Aapni Yojna Water Supply Project `

Thrust Blocks

PUBLIC HEALTH ENGINEERING DEPARTMENT, RAJASTHAN

AAPNI YOJANA II : RATANGARH SUJANGARH SECTION

DESIGN DOCUMENT SUBMISSIONS

SUBMISSION DETAILS Project Submission No Document Submission Date Aapni Yojana Phas II Ra!an"a#h S$jan"a#h S %!ion AYPhII&TB&'( D si"n R po#! )o# Th#$s! B*o%+s )o# Aapni Yojna,II Ra!an"a#h S$jan"a#h S %!ion (-,'.,-'(/ Revision No R'

SUBMITTED TO SUPERINTENDING ENGINEER, PHED, PMC CIRCLE, CHURU, R

! STH N

SUBMITTED BY
NCC LIMTED,

"#E DI$ISI%N, M
H&DER

DH%PUR

' D ( )***+,

CONSULTANTS SARAS0ATI TECHNICAL SER1ICES,

C(,--, ' PU N G R, ! IPUR PIN(-*.*,) TEL / *,0,(.1*+023, 4 5 / *,0,(0*-+,-E(M IL / STS$ISHNU6& H%%7C%7IN

Consultant Saraswati Technical Services (P) Ltd.

Contractor NCC Ltd.

Aapni Yojna Water Supply Project

Thrust Blocks SUBMISSION NO

Project Submission No Document

Submission Date

a8ni &ojana P9ase II : Ratan;ar9 Sujan;ar9 Section AYPhII&TB&'( D si"n R po#! )o# Th#$s! B*o%+s )o# Aapni Yojna,II Ra!an"a#h S$jan"a#h S %!ion
(-,'.,-'(/ Revision No R'

DOCUMENTS ATTACHED Do%$2 n! No &RS<T'<*,<DD(*, &RS< T' <*,<DN(*. Do%$2 n! D !ai*s Desi;n Re8ort T9rust '=oc> Desi;n S9eet ?or ?o==o@in; cases Pi8e C=assi?ication 1** mm MS +** mm MS ,,** mm MS 0** mm DI )** mm DI 2** mm DI &RS< T' <*,<DN(*&RS< T' <*,<DN(*0 "or>in; Pressure 27* B;<sCcm ,.7)* B;<sCcm ,)7* B;<sCcm +7* B;<sCcm +7* B;<sCcm +7* B;<sCcm n;=e o? 'enA ,*, ,2, .., -*, 0),2*, 1), 3* De;rees ,*, ,2, .., -*, 0),2*, 1), 3* De;rees ,*, ,2, .., -*, 0),2*, 1), 3* De;rees ,,7.), ..7), 0), 3* De;rees ,,7.), ..7), 0), 3* De;rees ,,7.), ..7), 0), 3* De;rees

Detai=eA Dra@in; anA Dimensions o? T9rust '=oc>s ?or MS Pi8e Detai=eA Dra@in; anA Dimensions o? T9rust '=oc>s ?or DI Pi8e

RE1ISION HISTORY Rev No R* Submission Date ,.(*-(.*,0 Detai=s

Consultant Saraswati Technical Services (P) Ltd.

Contractor NCC Ltd.

Aapni Yojna Water Supply Project

Thrust Blocks

Name of Project: Client:

Document Name: 1. Theory

PMC Phase-II, Ratangarh-Sujangarh Section Additional Chief Engineer, Department, Region Churu
Design of Thrust Blocks

Public

Health

Engineering

The Horizontal thrust at the bend is given by T = 2 P x A x Sin /2 Where T P A Horizontal Thrust at the Bend Internal Pressure Internal area of Pipe Deviation Angle

Thrust blocks for DI pipes, having rubber gasket be flexible shall be designed for free joints, thrust calculated, as above, with safety factor of 1.5 MS pipes having welded joints shall be designed for half the thrust as per following provisions of CPHEEO manual. CPHEEO Manual of Water Supply have provisions in Clause 6.16.18 at Page No 61 for MS pipe anchorage and is reproduced below; Where steel pipes with welded joints are used, full anchorage is not generally necessary, since the longitudinal continuity of the pipe is capable of distributing the forces into the ground. If the pressures are high enough to merit it and sleeve joints are being used, the joints on the bends and on two pipes either side of them should be fully welded inside & outside and the trench is refilled with concrete to 150 mm above these pipes and bends. About half of thrust will be taken by the weight of the concrete and the remainder by the longitudinal stresses in the pipe. Page 1 of 12

