Compressive Tensile
N/mm2 N/mm2
= 1 411.84 × 5 × 5 × 1000 = 4 412 000 Nmm Maximum local — – 3.026 7
8 longitudinal tensile stress
Stress due to self weight of core due to bending
during winding
BM
= = ± 0.594 9 N/mm 2 Beam action + 1.376 9 – 1.376 9
Z2
Self weight of core + 0.594 9 – 0.594 9
D-3.8 Stress Due to Transport and Handling Transport and unloading + 6.6291 – 6.629 1
Bending moment (see Note 3 under 7.4.1) Initial precompression + 4.397 5 —
= 8.44 × 107 Precompression at winding + 3.743 2 —
Final precompression + 3.670 5 —
Modulus of circular section of pipe, Z1
3.141 6 614 4 – 500 4 D-3.10 Load Combination of Longitudinal Stresses
= × = 12 731 728 mm3
32 614 Under Different Condition (see 7.4.1)
See Table 4.

Table 4 Actual Against Permissible

(Clause D-3.10)
Sl Loading Longitudinal Stresses, N/mm2
No. Combination
Tensile Compressive
Permissible
Actual Permissible Actual Minimum Residual
Compressive Stress
(1) (2) (3) (4) (5) (6)
i) Longitudinal
prestress in barrel – – + 3.6705 + 2.5
(after losses)
ii) Longitudinal = -(3.026 7+0.594 9) = 0.56 × (fp2)0.5 = (0.594 9 + = 0.5 ×fp2
prestress during +3.743 2 = 0.56 × (25)0.5 3.743 2) = 0.5 × 25
winding = + 0.121 6 = -2.800 0 = + 4.338 1 = 12.50
+ 0.1216 < - 2.800 0 + 4.338 1 < 12.500 0
Longitudinal = (-1.376 9 +3.670 5) = 0.34 × (fck)0.5 = (1.376 9 + = 0.5 ×fck
iii) prestess after = + 2.293 6 = 0.34 × (40)0.5 3.670 5) = 0.5 × 40
losses plus beam = -2.1503 = + 5.047 4 = 20.00
action + 2.293 6 < - 2.150 3 + 5.047 4 < 20.00
iv) Handling before = (-0.594 9 + 3.743 2) = - 0.67 = (0.594 9 + = 0.5 ×fpl
winding = + 3.148 3 3.743 2) = 0.5 ×15
= + 4.338 1 = 7.50
+ 3.148 3 < - 0.67 + 4.338 1 < 7.50
0.5
v) Transport and = - 6.629 1 + 3.670 5 = 0.56 × (fck) = + 6.629 1 + = 0.5 ×fck
unloading = - 2.958 6 = 0.56 × (40)0.5 3.670 5 = 0.5 × 40
= - 3.5417 = + 10.299 6 = 20.00
- 2.958 6 < -3.541 7 + 10.299 6 < 20.00

16
 IS 784 : 2019

ANNEX E
(Clause 7.4.3)
THRUST AND MOMENT COEFFICIENTS
E-1 The coefficients at control sections for bedding angles from 30° to 180° developed by use of Olander’s
Equations are as given below:

Bedding Location of Thrust Coefficients, Ct Moment Coefficient, Cm

Angle Control
Section, θ Pipe Water Earth Pipe Water Earth
Ctp Ctw Cte Ctp Ctw Cte
(1) (2) (3) (4) (5) (6) (7) (8)
0o - 0.078 -0.237 +0.487 +0.079 +0.079 +0.062
30o 104o +0.302 -0.058 +0. 633 + 0.100 +0.100 +0.085

180o +0.125 -0.352 +0.376 +0.194 +0.194 +0.173

o
0 -0.071 -0.230 +0.425 +0.076 +0.076 +0.065
60o 104o +0.302 -0.059 +0.576 +0.096 +0.096 +0.086
o
180 +0.168 -0.310 +0.345 +0.155 +0.155 +0.145
0o -0.061 -0.220 +0.382 +0.070 +0.070 +0.069
o o
90 104 +0.295 -0.062 +0.539 +0.088 +0.088 +0.089
180o +0.207 -0.270 +0.326 +0.121 +0.121 +0.125
o
0 -0.046 -0.205 +0.351 +0.063 +0.063 +0.073
120o 100o +0.282 -0.065 +0.516 +0.077 +0.077 +0.091
o
180 +0.245 -0.233 +0.316 +0.091 +0.091 +0.109
0o -0.026 -0.185 +0.331 +0.054 +0.054 +0.079
o
150o 96 +0.267 -0.067 +0.504 +0.063 +0.063 +0.094
180o +0.282 -0.196 +0.313 +0.065 +0.065 +0.097

0o -0.000 -0.159 +0.318 +0.044 +0.044 +0.087

180o 90o +0.250 -0.068 +0.500 +0.047 +0.047 +0.095
o
180 +0.318 -0.159 +0.318 +0.044 +0.044 +0.087

17
IS 784 : 2019

ANNEX F
(Clause 7.5)
LOSS OF PRESTRESS

F-1 Explanation of various symbols used in subsequent F-2 CALCULATION FOR LOSS OF PRESTRESS
clause is given in Annex K.

Sl Loss of Prestress Longitudinal Circumferential

No. Due to (Pre-Tensioning) (Post-Tensioning)
(1) (2) (3) (4)
i) Elastic deformation — 3.2 fci
ii) Relaxation of wire 0.08fsil 0.08 fsi
iii) Deformation due to creep 2.5 fcil 2.5fci
iv) Deformation due to shrinkage 0.000 1 Es 0.000 1 ES
v) Yield due to mould shortening 2 ES —
(wire stretch due to filling, L  80
vibrations during spinning, etc.
slippage = 2 mm)
where
fcil = initial precompression in core due to longitudinal prestressing, in N/mm2.
fci = initial compressive stress induced in coredue to circumferential prestressing, in N/mm2.
fsi = initial stress in circumferential wire during winding, in N/mm2.
fsil = initial stress in longitudinal wire at longitudinal prestressing, in N/mm2 .
Es = modulus of elasticity of high tensile wire.
= 2.00 × 10 5 N/mm 2 ( for stress relieved), and
= 1.93 × 105 N/mm2 (for as drawn).
L = effectiv e length o f p ipe, in mm.
NOTE — Loss of stress in high tensile wire at factory test pressure will be 90 percent of the total losses

F IG. 1 AR

ANNEX G
(Clause 7.6 )
TYPICAL DESIGN OF PRESTRESSED CONCRETE NON-CYLINDER PIPE OF
DIAMETER 1 200 mm — WINDING BY PROCESS OF COUNTER WEIGHT/BREAK

G-1 Explanation of various symbols used in subsequent Working pressure , Pw (see 3.4) = 0.700 N/mm2
clauses is given in Annex K. Site test pressure, Ps = 1.050 N/mm2
Factory test pressure,Pt = 1.150 N/mm2
G -2 DATA
Height of fill, H = 1.00 m
Diameter of pipe, D = 1 200 mm Density of fill material , ke = 15 700 N/m3
Effective length of pipe, L = 5.0 m Live load = Class AA (IRC)

18
 IS 784 : 2019

G-3 ASSUMPTIONS Centre to centre spacing of spiral wire

Density of core concrete, Kc = 24 000 N/m 3 1 000
=
49.57
Density of coating, Kb = 21 600 N/m3
= 20.17 mm
Density of water, Kw = 10 000N/m3
Clear spacing of spiralwire = 20.17 – 4
Process for winding = Counter weight/ = 16.17 mm
Break
Clear spacing of spiralwire is 16.17 mm is in between
Core thickness, Tc = 70 mm 50 mm and 6 mm. Hence, the area of spiral (AS)
Coat thickness, Tb = 22 mm considered is correct.

