13112_Impressed_Current_Cathodic_Protection_for_Water_Sewer_Pipelines_2026.pdf

13112-1 2026

STANDARD SPECIFICATION

SECTION 13112

IMPRESSED CURRENT CATHODIC PROTECTION FOR WATER

AND SEWER PIPELINES

PART 1 GENERAL

1.1 DESCRIPTION

A. Section includes requirements for complete impressed current cathodic protection system as well as for repair and restoration of existing cathodic protection test stations numbers as shown on plans.

B. For galvanic anode cathodic protection system follow Section 13110.

1.2 QUALITY ASSURANCE

A. Materials:

Follow applicable Standards for corrosion control.

Supplied by manufacturer regularly engaged in production of corrosion control materials.

B. Installer:

Install deep anodes, rectifiers, remote monitoring units and associated work under supervision of corrosion control technician or corrosion engineer experienced in corrosion control work.

Install test stations, insulating joints, anodes, and joint bonding under supervision of corrosion control technician or corrosion engineer experienced in corrosion control work.

C. Well Driller Qualifications:

Licensed well driller by the State of Maryland.

Installed minimum of 10 deep anode groundbeds similar to those included in this contract over the past 5 years.

D. Corrosion Control Testing: Performed by NACE International certified Corrosion Specialist, Cathodic Protection Specialist, Senior Corrosion Technologist, or corrosion engineer with a minimum of 5 years experience in corrosion engineering.

1.3 SUBMITTALS

A. Submit following Section 01330.

Catalog Data:

a. Materials to be used for deep anode groundbeds, casings, vents, centralizers, wire and cable, junction boxes, deep anode backfill, rectifiers, remote

13112-2 2026 monitoring units, AC disconnect switches, conduit, exothermite weld caps, and pipe coating repair materials.

b. Exothermic weld packages, including manufacturer's recommended cartridge and charge size for each application required.

c. Test stations

B. Submit following Section 01450.

Quality Assurance/Control Submittals

a. Certificates:

Installer and tester qualifications.

Applicable NACE International Corrosion Certifications.

b. Well driller qualifications.

List of specific projects and locations that include installations of at least 10 deep anode groundbeds similar to those included in this contract over the past 5 years.

c. Corrosion control tester's qualifications, methods, and procedures for testing corrosion control system, including description of equipment and instruments to be used.

Methods and procedures for testing corrosion control system, including description of instruments and equipment to be used.

a. Test procedures for:

Verifying electrical isolation at insulating joints and insulating casing spacers.

Post installation testing of test stations and cathodic protection system.

Continuity testing (joint bond resistance).

List of minimum 5 projects that involve testing of corrosion control systems.

Documentation for each project shall include:

a. Project name.

b. Project location (City and State).

c. Pipe diameters and type of pipe material installed.

d. Length of pipeline.

e. Type of corrosion control provided on the pipeline.

f. Name and phone number of a contact at the pipeline owner.

g. Names of responsible corrosion control company staff members that participated in the project.

C. Submit all test results in a Final Acceptance Report for Engineers approval.

Include sketches of test station wire terminations in each test box.

a. Number each test station and identify type of station.

PART 2 PRODUCTS

2.1 MATERIALS

A. WSSC will furnish the following;

Standard WSSC locks for rectifiers, anode junction box, remote monitoring unit, and AC disconnect switch.

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B. Wire:

Negative Cables: Cable from structure connections to rectifier DC negative terminal connections or to terminals in pipeline junction box.

a. AWG No. 2 insulated concentric lay, stranded, annealed copper wire with

HALAR internal jacket and HMWPE (high molecular weight polyethylene), 7/64-inch thick external insulation, 600-volt rating.

b. Sufficient length to reach from connection point to rectifier or pipeline junction box terminals without splicing.

Positive Cables: Cable from anode junction box to rectifier DC positive terminal connections.

a. AWG No. 2 insulated concentric lay, stranded, annealed copper wire with

HALAR internal jacket and HMWPE external insulation, 600-volt rating.

b. Sufficient length to reach from anode junction box to rectifier terminal without splicing.

Rectifier Ground Cable from rectifier cabinet grounding lug to ground rod:

a. AWG No. 6 bare solid copper wire.

Power Service at 600 Volts or Less:

a. Three AWG No. 8 insulated concentric lay, annealed copper wire with THHN or THWN insulation.

Test Lead Wires: Single conductor No. 6 through No. 12 AWG stranded copper rated at 600 volts with THW, THHN, and THWN insulation. Wire sizes and insulation colors following Standard Details and Drawings.

C. Exothermic (thermite) Weld Materials:

Exothermic Weld Molds, Weld Powder and Weld Metal Cartridges: Use proper mold and proper size and amounts for wire size, pipe size, pipe material, and weld position. Utilize adapter sleeves as recommended by exothermic weld manufacturer.

Approved Manufacturers:

a. Exothermic weld material:

ERICO International – CADWELD products Continental Industries – thermOweld products Or equal.

b. Weld powder: As recommended by each exothermic weld manufacturer for specific wire size and pipe material.

c. Exothermic Weld caps:

Continental Industries, Division of Burndy LLC – Ci thermOcap or Ci theromOcap PC weld caps.

Royston Laboratories Division, Chase Corporation – Royston Handy Cap or Royston Handy Cap IP.

Or equal.

d. Exothermic weld cap, pre-filled with mastic.

Royston Handy Cap – use Royston Roybond 747 primer Royston Handy Cap IP – no primer needed (has integrated primer).

Ci thermOcap – use thermOprimer primer.

