AMERON PRESTRESSED CONCRETE CYLINDER PIPE

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Egbert Bennett
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1 AMERON PRESTRESSED CONCRETE CYLINDER PIPE

2 Specify prestressed concrete cylinder pipe and Prestressed concrete cylinder pipe (PCCP) is a rigid pipe designed to take optimum advantage of the tensile strength of steel and of the compressive strength and corrosion inhibiting properties of concrete. PCCP is designed and manufactured in accordance with American Water Works Association Standard C301. PCCP is produced in diameters of 3 to 30 feet and in laying lengths of 16 to 24 feet. It has been used for over 40 years for such applications as water transmission and distribution pipelines, cooling water systems, sewer force mains, inverted siphons, subaqueous pipelines and liners for pressure tunnels. Combined-load design PCCP is designed by a proven analytical method which considers all elastic and inelastic deformations in the pipe and conservatively limits tensile and compressive stresses for any combination of internal pressure and external load. A typical design curve is shown, the most economical design being one which falls on the curve. The overload curve, also shown, provides for live load, water hammer or other transient loads. The following installations illustrate the adaptability of PCCP to a wide range of load conditions: 9-foot diameter waterline operating under 950 feet of head and 15 feet of earth cover. 21-foot diameter inverted siphon operating under 250 feet of head and 23 feet of earth cover foot diameter tunnel liner. 8-foot diameter culvert under 230 feet of embankment. 18-foot diameter subaqueous seawater cooling lines for nuclear generating station. The operating pressure range for pipe 3 feet to 30 feet in diameter is shown for one and two layers of prestressing wire. Pipe can be designed and manufactured for operating pressures higher than shown with three or more layers of prestressing wire.

3 get a complete, custom designed system, Customized system design Ameron provides the customer s engineer with a complete engineering package for each PCCP project. This includes pipe design calculations, pipeline layout drawings showing station and elevation for each component of the system, and fabrication details for each item furnished. Each component is numbered to identify its position in the line. Fittings fabricated at the PCCP manufacturing facility are designed to avoid the need for cutting and fitting in the field. Almost any size or configuration of fitting can be furnished to satisfy requirements of the system. reliability and watertightness of this type of joint has been proved by more than 40 years of field experience. Installation rates of 30 to 50 pipe sections per day per installation crew are frequently obtained. encasement (ph at least 12.5). Supplemental protection is rarely required but can be provided, if needed, for any anticipated set of environmental conditions. Carrying capacity The smooth interior surface of PCCP provides hydraulic carrying capacity with a Hazen-Williams flow coefficient in the range of C=140 to 150. Because concrete does not corrode, the carrying capacity is not decreased by age. Structural integrity The rigid construction of PCCP makes it highly resistant to physical damage and eliminates the possibility of vacuum collapse. Because of its high load-carrying capacity, PCCP is not dependent on lateral soil support, and therefore bedding and backfilling procedures are much less stringent than for flexible pipe. Change in direction Long-radius curves and minor changes in pipeline alignment and grade are accommodated by deflecting the pipe joints or by using pipe sections with ends beveled up to 5. For short-radius turns, fabricated elbows are provided. Restraint of thrust Field assembly PCCP is rapidly and economically installed by means of self-centering steel joint rings sealed with a confined rubber ring. The Hydraulic thrust in the pipeline can be resisted by field welding the joint rings of assembled pipe sections for a sufficient distance each side of the thrust point to develop the required longitudinal restraint. This method eliminates the need for expensive and sometimes unreliable concrete thrust blocks. Corrosion prevention Corrosion of steel elements in PCCP is prevented by a passivating iron oxide film which quickly forms and is maintained in the highly alkaline concrete or cement-mortar

4 Pipe dimensions and weight Nominal inside pipe Standard core thickness Nominal joint diameter Nominal joint Normal joint space lap inside outside Unit (2) pipe weight (in.) (in.) (in.) (in.) (in.) (in.) (Ib/ft) A B C D E Notes: 1 Pipe is manufactured in standard laying lengths of 16 to 24 feet. For standard pipe lengths, consult with one of the offices listed on the back cover about the availability of molds and tooling prior to specifying a particular dimension. 2 The unit pipe weights given are for standard concrete core thickness shown plus oneinch cement-mortar coatings thickness. Pipe design may require thicker core and coating thickness.