Width of trench (D + 2Tc + 2Tb +600), Bt Initial stress in wire during winding ( see 8.4.2 ), fsi
= 0.75 × 1 715
= 1.984 m = 1 286.25 N/mm2
Diameter of circumferential wire, ds
= 4 mm G-4.2 Initial Compressive Stress Induced in Core, fci
Diameter of longitudinal wire, d1 1 286.25 × 0.623
=
= 4 mm 70
= 11.447 6 N/mm2
Number of longitudinals, N = 28
G-4.3 Loss of Stress in Wire ( see Annex F )
Ultimate tensile strength of circumferential wire
(see 4.5.1) = 1 715 N/mm2 a) Elastic deformation
Ultimate tensile strength of longitudinal wire (see 4.5.1) = 3.2 ×fci = 3.2 × 11.447 6
= 1 715 N/mm2 = 36.63 N/mm2
Area of circumferential wire, As = 0.623 mm2/mm b) Relaxation of wire
= 0.08 ×fsi = 0.08 × 1 286.25
Modulus of elasticity of steel, ES = 20 × 104 N/mm2
= 102.90 N/mm2
Modulus of elasticity of concrete, Ec
= 4× 104 N/mm2 c) Deformation due to creep
= 2.5 × 11.447 6
Modular ratio, n =5
= 28.62 N/mm2
Minimum compressive strengthof core concrete (spun)
d) Deformation due to shrinkage
at various stages:
= 0.000 1 × Es= 0.000 1×20 × 104
a) Characteristic compressive design strength, fck = 20.00 N/mm2
= 40 N/mm2
Total losses = 36.63+102.90+28.62+20.00
b) At winding, fp2 ( see 8.4.1 ) = 188.15 N/mm2
= 25 N/mm2
Losses of factory test
c) At detensioning longitudinal, fp1 ( see 8.3.2 ) = 0.9 × Total loss = 0.9 × 188.15
= 15 N/mm2 = 169.34 N/mm2
G-4 CALCULATION OF PRESTRESS IN CORE Stress in wire at factory test, fsf
IN CIRCUMFERENTIAL DIRECTION = 1 286.25 – 169.34
G-4.1 Spacing of Circumferential Wire = 1 116.91 N/mm2
Stress in wire at site test, fs
Allowable clear spacing ( see 8.4.5 )
=1 286.25 × 188.15
Maximum clear spacing of wire = 50 mm = 1 098.10 N/mm2
Minimum clear spacing of wire = 6 mm
G-4.4 Compressive Stress Induced in Core at
Area of spiral considered indesign, As Factory Test, fcf
= 0.623 mm2 /mm
Number of turns permetre length 1 116.91 × 0.623
=
70
0.623 × 1 000 = +9.940 5 N/mm2
=
0.785 4 × ( 4 )
2

G-4.4.1 Compressive Stress in Core at Site Test, fct

= 49.57

19
IS 784 : 2019

G-4.8 Weight of Earth Fill (see Fig. 4 of IS 783 ), We

1098.10 × 0.623
=
70 = (Ct× Ke×Bt2)
= + 9.773 1 N/mm2 = 0.472 3 × 15 700 × (1.984)2
= 29 187.77 N/m
G-4.5 Section Constant
where
a) Outside diameter of core, ODC
ke = 15 700 N/m3
= D + 2 ×Tc
Ct = 0.472 3
=1 340 mm
b) Outside diameter of pipe, ODP H 1.00
= 0.5040
= D + 2 ×Tc + 2 ×Tb Bt = 1.984
= 1 384 mm
We = (Ct× Ke×Bt2) = 0.472 3 × 15 700 × (1.984)2
c) Mean radius of pipe, r
= 29 187.77 N/m
D + Tc + Tb G-4.9 Live Load ( see 10.1 ), W1
=
2
= 646 mm = Cp × P/l × O
d) Modulus of section for circumferential stress, Z 0.664 × 613001×1
= 1/6× (TC+ Tb)2 × 1 000 =
3.918
= 1 410 667 mm3/m = 10 388.80 N/m
e) Sectional area, A
where
= (Tc+ Tb) × 1 000
= 92 000 mm2 P = Axle load = 61 300 N
f) Modulus of circular section of core, Z2 O = Impact factor = 1.0
l = 1.15 H + 2 ODP + S = 3.918 m
3.1416 ODC 4 – D 4 (Assuming S =0)
= ×
32 ODC
CP = 0.664 {the value of is obtained from Fig. 3
= 84 297 111 mm3 of IS 783, using the values, for ratio
g) Modulus of circular section of pipe, Z1
l 3.918
3.1416 ODP 4 – D 4 = = 1.959, and
= × 2H 2 ×1
32 ODP ODP 1.384
= = 0. 692
= 113 168 797 mm3 2H 2 ×1
G-4.6 Self Weight of Pipe, Ws 0.664 × 61 3 00 × 1
W1 = = 10 388.80 N/m
a) Self weight of core, Wc 3.918
= 3.141 6 ×(D + T)× Tc× Kc G-4.10 Calculations of Stresses Due to External
Loads
= 3.141 6× (1.200+ 0.070) × 0.070
× 24 000 Circumferential stresses due to external load Olander’s
= 6 702.92 N/m (coefficient for 90° bedding angle).
b) Self weight of coat, Wb
External Load At Bottom
= 3.1416 ×(D+ 2 ×Tc+Tb) × Tb× Kb
Moment ( Mb) Thrust ( Hb)
= 3.141 6 × (1.200 + 2 × 0.070 +
Self weight + 0.121 Wsr + 0.207 WS
0.022) × 0.022 × 21 600
Water weight + 0.121 Wwr – 0.270 Ww
= 2 033.31 N/m
Earth fill + 0.125 Wer + 0.326 We
c) Self weight of pipe, Ws Live load + 0.125 Wlr + 0.326 W1
= Wc + Wb
NOTES
= 8 736.23 N/m. 1 + Moment causes tension inside pipe at bottom.
2 Only stresses at bottom are calculated as those are more severe.
G-4.7 Weight of Water, Ww
= (3.141 6/4) × D2×Kw G-4.10.1 Stress Due to Self Weight of Pipe
= 0.785 4 × (1.200)2 × 10 000
= 11 309.76 N/m Moment, M = 0.121 × 8 736.23 × 646.0

20
 IS 784 : 2019

= 682 876.20 Nmm Stress due to moment

Thrust, T = 0.207 ×8 736.23 M 2 356 912.40
= 
= 180 840 N/m Z 1 410 667

Stress due to moment = 1.670 8 N/mm2

M 682 876.20 Stress due to thrust
= 
Z 1 410 667 T 9 515.67
= 
= 0.484 1 N/mm2 Z 9 2 000

Stress due to thrust = 0.103 4 N/mm2

T 1 808.40 Net tensile stress
= 
A 92 000 = (-1.670 8) + (+0.103 4)

