WA9301-SP 971103City of Dallas
Date: November 3, 1997
Submittal No. 15010~06
.-. To: Bar Constructors, inc.
P.O. Box 10 '-
Lancaster, Texas 75146-0010
Attention: Ms. Lucy Garcia
Subject: Coppell 2 Metering Station
Contract No~'94-81
Gentlemen:
~' We are returning the following submittal data:
DISPOSITION
IDENTIFICATION
DESCRIPTION
15O10-6
PSI, Inc. - Ductile Iron Pipe and NSF 60 & 61 Approval 9 3 X
Distribution:
Design Engineer - 1
Project Manager - 5 '
(File - 1), (Field - 2), (Co. ppell - 1), (Pumping - 1)
¢f~~Des'gn Services
Water Utilities Department
Design Services, 320 E. Jefferson, Rm 213 · Dallas, Texas 75203 · 214 / 948-4576 · FAX 214 / 948-4599
A city uffiity providing regional water and wastewater services vital to public health and safety.'
Baueh & Associates, Inc. Products Marketing Specialists
11203 Jones Rd. West · Houston, Texas 77065
Phone (281) 807-9696 · Fax (281) 807-4607
SUBMITTAL DATA
FoY
DUCTILE IRON PIPE
2 METERING STATION
FoY
CITY OF COPPELL, TX
PREPARED BY:
BAUGH & ASSOCIATES, INC.
September 29, 1997
NO EXCEPTION TAKEN
MAKE CORRECTIONS NOTED-.
REVISE AND RESUBMIT
REJECTED
FOR RECORD ONLY
REVIEW BY THE ENGINEER DOES NOT
RELIEVE THE CONTRACTOR FROM
RESF'ONSIBILITY FOR CONFORMANCE
WITH CONTRACT REQUIREMENTS.
PROJECT C4:T ~ X;)(J ? ~ V
CONTRACT ~ ~ ''''<:~'
DALLAS W~TER UTILITIES DEPT.
REVIEWED
BAR CONSTRUCTORS, INO.
DATE t i9 -Z.~ - '; "~
BY /j9.
TRANS. ~/,(~/d
BA~ Constructors, Inc. represents that ~
have ~a~,~rmin~ and ve;~fiad ~l field
dimensions a~e measurements, ~e~d
n~mb,:cs, ~'m~ s~n;ar ~.~t~ ~nd that we ha~
~{~c.k,~ ,~;~ ~ '3~ m~uh'~en'~ of the W~
an~ ~ht~ Cen~mc~ O~umen~.
800 Burlington Road
RO. Box 79266
Fort Worth, Texas 76179
(817) 847-0426
(817) 847-0623 FAX
PSI
SYSTemS
IN .
3150 North Arizona Ave.
Suite #.110
Chandler, Arizona 85224
(602) 813-5944
(602) 813-6659 FAX
SUBMITTAL DATA
Project: Coppell 2 Meter Vaults/94-81/2-7-97
Location; Coppe!!, Texas
Engineer: Dallas Water Utilities
Contractor: Bar Constructors, Inc.
Specification Section: 15010
Product: Ductile Iron Pipe
TABLE OF CONTENTS
ABBREVIATIONS & BILL OF MATERIAL
A. DUCTILE IRON PIPE - Specification Section 15010
1. Piping Systems - Flanged and Grooved Pipe per AWWA C-115 & C-600
2. Piping Systems - Flanged and Grooved Pipe per AWWA C-115 & C-600
NSF Standard 61 Certification
B. COATINGS AND LININGS - Specification Section 15010
1. Asphaltic Coated per AWWA C-151 - Ductile Iron Pipe
a. International B-523 Bituminous (Aspbaltic) Coating
b. B-523 NSF Standard 61 Certification
2. Cement Mortar Lining per AWWA C-104 - Ductile iron Pipe
COPPELL.WK4
DESCRIPTION
2 EACH METERING STATIONS
COPPELL, TEXAS
'TAG#
I 12" x 6'-0" FLG X FLG DIP **
2 12"x 1'-6" FLG x PE DIP **
12 12" POLYWRAP
10
20
30
I 24" x 2'~0" FLG x PE DIP **
I 24" x 7'.-0" FLG x PE DIP **
12,24" POLYWRAP
**NOTE: CONTRACTOR TO VERIFY
LAYING LENGTH
40
50
60
Page1
800 Burlington Road
RO. Box 79266
Fort Worth, Texas 76179
(817) 847-0426
(817) 847-0623 FAX
PSI
PIHE
3150 North Arizona Ave.
Suite #110
Chandler, Arizona 85224
(602) 813-5944
(602) 813-6659 FAX
N A'P'F - x o.
