docPipe Catalogue - RCPA Reinforced Concrete Pipes Australia
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Pipe Catalogue - RCPA Reinforced Concrete Pipes Australia
The Australian Pipe Company Pipe Catalogue i ii Contents Company Overview . ............................................................. 3 Concrete Pipes ..................................................................... 4 Rubber Jointed Pipes . ...................................................... 6 Flush Jointed Pipes ........................................................... 7 Low Carbon Concrete Pipes .............................................. 10 eCP Rubber Jointed Pipes ............................................... 12 eCP Flush Jointed Pipes .................................................. 13 Production Process ............................................................ 16 Pipelaying & Joining .......................................................... 18 Suppliers ............................................................................ 21 RCPA is the only national supplier of Steel Reinforced Concrete Pipe that is wholly Australian owned and we are enormously proud of that fact. All our Pipes comply with A.S. 4058 - 2007 & all our Box Culverts comply to A.S. 1597.2 - 2013 Quality ISO 9001 1 Company Overview 2 The Australian Pipe Company Reinforced Concrete Pipes Australia (RCPA) is the only national supplier of steel reinforced concrete pipe that is solely Australian owned. A major investment in new technology by RCPA is having a significant impact on pipe production in Australia - choosing plant that not only incorporates many production efficiencies but also minimises environmental impact and usage of power. The manufacturing techniques employed by RCPA allow the reprocessing of fresh product through the plant if defects are identified during production, reducing waste. RCPA uses concrete with a very low water requirement. RCPA is now firmly established as a force in the Australian Concrete Pipe market, with plants located in Brisbane, Perth and Melbourne. RCPA Steel Reinforced Concrete Pipes are manufactured to meet or exceed the requirements of AS4058-2007 Precast concrete pipes (pressure and non-pressure under a Quality Management System independently audited and certified to AS/NZS ISO 9001:2000. the latest vertically cast, Bi-directional machines as installed by RCPA. This technology is multiple times faster than traditional methods, and offers the customer a more cost effective product which can be virtually “made to order”. Pipes manufactured by RCPA have an effective and overall length to comply with legal restrictions placed on the transport of over width loads. This has been revised from the traditional length of 2.44 metres to comply with legal restrictions placed on the transport of over width loads. This pipe length permits efficient loading configurations and removes the restrictions placed on the movement of over width vehicles. Steel Reinforced Concrete Pipes are manufactured in both Flush Joint and Rubber Ring Joint profiles, with standard Load Classes of 2, 3 & 4. Higher Load Class pipes can be manufactured as special order items. Further capital investment has given RCPA the ability to manufacture large diameter pipe and also increase its product range into large box culverts. Concrete pipes have been an integral part of most civil contracts since the late 1800’s, and production of these pipes has progressed