Awwa c604-2006

SM

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AWWA C604-06(First Edition)

Installation of Steel Water Pipe4 In. (100 mm) and Larger

Effective date: Dec. 1, 2007.First edition approved by AWWA Board of Directors: Feb. 12, 2006.This edition approved: Feb. 12, 2006.

Copyright 2007 American Water Works Association. All Rights Reserved.

ii

AWWA StandardThis document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standardsdescribe minimum requirements and do not contain all of the engineering and administrative information normallycontained in specifications. The AWWA standards usually contain options that must be evaluated by the user of thestandard. Until each optional feature is specified by the user, the product or service is not fully defined. AWWA publicationof a standard does not constitute endorsement of any product or product type, nor does AWWA test, certify, or approveany product. The use of AWWA standards is entirely voluntary. AWWA standards are intended to represent a consensusof the water supply industry that the product described will provide satisfactory service. When AWWA revises or withdrawsthis standard, an official notice of action will be placed on the first page of the classified advertising section of JournalAWWA.The action becomes effective on the first day of the month following the month of Journal AWWA publication of theofficial notice.

Science and TechnologyAWWA unites the drinking water community by developing and distributing authoritative scientific and technologicalknowledge. Through its members, AWWA develops industry standards for products and processes that advance publichealth and safety. AWWA also provides quality improvement programs for water and wastewater utilities.

All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronicor mechanical, including photocopy, recording, or any information or retrieval system, except in the form of brief excerptsor quotations for review purposes, without the written permission of the publisher.

Copyright 2007 by American Water Works AssociationPrinted in USA


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Committee Personnel

The Steel Water Pipe-Manufacturers Technical Advisory Committee (SWPMTAC)Task Force for Development and Maintenance of AWWA C604, which developed thisstandard, had the following personnel at the time:

Nash Williams, Chair

H.H. Bardakjian, Ameron Concrete & Steel Pipe,

Rancho Cucamonga, Calif. (AWWA)

M. Bauer, Tnemec Company, North Kansas City, Mo. (AWWA)

R.J. Card, Brico Industries Inc., Atlanta, Ga. (AWWA)

R.R. Carpenter, American Cast Iron Pipe Company, Birmingham, Ala. (AWWA)

K. Clark, Mueller Company, Decatur, Ill. (AWWA)

R.R. Collins, JCM Industries, Nash, Texas (AWWA)

D. Eaton, Romac Industries Inc., Bothell, Wash. (AWWA)

R.W. Geary, Tek-Rap Inc., Houston, Texas (AWWA)

J.H. Hoff, Hoff Company Inc., Tulsa, Okla. (AWWA)

B.D. Keil, Continental Pipe Manufacturing Company,

Pleasant Grove, Utah (AWWA)

C.R. McCormick, Conduit Fabricator Inc., Redding, Calif. (AWWA)

S. McMillen, Continental Manufacturing Inc., Nacogdoches, Texas (AWWA)

M. Mintz, M-Square Associates Inc., Valley Stream, N.Y. (AWWA)

A. Parrish, CAB Incorporated, Oakwood, Ga. (AWWA)

G. Ruchti, American Spiral Weld Pipe Company, Punta Gorda, Fla. (AWWA)

R.N. Satyarthi, Baker Coupling Co. Inc., Los Angeles, Calif. (AWWA)

D.A. Scott, Scapa Tapes North America, Calgary, Alta. (AWWA)

K.L. Shaddix, Smith-Blair Inc., Texarkana, Texas (AWWA)

H.R. Stoner, Consultant, North Plainfield, N.J. (AWWA)

B. Stott, Metrotect Ltd., West Yorkshire, England (AWWA)

M. Topps, Glynwed Pipe Systems, Hixson, Tenn. (AWWA)

B. Vanderploeg, Northwest Pipe Company, Portland, Ore. (AWWA)


iv

D.R. Wagner, Consultant, St. Louis, Mo. (AWWA)

N. Williams, National Welding Corporation, Midvale, Utah (AWWA)

J.A. Wise, Canus Industries Inc., Port Coquitlam, B.C. (AWWA)

The Standards Committee on Steel Pipe, which reviewed and approved this standard,had the following personnel at the time of approval:

George J. Tupac, ChairJohn H. Bambei Jr., Vice-Chair

Dennis Dechant, Secretary

General Interest Members

E. Bakall, Consulting Engineer, Tustin, Calif. (AWWA)

W.R. Brunzell, Brunzell Associates Ltd., Skokie, Ill. (AWWA)

R.L. Coffey, Kirkham Michael Consulting Engineers, Omaha, Neb. (AWWA)

H.E. Dunham, Montgomery Watson, Bellevue, Wash. (AWWA)

K.G. Ferguson,* Montgomery Watson, Las Vegas, Nev. (AWWA)

S.N. Foellmi, Black & Veatch LLP, Irvine, Calif. (AWWA)

J.W. Green, Alvord Burdick & Howson, Lisle, Ill. (AWWA)

K.D. Henrichsen, HDR Engineering Inc., Denver, Colo. (AWWA)

M.B. Horsley,* Black & Veatch LLP, Overland Park, Kan. (AWWA)

J.K. Jeyapalan, Engineering Consultant, New Milford, Conn. (AWWA)

R. Ortega, Lockwood Andrews & Newnam Inc., Houston, Texas (AWWA)

A.E. Romer, Boyle Engineering Corporation, Newport Beach, Calif. (AWWA)

H.R. Stoner, Consultant, North Plainfield, N.J. (AWWA)

C.C. Sundberg, CH2M Hill Inc., Bellevue, Wash. (AWWA)

G.J. Tupac, G.J. Tupac & Associates, Pittsburgh, Pa. (AWWA)

J.S. Wailes, Standards Engineer Liaison, AWWA, Denver, Colo. (AWWA)

L.W. Warren, Seattle, Wash. (AWWA)

*Alternate

Liaison, nonvoting


vW.R. Whidden, Post Buckley Schuh & Jernigan, Orlando, Fla. (AWWA)

Producer Members

H.H. Bardakjian, Ameron Concrete & Steel Pipe,

Rancho Cucamonga, Calif. (AWWA)

R.J. Card, Brico Industries Inc., Atlanta, Ga. (AWWA)

R.R. Carpenter, American Cast Iron Pipe Company, Birmingham, Ala. (MSS)

D. Dechant, Northwest Pipe Company, Denver, Colo. (AWWA)

J.E. Hagelskamp,* American Cast Iron Pipe Company, Maitland, Fla. (AWWA)

B.D. Keil, Continental Pipe Manufacturing Company, Pleasant Grove, Utah (SPFA)

J.L. Luka, American SpiralWeld Pipe Company, Columbia, S.C. (AWWA)

B. Vanderploeg,* Northwest Pipe Company, Portland, Ore. (AWWA)

J.A. Wise, Canus Industries Inc., Port Coquitlam, B.C. (AWWA)

User Members

G.A. Andersen, New York City Bureau of Water Supply, Corona, N.Y. (AWWA)

J.H. Bambei Jr., Denver Water Department, Denver, Colo. (AWWA)

D.W. Coppes, Massachusetts Water Resources Authority, Chelsea, Mass. (NEWWA)

R.V. Frisz, US Bureau of Reclamation, Denver, Colo. (USBR)

T.R. Jervis, Greater Vancouver Regional District, Burnaby, B.C. (AWWA)

T.J. Jordan, Metropolitan Water District of Southern California,

La Verne, Calif. (AWWA)

T.A. Larson, Tacoma Water Division, Tacoma, Wash. (AWWA)

A.L. Linard, Los Angeles Department of Water & Power,

Los Angeles, Calif. (AWWA)

G.P. Stine, San Diego County Water Authority, San Diego, Calif. (AWWA)

J.V. Young, EPCOR Water Services Inc., Richmond, B.C. (AWWA)

*Alternate


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vii

Contents

All AWWA standards follow the general format indicated subsequently. Some variations from this formatmay be found in a particular standard.

