Section 10

Underground and Embedded Piping Systems

UNDERGROUND PIPING

Underground piping is installed early in the project concurrently with civil foundations, earth work,
and electrical duct banks. Prior to beginning any excavation, existing buried commodities must
be reviewed to identify any potential obstructions. In instances where underground obstructions
cannot be avoided, excavation is performed manually or by the use of an air spade or hydrostatic
excavation system.

Excavation activities at operating facilities must be done only with the approval and close
involvement of plant operations and maintenance personnel. Excavation permits documenting
verification of existing commodity locations is normally required at all Bechtel construction sites.

Typical buried piping systems include:

 Fire protection
 Storm water sewers
 Potable water
 Natural gas
 Drainage piping

Fire protection is usually installed in a ring around the site to encompass the work area with a
header provided for all branches. The system must meet National Fire Protection Codes (NFPA)
and any local code requirements. The fire protection system equipment is supplied with
Underwriters Laboratory (UL) or Factory Mutual (FM) approval and must be so identified.

Depending on the type of piping system used, thrust blocks are installed for fire protection piping
at changes in direction, at tees, and at fire hydrants . Thrust blocks provide lateral restraint to
waterhammer and loads imposed by water flow. They are usually constructed of poured concrete
or concrete block constructed at desired locations after the piping system has been installed and
tested.

Storm Water and Drainage systems are installed at the same time as the fire protection system,
but require that the slope and elevation of the pipe be maintained and checked per the design
drawings prior to the backfill of the trench. Specified slope tolerances ensure the completed
system will maintain a self-cleaning fluid velocity and prevent the formation of traps and pockets.
The pipe material used for drainage systems may include pre-cast concrete, carbon steel, PVC,
or HDPE.

Coatings

Coating and lining systems provide excellent corrosion resistance properties and provide the
required smoothness to maintain flow capacity in the line. External coating systems protect steel
pipe by electrically insulating the coated pipe from the environment. When reinforced, the
coatings provide additional resistance to physical damage.

© 1996 Bechtel Corp. Piping/Mechanical Handbook 10-1

Section 10 Underground and Embedded Piping Systems

Common types of underground pipe coatings include:

 Coal-Tar Enamel
 Coal-Tar Epoxy
 Hot or Cold Epoxy Enamel Applied Tape

Coal-Tar enamel is typically applied in a shop environment. To apply the coating, hot enamel is
placed on the pipe wall surface and then the exterior coating is covered with paint or kraft paper.
Pipe shipped or stored at cold temperatures (typically encountered in the winter months) may
require a different coating system since the coal-tar enamel is subject to cracking in cold weather.

The Cold-Applied Tape process uses a cold primer and cold-applied tape. This can be used on
steel pipe for soil conditions. Tape with both polyvinyl chloride and polyethylene backings are
used. Thickness of tapes vary depending on the overlap and performance condition
requirements including where mechanical damage may occur due to handling and construction.

Testing of underground piping coatings is done with high voltage, low amperage holiday detectors
and is done immediately prior to backfilling.

Cathodic Protection

This method of protecting underground piping is typically provided when soil resistivity is low.
Pipe protection can be provided by either sacrificial anodes or an impressed current system. This
will help prevent accelerated corrosion of the underground system.

Cathodic protection systems are usually specialized installations and their design, installation, and
inspection are best left to specialists.

EMBEDDED PIPING

The installation of piping systems embedded in concrete should comply with the following
installation guidelines:
 Verify top of concrete elevations for floor drains, equipment drains, and clean-outs to ensure
embedded piping is properly positioned. Pay particular attention to floor slope requirements.
 Piping that penetrates slabs or walls must be extended beyond the concrete surface to allow
sufficient space to make up the next joint.
 The embedded portion of piping systems must be hydrostatically tested prior to concrete
placement.
 Do not embed mechanical joints in concrete unless specifically required by the design
drawings.
 Check project requirements for cutting or modifying reinforcing bar and for added reinforcing
at penetrations prior to embedded piping installation.
 As-built embedded piping systems prior to concrete placement.
 Do not secure embedded piping by welding to other piping or to reinforcing bar.

10-2 Piping/Mechanical Handbook 1996:Rev.2

 Ensure that embedded piping is adequately secured so that it will not move during the
concrete placement. See Figures 10-1 through 10-6 for typical support details.

