Document aBB1d54EVLbmpR7193R3gVKde

SECTION I PLAINTIFF'S EXHIBIT CERTAIN-TEED ASBESTOS-CEMENT PIPE with the time saving, trouble saving FLUID-TITE Coupling ASBESTOS THE IDEAL PERMANENT MATERIAL Indestructible Asbestos is as permanent as rock itself. It will not burn, will not rot, cannot corrode. In ready-to-use form, these fibers are finer than silk, stronger than iron, flexible enough to be spun into threads and woven into cloth. The ancient Chinese, the early Greeks and the Egyp tians used Asbestos centuries ago. The Greeks named it "Amianthus," meaning "Incorruptible." We call it "Asbestos." The ancient people prized Asbestos for its resistance to fire, heat, most acids and the weather -- and its durability. They used it for centuries without finding the adequate substitute for these unusual properties. They learned how to card the flexible fiber, and to weave cloth from it. In the nineteenth century a third outstanding quality of Asbestos was discovered: ASBESTOS IS ONE OF THE VERY FEW MINERALS THAT CAN BE USED AS A REINFORCING MATERIAL WITH PORTLAND CEMENT The two ancient and durable materials of Asbestos and Portland Cement combine immediately, developing high bond strength. The Asbestos fibers add toughness and tensile strength to the mass. Silica is the third im portant ingredient that is added to the mixture in the manufacturing process, along with water. It is this perfect marriage of materials that makes Certain-teed Asbestos-Cement Pipe so outstanding. The stresses inherent in concrete are reduced to a minimum, while all the virtues of asbestos are retained. Certain-teed Asbestos-Cement Pipe was first manu factured at Ambler, Pennsylvania, in 1938. The first Asbestos-Cement Pressure Pipe from this factory was installed along Route 1, a main highway, in Pennsyl vania. It has been operating under a pressure of 110 lbs. ever since. That same year, a 6" force sewer main was installed. It, too, is delivering equal-to-new service after many years use. Experience like this has convinced engineers through out the United States that Certain-teed Asbestos-Cement Pipe, once laid, may be forgotten as far as maintenance is concerned. < ( 3 4 CERTAIN-TEED ASBESTOS-CEMENT PIPE IS MADE TO HIGH QUALITY STANDARDS The manufacture of top-quality Asbestos-Cement Pipe is a complex process. Certain-teed's reputation * for quality is built on strict control of the manufac turing process. Modern electronic instrumentation throughout the plant substitutes exact values for the i variables of human judgment. Certain-teed's precision control makes sure every piece of pipe and every coupling that leaves the plant is in f first class condition. If there are any defects that might cause a failure, these are found before shipment. Before it leaves the production line every piece of pipe is carefully inspected to assure our high standards of quality are maintained and is then tested for hydro static strength. Each 13 foot pressure pipe up to and including 8" is given a flexural test. After manufacturing and before curing, every piece of pipe is identified with a complete production code that tells exactly when the pipe was made: the year, month, day, shift and individual piece made by that FLEXURE TEST This test actually bends the pipe to make sure it can withstand outside pressure and loads without failure. shift. The Production Control Laboratory at Certain-teed is an integral part of the manufacturing process. It controls all materials going into the manufacturing process, checks the production of every shift and con trols the inspection of each pipe and coupling before shipment. 14 STAR ADVANTAGES OF CERTAIN-TEED ASBESTOS-CEMENT PRESSURE-PIPE EXCEPTIONALLY LONG LIFE Made from Asbestos, Pulverized sand, Portland Cement --known and used since ancient times for projects built to endure. Our first Asbestos-Cement Pipe laid is still in use . . . and still delivering full flow . . . and will continue to do so. CORROSION RESISTANT Note the Smooth Bore of Certain-teed Pipe Of all pipes in general use, Certain-teed AsbestosCement Pipe is one of the most resistant to attack by corrosion. One of the first uses was for piping salt water . . . rigorous service which few materials can withstand. This ability to give day after day service without need of replacement means big maintenance savings for you. $ EASY TO LAY Certain-teed Asbestos-Cement Pipe weighs approxi mately one-half as much as cast-iron pipe of equal size and class. These pipes are easier to handle and easier to join. They can be quickly laid under almost any ground or weather conditions by common labor. IMMUNE TO ELECTROLYSIS Once this pipe is in the ground, you can stop worry ing about electrolysis from nearby high voltage cables or ground transmission from a TV or radio station. Being non-metallic, Asbestos-Cement is not affected by stray currents. COSTS LESS TO TRANSPORT The light weight of Certain-teed Asbestos-Cement Pressure Pipe reduces transportation costs. You move more pipe per truckload, pay less freight per foot. i REDUCED FLOW LOSSES Certain-tced Asbestos-Cement Pipe has a smooth bore, uniform from end to end. This reduces the load on your pumps and keeps the load from increasing with age. The Hazcn-Williams Constant "C" is conserva tively placed at 140 for Asbestos-Cement Pipe. It will retain this initial figure. ("C" is a term used by the engineers