SEC. PAGE SEC. PAGE

Foreword

I Introduction........................................ix

I.A History of Standard ............................ix

I.B Discussion...........................................ix

I.C Acceptance ..........................................ix

II Special Issues.......................................xi

II.A Application .........................................xi

III Use of This Standard ..........................xi

III.A Purchaser Options and Alternatives ....xi

III.B Modification to Standard...................xii

IV Major Revisions .................................xii

V Comments .........................................xii

Standard

1 General

1.1 Scope ...................................................1

1.2 Purpose ................................................2

1.3 References ............................................2

1.4 Definitions...........................................3

1.5 Preconstruction Planning.....................6

1.6 Permeation...........................................7

2 Inspection, Unloading, Handling,

and Storage

2.1 Inspection ............................................7

2.2 Unloading, Handling, and Storage ......7

3 Installation

3.1 Alignment and Grade ..........................8

3.2 Trench Construction ...........................9

3.3 Pipe Installation.................................12

3.4 Joint Assembly and Testing ...............13

3.5 Fitting Installation .............................25

3.6 Thrust Restraint.................................27

3.7 Backfilling..........................................27

3.8 Flushing .............................................30

4 Hydrostatic Field Testing

4.1 Pressure and Leakage Test .................31

5 Disinfection.......................................32

6 Highway and Railroad Crossings

6.1 Casing Pipe........................................32

6.2 Carrier Pipe .......................................33

7 Subaqueous Crossings

7.1 Subaqueous Installations ....................33

Figures

1 Typical O-Ring Gasket Assembly ......14

2 Typical Installation of Pipe With

Gasketed Bell-and-Spigot Joints......15

3 Typical Installation of Pipe With

Welded Bell-and-Spigot Joints........17


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SEC. PAGE SEC. PAGE

4 Joint Deflection .................................18

5 Pipe Bedding ................................... 29


ix

Foreword

This foreword is for information only and is not a part of AWWA C604.

I. Introduction.

I.A. History of Standard. This standard pertains to the in-ground installation

of steel pipelines for use in the distribution and transmission of water, air, and other

products in water system facilities. It has been prepared by the AWWA Standards

Committee on Steel Pipe, initially formed as Committee A7A in 1939. At that time,

the Steel Water Pipe Manufacturers Technical Advisory Committee was organized as

a subsidiary group to function as a source of technical information for the parent

committee. Committee A7A and its successors, Committee 8310D and the AWWA

Standards Committee on Steel Pipe have assumed responsibility for all AWWA

standards and manuals pertaining to steel pipe, fittings, linings and coatings, field

installations, and related items.

In 1996 the AWWA Standards Council directed the Standards Committee on

Steel Pipe to develop a standard for the installation of steel pipelines and their

appurtenances used in water treatment or conveying facilities. This standard,

AWWA C604, is the first steel pipe installation standard developed by AWWA.

I.B. Discussion. AWWA C604 includes all types of steel pipe 4 in. (100 mm)

in diameter and larger typically used in the water industry, regardless of pipe

manufacturing source. With adequate quality assurance, pipe manufactured in a

fabricators shop or in a steel-pipe mill is suitable for water utility service. Pipe

produced in a fabricators shop or pipe mill for installation in accordance with

AWWA C604 shall meet the stringent design, quality control, and testing

requirements of AWWA Manual M11 and AWWA C200. Shop and mill-fabricated

pipe made from materials and in accordance with the quality control measures

stipulated in AWWA Manual M11 and AWWA C200 will ensure fabricated pipe of

high quality.

I.C. Acceptance. In May 1985, the US Environmental Protection Agency

(USEPA) entered into a cooperative agreement with a consortium led by NSF

International (NSF) to develop voluntary third-party consensus standards and a

certification program for all direct and indirect drinking water additives. Other

members of the original consortium included the American Water Works Association

Research Foundation (AwwaRF) and the Conference of State Health and Environ-


xmental Managers (COSHEM). The American Water Works Association (AWWA)

and the Association of State Drinking Water Administrators (ASDWA) joined later.

In the United States, authority to regulate products for use in, or in contact with,

drinking water rests with individual states.* Local agencies may choose to impose

requirements more stringent than those required by the state. To evaluate the health

effects of products and drinking water additives from such products, state and local

agencies may use various references, including

1. An advisory program formerly administered by USEPA, Office of Drinking

Water, discontinued on Apr. 7, 1990.

2. Specific policies of the state or local agency.

3. Two standards developed under the direction of NSF, NSF/ANSI 60,

Drinking Water Treatment ChemicalsHealth Effects, and NSF/ANSI 61, Drink-

ing Water System ComponentsHealth Effects.

4. Other references, including AWWA standards, Food Chemicals Codex, Water

Chemicals Codex, and other standards considered appropriate by the state or local

agency.

Various certification organizations may be involved in certifying products in

accordance with NSF/ANSI 61. Individual states or local agencies have authority to

accept or accredit certification organizations within their jurisdiction. Accreditation

of certification organizations may vary from jurisdiction to jurisdiction.

Annex A, Toxicology Review and Evaluation Procedures, to NSF/ANSI 61

does not stipulate a maximum allowable level (MAL) of a contaminant for substances

not regulated by a USEPA final maximum contaminant level (MCL). The MALs of

an unspecified list of unregulated contaminants are based on toxicity testing

guidelines (noncarcinogens) and risk characterization methodology (carcinogens).

Use of Annex A procedures may not always be identical, depending on the certifier.

AWWA C604-06 does not address additives requirements. Thus, users of this

standard should consult the appropriate state or local agency having jurisdiction in

order to

*Persons outside the United States should contact the appropriate authority having jurisdiction.

NSF International, 789 North Dixboro Road, Ann Arbor, MI 48105.

American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.

Both publications available from National Academy of Sciences, 500 Fifth Street, NW,Washington, DC 20001.


xi

1. Determine additives requirements, including applicable standards.

2. Determine the status of certifications by all parties offering to certify

products for contact with, or treatment of, drinking water.

3. Determine current information on product certification.

II. Special Issues.

II.A. Application. AWWA C604-06, Standard for Installation of Steel Water

Pipe4 In. (100 mm) and Larger, can be used as a reference when making

extensions to existing distribution or transmission systems or when constructing new

distribution or transmission systems using steel pipe. It is not the intent for this

standard to be used as a contract document, but it may be used as a reference in

contract documents. It is based on a consensus of the committee on the minimum

practice consistent with sound, economical service under normal conditions, and its

applicability under any circumstances must be reviewed by a responsible engineer.

The standard is not intended to preclude the manufacture, marketing, purchase, or

the use of any product, process, or procedure.

III. Use of This Standard. AWWA has no responsibility for the suitability or

compatibility of the provisions of this standard to any intended application by any

user. Accordingly, each user of this standard is responsible for determining that the

standard's provisions are suitable for and compatible with that users intended

application.

III.A. Purchaser Options and Alternatives. The following items should be

included in the purchasers specifications.

Considerable supplemental information is required in conjunction with the use

of this standard, including, but not limited to, contract documents consisting of

detailed plans and specifications. The specifications should cover, as a minimum,

detailed instructions pertaining to all references in this standard to as specified and

in accordance with the specifications. In addition, the purchaser shall provide

specific supplementary information to the contract documents regarding the

following:

1. Pipe design criteria and type of pipe ends.

2. Pipe laying schedules, line drawings, markings, appurtenances, vaults, valves,

and existing utilities.

3. Pipe bedding specification and drawing details.

4. Inspection for pipe joints, protective coatings and linings, and pipe zone

compaction.


xii

5. Surface restoration.

6. Special handling requirements.

III.B. Modification to Standard. Any modification to the provisions, defini-

tions, or terminology in this standard must be provided in the purchasers

specifications.

IV. Major Revisions. This is the first edition of this standard.

V. Comments. If you have any comments or questions about this standard,

please call the AWWA Volunteer & Technical Support Group at 303.794.7711, FAX

303.795.7603, write to the group at 6666 W. Quincy Avenue, Denver, CO 80235-

3098, or e-mail at [email protected].


1AWWA Standard

AWWA C604-06(First Edition)

Installation of Steel Water Pipe

4 In. (100 mm) and Larger

SECTION 1: GENERAL

Sec. 1.1 Scope

This standard provides the field installation guidelines for buried steel water

pipe, 4 in. (100 mm)* and larger, and their appurtenances.

The information contained in this standard is intended to be used as a guide to

assist in the installation of steel water pipe. Whenever the methods contained herein

conflict with those of the contract documents and/or the purchaser, the contract

documents and/or purchaser should be followed.

1.1.1 Conditions which may require additional considerations. Ins ta l l a t ions

that require special attention, techniques, and materials are not covered. Some of

these installations are

1. Piping through rigid walls.

*Metric conversions given in this standard are direct conversions of US customary units and are notthose specified in the International Organization for Standardization (ISO) standards.


2 AWWA C604-06

2. Piping on supports above or below ground, connected to appurtenances.

3. Piping requiring insulation.

4. Treatment plant or pump-station piping.

5. Industrial piping.

6. Piping through geologically hazardous areas.

7. Piping in high-density-stray-current environments.

8. Piping through corrosive soil.

9. Piping through unstable soil.

10. Piping subjected to excessive loads.

Sec. 1.2 Purpose

This standard is intended to cover typical pipeline construction practices that

are deemed adequate for the satisfactory installation of steel water pipe and

appurtenances. Individual project requirements can vary substantially and should

always be thoroughly reviewed prior to bidding or construction startup. For this

reason, some practices discussed in this standard may not be suitable for all project

conditions, and, in some cases specialized installation techniques may be required

that are beyond the scope of this standard.

