Bar/Wire Wrapped Steel Cylinder Pipes With Mortar lining and Coating (Including Specials)

IS 15155: Scope - Key Specifications & Formulas

Scope:
IS 15155 covers design, materials, and testing of bar/wire wrapped steel cylinder concrete pipes.

Key Specifications

• Straightness (Clause 13.1.5):
  Measured using a 1 m gauge.
  Max deviation: 5 mm over 1 m length.

• Pipe Dimensions & Design Parameters (Annex C Example for 1000 mm dia pipe):

Important Formula

• Internal diameter of steel cylinder:

[ D_{vi} = D + 2 t_l ]

• Site test pressure:

[ P_w = P_u \times 1.5 ]

• Factory test pressure:

[ P_f = P_u \times 1.2 ]

Additional Notes

• Refer Annex B for purchaser's info requirements (cement type, coatings, pressures, installation details).
• Design follows IS 456 for concrete and IS 2062 for steel materials.
• Rounding off numerical values per IS 2:1960.

flowchart LR
    A[Pipe Diameter D] --> B[Calculate Internal Diameter Dvi = D + 2tl]
    B --> C[Determine Working

IS 15155 References - Key Specifications and Tables

1. Straightness (Clause 13.1.5)

• Measured by a 1 m gauge.
• Max deviation from straight line over 1 m length: 5 mm.
• Use a gauge as per Fig. 2 (not shown here).

2. List of Referred Indian Standards (Annex A)

3. Typical Design Data for 1000 mm Dia Bar/Wire Wrapped Steel Cylinder Pipe (Annex C)

IS 15155: Key Definitions, Formulas & Tables Summary

Definitions (Clause 3.0)

• Definitions in Clauses 3.1 to 3.6 apply to terms used in the standard, e.g., working pressure, site test pressure, factory test pressure, etc.

Straightness (Clause 13.1.5)

• Measured with a 1 m gauge.
• Maximum deviation from a straight line between two points 1 m apart: 5 mm.

Flexural Rigidity & Deflection (Clause 3.6.2 & 3.6.2.2)

1. Flexural Rigidity (EI) is calculated by transforming steel areas using the modular ratio ( n ).

2. Spangler's Formula for Horizontal Deflection:

[ \Delta_x = \frac{D \times I \times K_b \times W \times r^2}{E \times I} + 0.0614 \times E \times r^3 ]

Where:

• (\Delta_x) = Horizontal deflection (increase in diameter at springline)
• (D) = Deflection lag factor (usually 1.0)
• (K_b) = Bedding coefficient
• (W) = Vertical load on pipe
• (E

IS 15155 — Key Materials Specifications & Formulas

1. Materials Referenced (Annex A)

• Cement Types:
  • IS 455: Portland Slag Cement
  • IS 8112: 43 Grade Ordinary Portland Cement
  • IS 1489: Portland Pozzolana Cement (Fly Ash & Calcined Clay based)
  • IS 12330: Sulphate Resisting Portland Cement
• Steel:
  • IS 2062: Steel for general structural purposes
  • IS 432 (Parts 1 & 2): Mild steel and hard-drawn steel wire for reinforcement
• Aggregates: IS 383: Coarse and fine aggregates for concrete
• Others: IS 5382 (Rubber sealing rings), IS 3597 (Concrete pipe testing)

2. Pipe Dimensions & Thickness (Table 5.2.3)

3. Straightness Tolerance (Clause 13.1.5)

• Measured over 1 m length gauge
• Max deviation from straight line ≤ 5 mm

4. Flexural Rigidity Calculation (Clause 3.6.2.2)

• Transform steel area by modular ratio ( n )
• Section properties about X-axis:

| Component | Area (A) | Centroid (Y) | ( A \times Y ) | Moment

IS 15155: Dimensions and Tolerances Key Points

1. Internal Diameter Tolerance (Clause 5.2.1 & Table 2)

• The internal diameter (ID) tolerances are specified in Table 2 (not fully provided here).
• Typically, tolerances depend on nominal diameter (DN) and manufacturing process.

