AMERON PRESTRESSEDCONCRETE CYLINDER PIPE

Specify prestressed concrete cylinder pipe andPrestressed concrete cylinder pipe(PCCP) is a rigid pipe designed totake optimum advantage of thetensile strength of steel and of thecompressive strength and corrosioninhibiting properties of concrete.PCCP is designed and manufacturedin accordance with American WaterWorks Association Standard C301.PCCP is produced in diametersof 3 to 30 feet and in laying lengthsof 16 to 24 feet. It has been used forover 40 years for such applicationsas water transmission anddistribution pipelines, cooling watersystems, sewer force mains, invertedsiphons, subaqueous pipelines andliners for pressure tunnels.

Combined-load design

PCCP is designed by a provenanalytical method which considersall elastic and inelastic deformationsin the pipe and conservatively limitstensile and compressive stresses forany combination of internalpressure and external load. Atypical design curve is shown, themost economical design being onewhich falls on the curve. Theoverload curve, also shown,provides for live load, waterhammer or other transient loads.

The following installationsillustrate the adaptability of PCCP toa wide range of load conditions:

• 9-foot diameter waterline

operating under 950 feet of headand 15 feet of earth cover.

• 21-foot diameter inverted siphonoperating under 250 feet of headand 23 feet of earth cover.

• 12.5-foot diameter tunnel liner.

• 8-foot diameter culvert under 230 feet ofembankment.

• 18-foot diameter subaqueousseawater cooling lines for nucleargenerating station.

The operating pressure rangefor pipe 3 feet to 30 feet in diameteris shown for one and two layers ofprestressing wire. Pipe can bedesigned and manufactured for

operating pressures higher thanshown with three or more layers ofprestressing wire.

get a complete, custom designed system,Customized system design

Ameron provides the customer’s engineerwith a complete engineering package foreach PCCP project. This includes pipedesign calculations, pipeline layout draw-ings showing station and elevation for eachcomponent of the system, and fabricationdetails for each item furnished. Eachcomponent is numbered to identify itsposition in the line.

Fittings fabricated at the PCCP manufactur-ing facility are designed to avoid the needfor cutting and fitting in the field. Almost anysize or configuration of fitting can befurnished to satisfy requirements of thesystem.

reliability and watertightness of this typeof joint has been proved by more than 40years of field experience. Installationrates of 30 to 50 pipe sections per dayper installation crew are frequentlyobtained.

encasement (pH at least 12.5).Supplemental protection is rarelyrequired but can be provided, ifneeded, for any anticipated set ofenvironmental conditions.

Carrying capacity

The smooth interior surface of PCCPprovides hydraulic carrying capacity with aHazen-Williams flow coefficient in therange of C=140 to 150. Because concretedoes not corrode, the carrying capacity isnot decreased by age.

Structural integrity

The rigid construction of PCCP makes ithighly resistant to physical damage andeliminates the possibility of vacuumcollapse. Because of its high load-carryingcapacity, PCCP is not dependent on lateralsoil support, and therefore bedding andbackfilling procedures are much lessstringent than for flexible pipe.

Field assembly

PCCP is rapidly and economically installed by means of self-centeringsteel joint rings sealed with aconfined rubber ring. The

Change in directionLong-radius curves and minorchanges in pipeline alignment andgrade are accommodated bydeflecting the pipe joints or by using pipe sections with ends beveled upto 5°. For short-radius turns,fabricated elbows are provided.

Restraint of thrust

Hydraulic thrust in the pipeline canbe resisted by field welding the jointrings of assembled pipe sections fora sufficient distance each side of thethrust point to develop the requiredlongitudinal restraint. This methodeliminates the need for expensiveand sometimes unreliable concretethrust blocks.

Corrosion prevention

Corrosion of steel elements in PCCPis prevented by a passivating ironoxide film which quickly forms andis maintained in the highly alkalineconcrete or cement-mortar

Pipe dimensions and weight

Normaljoint space

Nominalinsidepipe

Standardcore

thickness

Nominaljoint

diameter

Nominaljointlap inside outside

Unit(2)

pipeweight

(in.) (in.) (in.) (in.) (in.) (in.) (Ib/ft)

A B C D E42 3.50 45.000 3.25 0.88 1.00 71045 3.75 48.500 3.25 0.88 1.00 80048 4.00 51.500 3.25 0.88 1.00 90051 4.25 54.500 3.25 0.88 1.00 100054 4.50 58.000 3.25 0.88 1.00 111057 4.75 61.000 3.25 0.88 1.00 122060 5.00 64.000 3.25 0.88 1.00 134066 5.25 70.000 3.25 0.88 1.00 153072 5.25 76.500 3.25 0.88 1.00 165078 5.75 82.500 3.25 0.88 1.00 194084 6.25 88.500 3.25 0.88 1.00 224090 6.75 94.500 3.25 0.88 1.00 256096 7.25 100.500 3.25 0.88 1.00 2910