Sec. 1.3 References

This standard references the following documents. In their latest editions, the

referenced documents form a part of this standard to the extent specified herein. In

any case of conflict, the requirements of this standard shall prevail.

AASHTO T99*Moisture Density Relations of Soils Using a 5.5-lb (2.5-kg)

Rammer and a 12-in. (305-mm) Drop.

ANSI/AWWA C500Metal-Seated Gate Valves for Water Supply Service.

ANSI/AWWA C509Resilient-Seated Gate Valves for Water Supply Service.

ANSI/AWWA C651Disinfecting Water Mains.

AWWA Manual M3, Safety Practices for Water Utilities, AWWA, Denver, Colo.

(1990).

The reader is referred to the following standards for additional information on

the use or limitations of specific products.

*American Association of State Highway and Transportation Officials, 444 North Capitol Street N.W.,Suite 249, Washington, DC 20001-1512.


INSTALLATION OF STEEL WATER PIPE4 IN. (100 MM) AND LARGER 3

ANSI/AWWA AWWA C203Coal-Tar Protective Coatings and Linings for

Steel Water PipelinesEnamel and TapeHot-Applied.

ANSI/AWWA C205CementMortar Protective Lining and Coating for Steel

Water Pipe4 In. (100 mm) and LargerShop Applied.

ANSI/AWWA C206Field Welding of Steel Water Pipe.

ANSI/AWWA C207Steel Pipe Flanges for Waterworks ServiceSizes 4 In.

Through 144 In. (100 mm Through 3,600 mm).

ANSI/AWWA C208Dimensions for Fabricated Steel Water Pipe Fittings.

ANSI/AWWA C209Cold-Applied Tape Coatings for the Exterior of Special

Sections, Connections, and Fittings for Steel Water Pipelines.

ANSI/AWWA C210Liquid Epoxy Coating Systems for the Interior and

Exterior of Steel Water Pipelines.

ANSI/AWWA C216Heat-Shrinkable Cross-Linked Polyolefin Coatings for

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

ANSI/AWWA C217Petrolatum and Petroleum Wax Tape Coatings for the

Exterior of, Connections and Fittings for Steel Water Pipelines.

ANSI/AWWA C219Bolted Sleeve-Type Couplings for Plain-End Pipe.

ANSI/AWWA C222Polyurethane Coatings for the Interior and Exterior of

Steel Water Pipe and Fittings.

ANSI/AWWA C504Rubber-Seated Butterfly Valves.

ANSI/AWWA C800Underground Service Line Valves and Fittings.

OSHA 29 CFR 1986*Health Regulations for Construction.

AWWA M11Steel Water Pipe: A Guide for Design and Installation.

AWS D1.1Structural Welding Code.

Sec. 1.4 Definitions

In this standard, the following definitions shall apply:

1.4.1 Bevel: The angle formed between the prepared edge of a pipe end and

a plane perpendicular to the longitudinal axis of the pipe. Bevels are generally used

for butt welding of pipe ends.

*Occupational Safety and Health Administration, Code of Federal Regulations; available fromGovernment Printing Office, 720 N. Main, Pueblo, CO 81003.

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126-5699.


4 AWWA C604-06

1.4.2 Utility location service: The cooperative organization of major utilities

to provide services for the location and safe construction practices surrounding their

respective utilities. These utilities often provide a site representative during

construction when deemed necessary by the utility.

1.4.3 Butt joint: A pipe joint in which the two pipe ends are in the same

plane and do not overlap. This joint configuration is commonly beveled and usually

includes a backup ring on the side opposite of which welding is to be performed.

1.4.4 Dewatering: The removal of water in and around construction

operations. This usually pertains to underground water within construction zones,

which can adversely affect the construction activities.

1.4.5 Fillet weld: A weld of approximately triangular cross section, the throat

of which lies in a plane disposed approximately 45 with regard to the surface of the

parts joined. The size of the fillet weld is expressed in terms of the width, in inches,

of one of its adjacent fused legs (the shorter leg, if unequal).

1.4.6 Grade: The elevation of a structure or pipeline invert (bottom of the

flowline) at a specific location. This elevation is usually measured relative to

established survey points at the project.

1.4.7 Bell-and-spigot or lap joint: A circumferential joint in which one of the

members joined overlaps the other.

1.4.8 Manufacturer: The party or firm that manufactures or supplies the

products covered by this standard.

1.4.9 Mechanical cutting: The severing of materials by use of a thin flat

blade having a continuous line of teeth on its edge or high-speed abrasive disk.

1.4.10 Miter: The angle between the cut of a pipe end and a line drawn

perpendicular to the longitudinal axis of the pipe. Miters are used to fabricate elbows

and to facilitate pipe laying at changes in horizontal or vertical alignment.

1.4.11 Nominal diameter or size: The commercial designation or dimension

by which pipe is designated for simplicity. Commonly, it is the finished inside

diameter after lining.

1.4.12 Nominal wall thickness: The thickness named or given, as distin-

guished from the actual or measured thickness.

1.4.13 Nominal weight per foot (for bare pipe): The theoretical weight, per

foot, calculated from the nominal wall thickness, as distinguished from the actual and

measured weight per foot of the finished pipe. Unit weights of 0.284 lb per cubic



inch for steel sheet or 490 lb per cubic foot for steel plate shall be used when

calculating weight per foot.

1.4.14 Pipe bedding: The material immediately under the pipeline and by

which the pipeline is supported. This material is usually of a specific description and

may simply be the reuse of the originally excavated material.

1.4.15 Plain-end pipe: Pipe that is not threaded, belled, or otherwise given a

special end configuration.

1.4.16 Plans: Drawings normally prepared by an engineer employed or

retained by the purchaser system-operator entity showing the location and details for

the construction of the pipeline and appurtenances.

1.4.17 Plasma-arc cutting: An arc-cutting process that severs metal by

melting a localized area with a constricted arc and removing the molten material with

a high-velocity jet of hot, ionized gas blown at high speed from the constricting

orifice.

1.4.18 Purchaser: The person, company, or organization that purchases any

materials or work to be performed.

1.4.19 Random lengths: Pipe lengths as produced in a pipe mill, to which no

special treatment is given to make the lengths uniform.

1.4.20 Root: That portion of a joint to be welded where the members

approach closest to each other. In cross section, the root of a joint may be a point, a

line, or an area.

1.4.21 Seamless pipe: Pipe without welds or filler metal, made from solid

ingots, blooms, billets, or round bars that have been hot pierced and then brought to

the desired size by hot rolling, hot drawing, or a combination of both.

1.4.22 Select material: The native soil free of rocks, foreign or organic

materials, and frozen earth.

1.4.23 Special section: Any piece of pipe other than a normal full-length

straight section. This includes but is not limited to elbows, personnel access sections,

short pieces, reducers, adapter sections with special ends, and other nonstandard

sections.

1.4.24 Specifications: Detailed procedures and requirements initiated by the

purchaser or designee, outlining methods of design, manufacture, standards of

acceptability, methods of installation, or any other criteria the purchaser deems

necessary for the procurement of the product required. Installation specifications may


6 AWWA C604-06

incorporate this standard by reference, but should also include specification

requirements for matters not covered by the standard.

1.4.25 Specified lengths: Sections of finished pipe, the length dimensions of

which do not vary from a fixed figure specified by the purchaser by more than the

tolerance set forth.

1.4.26 Supplier: The party who supplies material or services. A supplier may

or may not be the manufacturer.

1.4.27 Trench zone: The area of excavation within which a pipeline or

structure will be placed.

1.4.28 Underground utilities: Previously installed utilities that are located

within the right-of-way of a pipeline or structure. These utilities commonly include

gas, power, water, cable TV, sewer, fiber-optic cable, steam lines, and telephone

lines.

Sec. 1.5 Preconstruction Planning

The installation of steel pipelines usually involves multiple suppliers and

subcontractors that have varying preparation requirements. For this reason a

preconstruction meeting is strongly recommended to schedule the critical path

aspects of all involved parties. In particular, pipe and valve materials are usually

manufactured to fit specific locations of the project and often require an extended

lead time for the purchase of raw material, drawing preparation, and drawing

approvals that must precede construction activities. Any preconstruction planning

meeting initiated by the purchaser should include all essential suppliers and

subcontractors. During the meeting a schedule should be prepared that is agreeable

to all parties and provides float for operations subject to potential delays. All parties

elaborate on their respective preparations, such as procurement of materials,

preparation of drawings, and submittals. The constructor shall be required to provide

the starting location and direction of construction. Care should be taken when

preparing the construction schedule as later changes in construction plans may affect

shop drawings, laying schedules, delivery dates, and other parties. Detailed shop

drawings must be approved by the constructor and purchaser prior to pipe

production.



