Bar-Wrapped Concrete Cylinder Pipe (CCP) Concrete Cylinder Pipe (CCP) ... Flexible Pipe and AWWA Manual M9. Ameron’s engineers can ... Guide specifications for Bar-Wrapped Concrete

Bar-Wrapped Concrete Cylinder Pipe (CCP)

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IntroductionCCP, a composite structure that combines the adaptability of steel with the durability and corrosion inhibiting properties of concrete and cement mortar, custom designed to the customer s system needs.

Bar-Wrapped Concrete Cylinder Pipe (CCP) consists of a steel cylinder lined with concrete or cement mortar, then helically wrapped with a mild steel bar and coated with dense cement mortar. Several easily assembled watertight joints are shown on the next page.

Since introducing the product in 1942, Ameron has supplied more than 6,000 miles of CCP for piping systems in the United States and throughout the world. Principal uses have been for the transmission and distribution of water in municipal, industrial and agricultural systems. CCP can be used to convey any liquid not corrosive to concrete, including seawater and sewage in force mains.

CCP is designed and manufactured in accordance with the American Water Works Association (AWWA) Standard C303 and AWWA Manual M9, and is normally supplied in standard diameters of 18 to 72 inches for operating pressures up to 400 psi. Pipe has been manufactured in larger sizes and for higher pressures based on the concepts of this standard.

Quality AssuranceThe national standard for Bar-Wrapped Concrete Cylinder Pipe is AWWA C303. This standard requires that every manufacturer maintain a quality assurance program, and that all materials used to manufacture the pipe conform to American Society for Testing and Materials (ASTM) standards. These nationally recognized standards ensure that the welders and welding operators are qualified and that the procedures and inspections are standardized. Quality assurance checks must be completed at every manufacturing process, including tests on the steel, the welds, the pipe lining and coating, and hydrostatic testing of the cylinders.

Ameron s customers require well developed standards and consistently high quality products. In addition to maintaining a quality assurance department, Ameron hires an annual audit by Lloyds Register, the world s premier classification society, of each of its plants, certifying that they are in compliance to the national standard.

The combination of Ameron’s commitment to its customers, the AWWA C303 standard, certifications from ISO 9001, Lloyd’s Register and National Science Foundation (NSF) verify to its customer that when delivered to the customer s jobsite, CCP conforms to specifications and is of consistent quality.

A Concrete or Cement Mortar Lining

B Dense Cement Mortar Coating

C Bar-wrapped Reinforcement*

D Round Rubber Gasket

E Steel Joint Rings*

F Steel Cylinder*

G Polyethylene foam-lined grout band

H Field applied cement mortar

* Mild Steel Components

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Water Transmission Group — Bar-Wrapped Concrete Cylinder Pipe (CCP)

Optimum DesignCCP is designed to resist internal hydrostatic pressure by a combination of the steel cylinder and helically wound bar. Thus, the pipe can be custom designed to provide the exact amount of steel needed for pipeline operating conditions by selecting the optimum combination of steel cylinder thickness, bar diameter and spacing. This flexibility in design can result in substantial cost savings.

Significance of Bar WrappingAfter the lining is cured, the steel cylinder is helically wrapped with a continuous mild steel bar applied at a tensile stress of 8,000 to 10,000 psi. The bar wrapping provides the balance of steel required to resist tensile hoop forces. In addition, the bar wrapping reinforces the mortar coating and locks it tightly against the steel cylinder so that cylinder, bar and coating act as a composite structure. This composite construction greatly increases the pipe’s rigidity, beam strength, and resistance to impact and vacuum.

Carrying CapacityField studies have proven that a Hazen-Williams coefficient, C, design value of 140, will be maintained over the service life of your project.

Corrosion ProtectionThe cement mortar coating maintains the steel elements in a highly alkaline environment, typically pH of 12.5 or greater. In this alkaline environment, galvanic corrosion is inhibited. The cured, shop-applied mortar coating must pass a water-absorption test that limits the average absorption value for any ten consecutive tests to 9% with no individual test exceeding a value of 11%. This dense mortar coating, along with the rich cement slurry which is applied to coat the portion of the bar bearing against the cylinder, provides a corrosion inhibiting and passivating environment for the steel cylinder and the bar wrap.

