The Flow Control Group of Companies recently completed a 24x16 inch hot tap on a Prestressed Concrete Cylinder Pipe (PCCP) transmission main. Projects like this demonstrate how municipalities and utilities can safely modify critical water infrastructure without disrupting service to customers.
Large-diameter PCCP pipelines are commonly used throughout North America to transport drinking water from treatment plants to communities. Because these pipelines often serve thousands of residents, hospitals, airports, industrial facilities, and other critical infrastructure, shutting them down for maintenance or modifications is often not practical. This is where hot tapping becomes an important solution.
What Is PCCP Pipe?
Prestressed Concrete Cylinder Pipe (PCCP), manufactured to AWWA C301 standards, is one of the most widely used materials for large-diameter water transmission systems.
PCCP consists of a steel cylinder surrounded by concrete and reinforced with high-strength prestressing wire. This design provides exceptional strength and durability while allowing the pipe to withstand high operating pressures.
PCCP is commonly used for:
• Municipal water transmission mains
• Regional water distribution systems
• Water treatment facilities
• Large infrastructure projects requiring reliable water delivery
Because many PCCP systems were installed decades ago and continue to provide essential service, utilities regularly need ways to expand, modify, and maintain these pipelines while keeping them operational.
What Is Hot Tapping?
Hot tapping, sometimes called pressure tapping, is a method of creating a new connection on a pressurized pipeline without shutting the system down.
The process allows technicians to install a branch connection, valve, monitoring point, or future tie-in while the pipeline remains in service.
The general process includes:
• Engineering review and planning
• Installation of a specialized fitting and valve
• Cutting into the live pipeline using a hot tap machine
• Retrieving the coupon while maintaining pressure integrity
• Placing the new connection into service
This approach allows utilities to complete upgrades and modifications without interrupting water service to customers.
Why Hot Tapping PCCP Is Important
Working on PCCP infrastructure requires specialized knowledge, equipment, and procedures.
Because these pipelines are often large-diameter transmission mains, taking them out of service can create significant operational challenges. Hot tapping provides a practical solution by allowing modifications to be completed while the pipeline remains operational.
Benefits include:
• No system shutdown required
• Reduced disruption to customers and operations
• Lower project costs compared to major shutdowns
• Increased flexibility for future system expansion
• Improved ability to maintain critical infrastructure
For municipalities, this means essential upgrades can be completed while maintaining continuous water service.
Supporting Aging Water Infrastructure
Although PCCP is known for its durability, aging infrastructure can eventually require upgrades, repairs, new connections, or system expansions.
Utilities may need to:
• Add new transmission connections
• Install additional valves or chambers
• Expand existing systems
• Improve operational flexibility
• Connect new developments to existing infrastructure
Hot tapping allows these improvements to be completed efficiently while minimizing operational impacts.
Where We Work
Flow Control Solutions supports municipal, industrial, and utility infrastructure projects throughout Ontario and Eastern Canada.
Our team regularly serves municipalities, industrial facilities, and commercial properties across Ontario, including Milton, Oakville, Burlington, Pickering, Ajax, Whitby, Oshawa, Newmarket, Aurora, Barrie, Guelph, Cambridge, Brantford, St. Catharines, Niagara Falls, and surrounding communities.
We also support wastewater treatment plants, manufacturing facilities, power plants, hospitals, universities, and other critical infrastructure sites throughout Southern Ontario, the Greater Toronto Area (GTA), and nearby regions.
Need PCCP Hot Tapping Services?
Projects such as this 24x16 inch hot tap demonstrate how specialized live pipeline intervention techniques can help utilities maintain, expand, and improve critical infrastructure while keeping water systems operational.
Whether your project involves PCCP, BWCCP, steel pipe, ductile iron pipe, or other transmission infrastructure, the Flow Control Group has the experience, equipment, and expertise to help complete the work safely and efficiently.