SPECIAL_PROVISION_SPECIFICATION_SECTION_SP-02513.pdf

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January 2021, Rev. No. 2 – June 2024

SPECIAL PROVISION SPECIFICATION

SECTION SP-02513

STEEL PIPE FOR BURIED WATER SERVICE

PART 1 GENERAL

1.1 DESCRIPTION

A. This Special Provision Specification Section includes requirements to furnish, construct, and test Steel Pipe for Buried Water Service.

B. This Special Provision Specification Section also includes requirements for external coating of all steel pipe and fittings for corrosion protection. The Contractor may elect to use any one of the following three coating systems (as more fully described under PART 2 – PRODUCTS of this specification):

1. Polyurethane: A liquid-applied polyurethane coating, PipePro Ultra by Polycoat

Products, DuraShield 110 by LifeLast or approved equal.

2. Tape Wrap: A three-layer tape wrap system, YGIII as manufactured by Polyken

Technologies or approved equal.

3. Butyl Rubber Adhesive with Polyethylene Top Coat, Pritec as manufactured by

Bredero Shaw Company or approved equal.

C. Pipe and fittings installed in vaults shall be primed and painted, as specified herein.

D. Refer to Special Provision Specifications Section SP-02315, EARTHWORK FOR PIPELINE CONSTRUCTION for requirements related to additional requirements for pipeline backfill.

E. Refer to WSSC Standard Specification Section 02510 - Water Distribution System, for requirements on other materials, or work that is related or similar that is shown, specified, or required by this Contract, but not specified herein, or in other Sections of this Contract.

F. Chlorinate and de-chlorinate following WSSC Standard Specification Section 02511

– Chlorination and Dechlorination.

G. Refer to WSSC Standard Specification 13110 - Galvanic Anode Cathodic Protection for corrosion control requirements.

H. Contractor’s Qualifications: Submit information on the company that will install the water main. The Company shall have a minimum of 5 years of experience, including a minimum of 5 projects, and a minimum of 1,000 linear feet in the installation of welded steel pipe 48-inch and larger. At least 2 of the projects shall be completed within the past 3 years. The information shall include a client list where steel pipe water mains have been installed on similar sized pipe. The client list shall include the names and telephone numbers of the client contacts along with email addresses.

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1.2 COATING QUALITY ASSURANCE REQUIREMENTS

A. Comply with the following standards:

1. American Society for Testing and Materials (ASTM)

a. ASTM D149: Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies

b. ASTM D257: Test Methods for D-C Resistance or Conductance of Insulating Materials

c. ASTM D471: Test Method for Rubber Property-Effect of Liquids

d. ASTM D570: Test Method for Water Absorption of Plastics

e. ASTM D638: Test Method for Tensile Properties of Plastics

f. ASTM D1000: Test Methods for Pressure-Sensitive Adhesive-Coated

Tapes Used for Electrical and Electronic Applications

g. ASTM D1505: Test Method for Density of Plastics by the Density-

Gradient Technique

h. ASTM E96: Test Methods for Water Vapor Transmission of Materials

i. ASTM F1249: Test Method for Water Vapor Transmission Rate Through

Plastic Film and Sheeting Using a Modulated Infrared Sensor

j. ASTM G8: Test Method for Cathodic Disbonding of Pipeline Coatings

k. ASTM G13: Test Method for Impact Resistance of Pipeline Coatings

l. ASTM G14: Test Method for Impact Resistance of Pipeline Coatings

(Falling Weight Test)

m. ASTM G17: Test Method for Penetration Resistance of Pipeline Coatings

(Blunt Rod)

n. ASTM G95: Test Method for Cathodic Disbonding of Pipeline Coatings

(Attached Cell Method)

2. NACE International (NACE)

a. SP0274: High-Voltage Electrical Inspection of Pipeline Coatings Prior to

Installation

b. SP0188: Discontinuity (Holiday) Testing of Protective Coatings

3. American Water Works Association (AWWA)

a. AWWA C209: Cold-Applied Tape Coating for the Exterior of Special

Sections, Connections, and Fittings for Steel Water Pipelines

b. AWWA C214: Tape Coating Systems for the Exterior of Steel Water

Pipelines

c. AWWA C216: Heat-Shrinkable Cross-Linked Polyolefin Coatings for the

Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines

d. AWWA C222: Polyurethane Coatings for the Interior and Exterior of Steel Water Pipelines

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4. NSF International

a. NSF 61 Drinking Water System Components - Health Effects

B. Materials: In addition to the above standards, comply with the requirements of Part 2 of this specification. All materials shall be supplied by a manufacturer regularly engaged in production of protective coatings for pipelines.

C. Coating Applicator:

1. Factory-applied coatings: Coatings shall be factory-applied to the greatest extent possible. Applicator shall be regularly engaged in the pipe coating business and have a successful record of applying specified coating for at least 5 years. Pipe coating applicator shall be a member of the National Association of Pipe Coating Applicators (NAPCA). The Contractor shall notify the Owner 10 business days prior to the start of pipe coating operations, so that the Owner may witness the pipe coating operation at the factory, if the Owner so chooses.

2. Field-applied coatings: Repair coatings and joint coatings applied in the field shall be installed only by persons factory-trained and factory-certified for the particular product used. The Owner or his representative (Inspector) shall be afforded the opportunity to examine all field-applied coatings before the pipe is lowered into the trench.

D. Testing of Coatings: Factory-applied coatings shall be tested before they leave the factory. Field-applied coatings shall be tested before the pipe is lowered into the trench. Testing shall be supervised by a NACE International Certified Corrosion Specialist, Senior Corrosion Technologist, or corrosion engineer with at least 5 years’ experience in corrosion engineering.