102 7.75 106.500 3.25 1.00 1.00 3280108 8.25 112.500 3.25 1.00 1.00 3670114 8.75 118.500 3.25 1.00 1.00 4080120 9.25 124.500 3.25 1.00 1.00 4520132 9.25 137.875 4.50 1.00 1.50 4930144 10.25 149.875 4.50 1.00 1.50 5810156 11.25 161.875 4.50 1.00 1.50 6970168 12.25 173.875 4.50 1.00 1.50 8120180 13.25 185.875 4.50 1.00 1.50 9360

Notes :

1 Pipe is manufactured in standard layinglengths of’ 16 to 24 feet. For standard pipelengths, consult with one of the officesl isted on the back cover about theavailability of molds and tooling prior tospecifying a particular dimension.

2 The unit pipe weights given are for standardconcrete core thickness shown plus one-inch cement-mortar coatings thickness.Pipe design may require thicker core andcoating thickness.

Joint space and deflections

Interior joint space, D(1) (2)

Deflected joint

Nominalinsidepipe

diameter NormalMinimum Maximum

Maximum (2)

joint deflectionMaximum(3)

joint bevel

(in.) (in.) (in.) (in.) (in.) (degree) (degree)42 0.88 0.63 1.63 1 1.32 5.0045 0.88 0.63 1.63 1 1.23 5.0048 0.88 0.63 1.63 1 1.15 5.0051 0.88 0.63 1.63 1 1.09 5.0054 0.88 0.63 1.63 1 1.02 5.0057 0.88 0.63 1.63 1 0.97 5.0060 0.88 0.63 1.63 1 0.92 5.0066 0.88 0.63 1.63 1 0.84 5.0072 0.88 0.63 1.63 1 0.77 5.0078 0.88 0.63 1.63 1 0.71 5.0084 0.88 0.63 1.63 1 0.66 5.0090 0.88 0.63 1.63 1 0.62 5.0096 0.88 0.63 1.63 1 0.58 5.00102 1.00 0.75 1.75 1 0.55 4.50108 1.00 0.75 1.75 1 0.52 4.50114 1.00 0.75 1.75 1 0.49 4.00

120 1.00 0.75 1.75 1 0.47 4.00132 1.00 0.75 2.25 1.5 0.64 3.50144 1.00 0.75 2.25 1.5 0.58 3.50156 1.00 0.75 2.25 1.5 0.54 3.00168 1.00 0.75 2.25 1.5 0.50 3.00180 1.00 0.75 2.25 1.5 0.47 2.50

Notes:

1 To maintain pipeline stationing, pipe should beinstalled with normal interior joint space. Minorcorrections in stationing can be made byincreasing or decreasing the interior joint spaceto 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 andgrade. Joint deflection is accomplished byincreasing the interior joint space on one side ofthe pipe and decreasing the interior joint spaceon the opposite side. The deflection of a joint ininches is the difference between the widest andnarrowest interior joint space.

3 Pipe with beveled spigots are furnished forchanges in alignment or grade greater thancan be accommodated with deflected joints.Bevels are made by attaching the spigot tothe steel cylinder at the desired angle duringmanufacture of the pipe.

4 To determine the minimum pipeline radiususing deflected or beveled joints.

where: R = Pipeline curve radius in feet L = Pipe length in feet

angle = Deflected or beveled angle in degrees

=

2sin2

angleL

R

Applications

This six barrel 1.6-meter diameter concrete pipe is part of a systemthat will transport seawater to be used as cooling and process waterin the new Jubail Industrial City, Saudi Arabia.

A jack-up barge installs 216-inch diameter prestressed concretepipe in seabed trenches off coast of California. The pipeline willprovide cooling water for the San Onofre Nuclear GeneratingStation.

Ten miles of prestressed concrete cylinderpipe were installed as a sewer force main inNorthern California.

These 84-inch diameter prestressed concrete pipe underan 80-foot embankment will serve as a drainage culvertunder a major highway in California.

Ten miles of 96-inch diameter prestressed concretecylinder pipe, part of the San Diego Aqueduct, willtransport potable water to a large metropolitan area.

Special pipe sections and custom fittings are part ofprestressed concrete cylinder pipe system at a powergenerating station.

This 108-inch diameter pipe being installed withAmeron’s Tunnelmobile will serve as the tunnel linerin a water transmission pressure-system tunnel.

Manufacture

For maximum efficiency in production, work stations inAmeron pipe plants are located in parallel lines and areserved by custom railroad cranes.

The manufacture of prestressed concrete cylinder pipe beginswith a helically welded, watertight steel cylinder with steel jointrings attached.

The steel cylinder, enclosed by innerand outer molds, is placed on a basering which insures concentricity.