Hazcn and Williams to denote the resistance to the flow of water. The higher the "C" number the smoother the surface of the pipe; the lower the "C" number the rougher the surface.) I z DOES NOT TUBERCULATE Being non-metallic, Certain-teed Asbestos-Cement Pipe cannot tuberculate. It remains free from this enemy that chokes so many metallic water lines. EASY TO CUT AND MACHINE i IN THE FIELD * f Lightweight cutting and machining tools operated by one man can be used to cut pipe on the job site. NO LEAKAGE PROBLEMS The FLUID-TITE Coupling automatically forms a permanent leak-tight seal. There is no slow leakage to undermine the soil, or increase your pumping costs. Close tolerances, assure maximum performance. I THE PATENTED CERTAIN-TEED FLUID-TITE coupling Here is the latest and finest in pipe connections. The initial compression of the gaskets seals the joints. You get quick, easy, economical installations with a mini mum of skilled labor, regardless of weather or ground conditions. This outstanding coupling saves money all the way. Deepseated highly compressed gasket pro I vides freedom from leakage due to changing pressures f ( within the line. i- EASY ASSEMBLY Certain-teed Pipe slides into the FLUID-TITE Coup ling easily. Certain-teed lubricant is supplied to permit easy assembly of all sizes -- even the largest pipes. The couplings are strong yet light in weight. No special skills are needed for assembly. Certain-teed Pipe is joined with clearance between pipe ends for expansion and resistance to vibration. The pipe actually floats on the rubber rings within the coupling. * 7 NO STOPPING UNDER BAD LAYING CONDITIONS Under adverse circumstances, Certain-teed Pipe can be laid and assembled quickly with the FLUID-TITE self-aligning Coupling. DEFLECTION FOR CURVES WITHOUT FITTINGS FLUID-TITE Couplings 3" thru 12" allow 2'/, degrees deflection on each side of coupling (total 5 deflection). Sizes 14" thru 24" permit 1/2 degrees of deflection on each side of coupling (total 3 de flection) . NO HEAVY MACHINERY Lightweight Certain-teed Pipe and easily-handled FLUID-TITE Couplings cut costs by requiring fewer men and no machinery for laying and assembly under average conditions. (Machinery may be required under unusual conditions and for the larger pipe sizes. A lightweight coupling puller may also be required for the larger sizes of pipe). exclusive FLUID-TITE gaskets (Combined Coupling and Gasket-- Patented in the United States and foreign countries.) Used with the Certain-teed FLUID-TITE Coupling, they are tapered for ease of installation. The outer surface of the gasket fits into the corresponding grooves of the Coupling. The tapered inner surface of the gasket provides case of assembly for the pipe to slide into the Coupling. t 8 GASKET CROSS-SECTION The FLUID-TITE gaskets are initially compressed to seal the joint against internal pressure and also against negative back pressure caused by vacuum in the line. * 9 CERTAIN-TEED PIPE AND COUPLINGS MEET THE FOLLOWING SPECIFICATIONS: (latest issue) Underwriters Laboratories, Inc. of Chicago, Illinois American Water Works Association Specification C 400 American Society of Testing Materials Specification C 296 American Society of Testing Materials Specification D1869 Federal Specification SS-P-3 51 Associated Factory Mutual Fire Insurance Companies SECTION II THE RIGHT WAY TO: RECEIVE UNLOAD HANDLE STORE certain-teed Asbestos-Cement Pipe and Pipe Accessories These pages are written for the individuals responsible for the handling of Asbestos-Cement Pipe when it arrives at the storage area or at the job site. Remember: if there are any questions pertaining to the condition of the load, call your Certain-teed Pipe Agent or Representative who will be glad to help you. t FIG. 14 / FIG. 15 12 u INSPECT EACH SHIPMENT AS SOON AS POSSIBLE Step 1 -- Inspect the shipment for damage Every shipment has been carefully loaded, and the load braced to insure safe arrival. However, extremely rough handling enroute can cause pipe damage. (Illus tration of standard load on a flat bed truck. (Figure 14) Begin by making an overall inspection of the load. If the bands or wooden braces are intact and the load has not shifted, no overall damage has occurred. Make sure the wooden chocks are still in place, securely fas tened to each end of the stacking board. (Figure 15) Do not remove chains or hands until truck is positioned for unloading. If the load has shifted, straps or braces broken, inspect the load carefully. Examine each piece of pipe and accessory as it is unloaded. Have the truck driver make an itemized notation of any damage on the Deliv ery Receipt, and have it signed by the receiver. On rail shipments call the carrier's agent and note any damage on the carrier's receipt or on the inspection report supplied by the railroad and signed by the Inspector. Chipped ends or gouges may not mean the entire length of pipe is unusable. See Section III for proce dures to salvage the pipe by cutting out the damaged section. Step 2 -- Check the entire load and contents against the packing list Make a thorough check to make sure every item on the packing list is received. Any shortage must be shown on signed receipt. Check the number and foot age of standard, random and short lengths of pipe, the number of standard and special couplings, adaptors and fittings. The rubber rings and