Aapni Yojna Water Supply Project

Thrust Blocks

Accordingly, for design of Thrust Blocks for MS pipes, the concrete block sizing is done adopting half of the unbalanced horizontal thrust. For DI pipes, having flexible joints, TB would be designed for 100% value of thrust block. The passive soil reaction against the concrete is Pp = 0.5 (H12- H22) l2 Tan2 (45 + /2) Where Pp H1 H2 l2 Friction resistance Fr = (WTB + Wp+ We) x Where Wtb Wp We Weight of Thrust Block Weight of Pipe & Water Weight of Soil above Thrust Block Coefficient of friction between soil & Concrete = = = = = Specific weight of soil N/m3 Passive soil reaction, N Distance from GL to Concrete block base, m Distance from GL to Concrete block top, m Width of concrete block in contact with soil, m

This passive soil reaction and friction resistance of thrust block combined resist the horizontal thrust. Total Resistance = Pp + Fr The Factor of Safety which is ratio of Total resistance to unbalanced horizontal Thrust shall be more than 1.5 Moreover, the width of block shall be such to satisfy the criteria of Safe Bearing Capacity. 2. i. Provisions regarding Thrust Blocks in Tender Document Clause 4.4 (XXII), Page No XXXVI

Providing thrust blocks at vertical and horizontal bends, for the combination of loads as per site conditions of each thrust block for deflections exceeding 4 degrees in vertical/ horizontal alignment. ii. Clause 4.21, Page No CXLIII It is proposed to provide anchorage in the form of thrust block at each deflection in horizontal as well as in vertical alignment of the pipeline as per requirement of designs, which shall resist the unbalanced pressure at bends. Gravity type of thrust blocks shall be provided at horizontal and vertical deflection in pipeline and shall be designed according to the test pressure and the soil conditions at the site of the thrust block. The thrust shall be according to the field test

Page 2 of 12

Aapni Yojna Water Supply Project

Thrust Blocks

pressure of the pipe, acting on the outer diameter including the compressed rubber gasket. Before designing the thrust block the Contractor, in coordination with the Engineer-in-Charge shall assess the stability of the soil considering erosion due to wind and water. The thrust blocks shall be of concrete M15 or grade as specified in IS 456, cast on site with surface reinforcement of about 5 kg/m2. The calculations for the dimensioning and the shape of the thrust blocks have to be approved by the Engineer-in-Charge. Design of thrust block shall be done in accordance to the provisions laid down in IS 5330-1984. iii. Clause 4.11.2, Page No CLXVV Thrust blocks shall be provided at each bend, tee, taper, end piece to prevent undue movements of the pipeline under pressure. They shall be constructed as per actual design and approval of Engineer in Charge according to the highest pressure during operation or testing of the pipes, the safe bearing pressure of the surrounding soil and the friction coefficient of the soil. Nominal steel shall be provided as per the provisions of CPHEEO manual and the construction of block shall be done in M15 grade of concrete. iv. Clause 4.51, Page No CLXXX For construction of Valve Chambers, Anchor blocks and pedestal support, M20 grade of concrete shall be used. The thrust blocks shall be constructed using M-15 grade of concrete. The leveling course, wherever provided shall be of M10 grade. v. Clause 4.52, Page No CLXXXII It is proposed to provide anchorage in the form of thrust block at each deflection in horizontal as well as in vertical alignment of the pipeline as per requirement of designs, which shall resist the unbalanced pressure at bends. Gravity type of thrust blocks shall be provided at horizontal and vertical deflection in pipeline and shall be designed according to the test pressure and the soil conditions at the site of the thrust block. The thrust shall be according to the field test pressure of the pipe, acting on the outer diameter including the compressed rubber gasket. Before designing the thrust block the Contractor, in coordination with the Engineer-in-Charge shall assess the stability of the soil considering erosion due to wind and water. The thrust blocks shall be of concrete M15 or grade as specified in IS 456, cast on site with surface reinforcement of about 5 kg/m2. The calculations for the dimensioning and the shape of the thrust blocks have to be approved by the Engineer-in-Charge. Design of thrust block shall be done in accordance to the provisions laid down in IS 5330-1984. The thrust blocks shall be of reinforced cement concrete on site as per design and drawings to be approved by Engineer. There is no need to provide reinforcement for thrust blocks on pipeline of dia. 150 mm and below. Typical drawings of thrust blocks are enclosed in the volume III of the tender document. However, these drawings are for indicative purposes only. The contractor shall submit his own designs and drawings based on the actual site conditions for the approval of the Engineer-in-charge. The thrust blocks shall be cast directly against the undisturbed soil. If this is not possible, the backfilled soil at the contact surface shall be compacted well to full satisfaction of Engineer so that anchor block is not displaced during operation and testing. 3. Pipelines