Concrete, placed between molds, encasescylinder and is consolidated by pneumaticvibrators on outer mold.

After curing at controlled temperature, theconcrete encased cylinder (the core) isready for prestressing.

Completed prestressed cylinder pipe is tipped fromvertical to horizontal position and moved to storage yardwhere it is held until delivery to job site.

Pipeline fittings of almost any size or configura-tion call be fabricated at the prestressed manu-facturing facility.

The finished steel cylinder is subjected to a hydrostatic test toverify structural and hydrostatic integrity.

Prestressing is accomplished by helically wrapping the core with high tensile steel wireunder measured tension (left). The prestressed concrete core is then coated with cementmortar (right). Curing of the mortar coating completes manufacture.

Because of the strength and rigidity of prestressed concrete cylinderpipe, it can be easily handled by standard forklifts,yard or construction cranes.

On-site plant manufacture

A 252-inch diameter pre tressed concrete pipe core is castonsite at a field plant for the Central Arizona Project.

This cement-mortar coating machine coats 216-inch diameter pipesections during the on-site manufacture of prestressed concretepipe. Modular design of the equipment allows easy disassembly fortransporting to a new location.

This prestressing equipment wraps 252-inch diameter pipe coreswith high tensile steel wire under controlled tensions. It wasmoved forward as the pipeline project progressed through fourseparate desert locations. Six inverted siphons were installed forthe Central Arizona Project.

The 78-foot tall Ameron Liftmobile moves the pipe core betweenwork stations as its manufacture progresses. Like all equipmentunits of an on-site plant, the Liftmobile can be disassembled formovement to a new location.

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

Transportation

The Ameron Pipe Division delivers pipe ( from plant to project sitein the fastest, most economical manner. When plant and projectsite are close to navigable water, barges may be used.

Rail transportation is often used when shipping distances aregreat and the project is near a railroad line.

Ameron Pipemobiles, designed by Ameron Equipment Engineeringand built by the company’s Equipment Division, are highly special-ized off-road vehicles that carry large diameter prestressed con-crete pipe from the on-site plant to the trench and install it. Threedifferent models of Ameron Pipemobiles can carry pipe ranging indiameter from 120 to 300 inches, weighing up to 250 tons.

Folding ramps on sides of pipe hauling trailers makeoffloading fast and efficient. Pipe sections are scheduled toarrive in proper sequence for installation.

Installation

Prestressed concrete pipe is usually installed with a craneusing a single sling-. Long radius curves are formed bydeflecting standard joints or by pipe sections with beveledspigot ends.

Rail-mounted gantry crane installs section of 216-inch diametersubaqueous pipeline near shore for intake and discharge linesat a nuclear generating station.

Joining of pipe sections in the trench isaccomplished using a tugger device withcables attached to preceding pipe section.Tugger action pulls the pipe joint together.

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

AMERON’S OBJECTIVES

We believe the growth of our businesses will be based on how well we identifycustomer needs and satisfy them over the long term with products and services ofsuperior value.

We also believe that satisfied, repeat customers are the lifeblood of any successfulbusiness and must be nurtured and cared for in the most professional and courteousmanner

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 Headquarters10681 Foothill Boulevard, Suite 450Rancho Cucamonga, CA 91730-3857(909) 944-4100 FAX (909) 944-4112

• Western Region Headquarters10681 Foothill Boulevard, Suite 450Rancho Cucamonga, CA 91730-3857(909) 944-4100 FAX (909) 944-4113

Arrow PlantEtiwanda, CA(909) 899-1716 FAX (909) 899-3089

Fontana PlantFontana, CA(909) 822-1280 FAX (909) 356-1343

Lakeside PlantLakeside, CA(619) 561-6363 FAX (619) 443-4540

South Gate PlantSouth Gate, CA(213) 357-6740 FAX (213) 563-1397

Tracy PlantTracy, CA 95377(209) 836-5050 FAX (209) 832-2115

Internet: http//: www.ameronpipe.comE-mail: pipeinfo@ameronpipe.comcopyright 2002 Ameron Intl. • PCCP 10/02 • Printed in U.S.A

• Southwestern RegionHeadquarters and Plant2325 S. 7th StreetPhoenix, AZ 85034(602) 252-7111 FAX (602) 258-8456

• Protective Lining Products201 North Berry StreetBrea, CA 92621(714) 256-7755 FAX (714) 256-7750

Regional Sales OfficeHouston, Texas8000 Research Forest DriveSuite 115-118The Woodlands, TX 77382(936) 321-1159 FAX (936) 271-1081

• American Pipe andConstruction International• Contubos S.A.Calle 193 No. 31-02Santafé de Bogotá, Colombia57-1-6740600 FAX 57-1-6710175Mailing AddressApartado Aereo 90087Santafé de Bogotá, Colombia