1.3 REQUIREMENTS FOR MANUFACTURERS, SUPPLIERS AND CONTRACTORS

BEFORE DELIVERY

A. Standards (as applicable):

1. Steel Water Pipe 6 inches and Larger: ANSI/AWWA C200.

2. Cement-Mortar Protective Lining and Coating for Steel Water Pipe-4 inch and

Larger-Shop Applied: ANSI/AWWA C205.

3. Field Welding of Steel Water Pipe: ANSI/AWWA C206.

4. Steel Pipe Flanges for Waterworks Service, 4 inch – 144 inch: ANSI/AWWA

C207.

5. Dimensions for Fabricated Steel Water Pipe Fittings: ANSI/AWWA C208.

6. Tape Coating Systems for the Exterior of Steel Water Pipelines: Per Section 1.2 above.

7. Installation of Steel Water Pipe – 4 inch (100 mm) and Larger: AWWA C604.

8. Steel pipe design and installation: AWWA M11.

9. Structural Welding Code-Steel: AWS D1.1.

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B. Conduct quality assurance for furnished pipe and fittings following standards specified herein.

a. Commission may inspect piping materials following WSSC Standard Specification Section 01450.

1.4 SUBMITTALS

A. Submit following WSSC Standard Specification Section 01330 – Submittal Procedures.

1. Waiver for pipe and fittings: Submit letter naming the manufacturer who has on file with the Commission a certified standard drawing containing required Commission approved information. Provide new submittals if specifications change.

B. Catalog Data for the Coating System

1. Coating materials, including typical laboratory data, recommended application rates and methods, and Material Safety Data Sheets (MSDS).

2. Surface preparation instructions.

3. Coating defect repair procedures.

4. In-factory testing procedure.

C. Submit following WSSC Standard Specification Section 01450 on Contractor provided materials.

1. Certificates of Compliance or Materials Checklist Furnished by the Commission, for all applicable materials specified herein.

2. Manufacturer’s Certified Test Reports.

D. Coating Quality Assurance/Control Submittals.

1. Certificate of Compliance: Provide a certification from the coating manufacturer that the product furnished for this project complies with the applicable standards of AWWA and ASTM (list which standards in the certification.)

2. Installer’s qualifications.

a. Qualifications of (factory) pipe coating applicator, as a firm.

b. Qualifications of field coating applicator, as an individual(s).

3. Coating tester’s qualifications, methods, and procedures for testing coating system, including description of equipment and instruments to be used (both factory and field).

E. Submit for Coated Pipe:

1. From Pipe Manufacturer:

a. Recommended field coating of welded joints.

2. From Coating Manufacturer:

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a. Recommended guidelines for environmental conditions to protect pipe and fittings from moisture, humidity, and temperature in area where cleaning, coating application, curing, and repair of coating is performed.

b. Recommended repair methods and procedures for repair of defects and damage to coating, including limits for defects or damage considered repairable.

1) Include repair methods and procedures for use on Contract site and at coating applicator’s site.

2) Include cure times and consider all weather conditions in location of installation.

F. The following items shall also be submitted:

1. Pipe Manufacturers’ installation instructions for Steel pipe and fittings.

2. Shop Drawings, including pipeline layouts schedule showing stations and invert elevations.

3. Details of standard pipe, specials and fittings.

4. Details for the Dish inserts for testing on the end sections of pipe.

5. Details of the section of pipe with outlets.

6. Pipe Manufacturer shall be responsible for compiling their own design calculations. The submittal process must be overseen by a Professional Engineer (P.E.). Calculations shall be signed and sealed by a P.E. registered in the State of Maryland.

7. Welder certifications and qualifications.

8. Details of stulling and shipping packaging.

9. Copy of the manufacturer’s quality control check of pipe material and production.

10. Qualifications: All steel pipe and fittings shall be furnished by manufacturers who are fully experienced, SPFA or ISO 9001 certified, reputable, and qualified in the manufacture of the products to be furnished. Also, the plant in which the pipe is manufactured shall be SPFA or ISO 9001 certified. The pipe and fittings shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these Specifications as applicable.

11. Certifications: Manufacturer’s affidavits of compliance that all materials furnished are in compliance with the applicable requirements of the referenced standards and this specification.

12. Manufacturer: Pipe shall be the product of one manufacturer that has not less than ten (10) years successful experience manufacturing pipe of the particular type and size indicated. Pipe shall be as manufactured by the Northwest Pipe Company, American Spiralweld Pipe, Thompson Pipe Group, or approved equal.

1.5 VERIFICATIONS

A. Inspections: All pipe shall be subject to inspection at the place of manufacture in accordance with the provisions of ANSI/AWWA C200 and ANSI/AWWA coating and lining standard as supplemented by the requirements herein.

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B. Tests: Except as modified herein, all materials used in the manufacture of the pipe shall be tested in accordance with the requirements of ANSI/AWWA C200 and ANSI/AWWA coating and lining standards.

C. The Contractor shall perform said material tests at no additional cost to the Owner.

The Engineer shall have the right to witness all testing conducted by the Contractor.

D. Welding Requirements: All welding procedures used to fabricate pipe shall be qualified under the provision of ANSI/AWS B2.1 or ASME Sec. IX. Welding procedures shall be required for, but not limited to, longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections.

E. Welder Qualifications: All welding shall be done by skilled welders, welding operators, and tackers who have had adequate experience in the methods and materials to be used. Welders shall maintain current qualifications under the provisions of ANSI/AWS B2.1 or ASME Sec. IX. Machines and electrodes similar to those in the work shall be used in qualification tests. The Contractor shall furnish all material and bear the expense of qualifying welders. Field Welders shall have a minimum of three (3) years’ experience in welding large diameter steel water mains.