= 0.019 7 N/mm2 = -1.567 4 N/mm2

Net tensile stress = (-0. 484 1) + (+0.019 7) Net compressive stress

= (+1.670 8) + (+0.103 4)
= -0.464 4 N/mm2
= +1.774 2 N/mm2
Net compressive stress
= (+ 0.484 1) + (+ 0.019 7) G-4.10.4 Stress Due to Live Load

= + 0.503 8 N/mm2 Moment, M = 0.125 × 10 388.8 × 646.0

= 838 895.60 Nmm
G-4.10.2 Stress Due to Weight of Water
Thrust, T = 0.326 × 10 388.8
Moment, M = 0.121 × 11 309.76 × 646.0
= 884 038.70 Nmm = 3 386.75 N/m

Thrust, T = - 0.270 × 11 309.8 Stress due to moment

–1.150 1 200 M 838 895.60
= - 3 053.64 N/m = 
2×[70 + (5× 0.623)] Z 1 410 667
Stress due to moment
= 0.594 7 N/mm2
M 884 038.70
= 
Z 1 410 667 Stress due to thrust
T 3 886.75
= 0.626 7 N/mm2 = 
A 92 000
Stress due to thrust
= 0.036 8 N/mm2
T –3 053.64 Net tensile stress = (-0.594 7) + (+ 0.036 8)
= 
A 92 000
= - 0.557 9 N/mm2
2
= – 0.033 2 N/mm
Net compressive stress
Net tensile stress = (-0.626 7) + (-0.033 2) = (+0.594 7) + (+ 0.036 8)
= -0.659 9 N/mm2
= + 0.631 5 N/mm2
Net compressive stress
= (+0.626 7) + (-0.033 2) G-4.11 Calculation of stresses in Pipe Core Due to
Internal Pressure
= +0.593 5 N/mm2 – Pt + D
G-4.10.3 Stress Due to Weight of Earth Fill a) At factory test, fwf = 2×[T + (n × A )]
c s

Moment, M = 0.125 × 29 187.77 × 646.0

= 2 356 912.40 Nmm =
Thrust, T = 0.326 × 29 187.77
= - 9.437 2 N/ mm2
= 9 515.21 N/m

21
IS 784 : 2019

– Ps + D 3.1416 × ( D + Tc ) 3.141 6 × (1 200 + 70)

b) At site test, fws = 2×[T + ( n × A )] = =
c s N 28
–1.050 ×1 200 = 142.49 mm
= 2×[70 + (5× 0.623)] = 142.49 mm < 150 mm
= - 8.616 6 N/ mm2 Hence, number of longitudinal considered in design is
– PW + D correct.
c) At working test, fww = 2×[T + ( n × A )]
c s G-6.2 Initial Longitudinal Precompression in Core
( see 8.4.2 )
– 0.700 ×1 200
=
2×[70 + (5× 0.623)] Initial stress in longitudinal wire, fsil

= - 5.744 4 N/ mm2 = 1 715.0 × 0.75

= 1 286.25 N/mm2
G-4.12 Summary of Circumferential Stresses
Area of core concrete, Ac
Sl Stresses Due to Tensile Compressive
No. N/mm2 N/mm2 = 3.141 6 × 1 270 × 70

(1) (2) (3) (4) = 279 288.24 mm2

i) External Loads : Longitudinal precompression

a) Self weight of pipe -0.464 4 + 0.503 8 Longitudinal force N × Adl × fsil

= =
AC AC
b) Weight of water -0.659 9 + 0.593 5
c) Weight of earth fill -1.567 4 + 1.774 2 Initial precompression ( fcil)
d) Live load -0.557 9 + 0.631 5
28 × 12.57 × 1 286.25
ii) Internal Pressure : =
279 288.24
a) Site test pressure -8.616 6 — = 1.620 9 N/mm2
b) Working pressure -5.744 4 — Concrete strength required at detensioning of
c) Factory test pressure -9.437 2 — longitudinal, fpl ( see 8.3.2 )
iii) Compressive Stress in Core Due to = 2 × fcil or 15 N/mm2, whichever
Circumferential Winding : is greater
a) Initial compressive — + 11.447 6 = 2 × 1.620 9 = 3.24 or 15 N/mm2,
stressb) Prestress at factory test — + 9.940 5 Adopt fp1 = 15 N/mm2
c) Prestress at site test — + 9.773 1
G-6.3 Loss of Stress in Longitudinal Wires ( see
G-5 CIRCUMFERENTIAL PRESTRESS Annex F)
REQUIREMENTS (see 7.4.3) a) Relaxation of wire
See Table 5. = 0.08 × fsil = 0.08 × 1 286.25
= 102.9 N/mm2
G-6 CALCULATION OF STRESS IN b) Deformation due to creep
LONGITUDINAL DIRECTION
= 2.50 ×fcil = 2.50 × 1.620 9
G-6.1 Centreline Spacing Between Longitudinal = 4.05 N/mm2
Wires (see 8.3) c) Deformation due to shrinkage
Centreline spacing between longitudinal wires shall not = 0.000 1×Es= 0.000 1×20.0× 104
exceed twice the core thickness or 150 mm, whichever = 20.00 N/mm2
is greater, that is = 2 × 70 or 150 mm d) Yield due to mould shortening (Wire stretch
= 150 mm due to filling, vibration during spinning, etc)
Number of longitudinal considered in design 2 × ES
= 28 =
Effective length of pipe + 80 mm
Centreline spacing between longitudinal wires

22
 IS 784 : 2019

Table 5 Actual against Permissible

(Clause G-5)
Sl Loading Circumferential Stresses
No. Combination N/mm2
Tensile Compressive
Actual Permissible Actual Permissible
(1) (2) (3) (4) (5) (6)
i) Circumferential prestressing – – = (0.503 8 + = 0.55 ×fp2
condition 11.447 6) = 0.55 × 25
(Self weight +Initial prestress) = 11.951 4 = 13.750 0
+ 11.951 4 < 13.750 0
0.67
ii) Site test condition = - (0.464 4+ = 0.13 ( fck) = (0.503 8 + = 0.45 ×fck
(Self weight + Weight of water 0.659 9 + = 0.13 × 0.593 5 + = 0.45 × 40
+Earth fill load +Site test press+ 1.567 4 + (40)0.67 1.774 2 + = 18.0
Final prestress) 8.616 6) + = - 1.54 9.773 1)
9.773 1 = +12.644 6
= -1.535 2
-1.535 2 < - 1.54 +12.644 6 < 18.0
0.67
iii) Factory test condition = -(0.464 4 + = 0.13 (fck) = (0.503 8 + = 0.45 × fck
(Self weight + Weight of water 0.659 9 + = 0.13 × (40)0.67 0.593 5 + = 0.45 × 40
+ Factory test pressure + 9.437 2) + = -1.54 9.940 5) = 18.0
Prestress at factory test) 9.940 5 = + 11.037 8
= -0.621 0
- 0.621 028<-1.54
12.57  1 101.13 +11.037 8 < 18.0
iv) Operating condition = -(0.464 4 + 0.00279 288.24 = (0.503 8 + = 0.45 × fck
(Self weight + Weight of water 0.659 9 + 0.593 5 + = 0.45 × 40
+ Earth fill load + Working 1.567 4 + 1.774 2 + = 18.0
pressure + Final prestress) 5.744 4) + 9.731)
9.773 1 = +12.644 6
= +1.337 0
+ 1.337 0 < 0.00 +12.644 6 < 18.0
0.67
v) Live load condition = (+1.337 0) + = 0.13 ( fck ) = (+12.644 6) + = 0.45 × fck
0.67
[Operating condition+ (-0.557 9) = 0.13 × (40) (+0.631 5) = 0.45 × 40
live load (with impact)] = +0.779 1 = -1.54 = +13.276 1 = 18.0
+0.779 1 < -1.54 +13.276 1 < 18.0
2 2
(fck = 40 N/mm , fp2 = 25 N/mm ), – ve is tensile, + ve is compressive
GGD; K

