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American Water Works Association ANSI/AWWA C600-77 Revision of C600-64 [AMERICAN HAHONAL] ^STANDARDHP for INSTALLATION OF GRAY AND DUCTILE CAST-IRON WATER MAINS AND APPURTENANCES Approved by A WWA Board of Directors May 8, 1977. Approved by American National Standards Institute fun. 22, 1977. AMERICAN WATER WORKS ASSOCIATION 6666 West Quincy Avenue, Denver, Colorado 80235 CTD014411 Committee Personnel The AVVVVA Standards Committee on Installation of Cast-Iron Water Mains, which developed this standard, had the following personnel at the time of approval: A. M. Tinkey, Chairman W. Harry Smith. Vice-Chairman Robert Zimmerman, Secretary Consumer Members H. Kenneth Anderson, Water Bureau, Portland, OR (AWWA) E. M. Bonadeo, Detroit Water and Sewage Department, Detroit, MI (AWWA) Charles A. Froman Jr., Gary-Hobart Water Corp., Gary, IN (AWWA) Albert Helt, The Water Bureau, Metropolitan District, Hartford, CT (NEWWA) William H. Priester, Department of Water & Power, Los Angeles, CA (AWWA) John E. Readey, Department of Water & Sewers, Chicago, IL (AWWA) Mark Sadolf, Utilities Department, Broward County, Ft. Lauderdale, FL (AWWA) William R. Thompson,* Metropolitan District Commission, Boston, MA (NEWWA) A. M. Tinkey, St. Louis County Water Co., University City, MO (AWWA) General Interest Members Gordon C. Anderson,* Insurance Services Office, New York, NY William A. Barkley, College of Engineering, Las Cruces, NM Kenneth J. Carl, Insurance Services Office, New York, NY Martin P. Daly, Malcolm Pirnie, Inc., Paramus, NJ Joseph M. Dennis, Department of Human Resources, Raleigh, NC Edwin J. Laszewski, City of Milwaukee, Milwaukee, WI j! Samuel Slicer Jr., Factory Mutual Research Corp., Norwood, MA Joseph Vellano, Latham, NY Henry Wilkens Jr., Water Division, Houston, TX Robert Zimmerman, Greeley & Hansen, Chicago, IL (ISO) (ASCE) (ISO) (AWWA) (CSSE) (APWA) (FMR) (NUCA) (AWWA) (AWWA) Producer Members T. C. Jester. American-Darling Valve, Birmingham, AL Harold Kennedy Jr., U.S. Pipe & Foundry Co., Birmingham, AL Edward C. Sears, American Cast Iron Pipe Co.. Birmingham, AL W. Harry Smith, Cast Iron Pipe Research Assn., Oak Brook, IL (MSS) (CIPRA) (CIPRA) (CIPRA) * Alternate Copyright 1977 by American Water Works Assn. Printed in US u ^ J. CTD014412 Table of Contents SEC. PAGE Foreword I History of Standard .................... iv II Information Regarding the Use of This Standard ............................ iv Ill Major Revisions ............................. iv Standard 1 General ............................................ 1.1 Scope .............................................. 1.2 References ..................................... 1.3 Definitions ..................................... 1 1 1 2 2 Inspection, Receiving, Handling, and Storage .......... . 2.1 Inspection .......................... ............. . 2.2 Handling and Storage ................. 2 2 3 3 Installation .................................... 4 3.1 Alignment and Grade .................. . 4 3.2 Trench Construction .................... 4 3.3 Pipe Installation .......................... 6 3.4 Joint Assembly ............................ 7 3.5 Backfilling ..................................... . 11 3.6 Valve-and-Fitting Installation ... . 12 3.7 Hydrant Installation .................... . 13 3.8 Thrust Restraint .......................... . 13 4 Hydrostatic Testing .................. . 14 4.1 Pressure Test ............................... . 14 4.2 Leakage Test ............................... . 15 sec. pace 5 Disinfection .................................... 17 6 Highway and Railroad Crossings ...................................... 6.1 Casing Pipe ..................................... 6.2 Carrier Pipe ................................... 17 17 17 7 Service Taps .................................. 10 7.1 Tapping ............................................ 10 Tables 1 Maximum Stacking Heights--Gray Cast-Iron Pipe ............................ 3 2 Maximum Stacking Heights-- Ductile Cast-Iron Pipe ............... 3 3 Suggested Trench Widths at the Top of the Pipe .......................... 5 4 Mechanical Joint--Bolt Torques .. 10 5 Maximum Deflection Full Length Pipe--Push-on Type Joint ........ 10 6 Maximum Deflection Full Length Pipe--Mechanical-Joint Pipe ... 11` 7 Allowable Leakage per 1000 ft of Pipeline ................................... 16 Figures 1 Laying Conditions for Gray Cast-Iron Pipe ............................ 7 2 Laying Conditions for Ductile Cast-Iron Pipe ............................ 8 3 Push-on Joint Assembly ............... 9 CTD014413 Foreword This foreword is for information only and is not a part of AWWA C-600. I. History of Standard The first AWWA standard specifi cations. "Laying Cast Iron Pipe," (7D. 1-1938) were adopted in Apr. 1938. They were intended as a guide in making extensions to existing dis tribution systems, and in preparing specifications for contracts for the con struction of new systems or extensions. The standard was to be used as a guide for installing bell-and-spigot cast-iron pipe and did not cover the furnishing and delivery of material, any other type of pipe, or any other type of joint. The standard included a model addendum, which was to be used with project specifications, and was designed to be used as a part of the contract document. The standard was published in the Feb. 1938 edition of Journal AWWA. The standard was revised in 1949, including a change of title to, "Stan dard Specifications for Installation of Cast-Iron Water Mains," (7D.1-T1949 and C600-49T). The standard was expanded, adding numerous tables and installation