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Products > CCP > Manufacturing Process

 

[Features] [Pipe Designs] [Fittings] [Manufacturing] [Fittings Production] [Installation][Special Provisions] [Dimensions] [Deflections/Bevels] [Typical Designs] [References]

 

 

Joint Ring Fabrication

Bell and spigot rings, which form the rubber     O-ring sealed joint between adjacent pipes, are fabricated from flat bars and special hot-rolled sections, respectively.

Cylinder Fabrication

 An automatic helical weld machine forms a continuous cylinder from coils of steel sheet. At the appropriate point, a circumferential cutting operation separates the exact length of cylinder required for individual piece of pipe.

Spigot Rings are attached first and tack welded, followed by the bell ring which takes up the variance in the cylinder.
Hydro test 

Cylinders with joint rings attached are then rolled onto the next station for hydrostatic testing. Here the pipe is given a final visual inspection for any defects in cylinder welding and then positioned on the hydro test machine.

Stiffener Ring Attachment 

When the cylinder assembly passes hydro test, it is then rolled onto the lining station. Prior to mounting the cylinder on the lining machine, the pipe is fitted with end spinning rings to ensure correct lining thickness and stiffener rings to maintain the pipe’s roundness during the lining operation.

Lining 

 A measured quantity of cement-mortar, mixed under controlled conditions, is placed uniformly throughout the length of the cylinder while it rotates in a spinning machine.

CML Curing 

The lined cylinder is placed in a chamber where mortar cures for a specified period of time under controlled temperature and humidity. Pipe ends are covered with plastic caps in order to retain humidity necessary for curing the lining.

Rod Wrap

Upon completion of cure, the lined cylinder is wrapped circumferentially with steel rod at controlled tension and pre-determined spacing. A slurry, rich in Portland cement, is sprayed on the cylinder immediately ahead of the advancing rod wrap to fill all voids between the steel rod and the cylinder.

Mortar Coating. A stream of cement-mortar, mixed under controlled conditions, is impacted against its surface to produce a dense, durable coating. A second spray of Portland-cement-rich grout precedes the mortar to assure that the steel is encased in a highly alkali environment. The placement of mortar coating is followed immediately by the spraying on of a 100% solids coal-tar epoxy at a specified rate.
Painting Exposed Steel Areas 

The pipe is transferred to the curing building. The joint rings are cleaned and painted with a rush inhibitor. The ends of the pipe are covered with plastic caps for continued curing.

Pipes in Yard 

Pipe details including factory order number, pipe diameter, pipe class, pipe number, operating pressure and date of manufacture, are marked on the plastic end caps.

 

 

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