F. Welding Inspectors: Shall maintain current qualifications under the provisions of ANSI/AWS B2.1 or ASME Sec. IX, and have a minimum of two (2) years’ experience inspecting large diameter welded steel water mains.

1.6 HANDLING, STORAGE AND SHIPPING:

A. Pipe shall be stulled as required to maintain roundness of +/- 1 percent during shipping and handling.

B. Coated pipe shall be shipped on padded bunks with nylon belt tie-down straps or padded banding located approximately over stulling.

C. Coated pipe shall be stored on padded skids, sand or dirt berms, sand bags, old tires or other suitable means so that coating will not be damaged.

D. Coated pipe shall be handled with the wide belt slings, padded forks or other means that will not damage the pipe. Chains, cables or other equipment likely to cause damage to the pipe or coating shall not be used.

E. Prior to shipment, the pipe shall be visually inspected for damage to the coating. If repairs are required, they shall be in accordance with the requirements of this specification section.

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F. The pipe shall not be handled by use of forks on the interior of the pipe, as this practice may damage the cement mortar interior lining.

PART 2 PRODUCTS

2.1 MATERIALS

A. General

1. Provide pipe and fitting of same size and material by same manufacturer, marked with manufacturer’s name or trademark.

2. Bolts and nuts: Marked, cast, or forged with identification of material and producer. Painted markings are not acceptable.

3. External pipe surfaces (this includes all piping, joints, fittings, etc.) are to be coated. Predominant method to be shop application. The piping shall receive an exterior coating in the pipe manufacturer’s shop or at a separate applicator’s facility.

4. All components of the coating system shall be manufactured by a single supplier to assure compatibility of individual components.

5. Field applied coatings to be limited to repairing damage to shop coating; coating exposed metal at joints, fittings, bond and test wire connections (if any); and other appurtenances that are not shop coated.

6. Extent of piping to be shop coated and extent to be field coated shall be clearly identified in Contractor’s material and quality assurance submittals. Quality assurance submittals shall include pipe coating, handling and testing procedures.

7. All coatings used on project shall be as specified herein. All products comprising completed coating system shall be compatible and the same products shall be used throughout the project. On water mains, the pipe surfaces that will come in contact with potable water inside the pipeline (e.g. spigot ends of bell and spigot joints) shall be coated with materials having NSF-61 certification.

B. Steel Pipe:

1. Steel Pipe shall be designed, manufactured, tested, inspected and marked in accordance with the provisions of this Specification and shall conform to AWWA C200 Steel Water Pipe, 6 In. (150 mm) and Larger, except as herein modified.

2. Steel Pipe shall conform to AWWA MANUAL M11 (Fifth Edition) Steel Pipe – A Guide for Design and Installation and shall conform to AWWA C604 Installation of Buried Steel Water Pipe – 4 In. (100 mm) and Larger.

3. All steel used for the fabrication of pipe shall be of domestic origin and shall have a minimum yield strength of 42 ksi.

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4. Pipe manufacture shall conform to any of the following:

a. ASTM A139 Standard Specification for Electric-Fusion (Arc)-Welded Steel

Pipe (NPS 4 and Over) with a Grade C Minimum Yield Point = 42 ksi, or better.

b. ASTM A572 Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel with a Grade 42 Minimum Yield Point = 42 ksi, or better.

c. ASTM 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 with a Grade 45 Minimum Yield Point = 45 ksi, or better.

d. ASTM 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 with a Grade 45 Minimum Yield Point = 45 ksi, or better.

5. Pipe shall be 0.50 -inches minimum wall thickness.

6. Pipe shall be designed for a minimum internal pressure of 210 psi.

7. Pipe shall be designed to the cover conditions as shown on the drawings.

8. Coatings and Linings:

a. Coating system for the exterior of steel water pipelines shall conform to the requirement of this specification section.

b. Cement-mortar protective lining for the interior of steel water pipelines shall conform to AWWA C205. For the cement-mortar lining, 100 percent of the fine aggregate shall pass a 3/8-inch sieve. Minimum compressive strength of the cement-mortar shall be 4,500 psi. The allowable deflection under the cover condition load shall be 3% for pipe coated with cement mortar.

9. After the joint configuration is completed, and prior to lining with double cement-mortar, each length of each diameter shall be tested at a pressure of at least 75 percent of the specified yield strength of the pipe steel.

10. Pipe may be furnished in up to 40-foot laying lengths with special lengths, field trim pieces and closure pieces as required to meet the required lines and grades shown on the Plans as well as for pipe fittings and appurtenances. The pipe fabricator shall prepare a pipe laying schedule showing the location of each piece by mark number with station and invert elevation at each joint deflection and bell end. Pipe Closures shall be shown on the pipe laying schedule.

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11. All pipe segments, fittings and specials shall be marked with date of manufacture.

12. Pipe manufacturer shall conform to the following:

a. Have in-house pipe production experience including steel pipe, steel joints, specialty steel fittings, transition fittings, protective linings, and protective coatings.

b. Have in-house pipe production experience for a minimum of 1,000 feet of steel pipe for potable water mains over the last 5 years, with a minimum diameter of 30 inches.

c. Manufacturer shall be Northwest Pipe Company, Thompson Pipe Group US, United States Pipe & Foundry Company LLC, or an approved equal.

C. Fittings and Transition Adapters:

1. Fittings shall be fabricated in accordance with AWWA C200 Section 4 from pipe conforming to the above standards. Fittings fabricated from previously hydrostatically tested straight pipe shall require testing of only those welded seams that were not previously hydrostatically tested in the straight pipe. This testing shall be by the dye penetrant or magnetic particle method.