guidelines. The model addendum was also expanded. The revised standard was published in the Dec. 1949 edition of Journal AWWA. An additional section, Sec. 9b-- Jointing of Mechanical-Joint Pipe-- was added in May 1954. Section 9c-- Joining of Push-on Joint Pipe--was added in 1964. In 1975 the Standards Council formed the present C-600 Committee to revise C-600 to current practices and to add ductile iron as a pipe ma terial. In order to do this, the committee decided to completely change the char acter of the standard, removing the model addendum and making the stan dard more in compliance with the style of other AWWA standards. II. Information Regarding the Use of This Standard The AWWA standard, "Installation of Gray and Ductile Cast-Iron Water Mains and Appurtenances," can be used as a reference when making ex tensions to existing or constructing new distribution systems, using either ductile or gray cast-iron mains, with either mechanical- or push-on joints. It is not the intent for this standard to be used as a contract document but it may be used as a reference in the contract documents. It is based upon a consensus of the committee on the minimum practice consistent with sound, economical service under nor mal conditions, and its applicability under any circumstances must be re viewed by a responsible engineer. The standard is not intended to preclude the manufacture, marketing, purchase, or use of any product, process, or pro cedure. III. Major Revisions The standard has been rewritten completely and restructured to con form with the present style of AWWA standards. Ductile-iron pipe has been added to the standard, and normal in stallation practices have been updated completely. The addendum has been deleted. Allowable leakage for both mechan ical- and push-on joints has been re duced to one half of the value pre scribed in the 1964 standard. CTD014414 American Waler Vforks Association ANSI/AWWA C600-77 Revision of C600-64 eWOWNfflONALl STANDARDS* for Installation of Gray and Ductile Cast-Iron Water Mains and Appurtenances Section 1--General Sec. 1.1--Scope Sec. 1.2--References This standard covers installation procedures for gray and ductile castiron pipe and appurtenances for water service. 1.1.1 Conditions not covered. In stallations that require special atten tion. techniques, and materials are not covered. Each such installation re quires special considerations based on many influencing factors and cannot be covered adequately in a single stan dard. This type of installation can best be accomplished by competent en gineering design in consultation with representatives of the material manu facturing industry. Some of these typ ical installations are 1. Piping through rigid walls. 2. Subaqueous piping. 3. Piping on supports above or be low ground. 4. Piping requiring insulation. 5. Plant- or pump-station piping. This standard references the follow ing documents. They form a part of this standard to the extent specified herein. In any case of conflict, the re quirements of this standard shall pre vail. AWIVA ClOl, Thickness Design of Cast-Iron Pipe. AWIVA C104, Cement-Mortar Lin ing for Cast-Iron and Ductile-Iron Pipe and Fittings for Water. AWWA C105, Polyethylene Encase ment for Gray and Ductile Cast-Iron Piping for Water and Other Liquids. AWWA C106, Cast-Iron Pipe Centrifugally Cast in- Metal Molds, for Water or Other Liquids. AWWA C108, Cast-Iron Pipe Centrifugally Cast in Sand-Lined Molds, for Water or Other Liquids. AWWA CllO, Gray-Iron and Duc tile-Iron Fittings, 3 in. Through 48 in., for Water and Other Liquids. CTD014415 2 GRAY AND DUCTILE CAST-IRON MAINS AWWA Clll, Rubber-Gasket Joints for Cast-Iron and Ductile-Iron Pres sure Pipe and Fittings. AWWA Cl 15, Flanged Cast-Iron and Ductile-Iron Pipe With Threaded Flanges. AWWA C150, Thickness Design of Ductile-Iron Pipe. AWWA C151, Ductile-Iron Pipe, Centrifugally Cast in Metal Molds or Sand-Lined Molds, for Water or Other Liquids. AWWA C500, Gate Valves--3-in. Through 48-in.--for Water and Other Liquids. AWWA C502, Dry-Barrel Fire Hydrants. AWWA C503, Wet-Barrel Fire Hydrants. AWWA C504, Rubber Seated But terfly Valves. AWWA C601, Disinfecting Water Mains. AWWA No. 20104. Handbook of Occupational Safety and Health Stan dards for Water Utilities. AASHTO * T-99, Standard Method of Test for Moisture-Density Relation ship for Soil's. Sec. 1.3--Definitions Under this standard, the following definitions shall apply: 1.3.1 Gray cast iron. Cast ferrous material in which a major part of the carbon content occurs as free carbon in the form of flakes interspersed through the metal. 1.3.2 Ductile cast iron. Cast fer rous material in which a major part of the carbon content occurs as free carbon in nodules or spheroidal form. 1.3.3 Owner. The municipality or other organization that will own and operate the completed piping system. The owner may designate agents, such as an engineer, purchaser, or inspector for specific responsibilities with regard to piping construction projects. 1.3.4 Contractor. The party re sponsible for water main construction. 1.3.5 Mechanical joint. The gas keted and bolted joint as detailed in AWWA Clll. 1.3.6 Push-on joint. The single rubber-gasket joint as described in AWWA Clll. Section 2--Inspection. Receiving. Handling, and Storage Sec. 2.1--Inspection At the discretion of the owner, all materials furnished by the contractor are subject to inspection and approval at the manufacturer's plant. 2.1.1 Post delivery. All pipe and appurtenances are subject to inspec tion at the point of delivery by the owner. Material found to be defective * American Association of State Highway and Transportation Officials. 