Search Results (15)

While a large diameter is critical for maintaining water delivery efficiency in prestressed concrete cylinder pipes (PCCPs), excessive weight fundamentally limits their practical application. This study proposes a weight reduction strategy through material optimization and structural redesign. A full-scale experimental model of 2.8 m inner diameter PCCP was used to validate the finite element analysis method. Comparative numerical models were established to analyze strain/stress distribution in mortar coatings when using ultra-high-performance concrete (UHPC) versus conventional concrete cores. The key findings reveal that UHPC implementation reduces maximum coating strain by 20–30% compared to its conventional concrete counterparts. Multivariate linear regression analysis yielded a predictive formula that explicitly correlates the elastic modulus of the concrete core, core thickness, and mortar stress. This relationship permits the direct optimization of core thickness reductions according to the elastic modulus characteristics of UHPC materials. Verification through two case studies demonstrated a 25–35% core thickness reduction compared to the Chinese standard specifications while maintaining structural integrity, corresponding to an 18–22% total weight reduction. The proposed methodology successfully resolves the inherent weight limitation of conventional PCCPs while achieving equivalent hydraulic capacity, providing an effective pathway for sustainable infrastructure development through material-efficient design. Full article

The failure accidents of prestressed concrete cylinder pipe (PCCP) seriously affect the economic feasibility of the construction site. The traditional method of needing to stop construction for pipe inspection is time-consuming and laborious. This paper studies the PCCP broken wire identification algorithm based on deep learning. A PCCP wire-breaking test platform was built; the Distributed Fiber Acoustic Sensing Monitoring System (DAS) monitors wire-breakage events in DN4000mm PCCPs buried underground. The collected broken wire signal creates a time-frequency spectrum diagram dataset of the simulated broken wire signal through continuous wavelet transform (CWT). Considering the location of equipment limitations, based on the YOLOv5 algorithm, a lightweight algorithm, YOLOv5-Break is proposed for broken wire monitoring. Firstly, MobileNetV3 is used to replace the YOLOv5 network backbone, and Dynamic Conv is used to replace Conv in C3 to reduce redundant computation and memory access; the coordinate attention mechanism is integrated into the C3 module to make the algorithm pay more attention to location information; at the same time, CIOU is replaced by Focal_EIoU to make the algorithm pay more attention to high-quality samples and balance the uneven problem of complex and easy examples. The YOLOv5-Break algorithm achieves a mAP of 97.72% on the self-built broken wire dataset, outperforming YOLOv8, YOLOv9, and YOLOv10. Notably, YOLOv5-Break reduces the model weight to 7.74 MB, 46.25% smaller than YOLOv5 and significantly lighter than YOLOv8s and YOLOv9s. With a computational cost of 8.3 GFLOPs, YOLOv5-Break is 71.0% and 78.5% more efficient than YOLOv8s and YOLOv9s. It can be seen that the lightweight algorithm YOLOv5-Break proposed in this article simplifies the algorithm without losing accuracy. Moreover, the lightweight algorithm does not require high hardware computing power and can be better arranged in the PCCP broken wire monitoring system. Full article

Uniform support from the surrounding soil is important for maintaining the stable operation of buried pipelines. For segmented prestressed concrete cylinder pipe (PCCP), localized soil voids around the joint due to leakage or engineering activities make the pipe unsupported partially and threaten its integrity and strength. In this paper, the impact of a localized soil void on a pipe joint is qualitatively assessed using a beam-on-elastic-spring approximation model. It further provides quantitative analysis through a nonlinear finite element (FE) model of PCCPs and the surrounding soil. The derived algebraic solutions indicate that a unilateral local void induces shear force and rotation at the joint, whereas shear force becomes negligible when the void spans the joint, leading to increased rotation. Moreover, the rotation angle shows a positive correlation with soil load and a negative correlation with pipe diameter. Numerical analysis reveals that void elongation along the pipe length has a more pronounced effect on structural response than void depth and angle. When the void length reaches 2.5 m, the maximum principal stress on the mortar layer of the PCCP increases approximately eight-fold compared to the scenario without voids. Due to the rigidity and safety factor of the PCCP, small voids in the bedding typically do not cause immediate pipe damage or joint leakage; however, they can significantly alter the stress distribution within both the pipe and surrounding soil. As the void develops, the soil may collapse and compromise support, leading to additional secondary disaster risks and potential threats to pipeline safety. This research emphasizes the importance of effective pipe-soil interactions and provides theoretical insights for developing repair strategies for PCCP. Full article