As per TD clause No 4.1 (Page No xxi-xxii), following pipelines are in scope of work under this contract Page 3 of 12

Aapni Yojna Water Supply Project

Thrust Blocks

S.No. 1 2 3 4 5 6 7

Material MS MS MS MS DI DI DI

Diameter 1100 mm 1100 mm 800 mm 700 mm 600 mm 500 mm 400 mm

Class etc 9.0 mm 7.1 mm 7.1 mm 7.1 mm K-7 K-7 K-7

4.

Design Pressure for Thrust Blocks

Design pressure for the thrust block shall be 1.5 times the maximum working pressure in particular stretch of the pipeline corresponding to the design flow. The following table shows the maximum and minimum working pressure in the pipeline and ranges of working pressure for which thrust blocks have been designed. Pipe Classification Working Pressure (Kg/sqcm) Maximum MS 1100 mm MS 800 mm MS 700 mm 15 15 6 Minimum 2 5 2 Design Pressure Range for Thrust Blocks (Kg/sqcm) 3, 6, 9, 12, 15, 18, 22.5 7.5, 12, 15, 18.75 3, 6, 9

Maximum and minimum design pressure for different diameters DI-K7 pipes are as below: Pipe Classification Working Pressure (Kg/sqcm) Maximum DI K-7 600 mm DI 500 mm DI 400 mm 8 8 8 Minimum 2 2 2 3,6,9,12 3,6,9,12 3,6,9,12 Design Pressure Range for Thrust Blocks (Kg/sqcm)

Page 4 of 12

Aapni Yojna Water Supply Project 5. Angle of Bend for Design

Thrust Blocks

MS bends shall be fabricated as per site requirements. In design we have provided angles of 10, 16, 22, 30, 45, 60, 75, 90 degrees. Thrust blocks are designed for these deviation angles. For angles more than 4 degrees and up to 10 degrees, TB designed for 100 deflections. Similarly, for bends falling in between two type designs, TB designed for higher degree bend shall be used and intermediate deviations, deflection shall be adjusted in flexible joints of pipes. DI bends are available in standard degrees of 11.25, 22.5, 45 and 90. Thrust blocks are designed for these deviation angles and different pressure ratings.. For smaller angles and intermediate deviations, deflection shall be adjusted in flexible joints of pipes. 6. Selection of thrust block

Type design of thrust block shall be selected for maximum working pressure in a stretch and corresponding field test pressure 7. Design Sheets

Sample design calculation sheets, for each size of pipe and degree of bend for maximum pressure is annexed with the report. 8. Design Summary

The detailed design sheet for one typical thrust block is attached. The dimensional details of thrust blocks for various MS pipes for different pressure ranges and deviation angles are as follows;
%ength of $lock at centre on Pipe &ide Angle of Bend Nominal Pipe Diameter #eight of the $lock idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 %ength of $lock on the soil side mm "00 "00 #00 $00 1000 1200 1"00 1#00 Pipe Thickness (mm) "ield Test Press!re 'g(s)cm

mm *++ *++ *++ *++ *++ *++ *++ *++

mm 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1

Degrees 10 1# 22 0 "! #0 7! %0

'g(s)cm 2 2 2 2 2 2 2 2

orking Press!re

mm 7!0 7!0 7!0 7!0 $00 $00 %00 %00

mm 200 200 00 "00 !00 #00 700 $00

Page 5 of 12

Aapni Yojna Water Supply Project

%ength of $lock at centre on Pipe &ide Angle of Bend

Thrust Blocks

Nominal Pipe Diameter

#eight of the $lock

mm *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ *++ -++ -++ -++ -++ -++ -++ -++

mm 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1

Degrees 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "! #0 7!

'g(s)cm " " " " " " " " # # # # # # # # ! ! ! ! ! ! !