Ci thermOcapPC – no primer needed (pre primed cap)

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e. Other exothermic weld caps: Field fill with mastic, following manufacturer’s instructions.

Mastic:

a. Properties:

Composition: Pyrobituminous resin processed by homogenization with inhibitive pigments and aromatic solvents.

Electrical volume resistivity: 2.12 x 1013 ohms-cm.

Exothermic weld material:

Percent solids: 58.6% by volume, 68.2% by weight.

Service temperature: 0 to 250o F.

Weight per gallon: 9.42 pounds.

Specific gravity: 1.13 Flash point: 44o F – seta closed cup Color: Black

b. Approved manufacturer.

Roskote R28 Rubberized Mastic.

Or equal.

D. Protective Coating Materials for Pipe Coating Repairs.

Approved Manufacturers:

a. Royston Laboratories.

b. Tapecoat Company.

c. Polyken Technologies.

E. Terminals, Terminations and Connectors:

Terminals for terminating test lead wires in test stations: One piece, burr-free, crimp-type, non-insulated brazed seam terminals for 1/4 inch terminal studs, made of annealed electrolytic copper, sized to match various wire and stud sizes.

Wire terminations for bolted connections: One piece bar lugs made of electrolytic grade copper bar stock and tin-plated, assembled or fabricated before field delivery.

a. Approved Manufacturer.

ERICO, Type LA.

Or equal.

Compression Connectors: One piece “C” shaped manufactured from high conductivity wrought copper for splicing copper cables together.

a. Approved Manufacturer.

Burndy, Type YC-C.

Or equal.

F. Insulating Materials.

Flange insulating kit.

a. Flange Insulating Gasket: Full flange diameter, Type E, made of laminated phenolic with neoprene on each side of gasket with minimum total thickness of 1/8 inch.

Dielectric strength: Not less than 500 volts per mil.

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Compressive strength: Not less than 24,000 psi.

Water absorption: Maximum 2.5%.

Approved manufacturers/suppliers:

Advance Products & Systems, Inc.

Central Plastics Company.

Pipeline Seal and Insulator, Inc. (PSI).

Or equal.

b. Insulating Flange Bolt Sleeves: High density polyethylene or spiral wrapped Mylar with dielectric strength not less than 1,200 volts per mil.

c. Insulating Flange Bolt Washers: High strength phenolic with minimum thickness of 1/8 inch, dielectric strength not less than 500 volts per mil, and compressive strength not less than 25,000 psi.

d. Steel Flange Bolt Washers for placement over insulating washers: Minimum thickness of 1/8 inch and cadmium plated.

e. One Piece Combination Sleeve and Washer, only when noted on Drawings.

One piece sleeve and washer of molded acetyl or nylon resin having minimum thickness of 1/8 inch.

Dielectric strength not less than 500 volts per mil.

Compressive strength not less than 15,000 psi.

Copper House Connections and Small Pipe Insulator.

a. Copper house connection insulator: Two brass parts and nylon dielectric bushing.

b. Insulator for other pipe 2 inch and smaller diameter: One piece threaded bushing made of nylon and sized to fit pipe.

G. Polyethylene Mesh Separator Pad.

Medium density flexible polyethylene mesh pattern webbing pad, nominal thickness 160 mils.

a. Approved Manufacturer.

Stuart Steel Protection Corporation, Model Stuart Diamond Rockstop Or equal.

H. Electrical Tape Conformable water tight sealant having dielectric strength not less than 15kV for

1/8 inch thick layer.

a. Approved Products.

Scotch Vinyl Electrical Tape Super 88 Scotch Linerless Rubber Splicing Tape 130C Or equal.

I. Test Stations:

Flush Mounted At Grade

a. Tube: Follow Standard Details.

b. Cast iron or high impact plastic collar with ribs.

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c. Cast iron or high impact plastic locking lid, blue with permanent marking “WSSC Test Station” to withstand AASHTO H-20 traffic loads and ultra violet rays.

d. Terminal Block: Phenolic resin, plastic, Micarta, Lexan, or Bakelite high dielectric material, with minimum of 7 terminals, unless otherwise shown on Drawings.

e. Terminals: Nickel plated brass 1/4 inch threaded studs, nuts, and washers.

f. Shunt: 0.01 ohm with minimum of 6 ampere capacity in test stations with galvanic anodes following Drawings.

Post Mounted Above Grade

a. Weatherproof Enclosure: Cast aluminum, galvanized steel, or high impact plastic, Lexan, Gyrlyn or equal.

b. Test Box Enclosure with Locking Waterproof Cover: Fasten on pipe using non-rusting materials: stainless steel, galvanized steel, or cadmium plated steel fasteners.

c. Terminal Block: Phenolic resin, plastic, micarta, Lexan, or Bakelite high dielectric material, with 7 terminals unless otherwise shown on Drawings.

d. Terminals: Nickel plated brass ¼ inch threaded studs, nuts, and washers.

e. Shunt: 0.01 ohm with minimum of 6 ampere capacity in test stations with galvanic anodes following Drawings.

J. Reference Electrodes Permanent copper-copper sulfate reference electrode.

a. Designed for minimum 20 year life.

b. Size: 2 inches diameter by 8 inches long, Schedule 80 PVC body or 2 inches diameter by 7 inches long, high impact resistant Lexan tube and minimum overall package size of 6 inches diameter by 10 inches long.

c. Prepackaged in permeable cloth bag with special copper-copper sulfate reference electrode backfill.

d. Contents: High purity copper element, 99.99 percent pure, inside a tube containing super saturated solution of copper sulfate.

e. Lead wire:

Sufficient length to reach test station terminals without splicing.