~ITH THREADED FLANGES
N~IONAL ASI~IATION
OF PIPE FAIRIO~0RI
Flange Ductile-Iron pipe size 3-54 for flange pipe with
threaded flanges for water or other liquids. All flanges
furnished iR accordance with]~TSI/AWWA Cl15/A21.15 are rated for
water service of 250 p~i working pressure. ~hese'flanges have
facing a~d drilling identical to class 125 B16.1 flanges and
match class B16.1 flanges.
ANSI/ASME B16.1 also contains the details of a class 250
flange that is heavier, has a larger bolt circle, and uses larger
size bolts than the class 125 B16.1 flange and the flanges
specified in ANSI/AWWA Cl15/A21.15 and ANSI/AWWA Cl10/A21.10.
This class 250 B16.1 flange will not match the class 125 B16.1 or
ANSI/AWWA Cl15/A21.10 flange. The heavier class 250 B16.1 flange
may be furnished when specified.
FABRICATION:
Ductile-Iron pipe barrels shall conform to the requirements
of ANSI/AWWA C151/A21.51.
The nominal thicknesses of Ductile-Iron flange pipe shall
not be less than shown in table 15.1.
Threads on the pipe barrel shall be taper pipe threads (NPT)
in accordance with ANSI B1.20.1 adapted to the Ductile-Iron pipe
outside diameters shown in table 15.1.
Flanges shall conform to the dimensions shown in table 15.2.
All flanges shall have a taper pipe threads (NPT) in
accordance with ANSi B1.20.1 adapted to the Ductile-Iron pipe
outside diameters shown in table 15.1
Ductile-Iron flanges will be used unless otherwise
specified. Flanges shall conform to the respective chemical and
physical properties specified for Ductile-Iron fittings in
ANSI/AWWA Cl15/A21.15, threaded, 250 psi working pressure ANSI
125-pound drilling flanges.
Bolt holes shall be in accordance with the dimension shown
in table 15.2.
Both flanges and pipe threads shall be clean prior to
application of thread compound. The thread compound shall give
adequate lubrication and sealing properties to provide
satisfactory pressure-tight joints. Threaded flanges shall be
individually ~itted and machine tightened on threaded pipe by
pipe fabricators.
The flange and pipe ends shall be faced after fabrication.
Flanges shall be plane faced without projection or raised face
and shall be furnished smooth or with shallow serration. Flanges
may be back faced or spot faced for compliance with the flange
thickness tolerance specified in the standard. Bearing surfaces
for bolting shall be parallel to the flange within 3 degrees.
When pipe is furnished with two flanges, the bolt holes
shall be aligned, unless otherwise specified. Misalignment of
corresponding bolt holes of the two flanges shall not exceed the
pipe centerline and shall be parallel such that any two
face-to-face dimension 180 apart at the flange od shall not
differ by more than 0.06 in.
Flanged pipe shall be furnished to the lengths specified.
When pipe is furnished with two flanges the face-to-face
dimensions shall conform to a tolerance of 0.12 in. The overall
length of flanges and lane end shall conform to a tolerance of
0.25 in.
All groove Ductile-Iron pipe will be grooved to dimensions
of AWWA C-600 and be rigid.
Wall pipes shall be furnished with either cast or screwed on
type bells. Flange and screwed on bells shall be manufactured
according to procedures governing fabricated flange pipe.
Flange and screwed on bells my be supplied tap for studs.
Wall collars for wall pipe will be of cast Ductile-Iron.
Wall collars will be attached by continuous weld on both sides to
insure a water tight joint.
The pipe fabricator shall furnish a sworn statement that the
flanged pipe complies with the requirements of
ANSI/AWWA/Cll5/A21.15 when specified.
SIZE
3
6
$
10
14
16
18
~0
~4
~0
~6
42
48
O.D.
B.C. T. TI WGT BOLT BOLT DL~. &
HOLE LE'SG'rH
DLA.
