BUREAU OF INDIAN STANDARDS CENTRAL MARKS DEPARTMENT-III Our Ref: CMD-III/16:458 31 March 2005

Subject: Implementation of Amendment No.1 to IS 458:2003 and revised STI Doc:STI/458/13 April 2005, pertaining to IS 458:2003 - Precast concrete pipes (with and without reinforcement) IS 458:1988 was revised as IS 458:2003 incorporating certain changes and accordingly the STI was revised and circulated for implementation w.e.f. 1 July 2004. Representations were received from the manufacturers Associations specially for deletion of Plain ended Collar jointed (NP3 and NP4) pipes from IS 458:2003. During technical committee meeting this matter was discussed and committee decided to issue Amendment No.1.This Amendment permits use of Collar jointed(NP3 and NP4) pipes for culverts/cross drains. Copy of the finalised Amendment No.1 to IS 458:2003 sent for printing is enclosed. It has been decided by the competent authority to implement it with immediate effect,in view of difficulties faced by the industry in implementation of IS 458:2003. Accordingly the revised STI Doc: STI/458/13, April 2005 has been prepared incorporating Amendment No.1, for implementation with effect from 01 April 2005 In all such cases where collar jointed NP3 and NP4 pipes have been deleted from the scope of the licence at the time of endorsement of revised Standard /STI in the licence same may be restored in view of Amendment No.1 without any verification. BOs may inform the licensees under their jurisdiction accordingly.

(B.K. Shreevastava) Director (CMD-III) Encl:As above

D&H(CMD-III) DDGM All ROs/BOs/BIS Labs Cc to CMD-I CED - For gazette notification. Please also ensure that Amendment No.1 is printed on priority at the earliest in April 2005.

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SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF PRECAST CONCRETE PIPES (WITH AND WITHOUT REINFORCEMENT) ACCORDING TO IS 458:2003 (Including Amendment No. 1) (FORTH REVISION) 1. LABORATORY - A laboratory shall be maintained which shall be suitably equipped and staffed where different tests given in the specification shall be carried out in accordance with the methods given in the specification. 2. TEST RECORDS - All records of tests, inspection and calibration shall be kept in suitable forms approved by the Bureau. 2.1 All testing apparatus/measuring instruments shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.2 Copies of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 3. QUALITY CONTROL It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397(Part 1):1972, IS 397(Part 2):2003 and IS 397(Part 3): 2003]. 3.1 In addition, effort should be made to gradually introduce a quality management system in accordance with IS/ISO 9000 as appropriate to the activities of the organization. 4. STANDARD MARK The Standard Mark, as given in Column (1) of the First Schedule of the licence, in the form of a transfix or stencill label. The mark may also be applied by engraving in such a manner that it does not impair the strength of the pipe in any way. Marking may also be done by screen printing. 4.1 MARKING In addition, each pipe/collar shall be marked in indelible ink/paint with the following information: a) Manufacturers name or trade-mark. b) Class and size of Pipe /Collar. c) The words SPUN PIPE or VIBRATED CAST PIPE (UNREINFORCED) or VIBRATED CAST PIPE (REINFORCED) as may be applicable. d) Date of manufacture (casting) e) Licence No. (CM/L).

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4.2 The above information shall be clearly marked on outside only for pipes up to and including 350 mm internal diameter , and both outside and inside for pipes above 350 mm internal diameter. The information shall be clearly marked only on the outside for Collars.

5.0

same class and size, manufactured/cast in a month under similar conditions (From same consignment of cement, same mix ratio for concrete and similar curing condition) shall constitute one control unit. On the basis of results of tests, decision regarding conformity or otherwise of the control unit to the requirements of the specification shall be taken as under. Design, Reinforcement, Ends of Pipes and Manufacture of pipes shall conform to the requirements given in Cl. 6 and 7 of IS:458:2003. Reinforcement cages requirements shall be checked and ensured before casting of pipes/ collars and records maintained. Minimum clear cover shall be ensured as per Clause 6.4 of specification.

Control unit: For the purpose of this scheme every 50 pipes/collars or part thereof, of

5.1 5.2

6.0 Water- Water used for mixing of concrete and curing of pipes shall conform to clause 5.4 of IS 456:2000. 6.1 7.0 Chemical Admixture The admixture where used shall conform to IS 9103:1999. LEVELS OF CONTROL

The tests, as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on the whole production of the factory which is covered by this scheme and appropriate records maintained in accordance with para 2 above. All the production which conforms to the Indian Standard and covered by the licence shall be marked with the certification mark of the Bureau. 8.0 Rejection - A separate record providing the detailed information regarding the rejected control units and mode of their disposal shall be maintained. Such material shall in no case be stored together with that conforming to the specification. 9. Samples - The licensee shall supply, free of charge, the sample(s) required in accordance with Regulation 11(e) of the Bureau of Indian Standards(Certification) Regulations, 1988, as subsequently amended from his factory or godowns. The BIS shall pay for the samples taken by it from the open market. 10. Replacement - Whenever a complaint is received soon after the goods with Standard Mark have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods are replaced free of cost by the licensee, in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge the conformity of the product to the Indian Standard shall be with BIS.

