SECTION ________

WELDED STEEL PIPE AND FITTINGS,

CEMENT MORTAR LINED AND TAPE COATED
WITH CEMENT MORTAR OVERCOAT

PART 1 – GENERAL

1.01 SUMMARY

A. Section includes requirements for furnishing and installing cement mortar lined and
coated welded steel pipe (WSP), and fittings. WSP and fittings shall be fabricated in
accordance with AWWA C200 and C208 for minimum fitting dimensions, lined in
accordance with C205 Standard and coated in accordance with C214 and C205
Standards, as supplemented by the requirements herein.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME)

1. B16.47, Large Diameter Steel Flanges, NPS 26 Through NPS 60

2. BPVC, Section VIII, Division 1, Rules for Construction of Pressure Vessels
3. BPVC, Section IX, Part QW, Qualification Standard for Welding and Brazing
Procedures, Welders, Brazers, and Welding and Brazing Operators
4. BPVC, Section V, Non-destructive Examination

B. American Society for Testing Materials (ASTM)

1. A36, Standard Specification for Carbon Structural Steel

2. A193, Standard Specification for Alloy-Steel and Stainless Steel Bolting for High
Temperature or High Pressure Service and Other Special Purpose Applications
3. A194, Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High
Pressure or High Temperature Service, or Both
4. A307, Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI
Tensile Strength
5. A370, Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
6. A563, Standard Specification for Carbon and Alloy Steel Nuts
7. A572, Standard Specification for High-Strength Low-Alloy Columbium-Vanadium
Structural Steel
8. A673, Standard Specification for Sampling Procedure for Impact Testing of
Structural Steel
9. A1011, 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
10. A1018, Standard Specification for Steel, Sheet and Strip, Heavy-Thickness Coils,
Hot-Rolled, Carbon, Commercial, Drawing, Structural, High-Strength Low-Alloy,
High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength
11. A1064, Standard Specification for Steel Wire and Welded Wire Reinforcement,
Plain and Deformed, for Concrete
12. C31, Standard Practice for Making and Curing Concrete Test Specimens in the
Field
13. C33, Standard Specification for Concrete Aggregates
14. C39, Standard Test Method for Compressive Strength of Cylindrical Concrete
Specimens
15. C150, Standard Specification for Portland Cement
16. C497, Standard Test Methods for Concrete Pipe, Manhole Sections, or Tile

WELDED STEEL PIPE AND FITTINGS, CEMENT MORTAR LINED (SECTION NO.)-1
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 17. E165, Liquid Penetrant Examination for General Industry
18. E340, Standard Test Method of Macroetching Metals and Alloys

C. American Water Works Association (AWWA)

1. C200, Steel Water Pipe – 6 In. (150 mm) and larger

2. C205, Cement–Mortar Protective Lining and Coating for Steel Water Pipe – 4 In.
(100 mm) and Larger – Shop Applied
3. C206, Field Welding of Steel Water Pipe
4. C207, Steel Pipe Flanges for Waterworks Service – Sizes 4 In. Through 144 In.
(100 mm Through 3,600 mm)
5. C208, Dimensions for Fabricated Steel Water Pipe Fittings
6. C209, Cold-Applied Tape Coatings for the Exterior of Special Sections,
Connections, and Fittings for Steel Water Pipelines.
7. C210, Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water
Pipelines
8. C214, Tape Coating Systems for the Exterior of Steel Water Pipelines
9. C216, Heat-Shrinkable, Cross-Linked Polyolefin Coatings for the Exterior of
Special Sections, Connections, and Fittings for Steel Water Pipelines
10. C604, Installation of Steel Water Pipe – 4 In. (100 mm) or Larger
11. M11 (Manual), Steel Pipe – A Guide for Design and Installation

D. American Welding Society (AWS)

1. D1.1, Structural Welding Code – Steel

2. A3.0, Standard Welding terms and Definitions
3. QC1, Standard for AWS Certification of Welding Inspectors

E. International Organization for Standardization (ISO)

1. 9001, Quality Management Systems – Requirements

F. National Association of Corrosion Engineers (NACE):

1. NACE RP-02-74, High Voltage Electrical Inspection of Pipeline Coatings Prior to

Installation.