7.50" 6.00' .75 +-0.12 0.38 5 3/4 518" X2-I/2
9.00" 7.50" .94 +-0.12 0.44 8 3/4 3/8 X 3
11.00" 9.50" 1.00+-0.12 0.5 11 7/8 3/4 X 3-1/2
13.$0" 11.7.5" 1.12+-0.12 0.58 18 7/8 3/4 X 3-1/2
16.00" 14.25" 1.19+-0.12 0.59 27 I 7/8 X 4
~19.00" 17.00" 1.25+-0.12 0.62 42 I 7/8 X4
21.00" 18.75" 1.38+-0.19 0.69 4f 1-1/8 I X4-112
2t.50" 21.25" 1.44+-.019 0.72' 65 1-1/8 1 X4-1/2
2,$.00" 22.75" 1.58+-0.19 0.78 67 1-114 I-1/8 X5
27.50" 25.00" 1.69+-0.19 0.8.4 92 1-1/4 1-1/8 X 5
27.50" 29.50" 1.88+-0.19 0.94 117 1-3/8 1-1/4 X5-II2
32.00" 36.00" 2.12+-.025 1.08 162 1-318 1-114 X 6-112
38.75" 42.75°° 2.38+-0.25 -'= lag 268 1-5/8 1-1/2 X 7
45.00" 49.50" 2.62+-0.25 1.31 450 1-518 1-1/2 X 7-1/2
59.50" 58.00" 2.75+-0.25 1.38 585 1-5/8 1-1/2 X 8
62.75" 62.7.$" 3.00+-.025 1.5 650 2" 1-3/4 X 8-1/2
FLANGED DUCTILE-IRON
TABLE 15.1
DUCTILE-IRON FL~tArGED PIPE H'7TH THREADED FL.~/VGES
SLZ'E
THICIQNfSS ~La, X NOMZ~N'.4L O.D. WEIGHT ONE WEIGHT
CkASS WOP, KLNG TH2ICIQ~ESS L'C. FLANGE PIPE
PKESSO'RE D.~CKES ONLY B'aJCKEL
PEK FT
3 53 250
4 53 250
6 531 250
8 53 250
10 53 230
lZ 53 250
l-t 53 250
16 53 250
18 53 250
20 53 250
24 53 250
30 53 250
36 53 250
42 53 2~0
,|8 53 250
0.3|t 1.96"
0.321 4.8"
.3-! 6.9"
0.36! 9.0Y'
.~ ! 11.10"
0.4 13.20"
0.42 15.30"
0.43' 17.30"
0.44 19.50.°
0.45 21.60"
0.47 25.80"
0.51 3LO0"
0.58 38.30"
0.65 4~.50"
0.7~ 50,80"
0.$1 57.10"
# OF
BOLTS
7 10.9
13 13.8
17 2[.4
271 30.1
38] 39.2
58 49.2
72 60.1
90 70.1
90 80.6
115[ 91.5
160~ 114.4
240 15~l.,I
350 210.3
5001 274
615 3-16.6
760! 438.3
]i I
A
4
8
8
8
12
12
12
16
16
20
20
28
32
36
44
44
1.25
1.38
1.58
1.88
2
2.25
2.5
2.75
3
3.2..s
3.5
3.38
4
4.5
5.12
5.75
O.D. B.C. T. T 1 WG'T
~ 7.50" 6.00" .7.s +-0.1! 0.38
4 9.00" 7.50' .94 +-0.12 0.44
6 11.oo"[ 9.50" 1.00+-0.12 0..~
8 13..~0" II.7Y' 1.12+-0.12 0.58~
I0 16.00" 14.25" 1.19+-0.12 0.59
12 19.00" 17.00" 1.25+-0.12 0.63
14 21.00" 18.75" 1.38+-0.19 0.69
' 16 23.50" 21.25" 1.44+-.019 0.72.
18 25.00" 23.7.~" 1.58+-0.19 0.78
20 27.50" 25.00" 1.69+-0.19 0.84
24 27.50" 29.50" 1.88+-0.19 0.94
30 32.00' 36.00" 2.12+-.035 1.08
36 38.75" 42.75" 2.38+-0.2.~ ..: 1.18
42 45.00" 49.50" 2.62+-0.25 1.31
48 59.50" 58.00" 2.7.~.~--0.25 1.38
54 1 62.7Y' 62.75" 3.00+-.0 !5 1.5
BOLT
HOLE
DL~
8
11
18}
-,
65
67
117{
162[
268I
650}
BOLT DL~- &
LENGTH
314. SI8'" X3-1t3
3/4 } 5/8 X 3
7/8 ! 3/4 X 3-1!2
~' t 3/4 X 3-1/2
1 ] 7/8 X 4
{
11 7i8 X4
1-1/8[ I X4-1/2
1-I/8 1 X 4-I/2
1-114 1-118 X 5
1-378 1-1!4 X5-1/2
1-3/8 1-1/4 X 6-1/2
1-5/8 1-1/2 X 7
1-5/8 1-1/2 X 7-1/2
2" 1-3/4 X 8-I!2
,i OF
BOLTS
4
8
8
8
13
II
13
16
16
20
20
28
33
36
44
A
1.25
1.38
1.53
1.88
2
2.25
2.5
2.7.5
3
3.25
3.38
5.12
5.75
0.0.
C ]]'
OROOVE X OROOVE
SEEP RINO DETAIL
Q
L
C
J
HJ X GROOVE
L
C I)
D
PLAIN END X PLAIN END
J
MJ ADAPTER BELLS
THREADED
PIPING
SYSTEMS, ING.
