PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA

Pipe Properties : Case : Tandem Axles

- Pipe outside diameter, OD (in.) : 8.630 Operating Load, W (lbs) : 16,000
- Design Factor, F : 0.4 Safety Factor : 1.25
- Pipe wall thickness, tw (in.) : 0.322 Design Load, Pt (lbs) : 20,000
- Material : API 5L Gr. B Contact Area, Ap (in.²) : 144
- Specified Minimum Yield Strength, SMYS (psi) : 35,000
- Specified Minimum Tensile Strength, SMTS (psi) : 60,000 Depth of pipe, H (ft) : 6.56 2.00 Meter
- Modulus of Elasticity, ES (ksi) : 3.00E+07 Bored Diameter, Bd (in.) : 8.63
- Density, r (lb/ft³) : 490 Soil Type : A
- Poisson's Ratio, nS : 0.3 Modulus of soil reaction, E' (ksi) : 0.5
- Linear coefficient of thermal expansion, aT (in./in.°F) : 6.50E-06 Resilient modulus, Er (ksi) : 5
- Design Pressure, p (psi) : 725.2 Soil Unit Weight, g (lb/ft³) : 120 0.06944 lb/in³
- Temperature Derating Factor, T : 1
- Longitudinal Joint Factor, E : 1
- Type of Longitudinal Weld : Seamless

A. Check Allowable Barlow Stress B. Circumferential Stress Due to Earth Load

S Hi ( Barlow) £ Allowable Stress tw/ D = 0.03731

E' (ksi) = 0.5
pD
S Hi( Barlow )= From Fig.3 - Stiffness Factor for Earth Load Circumferential Stress, KHe ,
2t w API RP 1102
SHi = 9,718 psi KHe = 800

Allowable Stress, S (psi) : H/ Bd = 9.1240

S=SMYS×F×E×T Soil Type = A

From Fig.4 - Burial Factor for Earth Load Circumferential Stress, Be , API
S = 14,000 psi RP 1102
SHi (Barlow) £ Allowable Stress ® OK Be = 1.340

C. Impact Factor, Fi, and Applied Design Surface Pressure, w Bd/ D = 1.00
H = 6.56 ft From Fig.5 - Excavation Factor for Earth Load Circumferential Stress,
Ee , API RP 1102
From Fig. 7 - Recommended Impact Factor Versus Depth, API
RP 1102 :

Ee = 0.83
Fi = 1.453
Applied design surface pressure, w :
So, the circumferential stress at the pipeline invert caused by earth load :
Critical case = Tandem Axles

Page 1 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
Pavement Type = Rigid Pavement
S He =K He Be Ee γ D
Design Wheel Load from Tandem Axles, Pt (kips) : 20
Applied Design Surface Pressure, w (psi) : 138.89 SHe = 533.24 psi

Page 2 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
D. Cyclic Stresses, DSHh and DSLh
D.1 Cyclic Circumferential Stress, DSHh D.2 Cyclic Longitudinal Stress, DSLh

From Fig. 14 - Highway Stiffness Factor for Cyclic Circumferential From Fig. 16 - Highway Stiffness Factor for Cyclic Longitudinal Stress, K Lh
Stress, KHh , API RP 1102. , API RP 1102.
tw/ D = 0.03731 tw/ D = 0.03731
Er = 5 ksi KHh = 10.00 Er = 5 ksi KLh = 10.00

From Fig. 15 - Highway Geometric Factor for Cyclic From Fig. 17 - Highway Geometric Factor for Cyclic Longitudinal Stress,
Circumferential Stress, GHh , API RP 1102. GHh , API RP 1102.

D = 8.63 in. D = 8.63 in.

H = 6.56 ft GHh = 1.375 H = 6.56 ft GLh = 1.300

From Table 2 - Highway Pavement Type Factors, R, and Axle From Table 2 - Highway Pavement Type Factors, R, and Axle
Configuration Factors, L , API RP 1102. Configuration Factors, L , API RP 1102.