2. Fittings shall conform to the dimensions of AWWA C208 or may be fabricated into standard or special pipe lengths. Fittings shall be of the same material and minimum thickness as the pipe. Fittings shall be equal in pressure design strength and shall have the same lining and coating as the abutting pipe. Elbows over 0 degrees through 22-1/2 degrees shall be two pieces; over 22-1/2 degrees through 45 degrees shall be three pieces; over 45 degrees through 67-1/2 degrees shall be four pieces; and over 67-1/2 degrees through 90 degrees shall be five pieces.

Elbows shall have a minimum radius of 2-1/2 times the pipe O.D. All tees, laterals and outlets shall be reinforced in accordance with AWWA M11.

3. All fittings shall be restrained using double welded lap joints per AWWA M11 and the detail on the Contract Drawing.

4. Bell and spigot joint ring of the transition adapter shall be steel, self-centering type, and otherwise as specified in Section 4.5.3 of AWWA C301. The rubber gaskets shall be in compliance with Sections 4.4.11 and 4.5.4 of AWWA C301 and shall be designed and manufactured so the completed joint will withstand an internal water pressure of the 250 psi design pressure of the pipe itself without showing any leakage by the gasket or displacement of it.

5. Steel fittings shall be manufactured by the same manufacturer of the steel pipe.

D. Pipe and Fitting Joints:

1. Unless otherwise shown or specified, all pipe joints shall be Lap-Welded Slip

Joint with double field welded (exterior and interior), in conformance with AWWA M11 and AWWA C206 and the details on the Contract Drawing.

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2. Prepare all joints for field welding in accordance with the requirements of

AWWA C200.

a. 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 expanding with segmental dies. If approved by the Engineer, bell ends formed by a rolling process shall be accomplished in not more than 6 passes (revolutions) over the bell surface and any resulting radius shall be not less than 15 times the thickness of the material being formed.

b. Shop-applied exterior coatings shall be held back a minimum of 9-inches from the spigot and bell ends. Minimum spigot/bell overlap shall be 4-inches for lap welded joints. See Detail on the Contract Drawings.

c. All lap-joint pipe prepared for field welding, both bell and spigot ends shall be sized to provide a difference in circumferential measurement between the outside circumference of the spigot and the inside circumference of the bell.

3. Flanges:

a. Flanges shall be in accordance with AWWA C207 Class E for pressures over

150 psi to 275 psi when mating steel to steel. Shop lining and coating shall be continuous to end of the pipe or back of flange. Flange faces shall be shop coated with a soluble rust preventive compound.

b. Gaskets: shall be 1/8 inch thick of the full face rubber type per AWWA C207 unless otherwise specified.

c. Bolts and Nuts for Flanges: Bolts and nuts for buried and submerged flanges and flanges located outdoors above ground or in open vaults in structures shall be Type 316 stainless steel conforming to ASTM A194, Grade B8M for bolts, and ASTM A194, Grade B7. Nuts shall comply with ASTM A194, Grade 8M. Threads on bolts and nuts shall be treated with a coating to prevent galling of the stainless steel.

d. Provide specially drilled flanges when required for connection to existing piping or special equipment.

E. Deflected Pipe Joints:

1. As allowed by AWWA C-208, a small deflection angle in the pipeline may be taken in a welded lap joint using a miter-cut bell end provided the following are maintained:

a. To form a miter-cut bell, the pipe end is miter cut, and then the bell is expanded square with the face of the miter cut (see Figure 2B of AWWA C-208).

b. The miter-cut angle of a weld bell is limited to deflections less than 5 degrees.

F. Shop Applied Materials of the external coating for all steel pipe shall be one of the following coating systems:

1. Polyurethane: 100 percent solids polyurethane in accordance with AWWA C222, with the following minimum properties, or approved equal:

a. Adhesion to steel (SSPC SP5): 1,300 to 1,800 psi.

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b. Cathodic disbondment (ASTM G8 OR G95): <10 mm rad.

c. Resistivity: l x 1014 ohms-cm.

d. Dielectric strength: > 200 volts per mil.

e. Water Absorption (ASTM D471): <3% (no absorption below surface).

f. Solids Content (Conversion to Solids by Volume): 99%.

g. Volatile Organic Compounds (VOC’s): 0.08 lbs. per US gallon.

h. Final coating shall have a nominal dry film thickness of 35 mils with a minimum dry film thickness of 30 mils.

i. Coating shall be PipePro Ultra by Polycoat Products, DuraShield 110 by

LifeLast, CorroPipe® II PW Ultra by Sherwin Williams, or approved equal.

2. Tape Wrap: Three layer tape wrap system in accordance with AWWA C214 with the following minimum properties, or approved equal:

a. Primer: A liquid primer composed of butyl, tackifiers, and other ingredients to protect against soil oxidation and bacteria growth. Total solids shall be 20% (plus or minus 2%) by weight.

b. Innerwrap: A two component extruded black tape consisting of polyethylene and butyl rubber adhesive specially designed to conform to the particular pipe material being coated. The innerwrap shall have the following properties:

1) Thickness: 20 mils (9 mils polyethylene backing, 11 mils butyl rubber adhesive).

2) Adhesion to primed steel: 20 oz/in width (ASTM D1000).

3) Tensile strength: 30 lbs/in width (ASTM D1000).

4) Water vapor transmission rate: <0.2 gm/l00 in2/24 hr.

5) Dielectric strength: 21 kV (ASTM D149).

6) Insulation resistance: 1,000,000 M Ohms (ASTM D257).

