BUREAU OF INDIAN STANDARDS (CENTRAL …

1 BUREAU OF INDIAN STANDARDS ( central MARKS DEPARTMENT-III) Our Ref: CMD/16:458 06 August 2009 Subject: Grouping and procedure of Precast concrete pipes (with and without reinforcement) as per IS 458:2003 for grant of licence / inclusion In view of revision of IS 458:2003, and feed back from ROs/BOs, grouping guidelines for Grant of licence and Inclusion of new varieties for Precast Concrete Pipes (with and without reinforcement) as per IS 458:2003, modifying the earlier CMD guidelines vide circular :458 dated 20-03-1991 are as under: Group Size Group 0 mm Group 1 mm Group 2 mm Group 3 mm Group 4 mm Group 5 mm NP1 class 80-225 250-450 - - - - NP2 Class -do- -do- 500-800 900-1200 1400 - 2200 - NP3 Class -do- -do*- 500-900 1000 - 1200 1400 - 1800 2000 2600 NP4 Class -do- -do*- -do- -do- -do- -do- P1 class -do- -do- 500-800 900- 1200 - - P2 class -do- -do- 500-700 800 - 1000 - - P3 class -do- 250-500 600-800 - - - Note: 1.

2 Grouping as given above for NP1, NP2, NP3 and NP4 class will also be applicable to collars. 2. Group 1* for class NP3 and NP4 for vibrated casting process will be for sizes from 300 to 450 mm. Precast concrete pipes and collars as applicable of any two sizes from each group and each class shall be tested in the factory for all the requirements with a view to cover the complete range of sizes against that class under the licence. However it shall be ensured that all sizes of pipes are tested in rotation during the course of operation of the licence. For covering each variety such as collar joint (plain ended), flush joint ended and spigot and socket ended pipes and for each processes such as spun casted and vibrated casted pipes, samples of each of the variety and processes will have to be tested as per above grouping for covering the respective variety and processes.

3 Samples of different raw materials such as 1) All types and sizes of steel used for longitudinal and spiral reinforcement 2) All types and sizes of coarse and fine aggregate 3) Cement concrete cube 4) Water and 5) Mineral admixtures etc, shall also be drawn for independent testing as is being done at present. It shall be ensured that the applicant/licensee has got complete manufacturing as well as testing facilities including moulds for the sizes required to be covered under the licence. However, if firm procures moulds later on and request for inclusion for sizes (other than already covered), as per above grouping, the same shall be done after verification of moulds and factory testing only, even though two samples from the groups had already been tested in the factory and covered under scope of licence.

4 PROCEDURE FOR GOL & INCLUSION Firm can only apply for obtaining licence as per old procedure since the transport of the product is difficult to the BIS recognized/any other laboratories. After recording of application, preliminary technical evaluation at factory is done and report be given in prescribed proforma (CMPF201) apart from complete factory testing report as per Annex 1 enclosed. Samples of different raw materials such as 1) All types and sizes of steel used for longitudinal and spiral reinforcement 2) All types and sizes of coarse and fine aggregate 3) Cement concrete cube 4) Water and 5) Mineral admixtures etc, shall also be drawn for independent testing. After satisfactory preliminary evaluation and passing of samples in independent testing, case shall be processed for GOL.

5 Similar procedure is followed for considering inclusion also and samples of additional raw material be drawn for independent testing. It is to clarify that if firm is using different type and/or sizes of steel for reinforcement, it is to be treated as additional raw material. Similarly if firm has changed the source and/or size and types of coarse and fine aggregate it shall be treated as additional raw material. If firm has changed the concrete mix design and cement content, samples of cement concrete cubes shall also be drawn for independent testing. In view of the above, inclusions already made or in progress need not be reviewed. Any further inclusion of a size in the groups already covered based on earlier grouping shall be based on testing only.