Sec. 1.6 Permeation

The selection of materials is critical for water service and distribution piping in

locations where the pipe is likely to be exposed to significant concentrations of

pollutants composed of low-molecular-weight petroleum products, organic solvents,

or their vapors. Documented research has shown that pipe materials such as

polyethylene, polybutylene, polyvinyl chloride, and asbestos cement, as well as

elastomers, such as those used in jointing gaskets and packing glands, may be subject

to permeation. If a water pipe must pass through such a contaminated area or an area

subject to contamination, consult with the manufacturer regarding permeation of

pipe joints coatings, and so on, before selecting materials for use in that area.

SECTION 2: INSPECTION, UNLOADING, HANDLING, AND STORAGE

Sec. 2.1 Inspection

2.1.1 Pipe inspection at the plant. All materials shall be subject to inspection

and acceptance at the manufacturers plant. Acceptance criteria shall be based on

criteria agreed to by the purchaser and constructor in accordance with the contract

documents.

2.1.2 Inspection on delivery. All pipe and appurtenances are subject to

inspection at the point of delivery. Material found to be defective because of

manufacture or damage in shipment shall be rejected or recorded on the bill of

lading. There shall be agreement regarding any necessary repairs. These repairs shall

be made and the purchaser shall monitor the repairs prior to installation.

Sec. 2.2 Unloading, Handling, and Storage

Care shall be exercised when unloading, handling, and storing pipe. Steel pipe

is generally manufactured in lengths exceeding 20 ft (6 m), which may warrant the

use of a two-point lifting method for proper and safe handling. Nylon or protected

slings at least 4 in. (100 mm) wide shall be used to handle coated pipe. Cables,

chains, ropes, or other equipment that is likely to damage pipe coatings shall not be

used.

Coated pipe shall be handled, stored, and shipped in a manner that will prevent

damage to the coating. If the coating is damaged during handling, storage, or


8 AWWA C604-06

shipping, it shall be repaired with the original or a compatible repair coating as

recommended by the coating manufacturer and in accordance with the applicable

AWWA standard.

All pipe, fittings, and accessories shall be loaded and unloaded carefully to avoid

impact or damage. Under no circumstances shall such material be dropped.

2.2.1 Secure pipe. Before release of tie-downs around the pipe, the loads shall

be checked to ensure the pipe is secure and stable.

2.2.2 Padding. Slings, hooks, and pipe tongs shall be padded and used in

such a manner to prevent damage to the exterior surface or internal lining of the

pipe, fittings, or related product.

2.2.3 Internal bracing. Usually pipe manufacturers provide internal bracing

for handling and shipping purposes only. It is the responsibility of the constructor to

maintain the bracing and ensure their need or adequacy during installation. See also

Sec. 3.7.1.7.

2.2.4 Jobsite storage. Stored materials shall be kept safe from damage. The

interior of all pipe, fittings, and other appurtenances shall be kept reasonably free

from dirt or foreign matter at all times.

Coated pipe shall be protected from ultraviolet and weathering damage as

recommended by the coating manufacturer. Coated pipe should never be placed,

dragged, or rolled directly on the ground. Padded skids, earthen berms, burlap sacks

filled with sand, and old car tires are some of the means to adequately bunk the pipe

at the jobsite. Pipe shall not be stacked without proper padding. Plastic caps on the

pipe ends for pipe that is cementmortar lined shall be left in place until just prior

to installation.

SECTION 3: INSTALLATION

Sec. 3.1 Alignment and Grade

Pipelines shall be laid and maintained to lines and grades established by the

contract documents for the project. Pipe laying in urban areas shall not exceed 0.10 ft

(30 mm) in grade nor 3 in. (150 mm) in alignment unless otherwise specified in the

contract documents. Valves and special fittings shall be installed at the required

locations unless field conditions warrant otherwise and such changes are agreed to by



the purchaser and constructor. Valve-operating stems shall be oriented in a manner to

allow proper operation.

3.1.1 Prior investigation. Prior to excavation, investigation shall be made to

the extent necessary to determine the location of existing underground utilities,

structures and conflicts. This will require the constructor to contact the utility

location service for proper coordination and locating utilities. In addition, care shall

be exercised during excavation to avoid damage to existing structures, which may not

be identified by the utility location service. Special precautions shall be taken when

the pipeline being installed crosses or is adjacent to a facility that is cathodically

protected. When obstructions that are not shown on the contract documents are

encountered during the progress of work and interfere so that an alteration is

required, such alterations or deviation in line and grade or the removal, relocation, or

reconstruction of the obstructions shall be performed in accordance with the contract

documents.

3.1.2 Clearance. When crossing existing pipelines or other structures,

alignment and grade shall be adjusted in accordance with the contract documents.

Installed pipe and structures shall provide clearance as required by federal, state or

provincial, and local regulations. Wherever possible, pipe and structures shall have a

minimum clearance of 12 in. (300 mm) from existing pipelines or structures to allow

for proper compaction.

Sec. 3.2 Trench Construction

The trench shall be excavated to the required alignment, depth, and width

specified or shown on the contract documents and shall be in conformance with all

federal, state or provincial, and local regulations for the protection of workers.

3.2.1 Trench preparation. Trench preparation shall proceed in advance of the

pipe installation. The amount of open trench length allowed is limited by the

amount of nonbackfilled pipe according to Sec. 3.3, the contract documents, and any

safety considerations (such as traffic, slope, etc.).

3.2.1.1 Discharges from trench dewatering pumps shall be directed away from

the trench, in order not to affect trench stability, and shall be in accordance with

federal, state, and local point discharge requirements.

3.2.1.2 Excavated material shall be placed in a manner that will not obstruct

the work, endanger workers or the public, or obstruct sidewalks, driveways,

roadways, and other structures. If obstruction of such structures becomes necessary,


10 AWWA C604-06

the constructor shall plan for alternate means to accommodate the public. Placement

of excavated material shall be done in compliance with federal, state or provincial,

and local regulations.

3.2.2 Pavement removal. Removal of pavement and road surfaces shall be a

part of the trench excavation. The amount removed shall depend on the width of

trench required for installation of the pipe, including safety requirements and the

dimensions of the area into which valves, specials, manways, or other structures will

be installed. Methods such as sawing, drilling, or chipping shall be used to ensure the

breakage of pavement along straight lines.

3.2.3 Width. The width of the trench at the top of the pipe shall be as

dictated by the contract documents or as necessitated by safety requirements. In any

case, the trench width shall provide ample clearance to permit the pipe to be installed

and joined properly and to allow the backfill to be placed in accordance with the

contract documents. Trenches shall be of such extra width, when required, to permit

the placement of sheeting, bracing, and appurtenances as required by the safety

requirements of the agency having jurisdiction. In addition, the trench width at the

bottom of the pipe will be governed by the space required for compaction/

consolidation equipment, but never less than the outside diameter of pipe plus 20 in.

(500 mm) (see Figure 5).

3.2.4 Depth. The trench shall be excavated to the specified grade. The

trench bottom shall provide uniform support for the full length of the pipe barrel,

except that a slight depression may be provided to facilitate the removal of pipe slings

or other lifting tackle without damaging the pipe coating. Pipe bedding and backfill

material shall be installed so as to avoid abrasion or other damage to the coating on

the pipe.

3.2.5 Bell holes. Holes for the bells shall be provided at each joint. Holes

shall be adequately sized for completing any external coatings, but shall be no larger

than necessary to allow joint assembly. If the pipe joints are welded or coupled, the

bell holes shall provide adequate clearance for welding or assembly and subsequent

external coatings. A 24-in. (600-mm) clearance below or on the sides of the pipe is

usually adequate for this purpose.

3.2.6 Rock conditions. If excavation of rock is necessary, all rock shall be

removed to provide a clearance below and on each side of all pipe, valves, and

fittings. The minimum clearance shall be 6 in. (150 mm) for pipe with an outside

diameter (OD) up to 24 in. (600 mm) and 10 in. (250 mm) for pipe with an OD



greater than 24 in. (600 mm). When the excavation is completed, a layer of

appropriate backfill material (see Sec. 3.7) shall be placed on the bottom of the

trench to the previously mentioned depths, graded, and tamped. These clearances

and bedding procedures shall also be observed for pieces of concrete or masonry and

other debris or subterranean structures, such as masonry walls, piers, or foundations

that may be encountered during excavation.

3.2.7 Previous excavations. Should the trench pass over a sewer or other

previous excavation, the trench shall be sufficiently compacted to provide support

equal to that of the native soil or conform to other regulatory requirements in a

manner that will prevent damage to the existing installation.

