Section 15008 STEEL PIPE – MORTAR-LINED AND MORTAR-COATED

Section 15008

STEEL PIPE – MORTAR-LINED AND MORTAR-COATED

1.1 THE REQUIREMENT

A. The CONTRACTOR shall furnish and install mortar-lined and mortar-coated steel pipeline, where indicated, complete and in place, in accordance with the requirements of the Contract Documents.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. The requirements of the following sections and divisions apply to the Work of this section. Other sections and divisions of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work.

1. Section 03600, Grout

2. Section 09800, Protective Coating

3. Section 15000, Piping, General

4. Section 15009, Steel Pipe - Fabricated Specials

1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS

A. All Work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following publications to the extent that the provisions thereof are not in conflict with other provisions of these Specifications.

B. Comply with the applicable editions of the following codes, regulations and standards.

1. Codes and Regulations:

ASME BPVC International Boiler and Pressure Vessel Code

CCR California Code of Regulations, Title 24, Building

Standards Code

NFPA 70 National Electrical Code (NEC)

NFPA 70E Standard for Electrical Safety in the Workplace

2. Industry Standards:

ASTM A 36 Standard Specification for Carbon Structural

Steel

ASTM A 139 Standard Specification for Electric-Fusion (Arc)- Welded Steel Pipe (NPS 4 and Over)

ASTM A 283 Standard Specification for Low and Intermediate

Tensile Strength Carbon Steel Plates

ASTM A 572 Standard Specification for High-Strength Low- Alloy Columbium-Vanadium Structural Steel

ASTM A 1011 Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High- Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM C 150 Standard Specification for Portland Cement ASTM E 94 Standard Guide for Radiographic Examination ASTM E 165 Standard Practice for Liquid Penetrant

Examination for General Industry

AWS D1.1 Structural Welding Code- Steel

AWWA C200 Steel Water Pipe - 6 in. (150 mm) and Larger

AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe - 4 In. (100 mm) and Larger - Shop Applied

AWWA C206 Field Welding of Steel Water Pipe

AWWA C208 Dimensions for Fabricated Steel Water Pipe

Fittings

AWWA C602 Cement-Mortar Lining of Water Pipelines in

Place - 4 in. (100 mm) and Larger

AWWA M11 Steel Water Pipe - A Guide for Design and

Installation

C. Comply with the applicable reference Specifications as directed in the General

Requirements and Additional General Requirements.

1.4 CONTRACTOR SUBMITTALS

A. Submittals shall be made in accordance with the General Requirements, Additional

General Requirements and as specified herein.

B. Shop Drawings: The CONTRACTOR shall submit shop drawings of pipe and fittings and the following supplemental requirements as applicable:

1. Joint and pipe/fitting wall construction details that indicate the type and thickness of cylinder; the position, type, size, and area of reinforcement; manufacturing tolerances; and all other pertinent information required for the manufacture of the product.

2. Fittings and specials details such as elbows, wyes, tees, outlets, connections, test bulkheads, and nozzles or other specials where shown that indicate amount and position of all reinforcement. All fittings and specials shall be properly reinforced to withstand the internal pressure, both circumferential and longitudinal, and the external loading conditions as indicated in the Contract Documents.

3. Design calculations of each critical section of pipe wall, girth joints, and specials - all sufficient to ascertain conformance of pipe and fittings with the Specifications.

4. Material lists and steel reinforcement schedules that include and describe all materials to be utilized.

5. Line layout and marking diagrams that indicate the specific number of each pipe and fitting, the location of each pipe, and the direction of each fitting in the completed line. In addition, the line layouts shall include the pipe station and invert elevation at all changes in grade or horizontal alignment; the station and invert elevation to which the bell end of each pipe will be laid; all elements of curves and bends, both in horizontal and vertical alignment; and the limits of each reach of restrained and/or welded joints, or of concrete encasement.

6. Full and complete information regarding location, type, size, and extent of all welds shall be shown on the shop drawings. The shop drawings shall distinguish between shop and field welds. Shop drawings shall indicate by welding symbols or sketches the details of the welded joints, and the preparation of parent metal required to make them. Joints or groups of joints in which welding sequence or technique is especially important shall be carefully controlled to minimize shrinkage stresses and distortion.

C. Certifications: The CONTRACTOR shall furnish a certified affidavit of compliance for all pipe and other products or materials furnished under this section of the Specifications, as specified in AWWA C200 and C205, respectively.

