S-430-FF-1

Statewide

IRRIGATION WATER CONVEYANCE (FT)

Pipeline

Steel

[Installation Requirements]{.underline}

A. Placement: Buried Pipelines

> Pipelines shall be laid to the lines and grades as shown on the
> drawings and/or as staked in the field, and shall be placed deep
> enough below the land surface to protect it from the hazards imposed
> by traffic crossings, farm operations, freezing temperatures or soil
> cracking. Two feet minimum cover shall be provided except in soils
> subject to deep cracking where the cover shall be a minimum of three
> feet. Where necessary to place the pipe at lesser depth, adequate
> protection shall be provided by means of the placement of extra fill
> over the pipeline, by the use of a fence or other surface barrier, or
> by the use of extra heavy gage pipe.
>
> Where trenches are excavated in soils containing rock or other hard
> material that might damage pipe or coating material, the trenches
> shall be excavated slightly deeper than required and then filled to
> grade with sand or fine earth.
>
> Coated pipe shall be handled so as to prevent abrasion of the coating
> during transportation and handling and during placement and
> backfilling of the pipeline. No pipe shall be dropped from cars or
> trucks or allowed to roll down skids without proper restraining ropes.
> Each section of pipe shall be delivered in the field as near as
> practicable to the place where it is to be installed. When stockpiled
> it shall be neatly piled and blocked with strips between tiers.
>
> Where it is necessary to it shall be done in such a manner as not to
> damage the pipe or coating. Pipe shall not be rolled or dragged on the
> ground. If the pipe is supported, as for welding, supports shall be
> sufficient width and number, and padded if necessary, to prevent
> damage to the coating.

B. Joints and Connections

> Special field joints shall be installed in strict accordance with the
> manufacturer\'s recommendations. On buried pipelines, high resistance
> joints between pipe lengths shall be electrically bridged with a
> welded, brazed, or soldered copper wire not smaller than 4/0 gauge in
> size. If coated pipe is field welded, special care shall be taken to
> avoid burning the protective coating. After the joints have been
> welded, they shall be covered with a coating equal in quality to that

Section IV NE-SCS-MARCH 1981

S-430-FF-2

Statewide

> specified for the pipe. Dielectric connections shall be placed as
> specified on the drawings.

C. Placement: Above-Ground Pipelines

> Concrete, timber or other pipe supports and anchor and thrust blocks
> shall be constructed at the locations and to the dimensions as shown
> on the drawings and/or as staked in the field. Saddles shall be shaped
> to firmly support the pipe throughout the full arc of the contact. At
> least two layers of felt strips shall be placed between the pipe and
> its support. The felt shall cover the entire area of contact between
> the pipe and the saddle. A graphite lubricant shall be placed between
> the felt strips before the pipe is placed in the saddle.

D. Paint

> Unless otherwise specified, all above-ground pipelines shall be
> painted as follows:
>
> 1\. All grease and oil shall be removed from the pipe surface by steam
> cleaning or by solvent cleaning and all dirt, surface rust, and loose
> scale shall be removed by means of wire brushing, flame cleaning, use
> of rotary abrading tools or by light sand-blasting.
>
> 2\. To the cleaned pipe there shall be applied one priming coat of red
> lead base paint conforming to the requirements of Federal
> Specification TT-P-86e Type I, II or III, or one priming coat of
> synthetic primer conforming to the requirements of Federal
> Specification TT-P-636c(l).
>
> 3\. The painting shall be completed by the application of two coats of
> aluminum paint. The aluminum paint shall be prepared by mixing
> aluminum paste conforming to Federal Specification TT-P-320b(l), Type
> II, Class B with mixing varnish conforming to the requirements of
> Federal Specification TT-V-81d, Type II, Class B, at the rate of two
> pounds of aluminum paste per gallon of varnish. The paint shall be
> mixed at the time of use.

E. Coatings

> Coating material and application procedures shall be as specified in
> Engineering Specifications for Materials by class of coating.

F. Cathodic Protection:

> Buried steel pipelines will be protected with sacrificial galvanic
> anodes where specified to supplement the protection provided by the
> pipe coating. The anodes shall be of the kind

Section IV NE-SCS-MARCH 1981

S-430-FF-3

Statewide

> and number as specified for the job and/or as shown on the drawings.
> Anode materials shall be as specified in Engineering Specifications
> for Materials.

G. Anode Installation

> Anodes shall be placed as shown on the drawings. When placed
> horizontally, they shall be at or below the bottom elevation of the
> pipeline. Vertically placed anodes shall have a minimum distance to 3
> feet between the ground surface and the top of the anode. Anodes shall
> not be placed in fill areas, and magnesium anodes must be placed a
> minimum distance of 10 feet from the pipeline.
>
> Anodes shall be bedded in moist fine clay, clay loam, silt, or silt
> loam. In sandy and gravelly areas, fine material must be imported for
> bedding and for covering the anodes to a depth of 6 in. The packaged
> anodes and the fine textured soil used for bedding and backfill shall
> be thoroughly wetted.
>
> The lead wire from the anode, or the header wire for multiple anode
> installations, shall be attached to the pipeline by cadwelding,
> thermowelding, or other similar processes. The area of damaged pipe
> coating and the weld shall then be covered with a coating equal in
> quality to that of the specified original pipe coating.