Attached to electrode core with manufacturer's standard connection.

Connection shall be stronger than the wire.

No splicing of electrode lead wire permitted under any circumstances.

f. Approved Manufacturer.

Electrochemical Devices, Inc., Model UL-CUG-SW Or equal.

K. Detectable Warning Tape for Coated Pipe and Test Station lead wires: See this Section and Section 02315

L. Impressed Current Anodes:

High Silicon Cast Iron Anodes

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a. Tubular with nominal weight of 135 pounds, 60 inches long and 3.80 inches in diameter.

b. Composition: ASTM A518, Grade 3 as follows:

Silicon 14.20 - 14.75% Chromium 3.25 - 5.00% Carbon 0.70 - 1.10% Manganese 1.50% max Copper 0.50% max Molybdenum 0.20% max Iron Remainder

c. Lead wire connection to anode: Made by anode fabricator. Connection shall be by a conical anchor located near the center of the anode. Capture grooves shall lock the cable connection anchor by extrusion. Connection shall be protected by interior retention ribs which positively lock the epoxy sealant.

Anode lead wire shall be a minimum of AWG No. 8 stranded copper with HALAR internal jacket and HMWPE external insulation. Sufficient length to reach the anode junction terminals box without splicing.

No splices shall be permitted in the anode lead wires.

d. Fabricated with 175 feet of 3/8" polyethylene lowering rope permanently attached.

e. Approved Manufacturers:

Type 4860HZ Z-Series Centertec Tubular as manufactured by Anotec Industries Ltd.

Or equal.

Mixed Metal Oxide Anodes

a. Tubular with nominal weight of 27 pounds without lead wire, 60 inches long and 3 inches in diameter.

b. Composition: ASTM B338-13 Grade 2, as follows:

Carbon 0.08% max Iron 0.30% max Nitrogen 0.03% max Oxygen 0.25% max

Residual elements less than 0.10% maximum 0.40% maximum total Hydrogen 150 ppm max

Titanium Remainder

c. Mechanical Properties: ASME SB338-13 Grade 2 as follows:

Tensile Strength 50, 000 lb/in2 min Yield Strength 40, 000 lb/in2 min

65, 000 lb/in2 max

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d. Primary anode element: precious metal oxide coating applied to a copper cored titanium wire, wire is electrically connected to outer galvanized steel canister.

e. Area between wire and canister filled with highly conductive calcined petroleum backfill.

f. Anode lead wire shall be a minimum of AWG No. 8 stranded copper with HALAR internal jacket and HMWPE external insulation. Sufficient length to reach the anode junction terminals box without splicing.

No splices shall be permitted in the anode lead wires.

g. Fabricated with 175 feet of 3/8" polyethylene lowering rope permanently attached.

h. Approved Manufacturers:

Type LP 3 x 60 H LIDA Pack Canistered Wire Anodes as manufactured by DeNora Tech, Inc.

Or equal.

M. Anode Centralizers for Deep Anode Groundbeds.

Steel centering device: Capable of maintaining each anode in concentric position within the hole.

Approved Manufacturers:

a. Ventralizer Model as manufactured by Elgard Corporation.

b. Or equal.

N. Anode Vent for Deep Anode Groundbeds.

One-inch diameter PVC anode venting conduit: Installed full length of each deep anode bed. Openings of 1.5 inches in length by 0.006 inches in width positioned 1-inch in circumferential distance from one another and 6-inches center-to-center longitudinally.

Manufacturers:

a. Allvent as manufactured by Loresco International

b. Or equal.

Solid vent pipe for inactive area of deep anode: Without slots and same nominal diameter as slotted pipe.

Well vent cap:

a. PVC Cap mounted to top of 12 inch diameter PVC schedule 80 well casing above grade.

b. Minimum of four (4) 0.375” diameter holes drilled in lid to allow for venting.

O. Anode Backfill for Deep Anode Groundbeds Backfill space between anode and augured hole with carbonaceous earth contact backfill with the following composition:

Fixed Carbon 99.35% Ash 0.10% Moisture 0.05% Volatiles 0.00% (950o C) Bulk Density 74 lbs. /cu. ft.

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Particle Size Dust-free with maximum particle size of 1.0 millimeter Manufacturers:

a. Loresco Type SC-3 as manufactured by Loresco International

b. Or equal.

P. Environmental Plug Seal for Deep Anode Groundbeds.

Installed within 12-inch diameter PVC schedule 80 above top of anode column.

Manufacturers:

a. Loresco Perma Plug Seal, as manufactured by Loresco International

b. Or equal.

Q. Deep Anode Groundbed Casing Materials.

PVC Surface Casing: 12 inch diameter solid, schedule 80, ASTM D-1785 PVC casing above anode column. Length sufficient to reach the first organic layer below the surface.

Slotted PVC Casing for Anode Column (only if necessary to install deep anode system): Perforated casing for active anode area of deep anode, fabricated of Schedule 40 PVC following ASTM D-1785.

a. Casing:

Diameter: 8-inches nominal.

Length: 20-foot sections, to make up total length of active anode column.

Slots: 224 slots per 20-foot length (each slot 0.75", min. wide x 5.5" long), to permit normal current output of at least 0.35 Ampere/linear foot in 12 inch diameter well;

Metallic membrane: 26 gauge sheet metal membrane covering exterior of perforated pipe.

Manufacturers:

Loresco International.

Or equal.