G. NSF International (NSF)

1. 61, Drinking Water System Components – Health Effects

H. Society for Protective Coatings (SSPC):

1. SP-1, Solvent Cleaning.

2. SP-2, Hand Tool Cleaning.
3. SP-3, Power Tool Cleaning.
4. SP-6, Commercial Blast Cleaning.

I. Steel Pipe Fabricators Association (SPFA)

1. Quality Certification Program for Steel Pipe and Accessory Manufacturers

1.03 SUBMITTALS

A. Shop Drawings – The Contractor shall submit shop drawings of pipe and fittings in
accordance with the following requirements:

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 1. Joint and pipe/fitting wall construction details which indicate the type and
thickness of cylinder; the position, type, size, and area of reinforcement; coating
and lining holdbacks and all other pertinent information required for the
manufacture of the product.
2. Line layout shall be provided for the completed line. In addition, the line layouts
shall include: the pipe station and invert elevation at all changes in grade or
horizontal alignment; all elements of curves and bends, both in horizontal and
vertical alignment; and the limits within each reach of restrained and/or welded
joints or of concrete encasement.
3. Details and locations of closures for length adjustment and for construction
convenience.

B. Product Data

1. Pipe
a. Material data
b. Chemical and physical test reports for each heat of steel
2. Epoxy Coating (Exposed Pipe)
a. Technical data sheets
b. Color charts, if applicable
c. Manufacturer’s name, product name and number, and thickness

1.04 QUALITY ASSURANCE

A. Qualifications

1. Pipe fabrication process at the plant facility shall have current Steel Plate
Fabricators Association (SPFA) and ISO 9001 Certification.
2. The pipe manufacturer shall have a minimum of five (5) years continuous
experience in manufacturing the pipe and fittings specified for this project.
3. Qualifying experience for pipe and fittings fabrication shall include a minimum of
three projects completed or in current fabrication within the past five (5) years
with similar diameters and wall thickness.

B. Tests

1. All materials used in the manufacture of the pipe shall be tested in accordance
with the requirements of the applicable AWWA Standards. 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.

PART 2 – PRODUCTS

2.01 GENERAL

A. All steel cylinders, linings, and coatings for the main pipeline shall be completed by one
pipe manufacturer. Fittings and other miscellaneous pipe may be manufactured by
multiple suppliers.

B. Pipe and fittings shall be manufactured, tested, inspected, and marked to comply with
AWWA C200.

C. Pipe Dimensions

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 1. Unless shown otherwise, the diameter of the pipe shown on the drawings is the
finished inside diameter after application of the lining.
2. Wall thickness shall be nominal thickness as shown on Drawings. Where wall
thickness is not shown on plans, thickness shall be calculated per AWWA
Manual M11 or based on a minimum D/t = 240, whichever is greater.
3. Maximum length of standard sections shall be limited to 50 feet with shorter
lengths allowed as required for construction.
4. The minimum length of closure and correction pieces shall be four feet.

D. NSF Certification – All materials which may be in contact drinking water shall be in
compliance with NSF/ANSI 61, Drinking Water System Component.

2.02 STEEL CYLINDER

A. Steel:

1. Steel pipe and fittings shall be fabricated from steel sheet or coil that conforms
to:
a. Yield Strength: 36,000 psi minimum.
b. Coils: Steel coils shall be made from the continuous cast process or
continuous cast slabs conforming to the physical and chemical
characteristics of ASTM A1011 (for thickness up to 0.239 inch) or ASTM
A1018 (for thickness greater than 0.239 inch).
c. Fittings can also be fabricated from plate conforming to ASTM A36 or
ASTM A572 Grade 42.
2. Steel coils or plates shall be fine grained, fully killed, and manufactured using
continuous casting process. The maximum carbon content shall be 0.25%. The
maximum sulfur content shall not exceed 0.015 percent. The steel shall also
meet a maximum carbon equivalent of 0.45 as determined by the criteria
specified in AWS D1.1.
3. Steel pipe and fittings shall be fabricated and tested in conformance with AWWA
C200. The cylinders shall be fabricated by butt-welding spiral seam, girth seam
or longitudinal seam.
4. All welders and welding operators shall be qualified under the standard
qualification procedures of the ASME Boiler and Pressure Vessel Code, Section
IX or AWS D1.1.
5. An expanding press or swaging die shall form bells for the lap-welded field joints.