2. Out-of-Roundness Tolerance (Clause 5.2.5)

• Out-of-roundness refers to deviation from perfect circularity of socket inner and spigot outer surfaces.

3. Circumference Tolerance of Joint Rings (Clause 5.2.4)

• Ensures proper joint fit and sealing.

4. Joint Dimensions (Clause 6)

• Manufacturer must provide joint dimensions with tolerances for socket and spigot diameters for inspection.

5. Dimensional Checks (Clause 13.1)

• Specifies procedures for verifying dimensions and tolerances during quality control.

Summary Table of Key Tolerances

This ensures proper fit, sealing, and structural integrity of pipe joints per IS 15155.

IS 15155 — Joint Dimensions Key Details

1. Tolerance on Circumference of Joint Rings (Clause 5.2.4)

2. Tolerance on Out-of-Roundness (Clause 5.2.5)

3. Minimum Thicknesses & Dimensions (Table 1, Clause 5.1.1)

4. Tolerances on Internal Diameter (Table 2, Clause 5.2.1)

IS 15155: Design Requirements - Key Formulas & Specifications

1. Design Criteria (Clause 7.3)

• Design must consider working pressure (Pu), test pressures, soil and backfill conditions, and loading.
• Manufacturer must declare wall thickness; tolerance ±5% or 5 mm (Clause 5.2.2).

2. Straightness (Clause 13.1.5)

• Measured by a 1 m gauge.
• Maximum deviation from straight line over 1 m ≤ 5 mm.

3. Wall Thickness (Clause 5.2.2)

• Minimum wall thickness = design thickness - 5% or 5 mm (whichever is greater).

4. Flexural Rigidity Calculation (Clause 3.6.2.2)

• Transform steel area by modular ratio ( n ) to equivalent cement mortar section.
• Calculate section properties:

5. Typical Design Example (Annex C)

• Pipe diameter, D: 1000 mm
• Working pressure, Pu: 0.7846 N/mm²
• Lining thickness, t: 20 mm
• Cylinder thickness, ty: 2.5 mm

Fabrication Key Points from IS 15155 (Clause 9.1)

• Material: Steel plates per IS 7322 thickness.
• Process: Cutting, shaping, butt welding of adjacent segments.
• Welding Inspection:
  • Use hot oil or dye penetrant test (IS 3658).
  • Dye penetration test: Apply whitewash on one side, colored penetrant on the other. No colored spot should appear within 4 hours; otherwise, weld repair is needed.

Straightness Check (Clause 13.1.5)

• Use a 1 m gauge to measure deviation.
• Maximum deviation allowed: 5 mm over 1 m length.

Fabrication & Testing Summary Table

Additional Notes

• Welding defects must be repaired and retested.
• Fabrication ensures dimensional accuracy and weld integrity before lining/coating.
• Refer to IS 3658 for detailed dye penetrant testing procedure.

flowchart TD
    A[Steel Plate Cutting & Shaping] --> B[Butt Welding of Segments]
    B --> C[Welding Inspection]
    C -->|Pass| D[Proceed to Lining & Coating]
    C -->|Fail| E[Repair Weld & Retest]
    D --> F[Final Fabricated Special]

This concise guide ensures compliance with IS 15155 fabrication requirements.

Key Testing Specifications & Formulas from IS 15155

1. Rounding Off Test Results

• Follow IS 2:1960 for rounding off numerical values.
• Retain the same number of significant digits as specified in the standard.

2. Site Test Pressure (Clause 3.4)

• Site test pressure is typically 1.5 times the working pressure (Pu).
• Example:
  [ P_{site} = 1.5 \times P_u ]

3. Hydrostatic Test Pressure of Cylinder (Clause 3.5 & C-3.5)

• Hydrostatic test pressure (P) is calculated as:
  [ P = \frac{2 S t}{D} ]
  Where:

  • (S) = Stress in pipe wall during test (N/mm²)
  • (t) = Thickness of cylinder (mm)
  • (D) = Diameter of pipe (mm)

• Manufacturer tests each steel cylinder with welded joint rings to this minimum pressure.