7) Tape width: As recommended by coating manufacturer.

c. Middlewrap: A two component extruded grey tape consisting of polyethylene and butyl rubber adhesive. The middlewrap shall contain stabilizers and inhibitors to resist the destructive effects of ultra-violet light.

The middlewrap shall have the following properties:

1) Thickness: 30 mils (25 mils polyethylene backing, 5 mils butyl rubber adhesive).

2) Adhesion to backing: 45 oz/in width.

3) Tensile strength: 60 lbs/in width (ASTM DI000).

4) Abrasion resistance: Excellent (ASTM D1000).

5) Water vapor transmission rate: <0.2 gm/100 in2/24 hr.

6) Dielectric strength: 23 kV (ASTM D149).

7) Insulation resistance: 1,000,000 M Ohms (ASTM D257).

8) Tape width: As recommended by coating manufacturer.

d. Outerwrap: A two component extruded white tape consisting of polyethylene and butyl rubber adhesive. The outerwrap shall contain

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stabilizers and inhibitors to resist the destructive effects of ultra-violet light.

The outerwrap shall have the following properties:

1) Thickness: 30 mils (25 mils polyethylene backing, 5 mils butyl rubber adhesive).

2) Adhesion to backing: 45 oz/in width.

3) Tensile strength: 60 lbs/in width (ASTM D1000).

4) Abrasion resistance: Excellent (ASTM D1000).

5) Water vapor transmission rate: <0.2 gm/100 in2/24 hr.

6) Dielectric strength: 23 kV (ASTM D149).

7) Insulation resistance: 1,000,000 M Ohms (ASTM D257).

8) Tape width: As recommended by coating manufacturer.

e. Coating system shall be YGIII as manufactured by Polyken Technologies or approved equal.

f. YGIII 80 Mils System Properties:

1) Peel adhesion to primed steel: 300 % (ASTM D1000).

2) Cathodic disbondment: 0.25 in radius (ASTM G8).

3) Water vapor transmission: 0.07 perms (ASTM E96B).

4) Water vapor transmission rate: 0.03g / 100 in2 / 24 hrs (ASTM F1249).

5) Volume resistivity: 1015 ohm-cm (ASTM D257).

6) Dielectric breakdown: 650 volts/mil (D1000).

7) Dielectric strength: 20-23 kV (ASTM D149).

8) Impact resistance: 90 in-lbs (ASTM G14).

9) Impact resistance: 1000 lbs, no holidays (ASTM G13).

10) Penetration resistance: 11-15% (ASTM G 17).

3. Butyl Rubber Adhesive with Polyethylene Top Coat; Polyolefin (extruded butyl rubber adhesive with polyethylene top coat) system with the following minimum properties, or approved equal:

a. Compounded butyl rubber adhesive coating with less than 0.1% water absorption. Nominal thickness 10 mils.

b. Top coat: High density polyethylene resin top coat that is spirally extruded onto adhesive coating in multiple layers to form a seamless bonded coating.

The polyethylene top coat shall have the following properties:

1) Nominal thickness: 40 mils.

2) Density: >0.95 (ASTM D1505).

3) Elongation: >600% (ASTM D638).

4) Tensile strength: <2800 psi (ASTM D638).

c. Total coating system shall have the following properties:

1) Thickness: 50 mils (40 mils polyethylene top coat, 10 mils butyl rubber adhesive).

2) Impact resistance: >60 inch lbs (ASTM G14).

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3) Cathodic disbondment: 6 mm radius (ASTM G8 OR G95).

4) Water absorption: 0.06% (ASTM D570).

d. Coating system shall be Pritec as manufactured by Bredero Shaw Company or approved equal.

G. Shop Applied Materials for Coating Special Sections, Connections, and Fittings:

The shop applied materials for coating special sections, connections, and fittings shall be a two component extruded tape consisting of polyethylene and butyl rubber adhesive in accordance with AWWA C209. The jointwrap and repair tape (Polyken 934 or approved equal) shall have the following properties:

1. Thickness: 35 mils (7 mils polyethylene backing, 28 mils butyl rubber adhesive).

2. Elongation: 150% (ASTM D 1000).

3. Tensile strength: 15 lbs/in width (ASTM D1000).

4. Water vapor transmission rate: 0.05 gm / 100 in2 / 24 hr (ASTM F1249)

5. Dielectric strength: 23 kV (ASTM D149).

6. Insulation resistance: 1.4 x 107 M Ohms (ASTM D1000).

7. Tape width: As recommended by the coating manufacturer.

8. The filler tape (Polyken 939 or approved equal) recommended by the jointwrap tape manufacturer shall be used to fill uneven areas of the sections, connections, and fittings to assure a smooth application of the jointwrap tape.

H. Pipe and Fittings in Vaults: Outside surfaces of all ferrous metals (except stainless steel) within vaults, including but not limited to pipe, fittings, supports, hangers, and mechanical equipment shall be coated as follows: one shop-applied primer coat TNEMEC Series 66 Hi-Build Epoxoline or approved equal applied at 3 – 5 mils DFT, plus one field-applied topcoat TNEMEC Series 66 Hi-Build Epoxoline or approved equal applied at 4 – 6 mils DFT. Color to be selected by Owner. Components with factory-applied fusion bonded epoxy (FBE) coating need not be field painted. Touch-up any damage to FBE as recommended by the coating manufacturer.

I. Pipe and Fittings Exposed to Weather: Outside surfaces of all ferrous metals (except stainless steel) exposed to weather, including but not limited to pipe, fittings, supports, hangers, and mechanical equipment shall be coated as follows: one shop-applied primer coat TNEMEC Series 66 Hi-Build Epoxoline or approved equal applied at 3 – 5 mils DFT; plus one field-applied coat TNEMEC Series 66 Hi-Build Epoxoline or approved equal applied at 4 – 6 mils DFT; plus one field-applied topcoat TNEMEC Series 73 Endura-Shield or approved equal applied at 2 – 5 mils DFT.