341 National Press Bldg., Washington, D.C. 20004. due to manufacture or damage in ship ment shall be rejected or recorded on the bill of lading and removed from the job site. The owner may perform tests as specified in the applicable AWWA standard to ensure conform ance with the standard. In case of failure of the pipe or appurtenance to comply with such specifications, re sponsibility for replacement of the de fective materials becomes that of the manufacturer. CTD014416 SECTION 2--INSPECTION 3 2.1.2 Workmanship. All pipe and appurtenances shall be installed and joined in conformance with this stan dard and tested under pressure for defects and leaks in accordance with Sec. 4 of this standard. Sec. 222--Handling and Storage All pipe, fittings, valves, hydrants, and accessories shall be loaded and un loaded by lifting with hoists or skid ding in order to avoid shock or dam age. Under no circumstances shall such material be dropped. Pipe han dled on skidways shall not be rolled or skidded against pipe on the ground. 2.2.1 Padding. Slings, hooks, or pipe tongs shall be padded and used in such a manner as to prevent damage to the exterior surface or internal lin ing of the pipe. 2.2.2 Storage. Materials, if stored, shall be kept safe from damage. The interior of all pipe, fittings, and other appurtenances shall be kept free from dirt or foreign matter at all times. Valves and hydrants shall be drained and stored in a manner that will pro tect them from damage by freezing. 2.2.2.1 Pipe shall not be stacked higher than the limits shown in Tables 1 and 2. The bottom tier shall be kept off the ground on timbers, rails, or concrete. Pipe in tiers shall be alter nated: bell, plain end; bell, plain end. At least two rows of 4-in. X 4-in. tim bers shall be placed between tiers and chocks affixed to each end in order to prevent movement. 22.2.2 Gaskets for mechanical- and push-on joints to be stored shall be placed in a cool location out of direct sunlight. Gaskets shall not come in contact with petroleum products. Gas kets shall be used on a first-in, firstout basis. TABLE 1 Maximum Stacking Heights-- Gray Cast-Iron Pipe Pipe Size (in.) 3 4 6 8 10 12 14 16 18 20 24 Number of Tiers 18-ft length 18 16 13 11 9 8 7 6 6 5 4 20-ft length 18 16 13 11 8 7 7 6 S 4 3 TABLE 2 Maximum Stacking Heights--Ductile CastIron Pipe* Pipe Size (**.) 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 54 Number of Tiers 18 16 13 11 10 9 8 7 6 6 5 4 4 3 3 3 * For IS- or 20-ft lengths. 2.2.2.3 Mechanical-joint bolts shall be handled and stored in such a man ner that will ensure proper use with respect to types and sizes. CTD014417 4 GRAY AND DUCTILE CAST-IRON MAINS Section 3--Installation Sec. 3.1--Alignment and Grade The water mains shall be laid and maintained to lines and grades estab lished by the plans and specifications with fittings, valves, and hydrants at the required locations unless otherwise approved by the owner. Valve-operat ing stems shall be oriented in a man ner to allow proper operation. Hy drants shall be installed plumb. 3.1.1 Prior investigation. Prior to excavation, investigation shall be made to the extent necessary to determine the location of existing underground structures and conflicts. Care should be exercised by the contractor during excavation to avoid damage to existing structures. 3.1.2 Unforeseen obstructions. When obstructions that are not shown on the plans are encountered during the prog ress of work and interfere so that an alteration of the plans is required, the owner will alter the plans or order a deviation in line and grade or arrange for removal, relocation, or reconstruc tion of the obstructions. 3.1.3 Clearance. When crossing ex isting pipelines or other structures, alignment and grade shall be adjusted as necessary, with the approval of the owner, to provide clearance as re quired by federal, state, or local reg ulations or as deemed necessary by the owner to prevent future damage or contamination of either structure. Sec. 3.2--Trench Construction The trench shall be excavated to the required alignment, depth, and width and in conformance with all federal, state, and local regulations for the pro tection of the workmen. 3.2.1 Trench preparation. Trench preparation shall proceed in advance of pipe installation for only as far as stated in the specifications. 3.2.1.1 Discharge from any trench dewatering pumps shall be conducted to natural drainage channels, storm sewers, or an approved reservoir. 3.2.1.2 Excavated material shall be placed in a manner that will not ob struct the work nor endanger the workmen, obstruct sidewalks, drive ways, or other structures and shall be done in compliance with federal, state, or local regulations. 3.2.2 Pavement removal. Removal of pavement and road surfaces shall be a part of the trench excavation and the amount removed shall depend upon the width of trench required for installa tion of the pipe and the dimensions of area required for the installation of valves, hydrants, specials, manholes, or other structures. The dimensions of pavement removed shall not exceed the dimensions of the opening required for installation of pipe, valves, hy drants, specials, manholes, and other structures by more than 6 in. in any direction unless otherwise required or approved by the owner. 