D. Physical and chemical properties of all steel:

1. Hydrostatic test reports.

2. Results of production weld tests.

E. All expenses incurred in making samples for certification of tests shall be borne by the CONTRACTOR.

F. Grooved joint couplings and fittings shall be shown on product submittals, and shall be specifically identified with the applicable style or series designation.

1.5 QUALITY ASSURANCE A. General:

1. Inspection: All pipes shall be subject to inspection at the place of manufacture in accordance with the provisions of AWWA C200 and C205, respectively, as supplemented by the requirements herein. The CONTRACTOR shall notify the ENGINEER in writing of the manufacturing starting date not less than 14 calendar days prior to the start of any phase of the pipe manufacture.

2. Tests: Except as modified herein, all materials used in the manufacture of the pipe shall be tested in accordance with the requirements of AWWA C200 and C205, as applicable.

a. Material Testing: The ENGINEER shall have the right at any time to call for and witness the making of test specimens by any welder in accordance with these Specifications. Any and all tests shall be at the CONTRACTOR's expense. The CONTRACTOR shall furnish the ENGINEER three certified copies of mill test reports. Mill test reports shall show results of the chemical and physical tests made on each melt of steel representing the steel plate furnished for the manufacture of the pipe.

b. After the joint configuration is completed and prior to lining with cement- mortar, each length of pipe of each diameter and pressure class shall be shop- tested and certified to a pressure of at least 80 percent of the yield strength of the pipe steel.

c. In addition to the tests required in AWWA C200, weld tests shall be conducted on each 5,000 feet of production welds and at any other times there is a change in the grade of steel, welding procedure, or welding equipment.

3. The CONTRACTOR shall perform said material tests at no additional cost to OCSD. The ENGINEER shall have the right to witness all testing conducted by the CONTRACTOR, provided that the CONTRACTOR's schedule is not delayed for the convenience of the ENGINEER.

4. In addition to those tests specifically required, the ENGINEER may request additional samples of any material including mixed concrete and lining and coating samples for testing by the ENGINEER. The additional samples shall be furnished at no additional cost to OCSD.

5. Specimen Plates: The ENGINEER may require the CONTRACTOR to furnish specimen plates of the steel to be used in the fabrication of the pipe. Specimen plates shall be large enough to provide the number of test specimens required. Should any test specimen fail to meet the requirements of the plate specification, a second specimen plate of the same heat number shall be furnished. Should any one test specimen from the second plate fail, then all plates furnished from the same heat number will be rejected. Tests of these specimens will be made by an independent laboratory accepted by the ENGINEER. The CONTRACTOR will be responsible for all expenses incurred in making the tests.

6. Required Tests: Specimen plates shall be tested as follows:

7. Reduced Section Tensile Test: The yield point and ultimate tensile strength shall not be less than the minimum of the specified tensile range of the plate used.

8. Guided Bend Test: Bend tests shall be performed on both root and face weld specimens. The specimen shall be bent cold without fracture 180 degrees around a pin or mandrel, having a diameter 3 times the thickness of the plate, and shall show an elongation of not less than 20 percent across the weld.

9. Radiographic Test: A 4-1/2-inch x 17-inch spot x-ray shall be taken at a location as directed by the ENGINEER. Procedures and interpretation shall be in accordance with the International Boiler and Pressure Vessel Code, Section VIII, Division 1, Part UW51, with the exception that ASTM E 94, Type I, industrial radiographic film shall be used.

10. Porosity: The maximum acceptable porosity shall be as set forth in Appendix IV

of the International Boiler and Pressure Vessel Code.

11. Retest of Welds: Should any of the tests taken from a shift's production fail to meet any of the requirements of these Specifications, one additional set of weld tests shall be made from each of the adjoining pipe sections. Retest of welds shall be performed at the CONTRACTOR's expense, and shall be made and accepted before beginning the next shift's production. Should any retest result in failure to meet any of the requirements of these Specifications, all pipe sections of that shift's production will be rejected.

12. Welding Procedures: Welding procedure specifications shall be furnished to the ENGINEER for acceptance prior to the welding of pipe. The welding procedure specifications shall specify, on a form equivalent to the ASME Welding Procedure form, the type of plate edge preparation, welding method, arc-voltage, arc-amperes, travel speed, wire size and type, flux type, and all other procedures necessary to make the weld.

13. Welding Requirements: All welding procedures used to fabricate pipe shall be prequalified under the provisions of AWS D1.1. Welding procedures shall be required for, but not necessarily limited to, longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections.

14. All Grooved products shall be of a single manufacturer. Gaskets for grooved systems shall be of the same manufacturer.