Color to be selected by Owner. Components with factory-applied fusion bonded epoxy (FBE) coating need not be field painted. Touch-up any damage to FBE as recommended by the coating manufacturer.

J. Field Applied Materials for Coating Repairs: Shop applied coatings that are damaged in transit or during handling shall be repaired prior to backfilling. The field applied

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repair coatings shall be as recommended by the shop applied coating manufacturer and shall be entirely compatible with the original coating system. The field coating repairs shall be performed in accordance with all recommendations of the coating manufacturer.

K. Coating for Thermite Welds: Follow requirements of WSSC Standard Specification Section 13110.

L. External Coating System for Insulating Flanges And Insulating Corporation Valves:

Insulating flanges and insulating corporation valves shall receive an exterior tape wrapping in the field. The coating applicator must abide by and follow all manufacturer's application specifications for the coating system. All components of the coating system shall be manufactured by a single supplier to assure compatibility of individual components. The coating system shall be manufactured by Trenton Corporation or an approved equal.

1. Primer: A blend of microcrystalline wax, plasticizer, and corrosion inhibitors having a paste-like consistency, designed to displace moisture, penetrate rust and wet the surface, ensuring adhesion of the tape. The primer shall be Trenton Wax-Tape Primer or approved equal.

2. Filler Putty: A cold applied anti-corrosive moldable filler material used to even the contours of irregular fittings and surfaces. The filler putty shall have the following properties:

a. Specific gravity: 1.15.

b. Density: 24 cu in/lb.

c. The filler putty shall be Trenton Fill-Putty or approved equal. Filler putty shall be used at all irregular surfaces to provide a smooth surface for the application of the innerwrap and outerwrap.

3. Innerwrap: A non-woven, non-stitch bonded synthetic fabric saturated with a blend of microcrystalline wax, plasticizer, and corrosion inhibitor (no clay fillers). The inner tape shall have the following properties:

a. Thickness: 70 to 90 mils.

b. Dielectric strength: 170 volt/mil.

c. The innerwrap shall be Trenton #1 Wax-Tape or approved equal.

4. Outerwrap: A white, resin coated, woven fiberglass fabric. The outerwrap shall have the following properties:

a. Thickness: 0.005 inch.

b. Tensile strength (per one inch width): 85 lb min.

c. Tape width: 6 inches.

d. The outerwrap shall be Trenton Glas-Wrap or approved equal.

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M. Inspection of Delivered Materials: See WSSC Standard Specification Section 01450

– Quality Control.

2.2 SURFACE PREPARATION PRIOR TO COATING

The exterior surface of the piping shall be cleaned in accordance with the coating manufacturer's recommendations.

2.3 CERTIFICATION OF EXTERNAL COATING

The pipe or fitting manufacturer or coating applicator, as appropriate, shall test and certify the exterior coating prior to shipping to the project site. When the pipe or fitting arrives at the job site, the Contractor shall visually inspect the pipe or fitting, and repair any and all damage as directed by the coating manufacturer and in accordance with these specifications.

PART 3 EXECUTION

3.1 INSPECTION AND TESTING

A. All pipe shall be inspected and tested at the manufacturing facility.

B. The Owner shall have the right to have any or all piping, fittings or specials inspected and tested by an independent testing agency at the manufacturing facility or elsewhere.

C. Mark as rejected and immediately remove from the jobsite, or repair to the Owner's satisfaction, all pipe lengths exhibiting signs of damage to the lining, coating, joints or pipe wall.

D. The Contractor shall retain the services of a Certified Independent Testing Agency (approved by the Owner) to test all field welded joints by the magnetic particle, ultrasonic, or radiographic testing methods. The Testing Laboratory shall furnish two

(2) bound copies of all results to the Engineer.

E. Hydrostatic Testing:

1. Complete hydrostatic testing of steel water pipe and fittings in accordance with AWWA C604 and WSSC Standard Specification Section 02510 – Water Distribution System. Test pressure, as indicated on the plans, shall be introduced at the water main low

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point. Hydrostatic testing of the new 72” steel water main shall be done prior to connecting to the existing 72” PCCP water main.

F. Handling of Pipe and Fittings: Steel pipe, fittings, and appurtenances shall be handled in accordance with AWWA C604:

1. If damage or coating abrasion occurs and is repairable, repair following approved manufacturer's recommendations and in accordance with the requirements of this specification section.

2. Cement Mortar Lining:

a. Remove and replace rejected pipe, fittings or appurtenance.

b. Field cut and remove damaged section of pipe to 6 inches beyond damaged lining.

3. Coated Pipe.

a. Repair as directed by coating manufacturer. Test coating for flaws electrically with holiday detector, following NACE SP0274 or SP0188. Repair holidays and recheck. Coating must be verified free of holidays prior to use.

4. Remove pipe and fittings when contaminated with oil, gasoline, kerosene, or other material that damages coating, and replace.

5. Keep interior of pipe clean during installation and thereafter.

6. Should foreign material or contaminants be observed in previously installed pipe or fittings cease work until foreign material is removed or contaminated pipe and fittings are decontaminated or replaced.

7. Close open ends of pipes and fittings with watertight seal during periods when work is not proceeding.

G. Trench Excavation, Backfill, and Test Pits: Follow Standard Detail M/8.1b for Flexible Pipe and Standard and Special Provision Specifications Section SP-02315, EARTHWORK FOR PIPELINE CONSTRUCTION, and as specified herein.