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 that of the single-pass capabilities of normally available excavating equip ment and ample to permit the pipe to be laid and joined properly and allow the backfill to be placed as specified. Trench widths as shown in Table 3 may be used as a guide. Trenches shall be of such extra width, when re quired, to permit the placement of tim-_ CTD014418 SECTION 3--INSTALLATION 5 TABLE 3 Suggested Trench Widths at the Top of the Pipe* Nominal Pipe Size in. 4 6 8 10 12 14 16 18 20 24 30 36 42 48 54 Trench Width in. 28 30 32 34 36 38 40 42 44 48 54 60 66 72 78 * The trench should never be wider than the width used as design criteria. ber supports, sheeting, bracing, and appurtenances. 3.2.4 Bell holes. Holes for the bells shall be provided at each joint but shall be no larger than necessary for joint assembly and assurance that the pipe barrel will lie flat on the trench bottom. Other than noted previously, the trench bottom shall be true and even in order to provide support for the full length of the pipe barrel, ex cept that a slight depression may be provided to allow withdrawal of pipe slings or other lifting tackle. 3.2.5 Rock conditions. When ex cavation of rock is encountered, all rock shall be removed to provide a clearance of at least 6 in. below and on each side of all pipe, valves, and fittings for pipe sizes 24 in. or smaller, and 9 in. for pipe sizes 30 in. and larger. When excavation is completed, a bed of sand, crushed stone, or earth that is free from stones, large clods, or frozen earth, shall be placed on the bottom of the trench to the previously mentioned depths, leveled, and tamped. 3.2.5.1 These clearances and bedding procedures shall also be observed for pieces of concrete or masonry and other debris or subterranean struc tures, such as masonry walls, piers, or foundations that may be encountered during excavation, 3.2.5.2 This installation procedure shall be followed when gravel forma tions containing loose boulders greater than 8 in. in diameter are encountered. 3.2.5.3 In all cases, the specified clearances shall be maintained between the bottom of all pipe and appurten ances and any part, projection, or point of rock, boulder, or stones of sufficient size and placement which, in the opinion of the owner, could cause a fulcrum point. 3.2.6 Previous excavations. Should the trench pass over a sewer or other previous excavation, the trench bottom shall be sufficiently compacted to pro vide support equal to that of the native soil or conform to other regulatory re quirements in a manner that will pre vent damage to the existing installa tion. 3.2.7 Blasting. Blasting for excava tion shall be permitted only after se curing the approval of the owner who will establish the hours of blasting. The blasting procedure, including pro tection of persons and property, shall be in strict accordance with federal, state, and local regulations. 3.2.8 Protection of property. Trees, shrubs, fences, and all other property and surface structures shall be pro tected during construction unless their removal is shown in the plans and spec ifications or approved by the owner. 3.2.8.1 Any cutting of tree roots orbranches shall be done only as ap proved by the owner. CTD014419 6 CRAY AND DUCTILE CAST-IRON MAINS 32.8.2 Temporary support, ade quate protection, and maintenance of all underground and surface struc tures, drains, sewers, and other ob structions encountered in the progress of the work shall be furnished by the contractor. 3.2.8.3 All properties that have been disturbed shall be restored as nearly as practical to their original condition. 3.2.9 Unstable subgrade. When the subgrade is found to be unstable or to include ashes, cinders, refuse, organic material, or other unsuitable material, such material shall be removed, to a minimum of at least 3 in., or to the depth ordered by the owner and re placed under the directions of the owner with clean, stable backfill mate rial. When such materials are encoun tered, polyethylene encasement should be provided (see paragraph 3.4.5). The bedding shall be consolidated and leveled in order that the pipe may be installed in accordance with Sec. 3.2.4. 3.2.9.1 When the bottom of the trench or the subgrade is found to con sist of material that is unstable to such a degree that, in the judgment of the owner it cannot be removed, a founda tion for the pipe and/or appurtenance shall be constructed using piling, tim ber, concrete, or other materials at the direction of the owner. 3.2.10 Safety. Appropriate traffic control devices shall be provided in accordance with federal, state, or local regulations to regulate, warn, and guide traffic at the work site. Sec. 3.3--Pipe Installation Proper implements, tools, and facil ities shall be provided and used for the safe and convenient performance of the work. All pipe, fittings, valves, and hydrants shall be lowered care fully into the trench by means of a derrick, ropes, or other suitable tools or equipment, in such a manner as to prevent damage to water-main mate rials and protective coatings and lin ings. Under no circumstances shall water-main materials be dropped or dumped into the trench. The trench should be dewatered prior to installa tion of the pipe. 3.3.1 Examination of material. All pipe fittings, valves, hydrants, and other appurtenances shall be examined carefully for damage and other defects immediately before installation. De fective materials shall be marked and held for inspection by the owner, who may prescribe corrective repairs or re ject the materials. 3.3.2 Pipe ends. All lumps, blisters, and excess coating shall be removed from the socket and plain ends of each pipe, and the outside of the plain end and the inside of the bell shall be wiped clean and dry and be free from dirt, sand, grit, or any foreign material before the pipe is laid. 3.3.3 Pipe cleanliness. Foreign ma terial shall be prevented from entering the pipe while it is being placed in the trench. During laying operations, no debris, tools, clothing, or other mate rials shall be placed in the pipe. 3.3.4 Pipe placement. As each length of pipe is placed in the trench, the joint shall be assembled and the pipe brought to correct line and grade. The pipe shall be secured in place with approved backfill material. 