2.03 FITTINGS

A. Fittings

1. Wall thickness for fittings shall be reinforced to withstand either internal

pressures, both circumferential and longitudinal, or external loading conditions,
whichever is greater. In no case shall wall thickness of fittings be less than that
of adjacent pipe.
2. All fittings shall be manufactured in conformance with AWWA C200 and
minimum dimension requirements of AWWA C208. All fittings shall be designed
in accordance with AWWA Manual M11 for the design pressures and external
loads shown.
3. Elbows
a. Mitered angles of two adjacent segments of the bend shall be a
maximum of 22-1/2 degrees per AWWA C208.
b. Radii for bends shall have an R/D ratio greater or equal to 2.5, where “R”
is the radius of bend and “D” is the diameter of pipe, both in inches.

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 Cylinders for bends with an R/D ratio less than 2.5 shall be thickened if
required by AWWA Manual M11.
4. Outlets
a. Outlets shall be fabricated per dimensions in AWWA C208.
b. Fabricate collar or wrapper reinforcement for outlets required by AWWA
Manual M11 using same steel as specified for steel cylinder.
5. Closure Pieces
a. Closure pieces include straight pipe fabricated using same steel as
specified for steel cylinder and buttstraps.
b. Buttstraps shall be same thickness as steel cylinder.
6. Beveled Pipe – Bell End
a. Beveled ends shall be fabricated with a miter-cut on bell end of pipe per
AWWA C208.
b. Bell ends shall be expanded square with face of miter cut.
c. Beveled ends shall maintain bell to spigot tolerances.
d. The maximum bevel angle shall not exceed 5 degrees.
7. Beveled Pipe – Spigot End
a. Beveled ends shall be fabricated with a miter-cut on the spigot end using
Carnegie spigot rings.
b. Beveled ends shall maintain bell to spigot tolerances.
c. The maximum bevel angle shall not exceed 5 degrees.
8. All fittings shall be furnished with the same joint options as for restrained joints.

B. Flanges

1. Flanges shall be Class D, E, or F ring flanges for internal pressures up to 150

psi, 275 psi, and 300 psi, respectively in accordance with AWWA C207. Flanges
shall be in conformance with ASME B16.47 for higher pressure applications.
2. Flange bolting shall be carbon steel with bolts and nuts in accordance with ASTM
A193 Grade B7 and ASTM A194 Grade 2H, respectively.

C. Blind Flanges

1. Blind flanges shall be in accordance with the appropriate standard as determined

by the maximum operating pressure.
2. Class of blind flange shall match that of mating ring flange.

D. Outlets for Welding Leads or Pass Holes

1. The number and locations of outlets for welding leads or pass holes, if used,
shall be determined by installation contractor and shall be indicated on the Shop
Drawings.
2. Plugs used for closing the weld lead outlets shall be suitable for the internal
pressure and allow zero leakage. Weld plugs closed after completion of work.

2.04 JOINTS

A. General – Single lap welded, double lap welded or rubber gasketed joints shall be
provided where shown or required. Mechanically coupled or flanged joints shall be
required where shown. Butt-strap joints shall be used only where required for closures or
where shown. Double welded lap joints and butt-strap joints shall be tapped and drilled for
air testing in accordance with AWWA C206.

B. Bell-and-Spigot with Rubber Gaskets

1. Manufactured in accordance with AWWA C200 and Manual M11.

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 2. 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, it will provide watertight joints under all operating conditions when
properly installed.
3. Unless otherwise approved 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 cylinder beyond its elastic limit to form a truly round bell of suitable
diameter and shape.

C. Single or Double Welded Lap Joints

1. Joints prepared for field welding shall be in accordance with AWWA C200.
Minimum lap shall be equal to 5 times the cylinder thickness, but not less than 2-
inches. For double lap weld joints which are required to be air tested, use 3-inches
minimum lap.
2. 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 approved 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.

D. Butt-Strap Joints

1. Minimum lap shall be equal to 5 times the cylinder thickness, but not less than 2-
inches. For double lap weld joints which are required to be air tested, use 3-inches
minimum lap.