Field AssemblyThe self-centering steel bell and spigot joint sealed with a confined rubber gasket and the long laying length permit CCP to be installed rapidly and economically. Laying rates of 30 to 50 pipe sections per day per crew are readily attainable. The confined rubber gasket joint has over 70 years of proven reliability.

Customized Pipeline DesignAmeron provides a complete engineering package for each CCP project, including pipe design calculations, pipeline layout drawings and fabrication details for each component.

Standard CCP Joint

Placing rubber gasket on the Carnegie Spigot end of pipe

Carnegie Spigot with Expanded Bell

Lap Welded Joint

Double Gasket Joint

Double-Gasket Spigot PipeThe reliability and durability of Ameron’s standard, single, rubber-gasket joints have been proven for more than 70 years. However, in special applications, Ameron’s double gasket spigot pipe (see figure right) can be specified and used for the following:

•Fieldtesting a field joint prior to laying the next pipe section•Fieldtestingthepipejointsafterthecompletionofthebackfill•Inareaswherewaterisnotreadilyavailableforfieldhydrostatictesting•Forsubaqueousinstallations•Forpipeinstallationsinornearseismicallyactiveareas•Inhigh-fillareaswiththepossibilityoflong-termsettlement•Inareaswheretheadded protection of an additional gasket is required

As part of a custom-designed system, special pipe and fittings are numbered to identify their location in the pipeline.

Restraint of ThrustHydraulic thrust in the pipeline can be resisted by appropriately field welding the joint of assembled pipe sections to develop the required longitudinal restraint.

Field Pressure TappingCCP can be economically tapped while in service with commercially available equipment and procedures, permitting the installation of a full range of outlets in any diameter pipe.

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Pipe DesignThe design of Concrete Cylinder Pipe conforms to AWWA Standard C303 and AWWA Manual M9.

The total cross-sectional area of the circumferential steel reinforcement (steel cylinder plus bar reinforcement) is:

where:As = total cross-sectional area of circumferential steel, in²/LF of pipe wallAy = cross-sectional area of circumferential steel in the cylinder, in²/LF of

pipe wallAb = cross-sectional area of circumferential steel in the bar

reinforcement, in²/LF of pipe wallS.F. = Safety Factor; 2.0Pd = design pressure, psiDy = inside diameter of steel cylinder, in.S = 36,000 psi

The actual yield strength of the steel used to manufacture the cylinders is typically greater than 36,000 psi, resulting in an actual safety factor greater than 2 to 1 in the equation.

The required circumferential steel area for a given diameter and pressure class of pipe can be provided by several combinations of steel cylinder thicknesses, and bar diameters and spacing. Any combination which satisfies the following criteria may be selected.

•MinimumsteelcylindergagethicknessesshallbeasshowninTable1.•Minimumyieldstrengthofsteel=36,000psi.•Minimumdiameterofbarreinforcementshallbe7/32in.•Minimumareaofbarreinforcementshallbe0.23squareinchesperfootof

pipe wall or numerically equal to 1 percent of the pipe diameter in inches.•Maximumcenter-to-centerspacingofbarreinforcementshallnotexceed

2 inches.•Designclearspacebetweenbarsshallnotbelessthan1.5timesthe

diameter of the bar used.

Each cylinder is hydrostatically tested after joint rings are attached.

Pipe Diameter Range (inches)Minimum Cylinder Thickness

gage* inches**18-21 16 0.06024-33 14 0.07536-39 13 0.09042-48 12 0.10551-60 10 0.13463-66 8 0.16469-72 3/16” 0.188

* US standard gage** Nominal thickness

Table 1. Minimum Cylinder Thickness

A 72-inch diameter cylinder pipe on Ameron’s spiral weld machine.

Hydrostatic DesignThe average circumferential stress in the steel cylinder and bar reinforcement of the pipe at design pressure is limited to 36,000 psi, the specified minimum yield strength of the steel used in the cylinder. The following procedure represents a minimum 2 to 1 safety factor.