2  20  10 4 = Total loss × 0.9

= = 205.69 × 0.9
5 000  80
= 78.74 N/mm2 = 185.12 N/mm2
Stress in longitudinal wire at winding, fslw
Total losses = 102.9 + 4.05 + 20.0 + 78.74
= 1 286.25 – 185.12
= 205.69 N/mm2
= 1 101.13 N/mm2
G-6.4 Precompression in Core in Longitudinal Precompression at winding, fclw
Direction
At the stage of winding =
Loss of prestress in longitudinal wire at winding = 1.387 6 N/mm2

23
IS 784 : 2019

At site test BM
= Z1
Stress in longitudinal wire after losses, fsl
= 1 286.25 × 205.69
= 0.637 6N /mm2
= 1 080.56 N/mm2
Final precompression, fcl G-6.7 Stress Due to Self Weight of Core

28 × 12.57 × 1 080.56 Self weight of core, Wc

= = 6 702.92 N/m
279 288.24
Bending moment due to mass of core, BM
= 1.361 7 N/mm2
6 702.92 × 5 × 5 × 1000
G-6.5 Longitudinal Stress Due to Circumferential =
8
Winding
= 20 946 625 Nmm
Maximum local longitudinal tensile stress during
winding ( see Note 1 under 7.4.1 ) Modulus of circular section of core, Z2
= 84 297 111 mm3
= 0.284 × 11.447 6
= 3.251 1 N/mm2 Stress due to self weight of core
BM
G-6.6 Stress Due to Beam Action = Z
2
Self weight of pipe, WS
= +0.248 5 N/mm2
= 8 736.23 N/m
Weight of water, WW G-6.8 Summary of Stresses in Longitudinal
Direction
= 11 309.76 N/m
Earth load to be considered (see Note 2 under 7.4.1 ) Stresses Due to Tensile Compressive
= 2.2 × ODP N/mm2 N/mm2
—
1 384 Maximum local 3.251 1
= 2.2 × longitudinal tensile
1 000
stress due to bending
= 3.044 8 kN/m during winding
Total load, W = 8 736.23 + 11 309.76 + 3 044.80 Beam action + 0.637 6 – 0.637 6
= 23 090.79 N/m Self weight of core + 0.248 5 – 0.248 5
Bending moment, BM Initial precompression + 1.620 9 —
WL2 23 090.79 × 5 × 5 × 1000 Precompression at + 1.387 6 —
= =
8 8 winding
Final precompression + 1.361 7 —
= 72 158 719 Nmm
Modulus of circular section of pipe, Z1 G-6.9 Load Combination of Longitudinal Stresses
= 113 168 797mm3 Under Different Condition (see 7.4.1)
Stress due to beam action See Table 6.

24
 IS 784 : 2019

Table 6 Actual Against Permissible

(Clause G-6.9)
Sl Loading Longitudinal Stresses, N/mm2
No. Combination Tensile Compressive
Actual Permissible Actual Permissible
(1) (2) (3) (4) (5) (6)
i) Longitudinal prestress — — Minimum residual
+1.361 7
in barrel, (after losses) compressive stress
+1.361 7 > +1.0
0.5
ii) Longitudinal prestress = -(3.251 1 + = 0.56 × ( fp2) = (0.248 5 + = 0.5 × fp2
during winding 0.248 5) + = 0.56 × 250.5 1.387 6) = 0.5 × 25
1.387 6 = -2.800 0 = +1.636 1 = 12.500 0
= -2.112 0
-2.112 0 < -2.800 0 +1.636 1 < 12.500 0
0.5
iii) Longitudinal prestress = (-0.637 6 + = 0.34 × ( fck) = (0.637 6 + = 0.5 × fck
after losses plus beam 1.361 7) = 0.34 × (40)0.5 1.361 7) = 0.5 × 40
action = 0.724 1 = -2.150 3 = +1.999 3 = 20.0
0.724 1 < -2.150 3 +1.999 3 < 20.0
iv) Handling before = (-0.248 5)+ - 0.67 = (0.248 5 + = 0.5 × fpl
winding (+1.387 6) 1.387 6) = + = 0.5 × 15
= +1.139 1 1.636 1 = 7.50
+1.139 1 < - 0.67 +1.636 1 < 7.50
NOTE — As the diameter of pipe is above 600 mm, checking for load combination of transport and unloading is not necessary.

GFSGSDG '

ANNEX H
(Clause 7.8.1)
TYPICAL DESIGN OF PRESTRESSED CONCRETE CYLINDER PIPE OF DIAMETER 1 200 mm —
WINDING BY PROCESS OF COUNTER WEIGHT/ BREAK

H-1 Explanation of various symbols used in subsequent Height of fill, H = 1.0 m

clauses is given in Annex K. Density of fill material, Ke = 15 700 N/m3
Live load = Class AA (IRC)
H-2 DATA
H-3 ASSUMPTIONS
Diameter of pipe, D = 1 200 mm
Effective length of pipe, L = 5.0 m Density of core concrete, Kc = 24 000N/m3
Density of steel cylinder, Ks = 77 000 N/m3
Working pressure, Pw = 0.70 N/mm2
Density of coating, Kb = 21 600 N/m3
Site test pressure, Ps = 1.05 N/mm2
Density of water, Kw = 10 000 N/m3
Factory test pressure, Pt = 1.15 N/mm2
Core thickness, Tc = 75 mm