Rockfalls are major geological hazards threatening prestressed concrete cylinder pipes (PCCPs) in water diversion projects. To accurately assess the impact of large deformation movements of rockfalls on PCCPs, this study utilized the continuous–discontinuous method to investigate the dynamic response of a PCCP under a rockfall. The impact mode of rockfalls, the mechanical characteristics of PCCP, and the nonlinear-contact characteristics between soil and PCCP were considered in this study. The advantages of continuous and discontinuous numerical simulation methods were utilized to establish a continuous and discontinuous coupling model of “tube-soil-rock” considering the interaction of soil and structure. The impact mechanism and process of PCCP under the rockfall were investigated by simulating the rockfall process and analyzing its spatiotemporal evolution. The influence of PCCP under rockfalls with different heights and radii was studied to clarify the effects of these two parameters on the PCCP. Combined with a practical application example of large-scale water transfer projects, there is a tendency of center flattening under static load and dynamic impact load, and the PCCP part directly below the impact point is the most dangerous. This investigation provided a comprehensive understanding of the impact mechanism of the PCCPs under rockfall. The findings of this study have significant implications for the design of the protection engineering of PCCPs and ensuring the safe operation of water diversion projects. Full article

Ignoring the effect of a concrete core on bearing performance, the current design of prestressed concrete cylinder pipes (PCCPs) under internal water pressure only focuses on the fracture of prestressed steel wire, while the complexity of the AWWA C304 design method leads to a strong dependence on software that cannot be sufficiently mastered by the designers. In view of these issues, a simplified limit-state design process was induced to eliminate a large number of iterative operations and was verified by a three-dimensional finite element model (FEM) with a prototype test of PCCPs under internal water pressure. Meanwhile, the bearing performance of PCCPs was investigated using the parametric simulations of the FEM. The results showed that the cross-sectional area of the prestressed steel wire is higher by about 10% than that designed using the AWWA C304 method. The FEM provides a complete evolution process of the mechanical response of the structural constituents and simulates the strain mutation phenomenon of the prototype test well. The internal water pressure of the PCCPs designed using the simplified limit-state design process has enough safety to reach 4.7 times the working pressure at serviceability and 5.5 times the pressure at the ultimate limit state. A burst in the PCCPs took place under an internal pressure greater than 6.75 times the working pressure. The result of the FEM shows that an increase in the tensile strength of the concrete core is of great significance for improving the bearing performance of the PCCPs. Full article

Wire breakage is a major factor in the failure of prestressed concrete cylinder pipes (PCCP). In the presented work, an automatic monitoring approach of broken wires in PCCP using fiber-optic distributed acoustic sensors (DAS) is investigated. The study designs a 1:1 prototype wire break monitoring experiment using a DN4000 mm PCCP buried underground in a simulated test environment. The test combines the collected wire break signals with the previously collected noise signals in the operating pipe and transforms them into a spectrogram as the wire break signal dataset. A deep learning-based target detection algorithm is developed to detect the occurrence of wire break events by extracting the spectrogram image features of wire break signals in the dataset. The results show that the recall, precision, F1 score, and false detection rate of the pruned model reach 100%, 100%, 1, and 0%, respectively; the video detection frame rate reaches 35 fps and the model size is only 732 KB. It can be seen that this method greatly simplifies the model without loss of precision, providing an effective method for the identification of PCCP wire break signals, while the lightweight model is more conducive to the embedded deployment of a PCCP wire break monitoring system. Full article

A popular water pipe system, used in many countries, is one formed by prestressed cylindrical concrete pipes (PCCP). This study used the results of an experimental investigation on ten (10) PCCP samples taken from an existing water pipeline. The objective was to investigate their bearing capacity under three-edge bending or internal hydraulic pressure loads to check the capability of specific retrofitting/strengthening schemes to upgrade this bearing capacity and thus enhance the operational period (Part A). In this part B study, the measured response of the PCCP pipes was made to validate a numerical approach aimed at numerically simulating the behavior of the original and retrofitted PCCP pipes under hydraulic internal pressure. From the obtained numerical results, it was seen that the assumed nonlinear mechanisms for the concrete volume and steel membrane were verified by comparing numerical predictions with measurements in terms of strain response of the steel membrane, damage patterns of the concrete volume, and the overall internal pressure versus radial expansion response. The numerical predictions of the bearing capacity contribution of the fully active prestress as well as the three specific jacketing schemes, including carbon fiber reinforced polymer (CFRP) or reinforced concrete (RC) jackets, were also verified from comparisons with the corresponding measured response. Full article

