Chesapeake Section AWWA Symposium

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1 PRESTRESSED CONCRETE CYLINDER PIPE (PCCP) Chesapeake Section AWWA Symposium HANSON PRESSURE PIPE Steve Smith January 16,2014

2 Interpace Projects with Problems INTERPACE 45 MILLION FEET 11,500 PROJECTS Slide 2-06.August 2007 Hanson sample slides Group Comm & IR

3 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 360º 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

4 AWWA C301 Prestressed Concrete Pressure Pipe, Steel Cylinder Type Slide 4 - June 2009 Toronto and Ottawa Ontario Canada Seminars

5 The New Hanson Pressure Pipe Manufacturing Locations Uxbridge, ON, Canada St. Eustache, QC, Canada South Beloit, IL Stouffville, ON, Canada Bakewell, TN Lubbock, TX Hattiesburg, MS Grand Prairie, TX Palatka, FL Victoria, TX Slide 5 - June 2009 Toronto and Ottawa Ontario Canada Seminars

6 PCCP History First Installation (LCP) First AWWA Standard (Tentative) 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

7 STEEL CYLINDER FABRICATION

8 JOINT RING ATTACHMENT

9 CYLINDER HYDRO TEST

10 APPLYING CONCRETE CORE LCP & BWP

11 ECP VERTICAL CASTING

12 HORIZONTAL PRESTRESSING

13 VERTICAL PRESTRESSING

14 MORTAR COATING

15 MORTAR COATING VERTICAL COATING MACHINE FOR ECP Slide 15 - June 2009 Toronto and Ottawa Ontario Canada Seminars

16 MORTAR CURING

17 CONCRETE CURING

18 STEEL PLATE FABRICATION Slide 18 - June 2009 Toronto and Ottawa Ontario Canada Seminars

19 RAW FITTING Slide 19 - June 2009 Toronto and Ottawa Ontario Canada Seminars

20 MORTAR APPLICATION Slide 20 - June 2009 Toronto and Ottawa Ontario Canada Seminars

21 ECP vs LCP

22 Field Services Emergency Repair

23 CPP Emergency Repair Questionnaire

24 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 October 2012 VC Summer Nuclear Plant Seminar

25 PCCP Emergency Repair Kit

26 PCCP Closures

27 Closure Installation Squareness Top and Bottom

28 Closure Installation Squareness Top and Bottom

29 Closure Installation Squareness Side to Side

30 Closures Squareness Side to Side

31 Closure Cutting

32 Field Weld Closure

33 Field Weld Closure

34 Field Weld Closure

35 Closure Using Come Along to Pull Joint Home

36 Closure Hydraulic Jacking Bell

37 FOLLOWER RING CLOSURE

38 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 October 2012 VC Summer Nuclear Plant Seminar

39 Concrete Pressure Pipe Repair Saddle

40 MECHANICAL JOINT SPIGOT AND MECHANICAL JOINT BELL ADAPTERS

41 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 October 2012 VC Summer Nuclear Plant Seminar

42 STANDARD JOINT

43 SNAP RING JOINT

44 SNAP RING JOINT

45 ASSEMBLED SNAP RING JOINT

46 HARNESS CLAMP JOINT - ECP

47 HARNESS CLAMP JOINT

48 Tapping Saddles

49 Tapping PCCP

50 Grouting with Diaper

51 Questions and Answers

52 Tapping Saddle Removing Prestress Wire

53 PCCP is a Rigid Pipe

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