25
IS 784 : 2019

Steel cylinder thickness, Ty = 1.6 mm Initial Compressive Stress Induced in Core, fci
Coat thickness, Tb = 22 mm = fsi×As / ( Tc+ n Ty )
Width of trench, Bt = (D+2Tc+2Ty +
2Tb + 600) = 1 286.25 × 0.656/ (75 +
5 × 1.6)
= 1 997.20 mm
Diameter of circumferential wire, ds = 10.166 0 N/mm2
= 4 mm
H-4.3 LOSS OF STRESS IN WIRE (see Annex F)
Ultimate tensile strength of circumferential wire
= 1 715 N/mm2 a) Elastic deformation
Area of circumferential wire, As = 0.656 mm2/mm = 3.2 ×fci= 3.2 × 10.166 0
Area of steel cylinder, Ay = 1.6 mm2/mm = 32.53 N/mm2
Modulus of elasticity of steel, Es = 200 000 N/mm2 b) Relaxation of wire
Modulus of elasticity of concrete, Ec = 0.08 ×fsi = 0.08 × 1 286.25
= 40 000 N/mm2 = 102.90 N/mm2
Modular ratio (Es /Ec) = 5 c) Deformation due to creep
Minimum compressive strength of core concrete (spun) = 2.5 ×fci = 2.5 × 10.166 0
at various stages = 25.42 N/mm2
Characteristic compressive design strength, fck d) Deformation due to shrinkage
= 0.000 1 × Es = 0.000 1 ×
= 40 N/mm2 200 000
At winding, fp2 = 28 N/mm2
= 20.00 N/mm2
H-4 CALCULATION OF PRESTRESS IN CORE Total losses = 32.53 + 102.90 + 25.42 +
IN CIRCUMFERENTIAL DIRECTION 20.00
= 180.85 N/mm2
H-4.1 Spacing of Circumferential Wire
Losses at factory test = 0.9 × Total losses = 0.9 ×
Allowable Clear Spacing (see 8.4.5) 180.85
Maximum clear spacing of wire = 50 mm = 162.77 N/mm2
Stress in wire at factory test, fsf = Initial stress in wire
Minimum clear spacing of wire = 6 mm
during winding – loss in stress at factory test
Area of spiral considered in design, As
= 1 286.25 – 162.77
= 0.656 mm2/mm = 1 123.48 N/mm2
Number of turn per meter length Stress in wire at site test, fs = Initial stress in wire during
winding – Total loss of stress in wire
= As× 1 000 / (0.785 4 × ds2)
= 1 286.25 – 180.85
= 52.20 = 1 105.40 N/mm2
Centre to centre spacing of spiral wire H-4.4 Compressive Stress Induced in Core at
Factory Test, fcf = fsf×As / [Tc+ n ( As+Ay) ]
= 1 000 /Number of turns
= 1 123.48 × 0.656 / [75 +
= 19.16 mm
5 (0.656 +1.6) ]
Clear spacing of spiral wire
= 8.542 0 N/mm2
centre to centre distance = 15.16 mm Compressive stress induced in core at site test, fct
15.16 is in between 50 mm and 6 mm. Hence, the area
= fs×As / [ Tc+ n ( As + Ay) ]
of spiral (As) considered satisfies 8.4.5.
= 1 105.40 × 0.656 / (75 +
H-4.2 Initial Stress in Wire During Winding, fsi 5 (0.656 + 1.6)
(see 8.4.2) = 8.404 5 N/mm2
= 0.75 × 1 715 (UTS of H-4.5 Section Constant
circumferential wire) a) Outside diameter of pipe, ODP
= 1 286.25 N/ mm2 = D+2Tc+2Ty+2Tb
= 1 397.2 mm

26
 IS 784 : 2019

b) Mean radius of pipe, r H-4.9 Live Load, Wl

= ( D+Tc+Ty+Tb) / 2 = (Cp×P×a) /l
= 649.30 mm
= (0.669 × 61 300 × 1.0)/
c) Modulus of section for circumferential stress, Z
3.944
= 1/6 × ( Tc+ Ty +Tb)2 × 1 000
= 1 620 326.67 mm3/m = 10 396.94 N/m
d) Sectional Area, A where
= (Tc+nTy+Tb) ×1 000 P = Axle load = 61 300 N
= 105 000 mm2/m a = Impact factor = 1.0
H-4.6 Self Weight of Pipe, Ws l = 1.15 H+ 2 ODP+ S = 3.944 m (Assuming
a) Self weight of core, Wc S = 0)
= 3.141 6 × (D+Tc)/1 000 × Cp = 0.669 {the value of Cp is obtained from Fig. 3
(Tc /1 000) × KcWc of IS 783, using the values, for ratio
= 3.141 6×(1 200+75)/ l / 2H = 3.944 / (2 × 1.0) = 1.972 2, and ODP/2H
1 000×(22/1 000)×24 000 = 1.397 2/ (2 × 1.0) = 0.698 6}
= 7 209.97 N/m
H-4.10 Calculations of Stresses due to External
b) Self weight of steel cylinder, Wsc Loads
= 3.141 6× (D+2Tc+Ty)/
1 000 ×Ty /1 000 ×Ks Circumferential stresses due to external load (Olander’s
coefficient for 90° bedding angle):
= 3.141 6 × (1 200 + (2× 75)
+ 1.6) /1 000 × 1.6/ External Load At Bottom
1 000 × 77 000
= 523.13 N/m Moment (Mb ) Thrust ( H b )

c) Self weight of coat, Wb Self weight +0.121 W s r +0.207 W s

= 3.1 416×(D+2Tc+2Ty+Tb)/ Water weight +0.121 W w r - 0.270 W w
1 000×Tb/1 000×Kb
= 3.1 416×(1 200+ (2×75) Earth fill +0.125 W e r +0.326 W e
+ (2 × 1.6 +22)/1 000 × Live load +0.125 Wl r +0.326 W l
(22/1 000)× 21 600
NOTES
= 2 053.02 N/m 1 + Moment causes tension inside pipe at bottom.
Self weight of pipe, Ws 2 Only stresses at bottom are calculated as those are more severe.
= Wc+Wsc+Wb H-4.11 Calculations of Stresses due to External
= 9 786.12 N/m Loads at Bottom
H-4.11.1 Stress Due to Self Weight of Pipe
H-4.7 Weight of Water, Ww
Moment, M = 0.121 × 9 786.12 × 649.30
= 3.141 6/4×(D/1 000)2×Kw
= 768 849.45 Nmm
= 3.141 6/4×(1 200/1000)2 ×
Thrust, T = 0.207 × 9 786.120
10 000
= 2 025.73 N/m
= 11 309.76 N/m
Stress due to moment = M/Z = 768 849.45 /1 620
H-4.8 Weight of Earth Fill, We (see Fig. 4 of IS 783)
326.67
= Ct ×Ke× (Bt /1 000)2 = 0.474 5 N/mm2
= 0.472×15 700× (1 997.20/ Stress due to thrust = T / A =2 025.73/105 000
1 000) = 0.019 3 N/mm2
= 29 558.66 N/m Net tensile stress = (-0.474 5) + (+0.019 3)
where = -0.455 2 N/mm2
H/Bt = 1.0/1.997 2 = 0.500 701 Net compressive stress = (+0.474 5) + (+0.019 3)
Ct = 0.472 = 0.493 8 N/mm2
Ke = 15 700