3.3.5 Pipe plugs. At times when pipe laying is not in progress, the open ends of pipe shall be closed by a water tight plug or other means approved by the owner. When practical, the plug shall remain in place until the trench is pumped completely dry. Care must be taken to prevent pipe flotation should the trench fill with water. ) * t CTDO14420 SECTION 3--INSTALLATION 7 Flat bottom trench, untamped backfill. Flat bottom trench, tamped backfill. Pipe bedded in sand or gravel, tamped backfill. Fig. 1. Laying Conditions for Gray Cast-Iron Pipe 3.3.6 Gray-iron laying conditions. The specified laying conditions for gray cast-iron pipe shall be completed in accordance with AWWA C101 and as illustrated in Fig. 1. 3.3.7 Ductile-iron laying conditions. The specified laying conditions for ductile-iron pipe shall be completed in accordance with AWWA Cl50 and as illustrated in Fig. 2 (page 8j. Sec. 3.4--Joint Assembly 3.4.1 Push-on joints. Push-on joints shall be assembled as described and illustrated in Fig. 3 (page 9). 3.4.2 Mechanical joints. Mechanical joints shall be assembled as follows: 1. Wipe clean the socket and plain end. The plain end, socket, and gasket should be washed with a soap solution to improve gasket seating. CTD014421 8 CRAY AND DUCTILE CAST-IRON MAINS Flat-bottom trench.'f Loose backfill. Flat-bottom trench.f Backfill lightly consol idated to centerline of pipe. Pipe bedded in 4-in. minimum loose soil.t Backfill lightly consolidated to top of pipe. Pipe bedded in sand, gravel, or crushed stone to depth of J pipe diameter, 4-in. minimum. Backfill compacted to top of pipe. (Ap proximately 80 per cent Standard Proctor, AASHTO T-99.) Pipe bedded in compacted granular material to centerline of pipe. Compacted granular or select J material to top of pipe. (.Ap- proximately 90 per cent Standard Proctor, AASHTO T-99.) * For 30-in. and larger pipe, consideration should be given to the use of laying conditions other than Type 1. t "Flat-bottom" is denned as undisturbed earth, t "Loose soil" or "select material" is defined as native soil excavated from the trench, free of rocks, foreign materials, and frozen earth. Fig. 2. Laying Conditions for Ductile Cast-Iron Pipe SECTION 3--INSTALLATION 9 1. Thoroughly clean the groove and bell socket and insert the gasket, making sure that it faces the proper direction and that it is correctly seated. 2. After cleaning dirt or foreign material from the plain end, apply lubricant in ac cordance with the pipe manufacturer's rec ommendations. The lubricant is supplied in sterile cans and every effort should be made to keep i sterile. 3. Be sure that the plain end is beveled; square or sharp edges may damage or dis lodge the gasket and cause a leak. When pipe is cut in the field, bevel the plain end with a heavy file or grinder to remove all sharp edges. Push the plain end into the bell of the pipe. Keep the joint straight while pushing. Make deflection after the joint is assembled. 4. Small pipe can be pushed into the bell socket with a long bar. Large pipe require additional power, such as a jack, lever puller, or backhoe. The supplier may provide a jack or lever pullers on a rental basis. A timber header should be used between the pipe and jack or backhoe bucket to avoid damage to the pipe. Fig. 3. Push-on Joint Assembly 2. Place the gland on the plain end with the lip extension toward the plain end, followed by the gasket with the narrow edge of the gasket toward the plain end of the pipe. 3. Insert the pipe into the socket and press the gasket firmly and evenly into the gasket recess. Keep the joint straight during assembly. Make de flection after joint assembly but before tightening the bolts. 4. Push the gland toward the bell CTD014423 10 GRAY AND DUCTILE CAST-IRON MAINS and center it around the pipe with the gland lip against the gasket. 5. Align bolt holes and insert bolts, with bolt heads behind the bell flange, and tighten opposite nuts to keep the gland square with the socket. 6. Tighten the nuts in accordance with Table 4. 3.4.3 Pipe deflection. When it is necessary to deflect pipe from a straight line in either the vertical or horizontal plane, or where long radius curves are permitted, the amount of deflection shall not exceed that shown in Tables 5 or 6. TABLE 4 Mechanical Joint--Bolt Torques Bolt Diameter in. f } i a Torque ft-lh 45-60 75-90 85-100 105-120 3.4.4 Pipe cutting. Cutting pipe for the insertion of valves, fittings, or clo sure pieces shall be done in a neat, workmanlike manner without creating damage to the pipe or cement-mortar lining. 3.4.4.1 Gray cast-iron pipe may be cut using a hydraulic squeeze cutter, abrasive pipe saw, rotary wheel cutter, guillotine pipe saw, or milling wheel saw. 3.4.4.2 Ductile cast iron may be cut using an abrasive pipe saw, rotary wheel cutter, guillotine pipe saw, mill ing wheel saw, or oxyacetylene torch. 3.4.4.3 Cut ends and rough edges shall be ground smooth, and for pushon joint connections, the cut end shall be beveled. 3.4.5 Polyethylene encasetnent. When polyethylene encasement is specified for gray and ductile cast-iron pipe, it shall be installed in accordance with Sec. 5-4 of AWWA C105. TABLE 5 Maximum Deflection Full Length Pipe--Push-on Type Joint Pipe Diameter in. 