from early hand tamped concrete, through spinning techniques to Company Overview 3 Concrete Pipes 4 RCPA, an Australian owned company, is the leading manufacturer of vertically dry cast concrete pipes in Australia. The dry cast method of manufacture involves efficient use of materials, without slurry waste and less impact to the environment. •Technically advanced precision process •High production rates •Minimal lead times •Products conform with AS/NZ 4058:2007 •Sustainable manufacturing process 5 RUBBER RING JOINTED PIPES WT BD l Effective length for 225mm to 900mm: 2340mm l Effective length for 1050mm to 3600mm: 2340mm l Rubber 6 ID Ring supplied Rubber Ring Jointed Pipes OD ID Inner Diameter OD Outer Diameter BD Bell Diameter WT Wall Thickness Victoria ID Queensland OD BD WT Class Weight 220mm 295mm 370mm 35mm 2,3,4,6 180kg 295mm 370mm 410mm 455mm 35mm 55mm 2,3,4,6 8,10 453mm 491mm 546mm 39mm 58mm 2,3,4,6 315kg 8 460kg 370mm 240kg 450kg ID OD BD WT Class Weight 295mm 376mm 416mm* 455mm 38mm 58mm* 2,3,4 260kg 380kg* 370mm 459mm 491mm* 546mm 42mm 58mm* 2,3,4 340kg 460kg* 445mm 544mm 544mm 567mm* 643mm 47mm 47mm 58mm* 2,3 4 2,3,4 430kg 448kg 540kg* 445mm 538mm 566mm 643mm 44mm 58mm 2,3,4 6,8 450kg 550kg 520mm 623mm 645mm 734mm 49mm 60mm 2,4 4,6 530kg 650kg 520mm 734mm 2,3 4,6 650kg 720kg 2,3 4 2,3 550kg 710kg• 710kg* 825mm 49mm 60mm 51mm 64mm• 64mm* 595mm 698mm 720mm 627mm 652mm• 652mm* 595mm 824mm 2,3 4,6 860kg 1150kg 2 2,3,4 710kg 820kg• 913mm 55mm 90mm 54mm 64mm• 670mm 785mm 855mm 708mm 728mm• 670mm 913mm 2,3 4,6 1070kg 1270kg 2 3,4 860kg• 1310kg• 1005mm 60mm 80mm 59mm• 93mm• 745mm 870mm 910mm 793mm• 860mm• 745mm 1004mm 2,3 4,6 1210kg 1500kg 2 3,4 1030kg• 1240kg• 1094mm 68mm 90mm 59mm• 79mm• 818mm 961mm 1005mm 868mm• 908mm• 893mm 1046mm 1076mm 1185mm 73mm 88mm 2,3 4,6 1360kg 1650kg 818mm 961mm 961mm* 1093mm 1012mm• 68mm 68mm* 94mm• 2 2 3,4 1200kg 1210kg* 1650kg• 1043mm 1188mm 1238mm 1344mm 69mm 94mm 2,3 4 1680kg 2095kg 893mm 1048mm• 1184mm 1077mm• 74mm• 89mm• 2 3,4 1450kg• 1710kg• 1193mm 1356mm 1396mm 1533mm 78mm 98mm 2 3,4 2100kg 2445kg 1043mm 1199mm• 1345mm 1237mm• 75mm• 94mm• 2 3,4 1680kg• 2030kg• 1343mm 1520mm 1580mm 1690mm 85mm 115mm 2 3,4 2610kg 3200kg 1193mm 1365mm• 1532mm 1406mm• 83mm• 103mm• 2 3,4 2180kg• 2610kg• 1493mm 1680mm 1730mm 1910mm 90mm 115mm 2 3,4 3185kg 4100kg 1343mm 1520mm• 1690mm 1567mm• 85mm• 110mm• 2 3,4 2640kg• 3250kg• 1643mm 1830mm 1910mm 2056mm 90mm 130mm 2 3,4 3720kg TBA 1493mm 1680mm• 1910mm 1730mm• 90mm• 115mm• 2 3,4 3200kg• 3840kg• 1793mm 1990mm 2070mm 2226mm 95mm 135mm 2 3,4 4360kg 5700kg 1643mm 1830mm• 2055mm 1930mm• 90mm• 140mm• 2 3,4 3580kg• 4685kg• 1943mm 2260mm 2390mm 155mm 2,3,4 6200kg 1793mm 1990mm• 2226mm 2106mm• 95mm• 153mm• 2 3,4 4059kg• 5780kg• 2093mm 2300mm 2556mm 100mm 2 5400kg 2033mm 2300mm 2556mm 130mm 3,4 7000kg 2093mm 2300mm• 2556mm 2400mm• 100mm• 150mm• 2 3,4 5000kg• 6570kg• 2393mm 2730mm 2920mm 165mm 2,3,4 8400kg 2693mm 3050mm 3250mm 175mm 2,3,4 9700kg 2993mm 3400mm 3400mm 200mm 2,3,4 12200kg 3293mm 3750mm 3750mm 225mm 2,3,4 15800kg 3593mm 4120mm 4120mm 260mm 2,3,4 20000kg Class Weight *Sewer options only available in these measurements. Contact us for more information. •Sewer options also available in these measurements. Contact us for more information. Western Australia ID OD BD WT 295mm 378mm 455mm 40mm 2,3,4 260kg 370mm 455mm 546mm 41mm 2,3,4 320kg 445mm 541mm 643mm 47mm 2,3,4 460kg 520mm 622mm 734mm 49mm 2,3,4 570kg 595mm 704mm 825mm 50mm 2,3,4 680kg 745mm 877mm 