lubricant are packed either in a burlap bag or carton. Check the contents. Don't throw the bag or carton from the truck or car -- handle carefully. Short lengths of pipe ( /z lengths 6'6" machined ends only, referred to as M. E. O.) may be placed end to end in the load and may appear as a single long length before you start unloading. Each M. E. O. section is marked to indicate the size, type (Pressure, Irrigation, Non-Pressure Sewer) Pipe, making it convenient to check a mixed load. In rail shipments the couplings are placed end to end in the center of the stack of pipe. ! Step 3 -- Unload Certain-teed Asbestos-Cement Pipe is manufactured to withstand normal field handling, but like any pipe, it can be damaged by careless handling. (Refer to Page 29 & i1', Section III, on repairing damaged pipe in the field). Before starting, make sure you have enough help and equipment on hand to properly handle the load. The following table should serve as a working guide: FIG. 16 Pipe Size 3 4 6 8 10 12 14 16 18 20 24 Approx. Wt. per Lin. Ft Pipe and Couplings Class 100 4.8 6.6 Class 150 5.2 7.4 Class 200 5.9 8.8 10.0 15.6 22.2 29.4 35.3 45.5 65.0 74.3 111.0 11.7 19.2 28.7 38.4 51.5 64.7 87.9 108.0 154.0 14.9 24.7 33.7 47.0 60.0 77.7 -- -- - Method of Unloading Truck Skids or Hand passing Freight Car Skids or Hand passing Ropes and Skids Ropes and Skids Ropes and Skids or Boom Ropes and Skids or Boom Sling and Boom Sling and Boom Standard lengths of 3" and 4" pipe, all types and classes, are the largest sizes that are normally handled by men (two on the truck and two on the ground) without ropes. Pipe 6" to 16" is lowered with ropes and skids or by the use of a crane. 18" and larger use sling and boom. NORMAL PROCEDURE FOR UNLOADING A TRUCK OR FREIGHT CAR 1. Spot the truck on level ground. Place supports of ample size on level ground so that the pipe, when stacked, will be resting on the supports and not on the ground. A support should be placed about three feet from each end of the 13-foot pipe lengths. 2. Insert a stake made from a 2 x 4 in the socket on the truck bed at a point about two feet from each end of the pipe pile to be unloaded. These stakes are placed on the side opposite the one to be un loaded. (Figure 17) 3. Use two lengths of rope at least 50 feet long as slings. Tie ohe end of each rope to the stakes placed in the previous step. (Figure 22) 4. Run the free end of each rope under the top layer of pipes, and double the rope back across the top of the load. (Figure 22) 5. Place two sturdy skids at least 14 feet long at the edge of the pipe to be unloaded. The top of the skids should be beveled. (Figure 22) I 13 FIG. 19 FIG. 22 14 6. Cut the metal straps holding the top rows. Use a hacksaw, heavy wire cutters or snips. Do not use a cold chisel. DO NOT CUT THE STRAPS WHILE STANDING ON THE PILE. (Figure 19) 7. For 6" and 8" pipes, station a man at one end of the pile to start the pipe down the skids. Two snub lines located on the pipe as illustrated in Fig. 22 are sufficient to lower the pipe down to the ground men. DO NOT ALLOW MEN ON TOP OF LOAD AFTER THE BANDS ARE CUT. 8. After the pipe is safely down, slide the rope out from underneath both ends. 9. Remove the two wooden chocks from the separa tor board between the top two rows of pipe. These chocks were left in place until now to keep other lengths of pipe in the top row from rolling off. 10. Place chocks between the next two lengths of pipe in the top row, and unload the next outside length as shown. (Figure 16) 11. Continue in this manner until the truck is un loaded. Be sure to use the chocks to keep loose pipes from rolling. 12. Pass couplings, fittings, and accessories, including burlap bag or carton down by hand. (Figure 18) BE VERY CAREFUL NOT TO DROP PIPE, OR BUMP THE ENDS TOGETHER When unloading pipe 10" to 16"-a crew of five men is required: one man snubbing rope at each snubber on the opposite side of unloading (a); one man at the end starting pipe on skid (b); and two men receiving pipe on the ground (c). (Figure 22) Pipe larger than 16" should be unloaded with a sling and boom. IF A CRANE OR HOIST IS AVAILABLE If slings are used: Use a continuous length of rope, cable or chain, fastened around the center of the pipe as illustrated in Figure 26. This type of sling prevents pipe from slipping. Tight single slings (Figure 26A) can be used for pipe sizes 10" and above. FORK LIFT TRUCKS When unloading with a fork lift, remove only the number of pipe lengths which the length of the fork arms will accommodate. TRUCKING FROM STORAGE AREA TO SITE When a flatbed truck is used, place two timbers across the floor of the truck about 30 inches from each end of the pipe. Nail stop blocks on each side of the timber to prevent movement. Pipe should not extend more than 3 feet out the back of the truck. If more than one tier of pipe is carried, use stacking boards between each tier. Secure the load with load binders, using two for each pile. Locate binders outside of and close to the bottom timbers. (Figure 27) NUMBER OF STANDARD LENGTHS WITH COUPLINGS PER TON Pipe Size Inches 3 4 6 8 10 12 14 16 18 20 24 Class 100 32.1 23.3 15.4 9.9 6.9 5.2 4.4 3.4 2.4 2.1 1.4 Class 150 29.6 20.8 13.1 8.0 5.4 4.0 3.0 2.4 1.8 1.4 1.0 Class 200 26.1 17.5 10.4 6.2 4.6 3.3 2.6 2.0 - STRINGING PIPE Certain-teed Asbestos-Cement pressure pipe with FLUID-TITE Couplings is