E. Full-Penetration Butt Welds

1. Prepare ends as required by AWWA C200.

F. Restrained Joints

1. Where shown, restrained joints shall be field welded.

2. For field welded joints at design working pressure, longitudinal design stresses
shall not exceed 50 percent of the specified minimum yield strength of the grade of
steel utilized.
3. or field welded joints at design transient/test pressure, longitudinal design
stresses shall not exceed 67 percent of the specified minimum yield strength of the
grade of steel utilized.

2.05 LINING

A. Cement Mortar Lining

1. Unless otherwise shown or specified in the Contract Documents, interior surfaces

of all pipe and fittings shall be lined with shop-applied cement mortar lining in
conformance with AWWA C205. The nominal lining thickness shall be per Table
1. Greater thicknesses may be used to maintain nominal pipe ID.
2. The steel cylinders shall be cleaned at the time of manufacture to remove loose
or other foreign matter that could interfere with the bonding of the cement mortar
to the steel.
3. Cement shall conform to the requirements of AWWA C205 and shall be ASTM
C150, Type II or Type V. Fly ash or pozzolan shall not be used as a cement
replacement.

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 4. Cement mortar lining cracks shall be classified and repaired in conformance with
AWWA C205.

2.06 COATING

A. Tape Coating with Cement Mortar Overcoat – Buried Pipe

1. All pipe for buried service shall be coated with a cold-applied, multilayer,
polyethylene tape coating system with a cement mortar overcoat.
2. The cold-applied, multilayer, polyethylene tape coating system shall compromise
of two layers with a total nominal thickness of 50 mils conforming to AWWA
C214. Buried dielectrically coated pipe and fittings passing through a structure
wall or floor shall be coated for a minimum of 2 inches beyond the interior wall.
3. The cement mortar overcoat shall have a nominal coating thickness of 3/4-inch
conforming to AWWA C205.

B. Epoxy Coating – Exposed Pipe

1. Exposed pipe includes above ground pipe and pipe in vaults.

2. Exposed pipe shall be coated with a minimum of 16 mils of epoxy coating per
AWWA C210.

2.07 PIPE YARDING

A. After primary cure of lining, manufacturer shall furnish and install wood stulls and wedges
for shipping, handling, and storage. The contractor may need to install additional bracing
as required by the installation method or other field conditions.

B. After installation of bracing, cover both pipe ends and any openings with
polyethylene or other suitable caps, which shall be maintained until delivery to the jobsite.

2.08 SOURCE QUALITY CONTROL

A. Conduct testing to evaluate physical properties of pipe components in accordance with

the requirements of AWWA C200, C205, and C214.

1. Provide copies of test results showing compliance with referenced standard:

a. Steel test reports.
b. Submit mill test certificates identifying chemical and physical properties
of each lot of steel delivered.
c. Mortar cylinder test reports.
d. Any other test reports required.
2. Certificates of Compliance.

B. Provide each pipe, fitting, or appurtenance with a clear, permanent, waterproof, marked
identification on the spigot end of the pipe. Markings shall include the following:

1. Identify each pipe, special, and fitting by the piece number shown on the pipeline
layout schedule corresponding to position along the pipeline.
2. Size and design class of pipe as indicated on the pipeline layout schedule
3. Date of manufacture
4. Manufacturer’s trademark or name
5. Bends: field top mark, long side of bend, deflection angle
6. Beveled pipe: field top mark, long side of bevel, bevel degree
7. Special notations and tagging of special items for location on pipeline

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 C. Tests of Shop Production Welds

1. Perform tests (tension, bend, and etching tests) of production welds in

conformance with AWWA C200.

D. Shop Hydrostatic Test

1. The pipe manufacturer shall perform hydrostatic pressure tests for straight pipe
in accordance with AWWA C200.
2. For fittings, no further test will be required of welded seams which have been
already hydrostatically tested. All welded seams not previously tested shall be
tested either by the visual inspection or the dye penetrant method at the option of
the manufacturer. Air soap testing of collars, wrappers, and flanges may be
performed by applying 40 psi of air, or other satisfactory gas, into the annular
space between fillet welds that must hold pressure for a period of 5 minutes.

