Code of Practice for Laying of Electrically Welded Steel Pipes for Water Supply

IS 5822: Scope - Key Specifications & References

Scope:
IS 5822 covers design and construction requirements for steel pipes used in waterworks, including sluice valves and penstocks.

Key Points from Clause 16.1 & Annex A:

• General Design Requirements:
  Refer to Annex B for steel pipe design guidelines (informative).

• Physical Constants for Steel (Clause B-12.1):

  • Coefficient of thermal expansion, α = 12 × 10⁻⁶ /°C (up to 120°C)
  • Modulus of elasticity, E = 2.0 × 10⁵ N/mm²
  • Poisson's ratio, ν = 0.3

• Thermal Expansion Consideration (Clause B-5.1):
  Design must allow for thermal expansion/contraction due to temperature variations on site.

Important IS References (Annex A):

Thermal Expansion Formula:

[ \Delta L = L \times \alpha \times \Delta T ]

• ΔL: Change in length
• L: Original length
• α: Coefficient of thermal expansion (12 × 10⁻⁶ /°C)
• ΔT: Temperature change (°C)

flowchart LR
    A[Steel Pipe Design] --> B[Consider Thermal Expansion]
    B --> C[Use α = 12×10⁻⁶ /°C]
    A --> D[Refer IS Codes]
    D --> E[IS 814, 816, 2062, 3589, 

IS 5822 - Referenced Indian Standards Summary

IS 5822 references multiple Indian Standards critical for design, testing, and construction of steel pipes and related components:

Key Notes:

• Anchor blocks must be designed per IS 5330:1984.
• Welding electrodes and procedures follow IS 814 and IS 816.
• Steel material properties align with IS 2062.
• Testing methods for welds include IS 3600, IS 4260, and IS 4853.
• Pipe laying and measurement standards are covered under IS 3114 and IS 1200.

Typical Reference Usage in Design:

1. Material Selection: IS 2062 (Steel grades)
2. Welding: IS 814 (Electrodes), IS 816 (Welding practice)
3. Testing: IS 3600 (W

IS 5822: Preliminary Work Before Pipe Laying

Key Specifications & Steps:

• Clearing the Route (Clause 3.1):

  • Remove all shrubs, grass, bushes, trees, hedges, fences, gates, old masonry, and debris along the pipeline route.

• Bench Marks (Clause 5.2.1):

  • Fix reference bench marks at a minimum of one per kilometre along the route.
  • Bench marks must be:
    • Located slightly away from the working area.
    • Securely fixed in cement concrete for stability.

• Preliminary Work Sequence (Clauses 5.2.1 to 5.2.5):

  • Includes pegging out the route, clearing, excavation marking, and setting out levels before pipe laying.

Typical Bench Mark Fixing Details:

flowchart TD
    A[Start Preliminary Work] --> B[Pegging Out Route]
    B --> C[Clearing Vegetation & Debris]
    C --> D[Fix Bench Marks (1 per km)]
    D --> E[Set Levels & Excavation Markings]
    E --> F[Ready for Pipe Laying]

Summary:
Before pipe laying, clear the route fully, peg out accurately, and fix durable bench marks at regular intervals to ensure precise alignment and elevation control during pipeline construction.

IS 5822 - Excavation & Preparation of Trenches for Underground Pipelines

Key Specifications (Clause 4.2 & related):

• Trench Width: Minimum width = Pipe diameter + 400 mm
  (200 mm clearance on each side of the pipe for working space)

• Trench Bottom:

  • Properly trimmed for even bedding.
  • For pipes > 1200 mm diameter, bottom curvature should match pipe curvature subtending ~120° at pipe center (Fig. 1A).
  • If rock/boulders present, trench bottom must be excavated at least 100 mm below pipe barrel level and filled with lean cement concrete or non-compressible material (e.g., sand) to provide curved seating (Fig. 1B, 1C).