D = 8.63 in. R = 0.90 D = 8.63 in. R = 0.90

H = 6.56 ft L = 1.00 H = 6.56 ft L = 1.00

So, the cyclic circumferential stress due to highway vehicular load : So, the cyclic longitudinal stress due to highway vehicular load :

ΔS Hh=K Hh GHh R L Fi w ΔS Lh=K Lh G Lh R L Fi w

DSHh = 2,498 psi DSLh = 2,361.37 psi

E. Circumferential Stress Due to Internal Pressurization, SHi G. Check Fatigue

G.1 Girth Weld
The circumferential stress due to internal pressure : F = 0.4
DSLh = 2,361.37 psi
p ( D−t w )
S Hi =
2tw Refer to Table 3 - Fatigue Endurance Limits, SFG and SFL , for Various
SHi = 9,355 psi Steel Grades, API RP 1102 , for API 5L B material pipe :
SFG = 12,000 psi
F. Principical Stresses, S1, S2, S3 SFG x F = 4,800 psi
For highway crossing, the girth weld fatigue check is given by the
The maximum circumferential stress, S1 : following :

S 1 =S He + ΔSH +S Hi ΔS Lh≤S FG ×F ® 2,361.37 £ 4,800.00 OK

S1 = 12,386.1 psi So, the cyclic longitudinal stress is less than the girth weld fatigue.
The design is ACCEPTABLE.
The maximum longitudinal stress, S2 :
G.2 Longitudinal Weld
S 2 =ΔS L−E s α T ( T 2 −T 1 ) +υ s ( S He + S Hi ) F = 0.4

Page 3 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
T1 = temperature at time of installation, °F = 80 DSHh = 2,497.60 psi
T2 = max. operating temperature, °F = 80
S2 = 5,327.92 psi Refer to Table 3 - Fatigue Endurance Limits, SFG and SFL , for Various
Steel Grades, API RP 1102 , for API 5L B material pipe :
The maximum radial stress, S3 : SFL = 21,000 psi (For Seamless or ERW pipe)
S 3 =− p=−MAOP or−MOP SFL x F = 8,400 psi

S3 = -725.18 psi For highway crossing, the girth weld fatigue check is given by the
following :
The total effective stress, Seff :
ΔS Hh≤S FL×F ® 2,497.60 £ 8,400.00 OK

S eff = √ 1
2
2 2
{( S1−S2 ) + ( S 2−S3 ) +( S 3 −S1 ) } 2
So, the cyclic circumferential stress is less than the longitudinal weld
fatigue.
Seff = 11,365.83 psi The design is ACCEPTABLE.

Check : F = 0.40 ® Seff £ SMYS x F ® 11,365.83 £ 14,000.00

S eff £ SMYS  F According to SNI 3474:2009 para , for location class 4, Effective Stress shall be less than or equal to 30% of
the pipe SMYS, so the design is

ACCEPTABLE.

Page 4 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA

Pipe Properties : Case : Tandem Axles

- Pipe outside diameter, OD (in.) : 15.984 Operating Load, W (lbs) : 16,000
- Design Factor, F : 0.4 Safety Factor : 1.25
- Pipe wall thickness, tw (in.) : 0.512 Design Load, Pt (lbs) : 20,000
- Material : API 5L Gr. B Contact Area, Ap (in.²) : 144
- Specified Minimum Yield Strength, SMYS (psi) : 35,000
- Specified Minimum Tensile Strength, SMTS (psi) : 60,000 Depth of pipe, H (ft) : 4.92 1.50 Meter
- Modulus of Elasticity, ES (ksi) : 3.00E+07 Bored Diameter, Bd (in.) : 15.98
- Density, r (lb/ft³) : 490 Soil Type : B
- Poisson's Ratio, nS : 0.3 Modulus of soil reaction, E' (ksi) : 0.5
- Linear coefficient of thermal expansion, aT (in./in.°F) : 6.50E-06 Resilient modulus, Er (ksi) : 5
- Design Pressure, p (psi) : 725.2 Soil Unit Weight, g (lb/ft³) : 120 0.06944 lb/in³
- Temperature Derating Factor, T : 1
- Longitudinal Joint Factor, E : 1
- Type of Longitudinal Weld : Seamless