609 BURLINGTON RD.
P.O. BOX ~9288
FORT lVORTH, TX.
(al"~)
L
C
D
FLANGE X FLANGE
L
FLANOE X PLAIN END
L
C ]]
FLANGE X GROOVE
SIZE R U
3 ,94 4.12
4 1,00 4 25
6 1.06 4,43
8 LIE 4,75
JO 1,19 4.87
18 1.25 5.18
14 1.31 6,50
16 1.38 6,75
18 1.44 7,00
20 1.50 7.24
24 1,62 7,50
30 1.81 913
36 8.00 9,75
L
FLANGE X NJ
L
·
C
,= - ] ' ,
MJ X PLAIN END
L
C ]]
NJ X NJ
Q J WT.
7,69 4,50 11
9.[2 5.32 16
11,18 7.56 83
13,37 9,73 3[
15.69 18,06 4i
17.94 14.16 55
E0.3~ 1625 85
22,56 18,43 105
84.83 80.53 125
27.09 22.63 150
31,58 86.88 235
39,[8 33,00 375
46,00 39.85 500
800 Burlington Road
RO. Box 79266
Fort Worth, Texas 76179
(817) 847-0426
(817) 847-0623 FAX
3150 North Arizona Ave.
Suite #110
Chandler, Arizona 85224
(602) 813-5944
(602) 813-6659 FAX
Classified 'o,.(:Recognized by Underwriters Laboratories Inc, ®
in Accordance with ANSI/NSF 60 & 61
Price
· U,S, $4,50
April 1997
:)rin <inc 'Na:er
Sys:em Com3onen:s,
Com3onem Ma:eria s
anc 'rea':men: Ac c i':ives
.~~L Underwriters Laboratories Inc.®
DRINKING WATER SYSTEM COMPONENTS - HEALTH EFFECTS
ANSI/NSF STANDARD 61
Pipes and Related Products
Pipe Works, Inc.
15629 Clanton Circle
Santa Fe Springs, California 90670
MIt19610
Plant Location:
Santa Fe Springs, California
Trade DesignSion
Size
Water Water
Contact Contact
Temperatm'e Material
Coated Ductile Iron
Pressure Pipe
~Piping Systems, Inc.
800 Burlington Road
Saginaw, Texax 76179
Plant Location:
Saginaw, Texas
Trade Designation
Coated Ductile Iron
N/A Cold Asphalt
Pipes and Related Products
· - MH19609
Water Water
Contact Contact
Size Temperature - Temperature
N/A C
Pipes And Related Products
Plant and Flanged Equipment Co.
400 851h Avenue North
Minneapolis, Minnesota 55443
MH17552
Plant Location:
Minneapolis, Minnesota
Trade Designation
Size
Water
- Contact
Temperature
Water
Contact
Material
Coated Ductile Iron
Pressure Pipe
N/A
Cold
Asphalt'
-94-
AMERICAN DUCTILE IRON PIPE
Several different generic types of exterior
p. rimers for pipe & fittings are available upon
re, quest. Because of the variables and complexi-
ties involved in the selection and application of
the proper coating for a given service. AME~RI-
"CAN invites inquiries for technical assistance.
~;~ASPHALTIC COATING
AMERICAN furnishes most pipe and fit-
tings coated outside with an asphaltic coating
approximately one rail thick per AVV~VA C151
for ductile iron pipe. AWWA Cl15 for flanged
pipe and AVVVVA C110 and C153 for fittings.
All across the United Stal~s ductile iron
and gray iron pipe and fittings with this stan-
dard coating have provided trouble-free service
for decades. Unless otherwise specified. an
aspbaltic coating is applied to the outside of all
pipe and fittings manufactured by AMERICAN.
The primary purpose of the asphaltic coat-
ing is to minimize atmospheric oxidation for
aesthetic reasons. If soils are deemed to be cot-
rosive to ductile iron pipe when tested in accor-
dance with Appendix A of AWWA C105, poly-
ethylene encasement should be used most of
the time.
UNIVERSAL PHENOLIC PRIMER
This is a fast drying. lead and chromate
free, corrosion-resistant primer formulated to
accept a wide variety of chemically resistant
topcoats. It is well suited for OEM applications
where the generic topcoats are unknown.
Typical (field) finish coatings include:
alkyds, aluminums. epoxies (amine, polyamide.
polyamidoamine. water-borne, coal-tar) and
polyurethane coatings. Reference ACIPCO
Coating System No. 1.
HIGH-SOLIDS EPOXY PRIMER
This is a high solids. chemical and corro-
sion resistance coating for protection against
abrasion. moisture. corrosive fumes, chem;cal
attack and immersion.