15. All castings used for coupling housings, fittings, valve bodies, etc., shall be date stamped for quality assurance and traceability.

B. CONTRACTOR Qualifications:

1. Welder Qualifications:

a. All welders and welding operators shall be qualified under the applicable provisions of the standard qualification procedure of the International Boiler and Pressure Vessel Code, Section IX.

b. All welding shall be done by skilled welders, welding operators, and tackers who have had adequate experience in the methods and materials to be used. Welders shall be qualified under the provisions of AWS D1.1 by an independent local, approved testing agency not more than 6 months prior to commencing work on the pipeline. Machines and electrodes similar to those used in the Work shall be used in qualification tests. The CONTRACTOR shall furnish all material and bear the expense of qualifying welders.

2. Comply with the requirements for the certifications, licenses, training, skills, experience, and other qualifications specified in Paragraph entitled “Cement-Mortar Lining for Shop Application” of Article entitled “Cement-Mortar Lining” of this Specification.

PART 2 - PRODUCTS

2.1 GENERAL

A. Mortar-lined and mortar-coated steel pipe shall conform to AWWA C200 and C205, subject to the following supplemental requirements. The pipe shall be of the diameter and class shown, shall be furnished complete with rubber gaskets or welded joints, as indicated in the Contract Documents, and all specials and bends shall be provided as required under the Contract Documents. For pipe 14 inches in diameter and larger, the inside diameter after lining shall not be less than the nominal diameter specified or shown. Pipe smaller than 14 inches in diameter may be furnished in standard outside diameters.

B. Markings: The CONTRACTOR shall legibly mark all pipes and specials in accordance with the laying schedule and marking diagram. Each pipe shall be numbered in sequence and said number shall appear on the laying schedule and marking diagram in its proper location for installation. All special pipe sections and fittings shall be marked at each end with top field centerline.

C. Handling and Storage: The pipe shall be handled by use of wide slings, padded cradles, or other devices, acceptable to the ENGINEER, designed and constructed to prevent damage to the pipe coating/exterior. The use of chains, hooks, or other equipment which might injure the pipe coating/exterior will not be permitted. Stockpiled pipe shall be suitably supported and shall be secured to prevent accidental rolling. All other pipe handling equipment and methods shall be acceptable to the ENGINEER.

D. The CONTRACTOR shall be fully liable for the cost of replacement or repair of pipe which is damaged.

E. Stockpiled pipe shall be supported on sand or earth berms free of rock exceeding 3 inches in diameter. The pipe shall not be rolled and shall be secured to prevent accidental rolling.

F. Strutting: Adequate strutting shall be provided on all specials, fittings, and straight pipe so as to avoid damage to the pipe and fittings during handling, storage, hauling, and installation. For mortar-lined or mortar-coated steel pipe, the following requirements shall apply:

1. The strutting shall be placed as soon as practicable after the mortar lining has been applied and shall remain in place while the pipe is loaded, transported, unloaded, installed and backfilled at the jobsite.

2. The strutting materials, size and spacing shall be adequate to support the backfill plus any greater loads which may be imposed by the backfilling and compaction equipment.

3. Any pipe damaged during handling, hauling, storage, or installation due to improper strutting shall be repaired or replaced.

4. The details of the strutting assembly shall be submitted for review by the

ENGINEER prior to the start of pipe manufacture.

G. Laying Lengths: Maximum pipe laying lengths shall be 40 feet with shorter lengths provided as required by the Drawings.

H. Offset Tolerances: For pipe wall thicknesses of 3/8 inch or less, the maximum radial offset (misalignment) for submerged arc and gas metal arc welded pipe shall be 0.1875 times the pipe wall thickness or 1/16 inch, whichever is larger. For pipe wall thickness of greater than 3/8 inch, the maximum radial offset shall be 0.1875 times the wall thickness or 5/32 inch, whichever is smaller.

I. Lining: The pipe lining shall have smooth dense interior surfaces and shall be free from fractures, excessive interior surface crazing and roughness.

J. Bonding and Electrical Conductivity: All unwelded pipe joints shall be bonded for electrical conductivity in accordance with the details shown.

K. Closures and Correction Pieces: Closures and correction pieces shall be provided as required so that closures may be made due to different headings in the pipe-laying operation and so that correction may be made to adjust the pipe laying to conform to pipe stationing shown on the Drawings. The locations of correction pieces and closure assemblies are shown on the Drawings. Any change in location or number of said items shall be acceptable to the ENGINEER.

