Pipelines don’t break open suddenly all the time. They quietly fail, through joint sagging, misalignment and the gradual development of stress at points not monitored. Precast concrete pipeline sleepers are designed to avoid just that type of slow failure. Whether you’re buying them for an oil and gas plant, a water network or an industrial plant, this guide explains what they are and how to find someone who won’t let you down during the project.
The Video Is Dedicated to Pipeline Sleepers, Detailing What They Actually Do
Precast concrete block placed under a pipeline to support it is called a pipeline sleeper. Not sexy engineering, but necessary engineering.
The four basic functions of sleepers are to hold the pipeline in place, guide it through its intended path, absorb vibration from nearby equipment or ground movement and carry the weight of the pipe and contents. If not supported, long lengths of pipe will droop causing stress on pipe joints and fittings causing pipe failure or leaking.
In industrial applications, sleepers also provide protection against corrosion and stress from thermal expansion and contraction in pipelines that transport hot or cold fluids, which tend to expand and contract with changes in temperature.
The Advantages of Precast Concrete Pipeline Sleepers Suppliers in UAE
Steel, wood or cast-in-place concrete sleepers can be used for pipelines. In the UAE’s climate and topography, precast concrete often prevails and the reasons are simple.
Steel sleepers are robust but prone to corrosion, particularly in coastal environments or where there is a risk of exposure to salt. Over time wood deteriorates and should be replaced regularly. The cast-in-place concrete process involves casting the concrete on site, which adds construction time, curing requirements, and weather delays, and has a negative impact on project timelines.
Most of these issues can be avoided with precast concrete sleepers. They last significantly longer than steel or wood, which can be corroded, decayed and affected by salt, particularly in the UAE where a large proportion of industrial infrastructure is at or close to the sea level and in high humidity areas. They are also pre-installed. No onsite forming, no curing delay, and no waiting on ready-mix trucks to get to a remote desert site.
The Location of Pipeline Sleepers Use Precast Concrete Pipeline Sleepers Suppliers in UAE
Sleepers are installed wherever pipelines must be physically supported, except for direct burial. That covers above ground pipe lines in oil and gas facilities, marine and coastal applications such as jetties, seawalls, power plants, petrochemical facilities and industrial applications that transport water, gas or process liquids over long distances.
In all of these applications the common thread is the need for regular ground support along the length of the pipeline on the surface or on unstable ground, or else pipelines begin to sag and stress in the least desirable area.
These Are the Main Design Features to Consider While Looking at a Commercial Office Space
There are many different types of precast sleepers and the differences are significant.
- Recessed lifting units. Quality sleepers will also have lifting points, allowing crews to easily handle and position the sleepers on site without any improvising with straps or chains. This is not a fancy feature, it’s a safety feature.
- Anchors and inserts imbedded in the structure. A great deal of sleepers are cast in the concrete with threaded inserts, straps or clips. They enable pipe saddle supports and couplings to be attached to pipe in such a way that they are capable of being adjusted in position and will not cause the pipe to move as time goes on.
- Reinforcement. The sleeper is made with a high strength reinforcement, usually high strength steel bar set into the concrete so as to provide the sleeper with heavy pipeline running capability without cracking under sustained loading.
- Saddle shaping. In some diameters of sleepers, a saddle-shaped profile is used that provides a more even support for the curvature of the pipe, as compared to a flat support surface.
When Installing LED Screens, Make Sure They Are the Right Size and Spaced Correctly to Suit the Application
The number one error on pipeline projects is to use an estimate for sleeper spacing, rather than calculating it. Depending on multiple factors, such as pipeline diameter and weight, fluid being transported, ground conditions, and factors such as the temperature variation of weather and seismic activity in the area.
Install pipeline spacers that are spaced too far apart and the pipeline sags between them. Place them too close together and you’ve purchased material and installation costs which did not need to be spent. A good supplier is going to ask about your pipeline specification prior to offering you a quote for an iron sleeper layout, not afterward.
The Following Are Questions You Should Ask a UAE Pipeline Sleeper Supplies Company
There are a few simple questions that will help you find a true manufacturer versus a middle man selling generic stock.
- Can they make custom sizes or do they only stock standard sizes? Pipeline projects are seldom of the one size fits all type. A supplier who offers to make sleepers to fit your exact pipe diameter, load rating and site requirements is a lot more valuable than a supplier that has a limited catalog.
- What type of reinforcement and what concrete grade are they using? Specifically inquire about the actual strength and reinforcement bar specification. If a supplier can give you a specific answer as opposed to a general answer about “high strength,” then he is likely to be producing to a standard that has been tested and proven.
- Are there embedded anchors or saddle profiles possible? If you require adjustable saddle supports or special anchor hardware, check to see if the supplier can provide it during the pipeline’s manufacture, and not add it at the end of the manufacturing process.
- Have they previous industrial project experience? Corrosion and load resistance are challenging requirements for oil, gas and petrochemical facilities. A supplier who has more experience in these specific industries has a different perspective than a supplier who primarily makes general precast for construction.
- How long does it take them to deliver the service at a remote or industrial location? Numerous pipeline projects are located in remote areas of the desert or industrial areas in which site access is limited. Inquire about delivery and set-up procedures with the supplier for areas the concrete truck is unable to access.
Errors That Should Be Avoided Precast Concrete Pipeline Sleepers Suppliers in UAE
Many of the same, recurring problems appear in pipeline support projects around the region, and almost all are preventable if planned adequately at the outset.
While selecting cast-in place sleepers to keep the unit cost low, the unfortunate side effects are realized when unit cost is compounded by onsite construction delays, weather delays, and supervision costs. Another common error, which becomes apparent months later as noticeable pipeline sagging, is the failure to correctly calculate the space between the pipes. Choosing a generic supplier without industrial pipeline experience could result in sleepers that may be good for mechanical load bearing but not for corrosion resistance or anchor hardware for the application.
Bringing It Together Precast Concrete Pipeline Sleepers Suppliers in UAE
Pipeline sleepers are not a sexy Purchasing item, but they can make the difference between a successful pipeline that operates for decades or one that begins to have issues within a few years. However, the corrosion resistance, more rapid installation and uniformity of precast concrete, make it the practical solution in most applications in the UAE over steel, wood or cast-in-place options.
Select a supplier that asks the real engineering questions related to your pipeline specifications, manufactures with proper reinforcement and embedded hardware, is experienced in industrial or oil and gas projects. If you get it right, your pipeline remains precisely where it belongs, and don’t gets its name in the paper.