In practical applications, the safe operation of large-diameter prestressed concrete cylinder pipes (PCCPs) depends on the loading performance under internal water pressure. However, there is lack of damage tests for the full-scale large-diameter PCCPs due to economic cost and experimental difficulty. In this paper, a full-scale PCCP with diameter of 3.2 m was tested to verify the bearing capacity for applying to an actual water transfer project. The PCCP was designed by the limit state method and manufactured in a prefabrication plant. During the test, the strains of concrete, prestressed steel wire, and mortar were detected to evaluate the limit state of bearing capacity under internal water pressure. Based on the test results and the strain analysis at the limit state, it was found that when the water pressure reached 1.9 MPa, the concrete outside the steel cylinder was at the serviceability limit state, and the prestressed steel wire was in elastic, while some protective mortar exceeded the serviceability limit state due to the appearance of visible cracks. A good accuracy of the theoretical calculation with the predicted results lower about 9.4% and 8% than tested pressures at decompression and cracking states. Moreover, the cracking pressure of concrete and bursting pressure of pipe were 2.5 and 6 times of the working pressure according to the calculation results. This indicated that the PCCP used in this study had sufficient safety in actual operation. However, it should be noted that the tensile control strain of mortar may be overestimated by the current code. Full article

A prestressed concrete cylinder pipe (PCCP) is created with a complex composition of concrete core, welded steel cylinder, prestressed steel wire, protective mortar and anti-corrosion coating. Due to the economy and complexity of structural prototype tests, the ultimate loading test on PCCP is rarely conducted. In this paper, the three-edge bearing test was carried out on a 3.2 m diameter PCCP with embedded steel cylinder. The strains of concrete core, prestressed steel wire and protective mortar were monitored, and the distribution and width of the concrete cracks were recorded. The test results show that the cracking on the inside concrete at the crown zone occurred before those on the invert zone of the pipe. The prestressed steel wire postponed the tensile stress of out-side concrete at the springing line until subjected to the calculated cracking load (P_c). Due to the moment redistribution caused by the cracking on the inside of the concrete at the crown/invert, the protective mortar at the springing line was cracked at 1.2 P_c and exhibited visible cracking after 1.4 P_c. The prestressed steel wire reached the elastic and strength limit states of 1.4 P_c and 1.6 P_c, respectively. The PCCP designed by the limit state design method can resist the increased external loads after reaching the serviceability limit state. The final failure load of the test pipe is greater than 1.6 P_c, and there is sufficient safety in actual operation. Due to the fact that the damage to the concrete at the crown/invert zone may become a fuse of PCCP failure, the tensile stress of the inside concrete at the crown/invert zone of the PCCP should be accurately verified in the design process. Full article

The precise analysis of the overall mechanical performance of prestressed concrete cylinder pipes (PCCPs) with broken wires is a complicated problem. In this article, powerful finite element numerical means are applied to solve this problem. Firstly, the advantages and shortcomings of the current prestress simulation methods in the finite element analysis (FEA) literature are discussed, and the initial stress method based on a novel single-spring joint element method to model the pre-stress of wires is proposed. Then, different distributions of broken zones, including random broken distributions, are developed for two typical PCCP pipes with different wire-wrapped layers. The established nonlinear FEA model considers actual service processes such as manufacturing, installation and operation to investigate the mechanical behavior of two typical PCCP pipes with different breakage distribution regions and breakage ratios, and in particular, the overall mechanical behavior of a pipe with random breakage is determined first. To verify the accuracy of the proposed pre-stress simulation method and the established nonlinear finite element model, the overall mechanical response of a pipe before wires broke is compared with the results obtained via the specifications. The computed results under the corresponding breakage assumptions are consistent with the conclusions in the existing literature, providing important guidance for pipeline management and operation. Full article

A popular water pipe system used in many countries is one formed by prestressed cylindrical concrete pipes (PCCPs) formed by identical precast moduli joined together in situ. This technology was and still is quite popular in many water supply systems internationally. This technology was mainly selected at the time due to its cost-based comparative advantage. However, over the years, numerous incidents of structural failures have been reported for this type of pipeline, causing, in some cases, serious disruption of the water supply. This study summarizes the results of an experimental investigation on ten (10) PCCP specimens taken from an existing water pipeline with the objective of investigating their bearing capacity under either three-edge bending or internal hydraulic pressure loads. Moreover, there is a need to check the capability of specific retrofitting/strengthening schemes to upgrade this bearing capacity and thus enhance the operational period. Provided that the prestressing wires are fully active according to design specifications, the original specimen performed satisfactorily for the set internal hydraulic pressure limit of 8.5 bar. Specimens retrofitted with either internal or external CFRP or RC jacketing performed satisfactorily for internal hydraulic pressure levels well above this 8.5 bar limit. A critical factor is, as expected, the loss of prestress. Full article