'g(s)cm # # # # # # # # % % % % % % % % 7.! 7.! 7.! 7.! 7.! 7.! 7.!

mm 7!0 $00 $00 %00 1100 1 00 1"00 1!00 7!0 $!0 1000 1100 1200 1700 1$00 2000 %00 1000 1100 1200 1 00 1#00 1700

mm 00 "00 !00 #00 700 $00 %00 %00 "00 !00 #00 700 1000 %00 1000 1100 00 !00 #00 700 %00 1000 1100

mm #00 $00 1000 1200 1"00 1#00 1$00 1$00 $00 1000 1200 1"00 2000 1$00 2000 2200 #00 1000 1200 1"00 1$00 2000 2200

Page , of 12

idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

%ength of $lock on the soil side

Pipe Thickness (mm)

"ield Test Press!re

orking Press!re

Aapni Yojna Water Supply Project

%ength of $lock at centre on Pipe &ide Angle of Bend

Thrust Blocks

Nominal Pipe Diameter

#eight of the $lock

mm -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++ -++

mm 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1

Degrees %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "! #0

'g(s)cm ! $ $ $ $ $ $ $ $ 10 10 10 10 10 10 10 10 12.! 12.! 12.! 12.! 12.! 12.!

'g(s)cm 7.! 12 12 12 12 12 12 12 12 1! 1! 1! 1! 1! 1! 1! 1! 1$.7! 1$.7! 1$.7! 1$.7! 1$.7! 1$.7!

mm 1$00 %00 1000 1200 1 00 1$00 2200 2200 2200 %00 1 00 1"00 1!00 1%00 2200 2"00 2#00 1200 1"00 1!00 1%00 2000 2"00

mm 1200 !00 700 $00 1000 1100 1200 1"00 1!00 #00 700 %00 1100 1 00 1"00 1!00 1#00 #00 $00 1000 1100 1!00 1#00

mm 2"00 1000 1"00 1#00 2000 2200 2"00 2$00 000 1200 1"00 1$00 2200 2#00 2$00 000 200 1200 1#00 2000 2200 000 200

Page * of 12

idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

%ength of $lock on the soil side

Pipe Thickness (mm)

"ield Test Press!re

orking Press!re

Aapni Yojna Water Supply Project

%ength of $lock at centre on Pipe &ide Angle of Bend

Thrust Blocks

Nominal Pipe Diameter

#eight of the $lock

mm -++ -++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++

mm 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1

Degrees 7! %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "!

'g(s)cm 12.! 12.! 2 2 2 2 2 2 2 2 " " " " " " " " # # # # #

'g(s)cm 1$.7! 1$.7!

mm 2!00 2#00 1200 1200 1200 1200 1200 1 00 1"00 1!00

mm 1$00 1%00 00 "00 "00 !00 700 $00 %00 1000 "00 !00 700 %00 1200 1 00 1"00 1!00 !00 7!0 700 %00 1100

mm #00 $00 #00 $00 $00 1000 1"00 1#00 1$00 2000 $00 1000 1"00 1$00 2"00 2#00 2$00 000 1000 1!00 1"00 1$00 2200

# # # # # # # # % % % % %

1200 1200 1200 1200 1"00 1#00 1$00 2000 1200 1200 1$00 2000 2"00

Page - of 12

idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

%ength of $lock on the soil side

Pipe Thickness (mm)

"ield Test Press!re

orking Press!re

Aapni Yojna Water Supply Project

%ength of $lock at centre on Pipe &ide Angle of Bend

Thrust Blocks

Nominal Pipe Diameter

#eight of the $lock

mm 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++

mm 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 7.1 % % % %

Degrees #0 7! %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0 "! #0 7! %0 10 1# 22 0

'g(s)cm # # # $ $ $ $ $ $ $ $ 10 10 10 10 10 10 10 10 12 12 12 12

'g(s)cm % % % 12 12 12 12 12 12 12 12 1! 1! 1! 1! 1! 1! 1! 1! 1$ 1$ 1$ 1$

mm 2!00 2#00 2$00 1200 1 00 1#00 2000 2"00 2#00 2$00 2$00 1200 1!00 1$00 2000 2"00 2#00 2$00 2%00 1"00 1#00 1$00 2000

mm 1 00 1!00 1!00 700 %00 1000 1100 1"00 1#00 1$00 2000 $00 1000 1200 1"00 1700 2000 2100 2 00 $00 1100 1"00 1700

mm 2#00 000 000 1"00 1$00 2000 2200 2$00 200 #00 "000 1#00 2000 2"00 2$00 "00 "000 "200 "#00 1#00 2200 2$00 "00

Page . of 12

idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

%ength of $lock on the soil side

Pipe Thickness (mm)

"ield Test Press!re

orking Press!re

Aapni Yojna Water Supply Project

%ength of $lock at centre on Pipe &ide Angle of Bend

Thrust Blocks

Nominal Pipe Diameter

#eight of the $lock

mm 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++ 11++

mm % % % % % % % % % % % %

Degrees "! #0 7! %0 10 1# 22 0 "! #0 7! %0

'g(s)cm 12 12 12 12 1! 1! 1! 1! 1! 1! 1! 1!

