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 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
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 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
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 RING JOINT
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