27
IS 784 : 2019

H-4.11.2 Stress Due to Weight of Water H-4.12 Calculation of Stresses in Pipe Core Due to
Internal Pressure
Moment, M = 0.121×11 309.76× 649.30
= 888 554.69 Nmm (Coating thickness is not considered for calculating
Thrust, T = -0.270 × 11 309.76 hoop stress)
= -3 053.64 N/m a) At factory test, fwf
Stress due to moment = M /Z = 888 554.69/1 620 = (-Pt ×D)/[2 ×(Tc+ nAs+ nAy)]
326.67 = 0.548 4 N/mm2 = (-1.15×1 200)/[2 × (75 + 5 ×
Stress due to thrust = T / A= -3 053.64 /105 000 0.656 + 5 × 1.6)]
= -0.029 1 N/mm2 = -7.997 2 N/mm2
Net tensile stress = (-0.548 4) + (-0.029 1) b) At site test, fws
= -0.577 5 N/mm2 = (-Ps ×D)/[2 × (Tc+ nAs+ nAy)]
Net compressive stress = (+0.548 4) + (-0.029 1) = (-1.05 × 1 200)/[2 × (75 + 5 ×
= 0.519 3 N/mm2 0.656 + 5 × 1.6)]
= -7.301 8 N/mm2
H-4.11.3 Stress Due to Weight of Earth Fill
c) At working pressure, fww
Moment, M = 0.125×29 558.66 × 649.30
= (-Pw ×D)/[2 × (Tc+ nAs+ nAy)]
= 2 399 054.74 Nmm
= (-0.70×1200)/[2×(75
Thrust, T = 0.326 × 29 558.66 +5×0.656 +5× 1.6)]
= 9 636.12 N/m = -4.867 9 N/mm2
Stress due to moment = M/Z =2 399 054.74/1 620 Summary of Circumferential Stresses
326.67
= 1.480 6 N/mm2 Stresses Due To Tensile Compressive
N/mm 2 N/mm 2
Stress due to thrust = T / A = 9 636.12/105 000
a) External Loads
= 0.091 8 N/mm2
Self weight of pipe -0.455 2 + 0.493 8
Net tensile stress = (–1.480 6) + (+0.091 8) Weight of water -0.577 5 + 0.519 3
= 1.3888 N/mm
Weight of earth fill -1.388 8 + 1.572 4
Net compressive stress = (+1.480 6) + (+0.091 8) Live load -0.488 5 + 0.553 1
= 1.572 4 N/mm2 b) Internal Pressure
H-4.11.4 Stress Due to Live Load Factory test pressure -7.997 2
Site test pressure -7.301 8
Moment, M = 0.125×10 396.94× 649.30
Working pressure -4.867 9
= 843 841.64 Nmm
c) Compressive Stress in Core Due to
Thrust, T = 0.326 × 10 396.94 Circumferential Winding
= 3 389.4 N/m Initial compressive + 10.166 0
Stress due to moment = M /Z = 843 841.64/ stress
1 620 326.67 Prestress at factory + 8.542 0
= 0.520 8 N/mm2 test
Stress due to thrust = T / A = 3 389.4/105 000 Prestress at site + 8.404 5
= 0.032 3 N/mm2 test
Net tensile stress = (-0.520 8) + (+0.032 3)
= -0.488 5 N/mm2 H-5 CIRCUMFERENTIAL PRESTRESS
REQUIREMENTS ( see 7.9 )
Net compressive stress = (+0.520 8) + (+0.032 3)
= 0.553 1 N/mm2 See Table 7.

28
 IS 784 : 2019

Table 7 Actual Against Permissible

(Clause H-5)

Sl Loading Combination Circumferential Stresses, N/mm2

No.
Tensile Compressive
Actual Permissible Actual Permissible

(1) (2) (3) (4) (5) (6)

i) Circumferential = 0.493 8+ = 0.55×f p2
Prestressing Condition — — 10.166 0 = 0.55 × 28
(Self weight + = 10.659 8 =15.40
Initial prestress)
+ 10.659 8 < 15.40
0.67
ii) Site Test Condition = – 0.455 2 + = 0.38(fck) = 0.493 8 + = 0.45 fck
(Self weight + – 0.577 5 + = 0.38 × 400.67 0.519 3 + = 0.45 × 40
weight of water + – 1.388 8 + = –4.50 1.572 4 + = 18.00
Earth fill load + – 7.301 8 + 8.404 5
Site test pressure + 8.404 5 = – = 10.990 0
Final prestress) 1.318 8
–1.318 8 < – 4.50 10.990 0 < 18.0
0.67
iii) Factory Test Condition = – 0.455 2 + = 0.38(fck) = 0.493 8 + = 0.45 fck
(Self weight + – 0.577 5 + = 0.38 × 400.67 0.519 3 + = 0.45 × 40
Weight of water + – 7.997 2 + = –4.5 8.542 = 18.00
Factory test pressure + 8.542 0 =9.555 1
Prestress at factory = – 0.487 9
test) –0.487 9 < – 4.50 9.555 1 < 18.0
iv) Operating Condition = – 0.455 2 + 0.00 = 0.493 8 + = 0.45 fck
(Self weight + – 0.577 5 + 0.519 3 + = 0.45 × 40
weight of water + – 1.388 8 + 1.572 4 + = 18.00
Earth fill load + – 4.867 9 + 8.404 5
Working pressure + 8.404 5 =10.990 0
Final prestress) = 1.115 1
1.115 < 0.00 10.99 < 18.0
0.67
v) Live Load Condition = 1.115 1+ = 0.38 (fck) = 10.99 + = 0.45 fck
[Operating condition + – 0.488 5 = 0.38 × 400.67 0.553 1 = 0.45 × 40
Live load = 0.626 6 = –4.50 =11.543 1 = 18.00
(with impact)]
0.626 6 < – 4.50 11.543 1 < 18.0

( fck = 40 N/mm2 , fp2 = 28 N/mm2 ), - ve is tensile, + ve is compressive

FIG

29
IS 784 : 2019

ANNEX J
(Clause 7.7)
DESIGN OF PRESTRESSED CONCRETE NON-CYLINDER PIPES FOR DRAINAGE, SEWERAGE
AND CULVERT

J-1 Explanation of various symbols used in subsequent Final prestress, fct = ( Stress due to three edge required
clauses is given in Annex K. bearing load ) – ( Flexural Strength of concrete)

J-2 DATA = 11.14 – 6.87

= 4.27 N/mm2
Diameter of pipe, D = 1 000 mm
J-4.2 Design of Circumferential Prestressing
Core thickness of pipe, Tc = 60 mm
Coat thickness of pipe, Tb = 22 mm J-4.2.1 Spacing of Circumferential Wire (see 8.4.5 )
Three edge bearing load, P = 72.6 kN/m Allowable clear spacing:
= 72 600 N/m Maximum clear spacing of wire = 50 mm
Flexural strength of spun concrete Minimum clear spacing of wire = 6 mm
Area of spiral considered in design, As
= 6.87 N/mm 2
= 0.240 mm2/mm
J-3 ASSUMPTIONS Number of turns per metre length
Process of winding = Counter weight/ 0.240×1 000
Break =
0.785 4× (4)2
Diameter of circumferential wire, ds = 19.09
Centre to centre spacing of spiral wire
= 4 mm
Ultimate tensile strength of circumferential wire 1 000
=  52.38 mm
= 1 715 N/mm2 19.09
Clear spacing of spiral wire = 52.38 – 4 = 48.38 mm
Area of circumferential wire, As
48.38 mm is in between 50 mm and 6 mm, Hence, the
= 0.240 m2/mm
area of spiral ( As ) considered is correct.
J-4 DESIGN
J-4.2.2 Calculation of Prestress in Core in
J-4.1 Calculation of Final Prestress Required Circumferential Direction
Calculation of moment at bottom, M Initial stress in wire during winding, fsi (see 8.3.2 )
= 0.159×P×Dm = 0.75 × 1 715
= 0.159 × 72 600 × 1 082 = 1 286.25 N/mm2
= 12 489 959 Nmm Initial compressive stress induced in core, fci
where 0.240
= 1 286.25 
Mean diameter of pipe, Dm = D+ tc+ tb 60
= 1 000 + 60 + 22 = 5.145 0 N/mm2
= 1 082 mm J-4.2.2.1 Loss of stress in wire ( see Annex F )
Calculation of section modulus of pipe, Z a) Elastic deformation
= 3.2×fci = 3.2×5.145 0
1 b  d 2 1 = 16.46 N/mm2
=   1 000  822
6 6 b) Relaxation of wire
= 112 066.76 mm3
= 0.08 ×f si = 0.08 ×
where 1 286.25
d = Tc +Tb= 60 + 22 = 82 mm = 102.90 N/mm2
M 12 489 959 c) Deformation due to creep
Stress = 
Z 112 066.7 = 2.5 × 5.145 0
= 11.14 N/mm2 = 12.86 N/mm2