1. Before submission of piping layout (lay schedule) and pipe installation:

a. Dig test pits to determine size, type, and exact location of existing pipe to which proposed pipe will connect.

b. Excavate sufficient trench in advance and test pit all existing underground utilities or structures, whether shown on Contract Drawings or visually identified in the field, to:

1) Verify actual locations.

2) Make reasonable changes in line and grade to resolve conflicts, with

Contract Manager’s approval.

c. Furnish Contract Manager location and elevation information when previously unknown or different underground utilities or structures are encountered.

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January 2021, Rev. No. 1 – February 2023

H. Pipe Placement:

1. Excavate bell holes at each joint to assemble joint so entire length of each pipe barrel and fitting is supported on firm bedding or soil.

2. Field Cutting: Smooth and at right angles to pipe axis with cutting/joints to meet pipe locations and elevations shown on Contract Drawings.

3. Continue backfill operations following specifications. Backfill shall be in accordance with Standard Detail M/8.1b for Flexible Pipe and Standard and Special Provision Specifications Section SP-02315, EARTHWORK FOR PIPELINE CONSTRUCTION, and as specified herein.

4. Buttresses and Anchors: See Contract Drawings. Advise Contract Manager in advance so that they may inspect and approve excavations before buttresses and anchors are placed.

a. Entire face of excavation against which buttresses will bear: Firm bearing, flat and at proper angle to pipeline and reaction force.

b. Wood form both sides of buttress and maintain dimensions following

Standard Details.

3.2 PROTECTION OF COATING SYSTEMS DURING CONSTRUCTION

A. At all times during construction of the pipeline, the CONTRACTOR shall take every precaution to prevent damage to the protective coating. No metal tools or heavy objects shall be permitted to come into contact unnecessarily with the finished coating. Workmen shall not be permitted to walk on the coating, except when absolutely necessary and approved by the ENGINEER, in which case, they shall wear shoes with rubber or composition soles and heels or other suitable footwear which will not damage the coating.

B. Externally coated pipe shall be hoisted from the trench side to the trench by means of a minimum of two 18-inch wide belt slings of sufficient strength to handle the weight of the piping safely.

C. Any and all coating damage shall be repaired with specified coating repair materials prior to installation.

3.3 TRANSPORTATION, HANDLING AND STORAGE OF COATED PIPE

A. Pipe shall be handled in accordance with AWWA C214 and in such a manner as to protect the pipe and the coating from damage.

B. At the pipe coating plant, if forklifts are used, all bearing surfaces of a forklift apparatus must be padded with suitable padding material. Web slings may also be used at the pipe manufacturer's plant.

C. At the project site, the pipe shall only be handled with slings. Metal chains, cables, tongs, forklifts or other equipment likely to cause damage to the coating, will not be permitted. Web slings shall be a type that will not damage the coating. When pipe

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is handled with slings, there should be a minimum of two slings. Slings should be a minimum of 18 inches wide and of sufficient strength to handle the weight of the pipe safely. Slings shall not pass through the pipe. Hooks on the end of the pipe will not be allowed. Handling equipment, materials, and procedures shall be submitted to the ENGINEER for approval. If possible, the pipe should be han1dled from cutback ends.

D. Storing of the coated pipe shall be on padded 12-inch wide (minimum) skids or select loamy or sand dirt berms, or suspended from cutback ends, where possible. In urban areas, the pipe should be suspended on padded skids or skids placed at cutback areas.

Where skid chucks are used in contact with coated pipe, they should be padded with several layers of carpeting. Padded chucks should be placed such that coated pipe is nested on the skid rather than the chuck. Coated pipe shall not be laid on pavement without benefit of padding at contact points. In preparation for transporting pipe, the web slings shall be used for tie downs.

3.4 COATING OF INSULATING FLANGES AND INSULATING CORPORATION

VALVES

Insulating flanges and insulating corporation valves, including all isolation components, shall be fully coated for a minimum of 12 inches on either side of the flange or corporation valve. The insulator shall be coated after verification of proper electrical isolation. The insulator shall be coated as described below.

A. Clean the surface of the insulator, and all of its components by power tool cleaning in accordance with the SSPC SP3. Follow all surface preparation recommendations of the coating manufacturer.

B. Apply a uniform coat of the primer to the external surface of the insulator, and all of its components including; bolts, nuts, etc. The primer shall extend a minimum of twelve inches on either side of the insulator.

C. Apply filler mastic to all irregular surfaces of the insulator to assure a smooth profile for application of the inner tape coating.

D. Apply innerwrap to the insulator, and its components in a spiral fashion with a minimum overlap of 55%. The innerwrap shall extend a minimum of twelve inches on either side of the insulator.

E. Apply outerwrap to the insulator, and its components in a spiral fashion with a minimum overlap of one inch. The outerwrap shall be applied with sufficient tension to provide continuous adhesion of the outerwrap tape. Install test facilities at the insulating flanges and insulating couplings as shown on the Contract Drawings.

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3.5 INSPECTION OF EXTERNAL COATING

Immediately prior to installation of the pipe or fitting, the CONTRACTOR shall perform ALL of the following:

A. Step One - Visually inspect all exterior coatings on pipe, fittings, specials, and closures for holidays and other defects.

B. Step Two - All visual holidays and defects if any, shall be repaired by the CONTRACTOR as directed by the coating manufacturer and in accordance with this specification and to the satisfaction of the ENGINEER.

C. Step Three - The coating must be tested, REGARDLESS if there are no visual defects, with a holiday detector by the CONTRACTOR. This electrical holiday test shall be in accordance with NACE SP 0274 or SP0188 as recommended by the coating manufacturer and must be witnessed by the INSPECTOR. Holiday detectors shall be manufactured by Tinker and Razor or approved equal.