• Trench Depth:

  • Sufficient for required pipe depth and alignment.
  • Minimum cover under roadways: 1.0 m (modifiable with precautions).

• Safety & Work Conditions:

  • Trench must be shored where necessary.
  • Keep trench dry; dewatering discharge must be properly drained away.

Summary Table

Visual Concept (Trench Bottom Curvature)

graph LR
A[Trench Bottom] --> B((Pipe))
B --- C{120° Curvature}

This ensures uniform support and prevents pipe damage during laying.

IS 5822: Pipe Handling and Inspection - Key Points

1. Pipe Inspection (Clause 5.2.3)

• Inspect pipes and specials for defects: protrusions, grooves, dents, notches.
• Defects must be rectified without reducing wall thickness below minimum specified.
• If wall thickness < minimum, cut out damaged cylinder section and replace with undamaged pipe.

2. Handling of Pipes and Specials (Clause 5.2.4)

• Avoid damage to circularity and coating.
• Do NOT throw pipes from trucks or drag/roll on hard surfaces.
• Use canvas slings or special pipe-end attachments to lift/lower coated pipes safely.

3. Stability of Embankment (Clause 4.3.2.3)

• Embankment must rest on a good foundation capable of supporting earth fill, pipeline, and service road.
• For soft soils (marshy/marine clay), stabilize with:
  • Sand piles or rubble piles, or
  • RCC/wooden piles driven to hard substrata.

Summary Table: Handling & Inspection Checks

Additional Notes:

• Refer to Annex B for general steel pipe design requirements.
• Related IS codes for welding, testing, and coatings are referenced for quality assurance.

flowchart TD
    A[Pipe Receipt] --> B{Inspect Defects?}
    B -- Yes --> C[Rectify Defects]
    C --> D{Wall Thickness ≥ Min?}
    D -- No --> E[Cut & Replace Section]
    D -- Yes --> F[Proceed to Handling]
    B -- No --> F
    F --> G{Handling Method}
    G --> H[Use Canvas Slings / Attachments]
    G --> I[No Throwing / Dragging]

This ensures pipe integrity and coating protection per IS 5822 standards.

Welding and Testing of Joints as per IS 5822

1. Welding Specifications:

• Field Welding: Must comply with IS 816:1969 (Code of practice for metal arc welding in mild steel).
• Electrodes: Use electrodes conforming to IS 814:1991 (Covered electrodes for manual metal arc welding of carbon and carbon manganese steel).
• Excavation for Welding: Provide pits around joints with max 600 mm depth and 900 mm length for welding access (Clause 4.2.2).

2. Testing of Welded Joints:

• Follow IS 3600 (Part 1):1985 for testing procedures.
• Test at least one specimen per 10 field joints.
• Tests include fusion weld tensile tests (cruciform fillet weld tensile test).
• Recommended NDT methods include ultrasonic testing (IS 4260:1986) and radiographic inspection (IS 4853:1982, IS 5330:1984).

Summary Table for Welding & Testing

Visual: Welding Pit Dimensions

graph LR
A[Pipe] --> B[Pit for Welding]
B --> C[Depth: 600 mm]
B --> D[Length: 900 mm]

This ensures proper access and quality welding/testing as per IS 5822 requirements.

IS 5822 - Key Specifications for Laying Pipes Underground

1. Trenching (Clause 4.2 & 4.2.1)

• Trench width: Minimum, with at least 200 mm clearance on either side of the pipe.
• Trench bottom: Properly trimmed for even bedding.
• For pipes >1200 mm diameter: Bottom curvature should match pipe curvature, subtending about 120° at pipe center (Fig. 1A).
• Rock/boulders: Trench bottom trimmed 100 mm below pipe barrel level, filled with lean cement concrete or non-compressible material (sand) to provide curved seating (Fig. 1B & 1C).

2. Bedding

• Ensure uniform support along pipe length.
• Use lean cement concrete or sand for bedding on uneven rock surfaces.