30
 IS 784 : 2019

d) Deformation due to shrinkage Stress in wire at site test, fs

= 1 286.25 – 152.22
= 0.000 1 ×Es = 1 134.03 N/mm2
= 0.000 1× 20 × 104 Compressive stress in core at site test, fct
= 20.00 N/mm2 0.240
Total losses = 16.46 + 102.90 + = 1134.03 
60
12.86 + 20.00 = + 4.536 1 N/mm2
= 152.22 N/mm2 As final prestress (4.536 1) is more than final prestress
Losses at factory test = 0.9 × Total loss required (4.270 0), the design is safe.
= 0.9 × 152.22 J-5 For design of longitudinal prestressing, the
= 137.00 N/mm2 procedure as given in D-1 is to be adopted.
Stress in wire at factory tes, fsf = 1 286.25 – 137.00
= 1 149.25 N/mm2

ANNEX K
(Clauses D-1, F-1, G-1, H-1 and J-1)
SYMBOLS USED IN THE DESIGN

A = cross-sectional area of pipe, mm2 fck = characteristic compressive strength of

Ay = area of steel cylinder concrete, N/mm2
Ac = cross-sectional area of core, mm2 fp1 = compressive strength of concrete at
detensioning of longitudinals, N/mm2
Adl = cross-sectional area of longitudinalwire, mm2
fp2 = compressive strength of concrete at winding,
AS = area of circumferential wire, mm2/mm
N/mm2
Bt = trench width, m
fs = final stress in circumferential wire after losses,
Ct = coefficient from Fig. 4 of IS 783 N/mm2
D = internal diameter of pipe, mm fsf = stress in circumferential wire at factory test,
dl = diameter of longitudinal wire, mm N/mm2
ds = diameter of circumferential wire, mm fsi = initial stress in circumferential wire during
Ec = modulus of elasticity of concrete, N/mm2 winding, N/mm2
Eci = initial modulus of elasticity of concrete, fsil = initial stress in longitudinal wire at longitudinal
N/mm2 prestressing, N/mm2
Es = modulus of elasticity of wire, N/mm2 fsl = final stress in longitudinal wire after losses,
N/mm2
fcf = compressive stress in core concrete at factory
test, N/mm2 fslw = stress in longitudinal wire at winding, N/mm2
fci = initial compressive stress induced in core, due fws = stress in core pipe at site test due to internal
to circumferential prestressing, N/mm2 pressure, N/mm2
fcil = initial precompression in core due to fwf = stress in pipe core due to internal pressure.
longitudinal prestressing, N/mm2 fww = stress in core pipe in operating condition due
fcl = final precompression in core, N/mm2 to internal pressure, N/mm2
fclw = pre-compression at winding, N/mm2 H = height of earth fill, m
fct = compressive stress in core concrete at site test, Kb = density of coating, N/m3
N/mm2 Ks = density of steel cylinder N/m3

31
IS 784 : 2019

Kc = density of core concrete, N/m3 Tb = soat thickness, mm

Ke = density of filling material, N/m3 Ty = steel cylinder thickness
KW = density of water, N/mm3 Tc = core thickness, mm
L = effective length of pipe, m Wb = self weight of coat, N/m
n = modular ratio Wsc = self weight of steel cylinder
N = number of longitudinals Wc = self weight of core, N/m
ODC = out side diameter of core, mm We = weight of earth fill, N/m
ODP = out side diameter of pipe, mm Wl = live load, N/m
P = axle load = 61 300 N (AA Class) Ws = self weight of pipe (Core + Coat), N/m
Ps = site test pressure, N/mm2 Ww = weight of water, N/m
Pst = maximum static pressure, N/mm2 Z = modulus of section for circumferential stress,
Pt = factory test pressure, N/mm2 in mm3/m
Pw = working pressure, N/mm2 Z1 = modulus of circular section of pipe, mm3/m
r = mean radius of pipe wall, mm Z2 = modulus of circular section of core, mm3/m

ANNEX L
(Clause 13.1)
TYPICAL TEST SET UP FOR DESIGN PROVING AND MANUFACTURING PROCESS
APPROVAL TEST IN FACTORY AS PER 13.1

L-1 The typical test set up shall be as shown in Fig. 5 After jacking each pipe, the rubber ring position at 4
by laying 3 pipes in the trench. points from the face of the socket to be checked with
Barrel of the pipes shall be supported on the sand the filler gauge to ensure final position of rubber ring
bed. Socket pits to be provided to observe leakage and perfect assembly of each pipe joint.
through joint. On both ends, there shall be mild steel Sequence of operation for approval test:
testing plates with rubber ring joint and concrete
a) Roll pipe No.1 on runners and lower down in
thrust block abutments to be designed and provided
trench with chain block.
as per the end thrust, soil bearing capacity of the
soil etc. It is a good practice to fill sand filled gunny b) Jack pipe No. 1 with rubber ring mounted in
bags on booth thrust blocks at the ends, when the spigot groove after lubricating rubber ring and
design of the thrust block is inadequate to resist the joint surfaces with soap solution. Jack all the
end thrust. screws simultaneously to maintain uniform joint
gap. check rubber ring position at 4 places.
Necessary arrangements with centrifugal pump for c) Roll pipe No. 2 on runners and lower down
filling water in the pipeline and reciprocating pump for with chain block.
racing pressure gradually shall be provided with gate
d) Jack pipe No. 2 with rubber ring mounted in
valves and non-return valves, pressure gauges, Air
spigot groove after lubricating rubber ring and
escape valves at top on both the testing plate.
joint surfaces with soap solution. Jacks all the
The pipes are to be laid in perfect alignment and level. screws simultaneously to maintain uniform joint
While jacking the pipes, jacks are to be operated by gap. Check rubber ring position at 4 places.
screwing opposite jacks gradually maintaining uniform e) Similarly assemble pipe No. 3 and check
gap between testing plates and pipe by maintaining rubber ring position at 4 places.
verticality of testing plates. Capacity and number of
f) Jack testing plate with dummy by screwing
jacks are to be provided as per end thrust.
gradually and simultaneously all jacks.
32
 IS 784 : 2019

g) Fill the pipes with water and allow air to k) Start reciprocating pump to raise required
escape. pressure and stop reciprocating pump.
h) Allow to flow the water from air escape at the m) Observe all joints for leakage. If there is no
both testing plates. leakage from any joints and damp patches on
j) Stop centrifugal pump, close inlet valve and the body of the pipe, the design is approved.
air vent valve.