5 Joint space and deflections Nominal inside pipe diameter (1) (2) Interior joint space, D Normal Deflected joint Maximum (2) joint deflection Maximum (3) joint bevel Minimum Maximum (in.) (in.) (in.) (in.) (in.) (degree) (degree) Notes: 1 To maintain pipeline stationing, pipe should be installed with normal interior joint space. Minor corrections in stationing can be made by increasing or decreasing the interior joint space to the maximum or minimum given in the table. 2 Standard joints can be deflected to form curves, to span angle points or to correct alignment and grade. Joint deflection is accomplished by increasing the interior joint space on one side of the pipe and decreasing the interior joint space on the opposite side. The deflection of a joint in inches is the difference between the widest and narrowest interior joint space. 3 Pipe with beveled spigots are furnished for changes in alignment or grade greater than can be accommodated with deflected joints. Bevels are made by attaching the spigot to the steel cylinder at the desired angle during manufacture of the pipe. 4 To determine the minimum pipeline radius using deflected or beveled joints. L R = angle 2sin 2 where: R = Pipeline curve radius in feet L = Pipe length in feet angle = Deflected or beveled angle in degrees

6 Applications This six barrel 1.6-meter diameter concrete pipe is part of a system that will transport seawater to be used as cooling and process water in the new Jubail Industrial City, Saudi Arabia. A jack-up barge installs 216-inch diameter prestressed concrete pipe in seabed trenches off coast of California. The pipeline will provide cooling water for the San Onofre Nuclear Generating Station. Ten miles of prestressed concrete cylinder pipe were installed as a sewer force main in Northern California. These 84-inch diameter prestressed concrete pipe under an 80-foot embankment will serve as a drainage culvert under a major highway in California.

7 Ten miles of 96-inch diameter prestressed concrete cylinder pipe, part of the San Diego Aqueduct, will transport potable water to a large metropolitan area. Special pipe sections and custom fittings are part of prestressed concrete cylinder pipe system at a power generating station. This 108-inch diameter pipe being installed with Ameron s Tunnelmobile will serve as the tunnel liner in a water transmission pressure-system tunnel.

8 Manufacture For maximum efficiency in production, work stations in Ameron pipe plants are located in parallel lines and are served by custom railroad cranes. The manufacture of prestressed concrete cylinder pipe begins with a helically welded, watertight steel cylinder with steel joint rings attached. The steel cylinder, enclosed by inner and outer molds, is placed on a base ring which insures concentricity. Concrete, placed between molds, encases cylinder and is consolidated by pneumatic vibrators on outer mold. After curing at controlled temperature, the concrete encased cylinder (the core) is ready for prestressing. Completed prestressed cylinder pipe is tipped from vertical to horizontal position and moved to storage yard where it is held until delivery to job site. Pipeline fittings of almost any size or configuration call be fabricated at the prestressed manufacturing facility.

9 The finished steel cylinder is subjected to a hydrostatic test to verify structural and hydrostatic integrity. Prestressing is accomplished by helically wrapping the core with high tensile steel wire under measured tension (left). The prestressed concrete core is then coated with cement mortar (right). Curing of the mortar coating completes manufacture. Because of the strength and rigidity of prestressed concrete cylinder pipe, it can be easily handled by standard forklifts, yard or construction cranes.

10 On-site plant manufacture A 252-inch diameter pre tressed concrete pipe core is cast onsite at a field plant for the Central Arizona Project. This cement-mortar coating machine coats 216-inch diameter pipe sections during the on-site manufacture of prestressed concrete pipe. Modular design of the equipment allows easy disassembly for transporting to a new location. This prestressing equipment wraps 252-inch diameter pipe cores with high tensile steel wire under controlled tensions. It was moved forward as the pipeline project progressed through four separate desert locations. Six inverted siphons were installed for the Central Arizona Project. The 78-foot tall Ameron Liftmobile moves the pipe core between work stations as its manufacture progresses. Like all equipment units of an on-site plant, the Liftmobile can be disassembled for movement to a new location.