R. Impressed Current Rectifiers Standard constant voltage

a. General: solid state electronic type provided by manufacturer who has minimum of ten years experience in the production of rectifiers.

b. Air cooled pole mount rectifier

c. AC Rating: 115/230 V AC, single phase

d. Cabinet: Hot dipped galvanized finish (after fabrication). Three sides open for easy access with locking hasp on door.

e. Chassis: Components mounted on single, slide out rack or frame assembly to facilitate tests, inspections and maintenance. Service entry wire locations permanently labeled to facilitate proper reconnection.

f. AC Breaker: Contain independent AC breaker that is readily accessible.

Rectifier shall be provided with panel mounted AC and DC fuses.

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g. Mode of Operation: Standard, solid state constant voltage transformer unit. It will utilize bridge connected silicon diodes and provide a range of operation as shown on plans.

h. Tap Settings: Equipped with five (5) Coarse and five (5) Fine tap settings to adjust DC output of rectifier.

i. Metering: Continuous duty metering shall include one DC voltmeter and one DC ammeter connected to an external shunt, plainly marked to indicate ampere rating and millivolt drop. Ammeter shunt mounted in readily accessible location on the front panel of rectifier.

j. Lightning Protection: AC and DC lightning protection. DC lightning protection installed between negative and positive output of rectifier as well as between negative output and ground.

k. Interior Nameplate: Following information shall appear on nameplate affixed to the inside of rectifier door:

Manufacturer's name and address.

Rectifier model number.

Rectifier serial number.

Full load AC amperes.

AC line volts.

AC line frequency (60 Hz).

Number of phases.

DC output volts.

DC output amperes.

Ambient temperature rating shall be from minus 40 degrees F to plus 160 degrees F.

l. Manufacturers:

Universal Rectifiers, Inc.

Or equal.

Standard potential controlled:

a. General: capability of being potentially controlled and also manually operated in the constant voltage mode. Solid state electronic type provided by manufacturer who has minimum of ten years experience in the production of rectifiers.

b. Air cooled pole mount rectifier

c. AC Rating: 115/230 V AC, single phase

d. Cabinet: Hot dipped galvanized finish (after fabrication). Three sides open for easy access with locking hasp on door.

e. Chassis: Components mounted on single, slide out rack or frame assembly to facilitate tests, inspections and maintenance. Service entry wire locations permanently labeled to facilitate proper reconnection.

f. AC Breaker: Contain independent AC breaker that is readily accessible.

Rectifier shall be provided with panel mounted AC and DC fuses.

g. Mode of Operation: Standard, solid state constant voltage transformer unit. It will utilize bridge connected silicon diodes and provide a range of operation as shown on plans.

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h. Tap Settings: Equipped with five (5) Coarse and five (5) Fine tap settings to adjust DC output of rectifier.

i. Metering: Continuous duty metering shall include one DC voltmeter and one DC ammeter connected to an external shunt, plainly marked to indicate ampere rating and millivolt drop. Ammeter shunt mounted in readily accessible location on the front panel of rectifier.

j. Lightning Protection: AC and DC lightning protection. DC lightning protection installed between negative and positive output of rectifier as well as between negative output and ground.

k. Interior Nameplate: Following information shall appear on nameplate affixed to the inside of rectifier door:

Manufacturer's name and address.

Rectifier model number.

Rectifier serial number.

Full load AC amperes.

AC line volts.

AC line frequency (60 Hz).

Number of phases.

DC output volts.

DC output amperes.

Ambient temperature rating shall be from minus 40 degrees F to plus 160 degrees F.

l. Manufacturers:

Universal Rectifiers, Inc.

Or equal.

S. Remote Monitoring Unit.

American Innovations Model Bullhorn RM4010 with 125 ampere solid state relay for interruption of AC power. No substitutions will be accepted.

T. Anode Junction Boxes Size: 16 inches high by 12 inches wide by 6 inches deep.

Type: Fiberglass reinforced plastic (FRP), complete with hinged covers and locking hasps, meeting the requirements of NEMA 4X. Provided with mounting brackets and sufficient conduit connections for the required wiring.

Interior: Provided with non-conductive mounting board, number of shunts as shown on plans for each respective location, (5 ampere capacity minimum), copper bus bars (1 inch wide by 1/8 inch thick by length as required), and cable mounting lugs as shown on plans.

Location as shown on plans.

Or equal.

U. Pipeline Junction Boxes Size: 16 inches high by 12 inches wide by 6 inches deep.

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Type: Fiberglass reinforced plastic (FRP), complete with hinged covers and locking hasps, meeting the requirements of NEMA 4X. Provided with mounting brackets and sufficient conduit connections for the required wiring.

Interior: Provided with non-conductive mounting board, number of shunts as shown in Details and as shown on plans. (5 ampere capacity minimum), copper bus bars (1 inch wide by 1/8 inch thick by length as required), and cable mounting lugs as shown on plans.

Location as shown on plans.

Or equal.

V. AC Disconnect Switch: See Specification 16170.

W. Grounding: See Specification 16450

PART 3 EXECUTION

3.1 BASIC REQUIREMENTS

A. General Contractor: Familiar with the following factors at all deep anode groundbed installation sites:

a. Access for equipment to hole locations.

b. Prohibitions to the discharge of drilling water, grout, cuttings, coke backfill or other liquid waste to the surrounding environment.

c. Subsurface utilities and other obstructions.

d. Availability of water.

B. Preparation Provide all necessary equipment, manpower, and materials to perform the installation in an uninterrupted manner.

If any anode hole fails to reach the required depth due to unusual obstruction, notify Engineer.

