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