2.2 MATERIALS

A. Cement: Cement for mortar shall conform to the requirements of AWWA C205; provided, that cement for mortar coating shall be Type II and mortar lining shall be Type II or V. A fly ash or pozzolan shall not be used as a cement replacement.

B. Steel for Cylinders and Fittings: Pipe manufactured under AWWA C200 shall be fabricated from sheet conforming to the requirements of ASTM A 1011, Grade 36, or from plate conforming to the requirements of ASTM A 36, A 283, Grades C or D, or A 572, Grade 42, or coil conforming to the requirements of ASTM A 139, Grades B or C. All longitudinal and girth seams, straight or spiral, shall be butt-welded using an approved electric-fusion-weld process.

C. All steel used for the fabrication of pipe shall have a maximum carbon content of 0.25 percent and shall have a minimum elongation of 22 percent in a 2-inch gauge length.

2.3 SPECIALS AND FITTINGS

A. Unless otherwise necessary under the requirements of the Contract Documents, all specials and fittings shall be in accordance with Section 15009, Steel Pipe - Fabricated Specials, and shall conform to the dimensions of AWWA C208.

2.4 DESIGN OF PIPE

A. General: The pipe furnished shall be steel pipe, mortar-lined and mortar-coated, with rubber-gasketed or field-welded joints as shown. The pipe shall consist of a steel cylinder, either shop-lined or lined-in-place with Portland cement-mortar with an exterior coating of cement-mortar.

B. The pipe shall be designed, manufactured, tested, inspected, and marked according to applicable requirements previously stated and, except as hereinafter modified, shall conform to AWWA C200.

C. Pipe Dimensions: The pipe shall be of the diameter and class shown. The minimum steel cylinder thickness for each pipe size shall be as specified or shown.

D. Fitting Dimensions: The fittings shall be of the diameter and class shown.

E. Joint Design: The standard field joint for steel pipe shall be either a single-welded lap joint or a rubber-gasketed joint for all pipe sizes up to and including diameter of 54 inches and shall be a single-welded lap joint for pipe sizes above diameters of 54 inches. Mechanically coupled or flanged joints shall be required where shown. Butt-strap joints shall be used only where required for closures or where shown. The joints furnished shall have the same or higher pressure rating as the abutting pipe. Gaskets shall be captured between the ends of the pipe to protect the ends of the exposed metal from corrosion.

F. Lap joints prepared for field welding shall be in accordance with AWWA C200. The method used to form, shape, and size bell ends shall be such that the physical properties of the steel are not substantially altered. Unless otherwise accepted by the ENGINEER, bell ends shall be formed by an expanding press or by being moved axially over a die in such a manner as to stretch the steel plate beyond its elastic limit to form a truly round bell of suitable diameter and shape. Facing surfaces of the bell and spigot shall be essentially parallel, but in no case shall the bell slope vary more than 2 degrees from the longitudinal axis of the pipe.

G. For bell-and-spigot ends with rubber gaskets, the clearance between the bells and spigots shall be such that, when combined with the gasket groove configuration and the gasket itself, will provide watertight joints under all operating conditions when properly installed. The CONTRACTOR shall require the pipe manufacturer to submit details complete with significant dimensions and tolerances and also to submit performance data indicating that the proposed joint has performed satisfactorily under similar conditions. In the absence of a history of field performance, the results of a test program shall be submitted. Unless otherwise accepted by the ENGINEER, bell ends shall be formed by an expanding press or by being moved axially over a die in such a manner as to stretch the steel plate beyond its elastic limit to form a truly round bell of suitable diameter and shape. No process will be permitted in which the bell is formed by rolling. Shop-applied interior linings and exterior coatings shall be held back from the ends of the pipe as shown or as otherwise acceptable to the ENGINEER.

H. Restrained Joints: Where shown restrained joints shall be field-welded joints, designs shall include considerations of stresses induced in the steel cylinder, the joint rings, and any field welds caused by thrust at bulkheads, bends, reducers, and line valves resulting from the design working pressure. For field welded joints, design stresses shall not exceed 50 percent of the specified minimum yield strength of the grade of steel utilized, or 16,500 pounds per inch, whichever is less, for the part being examined when longitudinal thrust is assumed to be uniformly distributed around the circumference of the joint. At the CONTRACTOR's option, the steel cylinder area may be progressively reduced from the point of maximum thrust to the end of the restrained length. All joints to be field welded for thrust restraint shall have the joint rings attached to the cylinder with double fillet welds.