= +

= 6 [ . .]

s y

y d

b

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Water Transmission Group — Bar-Wrapped Concrete Cylinder Pipe (CCP)

External Load DesignCCP is a semi-rigid pipe designed as a composite wall steel and concrete structure. External loads of buried CCP pipelines are resisted by the ring flexural strength of the pipe (pipe stiffness) and by the passive lateral earth pressure on the sides of the pipe. The composite wall construction of CCP contributes significantly to its rigidity and, consequently, to its external load carrying capacity.

Recommended bedding and back filling procedures are included in Ameron’s Installation Guide for Semi-Rigid to Flexible Pipe and AWWA Manual M9. Ameron’s engineers can help determine your project’s specific pipe design based on pressure and earth cover load.

Standard DesignsStandard designs for Bar-Wrapped Concrete Cylinder Pipe based on a safety factor of 2.0 and a minimum yield of 36,000 psi for the steel are available on Ameron’s website. The steel cylinder thicknesses and bar diameters may vary provided the total steel area, As, is equal to or greater than shown. The standard designs provide an allowance for transient pressure 1.5 times the design pressure in the pipe.

SpecificationsGuide specifications for Bar-Wrapped Concrete Cylinder Pipe are available on Ameron’s website.

A combination of graded backfill material and native soils are used to backfill CCP.

Ameron supplied this 72-inch diameter Bar-Wrapped Concrete Cylinder Pipe.

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Bc = Outside diameter of pipe barrel, ftdb = Bar diameter, in.D = Inside diameter of pipe, in.Dy = Inside diameter of steel cylinder. in.Dj = Joint diameter, in.Js = Interior joint space

L = Standard laying length. fts = Bar spacing. center-to-center, in.tb = Bell thickness, in.tc = Minimum cement mortar coating thickness over steel bar, in. (0.75” minimum)tl = Nominal concrete or cement mortar fining thickness, in.ty = Cylinder thickness, in.

Pipe Inside Diameter

D

StandardLaying Length*

L

Outside Diameter Steel

CylinderDy + 2ty

Joint Diameter

Dj

Outside Diameter Pipe Barrel

Bc

Deflected Joint Beveled Joint Pipe Weight***

MinimumDeflection

MinimumRadius**

MaximumBevel

MinimumRadius**

t1 = 0.75”tc = 0.75”

inches feet inches inches feet degrees feet degrees feet lb/LF

18 36 19.78 20.28 1.82 2.11 978 5.00 412 140

20 40 21.78 22.28 1.98 1.92 1194 5.00 458 160

21 40 22.78 23.28 2.07 1.84 1246 5.00 458 165

24 45 25.75 26.25 2.31 2.18 1183 5.00 515 190

27 45 28.78 29.28 2.57 1.95 1323 5.00 515 215

30 45 31.875 32.375 2.82 1.76 1466 5.00 514 250

33 45 34.875 35.375 3.07 1.61 1602 5.00 514 280

36 45 37.875 38.375 3.32 1.49 1731 5.00 514 315

39 45 40.875 41.375 3.57 1.38 1869 5.00 514 340

42 45 43.875 44.375 3.82 1.29 2000 5.00 514 370

45 45 46.875 47.375 4.07 1.20 2150 5.00 514 400

48 45 49.875 50.375 4.33 1.13 2283 5.00 514 430

51 45 52.875 53.375 4.58 1.07 2411 5.00 514 470

54 45 55.875 56.375 4.83 1.01 2554 5.00 513 500

57 45 58.875 59.375 5.08 0.96 2687 5.00 513 540

60 45 61.875 62.375 5.33 0.92 2804 5.00 513 570

63 45 64.875 65.375 5.58 0.87 2965 5.00 513 610

66 45 67.875 68.375 5.85 0.84 3071 5.00 513 650

69 45 70.875 71.375 6.09 0.80 3224 5.00 513 690

72 45 73.875 74.375 6.37 0.77 3350 5.00 513 730

* Shorter lengths are available. ** Based on Standard Laying Lengths shown. Tighter radius can be achieved with shorter lengths. *** Pipe weight is for Class 150.