6 The above grouping will be applicable with immediate effect. It shall be ensured that all recommendations for GOL/Inclusion in the licence are based on above grouping. ANNEX 1 FACTORY TESTING FOR PRECAST CONCRETE PIPES AS PER IS 458: 2003 Name of Licensee/Applicant: BO/L-/A- Date(s) of Test: Size: Class: Type of Pipe: Suitable for collar /Flush/Spigot and Socket jointed/ Vibrated casted Pipes/Spun Casted Table Nos.: Requirement Results Results 1 CLAUSE 12:MARKING: Source of manufacture : Class & Size of Pipe/ collar : Spun Pipe of vibrated cast pipe: (Reinforced/unreinforced) Date of manufacturing (casting): Licence No. (where applicable): Marking outside/outside & inside (for above 350 mm size): Standard Mark: 2 Clause : FINISH a)Pipe/ collar shall be free from cracks except that craze cracks may be permitted b) Ends of the pipes shall be square with their longitudinal axis Clause c) i) The outside and inside surface shall be dense and hard and shall not be coated with cement wash or other preparations (unless agreed between the purchaser and the manufacturer) ii)Inner surface of the pipe shall be smooth and for the collars it may be finished rough Clause d) Pipe shall be free from defects resulting from imperfect grading of aggregates, mixing or molding.

7 Clause e) Pipe shall be free from local dents or bulges greater that mm in depth and extending over a length in any direction greater than twice barrel wall thickness Pipe / collar Pipe / collar 3 Clause : DEVIATION FROM STRAIGHT throughout its effective length shall not exceed 3 mm for every meter run. 4 CLAUSE 8: DIMENSIONS Length, mm ( ) Internal Diameter mm ( ) Barrel wall thickness mm ( ) Critical Dimensions of S& S Pipe (As per table ) DS 2/ Lb DS 3 LSP/lt TS T H S HT K LS L b Do Specified Value Observed Value Specified Value Observed Value s for NP1 class pipes D2 H e Dimension of flush joint External/internal caulking space t min t min s( of ID or 2 mm Min) collar DIMENSIONS (Table No. 21 & 22) a) Caulking space (minimum), mm b) Thickness (minimum), mm c) Length (minimum),mm 5.

8 CLAUSE : REINFORCEMENT IN PIPES (Reinforcement as per table Table ) Longitudinal Steel * a) Size and Type of Steel Used: of Steel Used: Available/Not available b) No. of Bars of Longitudinal Steel: i) Inner Cage ii) Outer Cage c)Weight of Longitudinal Steel: i) Inner Cage ii) Outer Cage d) Longitudinal reinforcement in socket shall be proportional to the length of socket cage as given in Table 2,3,5,6,9,10 & 11. e)Mass of longitudinal in Outer and Inner cage should be same Spiral Reinforcement * a) Size and Type of Steel used: of Steel Used: Available/not available b)Weight of Spiral Reinforcement i) Inner cage ii) Outer Cage iii) Total weight c) Weight of Spiral Reinforcement in Socket of R/R joints, kg/Number (Table20) i) Inner Cage ii) Outer Cage iii) Total weight d) Spiral reinforcement in the outer cage shall be 75% of the mass of spiral in the inner cage.

9 * Note: Diagonal reinforcement is a process requirement and shall not be counted against longitudinal or spiral reinforcement. a) Reinforcement cage shall extend throughout the length of pipe based. b)Spiral shall end in complete ring at both the ends of a cage( ) c)Pitch of spiral reinforcement shall not be more than 200/150/100 mm ( ) d)Pitch shall not be less than maximum size of aggregate +diameter of reinforcement bar used. e)In non-welded cages spiral reinforcement of the same diameter shall be closely spaced at the end of the pipe for a length of 150 mm and spacing shall not exceed 50 mm or half the pitch whichever is less( ) Reinforcement of Collars (Table 21& 22) a)Size and type of steel used of Steel Used: Available/Not available b)No.

10 Of Bars of Longitudinal Steel i) Inner Cage ii)Outer Cage iii) Total Weight c)Weight of longitudinal Steel per collar , kg i)Inner Cage ii)Outer Cage iii)Total Weight d)Size and Type of Steel Used e)Weight of Spiral per collar , kg i) Inner Cage ii) Outer Cage iii)Total Weight f)Ends of collar reinforcement shall have a complete ring at both ends 6 MINIMUM CLEAR COVER IN PIPE & collar (as applicable)( ) The minimum clear cover for reinforcement i) Barrel Wall thickness: ii)At Spigot Steps: iii)At end of longitudinal: 7 HYDROSTATIC TEST at MPa ( , and ) MPa for Non Pressure Pipes (7m head) MPa for P1 Pressure Pipes (20m head) MPa for P2 Pressure Pipes (40m head) MPa for P3 Pressure Pipes (60 m head) 8 THREE EDGE BEARING TEST (cl.