4. Straightness (Clause 13.1.5)

• Measured with a 1 m gauge.
• Maximum deviation allowed: 5 mm over 1 m length.

5. Typical Design Parameters (Annex C Example for 1000 mm Pipe)

Summary Diagram: Testing Pressure Hierarchy

flowchart TD
    A[Working Pressure, Pu] --> B[Site Test Pressure = 1.5 × Pu]
    B --> C[Factory Test Pressure

Marking of Sealing Rings (IS 15155 Clause 4.7.2):

• Each rubber sealing ring shall be clearly marked with:
  • Chord diameter
  • Internal diameter
  • Manufacturer's name

This ensures traceability and correct sizing during installation.

Straightness Tolerance (Clause 13.1.5):

• Measured using a 1 m gauge.
• Maximum deviation from a straight line over 1 m length: 5 mm.

Summary Table for Marking & Straightness

Additional Notes:

• Marking helps in quality control and installation accuracy.
• Straightness ensures proper pipe alignment and jointing.

flowchart TD
    A[Sealing Ring] --> B{Marking}
    B --> C[Chord Diameter]
    B --> D[Internal Diameter]
    B --> E[Manufacturer Name]
    F[Pipe Barrel] --> G[1 m Gauge]
    G --> H{Straightness Check}
    H --> I[Deviation ≤ 5 mm]

For detailed design and testing, refer to IS 15155 Clauses 4.7.2 and 13.1.5.

IS 15155: Handling and Storage - Key Specifications

Straightness (Clause 13.1.5)

• Measurement: Use a 1 m long gauge.
• Tolerance: Deviation from a straight line between two points 1 m apart shall not exceed 5 mm.

Pipe Dimensions & Thickness (Table 5.1.1)

Diameter Tolerances (Table 5.2.1)

Design & Testing Parameters (Annex C)

• Working pressure, Pu: e.g., 0.7846 N/mm² for 1000 mm pipe.
• Site test pressure: 1.5 × Pu.
• Factory test pressure: 1.2 × Site test pressure.
• Typical lining thickness: 20 mm.
• Cylinder thickness: 2.5 mm (for 1000 mm dia).
• Coating thickness: 26 mm.

Handling & Storage Recommendations:

• Store pipes on firm, level ground with supports spaced to avoid bending.
• Avoid dropping or impact to maintain straightness within limits.
• Protect cement mortar lining and coatings from damage.
• Use lifting gear at designated

IS 15155: Sampling and Criteria for Acceptance

1. Sampling Procedure (Clause 12.1)

• Pipes made under similar raw material and processing conditions form a lot.
• Sampling is done lot-wise for quality evaluation.
• Sampling scale follows Table 3 (not fully provided, but typically includes sample size vs. lot size).

2. Acceptance Criteria

• Each sample is tested for compliance with specified requirements.
• Final test values are rounded off per IS 2:1960 rules.
• Number of significant digits in results = number of digits in specified values.

3. Key Notes

• Defects repaired (Clause 11.4) must pass tests post-repair and curing.
• Acceptance depends on test conformity after repair.

Typical Sampling Table Format (Example from IS standards):

Note: Refer IS 15155 Table 3 for exact values.

Summary:

• Group pipes into lots.
• Sample as per Table 3.
• Round test results as per IS 2.
• Accept lot if samples meet criteria; reject otherwise.

flowchart TD
    A[Manufacture Pipes] --> B[Group into Lots]
    B --> C[Sample per Table 3]
    C --> D[Test Samples]
    D --> E{Test Results}
    E -->|Pass| F[Accept Lot]
    E -->|Fail| G[Reject Lot or Repair]
    G --> H[Repair & Retest]
    H --> E

IS 15155: Inspection Procedures - Key Points

1. Straightness (Clause 13.1.5)

• Measured using a 1 m long gauge along pipe barrel.
• Maximum deviation from a straight line between two points 1 m apart: 5 mm.
• See Fig. 2 for gauge details.

