prestressed concrete pipe
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We also have manufacturing units at different locations spread over Karnataka like Yelahanka in Bangalore, Mysore, Mandya and Belgaum. Malu Engineering Metal Works Gulbarga is one of the core companies of Malugroup. We are leading manufacturers & Suppliers of RCC PCC PSC Transmission Poles in Karnataka for the last 4 decades. Prestressed poles are basically cement concrete poles which are prestressed using steel wires to provide more structural strength. They are manufactured as per standard REC specifications followed by various customer organizations implementing Rural Electrification Programmes launched by various State Government controlled Electricity Boards.
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prestressed concrete pipes
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This product is the best choice for applications like: Pressure water transmission and distribution mains (Pumping & Gravity) for water supply, Drainage, Lift Irrigation Schemes. Re-circulation and cooling water pipe lines. For plants like Thermal Power, Chemical, Cement, Fertilizer, Paper, Refineries etc. Pressure water lines. Gravity Sewer Systems. Conveying any liquid, not corrosive to concrete including sea water and sewage force main. The Design When transient loads such as surge or traffic are added to sustained loads, tensile stresses up to 30 kg/cm2 maximum may be permitted in concrete. It is usual to divide pipelines in steps of Internal Pressure and design pipe for each section taking advantage of economy to be gained by tailoring design to suit actual needs without reducing safety. Where local high pressures or heavy external loads occur, pipes in these places can be strengthened without affecting cost of the remainder of the pipeline. without affecting cost of the remainder of the pipeline. The following load components are taken into account. Mass of Pipe Mass of water in pipe Sustained Internal Pressure Surge Bedding and Backfill Construction traffic wheel loads Highway traffic wheel loads Best economy and safety are achieved when pipe is designed for realistic in-service pressures and loads. The alternative method of designing pipes for a factory test, based on working pressure plus an arbitrary factor without regard to surge, earth or traffic loads is sometimes inadequate for low pressure.The same method can be wasteful for high pressure pipelines. Following determination of wall thickness and prestressing the next step is to calculate factory test pressure which will stress pipe as severely as it will be stressed in service taking into account mass of pipe and water and support condition. If a pressure, test is required on pipes after installation the value may be similarly calculated. The required ring strength of pipe can be readily established because internal pressure and external load conditions of the pipeline are known. However, since loads causing longitudinal stresses are not known with certainty, it is assumed for design purposes that bedding is deficient and that pipe is a beam supported as its ends with backfill loads distributed evenly along the length of the pipe. This is conservative because installation specifications require bedding to be uniform along the length of pipe. Joint assembly design is related to clearances between joint surfaces,tolerance to pipe ends, rubber ring size, rubber hardness, creep of rubber on concrete.Blow-out resistance is produced for the most unfavorable combination of joint deflection and tolerance of pipe ends. The Manufacturing Process: The process of Manufacturing Pre-stressed Concrete (PSC) Pipes consists of the following steps: 1) Longitudinal Pre-stressing Longitudinal wires of specified diameter and length are placed between two end rings of the mould assembly, and stretched to the required tension. 2) Batching & Mixing of concrete Required quantity of aggregates, cement and water are mixed to produce high strength concrete. 3) Spinning Concrete is fed into the mould and is compacted by centrifugal spinning process to produce a high strength concrete core pipe. 4)Demoulding The tension in the longitudinal wires is released, making longitudinal pre-compression to the core pipe and then the core pipe is taken out of the mould. 5) Core Curing The core pipe is put in sprinkler yard until the concrete in the core pipe has attained adequate strength to withstand circumferential prestressing load. 6)Winding The core pipe is wrapped with high tensile wire at pre-determined pitch and tension to induce the desired pre-compression in the body of the core pipe. 7) Coating The steel wrapping is covered with a dense cement mortar coat by means of a brush coater developed by IHP. This coat creates and maintains a high alkaline environment around the prestressing wire and protects it from corrosion. 8)Curing The completed pipe is cured until it attains the desired strength. 9)Hydrostatic Testing Each and every pipe is subjected to hydrostatic pressure test in the factory before dispatch. Specials The necessary special fittings such as bends, tees and others supplied with the pipe are made of steel shells with a concrete lining and outer coating or corrosive resistant paint. The ends are fitted with rubber ring joints for connecting them to the concrete pipe.
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