This 30" AMERICAN Ductile Iron Fastite Joint treated water transmission main was
furnished and installed --as is most Ductile Iron Pipe--with standard aspbaltic coat-
ing approximately one mil thick on the outside. 11-7
AMERICAN DUCTILE IRON PIPE
High-build properties provide outstanding
corrosion protection with fewer coats, particu-
larly on edges. Such high solids, high film-build
epoxies are compatible with most catalyzed fin-
ish colts.
Typical (field) finish coatings include:
Epoxies (amine. polyamide, polyamidoamine,
water-borne, coal-tar) and polyurethane coat-
ings. Reference ACIPCO Coating System No. 2.
cial exterior coating systems, lead times and
costs.
UNCOATED PIPE
Because some customer applications may
require piping or fittings that have no coating
applied to the exterior, AMERIC~,.N furnishes
when specified at time of purchase any of its
products without exterior coatings.
OTHER SPECIAL COATINGS
AMERICAN can also furnish other special
exterior coating systems. Contact AMERICAN
for technical assistance in the selection of spe-
NOTE: AMERICAN also has the abili-
ty to furnish other primers, but this may
affect price and availability.
AMERICAN' Cast Iron Pipe Company
Standard O.D. Shop Primer Systems
· ACIPCO Primer No. I Universal Phenolic *
Above grade - Interior/Non-immersion (Mild Exposure)
Surface Preparation:
Shop Coat Thickness:
Typical Topcoats:
AMERICAN Specification No. 3
2.0-4.0 mils dry film thickness
Alkyds, aluminures, epoxies (polyamide, poly-
amidoamine, water-borne & coal-tar) & urethanes
· ACIPCO Primer No. 2 High Solids Epoxy*
Interior/Exterior/Immersion (Aggressive Exposur.e)
Surface Preparation:
Shop Coat Thickness:
Typical Topcoats:
AMERICAN Specification No. 3
3.0-8.0 mils dry film thickness
Epoxies (amine, polyamide, polyamidoamine,
water-borne, coal-tar) & urethanes
'Unless otherwise specified at time of purchase:
1 .) All primers used by AMERICAN are standard products meeting the formulation standards and performance criteria
of Tnemec Company, Inc., Kansas City, Mo.
2,) All coatings will be red-oxide in color. ('l'nemec color numbe~' - 1211 .)
3.) The coatings used for ACIPCO Primer No. 2 will be Tnemec products certified by the National Sanitation
Foundation (NSF") in accordance with ANSI/NSF Std. 61 for potable water contact.
Contact AMERICAN for additional information on coating products and potential uses.
11-8
INTERNATIONAL OIL
Box 6726 · Birmingham, AL 35210
Phone 205.-956-1112
INTERNATIONAL B-523 Bitruinous Coating
PRINCIPAL USES
Internal and external application to ductile iron and cement-lined pipe.
International B-523 has been tested by 'Guardian 'Sys.~s'Labn..:.- and
meets ANSI A21.4 and AWWA C104', Par~ 4, 12.3.,f~ potable water and was found to be
acceptable. International B-523 has also been tested by National Sanitation
Foundation and meets the~requirements of Standard 61.
SURFACE PREPARATION
No surface preparation needed.
TYPICAL PHYSICAL PROPERTIES
Solids by wt. + 5.0%
Pot life mixed'
Application
Thinning reduction/as required
53 - 58
N/A
Conventional spray/airless/brush/roller
N/A
Viscosity, SFS e 77oF
Specific gravity@ 60oF
Pound per gallon, 60oF
Base asphalt, R&B oF
Penetration @ 77oF ~
Color
V.O.C. (lbs/gal)
100- i75
0.901
7.35 - 7.50
185 - 205
5-15
Black
3.15-3.34
MATERIAL SOLD IN 55/gal.DRUMS - FREIEHT COLLECT
Asphalt and Polyarmor Pipe Coatings
NSF LISTINGS
Drinking Water Additives
- Health Effects
May 7, 1997
NSF
ANSI/NSF STANDARD 61 [ 47~i
,LISTING OF CERTIFIED DRINKING WATER SYSTEM COMPONENTS - HEALTH EFFECTS
1i ;ST STREET N ' ~ C , '* '
2
IRONDALE, AL 35210
205-956-11
Most Recent Listing Date: O4/01/96
301 SOUT
Plant At: IRONDALE, AL
Prote;tive (Barrier) Materials
Trade Designation - Water Water Water
. ' Contact Contact ontac't
· ' Size Restriction Temp Mater'al
~ B-523M >= 3' CLD 30 ASPH
~: International 550* >= 3' CLD 30 ASPH
~: International 60~ >= 3" CLD 30 ASPH
~ PFe00* >= '3 ' CLD 30 ASPH
~. Slokure D* ' >= 3' ' CLD 30 ASPH
;:.international CB42 . ,. >= 3' CLD 30 ASPH
· Certification was based on a single application of not more than 1,5 dry
, m~}s end cure t~me not less than 48 hours . ,,,
VERSAND COMPANY
226 AT~NTIC AVE. ..
BOX 650
NJ 08312
11-2345
Recent Listing Date: 07/09/96
At= SEWELL, NJ
Media
Trade Des ignat ion
Size
Media
anganese Greensand HA
frosand NA
led for water treatment plant applications.