light enough to handle and assemble easily. It is not necessary to distribute the pipe along the trench before the trench is opened. Most contractors prefer to string the pipe as the trench is ex cavated. This cuts handling time to a minimum. When unloading pipe, be careful not to drop or let it strike against another pipe. Make sure you have enough men and equipment on hand. A crew of four men is needed for 6-inch and 8-inch pipe, two on the ground and two on the truck. Handle each length separately. Be careful not to damage the machined areas of the pipe. Scratches or chipping may necessitate cutting and re-machining the pipe end. Short lengths of pipe, fittings, lubricant and rubber gaskets should be stored at a central point where they will be protected against loss. Keep rubber gaskets away from oil and grease, sunlight, heat and ozone producing equipment. Store in their original, container in a cool, dark place. CHAIN BINDERS When reloading and banding is not available, chain binders may be used. Padding should be placed under the chain at points where the chain binds on the pipe. Place the chain over the area where stacking boards are placed. Do not use a pipe or other extension to increase the leverage on the binder. WRONG CORRECT FIG. 27 ALL CERTAIN-TEED ASBESTOS-CEMENT PRESSURE PIPE AND COMPONENT PARTS ARE COLOR CODED AT THE FACTORY. - CAUTION - DO NOT JOIN DISSIMILAR COLORS; DO NOT STOCK IN SAME LOCATION. PRESSURE clss 100........................................................ black class 150........................................................... orange class 200 ............... black Make sure to check FLUID-TITE Gaskets (or proper size and class. i SECTION III I! t 16 EXCAVATION AND PREPARATION OF TRENCH General: The trench shall be dug to the required alignment and depth shown on the contract drawings or as directed by the Engineer and only so far in ad vance of pipelaying as the Engineer shall permit. The trench shall be braced and drained when necessary so that workmen may work therein safely and efficiently. (total 5 deflection). Sizes 14" thru 24" permit I l/z degrees of deflection on each side of coupling (total 3 deflection). If less radius is needed, shorter lengths of pipe may be used. The table on right side of this page shows the amount of offset in inches and the radius of the curve that will be made. Width: The trench width at the ground surface may vary with, and depend upon, its depth and the nature of the ground encountered. The minimum clear width of unsheeted or unshored trench measured at the hori zontal diameter of the pipe shall be 18 in., or 1 ft. V- greater than the outside diameter of the barrel of the pipe, whichever is greater. The maximum clear width of trench at the top of the pipe shall be not more than the outside diameter of the barrel of the pipe plus 2 ft. Greater width of trench at the top of the pipe shall be permitted only on written approval by the Engineer. Foundation: The pipe shall be laid on stable s<5il. Any part of the trench excavated below grade shall be backfilled to grade with thoroughly compacted material approved by the Engineer. When an unstable subgrade condition is encountered and, in the opinion of the Engineer, it cannot support the pipe, an additional depth shall be excavated and refilled to pipe founda tion grade with crushed stone or other suitable material I as required by the Engineer to achieve a satisfactory trench bottom. Rock excavation: Ledge rock, boulders, and large stones shall be removed to provide 6 in. of clearance to each side of and below all pipe and accessories. Excava tions below subgrade in rock or in boulders shall be refilled to subgrade with material approved by the Engineer, and thoroughly compacted. Sheeting and Bracing: Many state and federal regu lations require sheeting or bracing of the trench. It is important to point out that if sheeting is extending Figure 29 below the top of the pipe, it can cause a change in the lateral support offered by the backfill. Where sheeting is to be reclaimed, it is good practice to have it cut above the top of the pipe prior to backfill, so that the portion extending down to the bottom of the pipe can be permanently left in place. If sheeting is pulled out completely, hand tamp while pulling is being done. Dewatering: In some areas, the ground water table is so high that special problems are added during the installation of pipe. In such areas, before trench exca vation can be started, the trench must be dewatered. OFFSET OF PIPE AND RADIUS OF PERMISSIBLE CURVE Degree LENGTH OF PIPE IN FEET of 3 Z4 feet 6 Vz feet 13 feet Deflec Offset Radius Offset Radius Offset Radius tion Inches Feet Inches Feet Inches Feet i .7 187 1.3 374 2.7 748 2 1.4 93 2.7 186 5.4 372 3 2.0 62 4.0 124 8.0 248 CURVES 4 2.7 4 6 5.4 93 10.8 186 3 3.4 37 6.8 74 13.6 148 I The FI.UID-TITE Couplings 3" thru 12" permit 2 /z degrees of deflection on each side of the coupling 17 TRENCHING FOR CURVES The coupling is assembled on the pipe in a normal straight line position. Then the coupling is cocked to the right or left to allow the next section of pipe to follow the curvature of the trench. (Figure 30). SHARP CHANGES IN DIRECTION Use a 90, 45, 22/2, or 1114 bend where sharp changes in direction are necessary. These may be ob tained from your waterworks supply house. Leave room for thrust blocking (Page 