H. Testing

> Underground steel pipelines shall be tested before placing the
> backfill over the field joints. Above ground steel pipelines may be
> tested at any time after they are ready for operation.
>
> The pipeline shall be filled with water, taking care to bleed air and
> prevent water hammer. When the line is full, all valves shall be
> closed, and the line shall be brought up to full design working
> pressure. All joints shall then be carefully inspected for leakage,
> and any visible leaks shall be repaired.
>
> It shall be demonstrated by testing that all valves, vents, surge
> chambers, and other appurtenances function properly when the pipeline
> is operated at design capacity. Objectionable surge, water hammer,
> unsteady delivery of water, damage to the pipeline, and detrimental
> discharge from control valves are evidence of malfunction.

[Materials]{.underline}

A. Pipe

> Pipe shall equal or exceed the requirements specified in the
> following: American Water Works Association Designation C200, \"Steel
> Water Pipe 6 inches and Larger\"; ASTM-A-53, \"Pipe,

Section IV NE-SCS-MARCH 1981

S-430-FF-4

Statewide

> Steel, Black and Hot-Dipped, Zinc-Coated (Galvanized) Welded and
> Seamless for Ordinary Uses\"; or ASTM-A-2119 Spiral-Welded Steel or
> Iron Pipe\".

B. Appurtenances

> Standard fittings for the pipe shall be used. Elbows, tees, crosses,
> reducers, gate valves, check valves, air and vacuum release valves,
> pressure relief valves, and pressure regulators shall be of the size
> and type of material specified and/or shown on the drawings.

C. Interior Coatings

> When an interior coating is specified, the coating shall meet the
> requirements of one of the following:

D. Coal-Tar Enamel

> The interior of the pipe shall receive a coat of coal-tar primer
> followed by a hot coat of coal-tar enamel applied either by manual or
> mechanical means. All material and application shall be in accordance
> with applicable parts of American Water Works Association
> Specification C 203 pertaining to interior coatings.

E. Cement Mortar

> Materials and workmanship shall be equal to American Water Works
> Association Specification C 205.

F. Epoxy Resin

> Epoxy resin interior coatings shall meet the requirements given in the
> following section of these specifications for epoxy resin exterior
> coatings.

G. Exterior Coatings

> Exterior coatings shall be Class A, Class B, or Paint as specified for
> the job.

H. Class A Coatings

> When a Class A coating is required, the coating shall meet the
> requirements of one of the following:
>
> 1\. [Coal-Tar]{.underline} Enamel -The outside of the pipe shall
> receive a coat of coal-tar primer followed by a hot coat of coal-tar
> enamel into which shall be bonded an asbestos felt wrapper and
> finished with a kraft paper or one coat of water-resistant whitewash.
> All materials and application shall be in accordance with American
> Works Association specifications C 203.

Section IV NE-SCS-MARCH 1981

S-430-FF-5

Statewide

> 2\. [Epoxy]{.underline} Resin Epoxy resin coatings shall have physical
> characteristics and be applied as follows:
>
> a\. Pipe shall be cleaned of all contaminants such as lacquer, wax,
> coal-tar, asphalt, oil or grease.
>
> b\. Pipe shall be shot blasted to white metal in accordance with steel
> structure Painting Council Specification SSPC-SP5-63 using S-170 shot
> or equivalent.
>
> c\. After blasting the pipe surface shall be power wire brushed.
>
> d\. The coating shall be applied to the clean preheated (450\" to
> 475\") pipe, using best commercial practice, to a minimum thickness of
> 7 mils. The thickness shall be determined by using a magnetic
> thickness gauge. The heat source shall not leave a residue on the
> pipe-surface.
>
> e\. The coated pipe shall be maintained at or above 425\" for a
> minimum of 20 seconds for full cure. At the end of this time the pipe
> shall be water quenched before a supporting roller comes in contact
> with the coated surface.
>
> f\. All epoxy resin coated pipe shall be electrically inspected for
> holidays using a wet electrode to apply 1000 volts, D.C. across the
> coating. All imperfections shall be repaired.
>
> g\. The epoxy resin coating shall meet the physical requirements of
> Class A cured epoxy resin coating as indicated in Table 1.