Measure depth of anode holes and provide samples of materials recovered before start of installation of anodes and/or removal of drilling equipment.

Abandon and backfill any holes rendered useless due to problems with equipment or materials. Drill replacement holes at location approved by Engineer at no additional cost to the Commission.

3.2 DEEP ANODE GROUNDBEDS

A. Installation.

Drill anode hole as indicated on Contract Drawings.

Maintain accurate log of drilled holes and submit to Engineer within 24 hours of completion of drilling. Include;

a. Equipment used.

b. Date and time of drilling.

c. Complete log of materials encountered.

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d. Include soil classification.

e. Elevation of water table.

f. Location of special features such as mud seams, open cracks, soft or broken ground, points where loss or gain of drill water occurred and all other items of interest in connection with the Work.

Install deep anode surface casing as indicated on Contract Drawings.

a. Perforated anode casing may be installed only if site conditions require it to maintain the active anode portion of hole open during installation of deep anodes and vent pipe.

Deep anode holes: Minimum two feet clearance with other underground structures.

Dispose of excess materials from excavation following WSSC Standard Specifications.

Before anode installation, obtain a resistivity profile (log) at five foot intervals in the active zone of deep anode groundbed.

B. Anode Vent.

Vent pipe installed to full depth of each deep anode groundbed. Install vent cap as indicated on the Contract Drawings.

C. Installation of Anodes.

Install in deep anode holes as shown on the Contract Drawings.

a. Prior to installation, remove all shipping covers from the anode.

b. Perform work carefully to avoid damage to anodes and cables.

Lower into augured hole by using polyethylene ropes provided with anodes.

a. Do not lower using anode lead wires.

Suspend anodes in the deep anode hole by tying the anode support ropes to hanging rod installed at top of casing for this purpose.

D. Deep Anode Backfill.

Backfill with coke breeze (Loresco Earth Contact Backfill Type SC-3 or equal).

a. Mix coke breeze with water to form a coke breeze slurry.

b. Continuously agitate to assure that coke breeze is maintained in colloidal suspension while being pumped into deep anode hole.

c. Pump into bottom of hole via PVC piping that is installed for this purpose.

Remove PVC slurry piping immediately after coke breeze is installed to the required level and before the slurry can solidify.

Do not use anode vent pipe for this purpose.

Measure depth to top of coke breeze column to verify proper installation.

a. Allow coke breeze column to set a minimum of 24 hours after installation before making this measurement.

b. If top of the coke breeze column is not at the correct depth, finish filling deep anode hole in the same manner.

Utilize a second pump to collect excess material from the deep anode hole during installation of slurry.

Collect and dispose of excess material. Avoid spillage onto adjacent pavement.

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Seal top of anode column with environmental seal as indicated on the Contract Drawings.

3.3 HORIZONTAL ANODE GROUNDBED

A. Excavation of horizontal anode trench Excavate trench for horizontal anode groundbed as indicated on Contract

Drawings.

a. Parallel to pipe at a horizontal separation of 10 feet from OUTER edge of pipeline at springline.

b. Depth: bottom of trench a minimum of pipe invert depth.

c. Width: 12 inches.

d. Length: Sufficient length to allow for nominal 10 foot center to spacing of anodes with 6 inch clearance between anodes at each end and trench wall

e. Spoils to be handled in accordance with applicable regulations.

B. Installation of Anode Backfill and Anodes.

Backfill entire length and width of trench with coke breeze (Loresco SW (or equal) Coke Breeze Anode Backfill for Shallow Ventless Installation to a minimum depth of 3 inches from bottom of trench.

Prior to installation, remove all shipping covers from the anode.

a. Perform work carefully to avoid damage to anodes and cables.

Lower anodes into trench on top of Coke Breeze placed in B.1 by using polyethylene ropes provided with anodes.

a. Do not lower using anode lead wires.

Place anodes in trench with nominal 10 foot center to center spacing.

Anodes at each end of placement shall have a 6 inch clearance from length ends of trench.

Route anode lead wires to location shown on Contract Drawings so lead wires can be installed in Anode Junction Box.

Backfill entire length and width of trench with coke breeze (Loresco SW (or equal) Coke Breeze Anode Backfill for Shallow Ventless Installation to a minimum depth of 12 inches from bottom of trench.

a. Ensure that anodes are completely covered by anode backfill.

Above anode backfill, trench can be backfilled with suitable earth back fill.

3.4 ANODE JUNCTION BOXES

A. Install where shown on Contract Drawings, complete with hinged covers and locking hasps.

B. Connect anode lead wires and positive cables that run to rectifiers using hardware supplied with anode junction box as shown on Contract Drawings.

C. Follow National Electrical Code (NEC) requirements and all other applicable State and Local electrical codes. Accomplish Work in a neat and workman type manner.

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3.5 PIPELINE JUNCTION BOXES

A. Install where shown on Contract Drawings, complete with hinged covers and locking hasps.

B. Connect pipeline lead wires to junction box terminals using hardware supplied with pipeline junction box as shown on Contract Drawings.

C. Pipeline lead wires shall be marked to distinguish individual leads. A list denoting how leads are marked indicating pipe size and contract number shall be placed in junction box and included with final report.

D. Attach pipeline lead wires to pipeline per Section 3.5 STRUCTURE CABLE

CONNECTION

E. Follow National Electrical Code (NEC) requirements and all other applicable State and Local electrical codes. Accomplish Work in a neat and workman type manner.

