REPAIR/STRENGTHENING

DURABLE PCCP REPAIR

TECHNOLOGIES

Our philosophy
Problems
Corrosion of the outer wire from chloride migration
Premature failure of prestressing wire due to hydrogen embrittlement
Corrosion of the liner initiating from inside the pipe
Leakage at joints due to construction defects and differential settlement

Research
In 1999 Freyssinet was retained on an emergency basis after a major
PCCP burst and is still engaged in a continuous repair program with
an emphasis on long-term durability.
PCCP is a prestressed structure. As such, Freyssinet developed
specific methods to assess each structural deficiency and define
an appropriate technical repair strategy :

Monitoring
& Risk
Assessment

Analysis
of Causes

Finite
Element
Model
(Linear or
Non Linear)

Durable
Technology
Design

Full
Scale
Testing

Operations

Durability
PCCP have a minimum design life of 50 years
Low quality repair solutions have been implemented, usually under
emergency repair contracts
Well-designed repair solutions, specific to PCCP repairs were,
not commercially available.
Damaged or defective PCCP in aggressive soils, are subject to
accelerated deterioration.
To combat this, Freyssinet developed repair solutions with 50-year
design lives, even in severe environments.

Repair, a Cost Effective Solution

Freyssinet engineered PCCP repair solutions present the following advantages :
Savings of 60% to 75% in terms of global costs
Limited duration of intervention
Possibility to implement in-service PCCP repairs
Standardization of repair methods

Unique Technologies to Provide

Our solutions
Repair Solutions

External Repairs
DURALOOP : an External Durable Pre-Grouted PT System
Application of additional externally applied Post-Tensioning to compensate
the failing prestressing force is a natural idea. Freyssinets PCCP External
Durable Pre-grouted PT System, DURALOOP, is based on the use of Freyssinets
patented 2MX15 Anchorage and special indented strand centering external
HDPE/PP sheathing to achieve a fully encapsulated and durable post-tensioning
system. Pre-grouting of centralized strands prior to stressing provides uniform
support of the unbonded monostrands thus ensurign that the corrosion
protection systems remain intact.

Sand Recompaction
After excavation and additional post-tensioning operations, the strengthened
area is backfilled below the pipe and the soil re-compacted to allow the
support of the PCCP load with no settlement. Freyssinets patented sand
re-compaction technique compresses the sand below the pipe to provide
uniform pressure and pipe support. It is the only known PCCP repair technique
that avoids pipe settlement and is applicable for repairs carried out with
dewatered or in-service pipes

Internal Repairs
Frey-CWrap
Freyssinet has developed a unique technique using carbon fiber fabric
impregnated with a specifically designed resin for application onto surfaces of
PCCP. This system is designed to ensure there will be no risk of delamination
due to either internal or external pressure. The porosity of Frey-CWrap is such
that complete watertightness is guaranteed. Frey-CWrap has been approved by
NSF for use with PCCP carrying potable water and makes use of the Freyssinet
Carbon Fiber Techniques (TFC) used in more than 500 structures.

Frey-CWrap Relining
Specific automated equipment has been designed to place Frey-CWrap with
a carefully controlled pitch, which may be varied to accommodate various
design criteria. The equipment is currently designed for pipes with diameters
between 1.5 m and 3 m. Details to treat special cases such as manholes and
valves are available.

Durable Repair

Soft Joint Resealing System

A special compound has been developed to reseal joints from the inside.
The compound adheres to the PCCP surface in wet or dry conditions and has
a tensile/shear strength of more than 2 MPa thus providing an adequate
surface for the relining process. The compound remains flexible and
accommodates local distortion, compressive and tensile stresses.

Monitoring and Risk Analysis

Freyssinet has developed strategic partnerships with Advitam and
Pure Technologies to provide monitoring and risk assessment capabilities.
The following techniques are available :
SmartBall is a leak detection system using an acoustic/electromagnetic
sensor placed in a ball (photograph 1).
SoundPrint is an acoustic monitoring system locating wire breaks
(photograph 2).
1

PWave is an electromagnetic system to inspect pipe from the inside and

quantify number of wire breaks (photograph 3).
ScanPrint is a GIS data management software capable to schedule
inspection and maintenance work in a cost-effective way (photograph 4).
A Special Risk Analysis Method has been developed and is integrated in
ScanPrint to calculate from soil and pipe construction data and monitoring
the expected life duration of pipes (photograph 5).

Almost any pipe

can be saved
Prestressed Concrete Cylinder Pipe (PCCP) has been widely used worldwide
for over 60 years. In 1939 Freyssinet manufactured and installed the first
PCCP in Algeria, which is still in service today !
The PCCP industry grew tremendously as it represented a very durable,
reliable and economical solution for large diameter pipelines.
However, due to various factors including material deficiencies and severe
environmental conditions, PCCP has encountered isolated problems,
especially in the past 10 years. These problems can lead to catastrophic
bursts resulting in huge financial losses to pipeline owners due to disruptions
in service, environmental impacts, as well as in unanticipated repair
and/or replacement costs.

CONTACT

www.freyssinet.com