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 54 Deflection Angle deg 5 5 5 5 5 5 3 3 3 3 3 3 3 2 2 1* Maximum Deflection--in. Approx. Radius of Curve Produced by Succession of Joints--ft (18-ft length) 19 19 19 19 19 19 11 11 11 11 11 11 11 a n 5i (20-ft length) 21 21 21 21 21 21 12 12 12 12 12 12 12 8 8 6 (18-ft length) 205 205 205 205 205 205 340 340 340 340 340 340 340 510 510 680 (20-ft length) 230 230 230 230 230 230 380 380 380 380 380 380 380 570 570 760 CTD014424 Size of Pipe in. 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 SECTION 3--INSTALLATION 11 TABLE 6 Maximum Deflection Full Length Pipe--Mechanical Joint Pipe Deflection Angle dtg-min 8-18 8-18 7-7 5-21 5-21 5-21 3-35 3-35 3-0 3-0 2-23 2-23 2-5 2-0 2-0 Maximum Deflection--in. Approx. Radius of Curve Produced by Succession of Joints--ft (18-ft length) 31 31 27 20 20 20 13} 13} 11 11 9 9 8 7} 7} (20-ft length) 35 35 30 22 22 22 15 15 12 12 10 10 9 8 8 (18-ft length) 125 125 145 195 195 195 285 285 340 340 450 450 500 510 510 (20-ft length) 140 140 160 220 220 220 320 320 380 380 500 500 550 570 570 Sec. 3.5--Backfilling Backfill shall be accomplished in ac cordance with the specified laying con dition as described in Sec. 3.3. 3.5.1 Backfill material. All backfill material shall be free from cinders, ashes, refuse, vegetable or organic ma terial, boulders, rocks or stones, frozen soil, or other material that, in the opinion of the owner, is unsuitable. 3.5.1.1 From 1 ft above the top of the pipe to the subgrade of the pave ment, material containing stones up to 8 in. in their greatest dimension may be used, unless otherwise specified. 3.5.1.2 When the type of backfill material is not indicated on the draw ings or is not specified, the excavated material may be used, provided that such material consists of loam, clay, sand, gravel, or other materials that, in the opinion of the owner, are suit able for backfilling. 3.5.1.3 If excavated material is in dicated on the drawings or specified for backfill, and there is a deficiency due to a rejection of part thereof, the required amount of sand, gravel, or other approved material shall be pro vided. 3.5.1.4 All sand used for backfill shall be clean, graded from fine to coarse, not lumpy or frozen, and free from slag, cinders, ashes, rubbish, or other material that, in the opinion of the owner, is objectionable or delete rious. It should not contain a total of more than 10 per cent by weight of loam and clay, and all material must be capable of being passed through a 5-in. sieve. Not more than 5 per cent shall remain on a No. 4 sieve. 3.5.1.5 Gravel used for backfill shall consist of clean gravel having durable particles graded from fine to coarse in a reasonably uniform combination with no boulders or stones larger than 2 in. in size. It shall be free from slag, cinders, ashes, refuse, or other delete rious or objectionable materials. It shall not contain excessive amounts of CTD014425 12 GRAY AND DUCTILE CAST-IRON MAINS loam and clay and shall not be lumpy or frozen. No more than 15 per cent shall pass a No. 200 sieve. 3.5.1.6 Screenings used for backfill shall consist of the products obtained from crushing sound limestone or do lomite ledge rock and shall be free from shale, dust, excessive amounts of clay, and other undesirable materials. All materials shall pass a 4-in. sieve, and no more than 25 per cent shall pass a No. 100 sieve. 3.5.2 Compaction. When special backfill compaction procedures are re quired, they shall be accomplished in accordance with project specifications or applicable federal, state, and local regulations. 3.5.3 Partial backfilling during test ing. When specified by the owner, pressure and leakage testing may be accomplished before completion of backfilling and with pipe joints acces sible for examination. In such cases, sufficient backfill material shall be placed over the pipe barrel between the joints to prevent movement. Sec. 3.6--Valve-and-Fltting Installation 3.6.1 Examination of material. Prior to installation, valves shall be inspected for direction of opening, freedom of operation, tightness of pressure-con taining bolting, cleanliness of valve ports and especially seating surfaces, handling damage, and cracks. Defec tive valves shall be corrected or held for inspection by the owner. 3.6.2 Placement. Valves, fittings, plugs, and caps shall be set and joined to the pipe in the manner specified in Sec. 3.3 for cleaning, laying, and join ing pipe, except that 12-in. and larger valves should be provided with special support, such as treated timbers, crushed stone, concrete pads, or suffi ciently tamped trench bottom so that the pipe will not be required to sup port the weight of the valve. 3.6.3 Valve location. Valves in water mains shall, where practical, be located on the street property lines ex tended in unpaved areas unless shown otherwise on the plans. 3.6.3.1 Mains shall be drained through drainage branches or blowoffs. Drainage branches, blowoffs, air vents, and appurtenances shall be pro vided with valves and shall be located and installed as shown on the plans. Drainage branches or blowoffs shall not be directly connected to any storm or sanitary sewer, submerged in any stream, or be installed in any other manner that will permit back siphonage into the distribution system. 3.6.4 Valve protection. A valve box or a vault shall be provided for every valve. 3.6.4.1 A valve box shall be pro vided for every valve that has no gear ing or operating mechanism or in which the gearing or operating mech anism is fully protected with a gear case. The valve box shall not transmit shock or stress to the valve and shall be centered over the operating nut of the valve, with the box cover flush with the surface of the finished area or such other level as may be directed by the owner. 