24). LAYING PIPE Figure 31 FLUID-TITE Asbestos-cement Pipe and Piping System Components These products are especially designed and adapted for use in the pipe coupling system. Patented in the United States and foreign countries. FLUID-TITE is a registered trademark of Certain-teed Products Corporation, Valley Forge, Pennsylvania, U.S.A. LOWERING PIPE INTO TRENCH In most cases four men constitute a crew: two above the trench, and two in the trench. Pipe 8 inches in diameter and smaller can be lowered by hand into the trench. Larger pipe should be lowered with ropes. An chor one end of the rope by standing on it (Figure 31). Use as shown. Lower pipe slowly. The men in the trench should look through the pipe as it is being lowered to make sure the inside is free from earth and foreign matter. Where the pipe is being low ered by ropes, the men in the trench guide the pipe. METHODS OF SUPPORTING PIPE 1. Pipe Laid on Trench Bottom 2. Pipe Laid on Earth Pads They are listed and described below. No matter what method is used, it is necessary to provide sufficient clear ance under the coupling so the weight of the pipe does not rest on the coupling. It is necessary to align each succeeding length of pipe to the coupling before assembly. PIPE LAID ON TRENCH BOTTOM Pipe can be laid directly on the trench bottom, pro vided the bottom has been properly leveled. It is neces sary to dig a coupling hole 3 inches deep and 6 inches longer than the coupling wherever a coupling will be located. (Figure 33). A leveling board or straight edge 14-feet long (Figure 29) is recommended to be sure there are no voids or high spots and that the grade is correct. Any uneven areas in the trench bottom should be shaved off or filled in with well-tamped soil. Recheck with leveling board. If the trench bottom is cut through shale, the trench bottom should be lowered 6 inches and brought back to 18 grade with crushed stone. Sand can filter into shale and cause an uneven support under the pipe. If rock ledge or soils which are too hard to level are encountered, the trench bottom should be lowered 6 inches and brought up to grade with sand or select soil, well-tamped. PIPE LAID ON EARTH PADS In this method, the pipe is laid on two earth pads, 12 V. inches wide, minimum 2 inches high and the full width f. of trench (Figure 34). These provide the clearance needed for coupling the pipe. The pads must be built from good backfill material and tamped. Do not use stones, lumps or other hard material. The pads should be located 31 inches from each end of the 13-foot h length of pipe. If shorter lengths are used, locate onefifth of the pipe length from each end. Place pipe firmly in position on these pads with the ends in alignment. It may be necessary to add or re move pad material to bring the pipe faces into align ment. Check to make sure that a minimum of two inches clearance is left under the unsupported area of the pipe (Figure 34). Suitable material should then be carefully tamped under the barrel of the pipe between the pads and in 4-inch layers, above the pipe to a minimum depth of 12 inches. See "Initial Backfill" on Page 26 for details. > CERTAIN-TEED FLUID-TITE COUPLING ASSEMBLY INSTRUCTIONS Certain-teed FLUID-TITE Couplings are easily as sembled. The scientifically designed and patented rub ber gaskets have tapered surfaces that allow the pipe to assemble easily -- yet seal perfectly. (Figure 36). BEFORE ASSEMBLY, MAKE SURE THAT THE GASKET. COUPLING GROOVES. THE COUP LING. AND THE PIPE ENDS TO BE ASSEMBLED ARE CLEAN. A. Place rubber gaskets inside coupling groove with holes facing center. After placing, run your finger along the inside edge of the gasket to insure that the gasket is properly seated in the groove. (Figure 36).` ' B. Thoroughly clean pipe ends to be assembled before lubricating. The lubricant should be applied to the entire machined pipe surface of ODI and to the exposed rubber ring surface. Keep lubri cated pipe ends and coupling clean after lubricant has been applied. DO NOT LEAVE DRY SPOTS. C. A! ign the ends of each pipe, then separate about two feet (for UNbelled pipe) to allow for assembly. On PREbclled pipe, align pipe end with coupled end. (Figure 37). IMPORTANT: Make sure CERTA-SPACER l? band is flush against first shoul der of unboiled end of pipe. (Where Applicable) Figure 33 2" MINIMUM CLEARANCE Figure 34 Figure 36 l 19 I 20 D. Push pipe home. E. For UNbelled pipe place coupling over the lubri cated pipe end. Push couplings with a crowbar, use a protective wood block between bar and coup ling. Push coupling home, until coupling is against CERTA-SPACER band (where applicable). For PREbelled pipe, align the pipe end, with the coupled end and shove, until the assembly is made. (Figure 38). F. Proceed to make next joint in the same manner. Completed joint is shown in Figure 39. ITEMS NEEDED FOR JOINING THE PIPE 3" to 8" Pipe Large Crowbar Block of Wood Lubricant 2" Flat Paint Brush 10" to 24" Pipe FLUID-TITE Coupling Puller (optional) Large Crowbar Block of Wood Lubricant 2" Flat Paint Brush FOR LARGER PIPES WHEN USING PULLER G. Guide the end of the free pipe into the coupling. Use a coupling puller to complete the joint. H. Set base of coupling puller on top of fixed pipe, approximately 12 inches from the coupling. I. Place puller base chain tightly around pipe. Fasten link into slot. (Figure 39-A). J. Fasten