2.5 CEMENT-MORTAR LINING

A. Cement-Mortar Lining for Shop Application: Except as otherwise provided herein, interior surfaces of all steel pipe, fittings, and specials shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with AWWA C205. During the lining operation and thereafter, the pipe shall be maintained in a round condition by suitable bracing or strutting. The lining machines shall be of a type that has been used successfully for similar work and shall be subject to ENGINEER's acceptance. Every precaution shall be taken to prevent damage to the lining. If lining is damaged or found faulty at delivery site, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications at no additional cost to OCSD.

B. The minimum lining thickness shall be as follows, with a tolerance of plus or minus 25 percent:

Nominal Pipe Diameter (inches)	Lining Thickness (inches)
4 – 12	5/16
13 – 16	3/8
17 – 24	1/2
Over 24	3/4

C. The pipe shall be left bare where field joints occur as shown. Ends of the linings shall be left square and uniform. Feathered or uneven edges will not be permitted.

D. Defective linings, as determined by the ENGINEER, shall be removed from the pipe wall and shall be replaced to the full thickness required. Defective linings shall be cut back to a square shoulder in order to avoid feather edged joints.

E. The progress of the application of mortar lining shall be regulated in order that all handwork, including the repair of defective areas is cured in accordance with the provisions of AWWA C205. Cement-mortar for patching shall be the same materials as the mortar for machine lining, except that a finer grading of sand and mortar richer in cement shall be used when field inspection indicates that such mix will improve the finished lining of the pipe.

G. Protection of Pipe Lining/Interior: For all pipe and fittings with plant-applied or cement-mortar linings, the CONTRACTOR shall provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special openings to prevent drying out of the lining. All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed.

2.6 EXTERIOR COATING OF PIPE

A. Exterior Coating of Exposed Piping: The exterior surfaces of pipe which will be exposed to the atmosphere inside structures or above ground shall be thoroughly cleaned and then given a shop coat of rust-inhibitive primer conforming to the requirements of Section 09800, Protective Coating.

B. Exterior Coating of Buried Piping: All pipe for buried service, including bumped heads, shall be coated with a 1.5-inch minimum thickness of reinforced cement-mortar coating. Unless otherwise shown on the Drawings, exterior surfaces of pipe or fittings passing through structure walls shall be cement-mortar coated from the center of the wall or from the wall flange to the end of the underground portion of pipe or fitting. The coating shall be reinforced with a spiral wire reinforcement or welded wire fabric in accordance with AWWA C205. The welded wire fabric shall be securely fastened to the pipe with welded clips or strips of steel. The wire spaced 2 inches on centers shall extend circumferentially around the pipe. The ends of reinforcement strips shall be lapped 4 inches and the free ends tied or looped to assure continuity of the reinforcement.

C. Coal-Tar Epoxy Protective Coating: The exterior surface of all mortar-coated pipe and fittings shall be protected with a minimum of 25-mil-thick 100 percent solids coal-tar epoxy coating, Carboline Bitumastic 300M, Tnemec Hi-Build Tnemec-Tar Series 46H-413

Or Equal. The coating may be applied to freshly placed, partially cured, or cured cement- mortar coating. Application shall be in accordance with the manufacturer's printed instructions.

2.7 PIPE APPURTENANCES

A. Pipe appurtenances shall be in accordance with Section 15000, Piping, General.

PART 3 - EXECUTION

3.1 INSTALLATION OF PIPE

A. Handling and Storage: All pipe, fittings, etc., shall be carefully handled and protected against damage to lining and coating/interior and exterior surfaces, impact shocks, and free fall. All pipe handling equipment shall be acceptable to the ENGINEER. Pipe shall not be placed directly on rough ground but shall be supported in a manner which will protect the pipe against injury whenever stored at the trench site or elsewhere. Pipe shall be handled and stored at the trench site in accordance with the requirements stated in Part 2 of this Specification. No pipe shall be installed when the lining or coating/interior or exterior surfaces show cracks that may be harmful as determined by the ENGINEER. Such damaged lining and coating/interior and exterior surfaces, shall be repaired, or a new undamaged pipe shall be furnished and installed.

B. All pipe damaged prior to Substantial Completion shall be repaired or replaced by the

CONTRACTOR.

C. The CONTRACTOR shall inspect each pipe and fitting to insure that there are no damaged portions of the pipe. The CONTRACTOR shall remove or smooth out any burrs, gouges, weld splatter or other small defects prior to laying the pipe.