A. Check Allowable Barlow Stress B. Circumferential Stress Due to Earth Load

S Hi ( Barlow) £ Allowable Stress tw/ D = 0.03202

E' (ksi) = 0.5
pD
S Hi( Barlow )= From Fig.3 - Stiffness Factor for Earth Load Circumferential Stress, KHe ,
2t w API RP 1102
SHi = 11,324 psi KHe = 1,500

Allowable Stress, S (psi) : H/ Bd = 3.6946

S=SMYS×F×E×T Soil Type = B

From Fig.4 - Burial Factor for Earth Load Circumferential Stress, Be , API
S = 14,000 psi RP 1102
SHi (Barlow) £ Allowable Stress ® OK Be = 0.800

C. Impact Factor, Fi, and Applied Design Surface Pressure, w Bd/ D = 1.00
H = 4.92 ft From Fig.5 - Excavation Factor for Earth Load Circumferential Stress,
Ee , API RP 1102
From Fig. 7 - Recommended Impact Factor Versus Depth, API
RP 1102 :

Ee = 0.83
Fi = 1.500
Applied design surface pressure, w :
So, the circumferential stress at the pipeline invert caused by earth load :
Critical case = Tandem Axles

Page 5 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
Pavement Type = Rigid Pavement
S He =K He Be Ee γ D
Design Wheel Load from Tandem Axles, Pt (kips) : 20
Applied Design Surface Pressure, w (psi) : 138.89 SHe = 1,105.58 psi

Page 6 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
D. Cyclic Stresses, DSHh and DSLh
D.1 Cyclic Circumferential Stress, DSHh D.2 Cyclic Longitudinal Stress, DSLh

From Fig. 14 - Highway Stiffness Factor for Cyclic Circumferential From Fig. 16 - Highway Stiffness Factor for Cyclic Longitudinal Stress, K Lh
Stress, KHh , API RP 1102. , API RP 1102.
tw/ D = 0.03202 tw/ D = 0.03202
Er = 5 ksi KHh = 12.50 Er = 5 ksi KLh = 12.50

From Fig. 15 - Highway Geometric Factor for Cyclic From Fig. 17 - Highway Geometric Factor for Cyclic Longitudinal Stress,
Circumferential Stress, GHh , API RP 1102. GHh , API RP 1102.

D = 15.9843 in. D = 15.9843 in.

H = 4.92 ft GHh = 1.375 H = 4.92 ft GLh = 1.200

From Table 2 - Highway Pavement Type Factors, R, and Axle From Table 2 - Highway Pavement Type Factors, R, and Axle
Configuration Factors, L , API RP 1102. Configuration Factors, L , API RP 1102.

D = 15.9843 in. R = 1.10 D = 15.9843 in. R = 1.10

H = 4.92 ft L = 1.00 H = 4.92 ft L = 1.00

So, the cyclic circumferential stress due to highway vehicular load : So, the cyclic longitudinal stress due to highway vehicular load :

ΔS Hh=K Hh G Hh R L Fi w ΔS Lh=K Lh G Lh R L Fi w
DSHh = 3,939 psi DSLh = 3,437.50 psi

E. Circumferential Stress Due to Internal Pressurization, SHi G. Check Fatigue

G.1 Girth Weld
The circumferential stress due to internal pressure : F = 0.4
DSLh = 3,437.50 psi
p ( D−t w )
S Hi =
2 tw Refer to Table 3 - Fatigue Endurance Limits, SFG and SFL , for Various
SHi = 10,961 psi Steel Grades, API RP 1102 , for API 5L B material pipe :
SFG = 12,000 psi
F. Principical Stresses, S1, S2, S3 SFG x F = 4,800 psi
For highway crossing, the girth weld fatigue check is given by the
The maximum circumferential stress, S1 : following :

S 1 =S He+ ΔS H +S Hi ΔS Lh≤S FG ×F ® 3,437.50 £ 4,800.00 OK

S1 = 16,005.8 psi So, the cyclic longitudinal stress is less than the girth weld fatigue.
The design is ACCEPTABLE.
The maximum longitudinal stress, S2 :
G.2 Longitudinal Weld
S 2 =ΔS L−E s α T ( T 2 −T 1 ) + υ s ( S He+ S Hi ) F = 0.4