3.2.8 Blasting. Blasting for excavation shall be permitted only after securing

approval(s) and establishing the hours of blasting as required by the contract

documents. The blasting procedure, including protection of existing utilities,

persons, and property, shall be in strict accordance with federal, state or provincial,

and local regulations.

3.2.9 Protection of property. Trees, shrubs, fences, and all other property and

surface structures and underground shall be protected during construction unless

their removal is shown in the contract documents.

3.2.9.1 Temporary support, adequate protection, and maintenance of all

underground and surface structures, drains, sewers, and other obstructions encoun-

tered in the progress of the work shall be provided in accordance with the contract

documents or applicable regulations.

3.2.10 Unsuitable subgrade material. When the subgrade is found to include

ashes, cinders, refuse, organic material, or other unsuitable material, such material

shall be removed at least to 6 in. (150 mm) below the bottom of the pipe or to the

depth required by the contract documents. The removed material shall be replaced

with clean, stable backfill material. The bedding shall be compacted and graded so

that the pipe may be installed in accordance with Sec. 3.3.

3.2.11 Unstable subgrade. When the bottom of the trench or the subgrade

consists of material that is unstable to such a degree that it cannot be removed, a

foundation for the pipe and/or appurtenance shall be constructed in accordance with

the contract documents.


12 AWWA C604-06

Sec. 3.3 Pipe Installation

Proper implements, tools, and facilities shall be provided and used for the safe

and convenient performance of the work. All pipe, fittings, and valves shall be

lowered carefully into the trench by means of a backhoe or crane, using nylon slings,

guide ropes, or other suitable tools or equipment, in such a manner as to prevent

damage to the pipe, protective coatings, and linings. Pipe shall not be dropped or

dumped into the trench. The trench shall be dewatered prior to installation of the

pipe and maintained until the pipeline is substantially covered as necessary to prevent

pipe from floating.

The length of pipe that may be installed prior to backfilling shall not exceed

1,000 ft (330 m) or a length approved by the purchaser. Backfilling for this purpose

is described as material covering the top of the pipe. If the constructor chooses to

backfill between pipe joints, the exposed portion of the joint area will be

accumulated toward the limit.

3.3.1 Examination of material. All pipe, fittings, coatings and appurtenances

shall be examined carefully for damage and other defects immediately before

installation. Defective materials shall be marked and held for final disposition as

required by the contract documents.

3.3.2 Pipe ends. All deleterious materials shall be removed from the ends of

each pipe. For bell- and spigot-pipe, the outside of the spigot end and the inside of

the bell shall be wiped clean and dry so that it is free from dirt, sand, grit, and other

foreign matter before the pipe is installed.

3.3.3 Pipe cleanliness. Foreign material shall be prevented from entering the

pipe while it is being placed in the trench. No debris, tools, clothing, or other

materials shall be allowed to accumulate during construction and shall be promptly

removed as work progresses.

3.3.4 Direction of bells. It is common practice to lay welded pipe joints with

the spigot facing the direction in which work is progressing; however, this practice is

not mandatory. For gasketed pipe, common practice is to lay the pipe joints with the

bell facing the direction in which work is progressing to prevent debris from being

scooped into the bell. The direction of the bells is not functionally related to the

direction of flow within the system.

3.3.5 Pipe end caps. When pipe laying is not in progress, the open ends of

pipe may be required to be closed by a plug or other means as specified. If utilized,



the end caps shall remain in place until the trench work proceeds. Care must be

taken to prevent pipe flotation should the trench fill with water.

Sec. 3.4 Joint Assembly and Testing

Proper implements, tools, and facilities shall be provided and used for the safe and

convenient performance of the work. The types of joints covered in this standard include

gasketed, flanged, sleeve coupling, and welded joints, all of which have specific

applications. The joint types required for a project will be dictated by the contract

documents.

The joint assembly shall be coated with a compatible coating according to the

coating manufacturers recommendations and the applicable AWWA standard.

3.4.1 Gasketed joints. The gasketed joint design consists of a bell-and-spigot

end configuration formed directly into the steel pipe cylinder or attached to the steel

pipe cylinder. The spigot end includes a groove that retains an O-ring gasket. The

gasket groove and the bell end of the mating pipe shall be cleaned thoroughly. When

the spigot is inserted into the bell, the gasket compresses between the steel surfaces to

form a watertight seal. Gasketed joints shall be assembled as described in Sec. 3.4.1.1

and illustrated in Figures 1 and 2. Gaskets shall be designed properly for the joint to

be assembled and shall be properly seated.

3.4.1.1 Pipe placement for gasketed joints. Mark the outside of the pipe at

the quarter points for the full stab depth. This dimension is provided as the length

on the joint detail drawings and typically ranges from 3 in. (75 mm) to 7 in.

(175 mm). Lift the pipe using the appropriate method. On steep slopes it may be

advisable to use slings as chokers. Visually inspect the O-ring gasket for any visible

defects, cuts, or tears. Before placing the gasket in the spigot groove, apply a light

coat of vegetable-based pipe lubricant to the bottom of the spigot groove. Stretch the

O-ring gasket over the pipe spigot end by hand or by using a dull pry bar (to avoid

cuts or tears), and then carefully seat the gasket into the O-ring groove on the spigot

(see Figure 1). After placement, tension relieve the gasket by running a dull object,

such as a wooden dowel, between the gasket and the spigot groove, around the pipe

circumference several times. Just prior to stabbing, apply a light coat of vegetable-

based pipe lubricant to the spigot end exterior and the bell end interior, being sure to

keep the joint clean. The spigot end shall be stabbed approximately 1 in. (25 mm)

into the bell end, with the two mating pieces parallel to each other (see Figure 2).

The spigot shall then be engaged the appropriate distance. Small-diameter pipe


14 AWWA C604-06

spigots can be pushed into the bell with a long bar. Large-diameter pipe requires

additional power, such as from a jack, lever puller, or backhoe. Before the pipe slings

are removed, drive the gasketed joint together. It can be driven home as it is

suspended from the lifting boom, pushed home with the backside of the bucket

(place a heavy timber between the bell end of pipe and the back of the backhoe

bucket to protect the pipe from damage), or pulled with a winch. As each length of

pipe is placed in the trench, the pipe shall be brought to the correct line and grade.

After the joint is fully engaged, deflect the joint, if required, within the prescribed

limits in Sec. 3.4.3 (see Figure 4) or the contract documents. The pipe shall be

secured in place with approved backfill material.

3.4.1.2 Rubber gasket testing. After the pipe has been laid to final grade, the

rubber gasketed joint shall be tested by a feeler gauge. This test ensures that the

gasket has not rolled out of the groove, or "fish-mouthed. Perform this test by

inserting a feeler gauge between the bell and spigot until reaching the gasket.

Continue completely around the pipe circumference to ensure that the gasket is

Figure 1 Typical O-ring gasket assembly



Figure 2 Typical installation of pipe with gasketed bell-and-spigot joints


16 AWWA C604-06

continuous. Do not use a stabbing motion, as the feeler gauge can pass through the

gap between the shoulder of the spigot and the inside of the bell and possibly damage

the gasket. The only purpose of the feeler gauge test is to determine whether the

gasket has rolled out of the groove during installation; it is not performed to

determine the amount of clearance between the spigot and the bell.

3.4.1.3 Repair of rubber gasket joints. If the gasket has disengaged, the joint

shall be pulled apart, and the gasket shall be removed and checked for any damage.

Reinstall the gasket, or if damaged, install a new gasket following the procedure in

Section 3.4.1.1. Alternatively, if a pipe segment cannot be removed, insert a rolled

steel round bar into the flare of the bell and seal weld the round bar to the bell and

spigot.

3.4.2 Pipe placement for welded lap joints. Mark the outside of the pipe at the

quarter points for the full stab depth. This dimension will be provided with the

length of the joint detailed in the drawings and will typically range from 2 in. (50

mm) to 3 in. (75 mm). Lift the pipe using a two-point lifting method. On steep

slopes, it may be advisable to use the slings as chokers. Lower the pipe segment, bell

end first, at an approximate 5 to 10 degree angle relative to the previously laid pipe

segment. This will allow the bell edge to overlap the spigot (of the previously laid

pipe) to the proper stab depth mark. On large-diameter pipe, tack weld the joint

edge to provide a hinge that will guide the remainder of the bell insertion as the pipe

is lowered (see Figure 3). The tack welds may remain as part of the permanent weld

if the welder is properly qualified and the weldment meets the requirements of ANSI/

AWWA C206 and the contract documents. Thermal stresses should not be allowed

to accumulate due to the tack weld. Under certain circumstances, some constructors

may choose to insert the spigot straight into the bell by methods described in

Sec. 3.4.1.1. As each length of pipe is placed in the trench, the joint shall be

assembled and checked for stab depth, and the pipe shall be brought to correct line

and grade. After the joint is fully engaged, deflect the joint, if required, within the

prescribed limits in Sec. 3.4.3 or the contract documents. Proceed with the welding

of the joint in accordance with ANSI/AWWA C206 followed by any required testing.