)roduct has not been evaluated for point o~ use applications.
Follow manufacturer's use
manganese greensand.
Water Water
Contact Contact
Tamp Material
CLD 23 NA
CLD 23 NA
instructions for installation and regeneration of
Certification is only for Water Contact Material shown In Listing,
AMERICAN DUCTILE IRON PIPE
AMERICAN Linings
for Pipe and Fittings
The principal standard covering cement lining is ANSI/AWWA C104/A21.4. This
an.d other standards are referenced throughout this Section either by the full
AI~ISI/AWWA designation or by only the AWWA numbering, such as AWWA C104.
Along with technical and metallurgi-
cal advancement in piping materials,
research on lining requirements for pipe
and fittings has resulted in the develop-
ment of linings to meet many different
service requirements. AMERICAN offers
several types of linings, the most common
being cement lining.
Pipe and fittings furnished by AMER-
ICAN are offered unlined or with' linings
as follows:
.1. Cement Lined 'per AWWA 'C104.
2. Asp~altic 'Lined per AWWA C110,
Cl15, C151, or C153.
*3. Polybond Lined - AMERICAN's
polyethylene lining.
*4. Coal Tar Epoxy Lined - resin and
tar combination.
5. Special Lining - for unusual service
conditions.
*Polybond and Coal Tar Epoxy are for spedtic sen~ce
conditions and their usage sh:~ld be restricted
Cement Lining
Cement-mortar lining for ductile iron
pipe and fittings for water service is in
accordance with ANSI/AWWA
C 104/A21.4
Cement-lined pipe is also furnished
for sewage service and a number of other
applications. In fact, most pipe furnished
is cement lined, providing improved flow
characteristics and the required protection
against internal corrosion. The cement lin-
ing is satisfactory for temperatures nor-
mally encountered in water and in sewage
service and the aspbaltic seal coat is ade-
quate for temperatures up to 150°F; for
other services contact AMERICAN regard-
ing abilities and limitations of cement lining.
The first recorded installation of
cement-lined gray iron pipe was in 1922
at Charleston, S.C. This lining was devel-
oped by the Charleston Commission of
Public Works in cooperation with
American Cast Iron Pipe Company. Since
this beginning, AMERICAN has furnished
most of its pipe with cement lining. The
lining is applied centrifugally with speed
of rotation and vibration designed to pro-
duce a smooth waterway surface, free
from voids and yet retaining enough
moisture for proper curing.
Flow tests on cement-lined pipe under
varying service conditions have established
that the Hazen-Williams flow coefficient
remains as expected at about 140.
Handling Cement-Lined Pipe and
Fittings
Pipe and fittings with cement lining
should be handled with rubber covered
hooks or other type equipment to prevent
damage to the cement lining. Bare fork lift
arms or bare hooks should not be inserted
into open ends.
Characteristics of Cement Lining
AVVVVA C104 allows for surface craz-
ing and cracks of a specified nature and
magnitude. Occasionally cracks and loose-
ness in linings may occur prior to installa-
tion, particularly where pipe is stored for a
considerable time. Many years' experience
with cement-lined pipe and fittings has
verified that this condition is in no way
detrimental to the performance and effec-
tiveness of the lining.
When a cement-lined pipe is placed
in service and filled with water, two reac-
tions begin immediately. The first is a
gradual elimination of the temperature
11-1
AMERICAN DUCTILE IRON PIPE
differential between pipe and lining, thus
eliminating any stresses in the lining due
to this condition.
Secondly, the lining begins to absorb
water. Water is absorbed into the pores of
the cement and into the capillary channels
of l~he calcium silicate gel. The water
absorption causes the lining to swell,
restoring it to intimate contact with the
pipe wall and virtually closing any cracks"
present in the lining. This swelling process
is relatively slow. taking up to several
weeks for the lining to be restored to its
maximum volume. This process has been,.
demonstrated on a number of occasions
to the satisfaction of customers, contrac-
tors and engineers by immersing a pipe or
fitting in water for one or two weeks.