D. Before placement of pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance, which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the Work.

E. Pipe Laying: When the pipe is being laid, it shall be turned and placed where possible, so that any slightly damaged portion will be on top. The damaged area shall be repaired for the protection of any exposed steel. All damaged areas shall be repaired using materials and methods acceptable to the ENGINEER.

F. Pipe shall be laid directly on the bedding material. No blocking will be permitted, and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent point loading at the bells or couplings. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coating on field joints.

G. Each section of pipe shall be laid in the order and position shown on the laying schedule. In laying pipe, it shall be laid to the setline and grade, within approximately one (1) inch plus or minus. On grades of zero slope, the intent is to lay to grade.

H. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the ENGINEER may change the alignment and/or the grades. Such change shall be made by the deflection of joints, by the use of bevel adapters, or by the use of additional fittings. However, in no case shall the deflection in the joint exceed the maximum deflection recommended by the pipe manufacturer. No joint shall be misfit any amount that will be detrimental to the strength and water tightness of the finished joint. In all cases the joint opening, before finishing with the protective mortar inside the pipe, shall be the controlling factor.

I. Except for short runs that may be permitted by the ENGINEER, pipes shall be laid uphill on grades exceeding 10 percent. Pipe that is laid on a downhill grade shall be blocked and held in place until sufficient support is furnished by the following pipe to prevent movement. All bends shall be properly installed as shown.

J. Pipe struts shall be left in place until backfilling operations have been completed for pipe 42 inches in diameter and larger. Struts in pipe smaller than 42 inches may be removed immediately after laying, provided, that the deflection of the pipe during and after backfilling does not exceed that specified. After the backfill has been placed, the struts shall be removed and shall remain the property of the CONTRACTOR.

K. Pipe and Specials Protection: The openings of all pipe and specials where the pipe and specials have been cement-mortar lined in the shop shall be protected with suitable bulkheads to maintain a moist atmosphere and to prevent unauthorized access by persons, animals, water or any undesirable substance. The bulkheads shall be so designed to prevent drying out of the interior of the pipe. The CONTRACTOR shall introduce water into the pipe to keep the mortar moist where moisture has been lost due to damaged bulkheads. At all times, means shall be provided to prevent the pipe from floating.

L. Pipe Cleanup: As pipe laying progresses, the CONTRACTOR shall keep the pipe interior free of all debris. The CONTRACTOR shall completely clean the interior of the pipe of all sand, dirt, mortar splatter and any other debris following completion of pipe laying, pointing of joints and any necessary interior repairs prior to testing and disinfecting the completed pipeline.

3.2 RUBBER GASKETED JOINTS

A. Rubber-Gasketed Joints: Immediately before jointing pipe, the spigot end of the pipe shall be thoroughly cleaned, and a clean rubber gasket lubricated with an approved vegetable-based lubricant shall be placed in the spigot groove. The volume of the gasket shall be "equalized" by moving a metal rod between the gasket and the spigot ring around the full circumference of the spigot ring. The bell of the pipe already in place shall be carefully cleaned and lubricated with a vegetable-based lubricant. The spigot of the pipe section shall then be inserted into the bell of the previously laid joint and telescoped into its proper position. Tilting of the pipe to insert the spigot into the bell will not be permitted. After the pipe units have been joined, a feeler gauge shall be inserted into the recess and moved around the periphery of the joint to detect any irregularity in the position of the rubber gasket. If the gasket cannot be "felt" all around, the joint shall be disassembled. If the gasket is undamaged, as determined by the ENGINEER, it may be reused, but only after the bell ring and gasket have been re-lubricated.

3.3 WELDED JOINTS

A. General: Field-welded joints shall be in accordance with AWWA C206.

B. Where exterior welds are performed, adequate space shall be provided for welding and inspection of the joints.

C. During installation of welded steel pipe in either straight alignment or on curves, the pipe shall be laid so that at any point around the circumference of the joint there is a minimum lap of 1/2 inch and a minimum space of 3/4 inch plus the thickness of the steel pipe wall between the spigot end of the pipe and the nearest tangent to a bell radius.

D. Butt straps, where used or required, shall be a minimum of 6 inches wide, the same thickness as the pipe wall and shall provide for a minimum of 3/4 inch lap at each pipe joint.

E. After the pipe and pipe joint are properly positioned in the trench, the length of pipe between joints shall be backfilled to at least one (1) foot above the top of the pipe. Care shall be exercised during the initial backfilling to prevent movement of the pipe and to prevent any backfill material from being deposited on the joint.