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9.1 In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by the consumers against BIS Standard Mark and not conforming to the relevant Indian Standard, entire liability arising out of such non conforming product shall be of licensee and BIS shall not in any way be responsible in such cases. 10.0 STOP MARKING The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau. 10.1 The marking of the product shall be stopped immediately if directed to do so by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of markings shall also be sent to the Bureau.

11.0

PRODUCTION DATA The licensee shall send to BIS as per the enclosed proforma-1 to be authenticated by a Chartered Accountant or by the manufacturer by giving an affidavit/undertaking, a statement of quantity produced, marked and exported by him and the trade value thereof at the end of each operative year of the licence.

Table 1

IS 458:2003 PRE CAST CONCRETE PIPES (WITH AND WITHOUT REINFORCEMENT) TABLE 1 LEVELS OF CONTROL (Clause 7 of the Scheme of Testing and Inspection) CL. 4.1 & 4.2 & 10.2(a) 10.2(b) TEST DETAILS REQUIREMENT TEST METHOD Hydrostatic test (Pressure pipe) Hydrostatic test (Nonpressure pipe) i)Three-edge bearing tests ii) Three-edge bearing test Permeability test CLAUSE 7 7 5 5 REFERENCE IS 3597 -do-doIS 3597 NO. OF SAMPLES Each pipe 1 2 1

DOC: STI/458/13 April 2005

LEVELS OF CONTROL FREQUENCIES Each Control Unit -do-doEvery tenth Control Unit

REMARKS

Minimum safe loads shall be applied results records as Pass/Fail

10.2 (c) & 10.2.1

IS 3597

Every 10th Control unit

Loads shall be applied till a crack of 0.25m is produced and further increased till ultimate load is reached

6.2 & 6.4

Clear cover and pitch of spirals Water Chemical admixture (if used)

6.2, & 6.4

IS 458:2003

-do-

5.7 5.8

5.4

IS 456 IS 9103

1 1

Once a year Each consignment

Clear cover shall be maintained by effective means and position of each cage in the mould shall be ensured before concerning Whenever source of water is changed the testing shall be carried out. No testing is required if the consignment is accompanied by manufacturer test certificate showing conformity to IS or the material is ISI marked.

IS 458:2003 PRE CAST CONCRETE PIPES (WITH AND WITHOUT REINFORCEMENT) TABLE 1 LEVELS OF CONTROL (Clause 7 of the Scheme of Testing and Inspection) CLAUSE 10.1.1 TEST DETAILS REQUIREMENT TEST METHOD Compression Test on Concrete cubes CLAUSE 10.1.1 5.5.1 5.5.3 REFERENCE IS 458:2003 NO. OF SAMPLES 1 a) Consisting of 3 cubes

DOC: STI/458/13 April 2005

LEVELS OF CONTROL FREQUENCIE REMARKS S Each consignment of cement Supply of cement executed against order spread over up to three months, shall be taken as one consignment for this test only. (One sample may be tested in a month in case same mix is used for different size/class of pipes. (For pressure pipes only) (One sample may be tested in a onth in case the same mix is used for different size/class of pipe.

10.1.1

Splitting tensile strength test Workmanship, finish and deviation from straightness Dimension and tolerances Reinforcement

5.5.2

IS 458:2003 IS 5816 IS 458:2003 IS 458:2003 -do-

1 (Consisting of 3 Each control cylinders) Unit Each pipe Each pipe Each cage

9 8.1 & 8.2 6.2

9.1 & 9.2 8.1 & 8.2 6.2

Gauging will suffice (Note: Each cage be checked for the requirement and range of observed values recorded)

Three edge bearing (ultimate load) test and permeability test shall be carried out after every 10th control unit for sizes upto 600 mm and after 20th control unit for sizes above 600 mm. Note: Hydrostatic test, Three-edge bearing test, permeability test and deviation from straightness test is not applicable to collars.