PART 3 – EXECUTION

3.01 GENERAL

A. Delivery, Handling, and Storage

1. 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. Pipe
shall not be placed directly on rough ground but shall be supported at 1/3 and 2/3
points along the length of the pipe section in a manner which will protect the pipe
against injury whenever stored at the trench site or elsewhere. No pipe shall be
installed where the lining or coating surfaces show cracks or other defects that
may be harmful as determined by the Engineer. Such damaged lining and/or
coating surfaces shall be repaired, or a new undamaged pipe shall be furnished
and installed.
2. Repair or replace damaged pipe fittings and appurtenances.
3. 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.
4. 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 until final
fit-up.
5. Lifting points shall be no closer than the 1/3 and 2/3 points along the length of the
section. Select lifting points that do not result in damage to the pipe. The pipe
shall be handled using two minimum 12-inch wide belt slings attached to a
spreader bar, unless otherwise approved by the Engineer. Do not use cable
slings or chains. Avoid damage to coating and lining.
6. Stulls installed by manufacturer are for storage, handling and delivery, only. Add
additional stulls if required for backfilling operations. Stulls shall be left in place
until the joints at each end have been completed and embedment and backfill for
the section have been placed to at least 12 inches above the top of the pipe.
Final inspection, repair, and checking of interior lining shall be performed after
the struts have been removed.
7. Keep plastics caps over the openings of pipe and fittings to prevent excessive
dryness of the cement-mortar lining. Maintain caps by fixing any tears or
replacing damaged caps. Introduce water into the pipe to keep the mortar moist
where moisture has been lost due to damaged caps.

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 B. Pipe Manufacturer’s Field Service Representative

1. The Pipe Manufacturer shall provide a qualified Field Service Representative,

who shall be available to be on the project site upon proper notice.
2. Experience – The Field Service Representative, who shall be an employee of the
Pipe Manufacturer, shall have experience as a representative of the
manufacturer in the area of providing such field services.
3. Onsite Services – The Contractor shall ensure the manufacturer’s Field Service
Representative will be onsite to provide the following services:
a. Perform initial pipe installation training.
b. Evaluate problems and provide advice during pipe installation.

3.02 PIPE INSTALLATION

A. General

1. Pipe shall be installed per AWWA C604 and the Contract Documents.
2. Each section of pipe shall be laid in the order and position shown on the laying
schedule. All fittings shall be properly installed as shown.
3. Except for short runs which may be permitted by the Engineer, pipes shall be laid
uphill on grades exceeding 10 percent. Pipe which 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.
4. Make minor field adjustments by pulling standard joints.

B. Trenching and embedment of buried piping shall conform to the details indicated on the
Drawings. Do not install pipe in the trench until groundwater has been mitigated and the
pipe subgrade has been properly stabilized.

C. Placement of Pipe in Trench

1. Pipe shall be laid directly on the imported 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.
2. Where CLSM is to be used for pipe bedding or where allowed by the Engineer,
pipe may be installed directly on moist sand bag supports. Place sand bag
supports to provide at least 6-inches of CLSM below bottom of pipe. Space
supports at a maximum interval of 8 feet and one set within 3 feet on both sides
of each joint. Provide additional sand bags as needed to support pipe on line
and grade.
3. Excavations shall be made as needed to facilitate removal of handling devices
after the pipe is laid.
4. 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.
5. 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 (pulling) of joints, adapters, or by the use
of additional fittings. No joint shall be misfit any amount which 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, or prior to
applying in-place mortar lining, shall be the controlling factor.
6. At all times, means shall be provided to prevent the pipe from floating. Closely
follow the installation and jointing of steel pipe with pipe embedment and

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 backfilling to prevent flotation of the pipe by water and longitudinal movement
caused by thermal expansion or contraction of the pipe. The backfill adjacent to
field joints may be temporarily omitted to provide adequate space for field coating
the joints.
7. Check each joint, including restrained joints, as recommended by the pipe
manufacturer’s field service representative, to determine that the joint and the
restraints are installed properly.
8. Whenever pipe laying is stopped, seal the open end of the line with a watertight
plug. Water shall be removed from the trench prior to removing the plug.
9. Cold Weather Protection: No pipe shall be installed upon a foundation into which
frost has penetrated or at any time that there is a danger of the formation of ice
or penetration of frost at the bottom of the excavation. No pipe shall be laid
unless it can be established that the trench will be backfilled before the formation
of ice and frost occurs.
10. Pipe Deflection: After completion of backfilling and before acceptance of the
Work, test for excessive deflection on pipes by measuring the actual inside
vertical diameter. Deflection measurements will be made by the Engineer. Pipe
diametrical deflection shall not exceed those values recommended in AWWA
M11.
11. 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.