3.6 STRUCTURE CABLE CONNECTION

A. Excavate to top of water main where indicated. Verify locations of all underground utilities and structures before performing any excavations.

B. Test pipe for integrity prior to making any exothermic weld connections.

No welding shall be performed on piping in area of any corrosion damage or surface imperfection (pitting, crack, etc.) or spiral weld.

Maintain minimum distance of 12 inches between spiral welds and thermite welds.

C. Install structure cable connections at locations shown on Contract Drawings by exothermic welding. Follow exothermic welding manufacturer’s instructions.

Clean structure surface by removing just enough of the existing coating to accommodate the exothermic weld, and clean surface of pipe to produce a clean, bright, smooth surface.

Utilize proper weld metal charge for pipe material and size to which connection is being made.

Test integrity of weld prior to coating by striking weld with a two pound hammer.

If weld fails, install new connection a minimum of six inches away from failed connection.

Clean weld slag from all connections and install thermite weld caps to protect connections.

If existing coating is damaged beyond the weld cap coverage area, repair following original pipe coating manufacturer's recommendations.

a. If original pipe coating is no longer available, replace with coating that is compatible with original coating.

Structure cable connection: Sufficient length to reach the negative DC terminal of rectifier without splicing.

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a. No splices shall be permitted in structure cable connections.

3.7 RECTIFIERS

A. Location.

Installed at approximate locations shown on Contract Drawings following manufacturer's recommendations.

Mounted to wood post installed as shown on Contract Drawings.

Install so doors and access panels can be fully opened for servicing and with sufficient clearance for easy removal of all interior components.

In no case will rectifier be located near areas where it may be exposed to roof drainage or damage by vehicular traffic.

B. AC Power Supplied to rectifiers as shown on Contract Drawings.

Conduit and wiring: Completed by electricians licensed to perform installations following local Electrical Code, NEC and NFPA 30.

Contractor is responsible for all AC Power applications, including coordination with Power Utility Company and WSSC’s representative.

C. DC Wiring Connect positive (anode) cable running from anode junction box bus to positive

DC terminal in rectifier. Cable shall be marked to distinguish it from negative cable.

Connect negative (structure) cable running from water main to negative DC terminal in rectifier.

D. Ground Rod Drive ground rod as shown on Contract Drawings and ground rectifier cabinet to it.

Ground rod: Completely below ground.

Ground cable: Attached to rod via thermite weld.

Ground cable: Protected from damage or theft.

E. Operation Check Following completion of installation, set rectifier taps to lowest available setting, turn on AC power supply and turn rectifier circuit breaker on.

Push meter switch and note readings on meter.

If there is no meter reading, check AC and DC circuits, locate any loose or open connections and re-test.

If circuit breaker trips or a fuse blows out during the test, a short circuit is indicated. Locate short circuit and correct it at no additional cost to the Commission.

Upon completion of operation check, turn off and leave off rectifier circuit breaker and AC power supply until final testing.

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F. Energize and adjust cathodic protection rectifier after all work is completed.

Testing shall include interference testing with utilities as determined necessary.

Notify Baltimore/Washington Underground Corrosion Coordinating Committee and other appropriate parties of the installation and energizing of the cathodic protection systems. A minimum of four weeks advance notice shall be given prior to energizing.

3.8 REMOTE MONITORING UNITS

A. Location Install at approximate locations shown on Contract Drawings.

B. AC Power Supply to remote monitoring units as shown on Contract Drawings.

Conduit and wiring: Following local Electrical Code, NEC and NFPA 30, and completed by electricians licensed to perform the installations.

Connect remote monitoring unit to rectifier following remote monitoring unit’s manufacturer recommendations.

3.9 INSULATING JOINTS

A. Install following Standard Details and Drawings.

B. Test each insulator for electrical insulation before backfilling. Provide Engineer a minimum of one week notice prior to testing.

If insulator is not properly isolated, repair or replace all defective components at no additional cost to the Commission.

Test the repaired insulator.

Continue this process until the insulator is tested to be properly isolated.

Insulation that passes for effective isolation during the pre-backfill test, but does not render positive isolation results during acceptance testing: Repaired at no additional cost to the Commission.

C. Coat entire joint including bolt ends and nuts with coating material specified herein.

Fully coat minimum of 12 inches on each side of flange.

Clean surface of flange and components and prepare surface following manufacturer’s recommendations.

Apply uniform coat of primer to flange and all components.

Apply filler mastic to all irregular surfaces of flange to provide smooth profile for tape application.

Apply innerwrap to flange and all components in spiral fashion; minimum overlap

55 percent.

Apply outerwrap to flange and all components in spiral fashion; minimum overlap

1 inch with sufficient tension to provide continuous adhesion of tape.

D. For copper house connections and other small pipe, install connection insulator following Drawings.

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Locate insulator at copper pipe tie-in following Standard Details.

3.10 JOINT BONDING OF PIPE

A. Bond pipe joints and fittings to form electrically continuous pipeline following Drawings and Standard Details.

B. Wire.

Joint bonding wire: Sized according to pipe diameter and following Standard

Details.

Cut bond wire to shortest length practicable, including some slack, for given span.

a. Locate bond wire welds on pipe and fittings following Standard Details.

b. Horizontal welds are preferable, but where there is insufficient space on a fitting, vertical welds will be permitted.

c. Where multiple parallel bond wires are involved, space wires neatly and without wires crossing each other.

Do not splice bond wires.

a. Replace bond wires broken during construction.

b. Reweld loose weld connections.