After a period of exposure to water,
not only does the lining tighten against
the pipe wall and the cracks close, but
finally the surfaces of the cracks actually
re-bond. This occurs by a process called
autogenous healing. This phenomenon,
long recognized by the cement industry.
has been documented by laboratory tests
to occur in cement-lined ductile pipe. In
one test, a 48" ductile iron pipe with
severely cracked cement lining was held
half full of water for several months. At
the end of that period, the lining both
above and below the water surface was
found to be tight, with all cracks either
healed completely or sealed by the forma-
tion of calcium carbonate.
Field inspections of lines that have
been in service for many years have veri-
fied the laboratory results; cement linings
do tighten and heal in service, and they
provide the corrosion protection to the
pipe and the high flow coefficients for
which they were designed.
Field Repair of Damaged Cement
Linings
Cement lining will withstand normal
handling; nevertheless, pipe or fittings
may be found at times to have damaged
linings which need to be repaired before
placing in service.
AWWA C104 provides that damaged
lining may be repaired, and the following
repair procedure is recommended:
1. Cut out the damaged lining to the
metal. Square the edges.
2. Thoroughly wet the cut-out area
and adjoining lining.
3. With the damaged area cleaned
and the adjoining lining wet, spread. the
mortar (see recommended mix below)
evenly over the area to be patched. (See
Table No. 11-1 for lining thicknesses.)
After the lining has become firm and
adheres well to the surface, finish it with a
wet 3" or 4" paint brush or similar soft
bristle brush.
4. The repaired lining should be kept
moist by tying canvas or wet burlap over
the ends of the pipe or fitting for at least
24 hours. As an alternative the repaired
lining may be seal coated with a cut back
type of asphaltic seal coating. This must
be sprayed or brushed on within 5 to 30
minutes after lining. To maintain NSF cer-
tification, the patch must be made using a
NSF certified cement for 4" pipe and larg-
er or the patch must be topcoated with
NSF certified asphalt paint.
Recommended Cement Mix
Cement mix by volume: 3 Parts
Portland Cement; 2 Parts Clean Sand;
necessary water for slump of 5' to 8".
The sand should be free of clay and
screened through a No. 20 Screen.
Precautions
1. Mortar for lining should not be
used after it has been mixed for more
than one hour.
2. Too rapid a loss of moisture from
fresh linings due to hot weather or high
wind will prevent proper cure, resulting in
the lining being soft and powdery. To pre-
vent this loss of moisture, (a) do not line
hot castings and (b) close the ends of the
castings with wet burlap.
3. Fresh linings which become frozen
will not be serviceable. Avoid lining in
freezing weather.
11-2
AMERICAN DUCTILE IRON PIPE
Cement Lining
ANSI/AWWA C104/A21.4
: Thicknesses and Weights
Table No. 11-1
Standard Thickness Double Thickness
Size Nominal
in. Pipe Length Minimum Weight ~/eigh~ Minimum Weight Weight
ft.' ' Thickness Per Foot Per Length Thickness Per Foot Per Length
In. Ib Ib in. Ib Ib
4 20 ~, .87 17 ~ 1.71 34
6 20 ~, 1.30 26 ~ 2.57 51
8 20 '/,, 1.74 35 '~ 3.45 69
10 20 '/,, 2.15 43 '~ 4.28 86
12 20 '~, 2.57 51 ~ 5.12 102
14 20 ~ 4.49 90 ~, 8.93 179
16 20 ~ .'.. 5.13 103 ~8 10.19 204
18 20 ~ 5.76 115 ~, 11.47 229
20 20 ~ 6.40 128 ~, 12.73 255
24 20 ~ 7.68 154 ~, 15.31 306
30 20 ~ 12.76 255 '/, 25.42 508
36 20 ~ 15.31 306 ~ 30.51 610
42 20 ~ 17.82 356 '/, 35.53 711
48 20 ~ 20.35 407 '/, 40.60 812
54 20 '~ 22.89 458 '/, 45.68 914
60 20 ~ 24.71 494 ~ 49.32 986
64 20 ~ 26.35 527 '/, 52.61 1052
Weights are based on the minimum lining thicknesses for minimum pressure classes of ductile iron pipe.
Actual weights may differ from above. Unings may taper at the ends.
Unless otherwise specified the cement lining is given an asphaltic seal coat.
AMERICAN recommends the use of standard thickness cement lining pe~ AWWA C104 for all normal installations.
. .,,-dr,~'e~.~':, _-.-_ .:~, ·
.
This 60" Ductile Iron Fastire Joint Pipe was furnished with
standard cement lining for continuing high flow performance.
11-3
AMERICAN DUCTILE IRON PIPE
Polyethylene Encasement
In the few areas where severely
aggressive soils are encountered, the use
"of a polyethylene tube or sheet encase-
ment has been proven to provide highly
effective and economical protection. The
protection against corrosion provided by
loose polyethylene is different in several
ways and should not be confused with
coatings applied directly to the barrel of
the pipe. The most significant difference is
its ability to protect without creation of
concentration cells at holidays. Also, since
the encasement is applied when the pipe
is actually put in the grbund, coating
damage due to shipping, handling, etc., is
minimized.