Upon successful weld testing, apply any required linings or coatings. The pipe shall

be secured in place with approved backfill material.

3.4.3 Joint deflection. When it is necessary to deflect gasketed or welded pipe

from a straight line in either the horizontal or vertical plane, the amount of joint

deflection shall not exceed a 1 in. (25 mm) pull, measured at the joint or in



Figure 3 Typical installation of pipe with welded bell-and-spigot joints


18 AWWA C604-06

accordance with the contract documents (see Figure 4). The pull is further described

as the dimension in which the pipe joint insertion varies when measured from

opposite sides (180 degrees apart). This pull does not diminish the minimum

required insertion dimension.

3.4.4 Flanged joints. Flanges commonly used for steel water pipe are slip-on type

ring flanges. Flanges are designed for use with rubber or nonasbestos gaskets (1/16 in.

[1.6 mm] or 1/8 in. [3.2 mm] thick). Both the size and type of gasket material are

controlling factors in the design of bolted joints and, as such, the AWWA M11

installation recommendations should be followed.

Regardless of the type of gasket being used or the materials of construction,

certain basic procedures must be followed if the joint is to be assembled, tested, and

put into operation easily. Regardless of the method used to apply stress to the studs,

the following procedure should be followed carefully:

Figure 4 Joint deflection

= deflection angleS = joint deflection offsetL = laying lengthR = radius of curve

R = L2tan 2

S

L

R



1. Inspect the gasket seating surfaces. Look for tool marks, scratches, or

pitting by corrosion, and make sure that the gasket seating surface is proper for the

type of gasket being used.

2. Inspect the gasket. Look for possible defects or damage in the gasket.

3. Lubricate all thread contact areas and nut facings. This step is very

important.

4. Loosely install the fasteners on the lower half of the flange. Insert the

gasket between the flange facings to allow the bolts to center the gasket on the

assembly. Install the remaining bolts and nuts and tighten them to a hand-tight or

snug condition.

5. Torque the bolts up to a maximum of 30 percent of the final torque value

required, following the sequence recommended in AWWA M11. Number the bolts

so that torquing requirements can be followed.

6. Repeat step 5, increasing the torque to 50 to 60 percent of the final torque

value required.

7. Continue with the sequence of retorquing all fasteners to the specified

torque value.

NOTE: For insulating flanges, refer to the manufacturers recommendations.

3.4.5 Transition couplings. Transition couplings may be required for joining

different types of pipe. Such transition devices are typically available. When ordering,

the actual outside diameter of the pipe ends shall be given.

3.4.6 Tapping sleeves. Tapping sleeves are a means of making branch

connections to existing pipelines. The procedures for proper installation of tapping

sleeves shall follow the manufacturers recommendations.

3.4.7 Sleeve couplings. Sleeve couplings are used on pipelines of all diame-

ters. The typical installation sequence for bolted, sleeve-type couplings is provided in

ANSI/AWWA C219.

3.4.8 Split-sleeve coupling. Split-sleeve couplings are used on pipelines of all

diameters. Follow the manufacturers recommendations for their installation.

3.4.9 Welded joints. The need for welded joints will vary by project and will

be dictated in the contract documents. Several types are common, including lap,

butt, and butt-strap welded joints.

Welding shall meet the requirements of ANSI/AWWA C206 and the contract

documents for the project. Shielded metal arc welding (SMAW), or stick welding, is

the most common method used. Semiautomatic and automated welding processes


20 AWWA C604-06

are practical when a large number of welded joints are required. These processes are

described in ANSI/AWWA C206.

In accordance with ANSI/AWWA C206, joint welding procedures, welders and

welding operators shall be qualified under tests prescribed by the American Welding

Society (AWS) D1.1 Structural Welding CodeSteel. Several common joint welding

procedures outlined in AWS D1.1 are already considered prequalified.

Preheating is required prior to welding when the steel temperature is less than

32F (0C). For most mild steel applications where the steel wall thickness is less than3/4 in. (19 mm) and using conventional welding processes, preheating is required if

the metal temperature of the steel is less than 32F (0C) as measured at any point

within 3 in. (75 mm) from the weld bead or 4 times the pipe wall thickness,

whichever is greater. The specific preheating requirements will vary depending on the

welding process, steel specification, steel thickness, and metal temperature and should

be determined by using the AWS D1.1 preheat tables or Annex equations.

The pipe shall be left bare a sufficient distance back from the ends to prevent

the heat produced during welding from damaging the protective coatings and to

prevent the coating from contaminating the in-process weld. In addition, a protective

cover shall be draped over the pipe near the vicinity of welding if further protection

is required. Field welding in the interior of steel pipe is ordinarily limited to 36-in.

(900-mm) or larger pipe, to provide for access and egress. When personnel are

working inside, ventilation shall be provided in strict accordance with federal, state or

provincial, and local regulations.

Wire brushing is usually sufficient to remove any dirt or light rust to prepare the

surface for welding. Small tack welds can be used to hold the pipe in position for

welding, provided the tacks are sound and meet the requirements of AWWA C206.

The number of weld passes needed to complete the joint is a function of the steel

wall thickness, the type of joint, and the type of welding.

3.4.9.1 Welded lap joints. Welded lap joints are frequently used when an

economical method of joint restraint is necessary or for diameters greater than can be

manufactured for a gasketed joint. There are several welding configurations for the

lap joint. The lap weld can be required on either the inside or outside of the pipe

joint. Sometimes a lighter seal weld will be required along with the lap weld to allow

for air testing. Less frequently, contract documents will require a full fillet weld both

inside and out. The nominal engagement of a lap-welded joint is 2 to 3 in. (50 to

75 mm) deep with a minimum required final overlap between the bell and the spigot



of 1 in. (25 mm) or 3 times the thickness of the belled pipe, whichever is greater. The

allowable pullout is 1 in. (25 mm), but in all cases the 1 in. (25 mm) minimum

required overlap must be maintained. No part of any field weld shall be closer than

1 in. (25 mm) to the nearest point of tangency to a bell radius. The allowable angle

of deflection is provided in AWWA Manual M11.

3.4.9.2 Welded butt joint. Welded butt joints are sometimes specified for

special design conditions. Butt joints are usually single-V-groove ends and include a

backup ring. The backup ring will be located on the pipe interior for smaller

diameter pipe and on the exterior or interior for larger pipe (over 36 in. [900 mm] in

diameter). Field joints shall be assembled so that seams in adjacent pipes are offset

from each other by at least five times the thickness of the thicker of the pipes being

joined. Single-V-groove butt joints may be welded from the outside of the pipe, or

from the inside of the pipe if the diameter is large enough. The backing rings may be

left in place after welding. Line-up clamps can assist in the pipe installation. The

installation procedure of field-welded butt joints is basically identical to the above

except that when the two ends have touched, caution should be exercised to ensure

that the proper root opening is achieved and the pipe is firmly secured in position

prior to installing subsequent pipe segments.

3.4.9.3 Welded butt-strap joints. Where welded butt-strap joints are used,

the butt straps shall have a minimum plate thickness equal to the thinnest member

being joined and shall be fabricated from material having equivalent chemical and

physical properties. In accordance with the ANSI/AWWA C206, the strap shall have

a minimum width of 4 in. (100 mm) or the width necessary to obtain a minimum

lap between pipe ends and the butt strap.

For butt-strap joints, the seams of adjacent pipe sections may be in alignment

provided that the butt-strap seams are offset from the pipe seams by at least five times

the thickness of the thicker member involved in the joint. The butt strap may be

welded on the pipe exterior, interior, or both.

3.4.9.4 Welded joint testing. Joint testing is generally performed by air

testing of double fillet welds, magnetic particle or dye penetrant testing of single fillet

welds, and magnetic particle testing of butt-welded joints. Limited use of vacuum

look box testing has been utilized as an alternate method for fillet welds and butt

welds. Limited use of radiographic testing and ultrasonic testing has been utilized as

alternate methods of testing butt joints. Radiographic testing is not recommended for

use on the joint types covered in this standard. The test method shall be specified in


22 AWWA C604-06

the contract documents. These test methods and repair of defective welds are further

described in ANSI/AWWA C206.