'g(s)cm 1$ 1$ 1$ 1$ 22.! 22.! 22.! 22.! 22.! 22.! 22.! 22.!

mm 2"00 2#00 2$00 2$00 1"00 1$00 2200 2"00 2$00 2$00 000 000

mm 2000 2 00 2!00 2700 1000 1 00 1"00 1700 2100 2#00 2%00 100

mm "000 "#00 !000 !"00 2000 2#00 2$00 "00 "200 !200 !$00 #200

Similarly, the summary of dimensions of Thrust Blocks for DI K-7 pipes is as given below;
#eight of the $lock idth of $lock $ehind Pipe %ength of $lock on the soil side "ield Test Press!re Nominal Pipe Diameter %ength of $lock at centre of pipe a/is orking Press!re

mm 4++ 4++ 4++ 4++ 4++ 4++

Degrees 11.2! 22.! "! %0 11.2! 22.!

Angle of Bend

'g(s)cm 2 2 2 2 " "

'g(s)cm

mm !00 #00 -++ 1+++

mm 200 00 "00 #00 00 !00

mm "00 #00 -++ 12++ ,++ 1+++

mm 00 00 00 00 00 00

# #

,++ *++

Page 1+ of 12

idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00

%ength of $lock on the soil side

Pipe Thickness (mm)

"ield Test Press!re

orking Press!re

Aapni Yojna Water Supply Project

#eight of the $lock

Thrust Blocks
idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

mm 4++ 4++ 4++ 4++ 4++ 4++ 4++ 4++ 4++ 4++ 5++ 5++ 5++ 5++ 5++ 5++ 5++ 5++ 5++ 5++ 5++ 5++ 5++

Degrees "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0 11.2!

'g(s)cm " " # # # # $ $ $ $ 2 2 2 2 " " " " # # # # $

'g(s)cm # # % % % % 12 12 12 12

mm .++ 13++ ,++ -++ 12++ 1*++ #00 700 1100 1700 #00 700 1000 1200

mm 700 %00 "00 #00 -++ 1+++ #00 %00 1200 1 00 2!0 !0 !00 700 "00 #00 $00 1000 !00 $00 1100 1200 #00

# # # # % % % % 12

700 $00 1200 1#00 700 %00 1 00 2000 $00

%ength of $lock on the soil side mm 14++ 1-++ -++ 12++ 1,++ 2+++ 1200 1$00 2"00 2#00 !00 700 1000 1"00 $00 1200 1#00 2000 1000 1#00 2200 2"00 1200

"ield Test Press!re

Nominal Pipe Diameter

%ength of $lock at centre of pipe a/is

orking Press!re

Angle of Bend

Page 11 of 12

Aapni Yojna Water Supply Project

#eight of the $lock

Thrust Blocks
idth of $lock $ehind Pipe mm 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

mm 5++ 5++ 5++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++ ,++

Degrees 22.! "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0 11.2! 22.! "! %0

'g(s)cm $ $ $ 2 2 2 2 " " " " # # # # $ $ $ $

'g(s)cm 12 12 12

mm 1100 1#00 2200 700 $00 1000 1"00

mm %00 1200 1!00 00 "00 700 $00 "00 700 %00 1100 !00 $00 1100 1!00 700 1000 1 00 1700

# # # # % % % % 12 12 12 12

$00 1000 1"00 2000 1000 1200 1$00 2200 1000 1"00 2000 2!00

%ength of $lock on the soil side mm 1$00 2"00 000 #00 $00 1"00 1#00 $00 1"00 1$00 2200 1000 1#00 2200 000 1"00 2000 2#00 "00

"ield Test Press!re

Nominal Pipe Diameter

%ength of $lock at centre of pipe a/is

orking Press!re

Angle of Bend

Page 12 of 12