1005mm 63mm 2,3,4 1020kg 893mm 1046mm 1079mm 1185mm 72mm 88mm 2 3,4 1460kg 1660kg 1043mm 1194mm 1239mm 1239mm 1344mm 71mm 94mm 94mm 2 3 4 1710kg 2080kg 2160kg 1193mm 1360mm 1405mm 1405mm 1532mm 80mm 102mm 102mm 2 3 4 2180kg 2680kg 2720kg Rubber Ring Jointed Pipes 7 FLUSH JOINTED PIPES WT ID l Effective length for 300mm to 900mm: 2340mm l Effective length for 1050mm to 2100mm: 2340mm l Effective length for 2400mm to 2700mm: 2425mm l Effective length for 3000mm to 3600mm: TBA l Sand 8 Bands available Flush Jointed Pipes OD ID Inner Diameter OD Outer Diameter WT Wall Thickness Victoria ID Queensland OD WT Class Weight 295mm 366mm 33mm 2,3,4 210kg 370mm 451mm 38mm 2,3,4 290kg 445mm 544mm 43mm 2,3,4 400kg 520mm 619mm 653mm 47mm 64mm 2,3 4 595mm 708mm 728mm 48mm 64mm 670mm 791mm ID OD WT Class Weight 295mm 416mm• 58mm• 2 3 4 191kg• 200kg 327kg• 480kg 640kg 370mm 458mm 458mm 491mm• 42mm 42mm 58mm• 2 3 4 408kg 308kg 408kg• 2,3 4 570kg 750kg 445mm 544mm 566mm• 47mm 58mm• 2,3 4 481kg• 58mm 2,3 740kg 60mm 79mm 2,3 4 920kg 1200kg 520mm 745mm 870mm 908mm 627mm 652mm• 51mm 64mm• 2 3,4 463kg• 590kg• 818mm 961mm 68mm 2,3 1210kg 595mm 73mm 89mm 2,3 4 1270kg 1500kg 53mm 53mm 64mm• 2 3 4 553kg 562kg 671kg• 893mm 1046mm 1078mm 706mm 706mm 727mm• 670mm 798mm• 62mm• 72mm 94mm 2,3 4 1510kg 1900kg 735kg• TBA• 1043mm 1194mm 1238mm 2,3 4 745mm 80mm 103mm 2 3,4 1900kg 2400kg 60mm 79mm• 2 3,4 798kg 1089kg• 1193mm 1360mm 1406mm 870mm 908mm• 85mm 110mm 2 3,4 2250kg 2700kg 962mm• 69mm• 1343mm 1540mm 1570mm 818mm 2 3 4 998kg• 1007kg• TBA• 1493mm 1680mm 1730mm 90mm 115mm 2 3,4 2800kg 4100kg 893mm 1040mm 1078mm• 70mm 89mm• 2 3,4 1107kg 1470kg• 1643mm 1830mm TBA 90mm TBA 2,3 4 3200kg TBA 1043mm 1195mm 1238mm 1238mm• 73mm 94mm 94mm• 2 3 4 1370kg• 1787kg• 1814kg• 1793mm 1990mm TBA 95mm TBA 2,3 4 3700kg TBA 1193mm 1363mm• 1398mm• 82mm• 99mm• 2 3,4 1724kg• 2177kg• 1943mm 2260mm 155mm 2,3,4 6100kg 2093mm 2300mm 100mm 2,3 5180kg 1343mm 1524mm• 1570mm• 87mm• 110mm• 2 3,4 1996kg• 2631kg• 2033mm 2300mm 2730mm 130mm 165mm 4 2,3,4 6900kg 8000kg 1493mm 1686mm• 1732mm• 93mm• 116mm• 2 3,4 2377kg• 3084kg• 2693mm 2950mm 175mm 2,3,4 9300kg 2993mm TBA TBA TBA 12300kg 1643mm 1848mm• 99mm• 124mm• 2 3,4 2903kg• 3629kg• 3293mm TBA TBA TBA TBA 1793mm 2001mm• 3593mm TBA TBA TBA TBA 101mm• 126mm• 2 3,4 3211kg• 4264kg• 2093mm 2330mm• 115mm• 140mm• 2 3,4 4345kg• 5443kg• •Sewer options also available in these measurements. Contact us for more information. Flush Jointed Pipes 9 Low Carbon Concrete Pipes 10 RCPA is the only Australian Company that offers a low carbon concrete pipe – The Environmental Concrete Pipe (eCP) •eCP is manufactured using supplementary cementations materials (primarily fly ash and slag) as a complete replacement for Portland cement. •The concrete uses a proprietary activator for the required setting and properties. •The pipes are specified in the same way as traditional concrete pipe. 11 RUBBER RING JOINTED PIPES WT BD ID l Effective l Rubber length for 225mm to 900mm: 2340mm Ring supplied Victoria ID OD BD WT Class Weight 220mm 295mm 370mm 35mm 2,3,4,6 180kg 295mm 370mm 410mm 455mm 35mm 55mm 2,3,4,6 8,10 370mm 453mm 491mm 546mm 39mm 58mm 2,3,4,6 315kg 8 460kg 445mm 538mm 566mm 643mm 44mm 58mm 2,3,4 6,8 450kg 550kg 520mm 623mm 645mm 734mm 49mm 60mm 2,4 4,6 530kg 650kg 595mm 698mm 720mm 825mm 49mm 60mm 2,3 4,6 650kg 720kg 670mm 785mm 855mm 913mm 55mm 90mm 2,3 4,6 860kg 1150kg 745mm 870mm 910mm 1005mm 60mm 80mm 2,3 4,6 1070kg 1270kg 818mm 961mm 1005mm 1094mm 68mm 