2. Internal Diameter Measurement (Clause 13.1.1)

• Measure at each pipe end approx. 50 mm from ends.
• Two measurements at 90° to each other at each end and center.
• Use 'Go' and 'No Go' gauges (stiff rods with hardened rounded ends).
• Example for 1200 mm pipe:

  Location	Tolerance (mm)	'Go' Gauge Length (mm)	'No Go' Gauge Length (mm)
  Ends	±9	1192	1210
  Centre	±12	1189	1213

3. Sampling and Acceptable Defectives (Table 3)

• Number of samples and defectives depend on lot size.
• For example, for 51-100 pipes:
  • Coating thickness samples: 5, defectives: 0
  • Dimensional test samples: 5, defectives: 0
  • Hydrostatic test samples: 1, defectives: 0

4. Marking (Clause 12.2)

• Pipes marked with color bands indicating pressure heads after acceptance.

Summary Diagram: Straightness Measurement

graph LR
A[Point 1 on Pipe] -- 1 m gauge --> B[Point 2 on Pipe]
B -- Max deviation 5 mm --> C[Straightness Check]

References:

• IS 2:1960 for rounding off values.
• Annex A lists related IS codes for materials and testing.
• Annex B & C provide purchaser info & typical design data.

This ensures dimensional accuracy and quality control during pipe manufacture and inspection.

IS 15155: List of Referred Indian Standards (Annex A) - Key Highlights

This standard references several important IS codes essential for design, materials, and testing of concrete pipes and steel cylinder pipes:

Important Specifications from IS 15155

• Straightness (Clause 13.1.5):
  Measured by a 1 m gauge; max deviation = 5 mm.

• Pipe Design Parameters (Annex C):
  Example for 1000 mm dia pipe:

  • Working pressure, Pu = 0.7846 N/mm²
  • Lining thickness, t = 20 mm
  • Cylinder thickness, ty = 2.5 mm
  • Coating thickness, to = 26 mm
  • Bar/wire diameter, d = 6 mm

Summary Diagram: Referenced IS Codes and Their Roles

graph TD
  A[IS 15155] --> B[Material Specifications]
  B --> IS383[IS 383 - Aggregates]
  B --> IS2062[IS 2062 - Structural Steel]
  B --> IS432[IS 432 - Steel Bars/Wires]
  A --> C[Concrete & Cement]
  C -->

IS 15155: Information to be Supplied by Purchaser (Annex B)

When ordering Bar/Wire Wrapped Steel Cylinder Pipes, purchaser must provide:

• Cement type for lining and cover coat (Clause 4.1)
• Requirement of bituminous or other coatings internally/externally (Clause 4.8)
• Maximum working pressure (Clause 3.3)
• Maximum site test pressure (Clause 3.4)
• Factory test pressure (Clause 3.5)
• Additional pressure due to surge (water hammer)
• Pipe installation details:
  • Max/min depth of cover over pipe crown
  • Trench width at pipe crown (usually pipe OD + 600 mm)
  • Number of pipelines in trench & trench width if multiple
  • Backfill material type and density
  • Bedding type
  • Anticipated superimposed ground loading
• Soil investigation and soil data

Key Tables & Specifications:

Straightness Tolerance (Clause 13.1.5):

• Measured by 1 m gauge
• Max deviation from straight line over 1 m length = 5 mm

Diameter Tolerances (Clause 5.2.1):

IS 15155 - Typical Design of Bar/Wire Wrapped Steel Cylinder Pipe (Annex C Summary)

Key Design Notes:

• Steel cylinder: Welded steel sheet with socket/spigot rings.
• Reinforcement: Continuous steel bars/wires helically wound and welded.
• Lining: Cement mortar centrifugally applied inside.
• Coating: Dense cement mortar covering the cylinder and reinforcement.
• Straightness tolerance: Max deviation 5 mm over 1 m length (Clause 13.1