Section IV NE-SCS-MARCH 1981

S-430-FF-6

Statewide

+--------------------+------------------+----------+------------------+
| Table 1 -          |                  |          |                  |
| Requirements for   |                  |          |                  |
| epoxy coating      |                  |          |                  |
+--------------------+------------------+----------+------------------+
| Test description   | Procedure        | Unit     | Minimum test     |
|                    |                  |          | value            |
+--------------------+------------------+----------+------------------+
|                    |                  |          |                  |
+--------------------+------------------+----------+------------------+
| Impact\.           | ASTM-G-14        | in.-lb   | 120              |
| ..\...\...\...\... |                  |          |                  |
+--------------------+------------------+----------+------------------+
| Hardnes            | ASTM-D-2583      | \-       | 10               |
| s\...\...\...\.... |                  |          |                  |
+--------------------+------------------+----------+------------------+
| Adhesio            | ASTM-D-1002      | lb/in.   | 4,500            |
| n\...\...\...\.... |                  | [2]{.und |                  |
|                    |                  | erline}/ |                  |
+--------------------+------------------+----------+------------------+
| Disbonding         | ASTM-G-8 (Method | \-       | [1]{.underline}/ |
| cathodic..         | A)               |          |                  |
+--------------------+------------------+----------+------------------+
| Chemical           | ASTM-G-20        | \-       | No visual effect |
| resistance..       |                  |          |                  |
+--------------------+------------------+----------+------------------+
| Thermal            | 320° F (160° C)  | 10       | No visual effect |
| shock\...\.....    |                  | cycles   |                  |
|                    | to -80° F (160°  |          |                  |
|                    | C)               |          |                  |
|                    |                  |          |                  |
|                    | 4 in. by 4 in.   |          |                  |
|                    | coated panel     |          |                  |
|                    | [2]{.underline}/ |          |                  |
+--------------------+------------------+----------+------------------+

[1]{.underline}/ No film failure (hydrogen gas at cathode or corrosion
products of iron at anode) during first hour of testing. After 30 days,
the maximum allowable equivalent circle diameter of the unsealed area
must be 25.4 mm.

[2]{.underline}/ Test at 320 degrees F for 30 min., then remove panel
and immediately test at -80 degrees F for 15 min. The relative humidity
of the laboratory room must be 50 percent when the sample is exposed.

I. Class B Coatings

> When a Class B coating is required, the coating shall meet the
> requirements of one of the following:
>
> 1\. [Coal-Tar Enamel]{.underline} - The outside of the pipe shall
> receive a coat of coal-tar primer followed by a hot coat of coal-tar
> enamel and finished with a kraft paper or one coat of water-resistant
> whitewash. All materials and application shall be in accordance with
> American Water Works Association Specification C 203, except that the
> asbestos felt wrapper may be omitted.
>
> 2\. [Coal-Tar]{.underline} Enamel [with]{.underline} Asbestos Felt
> Wrap - The outside of the pipe shall receive a coat of coal-tar primer
> followed by a hot coat of coal-tar enamel into which shall be bonded
> an asbestos felt wrapper and finished with a kraft paper or one coat
> of water resistant whitewash. All materials and application shall be
> in accordance with American Water Association Specification c 203,
> except that the minimum thickness of hot coal-tar enamel applied by
> pouring and spreading may be 1/32 inch.
>
> 3\. [Coal-Tar]{.underline}, Hot Applied Tape and Primer - All
> materials and workmanship shall be in accordance with Federal
> Specification HHT-30a, August 2, 1967, Tape, Pipe Coating, Coal Tar,
> Hot Applied, and Primer.

Section IV NE-SCS-MARCH 1981

S-430-FF-7

Statewide

> 4\. [Plastic Tape]{.underline} - Plastic tape coating shall be capable
> of with-standing the moisture and soil conditions to which it will be
> subjected. All material shall be according to American Water Works
> Association Specification C-209 or to Interim Federal Specification
> L-T-001512 for Type I, standard thickness tape, except that the tape
> coating may be of either rubber material or the specified plastic
> materials. Application shall be as follows:
>
> a\. The surface of the pipe to be coated shall be cleansed of all
> foreign material such as oil, grease, dirt, mud, etc. Any knurls,
> burrs, or other sharp points shall be removed by filing, peening, or
> wire brushing.
>
> b\. The continuity of the applied plastic coating shall be of such
> quality that all pipe, joints, and fittings, after assembly shall be
> capable of passing an inspection test conducted with a spark discharge
> holiday detector at 1500 volts.

J. Paint

> Paint shall be in accordance with Federal Specifications as specified
> in \"Installation Requirements.\"

K. Anodes

> Zinc anodes shall be \"Special High Grade\" zinc which is at least
> 99.99 percent pure zinc. Magnesium anodes shall have a nominal
> composition of 6% aluminum, 3% zinc, 0.2% manganese and the remainder
> magnesium.
>
> Each anode shall have a full length core with a single strand of
> insulated copper wire solidly attached to it. The wire shall be No. 12
> or larger.
>
> If a header wire is used, the gage must be sufficient to carry the
> design current with no more than a 20 millivolt I-R drop.
>
> All anodes shall be commercially packaged and the packaged backfill
> mix shall be of the following proportions by weight.
>
> Zinc - 20 to 30% bentonite, 70 to 80% gypsum
>
> Magnesium - 20 to 25% bentonite, 70 to 75% gypsum,

5% sodium sulfate

Section IV NE-SCS-MARCH 1981