3.4.10 Pipe cutting. Prior to cutting, pipe shall be checked to ensure it is

within the necessary tolerance for proper assembly with the adjoining pipe. If the

adjoining pipes are not within the needed longitudinal tolerance, either replace the

segment or use an alternate field joint such as a butt strap. Cutting pipe for insertion

of valves, fittings, or closure pieces shall be done in conformance with all safety

requirements. Cutting may be performed by abrasive saw, oxygen-acetylene torch,

plasma arc, air-arc, or other suitable means. The resulting cut end will require

corrective preparation prior to assembly with the adjoining pipe. Cut ends and rough

edges shall be ground smooth.

3.4.11 Expansion joints. Provisions shall be made for the expansion and

contraction of exposed lines. Where individual pipe lengths are anchored and sleeve-

type couplings are used for field joints, the joints must allow enough movement so

that expansion and contraction is not cumulative over an excessive length. Thermal

expansion is usually accommodated for trench-laid welded pipelines to avoid the

accumulation of expansion and contraction during installation. These joints usually

include a lengthened bell which is welded only after all adjacent pipe has been welded

and buried.

3.4.12 Bonding of joints. When required by the contract documents, the

bonding of nonwelded joints shall be utilized to make the line electrically continuous

to allow for monitoring of possible corrosion along the pipeline. Bonding jumpers

(or optional s or z bars) will have to be welded in the field, joining the spigot and

the bell. The weld should be kept close to the ends of the pipe to allow joint end

coatings to cover the bonding jumpers.

3.4.13 Protective coatings at field joints. Generally, pipe lengths are coated

and lined, excluding only the pipe ends that are completed in the field. After field

assembly, the exterior and interior joint ends shall be completed with coatings that

are compatible with the original coating system of the pipe and in conformance with

the applicable AWWA standards. The type of pipe coating and end coating shall be

determined by the contract documents. Various pipe end coatings and linings are

available, which are further described in ANSI/AWWA C203, ANSI/AWWA C205,

ANSI/AWWA C209, ANSI/AWWA C210, ANSI/AWWA C216, ANSI/

AWWA C217, and ANSI/AWWA C222. For application and repair of these

materials, follow the appropriate AWWA standard and the manufacturers recom-



mendations. Three commonly used materials for pipe end field coatings are heat-

shrink sleeves (ANSI/AWWA C216), tape coating (ANSI/AWWA C209), and mortar

coating (ANSI/AWWA C205). Field joint and repair applications for these two

materials are briefly described by this standard.

3.4.13.1 Tape wrapping field joints. Generally, pipe lengths are coated,

excluding only the pipe ends that are completed in the field. The tape is provided in

various widths for various needs, but is generally 6 to12 in. (150 to 300 mm) wide.

Taping can be completed at any temperature as long as the roll body temperature

of the tape is maintained above 70F (21C). The procedure for proper tape

wrapping of field joints is fully described in AWWA C209 and is summarized as

follows:

1. Make sure the joint to be taped is complete, the gasket is checked, the

weld is inspected and the metal is cool to a temperature below 130F (54C).

2. Clean the area to be taped with a rag to make sure all moisture has been

removed.

3. Prime all around the joint, including several inches on both sides beyond

the area where the actual joint tape will be applied. Place filler material at all pipe

joints and at irregularities to create a smooth surface. (Lap welds, where the exterior

is a full thickness weld, and butt welds do not require filler material.)

4. Start in a downhill direction of the pipe and wrap two complete layers

around the pipe until overlapping the starting point by a minimum of 4 in. (100

mm). Cut the tape so as not to damage the field coating. The start and stop spots do

not need to be much farther than 10 to 15 from off the top centerline.

5. Make sure the tape around the joint is wrinkle-free and stretched taut. It

is preferable to keep the welded bonding jumper close to the pipe ends and wrap the

whole area with the tape as the joint is wrapped.

6. Make sure that partial rolls of tape go around at least one complete wrap.

7. Inspect the completed wrap using a holiday detector.

3.4.13.2 Taped pipe repairs. Many taped pipelines include a 3-layer system.

The first layer that actually bonds to the pipe is typically a black tape. The second

layer is a higher-density tape to give durable protection during handling. The third

layer is a tape that provides good protection to the inner layers of tape. In most cases

this outer layer is white. The three layers are generally supplied in three different

colors so that in the event of damage, the colors will assist in determining the extent


24 AWWA C604-06

of damage to the total tape system. The procedure for properly taped pipe repairs is

fully described in ANSI/AWWA C209 and is summarized as follows:

1. Minor wrinkles, scuffs, or any tears located on the edge of the tape that

do not go past the overlap area are generally acceptable. These conditions listed still

give the tape a full film thickness, and it is not practical to remove the high-density

machine-applied tape and replace it with a softer patch-type material.

2. If a tear occurs in only the outer layer, repair the damaged area with one

layer of tape with a minimum overlap of 4 in. (100 mm) onto the existing coating

system.

3. If the damaged coating area shows evidence of going further into the

coating system, use the repair method outlined below.

a. Cut away the damaged tape at an angle tangent to the surface of the pipe

so that the tape system is not cut or damaged any further.

b. Wipe clean the area to be taped and make sure it is dry and free from dirt.

c. Prime the area to be repaired and let the primer dry to a tackiness before

applying the repair tape.

d. Cut the tape to such a size that it extends beyond the damaged area for a

minimum of 4 in. (100 mm) in all directions around the area to be repaired. Apply

the tape starting at the center and working toward the edge, making sure to smooth

out all wrinkles. Make sure the primed area extends past the tape edges.

e. Only one layer of repair tape is required on damages that affect the outer

layer of tape. If a second layer of tape is required to complete the patch, place the

second layer of patch material over the first with a minimum of 1 in. (25 mm)

overlap in all directions of the bottom patch. It will always require two pieces of tape

to accomplish this overlap process.

f. Perform a holiday test on the repair area.

3.4.13.3 Heat-shrink sleeves on field joints. Heat-shrink sleeves are used to

protect field joints from moisture and oxidation. The procedure for proper

application of heat-shrink sleeves is fully described in ANSI/AWWA C216 and is

summarized as follows:

1. Clean the area of the heat-shrink sleeve to remove all moisture, soil, and

foreign materials. Place filler material at all pipe joints and at irregularities to create a

smooth surface. (Lap welds, where the exterior is a full thickness weld, and butt welds

do not require filler material.)

2. Preheat the area according to the manufacturers requirements.



3. Fit the sleeve around the joint.

4. Heat the sleeve to shrink and seal the sleeve to the joint.

5. Using rollers, remove all wrinkles to ensure that the sleeve has intimate

contact to the pipe.

3.4.13.4 Cement mortar for field joints and repairs. Pipe manufacturers

generally coat and line the pipe lengths, excluding only the pipe ends that are

completed in the field. The pipe ends and areas needing repairs shall be clean of

deleterious materials and the surface prepared for the cement mortar in accordance

with ANSI/AWWA C205. When feasible, interior cement mortar for field joints and

repairs shall be applied after the trench has been backfilled. Cement mortar shall be

poured in the exterior joint space through a grout band that is wrapped around the

joint and firmly strapped onto both sides after field joint assembly. Repairs to the

exterior mortar coating of the pipe shall be made during pipe installation and before

backfilling. Cracks in cementmortar-lined steel pipe are a common occurrence.

These cracks are most commonly shrinkage cracks, which are caused when the

mortar dries out. Contributing factors may be unprotected pipe ends, rough

handling, or thermal stresses caused by weather. It is important to keep the pipe ends

capped and small amounts of water added to the inside in hot, dry climates. Cracks

of 1/16 in. (1.6 mm) or less are acceptable by ANSI/AWWA C205. If cracks exceed1/16 in. (1.6 mm), a slurry mixture can be made and brushed over the cracked area

prior to filling the pipeline. The material requirements and application procedures of

cementmortar for field joints and general repairs are described in ANSI/AWWA

C205. Do not fill pipe for 72 hr after the last concrete repair.

Sec. 3.5 Fitting Installation

3.5.1 Examination of material. Prior to installation, valves shall be inspected

for direction of opening, number of turns to open, freedom of operation, tightness of

pressure-containing bolting and test plugs, cleanliness of valve ports and especially

seating surfaces, handling damage, and cracks. Defective valves shall be marked and

held for final disposition as required by the contract documents. All bolts and nuts,

with the exception of seat-adjusting bolts or screws in butterfly valves, shall be

checked for specified tightness. Seat-adjusting bolts in butterfly valves shall only be

adjusted when recommended by the manufacturer.

3.5.2 Placement. Valves, fittings, plugs, and caps shall be set and joined to

the pipe in the manner specified in Sec. 3.3 for cleaning and laying and Sec. 3.4 for


26 AWWA C604-06

joining pipe, except that 12-in. (300-mm) and larger valves shall be provided with

special support, such as treated timbers, crushed stone, concrete pads, or a sufficiently

tamped trench bottom, so that the pipe will not be required to support the weight of

the valve. Valves installed aboveground or in plant piping systems shall be supported

to prevent bending of the valve end connections as a result of pipe loading. Valves

shall be installed in the closed position; however, valves should be reopened after

installation to provide access, allow ventilation, and ensure proper operation.