3. Clearance Formula

[ \text{Trench width} = \text{Pipe diameter} + 2 \times 200 \text{ mm (clearance)} ]

Diagram: Trench Bottom Curvature for Large Pipes

graph LR
    A[Trench Bottom] -->|Curved to 120°| B[Pipe]
    B --> C[Pipe Diameter > 1200 mm]
    A --> D[Lean Cement Concrete or Sand Bedding]

Summary: Maintain minimum 200 mm clearance, trim trench bottom for uniform bedding, and provide curved seating for large pipes with proper fill under rock/boulder conditions.

IS 5822: Laying of Pipes Above Ground (Clause 8.3)

• Handling & Laying: Follow pipe handling procedures as per Clause 5 and underground laying (Clause 8.1.2) for lifting and assembly on supports or ground.

• Resting on Ground: Allowed if soil is non-aggressive. The ground must be dressed to match pipe curvature over an arch length subtending 120° at pipe center.

• Supports: Pipes should be laid on:

  • Saddle supports (Fig. 5)
  • Roller and rocker supports (Fig. 6)

• Curvature Matching: The ground or support surface must conform to pipe curvature to avoid point loads and damage.

Key Specifications for Supports (from IS 5822):

Curvature Geometry for Pipe Bedding

• Angle subtended: 120° at pipe center
• Ensures uniform contact and load distribution

graph LR
  A[Pipe Cross-Section] --> B[120° Arch Length]
  B --> C[Ground/Support Surface]
  C --> D[Uniform Load Distribution]

Note: For underground laying (Clause 8.1), trench bottom should be trimmed similarly to match pipe curvature with at least 200 mm clearance on sides. For rock/boulders, provide at least 100 mm lean cement concrete or sand bedding below pipe barrel.

This ensures pipe integrity and longevity when laid above ground or on supports.

IS 5822: Key Points for Road, Rail & River Crossing

1. Anchorage (Clause 8.3.3)

• Use concrete anchor blocks or equivalent to resist:
  • Unbalanced water pressures
  • Temperature stresses
• Anchor pipes during construction and service to prevent flotation.

2. Crossing Method (Clause 9.1)

• The pipeline laying method for road, rail, or river crossings must comply with the requirements of the concerned authority.
• No fixed formula; design depends on site and authority conditions.

3. Excavation & Support (Clause 4.3.1)

• Bottom width of cutting must accommodate:
  • Pipeline + supports
  • Service passage
  • Side drains
• Side slopes for cutting:

4. Traffic Maintenance (Clause 4.2.10)

• Minimize traffic interruption.
• Provide temporary bridges over open trenches if traffic crossing is necessary.

flowchart TD
    A[Pipeline Crossing] --> B{Type of Crossing}
    B --> C[Road]
    B --> D[Rail]
    B --> E[River]
    C --> F[Authority Approval]
    D --> F
    E --> F
    F --> G[Method Selection]
    G --> H[Anchorage Design]
    G --> I[Excavation & Support]
    G --> J[Traffic Management]

Summary: IS 5822 emphasizes anchorage for stability, authority-approved crossing methods, proper excavation slopes, and minimal traffic disruption during road, rail, and river pipeline crossings.

Key Specifications & Formulas for Pipeline Support Structures (IS 5822)

Physical Constants for Steel (Clause 12.1):

• Coefficient of Thermal Expansion (α):
  ( 12 \times 10^{-6} / ^\circ C ) (up to 120ºC)
• Modulus of Elasticity (E):
  ( 2.0 \times 10^5 , \text{N/mm}^2 )
• Poisson's Ratio (ν):
  0.3

Support Design (Clause B-13):

• Support Types:

  • Saddle supports
  • Roller and rocker supports
  • Flat base supports (for controlled movement)

• Load Considerations:

  • Weight of pipe + fluid (water)
  • Hydrostatic head
  • Frictional resistance at supports

• Bearing Surface:
  Must be adequate to avoid local stress concentration.