11 When pipe size, distance or terrain make it impractical or uneconomical to utilize normal shipping procedures Ameron will establish a complete on-site manufacturing facility. This includes equipment to manufacture, transport and install the world s largest precast circular concrete structures. Plant shown above manufactured prestressed pipe and specials for use in a nuclear generating station cooling system in California.

12 Transportation The Ameron Pipe Division delivers pipe ( from plant to project site in the fastest, most economical manner. When plant and project site are close to navigable water, barges may be used. Rail transportation is often used when shipping distances are great and the project is near a railroad line. Ameron Pipemobiles, designed by Ameron Equipment Engineering and built by the company s Equipment Division, are highly specialized off-road vehicles that carry large diameter prestressed concrete pipe from the on-site plant to the trench and install it. Three different models of Ameron Pipemobiles can carry pipe ranging in diameter from 120 to 300 inches, weighing up to 250 tons. Folding ramps on sides of pipe hauling trailers make offloading fast and efficient. Pipe sections are scheduled to arrive in proper sequence for installation.

13 Installation Prestressed concrete pipe is usually installed with a crane using a single sling -. Long radius curves are formed by deflecting standard joints or by pipe sections with beveled spigot ends. Rail-mounted gantry crane installs section of 216-inch diameter subaqueous pipeline near shore for intake and discharge lines at a nuclear generating station. Joining of pipe sections in the trench is accomplished using a tugger device with cables attached to preceding pipe section. Tugger action pulls the pipe joint together.

14 In trench, the Pipemobile s forward wheels enter the preceding pipe action and move forward to make joint. Joining of large diameter pipe sections is accomplished with controls that can maneuver the pipe in 1/16-inch increments. With the aid of a winch, this function can be performed on steep slopes

15 AMERON S OBJECTIVES We believe the growth of our businesses will be based on how well we identify customer needs and satisfy them over the long term with products and services of superior value. We also believe that satisfied, repeat customers are the lifeblood of any successful business and must be nurtured and cared for in the most professional and courteous manner Our customers should expect and receive: Strong commitment from us to the markets we serve. Products and services of consistently superior value. Professional and dedicated technical services provided promptly where needed. Well-trained, knowledgeable and motivated direct sales people and representatives. Professionally prepared, well-documented sales proposals, product literature, technical data and other support materials. Fast, courteous response in any transaction. Consistent, on-time delivery of products and Water Transmission Group Headquarters Foothill Boulevard, Suite 450 Rancho Cucamonga, CA (909) FAX (909) Western Region Headquarters Foothill Boulevard, Suite 450 Rancho Cucamonga, CA (909) FAX (909) Arrow Plant Etiwanda, CA (909) FAX (909) Fontana Plant Fontana, CA (909) FAX (909) Lakeside Plant Lakeside, CA (619) FAX (619) South Gate Plant South Gate, CA (213) FAX (213) Tracy Plant Tracy, CA (209) FAX (209) Southwestern Region Headquarters and Plant 2325 S. 7th Street Phoenix, AZ (602) FAX (602) Protective Lining Products 201 North Berry Street Brea, CA (714) FAX (714) Regional Sales Office Houston, Texas 8000 Research Forest Drive Suite The Woodlands, TX (936) FAX (936) American Pipe and Construction International Contubos S.A. Calle 193 No Santafé de Bogotá, Colombia FAX Mailing Address Apartado Aereo Santafé de Bogotá, Colombia copyright 2002 Ameron Intl. PCCP 10/02 Printed in U.S.A Internet: http//: pipeinfo@ameronpipe.com

Pipelines 2013 ASCE Development History and Characteristics of the Bar-Wrapped Concrete Cylinder Pipe

Pipelines 2013 ASCE Development History and Characteristics of the Bar-Wrapped Concrete Cylinder Pipe 340 Development History and Characteristics of the Bar-Wrapped Concrete Cylinder Pipe By: Henry Bardakjian 1, P.E. and Mike Murphy 2, P.E. 1 Consulting Engineer, 1331 N. Maryland Ave, Glendale, CA 91207