F. Prior to the beginning of the welding procedure, any tack welds used to position the pipe during laying shall be removed. Any annular space between the faying surfaces of the bell and spigot shall be equally distributed around the circumference of the joint by shimming, jacking, or other suitable means. The weld shall then be made in accordance with AWWA C206. Where more than one pass is required, each pass except the first and final one shall be peened to relieve shrinkage stresses; and all dirt, slag, and flux shall be removed before the succeeding bead is applied.

G. Qualifications of Procedures and Welders: All welding procedures used to install pipe shall be prequalified under provisions of AWS D1.1. Welding procedures shall be required for field attachments and field welded joints.

H. Joints: The pipe ends shall be cut straight on joints where butt straps are used for realignment, adjustment, or deflection, and fillet welds shall be made as shown on the Drawings.

I. Unless double fillet welds are shown on the Drawings, field-welded lap joints may, at the CONTRACTOR's option, be made on either the inside or the outside of the pipe.

3.4 GROOVED MECHANICAL JOINTS

A. ASTM A53B/A106B, roll or cut grooved as appropriate to pipe material, wall thickness, pressures and size. Pipe ends to be grooved conforming to ANSI/AWWA C606.

1. Couplings, 2 Inches to 12 Inches: Two ASTM A536 ductile iron housing segments, pressure-responsive synthetic rubber gasket (Grade to suit the intended service) and plated steel bolts and nuts.

a. Style HP-70 Rigid coupling is for use in high pressure service applications.

b. Rigid Type: Housings shall be cast to provide system support and hanging in accordance with ASME B31.1 and B31.9,

1) 2 Inches through 8 Inches: “Installation Ready” stab-on coupling designed for direct ‘stab’ installation onto grooved end pipe without prior field disassembly and no loose parts.

2) 1 Inch through 12 Inches: Standard rigid coupling.

c. Flexible Type: Use in locations where vibration isolation and stress relief are required. Flexible couplings may be used in lieu of flexible connectors for vibration isolation at equipment connections. A minimum of three couplings, for each connector, shall be placed in close proximity to the vibration source.

1) 2 Inches through 8 Inches: Coupling designed for direct installation onto grooved end pipe without prior field disassembly and no loose parts.

2) 1 Inch through 24 Inches: Standard flexible couplings.

3) 24 Inches to 42 Inches: Standard flexible multi-segment couplings.

4) Couplings, 14 Inches to 60 Inches: Two ASTM A536 ductile iron housing segments with a pressure-responsive synthetic rubber gasket of a Flush Seal design (Grade to suit the intended service) and plated steel bolts and nuts.

a) Rigid Type: Provides a rigid joint that corresponds with support spacing as defined by ASMB B31.1 and B31.9,

b) Flexible Type: Allows for linear and angular movement, vibration isolation and stress relief.

d. Flange Adapters, 2 Inches through 24 Inches: ASTM A536 ductile iron casting, flat faced, designed for incorporating flanged components with ANSI Class 125, 150, or 300 bolt-hole patterns to a grooved piping system.

3.5 JOINT COATING AND LINING

A. General: The interior and exterior joint recesses shall be thoroughly wiped clean and all water, loose scale, dirt and other foreign material shall be removed from the inside surface of the pipe. The cement for joint grout shall be non-shrink grout as specified in Section 03600, Grout.

B. Joint Coating: After the pipe has been laid and after sufficient backfill has been placed between the joints to hold the pipe securely in place, the outside annular space between pipe sections shall be completely filled with non-shrink grout formed by the use of polyethylene foam-lined fabric bands. The grout shall be thoroughly mixed with water to a consistency of thick cream. The grout space prior to filling shall be flushed with water so that the surface of the joint to be in contact with the grout will be thoroughly moistened when the grout is poured. The joint shall be filled with grout by pouring from one side only, and shall be rodded with a wire or other flexible rod or vibrated so that the grout completely fills the joint recess by moving down one side of the pipe, around the bottom of the pipe and up the opposite side. Pouring and rodding the grout shall be continued to allow completion of the filling of the entire joint recess in one operation. Care shall be taken to leave no unfilled space. Grouting of the outside joint spaces shall be kept as close behind the laying of the pipe as possible except that in no case shall grouting be closer than three joints of the pipe being laid.