FIGURE 10-1 - TYPE A - SUPPORT ANCHORED FIGURE 10-2 - TYPE B - PIPE CLAMP
TO MUD MAT SUPPORTED FROM REBAR MAT

FIGURE 10-3 - TYPE C - PIPE SECURED TO FIGURE 10-4 - TYPE D - SUPPORT PIPE FROM
REBAR MAT WITH TIE WIRE REBAR SUPPORT FRAMEWORK

FIGURE 10-5 - TYPE E - PROVIDE SUPPORT FIGURE 10-6 - TYPE F - PROVIDE CLAMP AND
FRAME FOR LARGE PIPING ROD TO SUPPORT PIPE

© 1996 Bechtel Corp. Piping/Mechanical Handbook 10-3

Section 10 Underground and Embedded Piping Systems

 Provide sufficient restraint for the piping system to resist floating, movement, or deflection of
the piping resulting from the concrete placement buoyant forces. Table 10-1 provides
approximate buoyant forces and allowable pipe spans. The suggested allowable spans
calculated based on:
1/2
L = [SaZ/1.2F]

Where the following applies to the pipe in question:

Sa = Allowable Stress (1500 psi)
3
Z = Section Modulus (in )
F = Greater of Wt or Br (lb/ft)
L = Span (ft)

 Protect all piping openings prior to the concrete placement to prevent concrete from entering
the system. Plastic or metal caps, expandable test plugs, or wood or metal blind flanges are
acceptable. Cloth or paper is not acceptable.
 Protect valves located in the vicinity of the concrete placement by providing a wooden or
plastic enclosure around the valve.
 Make sure the embedded piping is properly coated per project requirements prior to concrete
placement.
 All embedded piping testing and welding documentation must be complete prior to the
concrete placement.
 If system connects to a piece of equipment nearby, check equipment location and
configuration drawings.

10-4 Piping/Mechanical Handbook 1996:Rev.2

© 1996 Bechtel Corp. Piping/Mechanical Handbook 10-5
Section 10 Underground and Embedded Piping Systems

10-6 Piping/Mechanical Handbook 1996:Rev.2

 TABLE 10-1
SUGGESTED MAXIMUM SPANS FOR EMBEDDED CARBON STEEL PIPING

Pipe Size Schedule Wt Br L

(inches) (lbs/ft) (lbs/ft) (feet)
1" 40 (STD) 2.05 N/A 9'
80 (XS) 2.48 N/A 9'
1 1/2" 40 (STD) 3.60 0.24 11'
80 (XS) 4.40 N/A 11'
2" 40 (STD) 5.10 1.00 12'
80 (XS) 6.30 N/A 12'
2 1/2” 10S 5.89 3.23 12'
40 (STD) 7.86 0.97 13'
80 (XS) 9.50 N/A 13'
3" 10S 7.94 5.69 13’
40 (STD) 10.78 2.44 14’
80 (XS) 13.11 N/A 15’
4” 10S 11.78 10.95 14’
40 (STD) 16.30 5.77 16’
80 (XS) 19.96 1.58 16’
6” 10S 23.77 26.62 14’
40 (STD) 31.48 16.93 18’
80 (XS) 39.86 7.33 20’
8” 10S 36.97 47.46 15’
40 (STD) 50.30 32.27 20’
80 (XS) 63.20 17.46 22’
10” 10S 55.54 75.89 15’
40 (STD) 74.70 54.04 22’
60 (XS) 87.10 39.84 24’
12” 10S 76.33 108.79 16’
STD 98.60 83.36 24’
XS 112.30 67.56 25’
14” 10 98.70 123.70 19’
30 (STD) 114.30 105.80 24’
XS 129.60 88.26 26’
16” 10 123.80 167.30 19’
30 (STD) 141.70 146.80 24’
40 (XS) 159.30 126.60 27’
18” 10 152.00 217.70 19’
STD 171.80 194.50 24’
XS 191.80 171.60 28’
20” 10 182.00 274.60 19’
20 (STD) 204.60 248.60 24’
30 (XS) 226.80 223.20 28’
22” 10 215.50 337.90 18’
20 (STD) 240.30 309.40 23’
30 (XS) 265.20 281.00 28’
24” 10 251.20 407.90 18’
20 (STD) 278.40 376.70 23’
XS 304.90 346.20 28’

WHERE: Wt = Total Weight of Pipe and Water in Pipe (lbs/ft)

Br = Resultant Buoyant Force Based on 150 lb/ft3 Concrete (Buoyant Force Minus Weight of Empty Pipe) (lbs/ft)
L = Suggested Maximum Span (ft)
NOTES: 1. Spans are based on maximum combined bending and shear stress of 1500 psi and a maximum mid span
deflection of 0.1".
2. This table not intended to limit placement of supports wherever special conditions exist.

© 1996 Bechtel Corp. Piping/Mechanical Handbook 10-7