F IG. 5 TYPICAL TEST SET UP

33
IS 784 : 2019

ANNEX M
(Foreword)
COMMITTEE COMPOSITION
Cement Matrix Products Sectional Committee, CED 53

Organization Representative(s)
National Council for Cement and Building Materials, Ballabgarh SHRI V. V. ARORA (Chairman)
All India A.C. Pipe Manufacturers’ Association, Secunderabad SHRI N. KISHAN REDDY
SHRI P. S. KALANI (Alternate)
Ambuja Cements Ltd, Ahmedabad SHRI J. P. DESAI
SHRI B. K. JAGETIAYA (Alternate)
Asbestos Information Centre, New Delhi SHRI AAROON K. SETHI
SHRI JOHN NICODEMUS (Alternate)
Central Building Research Institute, Roorkee DR B. K. RAO
SHRI S. K. AGARWAL (Alternate)
Central Pollution control board, Delhi DR J. S. KAMYOTRA
SHRI P. K. GUPTA (Alternate)
Central Public Health & Environmental Engineering Organization, REPRESENTATIVE
New Delhi
Central Public Works Department, New Delhi SHRI B. B. DHAR
SHRI MATHURA PRASAD (Alternate)
CSIR-Structural Engineering Research Centre, Chennai SHRI P. SRINIVASAN
DR B. H. BHARAT KUMAR (Alternate)
Delhi Development Authority, New Delhi REPRESENTATIVE
Director General of Factory Advise Services and Labour Institute, DR CHAMPAK BHATTACHARYA
Mumbai
Engineer-in-Chief’s Branch, New Delhi SHRI V. K. MANGLIK
SHRI P. K. GUPTA (Alternate)
Engineers India Limited, New Delhi SHRI RAJANJI SRIVASTAVA
SHRI ANURAG SINHA (Alternate)
Everest Industries Limited, New Delhi SHRI Y. SRINIVASA RAO
SHRI S. P. BOLAR (Alternate)
Gammon India Ltd, Mumbai, Maharashtra SHRI MANISH MOKAL
SHRI SUDEESH RAJENDRAN (Alternate)
HIL Limited, Hyderabad, Hyderabad SHRI R PRADEEP KUMAR
SHRI D. SATYANARAYAN (Alternate)
Housing & Urban Development Corporation Ltd, New Delhi CHAIRMAN AND MANAGING DIRECTOR
SHRI DEEPAK BANSAL (Alternate)
Ministry of Science & Technology, New Delhi SHRI CHANDER MOHAN
Ministry of Environment and Forest, New Delhi REPRESENTATIVE
Municipal Corporation of Delhi, New Delhi SUPERINTENDENT ENGINEER (PLANNING)
EXECUTIVE ENGINEER (PLANNING) (Alternate)
National Test House, Ghaziabad, UP SHRI B. R. MEENA
SHRI ALOKE DE (Alternate)
Rural Electrification Corporation, New Delhi SHRI DINESH KUMAR
SHRI P. K. SINGHAL (Alternate)
Spun Pipes Manufacturer’s Association Nanded, Maharashtra SHRI C. Y. GAVHANE
SHRI D. N. JOSHI (Alternate)
Tamil Nadu Water Supply & Drainage, Chennai SHRI S. HARIRAMASAMY
The Indian Hume Pipe Company, Mumbai, Maharashtra SHRI P. R. BHAT
SHRI S. J. SHAH (Alternate)
BIS Directorate General SHRI SANJAY PANT, Scientist F and Head (Civil Engg)
[Representing Director General (Ex-officio)]

Member Secretary
SHRI MANOJ KUMAR RAJAK
Scientist ‘C’ (Civil Engg), BIS

34
 IS 784 : 2019

Concrete Pipe, Subcommittee, CED 53:2

Organization Representative(s)
In Personal Capacity (Vikas Complex, L.B.S. Road, Thane (W), SHRI N. G. JOSHI (Convener)
Maharashtra )
Central Building Research Institute Roorkee, Uttaranchal SHRI S. K. SINGH
SHRI A. K. PANDEY (Alternate)
Central Public Works Department, New Delhi SHRI B. B. DHAR
SHRI MATHURA PRASAD (Alternate)
CSIR- Structural Engineering Research Centre Chennai, Tamil Nadu MS P. S. AMBILY
SHRI S. SUNDER KUMAR (Alternate)
Delhi Jal Board, New Delhi SHRI VARINDER SINGH THIND
Director General of Supplies & Disposals, Hyderabad ADDITIONAL DIRECTOR GENERAL (QA)
Essar Steel Ltd, Mumbai REPRESENTATIVE (Alternate)
Federation of U.P Pipe Manufacturers, Lucknow SHRI S. P URI
SHRI S. P. RASTOGI (Alternate)
Haryana Public Works Department, Chandigarh SHRI MAHESH KUMAR
SHRI MAHABIR SINGH (Alternate)
In Personal Capacity (2nd floor, Saket, 5 Manisha Housing Society, SHRI P. D. KHELKAR
Kavi Nagar, Pune)
Indian Water Works Association, Raipur, Chhattisgarh SHRI R. N. GUPTA
SHRI S. B. GANGOPADHYAY (Alternate)
Larsen & Toubro Limited, Manapakkam SHRI P. BALAKUMAR
SHRI T. S. S. PRASAD (Alternate)
Maharashtra Engg. Research Institute, Mumbai SHRI S. D. KULKARNI
SHRI R. M. RANGNEKAR (Alternate)
Millars Concrete Technologies Pvt Ltd, Mumbai SHRI NILESH KAUL
SHRI N. B. JOSHI (Alternate)
Ministry of Science& Technology, New Delhi SHRI CHANDER MOHAN
Municipal Corporation of Greater Mumbai, Mumbai REPRESENTATIVE
National Council for Cement & Building, Ballabgarh SHRI SATISH SHARMA
National Environmental Engg Research Institute, Nagpur DR TAPAN CHAKRABARTI
DR T. NANDY (Alternate)
National Highway Authority of India, New Delhi CHAIRMAN
Pakona Engineers (I) Pvt Ltd, Vadodara SHRI ROHIT J. SHAH
SHRI ASHOK J. KOTHARI (Alternate)
Public Health & Municipal Engineering Department, Hyderabad REPRESENTATIVE
Public Health Engineering Department, Chattisgarh REPRESENTATIVE
Public Health Engineering Department, Jaipur REPRESENTATIVE
Shah Technical Consultancy Pvt Ltd, Mumbai SHRI MAHAVEER K. TONE
SHRIMATI SUMEDHA S. SHAH (Alternate)
Spun Concrete Pipe Manufacturers Karnataka, Bengaluru SHRI K. V. SAKHAR RAJU
Spun Pipe Manufacturers Association of Maharashtra, Nanded SHRI C. Y. GAVHANE
SHRI D. N. JOSHI (Alternate)
Tamil Nadu Water Supply & Drainage Board, Chennai SHRI K. N AGARAJAN
Tata Consultancy Services, Mumbai REPRESENTATIVE
The Indian Hume Pipe Company Ltd, Maharashtra SHRI P. R. BHAT
SHRI S. J. SHAH (Alternate)
The Tata Iron and Steel Company Ltd (Wire Division), Mumbai SHRI S. G. JOSHI
SHRI GANESH P. CHAUDHARI (Alternate)
Waste and Land Management Institute, Aurangabad REPRESENTATIVE

35
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