3.5.2.1 In no case shall valves be used to bring misaligned pipe into alignment

during installation. Pipe shall be supported in such a manner as to prevent stress on

the valve.

3.5.2.2 Thrust resulting from closure of valves shall be carefully considered

during testing of the piping system and vaults.

3.5.2.3 Mains shall be drained through drainage branches or blowoffs.

Drainage branches, blowoffs, and appurtenances shall be provided with control valves

and shall be located and installed as shown on the contract documents. Discharges

shall be directed away from the pipe alignment, in order not to affect the trench

stability, and shall be in accordance with federal, state, and local point discharge

requirements.

3.5.2.4 Air release and vacuum vents shall be installed in accordance with the

contract documents at the high points in the line and in areas of potential negative

pressure. The location, number, and size of these air release and vacuum vents should

be provided in the contract documents. The air release and vacuum vents shall be

protected in locations where freezing temperatures are encountered.

3.5.3 Valve vaults. Valve vaults are designed to prevent any settlement that

may damage the valve and prevent its proper operation. Installation of the pipe and

valve in the vault shall be such that the operating nut shall be readily accessible for

operation through the opening in the valve vault, which shall be set flush with the

surface of the finished pavement or such other level as may be specified.

Valves and fittings shall be coated with a compatible coating according to the

coating manufacturers recommendations and the applicable AWWA standard.

Additional information regarding installation of gate valves can be found in the

appendixes of ANSI/AWWA C500 and ANSI/AWWA C509.

3.5.4 Plugs and caps. Before putting the installed pipe and appurtenances

under test pressure, consider all dead ends and the methods available to restrain the

dead ends, blowoff valves, and so on, against the force generated by the test pressure.



Sec. 3.6 Thrust Restraint

The need for thrust restraint is a design consideration that is not covered by this

standard. Such restraint is commonly provided by welded joints, thrust collars,

mechanical harnesses, or concrete thrust blocks. Installation of mechanical joints,

mechanical harnesses, fittings, and welded joints are described in Sec. 3.3 and

Sec. 3.4. Such restraint is commonly used when pipe pressure class can cause

excessive movement, when miter joints exceed 5, within vaults, and when the

known restraint mechanism, such as soil, is not adequate to ensure pipeline integrity

under operational and transient pressure loads. For design of thrust restraint, see

AWWA Manual M11.

NOTE: Restraining mechanisms shall be prepared and coated with a compatible

coating according to the coating manufacturers recommendations and the applicable

AWWA standard.

Sec. 3.7 Backfilling

The excavated pipe trench will usually also have to accommodate a specified

thickness of select graded foundation bedding material (see Figure 5). The

foundation bedding material shall be evenly spread in the bottom of the trench to

support the pipe along its entire length with the exception of a few feet near the joint

areas. Backfill shall be accomplished in accordance with the specified laying

conditions described in Sec. 3.3. Backfilling operations shall be maintained to avoid

having an excessive amount of exposed installed pipe.

3.7.1 Pipe zone backfill and foundation material. All pipe zone backfill and

foundation material shall be free from cinders, ashes, refuse, vegetable or organic

material, boulders, rocks or stones 3 in. (150 mm) in diameter and larger, frozen soil,

or other unsuitable materials described by the contract documents.

3.7.1.1 From 12 in. (300 mm) above the top of the pipe to grade, material

containing stones up to 8 in. (200 mm) in their greatest dimension may be used

unless otherwise specified.

3.7.1.2 When the type of backfill material is not indicated or is not specified,

the excavated material may be used provided that such material consists of loam, clay,

sand, gravel, or other suitable materials.

3.7.1.3 Pipe zone backfill shall be densified around the pipe in accordance

with Figure 5. The maximum dry density of cohesive soil shall be between 85 and

95 percent based on ASTM D698 or AASHTO T99 unless otherwise specified (see


28 AWWA C604-06

Figure 5). For free-draining soils, the relative density shall be at least 70 percent as

determined by ASTM D4253 and ASTM D4254 unless otherwise specified.

Regardless of the method of densification used, materials shall be brought up at

substantially the same rate on both sides of the pipe. When installing pipe 36 in.

(900 mm) and larger, use a probe rod method to confirm that the backfill is properly

consolidated within the pipe lower quadrant (between the pipe spring line and invert

elevation). Take care to ensure that the pipe is not floated or displaced before

backfilling is complete.

3.7.1.4 Cohesive soils shall be compacted with mechanical equipment or hand

tamping. Care shall be taken not to damage coatings during compaction. Proper

equipment and care in placement will ensure the required compaction under the

lower quadrant of the pipe. Pipe zone backfill for pipe up to 48 in. (1,200 mm) in

diameter shall be placed in layers of not more than 6 in. (150 mm) in thickness or

25 percent of the pipe diameter, whichever is greater. Pipe zone backfill for pipe

larger than 48 in. (1,200 mm) in diameter shall be placed in layers not exceeding

24 in. (600 mm) in thickness and subject to meeting the compaction requirements.

3.7.1.5 Free-draining soils may be densified by tamping with water-using

devices, or through methods such as water jets, immersion-type vibrators, or

flooding. These soils are usually placed in a minimum of two layers, with the first

layer placed loose to the spring line of the pipe. The thickness of the layers shall not

exceed the penetrating depth of the vibrators if consolidation is performed by jetting

and internal vibration.

3.7.1.6 Pipe zone bedding and backfill may be class C1, C2, or C3 (95, 90,

or 85 percent dry density or 70 percent relative density as expressed in Sec. 3.7.1.3)

or as specified in the contract documents. Pipe zone backfill shall be densified around

the pipe to the specified height over the top of the pipe. Regardless of the method of

densification used, backfill material shall be brought up at substantially the same rate

on both sides of the pipe. Care shall be taken not to float or displace the pipe before

backfilling is complete.

Trench backfill above the pipe zone shall not be placed until the compaction of

the pipe zone backfill and foundation are satisfactorily complete. To prevent damage

to the pipe, sufficient compacted backfill shall be placed over the pipe before allowing

any type of vehicle over it.



NOTE: Loosely placed backfill above the pipe may promote unwanted

settlement, which could be detrimental to improvements subsequently placed over

the trench.

3.7.1.7 When required, the pipe is delivered with internal bracing. The

vertical bracing limits the maximum vertical deflection of the pipe during installation

and backfilling operations and shall not be removed until backfilling is complete,

unless it can be demonstrated that the pipe roundness tolerance will not be adversely

affected and the pipe roundness can be verified after backfilling.

3.7.1.8 If excavated material is indicated or specified for backfill, and there is

a deficiency due to a rejection of a part thereof, the required amount of sand, gravel,

or other approved material shall be provided.

3.7.1.9 Maximum aggregate size for purposes of definition is as follows: (a)

sand is material graded from fine to coarse, containing not less than 95 percent

Figure 5 Pipe bedding


30 AWWA C604-06

passing a No. 4 sieve (4.75 mm) and not more than 5 percent passing a No. 200 sieve

(0.75 mm); (b) gravel is a reasonably uniform combination, containing no boulders

or stones larger than 3 in. (75 mm) and not containing excessive amounts of clay and

loam; (c) crushed rock is material with 100 percent passing a 3/4-in. (19 mm) sieve

and no more than 25 percent passing a No. 100 sieve.

The maximum backfill aggregate size for cementmortar coated pipe shall be 3-in.

(75 mm) minus. The maximum aggregate size for flexible coated pipe shall be 3/4-in.

(19 mm) minus.

3.7.2 Compaction. When special backfill compaction procedures are

required, they shall be accomplished in accordance with contract documents or

applicable federal, state or provincial, and local regulations.

3.7.3 Partial backfilling during testing. Newly installed pipelines are nor-

mally tested after backfilling. When unusual conditions require that pressure and

leakage testing be accomplished before completion of backfilling, or with pipe joints

accessible for examination, sufficient backfill material shall be placed over the pipe

barrel between the joints to prevent movement, and due consideration shall be given

to restraining thrust forces during testing. In particular, restrained-joint systems,

which derive their stability from the interaction of the pipe and soil, shall be

backfilled as necessary prior to testing.

Sec. 3.8 Flushing

Foreign material left in pipelines during installation can result in valve or

hydrant seat leakage during pressure tests. Every effort shall be made to keep lines

clean during installation. Thorough flushing is recommended prior to a pressure test;

flushing shall be accomplished by partially opening and closing valves several times

under expected line pressure, with flow velocities adequate to flush foreign material

out of the valves.

NOTE: Discharge shall be directed aw

Awwa c604-2006

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