D. Step Four - If any holidays are detected by the required holiday test than they shall be immediately repaired as mentioned in step two.

E. Step Five - Repeat the holiday test after the coating is repaired.

F. Step Six - Repeat step four and five until there are no holidays detected. Enter in a log that this pipe has successfully passed the holiday test on the date and time it was successfully performed. Each pipe should be assigned a number that corresponds to the stationing on this project. The INSPECTOR must approve the successful holiday testing and sign off on the log sheet.

G. Step Seven - Once the coating on the pipe or fitting is free of holidays and the Holiday Testing Log has been signed off by the INSPECTOR, the piping or fitting may be installed in the trench.

3.6 CHLORINATION

A. Chlorinate and dechlorinate in accordance with WSSC Standard Specification Section 02511 and specified herein.

B. Install 1 inch or 2 inch diameter corporation stops and couplings in water mains for chlorination as required.

1. Remove stops not used for services and replace with plug.

C. Place mains in service when analysis is complete and approved by Engineer.

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3.7 JOINTS

A. Field-coat uncoated metal components in accordance with the requirements of this specification section. Also, apply coating in accordance with referenced AWWA standards and manufacturer’s recommendations.

B. Flanged Joints:

1. Remove grease from flange surface using solvent-soaked rag and wipe clean of dirt and grit.

2. Align flanges accurately, using spirit level, and pipe properly supported before gasket and bolts are inserted.

a. Carefully place rubber gasket to ensure full flow and proper sealing of joint.

b. Give bolt threads light coat of thread lubricant and then insert and turn nuts by hand.

c. Pull up bolts with wrench, employing crossover method.

d. Bolt lengths and required torque: Follow manufacturer's requirements.

3. Field-coat uncoated metal components in accordance with the requirements of this specification section. Also, apply coating in accordance with referenced AWWA standards and manufacturer’s recommendations.

3.8 CONNECTIONS TO EXISTING MAINS AND DAMAGED PIPE REQUIREMENTS

A. Certain information is shown on Contract Drawings relative to existing pipe and other construction.

1. This information was transferred from existing records and is not guaranteed to be accurate.

B. Contractor shall take all precautions to protect the existing PCCP water main from any damage. If the existing PCCP water main is damaged during construction, the Contractor shall repair the damage per pipe manufacturer's recommendations. If WSSC Engineer deems that the damaged PCCP water main cannot be repaired, the Contractor shall replace with new steel pipe at no cost to the Owner.

1. Do not cut existing ductile iron or cast iron pipe closer than 18 inches to joint bell.

2. Cutting the existing PCCP pipe to make a connection is not permitted. Remove existing PCCP pipe back to the next joint to make a connection.

C. Cement-Mortar Lining:

1. Except as otherwise provided in AWWA Standard C205, interior surfaces of all steel pipe, fittings and specials shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with AWWA Standard C205.

Thickness shall be ½” for pipe as specified in AWWA C205. The lining machines shall be of the type that has been used successfully for similar work and shall be approved by the Engineer. Every precaution shall be taken to prevent damage to the lining. If the lining is damaged or found faulty at the delivery site, the

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damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications.

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

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

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

D. Pipe Closures:

1. Pipe closures shall be accomplished using a Butt Strap Joint. See Closure Detail on the Contract Drawing.

3.9 INSTALLATION

A. The Contractor shall provide and install all required piping and accessories in accordance with the Contract Documents and manufacturer's recommendations. Pipe installation as specified in this section supplements AWWA M11 and AWWA C604.

B. The manufacturer shall provide (for informational purposes only) to the Engineer and Contractor, at least 90 days prior to the scheduled arrival date of the initial pipe, fittings, and appurtenances, complete instructions for installation and repair of pipe, fittings, and appurtenances.

C. Care shall be taken when installing heavy fittings on steel pipe, providing good foundations so that the steel pipe does not carry the weight of the fitting.

1. Assembly Joints:

a. Lap field welded Joints:

1) Wire brush exposed end of joint surfaces.

2) Insert the plain end into the expanded bell to provide a minimum overlap of 4-inches at any location around the joint circumference.

3) A double full fillet weld shall be provided by certified welders qualified in accordance with AWS D1.1. Where installed in casing pipe, or otherwise noted on the plans, joint shall be provided with a full fillet weld and a seal weld to allow an air test of the joint through a threaded outlet provided by the pipe manufacturer. This threaded outlet shall be plugged following the successful air test.

2. Complete the interior joint by mortaring the annular space with a stiff mix of non-shrink grout. The grout shall be ANSI/NSF 61 certified for use with potable water.

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3. Flanged joints:

a. Bolt holes of flanges shall straddle the horizontal and vertical centerlines of the pipe. Clean flanges by wire brush before installing flanged fittings. Clean flange bolts and nuts by wire brushing, lubricate bolts with oil and graphite.

b. Insert the nuts and bolts (or studs), finger tighten, and progressively tighten diametrically opposite bolts uniformly around the flange to the proper tension.

c. Execute care when tightening joints to prevent undue strain upon other equipment.

d. If flanges leak under pressure testing, loosen or remove the nuts and bolts, reset or replace the gasket, reinstall or retighten the bolts and nuts, and retest the joints. Joints shall be watertight.

e. For Insulation Flange Bolts, only dielectric lubricants shall be used.

D. Installing Buried Piping:

1. Inspect each pipe and fitting before lowering the buried pipe or fitting into the trench. Inspect the interior and exterior protective coatings. Patch damaged areas in the field with material equal to the original. Clean ends of pipe thoroughly.

Remove foreign matter and…