Page 7 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
T1 = temperature at time of installation, °F = 80 DSHh = 3,938.80 psi
T2 = max. operating temperature, °F = 80
S2 = 7,057.60 psi Refer to Table 3 - Fatigue Endurance Limits, SFG and SFL , for Various
Steel Grades, API RP 1102 , for API 5L B material pipe :
The maximum radial stress, S3 : SFL = 21,000 psi (For Seamless or ERW pipe)
S 3 =− p=−MAOP or−MOP SFL x F = 8,400 psi

S3 = -725.18 psi For highway crossing, the girth weld fatigue check is given by the
following :
The total effective stress, Seff :
ΔS Hh≤S FL×F ® 3,938.80 £ 8,400.00 OK

S eff = √ 1
2
2 2
{( S1−S2 ) + ( S 2−S3 ) +( S 3 −S1 ) } 2
So, the cyclic circumferential stress is less than the longitudinal weld
fatigue.
Seff = 14,501.16 psi The design is ACCEPTABLE.

Check : F = 0.40 ® Seff ³ SMYS x F ® 14,501.16 ³ 14,000.00

S eff £ SMYS  F According to SNI 3474:2009 para , for location class 4, Effective Stress shall be less than or equal to 30% of
the pipe SMYS, so the design is

NOT ACCEPTABLE

Page 8 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA

Pipe Properties : Case : Tandem Axles

- Pipe outside diameter, OD (in.) : 4.500 Operating Load, W (lbs) : 16,000
- Design Factor, F : 0.4 Safety Factor : 1.25
- Pipe wall thickness, tw (in.) : 0.237 Design Load, Pt (lbs) : 20,000
- Material : API 5L Gr. B Contact Area, Ap (in.²) : 144
- Specified Minimum Yield Strength, SMYS (psi) : 35,000
- Specified Minimum Tensile Strength, SMTS (psi) : 60,000 Depth of pipe, H (ft) : 6.56 2.00 Meter
- Modulus of Elasticity, ES (ksi) : 3.00E+07 Bored Diameter, Bd (in.) : 4.50
- Density, r (lb/ft³) : 490 Soil Type : A
- Poisson's Ratio, nS : 0.3 Modulus of soil reaction, E' (ksi) : 0.5
- Linear coefficient of thermal expansion, aT (in./in.°F) : 6.50E-06 Resilient modulus, Er (ksi) : 5
- Design Pressure, p (psi) : 725.2 Soil Unit Weight, g (lb/ft³) : 120 0.06944 lb/in³
- Temperature Derating Factor, T : 1
- Longitudinal Joint Factor, E : 1
- Type of Longitudinal Weld : Seamless

A. Check Allowable Barlow Stress B. Circumferential Stress Due to Earth Load

S Hi ( Barlow) £ Allowable Stress tw/ D = 0.05267

E' (ksi) = 0.5
pD
S Hi( Barlow )= From Fig.3 - Stiffness Factor for Earth Load Circumferential Stress, KHe ,
2t w API RP 1102
SHi = 6,885 psi KHe = 500

Allowable Stress, S (psi) : H/ Bd = 17.4978

S=SMYS×F×E×T Soil Type = A

From Fig.4 - Burial Factor for Earth Load Circumferential Stress, Be , API
S = 14,000 psi RP 1102
SHi (Barlow) £ Allowable Stress ® OK Be = 1.320

C. Impact Factor, Fi, and Applied Design Surface Pressure, w Bd/ D = 1.00
H = 6.56 ft From Fig.5 - Excavation Factor for Earth Load Circumferential Stress,
Ee , API RP 1102
From Fig. 7 - Recommended Impact Factor Versus Depth, API
RP 1102 :

Ee = 0.83
Fi = 1.453
Applied design surface pressure, w :
So, the circumferential stress at the pipeline invert caused by earth load :
Critical case = Tandem Axles

Page 9 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
Pavement Type = Rigid Pavement
S He =K He Be Ee γ D
Design Wheel Load from Tandem Axles, Pt (kips) : 20
Applied Design Surface Pressure, w (psi) : 138.89 SHe = 170.16 psi

Page 10 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
D. Cyclic Stresses, DSHh and DSLh
D.1 Cyclic Circumferential Stress, DSHh D.2 Cyclic Longitudinal Stress, DSLh

From Fig. 14 - Highway Stiffness Factor for Cyclic Circumferential From Fig. 16 - Highway Stiffness Factor for Cyclic Longitudinal Stress, K Lh
Stress, KHh , API RP 1102. , API RP 1102.
tw/ D = 0.05267 tw/ D = 0.05267
Er = 5 ksi KHh = 7.50 Er = 5 ksi KLh = 7.50

From Fig. 15 - Highway Geometric Factor for Cyclic From Fig. 17 - Highway Geometric Factor for Cyclic Longitudinal Stress,
Circumferential Stress, GHh , API RP 1102. GHh , API RP 1102.