If insulation of bond wire is damaged between welds, repair insulation:

a. Thoroughly clean damaged area and 6 inches either side of it.

b. Wrap minimum of one overlapping layer of rubberized electrical tape around damaged area and extend at least 2 inches each side.

c. Wrap two overlapping layers of plastic electrical tape around rubberized tape and extend at least 1 inch beyond rubberized tape at each end.

3.11 INSTALLATION OF TEST STATIONS

A. Location of Test Stations:

Follow Drawings and Standard Details.

a. Locate surface of concrete pad at finish grade, unless otherwise directed by Engineer.

b. Locate directly over pipeline except in areas that would place the test station in a roadway.

Locate these test stations to closest point just off the edge of the road or curb.

Identify test station with number following Drawings or Engineer furnished number.

a. Paint number legibly inside test box lid or cover and on terminal block.

b. Use permanent and weatherproof paint for metal or plastic surfaces.

Immediately after installation in areas to be improved, protect and identify test station locations with 3 stakes extending at least 4 feet above existing grade, equally spaced around test station and wrapped with orange fluorescent flagging material within 6 inches from top of stakes.

Situate pipe for pipe mounted test stations directly over pipeline.

a. If this is not possible, locate at Engineer’s direction.

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B. Test Lead Wires:

Install test lead wires without splices as shown on Standard Details and attach to pipe using exothermic welding method.

a. Test leads: Sufficient length to reach test station terminal board without splicing and with 18 inches of slack.

Locate wires on top and along pipe and at right angles to pipeline when wires depart for offset test stations.

a. Test station wires: Routed minimum of two feet below finished grade.

b. Test lead wires: Routed under roadway to the test station through conduit, as necessary.

c. Protect wires from damage during backfilling operations with adequate slack and support.

Place continuous yellow detectable warning tape directly over test lead wires, 12 inches to 18 inches below finished grade.

Terminate test lead wires inside test box using proper sized crimp type connectors on wire ends.

a. Connect each wire to terminal, maintaining at least 18 inches slack in each wire at test station. Do not combine wires on a terminal except as necessary for anode connections.

b. Neatly coil slack wire in test station below terminal board.

Test each lead wire for continuity after backfill is completed.

a. If test for continuity fails, repair or replace at Engineer’s direction.

C. Reference Cells: Follow Standard Details or Drawings.

Use native trench material to backfill the reference electrode.

Before installation, remove the plastic shipping cover from the reference electrode.

Cloth bag containing the special backfill shall remain intact.

Protect cloth bag from tearing or damage.

If damage occurs, provide new prepackaged reference cell.

Reference cell lead wire: Sufficient length to reach test station terminal board without splicing and with 18 inches of slack.

Test lead wire from reference cell for proper function.

a. If reference cell is not functioning properly, repair or replace.

b. After reference cell is functioning properly, connect lead wire from reference cell to terminal block at test station.

c. Do not attach other test lead wires to terminal that is used for reference cell.

D. IR Drop Lead Wires:

Locate IR drop test stations following Drawings.

Wire size, type, and length: Following Standard Details.

Place long lead wires below springline of pipe and taped to pipe for protection, following Drawings.

Lead wires: Sufficient length to reach test station terminal board without splicing and with 18 inches of slack.

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E. Shunts:

1. Install shunts in test stations with anodes following Drawings.

F. Foreign Pipeline:

Provide test stations at foreign pipelines following Drawings and Standard

Details.

G. Notify owner of foreign pipeline at least 2 weeks before test station construction.

Unless otherwise indicated, only foreign pipeline owner or approved representative will be permitted to weld wires to foreign pipeline.

3.12 FINAL INSPECTION AND ACCEPTANCE

A. Notify Engineer when systems are ready for operation.

B. Test, inspect and energize system in presence of Engineer.

C. Correct deficiencies in materials and installation observed by these tests and inspections at no additional cost to the Commission.

D. Inspect and test the following items per NACE International's SP0169-2007 “Control of External Corrosion on Underground or Submerged Metallic Piping Systems”.

Initial Measurement of Structure to Soil Potentials, prior to initial energization of rectifiers

a. Measure using a digital voltmeter with selectable input impedance ranging between at least 20 Megohms and 200 Megohms.

b. Depolarized Potentials for existing pipelines with magnesium anodes:

Disconnect existing sacrificial anodes in order to allow depolarization of the pipelines. Allow a minimum of one calendar week for depolarization.

Record depolarized structure to soil potentials at all test stations shown on the Contract Drawings. Sacrificial anodes shall remain disconnected after the completion of this step.

c. Native Potentials for new pipeline construction: Record native structure to soil potentials at all test stations shown on the Contract Drawings.

Operation of Rectifiers

a. Voltage Output:

Energize each rectifier, and adjust output voltage, with no load attached, to verify rectifier voltage output can be adjusted from zero to the rated voltage of the rectifier unit.

Record voltage range on data sheet, including the rectifier designation and location, date, time of day, test conditions and other pertinent information.

b. Current Output:

Connect anode header cables to positive DC terminal of the rectifier, then connect structure cable to negative DC rectifier terminal. Adjust the rectifier voltage, to allow the current to be verified from zero to the rated current or voltage output (whichever is reached first) of the rectifier unit.

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Record each voltage value and corresponding current output on data sheet, including the rectifier designation and location, date, time of day, test conditions and other pertinent information.

c. After testing is completed, proceed to step 3 below.