Pipe-to-Ground Contact (Clause 8.1.2):

• If pipeline rests on ground, soil must be non-aggressive.
• Ground dressing to match pipe curvature over an arch length subtending 120° at pipe center.

Embankment Stability (Clause 4.3.2.3):

• Foundation must support earth fill, pipe, and service road loads.
• Soft ground stabilization by:
  • Sand or rubble piles
  • RCC or wooden piles transferring load to hard substrata

Summary Table: Steel Constants for Pipeline Design

flowchart LR
    A[Pipeline] --> B[Saddle Support]
    A --> C[Roller/Rocker Support]
    A --> D[Ground Support]
    D --> E[Soil Non-aggressive?]
    E -->|Yes| F[Ground Dressed to 120° Arch]
    E -->|No| G[Use Saddles or Roll

IS 5822: Testing and Commissioning of Pipelines – Key Points

1. Pressure Test (Clause 11.2.1)

• Test Pressure (P_test) = Greatest of:

  • a) Maximum sustained operating pressure (P_op)
  • b) Maximum pipeline static pressure (P_static)
  • c) Sum of maximum static pressure + surge pressure (P_static + P_surge)

• Test Duration:

  • If test pressure < 2/3 of design test pressure → minimum 24 hours.

• Pressure Increase Rate:

  • Gradually raised at ~0.1 N/mm² per minute.

• Pressure Measurement:

  • Measure at lowest point or adjust for static head difference.

• Leakage Allowance:

  • Max water addition ≤ 0.1 litre per mm dia per km per day per 30 m head.

2. Testing Procedure (Clause 11.2)

• Slowly fill valved section with clean water.
• Expel air via hydrants, air valves, blow-offs.
• Tighten expansion joints before test.

3. Special Considerations

• Welded joints at test gaps may not be pressure tested; monitor during commissioning.
• Pressure indicators, flow recorders, burst alarms to be installed (Clause 10.2.3).

4. Restrained Pipeline Temperature Stress (Clause B-11.2)

[ F = E \times L \times (t_2 - t_1) - m \times \sigma_h ]

Where:

Summary Table: Test Pressure Selection

IS 5822: Corrosion Protection & Coatings - Key Points

1. Corrosion Allowance (Clause 10.1, B-10.1)

• Must be based on specialist investigation per IS 5555:1990 or IS 7808:1975.
• Adjusted for the required pipeline life.
• Typical corrosion allowance ranges from 1.5 mm to 3 mm, depending on environment and material.

2. External Corrosion Protection

• Buried Pipes (Clause 12.1):

  • Use coatings as per IS 10221:1982 (e.g., bituminous, polyethylene).
  • Cathodic protection may be recommended.

• Above Ground Pipes (Clause 12.2):

  • Protect against atmospheric corrosion via paints, coatings, or wrapping.

3. Localized Stress near Supports (Clause 9.4.2)
For unstiffened pipes on saddle supports, max local stress:

[ S_{max} = k \cdot \frac{P}{t \cdot R} ]

Where:

• (k = 0.02 - 0.0012(\beta - 90)), (\beta) = support angle (°)
• (P) = total load on support (N)
• (t) = pipe thickness (mm)
• (R) = pipe radius (mm)

Summary Table for Corrosion Allowance

flowchart LR
    A[Corrosion Risk] --> B[Specialist Investigation]
    B --> C[Determine Corrosion Allowance]
    C --> D[Modify for Pipeline Life]
    D --> E[Apply Coatings & Protection]
    E

IS 5822: Flushing and Disinfection of Mains Before Commissioning

Key Steps & Specifications

• Flushing (Clause 13.1.3):

  • After pressure testing, flush mains with water at sufficient velocity to remove dirt and foreign materials.
  • Ensure velocity is enough to scour the pipe interior (typically >1.5 m/s).

