PRESTRESSED CONCRETE

CYLINDER PIPE (PCCP)

Chesapeake
Section AWWA
Symposium
HANSON PRESSURE PIPE
Steve Smith
January 16,2014

Interpace Projects with Problems

INTERPACE 45 MILLION FEET 11,500 PROJECTS

Slide 2 - 06.August 2007

Hanson sample slides Group Comm & IR

AWWA C-301 Key Improvements to Manufacturing

SUMMARY OF KEY IMPROVEMENTS TO PCCP
(to AWWA C301 since 1984)

MORTAR COATING
Increased mortar coating thickness
Added cement slurry coating prior to prestressing and coating
Increased the minimum moisture content, which reduces absorption
making the coating less permeable
Required minimum compressive strength
Required a nondestructive thickness check on every pipe prior to removal
from the coating machine
Required a soundness check on the cured coating on every pipe
PRESTRESSING WIRE
Increased the minimum size wire to 6 gauge, allowing better keying of
mortar to wire
Eliminated the possibility of using Class IV wire
Added a maximum temperature limit of 360 during wire drawing, which
eliminates the sensitivity of overheated wire to hydrogen embrittlement
Decreased the allowable fluctuation in wire wrapping tensile stress
Added tests to ensure high quality wire; i.e. Torsion, Bolt Cutter, Reduction of
Area, with testing required on every coil
ASTM A648 Supplementary HE Qualification Testing Requirement mandatory
CYLINDER STEEL
Eliminated Grade E cold rolled steel
Eliminated 18 gauge thickness; minimum is 16 gauge
Required testing of weld strengths
CONCRETE
Added minimum quality limits and testing frequencies for aggregates
Added limitation on allowable longitudinal cracks in core
OTHER

Required qualification of welders

Added requirement for test equipment calibration
Improved quality control of gaskets
Added allowable design stresses and minimum cylinder thicknesses for
fittings

AWWA C301

Prestressed Concrete
Pressure Pipe, Steel
Cylinder Type

Slide 4 - June 2009

Toronto and Ottawa Ontario Canada Seminars

The New Hanson Pressure Pipe

Manufacturing Locations

St. Eustache, QC,

Canada
Uxbridge,
ON, Canada

Stouffville,
ON, Canada
South Beloit, IL

Bakewell, TN
Lubbock, TX

Hattiesburg, MS

Grand Prairie, TX
Victoria, TX

Slide 5 - June 2009

Toronto and Ottawa Ontario Canada Seminars

Palatka, FL

PCCP History
First Installation (LCP) - 1942
First AWWA Standard (Tentative) - 1949
First Installation (ECP) 1953
Used in 90 of 100 Largest U.S. Municipalities
107,000,000 Feet (20,300 Miles), in U.S. and Canada

STEEL CYLINDER FABRICATION

JOINT RING ATTACHMENT

CYLINDER HYDRO TEST

APPLYING CONCRETE CORE LCP & BWP

ECP VERTICAL CASTING

HORIZONTAL PRESTRESSING

VERTICAL PRESTRESSING

MORTAR COATING

MORTAR COATING

VERTICAL
COATING
MACHINE FOR
ECP

Slide 15 - June 2009

Toronto and Ottawa Ontario Canada Seminars

MORTAR CURING

CONCRETE CURING

STEEL PLATE FABRICATION

Slide 18 - June 2009

Toronto and Ottawa Ontario Canada Seminars

RAW FITTING

Slide 19 - June 2009

Toronto and Ottawa Ontario Canada Seminars

MORTAR APPLICATION

Slide 20 - June 2009

Toronto and Ottawa Ontario Canada Seminars

ECP vs LCP

Field Services Emergency Repair

CPP Emergency Repair Questionnaire

Emergency Repair Program

Hanson Pressure Pipe has established an emergency repair

program for all concrete pressure pipe products

Customers can contact a Hanson employee 24/7 in the event of a
pipeline emergency
Pipe repair material is stocked in all manufacturing plants and
ready for immediate shipment

Slide 24 - 10 October 2012

VC Summer Nuclear Plant Seminar

PCCP Emergency Repair Kit

PCCP Closures

Closure Installation Squareness Top and Bottom

Closure Installation Squareness Top and Bottom

Closure Installation Squareness Side to Side

Closures Squareness Side to Side

Closure Cutting

Field Weld Closure

Field Weld Closure

Field Weld Closure

Closure Using Come Along to Pull Joint Home

Closure Hydraulic Jacking Bell

FOLLOWER RING CLOSURE

Repair Saddle Assembly

Repair Saddle Assembly can be used to address localized

problems on the pipe barrel

Broken prestressing wires
Punctured steel cylinder
Damage must be far enough away from the joint to allow the

saddle assembly to be seated onto the pipe barrel

Slide 38 - 10 October 2012

VC Summer Nuclear Plant Seminar

Concrete Pressure Pipe Repair Saddle

MECHANICAL JOINT SPIGOT

AND MECHANICAL JOINT BELL ADAPTERS

Field Welding
Leaking joints can be welded for repair

Lined Cylinder Pipe joints can be welded on the exterior

Embedded Cylinder Pipe joint usually will need to be welded on the
interior

Slide 41 - 10 October 2012

VC Summer Nuclear Plant Seminar

STANDARD JOINT

SNAP RINGJOINT

SNAP RING JOINT

ASSEMBLED SNAP RING JOINT

HARNESS CLAMP JOINT - ECP

HARNESS CLAMP JOINT

Tapping Saddles

Tapping PCCP

Grouting with Diaper

Questions
and
Answers

Tapping Saddle Removing Prestress Wire

PCCP
is a
Rigid
Pipe