90mm 2,3 4,6 1210kg 1500kg 893mm 1046mm 1076mm 1185mm 73mm 88mm 2,3 4,6 1360kg 1650kg 12 Low Carbon Rubber Ring Jointed Pipes 240kg 450kg OD ID Inner Diameter OD Outer Diameter BD Bell Diameter WT Wall Thickness FLUSH JOINTED PIPES WT ID l Effective l Sand OD ID Inner Diameter OD Outer Diameter WT Wall Thickness length for 300mm to 900mm: 2340mm Bands available Victoria ID OD WT Class Weight 295mm 366mm 33mm 2,3,4 210kg 370mm 451mm 38mm 2,3,4 290kg 445mm 544mm 43mm 2,3,4 400kg 520mm 619mm 653mm 47mm 64mm 2,3 4 480kg 640kg 595mm 708mm 728mm 48mm 64mm 2,3 4 570kg 750kg 670mm 791mm 58mm 2,3 740kg 745mm 870mm 908mm 60mm 79mm 2,3 4 920kg 1200kg 818mm 961mm 68mm 2,3 1210kg 893mm 1046mm 1078mm 73mm 89mm 2,3 4 1270kg 1500kg Low Carbon Flush Jointed Pipes 13 14 15 PRODUCTION PROCESS RCPA’s vertically drying cast concrete pipe manufacturing process begins with a cage placed in the steel mould which in turn is placed on the production turntable and rotated into position beneath the bi-directional compaction head. Concrete is fed directly into the mould and the pipe is compacted from the socket end, through the barrel to the spigot. Compaction is achieved using contra rotating machined rollers and steel trowels which produce a bore which is accurate and straight, with a high quality finish. Compaction is continuously monitored, and graphically recorded for traceability. Pneumatic cage positioners mounted on the mould ensure correct alignment of the reinforcement cage. The spigot former remains on the pipe machine, and each spigot is made using the same machined former. This ensures that all spigots are identical. The spigot former is “one piece”, eliminating the traditional problems with rough grout “feathering” at joints. Once completed the filled mould is taken for curing and immediately stripped. After curing, the pipes are inspected, branded, and delivered to the stock yard. Steel Cage on Pallet Bi-directional rollers and trowels Concrete Feed A36 Bidi 16 Production Process Schematic of pipe mould with section cut away to show the bi-directional trowel head CONCRETE RCPA produces concrete in a fully automated batch plant that incorporates the latest moisture sensing and correction technology. This method ensures consistent concrete of the highest standard and a product which is extremely durable. The designed concrete mix for the process, naturally ensures a very low water to cement ratio i.e. zero slump concrete which permits instant demoulding. KEY FEATURES AND BENEFITS Manufacture • Roller compaction successfully used for over 50 years • Pipe performance exceeding requirements of the AS4058 • One piece reinforcement cage throughout spigot and socket Typical concrete test results indicate compressive strengths in excess of 50mPa. • Highest cover to steel of any Australian manufacturer Specialty cements can be used for specific applications as required but in general the performance using GP cement is appropriate. • Rebar spacers minimised to reduce ingress paths STEEL REINFORCED • Durable and highly compacted with low sorptivity and carbonation rates RCPA steel reinforced concrete pipes exceed market standards. Australian thin walled concrete • Bi-directional trowels and rollers provide hard, high quality internal surface pipes leave little room for error in cover requirement, therefore RCPA wall thickness is deliberately designed to give more than adequate cover. • Precision manufacture ensures accurate cover, dimensional