As water may be present in the soil
around the pipe, water may also be pre-
sent between the pipe and wrap. Water
inside the polyethylene tubing initially
bears the characteristics of the soil envi-
ronment and corrosion may start. But
within a short period of time initial oxida-
tion depletes the oxygen supply in the
water, and other electrochemical corro-
sion reactions also progress to completion.
At this point a state of chemical equilibri-
um is reached.
Since the first field installation of
poly.ethylene wrap on gray iron pipe in
1958, installations have been made in
severely corrosive soils throughout the
United States. The polyethylene encase-
ment procedure developed in the United
5tares has been adopted by several other
countries and an International Standard
for Polyethylene 51(~eving (150-8180) has
been developed.
Research by the Ductile Iron Pipe
Research A~ssociation at several severely
corrosive test sites has verified that poly~
ethylene encasement provides a high
degree of protection and results in minimal
and generally insignificant exterior surface
corrosion of either ductile or gray iron pipe
thus protected. These findings have been
confirmed by the results of numerous
investigations of field installations.
Field tests have also indicated that- ·
the dielectric capabili{y of'polyethylene
provides shielding for ductile and gray
iron pipe against stray current at most lev-
els encountered in the field.
Because polyethylene encasement is
a passive method of protecting ductile
iron pipe in aggressive soils, it can' effect
greater reliability and savings than
cathodic protection systems which require
continual monitoring, maintenance and
other operating expenses, and trained
personnel. Cathodic protection systems
can also cause harm in some cases to
nearby unprotected ferrous structures.
For protection in the isolated areas of
severely aggressive soils, AWWA C105
covers materials and installation proce-
dures for polyethylene er~casement of
underground installations of ductile iron
piping for water and other liquids.
Polyethylene wrap in tube or sheet
form for piping encasement is manufac-
tured of virgin polyethylene material con-
forming to the requirements of
ANSI/ASTM Standard Specification
D1248. The specified nominal thickness
for low-density polyethylene film is 0.008
in. (8 mils). The specified nominal thick-
ness for high-density cross-laminated
polyethylene film is 0.004 in. (4 mils). The
minus thickness tolerance shall not exceed
10 per cent of the nominal thickness on
both material types.
Material and installation methods are
all in accordance with the requirements of
AWWA C105. This standard and more
detailed publications by DIPRA regarding
loose polyethylene encasement are avail-
able from AMERICAN.
11-9
Ir/
AMERICAN DUCTILE IRON PIPE
Polyethylene Tubing and Tape
ANSI/AWWA C105/A21.5
' "Tubing in Roll
Table No. 11-2
Accordion Type Bundle*
Approximate Weight in Pounds
8 mil low density P.E.
Appro~ wright Oh.) Tape Required'*
Rat Tube per 500' ron 4 m|l
Pipe Size Min. Widffi Per .1000' Per 22' Long high-density cross- Per Joint
in. In. ..of Tube Individual Tube lamlna~d P.E. ~'
4 14 89 2 21 5
6 16 102 3 24 6
8 20 128 3 30 8
10 . 24 154 4 36 9
12 27 173 4 40 10
14 30 192 5 45 11
16 34 218 5 51 12
18 37 237 6 55 13
20 41 262 6 61 15
24 54 346 8 80 17
30 67 429 10 100 21
36 81 518 12 120 25
42 81 518 12 120 28
48 95 608 14 141 32
54 108 689 16 161 35
60 108 689 16 161 36
64 121 772 18 180 39
· Individual tubes, 22' long, can be furnished folded as well as in accordion type bundles as shown above.
°'Based on one turn at each end, six 4' long strips to secure loose wrap plus approximately 5% extra.
Sheet Polyethylene
Sheet polyethylene is also available. The minimum width of sheet polyethylene for
each size pipe is shown in the following table.
Table No. 11-3
Min. Min. Min. Min. Pipe Min. Min.
Pipe Sheet Pipe Sheet Pipe Sheet Pipe Sheet Sheet 'Pipe Sheet
Size Size Size
Size Width Width Width Width
Size Width Size Width in. in. in. in,
in. in. in. in. in. in. in. in.
4 ~ 28 10 48 16 68 24 { 108 42 162 60 216
6 32 12 54 18 74 30 134 48 190 64 242
8 40 14 60 20 82 36 162 54 216
Installation of Polyethylene Encasement
Installment methods as set forth in ANSI/AWWA C105/A21.5 and DIPRA's
"Polyethylene Encasement" brochure should be followed.
11-10