D = 4.5 in. D = 4.5 in.

H = 6.56 ft GHh = 1.375 H = 6.56 ft GLh = 1.700

From Table 2 - Highway Pavement Type Factors, R, and Axle From Table 2 - Highway Pavement Type Factors, R, and Axle
Configuration Factors, L , API RP 1102. Configuration Factors, L , API RP 1102.

D = 4.5 in. R = 0.90 D = 4.5 in. R = 0.90

H = 6.56 ft L = 1.00 H = 6.56 ft L = 1.00

So, the cyclic circumferential stress due to highway vehicular load : So, the cyclic longitudinal stress due to highway vehicular load :

ΔS Hh=K Hh G Hh R L Fi w ΔS Lh=K Lh G Lh R L Fi w
DSHh = 1,873 psi DSLh = 2,315.96 psi

E. Circumferential Stress Due to Internal Pressurization, SHi G. Check Fatigue

G.1 Girth Weld
The circumferential stress due to internal pressure : F = 0.4
DSLh = 2,315.96 psi
p ( D−t w )
S Hi =
2 tw Refer to Table 3 - Fatigue Endurance Limits, SFG and SFL , for Various
SHi = 6,522 psi Steel Grades, API RP 1102 , for API 5L B material pipe :
SFG = 12,000 psi
F. Principical Stresses, S1, S2, S3 SFG x F = 4,800 psi
For highway crossing, the girth weld fatigue check is given by the
The maximum circumferential stress, S1 : following :

S 1 =S He+ ΔS H +S Hi ΔS Lh≤S FG ×F ® 2,315.96 £ 4,800.00 OK

S1 = 8,565.4 psi So, the cyclic longitudinal stress is less than the girth weld fatigue.
The design is ACCEPTABLE.
The maximum longitudinal stress, S2 :
G.2 Longitudinal Weld
S 2 =ΔS L−E s α T ( T 2 −T 1 ) + υ s ( S He+ S Hi ) F = 0.4

Page 11 of 12
 PIPELINE CROSSING CALCULATION

C
W
ROW W = Load Case, (lbs)
w
H = Depth, (ft)
D = Outside diameter, (in.)
Bd = Bored diameter, (in.)
Case : AASHTO HS 20-44
H

D Bd

DESIGN DATA
T1 = temperature at time of installation, °F = 80 DSHh = 1,873.20 psi
T2 = max. operating temperature, °F = 80
S2 = 4,323.61 psi Refer to Table 3 - Fatigue Endurance Limits, SFG and SFL , for Various
Steel Grades, API RP 1102 , for API 5L B material pipe :
The maximum radial stress, S3 : SFL = 21,000 psi (For Seamless or ERW pipe)
S 3 =− p=−MAOP or−MOP SFL x F = 8,400 psi

S3 = -725.18 psi For highway crossing, the girth weld fatigue check is given by the
following :
The total effective stress, Seff :
ΔS Hh≤S FL×F ® 1,873.20 £ 8,400.00 OK

S eff = √ 1
2
2 2
{( S1−S2 ) + ( S 2−S3 ) +( S 3 −S1 ) } 2
So, the cyclic circumferential stress is less than the longitudinal weld
fatigue.
Seff = 8,055.98 psi The design is ACCEPTABLE.

Check : F = 0.40 ® Seff £ SMYS x F ® 8,055.98 £ 14,000.00

S eff £ SMYS  F According to SNI 3474:2009 para , for location class 4, Effective Stress shall be less than or equal to 30% of
the pipe SMYS, so the design is

ACCEPTABLE.

Page 12 of 12