A prestressed concrete cylinder pipe (PCCP) consists of a concrete core, a steel cylinder, prestressing wires, and a mortar coating. Most PCCP failures are related to the breakage of prestressing wires. It is thus expected that the load-bearing capacity of PCCP is significantly affected by the length of the prestress loss zone and the stress distribution in the broken wire. Based on a tri-linear bond-slip model, the length of prestress loss zone and the stress transfer mechanism between a broken wire and a mortar coating are analysed in this paper. During the breaking (unloading) process of a prestressing wire, the interfacial bondline exhibits the following three stages: elastic stage, elastic-softening stage, and elastic-softening-debonding stage. The closed-form solutions for the interfacial slip, the interfacial shear stress, and the axial stress in the broken wire are derived for each stage. The solutions are verified by the finite element predictions. A parametric study is presented to investigate the effects of the size of the prestressing wires, the prestressing level, the interfacial shear strength, and the residual interfacial shear strength on the interfacial stress transfer. For an example PCCP with an inner diameter of 4 m, the length of prestress loss zone increases from 500 mm to 3300 mm as the radius of prestressing wire increases from 1 mm to 7 mm. It increases from 2700 mm to 7700 mm when the interfacial shear strength reduces from 3.94 MPa to 0.62 MPa and reduces from 13,200 mm to 7300 mm as the residual interfacial shear stress factor increases from 0.1 to 0.9. Full article

Prestressed concrete cylinder pipes (PCCPs) can suffer from prestress loss caused by wire-breakage, leading to a reduction in load-carrying capacity or a rupture accident. Reinforcement of PCCPs with external prestressed steel strands is an effective way to enhance a deteriorating pipe’s ability to withstand the design load. One of the principal advantages of this reinforcement is that there is no need to drain the pipeline. A theoretical derivation is performed, and this tentative design method could be used to determine the area of prestressed steel strands and the corresponding center spacing in terms of prestress loss. The prestress losses of strands are refined and the normal stress between the strands and the pipe wall are assumed to be distributed as a trigonometric function instead of uniformly. This derivation configures the prestress of steel strands to meet the requirements of ultimate limit states, serviceability limit states, and quasi-permanent limit states, considering the tensile strength of the concrete core and the mortar coating, respectively. This theory was applied to the reinforcement design of a PCCP with broken wires (with a diameter of 2000 mm), and a prototype test is carried out to verify the effect of the reinforcement. The load-carrying capacity of the deteriorating PCCPs after reinforcement reached that of the original design level. The research presented in this paper could provide technical recommendations for the application of the reinforcement of PCCPs with external prestressed steel strands. Full article

The prestressed concrete cylinder pipe (PCCP) suffers from cracks and degrades due to the prestress loss which is induced by wire breakage. Reinforcement with external prestressed strands is an option to return the deteriorating pipe’s ability to withstand internal pressures. This reinforcement contributes to actively compensating for the prestress loss caused by broken wires at an economic price. The crack propagation in the core is constrained by the strands. Moreover, the high tensile strength of strands does not decrease with an increase in the bending angle. It is also unnecessary to dewater the pipes during construction. To evaluate the reinforcement effect, a prototype test of a PCCP was performed in an assembled apparatus. The apparatus was mainly constituted by two PCCPs whose internal diameter is 2000 mm. The status of each component of the pipe was measured by resistance strain gauges in three sections along the axial direction at inverted (360°), crown (180°), and spring-line (90°, 270°) orientations. The maximum width of the cracks in the outer concrete core at spring-line reduced from 1.2 to 0.1 mm after strengthening. The cracks of the core concrete changed slightly when the internal water pressure increased to the design pressure of 0.9 MPa. The strengthened pipe was capable of sustaining the design internal water pressure and the water tightness property was in a good state. The strains of the steel strands were all below the tensile strain level. The reinforcement of the PCCP with external prestressed steel strands is able to meet the strengthen requirement of the test. Full article

This paper describes the most important results of a theoretical, experimental and in situ investigation developed in connection with a water supply pumping pipeline failure. This incident occurred after power failure of the pumping system that caused the burst of a prestressed concrete cylinder pipe (PCCP). Subsequently, numerous hydraulic transient simulations for different scenarios and various air pockets combinations were carried out in order to fully validate the diagnostic. As a result, it was determined that small air pocket volumes located along the pipeline profile were recognized as the direct cause of the PCCP rupture. Further, a detail survey of the pipeline was performed using a combination of non-destructive technologies in order to determine if immediate intervention was required to replace PCC pipes. In addition, a hydraulic model was employed to analyze the behavior of air pockets located at high points of the pipeline. Full article