pull chain around free pipe about one foot from the pipe end. K. With puller handle leaning slightly toward free pipe, tighten pull chain and fasten to pull hook. L. Pull handle toward fixed pipe with one continuous motion until coupling is seated against both CERTASPACER rings. (Where Applicable) (Figure 39-A). M. Unfasten chains. Remove puller. NOTE: Some contractors do not choose to assemble by the joining methods recommended above, but in stead, leave the pipe supported by the lowering cable and swing the pipe into the coupling. Using this method of assembly of stabbing or swinging, the con tractor must be extremely careful for if carelessly done, stabbing or swinging can result in broken pipe ends, fishmouthing of gaskets, or overbelling. If this method of stabbing or swinging is used, the following steps should be followed: 1. A minimum length of swing should be used to make the assembly complete. 2. The pipe end must be in perfect alignment with the receiving coupling. 3. The pipe end and rubber ring must be thoroughly lubricated. 4. If assembly is not made on the first attempt, re lubricate the pipe end before making the next swing. f 5. If there is a miss and the pipe end strikes the coup ling, examine both coupling and pipe end for damage. 6. Before disconnecting the cable from the pipe be sure tamped earth pads are at the right grade to receive the pipe. CONNECTING FLUID-TITE PIPE TO C.I. FITTINGS (Figure 40) See Inter-connection sheet page 45. Important: The ring grooves of the C.I. Fittings MUST be fully coated with lubricant before inserting the FLUID-TITE ring. The ring must also be lubricated. CHECKING RING POSITION To check the location of the gasket after field assem bly a feeler gage can be inserted between the coupling and the pipe to insure that the ring is in position in the groove. Where a CERTA-SPACER is used it should be removed by either cutting or pulling back over the shoulder. To assure total flexibility in the smaller sizes of pipe, 12" and below, the CERTASPACER must be positioned to its original location to prevent "closing" as succeeding assemblies are made. If the CERTA-SPACER has been cut it is sufficient to "drape" it over the pipe in its original position so that there is approximately 180 contact with the pipe. This will prevent further "closing" of the pipe ends. SUPPORTING FITTINGS Fittings should always be supported so their weigh is independent of the pipe. Use substantial supports under the fittings. When pouring concrete thrust blocks (Page 24) around a fitting, make sure the con crete runs under and against the body of the fitting. Be sure the joint is left exposed. (Figure 48). BELL TYPE END CAPS Cast iron end caps are available for ail sizes of Asbestos-Cement pipe. End caps are drilled and tapped off center with standard iron pipe threads, for bleeding air from the line. The 4-inch caps are tapped for 1-inch iron pipe; the larger sizes are tapped for 2-inch iron pipe. Thrust blocking is required when end caps are used. CERTA-SPACER (Where Applicable) Pipe Positioning Bands These positioning bands are especially adapted for use in the pipe coupling system patented in the United States and foreign countries. CERTA-SPACER is a registered trademark of Certain-teed Products Corporation, Valley Forge, Pennsylvania, U.S.A. LENGTH OF PIPE AT FITTINGS AND RIGID STRUCTURES When rigid joints -- that is, those formed by pouredor caulked-joint materials, or both, or by bolts with rubber ring seals -- are used at the fitting, the length of the pipe fitted into the bell of the fitting shall not be more than 3'3" in pipe of 6" diameter and smaller, or 6'6" in pipe of 8" diameter and larger. When a rubber ring is used to make the seal, and flexibility is provided by a grooved design profile similar to that of the coupling used to join pipe between fit tings, up to a full 13-foot length may be used. With all the rigid joints named above, the pipe connecting any two valves or fittings shall be in two or more lengths jointed with one or more couplings to provide flexibility. If a flexible seal is used, a single 13-foot or shorter length may be used to connect the two fittings without any intermediate coupling. A coupling shall be cast in the wall of rigid struc tures at the point of entry of pipelines to provide flexi bility at the wall. To provide additional flexibility, the pipe at the point of entry shall have a laying length of not more than 6'6". CONNECTING FLUID-TITE TO STEEL PIPE Special Certain-teed adaptors are available for con necting 3-inch Asbestos-Cement pipe to 2-inch steel pipe or connecting other sizes of Asbestos-Cement to steel pipes of the same nominal diameter. These adap tors have FLUID-TITE gaskets which seal both pipes. Assemble these adaptors in the same manner as a stand ard FLUID-TITE coupling. A strap clamp is necessary on the steel pipe against the coupling. (Page 44) CONNECTING F.T. PIPE TO OTHER TYPES OF ASBESTOS-CEMENT PIPE. (Figure 41). See interconnection sheet page 45. CPC FLUID-TITE CG Previously installed & current types of A.C. pipe Figure 41 I 21 POWER DRIVES FOR FIELD LATHES FIELD CUTTING AND MACHINING Any desired length of Certain-teed Asbestos-Cement pipe can be cut on the job. Cuts can readily be made by using a "Pilot," "Matthews," "Tapertool," "Reed," or similar cutter. Your Certain-teed Agent will be glad to quote prices for