accuracy and improved jointing RCPA pipe wall thickness are deliberately designed to provide cover to steel in access of the 10mm code requirement. This provides enhanced steel protection, therefore increasing pipe durability. • Non-slip exterior surface for safe handling A continuously welded reinforcement cage (including socket and spigot) is fabricated to close tolerances. The cover is precisely maintained by form-mounted pneumatic cage positioners that minimise the need for plastic/steel spacers. To confirm the cover, pipes are routinely tested physically and with a cover meter. • Dry cast concrete with 0.36 to 0.4 water cement ratio Supply • Process suited to rapid and mass production providing reduced lead times Environmental • Efficient use of materials and little wastage • No slurry waste • Produced using locally sourced materials with low energy inputs Production Process 17 PIPELAYING & JOINING Pipes are laid with the spigots pointing downstream with pipe laying operations commencing at the downstream drainage pit and working upstream. Rainfall runoff may therefor escape during construction and not flood the trench. In addition, gravity plus force applied to the pipe during jointing operations will assist in tightening and removing any remaining joint gap. PIPE JOINTING Rolling Rings - ‘D’ Ring Rolling rings become flattened as the roll up the spigot to seal the joint. They are assembled dry without the use of jointing lubricant. The pipe surfaces must be dry to allow the ring to roll (if the surface is partly wet, it must be dried). It is important that both the foundation and the bedding have been properly prepared and trimmed so that the grade of the pipeline is achieved. Bearing down on the pipes with an excavator/backhoe to adjust the grade can lead to both immediate and longer term damage to the pipeline. Each pipe should be carefully inspected again before lowering into trench to detect any damage in on-site handling. (Particular attention must be paid to the joint surface). Pipes should be lowered into the trench with tackle appropriate for the pipe mass and the depth of trench. The laying equipment e.g. excavator must be capable of smooth hoisting, lowering and travelling. When slings are used for pipe laying, their position should be checked when the pipe is initially lifted clear of the ground to ensure proper balance. Lifting from the lifting hole may also be adopted. When joining pipes, there is a nominal recommended joint laying gap and maximum laying gap. Joint areas must be dirt free and dry Fit rubber ring onto pipe feeler to check rubber position rubber ring Spigot about to enter socket Equalise tension around rubber ring Spigot entering socket Joint completed Sand Bands (or External Bands) Sand Bands can be used on Flush Jointed pipes to stop soil entering the pipeline and eroding away the backfill. Sand bands maybe adopted in sandy backfill conditions extending over the joint of the pipe. sand band Fit half band over pipe end and fold back remainder 18 Pipelaying & Joining Line up second pipe Flip band remainder over joint area Skid Rings - ‘V’ Rings V shaped skid rings are retained in a ring groove as the pipe slides into position. A lubricant is applied to the front face of the ring and the adjacent lead-in surface of the socket. The lubricant is supplied by the pipe manufacturer and is a special solution (often a soft soap mixture). Petroleum based products such as grease should never be used