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Form No.1________Mild Steel Bars IS 432(Pt.1) HD Wire IS:432 (Ph.II); High strength informed IS 1786 Stainless steel (Pipe/Collar) Structural Steel (Standard Quality) IS 2062
Date of receip t issue Open ing stock Qty. recei ved Suppl ier ISI mark ed Test Certificate No. & date Dia . 2 3 4 5 6 7 Y.S. or P.S. 8

Physical Properties

Chemical Comp.
Bend Deformation and surfaced characteristics 13 C S P

Resul ts

ITS

Test

Bend test 12

Qty. issue d Kg .

Closi ng stock Kg

Rema rks

10

11

14

15

16

17

18

19

20

Form No. 2 Reinforcement (cages) Date

Size/class.

(Pipe/collar)

No. of Outer cage cages Inner cage (in case of double reinforcement)

Reinforcement Remarks
Longitudinal As per No. Weight IS No. of Kg No. of Bars Bar weight 4 5 6 Spiral Pitch

As per Weight IS No. KG

A complete ring at both ends 10 11

Form No. 3 Coarse Aggregate Date of receipt 1 Quantity 2

Size. Source 3 Test Certificate (if any) 4 Test results 5 Remarks 6

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Form No. 4 Fine Aggregates Date of receipt 1. Quantity 2 Source 3 Test Certificate (if any) 4 Test results 5 Remarks 6

Form No. 5 Cement and concrete cubes compressive strength test Date Openi Qty of ng receive receip stock d t/issu e of ceme nt 1 2 3 Supplie Cement Qty rs name as per issued cement IS No. brand name Closing stock Date of Date of Date of casting of taking out of testing curing of tank cubes Compressive Varia strength at 28 -tion days from avera ge 1 2 3 Av 14 Rema rks

10

1 1

12

13

15

16

Form No. 6 Finish, Dimensions & Performance Tests Date of No. of Control casting pipes Unit cost No.
& No. of pipes in the C.U.

Minimum clear cover (to be checked before casting

Type of Clear means cover used maintai ned Cl. 6.4 a,b,c 4 5 6

Size .Class Date on No. of Finish Length Inner Thickne which pipes Diamet ss taken taken er out of out of curing curing tank tank

All critical dimensi on (in case of spigot and socket pipes 12

Deviati on from straight ness

10

11

13

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No. of 3 Bearing pipes load test passes in the c.u. in finish dimensi ons Safe load Ultimate to load produce a crack of 0.25 (2 sample every c.u.)pass/ fail 14 15 16

On pipes tested for ultimate load

Permeability test

Hydrostati c test (No. of pipes tested)

Pass/Fail

No. of pipes passe d and Mark ed

No. of pipes rejecte d

Marked pipes supplied to

Remark s

Clear cover
a, b,c

Pitch of spiral

Initial absorpt ion

Final p;erme ability

17

18

19

20

21

22

23

24

25

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Form No. 7 Permeability Test Date C.U. No. Permeability test class/size Initial absorption 1 2
2 hr

Remarks Final permeability

4 hr

Form No. 8 Splitting tensile strength test of concrete cylinders (for pressure pipes only). Date of Supplier receipt name of cement Cement Date of Cylinder as per IS casting identific NO. cylinders ation marks Date of taking out of curing tank and Date of test 6 Weight of cylinder Measure Measure d length d of diameter cylinder Maximu Splitting m load tensile applied strength in kg Remarks

10

11

12

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Form No. 9. Dimensions, workmanship and finish for collare Date of No. of Control (to be minimum clear coating collar Unit No. cover checked before cost & (No. of coating) collars in control unit) Type of Clear means cover used (see maintained note Cl. 6.4 below a,b, c cl.6.4 of specificati on) 1 2 3 4 5 No. of collars passed No. of collars rejected and marked in the control unit 12 13 Form No. 10 Rejected pipes/ collars Control Unit No. 1 Size/Class 2 No. of pipes/ collars Reason for rejection rejected 3 4 Method of disposal 5 Remarks 6 Date on which taken out of curing tank No. of Finish Cl. Dimensions (gauging will suffice) collars 9.1 taken out of curing tank Length Thickness Caulking space