3.6.4.2 A valve vault designed to prevent settling on the pipe shall be provided for every valve that has ex posed gearing or operating mecha nisms. 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. Vaults shall be constructed to permit minor valve CTD014426 SECTION 3--INSTALLATION 13 repairs and afford protection to the 3.7.2.3 When a dry-barrel hydrant valve and pipe from impact where they is set in soil that is pervious, drainage pass through the vault walls. shall be provided at the base of the 3.6.4.3 In no case shall valves be hydrant by placing coarse gravel or used to bring misaligned pipe into crushed stone mixed with coarse sand, alignment during installation. Pipe from the bottom of the trench to at shall be supported in such a manner as least 6 in. above the waste opening in to prevent stress on the valve. the hydrant and to a distance of 1 ft 3.6.S Plugs and caps. All dead ends on new mains shall be closed with plugs or caps that are suitably re strained to prevent blowing off under test pressure. If a blowoff valve pre cedes the plug or cap, it too shall be around the elbow. Where ground wa ter rises above the drain port or when the hydrant is located within 8 ft of a sewer, the drain port shall be plugged and water pumped from the hydrant when freezing may occur. restrained against blowing off. All 3.7.2.4 When a dry-barrel hydrant dead ends shall be equipped with suit with an open drain is set in clay or able blowoff facilities. other impervious soil, a drainage pit 2 ft X 2 ft X 2 ft shall be excavated Sec. 3.7--Hydrant Installation below each hydrant and filled with coarse gravel or crushed stone mixed 3.7.1 Examination of material. Prior with coarse sand, under and around to installation, inspect all hydrants for the elbow of the hydrant and to a level direction of opening, nozzle threading, of 6 in. above the drain port. operating-put and cap-nut dimensions, 3.7.3 Location. Hydrants shall be tightness of pressure-containing bolt ing, cleanliness of inlet elbow, handling damage, and cracks. Defective hy drants shall be corrected or held for located as shown on the plans or as directed by the owner. 3.7.4 Protection. In the case of hy inspection by the owner. drants that are intended to fail at the ground-line joint upon vehicle impact 3.7.2 Placement. All hydrants shall (traffic hydrants), specific care must ( stand plumb and shall have their noz be taken to provide adequate soil re zles parallel with, or at right angles to, sistance to avoid transmitting shock the curb, with the pumper nozzle fac ing the curb, except that hydrants hav ing two-hose nozzles 90 deg apart shall be set with each nozzle facing the curb moment to the lower barrel and inlet connection. In loose or poor loadbearing soil, this may be accomplished by pouring a concrete collar approx at an angle of 45 deg. imately 6 in. thick to a diameter of 3.7.2.1 Hydrants shall be set to the 2 ft at or near the ground line around established grade, with the centerline the hydrant barrel. of the lowest nozzle at least 12 in. above the ground, or as directed by the owner. Sec. 3.8--Thrust Restraint 3.7.2.2 Each hydrant shall be con 3.8.1 Hydrants. The bowl of each nected to the main with a 6-in. branch hydrant shall be well braced against a controlled by an independent 6-in. sufficient area of unexcavated earth at valve, unless otherwise specified by the the end of the trench with stone slabs I owner. or concrete backing, or it shall be tied CTD014427 14 GRAY AND DUCTILE CAST-IRON MAINS to the pipe with suitable metal tie rods, clamps, or restrained joints as shown or directed by the owner. 3.8.1.1 Tie rods, clamps, or other components of dissimilar metal shall be protected against corrosion by hand application of a bituminous coating or by encasement of the entire assembly with 8-mil thick, loose polyethylene film in accordance with AWWA C105. 3.8.1.2 Thrust-restraint design pres sure should be equal to the test pres sure. 3.8.2 Fittings. All plugs, caps, tees, and bends, unless otherwise specified, shall be provided with reaction back ing. or suitably restrained by attaching metal rods, clamps, or restrained joints as shown or specified by the owner. 3.8.3 Restraint materials. Vertical and horizontal reaction backing shall be made of concrete having a compres sive strength of not less than 2000 psi after 28 days. 3.8.3.1 Backing shall be placed be tween solid ground and the fitting to be anchored; the area of bearing on the pipe and on the ground in each instance shall be that shown or di rected by the owner. The backing shall, unless otherwise shown or di rected, be so located as to contain the resultant thrust force and so that the pipe and fitting joints will be accessi ble for repair. 3.8.3.2 Restrained push-on joints, mechanical joints utilizing set-screw retainer glands or metal harness of tie rods, or clamps may be used instead of concrete backing if so indicated in the plans and specifications. Tie rods, clamps, or other components of dis similar metal shall be protected against corrosion by hand application of a bi tuminous coating or by encasement of the entire assembly with 8-mil thick, loose polyethylene film in accordance with AWWA 005. i) Section 4--Hydrostatic Testing Sec. 4.1--Pressure Test After the pipe has been laid, all newly laid pipe or any valved section thereof shall be subjected to a hydro static pressure of at least 1.5 X the working pressure at the point of test ing. 4.1.1 Test pressure restrictions. Test pressures shall 1. Not be less than 1.25 x the work ing pressure at the highest point along the test section. 