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AMERON PRESTRESSED

CONCRETE CYLINDER PIPE

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.

operating under 950 feet of head


and 15 feet of earth cover.

The following installations


illustrate the adaptability of PCCP to
a wide range of load conditions:

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

9-foot diameter waterline

21-foot diameter inverted siphon


operating under 250 feet of head
and 23 feet of earth cover.
12.5-foot diameter tunnel liner.
8-foot diameter culvert under 230 feet of
embankment.
18-foot diameter subaqueous
seawater cooling lines for nuclear
generating station.

operating pressures higher than


shown with three or more layers of
prestressing wire.

get a complete, custom designed system,


Customized system design
Ameron provides the customers 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.

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.

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.

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

Pipe dimensions and weight

Nominal Standard
inside
core
pipe
thickness
(in.)

(in.)

42
45
48
51
54
57
60
66
72
78
84
90
96
102
108
114
120
132
144
156
168
180

Nominal
joint
diameter

Nominal
joint
lap

(in.)

(in.)

3.50
3.75
4.00
4.25
4.50
4.75
5.00
5.25
5.25
5.75
6.25
6.75
7.25
7.75
8.25
8.75
9.25
9.25
10.25
11.25
12.25
13.25

45.000
48.500
51.500
54.500
58.000
61.000
64.000
70.000
76.500
82.500
88.500
94.500
100.500
106.500
112.500
118.500
124.500
137.875
149.875
161.875
173.875
185.875

3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25
4.50
4.50
4.50
4.50
4.50

inside

outside

Unit(2)
pipe
weight

(in.)

(in.)

(Ib/ft)

Normal
joint space

0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.88
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.50
1.50
1.50
1.50
1.50

710
800
900
1000
1110
1220
1340
1530
1650
1940
2240
2560
2910
3280
3670
4080
4520
4930
5810
6970
8120
9360

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.

Joint space and deflections

Nominal
Interior joint space, D(1) (2)
inside
pipe
Deflected joint
diameter Normal Minimum Maximum
(in.)
(in.)
(in.)
(in.)
42
0.88
0.63
1.63
45
0.88
0.63
1.63
48
0.88
0.63
1.63
51
0.88
0.63
1.63
54
0.88
0.63
1.63
57
0.88
0.63
1.63
60
0.88
0.63
1.63
66
0.88
0.63
1.63
72
0.88
0.63
1.63
78
0.88
0.63
1.63
84
0.88
0.63
1.63
90
0.88
0.63
1.63
96
0.88
0.63
1.63
102
1.00
0.75
1.75
108
1.00
0.75
1.75
114
1.00
0.75
1.75
120
1.00
0.75
1.75
132
1.00
0.75
2.25
144
1.00
0.75
2.25
156
1.00
0.75
2.25
168
1.00
0.75
2.25
180
1.00
0.75
2.25

Notes:
(2)

(3)

Maximum
Maximum
joint deflection joint bevel

(in.) (degree)
1
1.32
1
1.23
1
1.15
1
1.09
1
1.02
1
0.97
1
0.92
1
0.84
1
0.77
1
0.71
1
0.66
1
0.62
1
0.58
1
0.55
1
0.52
1
0.49
1
0.47
1.5
0.64
1.5
0.58
1.5
0.54
1.5
0.50
1.5
0.47

(degree)
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
5.00
4.50
4.50
4.00
4.00
3.50
3.50
3.00
3.00
2.50

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.

R=

where:

L
angle
2 sin

R = Pipeline curve radius in feet


L = Pipe length in feet
angle = Deflected or beveled angle in
degrees

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.

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


Amerons Tunnelmobile will serve as the tunnel liner
in a water transmission pressure-system tunnel.

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 steel cylinder, enclosed by inner


and outer molds, is placed on a base
ring which insures concentricity.

The manufacture of prestressed concrete cylinder pipe begins


with a helically welded, watertight steel cylinder with steel joint
rings attached.

Concrete, placed between molds, encases After curing at controlled temperature, the
cylinder and is consolidated by pneumatic concrete encased cylinder (the core) is
vibrators on outer mold.
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.

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.

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.

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 worlds
largest precast circular concrete structures. Plant shown above manufactured prestressed pipe and specials for use in a
nuclear generating station cooling system in California.

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 companys 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.

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.

In trench, the Pipemobiles 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

AMERONS 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


10681 Foothill Boulevard, Suite 450
Rancho Cucamonga, CA 91730-3857
(909) 944-4100 FAX (909) 944-4112
Western Region Headquarters
10681 Foothill Boulevard, Suite 450
Rancho Cucamonga, CA 91730-3857
(909) 944-4100 FAX (909) 944-4113
Arrow Plant
Etiwanda, CA
(909) 899-1716 FAX (909) 899-3089
Fontana Plant
Fontana, CA
(909) 822-1280 FAX (909) 356-1343
Lakeside Plant
Lakeside, CA
(619) 561-6363 FAX (619) 443-4540
South Gate Plant
South Gate, CA
(213) 357-6740 FAX (213) 563-1397
Tracy Plant
Tracy, CA 95377
(209) 836-5050 FAX (209) 832-2115

copyright 2002 Ameron Intl. PCCP 10/02 Printed in U.S.A

Southwestern Region
Headquarters and Plant
2325 S. 7th Street
Phoenix, AZ 85034
(602) 252-7111 FAX (602) 258-8456

Protective Lining Products


201 North Berry Street
Brea, CA 92621
(714) 256-7755 FAX (714) 256-7750
Regional Sales Office
Houston, Texas
8000 Research Forest Drive
Suite 115-118
The Woodlands, TX 77382
(936) 321-1159 FAX (936) 271-1081

American Pipe and


Construction International
Contubos S.A.
Calle 193 No. 31-02
Santaf de Bogot, Colombia
57-1-6740600 FAX 57-1-6710175
Mailing Address
Apartado Aereo 90087
Santaf de Bogot, Colombia

Internet: http//: www.ameronpipe.com


E-mail: pipeinfo@ameronpipe.com