• Disinfection (Clauses 13.2, 13.3):

  • Use liquid chlorine, sodium hypochlorite, or calcium hypochlorite.
  • Methods include:
    • Continuous feed of chlorine solution.
    • Batch chlorination by filling the main with chlorinated water.
  • Maintain a chlorine residual of 2-5 mg/L after contact time (usually 24 hours).

• Precautions (Clause 13.4):

  • Prevent backflow of strong chlorine solution into supply.
  • After contact period, flush chlorinated water until chlorine residual matches the rest of the system.
  • Perform bacteriological tests; repeat disinfection if standards are not met.

Typical Contact Time & Concentrations

Summary Flowchart

flowchart TD
    A[Pressure Test Completed] --> B[Flush with High Velocity Water]
    B --> C[Disinfect with Chlorine Solution]
    C --> D[Maintain Contact Time (24 hrs)]
    D --> E[Flush to Waste Until Residual Chlorine Matches System]
    E --> F[Bacteriological Testing]
    F -->|Pass| G[Commission Main]
    F -->|Fail| C

Note: Always follow local health authority bacteriological standards before commissioning.

IS 5822: Design Requirements for Flexibility and Bending

Key Formulas

Longitudinal Compression Force due to Temperature Rise (Clause 11.2):

[ F = E \times \alpha \times L \times (T_2 - T_1) - m \times \sigma_h ]

• ( F ) = Axial force due to temperature (N/mm²)
• ( E ) = Modulus of Elasticity = ( 2.0 \times 10^5 , \text{N/mm}^2 )
• ( \alpha ) = Linear coefficient of thermal expansion = ( 12 \times 10^{-6} / ^\circ C )
• ( L ) = Length of pipeline (mm)
• ( T_2 ) = Operating temperature (°C)
• ( T_1 ) = Installation temperature (°C)
• ( m ) = Poisson’s ratio = 0.3
• ( \sigma_h ) = Hoop stress due to internal pressure (N/mm²)

Physical Constants for Steel (Clause 12.1)

Design Notes

• For temperatures between +5°C and +50°C, no change in design stresses is required.
• Longitudinal axial compressive and bending stresses must be checked against buckling criteria (Clause 9.4.1).
• Flexibility design must accommodate thermal expansion stresses, especially for restrained pipelines without expansion joints or loops.

flowchart LR
    A[Temperature Rise] --> B[Axial Force F]
    B --> C{Check Buckling}
    C -->|Safe| D[Design OK]
    C -->|Unsafe| E[Provide Expansion Joints or Supports]

This summary helps ensure pipeline flexibility and bending stresses are properly accounted for per IS 5822.

IS 5822: Removal, Restoration and Maintenance of Paved Footpaths After Laying of Pipe

Key Specifications (Clause 15)

• Restoration Requirement:
  All disturbed pavements, footpaths, curbing, gutters, and surface structures must be restored to their original condition or better.

• Materials for Restoration:

  • Sound granite blocks
  • Sound brick or asphalt paving blocks
    These may be re-used where suitable.

• Backfill Condition:
  Permanent pavement restoration is allowed only after the backfill is properly compacted and can support the pavement load as approved by the authority.

Important Steps for Restoration

1. Removal:
   Carefully remove paving blocks or slabs, preserving sound materials for reuse.

2. Backfilling & Compaction:
   Use suitable soil or granular material compacted in layers (typically 150-200 mm thick) to achieve required density (usually ≥ 95% Standard Proctor Density).

3. Restoration:
   Replace paving materials ensuring proper alignment and jointing.

Typical Compaction Control Formula

[ \text{Degree of Compaction} = \frac{\text{Field Dry Density}}{\text{Maximum Dry Density from Proctor Test}} \times 100% ]

Summary Table: Restoration Criteria

flowchart TD
    A[Removal of Pavement] --> B[Backfilling in Layers]
    B --> C[Compaction & Testing]
    C --> D[Approval by Authority]
    D --> E[Restoration of Pavement]
    E --> F[Final Inspection & Maintenance]

This ensures footpaths regain full strength and durability after pipe laying works.