3.03 PIPE JOINTING

A. Rubber Gasketed Joints

1. 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.
2. 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.
3. 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.
4. After the pipe units have been joined, a feeler gage 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. The gasket position shall be checked again with a feeler gage after
pipe has been relaid.

B. Welded Joints

1. Welds shall be sound and free from embedded scale or slag, shall have tensile
strength across the weld not less than that of the thinner of the connected
sections, and shall be watertight. Field-welded joints shall be either welded butt
strap joints, welded butt joints, or welded lap joints and shall conform to
AWS D1.1, AWWA C206, approved welding procedures, and referenced welding
codes.

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 2. Determine preheat and interpass temperature requirements for unlisted base
metals according to AWS D1.1, Annex XI guideline on Alternative Methods for
Determining Preheat.
3. Weld defects shall be removed to sound metal and repaired in accordance with
applicable welding codes.
4. Where exterior welds are performed, provide adequate space for welding and
inspection of the joints.
5. When fitting up the ends of pipe to be welded or fitting butt-strap pieces, minor
jacking or clamping will be allowed. Cold working the metal with sledges or
localized application of heat and working the metal with sledges will not be
allowed. If field displacement of joints, where butt strap joints are indicated, does
not allow proper fit up with the tolerances indicated, special closure butt straps or
mitered pieces shall be shop fabricated and installed.
6. 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 per AWWA C206.
7. 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 foot above the top of the
pipe. Care shall be exercised during the initial backfilling to prevent movement of
the pipe.
8. Control of Temperature Stresses – Control temperature stresses in accordance
with AWWA C206, the submitted and accepted temperature stress control
submittal, and these Specifications. Provide special temperature control lap
joints at intervals of 500 feet or less, unless otherwise approved by the Engineer.
9. Prior to beginning the welding procedure, remove any tack welds or joint stops
used to position the pipe during laying. Equally distribute any annular space
between the fraying surfaces of the bell and spigot 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.
10. The pipe ends shall be cut straight on joints where butt straps are used for
realignment, adjustment, or deflection.
11. Field-welded lap joints shall be full fillet welds on the inside and/or outside of the
joint.
12. Welded Butt Joints: Where used or required, shall be complete joint penetration
and as indicated.
13. Welded Butt Straps: Where used or required, shall be a minimum of 6 inches
wide and shall provide for a minimum of 2-inch lap at each pipe joint.

C. Inspection and Testing of Field Welded Joints

1. All field welds shall be tested per AWWA C206.

2. All welds that are defective shall be repaired by the Contractor to meet the
requirements of the applicable sections of these specifications. Defects in welds
or defective welds shall be removed to sound metal, and that section of the joint
shall then be re-welded. After the repair is made, the joint shall be checked by
repeating the original test procedure. Welds deficient in size shall be repaired by
adding weld metal.

D. Flanged Joints

1. 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

WELDED STEEL PIPE AND FITTINGS, CEMENT MORTAR LINED (SECTION NO.)-11
AND TAPE COATED WITH CEMENT MORTAR OVERCOAT
VER. 1.0 – 07-01-15
 connecting flanges drawn up watertight without unnecessarily stressing the
flanges.
2. All bolts shall be tightened in a progressive diametrically opposite sequence and
torqued with a suitable, approved and calibrated torque wrench. Torque values
shall be as recommended by the pipe manufacturer. All clamping torque shall be
applied to the nuts only.
3. All buried flanges shall be coated with a rust inhibitor.

E. Insulated Joints

1. Insulated joints and appurtenant features shall be made by the Contractor as

shown. Exercise special care to prevent electrical conductivity across the joint.
Conduct an electrical resistance test after the insulated joint is completed.
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.