hand operated cutters on request. These cutters are adjustable to the full range of pipe sizes and can be easily dismantled for storage (Figure 43). In emergencies, if only a few pieces are to be cut, a standard two-man cross-cut saw may be used. Since Certain-teed pipe is abrasive, frequent resharpening and resetting will be necessary. Teeth should be set wide. Before beginning cut, mark the pipe all the way around to help keep the cut square. Rotate pipe while cutting. Saw should follow a circular pattern. Do not try to cut completely through pipe wall on first cut. Do not use a cold chisel or standard iron pipe cutter as they may fracture the pipe, producing ragged, uneven edges. A portable electric saw with a flexible or abrasive blade may also be used. The pipe is rolled as the cut is made. BUTTERFLY VALVES IN A/C LINES The vane in the butterfly valve may not close if the PAD or FM piece is inserted too far into the valve. Butterfly valves do not always have retaining rings to restrict the insertion of the PAD or FM piece. After the valve is installed in the line, it should be operated from full open to full close to insure that installation is correct. FIELD MACHINING A coupling surface can be machined on the rough barrel of the pipe, using "Pilot," "Matthews," "Tapertool," "Reed" or similar machining tools (Figure 42). Mount pipe to provide sufficient clearance for the tool. Use the manufacturer's instructions for tool use. 22 SERVICE CONNECTIONS Certain-teed pipe can be tapped wet or dry, using a "Mueller," "Hays," "Dresser" or similar machine (Figure 44). The machine should employ a guiding mechanism for the drill-tap, which permits disengaging the pressure feed when tapping, and keeps the drill tap in alignment during the tapping operations. DRILLING The machine should be in good repair. It is important that the machine and boring-bar do not wobble. Always use a new or sharp drill-tap that is recommended for use with A/C pipe. Be sure that the drill section of this tool is long enough to go completely through the pipe wall before the tap engages. The machine may be clamped perpendicular to the top of unassembled pipe. When the pipe is assembled, clamp the machine at a 45 angle toward the service line, or as specified by the engineer. Use a mixture of powdered graphite and linseed oil to lubricate the drill and tap. Do not use any lubricant or sealant when inserting the corporation stop. DO NOT FORCE the drill through pipe wall. Bor ing-bar should rotate freely at all times -- use the follower lightly -- do not force the drill. 2-3 THREADS EXPOSED TAPPING After the drilling cycle is completed, release the feed mechanism. This will allow the tap to function properly and form a clean sharp thread. Tapping should be of sufficient depth to allow one to three threads exposed when the corporation stop is inserted. (Figure 45). It is advisable to make a test tap and mark the boring-bar to the proper depth. When a new or reconditioned drill-tap is used, this mark should be rechecked. The stop should be inserted with the machine in the same setting that the tap was made. When a dry tap ping machine is used, it will be necessary to insert the stop by hand. DO NOT TIGHTEN MORE THAN NECESSARY TO MAKE A WATER-TIGHT JOINT. DO NOT USE ANY LUBRICANT OR SEALANT WHEN IN STALLING THE CORPORATION STOP. Figure 44 Machine THREAD Figure 45 TOO DEEP THREAD Figure 47 23 MAXIMUM SIZE CORPORATION STOP THAT CAN BE TAPPED DIRECTLY INTO PIPE PIPE SIZE TAP SIZE 4" - 200 4" thru 16" - 150 inch 6" thru 16" - 200 8" thru 16" - 150 1 - inch If more than one corporation stop is to be used within the same area, stagger them at least 12 inches apart (Figure 46), and not on the same center line. A gooseneck is required between the corporation stop and the service pipe -- regardless of the type of service pipe (Figure 47). This provides a spring-like action to take care of pipe movement due to earth settlement or movement of the service pipe. Swing ells must not be used to connect the corporation stop to the service line, when taken directly from the barrel of Asbestos-Cement pipe. SERVICE CLAMPS, TAPPING SLEEVES AND .TAPPED COUPLINGS Where greater outlet size is required, service clamps, tapping sleeves, or threaded brass insert couplings are used. These may be obtained from your waterworks supply house. Double flat strap service clamps should be used where the outlet is over 1 inch. Do not use larger outlet sizes than those shown in the table below. Tighten bolts on saddle evenly and avoid over-tighten ing. When ordering Service Clamps or accessories, specify O.D. of pipe plus 54 inch. Swing ells may be used to connect corporation stop to the service line when saddles are used. MAXIMUM SIZE OUTLET FOR USE WITH DOUBLE STRAP SERVICE CLAMPS OR SADDLES PIPE SIZE 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" OUTLET SIZE 1" l/a" 2" 2 '/2 " 3" 3" 3" 3" 3" 3" File the surface of the pipe to clean off all loose ma terial before placing clamp or saddle on the pipe. Place corporation stop in outlet and drill through the corpor ation stop. Full circle clamps with side outlets of various sizes are available. Teflon Tape or Sealing Compound should be used when making a metal to metal threaded connection. See Page 43 For Threaded Brass Insert Couplings THRUST BLOCKING Thrust blocking prevents the line from moving when the pressure