as a substitute as these may attack the rubber compound. Recommended Nominal - Maximum Joint Deflections zero overlap - 0.25° IS M OS A N spigot end bell end Standard Joint DO NOT lubricate lubricate Maximum Deflection ID Inner Diameter OS Outer Spigot A Maximum Deflection Fit joint on edge of groove ID Lubricant Ratio Pipe Size R Pipes / 1L Lubricant 300mm 30 375 - 450mm 25 525 - 675mm 15 825 - 900mm 10 1200 - 1350mm 7 1500mm 5 1650mm 4 1800mm 2 2100mm 2 OD OD Outer Diameter IS Inner Socket M Maximum Gap N Nominal Gap R Bend Radius IS OS M N A R 300mm 368mm 72mm 55mm 17mm 3mm 2.4° 58° 375mm 449mm 72mm 55mm 17mm 3mm 1.9° 73 450mm 536mm 75mm 60mm 15mm 4mm 1.4° 103° 525mm 617mm 78mm 60mm 18mm 4mm 1.4° 98° 600mm 698mm 82mm 60mm 22mm 5mm 1.6° 90° 675mm 783mm 82mm 60mm 22mm 5mm 1.4° 103° 750mm 868mm 82mm 60mm 22mm 5mm 1.2° 116° 825mm 953mm 89mm 60mm 29mm 6mm 1.5° 94° 900mm 1038mm 89mm 60mm 29mm 6mm 1.4° 104° 1050mm 1188mm 89mm 60mm 29mm 6mm 1.1° 122° 1200mm 1356mm 89mm 60mm 29mm 7mm 1.0° 143° 1350mm 1510mm 93mm 79mm 14mm 7mm 0.3° 497° 1500mm 1700mm 94mm 79mm 15mm 7mm 0.3° 547° Pipe Handling 1650mm 1830mm 102mm 80mm 22mm 8mm 0.4° 319° Pipes should be handled by conventional lifting equipment, but care should be taken to ensure they are not handled carelessly. 2100mm 2300mm 102mm 80mm 22mm 8mm 0.3° 469° When lifting by way of mechanical equipment i.e. excavator, backhoe, crane, the recommended safe working load of the equipment must not be exceeded. A guide to the weight of the pipe is stenciled on the outside of the pipe. A cylindrical pipe lifting lug c/w pin is the recommended device for lifting RCPA pipes. This device should be passed through the lifting hole and secured with the locking pin under the lifting hole. Alternatively, a sling or chain may also be utilised to lift the pipe where there is no lifting hole. The sling or chain should be placed around the pipe and arranged to ensure the pipe is lifted evenly. 1800mm 1990mm 102mm 80mm 22mm 8mm 0.4° 365° Notes: Calculations of Maximum Gap M , Maximum Deflection A and Bend Radius R allow for a positive overlap (AS4058-2007 App H) equivalant to 0.25°. The join assembly is in full compliance with AS 4058 for Maximum Deflections and Gaps detailed above. The Maximum Deflection figures are determined with one side of the joint in the “fully home” position. These figures represent allowable deflections for drainage pipes produced by RCPA. Pipelaying & Joining 19 20 20 Suppliers The Australian Pipe Company RCPA can supply our customers a range of Stormwater & Sewer components. Contact your respective sales office in your state for further details. Our range of Pipes are complimented by products sourced from proven precast manufacturers with all relevant approvals. RCPA QLD 115 Pearson Road, Yatala, QLD 4207 (PO Box 1456 Beenleigh QLD 4207) Phone: 07 3804 6266 Fax: 07 3804 6226 RCPA WA Lot 90 Cocos Drive, Bibra Lake, WA 6163 (Po Box 1006 Bibra Lake WA 6163) Phone: 08 9434 4055 Fax: 08 9434 4196 RCPA VICTORIA (Melton) 69-99 Ferris Road, Melton South, Victoria 3338 PO Box 931 Melton, Victoria 3337 Phone: 03 9746 0600 Fax: 03 9746 9952 RCPA VICTORIA (Kilmore) Lot 5 Glanville Drive, Kilmore, Victoria 3764 PO Box 479 Kilmore Victoria 3764 Phone: 03 5781 0344 Fax: 03 5781 0355 We offer delivery all across Australia www.rcpa.com.au Suppliers 21 21 The Australian Pipe Company Contact VIC: (03) 9746 0600 N.S.W: 0428 977 120 QLD: (07) 3804 6266 W.A.: (08) 9434 4055 Website: www.rcpa.com.au