Measurement of Polarized Structure to Soil Potentials

a. Set initial rectifier output settings at a minimum of current values determined during design phase. Record rectifier output values, along with tap settings, AC and DC ratings, Manufacturer name, Model number, and Serial number.

b. After initial start-up allow rectifiers to operate for minimum period of two (2) weeks. At this time, an ON and OFF structure to soil potential survey will be conducted that includes all available test stations shown on Contract Drawings, with potentials recorded. Synchronized simultaneous interruption of ALL installed rectifiers shall occur.

If testing described in the above paragraph indicates pipeline is not meeting established cathodic protection criteria (NACE-SP-0169-2007), output of all rectifiers shall be increased by a minimum of ten (10) percent and repeat test.

c. Include in final report Depolarized, ON, and OFF structure to soil potential measurements for each station.

Rectifier voltage and current outputs.

Interruption cycle (seconds on, seconds off) used.

Individual Anode Current Measurements.

a. Measure output currents of individual anodes at each anode groundbed junction box with rectifiers operating at final output settings.

b. Take measurements by connecting across the individual current measuring shunts and converting the voltage drop measured to current using appropriate calibration factor.

c. Include the following data in the final report:

Anode number, voltage drop across the shunt, and corresponding anode current output.

d. Calculate the sum of the individual anode current outputs, and compare to the rectifier current output.

Individual Pipeline Current Measurements.

a. Measure output currents of individual pipelines at each pipeline junction box with rectifiers operating at final output settings.

b. Take measurements by connecting across the individual current measuring shunts and converting the voltage drop measured to current using appropriate calibration factor.

c. Include the following data in the final report:

Pipeline size, contract number, voltage drop across the shunt, and corresponding current output applied to each pipeline.

Stray Current Interference Tests.

a. Stray current effects on all foreign metallic structures identified through coordination with members of the Baltimore/Washington Underground Corrosion Committee shall be determined as practical, after final rectifier

13112-22 2026 current output adjustments have been made. These effects shall include the potential on the foreign structure with each rectifier both ON and OFF.

Evaluate the polarity of the potential shift to determine whether the effect is protective or corrosive. Provide test results to Engineer for determination of the need for stray current mitigation measures.

Include the following data on the operation of the ICCP systems in final report.

a. Rectifiers:

Designation – WSSC Test Station Number Location Manufacturer, Serial Number and Model Number AC rating Number of AC phases Frequency of AC DC voltage and current rating Final DC voltage output Final DC current output

10) Tap Settings

11) Interruption cycle (seconds ON, seconds OFF) used during measurement of structure to soil potentials.

12) Name of local Power company and meter number for AC service

b. Structure to soil potentials:

Depolarized potential ON potential OFF potential Potential shift, difference between the OFF potential and the Depolarized potential.

c. Anode Junction Boxes:

Shunt rating Milivolt drop across each shunt DC current output of each anode Total current output of each anode groundbed

d. Pipeline Junction Boxes:

Shunt rating Milivolt drop across each shunt DC current applied to each pipeline

e. Stray Current Interference Tests:

Participating utilities.

Results of testing indicating possible interference.

Acceptance Criteria

a. Operation of Rectifiers

Voltage output can be adjusted to maximum rated value and/or maximum rated current can be achieved.

b. Operation of Anode Groundbeds Individual anode currents are consistent.

Sum of the individual anode currents shall be equal to total output current of rectifier.

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c. Cathodic Protection Operating Levels Baseline potentials are commensurate with previous operating data.

Initial energized potentials indicate protective potential shift.

Long term potential measurements indicate attainment of NACE International SP0169 criteria.

Potentials on all insulating flanges indicate flange effectiveness.

d. Stray Current Interference Test Results Potentials on structures indicate no damaging stray current interference effects.

Final Report

a. Prepare after completion of installation of cathodic protection installations and testing. Include at minimum the following:

Marked-up As-built Drawings.

All Field Test Data as described in section above.

Discussion of the Installation.

Recommendations for Maintenance of the System.

Operations and Maintenance Manual.

E. Continuity Testing for new construction:

Submit records of joint bond resistance testing including:

a. Instruments and equipment used, with sketch of test connections.

b. Test amperages, voltages, and voltage changes during testing.

c. Joint resistance, measured and calculated.

d. Location of each test station, giving pipe station and street address, and GPS coordinates.

Measure joint bond resistances:

a. Conduct longitudinal pipe resistance measurements between consecutive test stations.

Measured by impressing a DC test current between pipe test lead wires at consecutive test stations.

Simultaneously measure DC voltage between pipe test lead wires at the same consecutive test stations while impressing the DC current.

b. Calculate the resulting span resistance and submit to Engineer for review and acceptance.

Submit all calculations and data in their entirety.

Provide GPS coordinates for each test station.

Calculate theoretical joint and bond resistances:

a. Measure distance between test stations.

b. Using Calculated Resistance Table herein at end of Section, multiply measured distance by Resistance per Foot (ohms) from table to obtain theoretical (or calculated) resistance of pipe and multiply number of bonded pipe joints by the theoretical resistance of a joint bond.

c. Acceptable resistance: Measured resistance shall not exceed 15 percent of calculated resistance.

PART 4 MEASUREMENT AND PAYMENT

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4.1 IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM

A. Measurement: By each complete in place.

B. Payment: At unit price for each as listed in Bid Schedule.

1. Payment includes provisions to provide necessary components for complete impressed current cathodic protection system.

4.2 TEST STATIONS

A. Measurement: By each complete in place.

B. Payment: At unit price for each as listed in Bid Schedule.

1. Payment includes provisions to provide test stations, including but not limited to, joint bonding, insulating joints, lead wires, anodes and other necessary components to complete corrosion control system.

**WSSC**