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HANSON PRESSURE PIPE Steve Smith
January 16,2014
PRESTRESSED CONCRETE CYLINDER PIPE (PCCP)
Chesapeake Section – AWWA
Symposium
Slide 2 - 06.August 2007 Hanson sample slides – Group Comm & IR
Interpace Projects with Problems
INTERPACE – 45 MILLION FEET – 11,500 PROJECTS
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
Slide 4 - June 2009 Toronto and Ottawa Ontario Canada Seminars
AWWA C301
Prestressed Concrete Pressure Pipe, Steel Cylinder Type
Slide 5 - June 2009 Toronto and Ottawa Ontario Canada Seminars
The New Hanson Pressure Pipe Manufacturing Locations
Lubbock, TX
Grand Prairie, TX
Victoria, TX
Palatka, FL
St. Eustache, QC, Canada
Hattiesburg, MS
Bakewell, TN
South Beloit, IL
Stouffville, ON, Canada
Uxbridge, ON, Canada
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
Slide 15 - June 2009 Toronto and Ottawa Ontario Canada Seminars
MORTAR COATING
VERTICAL COATING
MACHINE FOR ECP
MORTAR CURING
CONCRETE CURING
Slide 18 - June 2009 Toronto and Ottawa Ontario Canada Seminars
STEEL PLATE FABRICATION
Slide 19 - June 2009 Toronto and Ottawa Ontario Canada Seminars
RAW FITTING
Slide 20 - June 2009 Toronto and Ottawa Ontario Canada Seminars
MORTAR APPLICATION
ECP vs LCP
Field Services – Emergency Repair
CPP Emergency Repair Questionnaire
Slide 24 - 10 October 2012 VC Summer Nuclear Plant Seminar
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
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
Slide 38 - 10 October 2012 VC Summer Nuclear Plant Seminar
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
Concrete Pressure Pipe Repair Saddle
MECHANICAL JOINT SPIGOT AND MECHANICAL JOINT BELL ADAPTERS
Slide 41 - 10 October 2012 VC Summer Nuclear Plant Seminar
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
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