2. Not exceed pipe or thrust re straint design pressures. 3. Be of at least 2-hr duration. 4. Not vary by more than 5 psi. 5. Not exceed twice the rated pres sure of the valves or hydrants when CTD014428 SECTION 4--HYDROSTATIC TESTING IS the pressure boundary of the test sec- 4.2.1 Leakage defined. Leakage * tion includes closed gate valves or shall be defined as the quantity of I hydrants. water that must be supplied into the 6. Xot exceed the rated pressure of newly laid pipe, or any valved section the valves if resilient-seated butterfly thereof, to maintain pressure within valves are used. 5 psi of the specified test pressure after 4.1.2 Pressurization. Each valved the air in the pipeline has been ex section of pipe shall be filled with wa pelled and the pipe has been filled with ter slowly and the specified test pres water. sure, based on the elevation of the 4.2.2 Allowable leakage. No pipe lowest point of the line or section installation will be accepted if the leak under test and corrected to the eleva age is greater than that determined by tion of the test gage, shall be applied the following formula: by means of a pump connected to the pipe in a manner satisfactory to the owner. nd4p 7400 4.1.3 Air removal. Before applying the specified test pressure, air shall be expelled completely from the pipe, valves, and hydrants. If permanent air vents are not located at all high points, the contractor shall install corporation cocks at such points so that the air can be expelled as the line is filled with water. After all the air has been ex pelled. the corporation cocks shall be closed and the test pressure applied. in which L is the allowable leakage, in gallons per hour; N is the number of joints in the length of pipeline tested; D is the nominal diameter of the pipe, in inches; and P is the average test pressure during the leakage test, in pounds per square inch gage. 4.2.2.1 Allowable leakage at various pressures is shown in Table 7 (page 16). 4.2.2.2 When testing against closed At the conclusion of the pressure test, metal-seated valves, an additional leak the corporation cocks shall be removed age per closed valve of 0.0078 gal/ 1 and plugged, or left in place at the dis hr/in. of nominal valve size shall be cretion of the owner. 4.1.4 Examination. All exposed pipe, fittings, valves, hydrants, and joints shall be examined carefully dur ing the test. Any damage or defective pipe, fittings, valves, or hydrants that are discovered following the pressure test shall be repaired or replaced with sound material and the test shall be repeated until it is satisfactory to the owner. allowed. 4.2.2.3 When hydrants are in the test section, the test shall be made against the closed hydrant 4.2.3 Acceptance of installation. Ac ceptance shall be determined on the basis of allowable leakage. If any test of pipe laid discloses leakage greater than that specified in Sec. 4.2.2, the contractor shall, at his own expense, locate and repair the defective material until the leakage is within the specified Sec. 4.2--Leakage Test allowance. 4.2.3.1 All visible leaks are to be . A leakage test shall be conducted repaired regardless of the amount of % concurrently with the pressure test. leakage. CTD014429 16 CKAV AND DLCT1LE CAST-IKON MAINS - X X N ts c c c irt u* =? : -S ^ . * CC S v- t ^t c ^ f j 5.1 5. 5 5. 3 g S S a <" ii j I 6 CTD014430 SECTION 3--INSTALLATION 17 Section 5--Disinfection Upon completion of a newly in stalled main or when repairs to an existing pipe are made, the main shall he disinfected according to instructions listed in AWWA C601 of latest re vision. Section 6--Highway and Railroad Crossings Sec. 6.1--Casing Pipe When casing pipe is specified for highways or railroad crossings, the project shall be completed in accord ance with applicable federal, state, and local regulations. In the case of rail road crossings, the project should comply further with regulations estab lished by the railroad company. Gen eral practice permits boring for casing diameters through 36 in. with max imum length of about 175 ft; jacking for diameters 30 in. through 60 in. with lengths of about 200 ft; and tun neling for pipes 48 in. and larger for longer lengths. Sec. 6.2--Carrier Pipe The casing pipe should be 6-8 in. larger than the outside diameter of the gray or ductile cast-iron pipe bells. Carrier pipe may be pushed or pulled through the completed casing pipe. Chocks or skids should be placed on the carrier pipe to ensure approximate centering within the casing pipe and to prevent damage during installation. Care must be exercised in order to avoid metal-to-metal contact. In order to avoid the transfer of earth and live loads to the carrier pipe, the space be tween the carrier and casing pipes should not be filled completely. Section 7--Service Taps Sec. 7.1--Tapping Corporation stops may be installed either before or after pipe installation. Generally, they are located at ten or two o'clock on the circumference of the pipe and may be screwed directly into the tapped and threaded main without any additional appurtenances. When more than one tap in a gray cast-iron pipe is necessary to deliver the re quired flow, they should be staggered around the circumference at least 12 in. apart (not in a straight line). Duc tile-iron pipe in all classes may be directly tapped with standard corpo ration stops; however, torque require ment for the installation may be effec tively reduced by the application of two layers of 3-mil TFE tape to the male threads of the corporation stop. IP-- I7M--0 77 --4J600 CTD014432