C. Grout Bands (Diapers): The grout bands or heavy-duty diapers shall be polyethylene foam-lined fabric with steel strapping of sufficient strength to hold the fresh mortar, resist rodding of the mortar and allow excess water to escape. The foam plastic shall be 100 percent closed cell, chemically inert, insoluble in water and resistant to acids alkalis and solvents, and shall be BASF Sonneborn Sonolastic, Monmouth Rubber & Plastics Corp. Durafoam, Or Equal.

D. The fabric backing shall be cut and sewn into 9-inch-wide strips with slots for the steel strapping on the outer edges. The polyethylene foam shall be cut into strips

6 inches wide and slit to a thickness of 1/4 inch, which will expose a hollow or open cell surface on one side. The foam liner shall be attached to the fabric backing with the open or hollow cells facing towards the pipe. The foam strip shall cover the full interior circumference of the grout band with sufficient length to permit an 8-inch overlap of the foam at or near the top of the pipe joint. Splices to provide continuity of the material will be permitted. The polyethylene foam material shall be protected from direct sunlight.

E. The polyethylene foam-lined grout band shall be centered over the joint space with approximately equal widths extending over each pipe end and securely attached to the pipe with the steel straps. After filling the exterior joint space with non-shrink grout, the flaps shall be closed and overlapped in a manner that fully encloses the grout with polyethylene foam. The grout band shall remain in position on the pipe joint.

F. Joint Lining: After the backfill has been completed to final grade, the interior joint recess shall be filled with non-shrink grout of stiff consistency. The mortar shall be tightly packed into the joint recess and troweled flush with the interior surface, and all excess shall be removed. At no point shall there be an indentation or projection of the mortar exceeding 1/16 inch. With pipe smaller than 24 inches in diameter, before the spigot is inserted into the bell, the bell shall be daubed with non-shrink grout. The spigot end then shall be forced to the bottom of the bell and excess mortar on the inside of the joint shall be swabbed out.

3.6 INSTALLATION OF PIPE APPURTENANCES

A. Protection of Appurtenances: Where the joining pipe is concrete or coated with cement mortar, buried appurtenances shall be coated with a minimum thickness of one (1) inch of cement mortar having one part cement to not more than two (2) parts plaster sand. Following coating with cement mortar, the appurtenances shall be coated with coal- tar epoxy in accordance with Paragraph entitled "Coal-Tar Epoxy Protective Coating" of Part 2 herein.

B. Installation of Valves: All valves shall be handled in a manner to prevent any injury or damage to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation. The CONTRACTOR shall adjust all stem packing and operate each valve prior to installation to insure proper operation.

C. All buried valves shall be coated and protected in accordance with Section 09800, Protective Coating.

D. All valves shall be installed so that the valve stems are plumb and in the location shown.

E. Installation of Flanged Joints: Before the joint is assembled, the flange faces shall be thoroughly cleaned of all foreign material with a power wire brush. The gasket shall be centered and the connecting flanges drawn up watertight without unnecessarily stressing the flanges. All bolts shall be tightened in a progressive diametrically opposite sequence and torqued with a suitable, approved and calibrated torque wrench. All clamping torque shall be applied to the nuts only.

F. All buried flanges shall be coated and protected in accordance with Section 09800, Protective Coating.

G. Insulated Joints: Insulated joints and appurtenant features shall be made by the CONTRACTOR, as shown on the Drawings. The CONTRACTOR shall exercise special care when installing these joints to prevent electrical conductivity across the joint. After the insulated joint is completed, an electrical resistance test will be performed by the ENGINEER. Should the resistance test indicate a short circuit, the CONTRACTOR shall remove the insulating units to inspect for damages, replace all damaged portions, and reassemble the insulating joint. The insulated joint shall then be retested to assure proper insulation.

H. Flexible Coupled Joints: When installing flexible couplings, care shall be taken that the connecting pipe ends, couplings and gaskets are clean and free of all dirt and foreign matter with special attention being given to the contact surfaces of the pipe, gaskets and couplings. The couplings shall be assembled and installed in conformity with the recommendation and instruction of the coupling manufacturer.

I. Wrenches used in bolting couplings shall be of a type and size recommended by the coupling manufacturer. Coupling bolts shall be tightened so as to secure a uniform annular space between the follower rings and the body of the pipe with all bolts tightened approximately the same amount. Diametrically opposite bolts shall be tightened progressively and evenly. Final tightening shall be done with a suitable, approved and calibrated torque wrench set for the torque recommended by the coupling manufacturer. All clamping torque shall be applied to the nut only.

J. Upon completion of the coupled joint, the coupling and bare metal of the pipe shall be cleaned, primed and protected in accordance with Section 09800, Protective Coating.