Pipe Dimensions

Table 2. Pipe Dimensions

(left) Centrifugally casting cement mortar lining inside steel cylinder

(right) Wrapping bar on to steel cylinder

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Water Transmission Group — Bar-Wrapped Concrete Cylinder Pipe (CCP)

Special Pipe and FittingsA full range of special pipe and fittings is available to satisfy project requirements.They are custom fabricated at the pipe manufacturing facility and delivered with the pipe to the construction site in proper sequence for installation in the pipeline. The design and manufacture of steel fitting and special pipe conform to the applicable section of AWWA Standard C303; their dimensions conform to AWWA Standard C208. Flanges for service rating to 300 psi conform to AWWA Standard C207. Flanges for service rating greater than 300 psi conform to ANSI Standard B16.5.

Virtually any size and shape can be supplied with various end configurations including rubber gasket, lap weld, buttstrap, flanged, mechanical couplings and plain ends.

Changes in DirectionLong-radius curves and minor changes in pipeline direction are achieved by joint deflection of standard pipe or by the use of pipe sections with ends beveled up to 5 degrees. For shorter radius curves, fabricated elbows are provided.

Special PipeSpecial pipe has the same design as standard pipe but is modified to incorporate short lengths, beveled ends and built-in outlets for manholes, air valves, blowoffs and other connections. The steel cylinder at the outlet opening is reinforced with either a steel collar, a wrapper plate or a crotch plate, depending on cylinder thickness, pipe and outlet diameters, and operating conditions.

FittingsFittings include elbows, reducers, and connections to mainline valves and appurtenances. These are fabricated from steel plate or sheet and cement mortar, lined and coated. The cylinder diameter for the mainline portion of the fitting is equal to the cylinder diameter of standard pipe.

Fitting DesignThe design thickness of the steel cylinder used in a fitting is:

where:

S.F. = Safety Factor; 2.0Pd = design pressure, psiDy = inside diameter of steel cylinder, in.S = 33,000 psi

Fittings are designed to be equal in strength to the adjacent standard pipe sections. The minimum steel cylinder thicknesses used in fittings are shown in Table 3.

CCP can be furnished with various end configurations to meet project requirements. A Carnegie joint with a single gasket is shown.

= [ . .]

2 y y d

Table 3. Minimum Thickness of Sheet or PlateFitting Diameter Range

(inches)Minimum Thickness of Sheet or Plate

(inches)18-21 0.13424-36 0.17939-48 0.25051-60 0.31263-72 0.375

Applying mortar coating over bar-wrapped steel cylinder

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NOV Corporate Headquarters7909 Parkwood Circle Drive Houston, Texas 77036 USA

National Oilwell Varco has produced this brochure for general information only, and it is not intended for design purposes. Although every effort has been made to maintain the accuracy and reliability of its contents, National Oilwell Varco in no way assumes responsibility for liability for any loss, damage or injury resulting from the use of information and data herein. All applications for the material described are at the user’s risk and are the user’s responsibility.

© 2015 National Oilwell Varco | All Rights ReservedD392005308-MKT-001 Rev. 02

Ameron Water Transmission Group

Headquarters10681 Foothill Boulevard, Suite 450Rancho Cucamonga, California 91730United StatesPhone: 909 944 4100Fax: 909 944 4113

Tracy Plant10100 W. Linne RoadTracy, California 95377United StatesPhone: 209 836 5050

Phoenix Plant2325 S. 7th StreetPhoenix, Arizona 85034United StatesPhone: 602 252 7111

SLRC PlantVia Ameron #100Colonia Las Adelitas, San Luis Rio ColoradoSonora, C.P. 83520

American Pipe & Construction Intl. (APCI)Calle 193 No. 31-02Bogota D.C., ColombiaPhone: 011 57 1 6684800

Protective Linings Division201 North Berry StreetBrea, California 92821United StatesPhone: 714 256 7755

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