3.04 LINING AND COATING OF FIELD JOINTS

A. 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.

B. Lining of Field Joints

1. Protect the exposed interior steel joint surfaces by pointing with cement mortar in
accordance with AWWA C205.
2. Cement mortar for joint lining shall consist of one part cement (Type __) per
ASTM C150 to two parts sand and sufficient water for dry-pack consistency.

C. Coating of Field Joints

1. After completion of the joint assembly, wrap the joints with heat-shrinkable,
cross-linked shrink sleeves in accordance with AWWA C216 and manufacturer’s
instructions.

3.05 PIPELINE CLOSURES

A. Field trimming of pipe may be done only when approved by the Engineer.

B. Use pipeline closures to unite sections of the pipeline laid from opposite directions and to
adjust the field length of the pipeline to meet structures and other pipelines.

C. Connect closure section to pipeline using butt straps as shown on the Drawings.

D. Cement mortar line closures to a mortar thickness at least equal to the adjoining pipe
sections. Where more than a 4-inch wide strip of mortar is required, place welded wire
reinforcement over the exposed steel. Steel-trowel finish the interior mortar to match
adjoining mortar lined pipe sections.

E. After completion of the closure, wrap the joint with heat-shrinkable, cross-linked shrink
sleeves in accordance with AWWA C216.

3.06 HYDROSTATIC TESTING

WELDED STEEL PIPE AND FITTINGS, CEMENT MORTAR LINED (SECTION NO.)-12
AND TAPE COATED WITH CEMENT MORTAR OVERCOAT
VER. 1.0 – 07-01-15
 A. General

1. Test piping after installation in accordance with AWWA Manual M11 and as
specified herein.
2. Test piping with water. Contractor shall furnish all labor and material, and all
water required for pressure testing and obtain all permits for test water discharge
at no additional cost to the Engineer. All test water shall be potable. No other
water shall be allowed in the pipe.
3. All pressure pipelines shall be tested. All testing operations shall be performed in
the presence of the Engineer.
4. Prior to hydrostatic testing, all pipelines shall be thoroughly cleaned and flushed
or blown out as appropriate. The Contractor shall test all pipelines either in
sections or as a unit.
5. The test shall be made by closing valves when available, or by placing temporary
bulkheads in the pipe and filling the line slowly with water. The Contractor shall
be responsible for ascertaining that all test bulkheads are suitably restrained to
resist the thrust of the test pressure without damage to, or movement of, the
adjacent pipe. Any unharnessed sleeve-type couplings, expansion joints, or other
sliding joints shall be restrained or suitably anchored prior to the test, to avoid
movement and damage to piping and equipment.
6. The Contractor shall provide sufficient temporary air tappings in the pipelines to
allow for evacuation of all entrapped air in each pipe segment to be tested. After
completion of the tests, such taps shall be permanently plugged. Care shall be
taken to see that all air vents are open during filling.
7. The pipeline shall be filled at a rate which will not cause any surges or exceed
the rate at which the air can be released through the air valves at a reasonable
velocity and all the air within the pipeline shall be properly purged. Maximum
filling velocity shall not exceed 0.50 feet per second, calculated based on full
area of pipe.

B. Pressure Test Requirements

1. Test pipeline to pressure recommended in AWWA M11.

2. Duration of pressure test: 2 hours.
3. The pressure test shall begin after the pipe has been filled with water and
allowed to stand under a slight pressure for a minimum of 48 hours to allow the
mortar lining to absorb what water it will and to allow the escape of air from any
air pockets. During this period, bulkheads, valves, and connections shall be
examined for leaks. If leaks are found, corrective measures satisfactory to the
Engineer shall be taken.
4. All visible leaks shall be repaired in a manner acceptable to the Engineer.
5. The allowable leakage rate shall not exceed ten (10) gallons per inch of diameter
per mile of pipeline per 24-hour period.
6. If the pipeline fails to pass the leakage test, the Contractor shall determine the
cause of the leakage, shall take corrective measures necessary to repair the
leaks, and shall again test the pipeline. This shall continue until the pipeline
passes the test.

END OF SECTION

WELDED STEEL PIPE AND FITTINGS, CEMENT MORTAR LINED (SECTION NO.)-13
AND TAPE COATED WITH CEMENT MORTAR OVERCOAT
VER. 1.0 – 07-01-15