10

11

Marked collars Remarks supplied to (Parties name and address 14 15

Doc: CED 53 (7292) AMENDMENT NO. 1 APRIL 2005 TO IS 458:2003 PRECAST CONCRETE PIPES (WITH AND WITHOUT REINFORCEMENT) - SPECIFICATION (Page 4, clause 6.3) - Substitute the following for the existing: ' Spigot and socket ended pipes shall be used for water mains, sewer, irrigation and culverts / cross drains. Flush jointed (NP3 and NP4) and collar jointed (NP2) pipes shall be used for culverts / cross drains only (see Fig 1 and 2). However, as agreed to between manufacturer and purchaser, collar jointed (NP3 and NP4) pipes may also be used for culverts / cross drains. The ends of concrete pipes used for water mains, sewer and irrigation shall be suitable for spigot and socket, roll on or confined gasket joints. Dimensions of spigot and socket for various classes of pipes shall be as given in Tables 12,13,14,17,18 and 19 for pipes manufactured by spinning process. However, dimensions of spigot and socket shall be as given in Tables 15 and 16 in case of pipes manufactured by vibrated casting process. Reinforcement in socket of rubber ring jointed pipes shall be as given in Table 20. In case of flush joints, for pipes of internal diameters up to 700mm, external flush joint (see Fig 1B) and for pipe of internal diameter above 700mm, internal flush joint (see Fig 1 A) is recommended. Dimension of collars for NP1 and NP2 class pipes shall be according to details given in Table 1 and Table 21, respectively. Dimensions of collars for NP3 and NP4 class pipes when used shall be according to details given in Table 22. Reinforcement in collars shall be as given in Table 21 (NP2 class) and Table 22 (NP3 and NP4 class). The end of the collar reinforcement shall have a full ring at both ends. NOTES: 1. Bends, junctions and specials for concrete pipes covered under this standard shall conform to the requirements of IS 7322. 2. Some typical arrangement of reinforcement in socket are illustrated in Fig 3 and Fig 4. ' (Page 5, clause 8.1, second sentence) - Substitute the following for the existing: ' Dimensions of collar for class NP1 shall be as per Table 1. Dimensions and reinforcement of collars for class NP2 shall be as per Table 21 and for classes NP3 & NP4 shall be as per Table 22.' (Page 27, Table 20) - Under col (6), P2 class and against internal diameter of pipe of 1 000 mm, substitute ' 11.29'for ' 1.29' . (Page 28, Table 21) - Add the following new table after Table 21 and renumber ' Table 22' as ' Table 23' . Table 22 Design Requirements of Reinforced Concrete Collars for Pipes of Class NP3 and NP4 (Clause 6.3 and 8.1)

Collar Dimensions

Reinforcements

Nominal Internal Diameter of Pipe

Min. Caulking Space

Min. Thickness

Min. Length

Longitudinal, Mild Steel or Hard drawn steel

Spiral, Hard drawn steel Weight (7) kg per collar 0.07 0.08 0.10 0.12 0.14 0.16 0.22 0.40 0.50 0.60 0.70 1.05 1.85 2.05 2.25 3.09 4.11 5.08 6.55 9.00 12.15 13.30

Min. (1) mm 80 100 150 200 225 250 300 350 400 450 500 600 700 800 900 1 000 1 100 1 200 1 400 1 600 1 800 2 000 (2) mm 13 13 13 13 13 13 16 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 (3) mm 25 25 25 25 25 25 30 35 35 35 40 40 45 50 55 60 65 75 80 90 100 110 (4) mm 150 150 150 150 150 150 150 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 (5) nos. 6 6 6 6 6 6 8 8 8 8 8 8 8 8 8 8 8 12 12 or 8+8 12 or 8+8 12 + 12 12 + 12

Weight (6) kg per collar 0.08 0.08 0.08 0.08 0.08 0.08 0.11 0.15 0.15 0.15 0.15 0.23 0.23 0.23 0.33 0.33 0.33 0.50 0.67 0.67 1.00 1.00

NOTES 1 Collars of sizes 2200 mm and above shall be made out of mild steel plate of 6 mm thickness, steel conforming to IS 2062 with outside painted. 2 If mild steel is used for spiral reinforcement, the weight specified under col 7 shall be increased by a factor 140/125. 3 Soft grade mild steel wire for spirals may be used for collars of pipes of internal diameter up to 150mm only by increasing weight by a factor 140/84.

(Page 29, Clause 12.1) - Substitute the following for the existing:

' The following information shall be clearly marked on each pipe / collar: a) Indication of the source of manufacture b) Class and size of pipe / collar c) The words ' SPUN PIPE'or ' VIBRATED CAST PIPE (UNREINFORCED)'or ' VIBRATED CAST PIPE (REINFORCED)'as may be applicable, for pipes, and d) Date of manufacture

The above information shall be clearly marked on outside only for pipes up to and including 350mm internal diameter, and both outside and inside for pipes above 350mm internal diameter. The information shall be clearly marked only on the outside for collars. '

(Page 29, Clause 12.1.1) - Substitute the following for the existing:

' Each pipe / collar may also be marked with the Standard Mark. '

(CED 53)