load is applied. In effect, the thrust block transfers the load from the pipe to a wide load-bearing area. Thrust blocks are required at points where the pipe changes direction such as: At All Tees, Elbows, Wyes, Caps, Valves, Hydrants, Reducers, etc. (Figure 48) Thrust Block all in-line valves The size and type of thrust block depends on pipe size, line pressure, type of fitting, degree of bend and type of soil. In most cases, the size and type of thrust block will be determined by the engineer. Thrust block size can be calculated by the following procedures: For an example, use 8" Class 150 pipe with a 90 elbow. The soil is medium clay which can be spaded. Step 1. Add 50 lbs. for pressure testing to the maxi mum rating of the pipe. Multiply this figure by the appropriate value shown in the following table: THRUST PER POUND OF WATER PRESSURE AT VARIOUS FITTINGS Oo ON Pipe Size 4 6 8 10 12 14 16 18 20 24 Dead End or Tee 19 39 67 109 155 210 272 351 434 623 Elbow 27 55 94 154 218 296 383 494 611 878 45 Elbow 15 30 51 84 119 161 209 269 333 478 22 y2 Elbow 7 15 26 43 61 82 106 137 169 244 Example: The thrust of an 8-inch 90 elbow at 150 pounds pressure plus an additional 50 lbs. for testing totals 200 lb. maximum pressure. Using the foregoing table, the thrust would be 18,800 lbs. (94 x 200). I 24 Step 2. Determine the bearing strength of the soil from the table below. BEARING STRENGTH OF SOILS Soils and Safe Bearing Loads Sound Shale Cemented Gravel and Sand difficult to pick Coarse and fine compact Sand Medium Clay -- Can be spaded Soft Clay Muck Lbs. Sq. Ft. 10,000 4,000 3,000 2,000 1,000 0 Step 3. Divide the total 'thrust obtained in Step 1 by the bearing strength of the soil. Example: From the table-bearing strength of soils-- it shows that medium clay which can be spaded has a bearing strength of 2000 lbs. per sq. ft. Divide the total thrust (18,800 lbs.) by 2000, which gives the sq. ft. of area needed. In this case it is 9.4 sq. ft., for which an approximate area of 3 x 3 ft. can be used. s Side Thrust on Curves Jr j \ An outward pressure exists on all deflections from a straight line. Good soil, properly tamped, is sufficient to hold side thrust -- unless soil conditions are un > stable. In that case, some anchorage must be provided on each side of the coupling (Figure 49). Do not thrust block the coupling. SIDE THRUST PER 100 Ibs./sq. in. PRESSURE PER DEGREE OF DEFLECTION Pipe Size -- Inches 4 6 8 10 12 14 16 18 20 24 Side Thrust -- Lbs. 35 72 122 197 278 377 486 665 790 1150 Note: Multiply thrust by degree of deflection to obtain total side thrust. Construction of Thrust Blocks Thrust blocks are anchors placed between the pipe or fitting and the solid trench wall. They can be con structed from available lumber, if braced properly. I 25 However, the recommended blocking is concrete calculated to have a compressive strength of 2000 lbs. per sq. inch. The mixture is 1 part cement, 2 parts washed sand and 5 parts gravel. Thrust blocks should be constructed so their bearing surface is in direct line with the major force created by the pipe or fitting (Figure 48). The earth bearing surface should be undisturbed. Only the simplest of forms are required. Use concrete, fluid enough so it can be worked under the fitting, around and up to the top of the fitting. Keep all joints free from concrete. Hydrants require thrust blocking at both the 90 elbow and the Tee in the main line (Figure 50). INITIAL BACKFILL Initial backfill should be done as soon as possible after the pipe has been laid. This protects the pipe-- and avoids shifting due to cave-ins. Initial backfilling is very important. It provides the firm bed that will cushion the pipe during the period when the earth settles. All pipe lines are subjected to considerable stress from earth and other loads. Unless these loads are evenly distributed, a break may result. The couplings are normally exposed until the line has been tested. However, if conditions are such that the exposed coupling area may be filled with water, snow or objectionable material which might cause the pipe bed to become unstable, or rain and freezing con ditions prevail, the trench should be completely back filled. (See "Final Backfill" -- Page 29). BACKFILL with Hand Tamping Place selected dirt (that is, dirt free from rocks, frozen lumps and other objectionable material) along each side of the pipe but not higher than the center tine. Then using a bar made from iron pipe and fittings (Figure 5/) tamp dirt under the pipe so no voids are left (Figure 55). Continue adding selected dirt in approximately 4" layers, tamping each layer, until you have fully compacted dirt over the pipe. Then a flat tamper (Figure 54) can be used. Initial backfill should proceed until the pipe has been covered by at least 12 inches of well compacted material. Mechanical compactors should not be used directly on top of the pipe until a minimum of 12" of handtamped backfill has been completed. t BEFORE TAMPING AFTER TAMPING BEFORE TAMPING AFTER TAMPING TOO MUCH DIRT BEFORE TAMPING TAMPING BAR CANNOT COMPACT BACKFILL PROPERLY UNDER PIPE PROPER AMOUNT OF BACKFILL WHICH CAN BE TAMPED FIRMLY UNDER PIPE TEMPORARY THRUST BLOCKING Install an end cap or valve (Figure 5 6) as a tem porary line seal. Notch the sides of the trench for a heavy timber or put heavy sheathing at the end of the trench. Use table on page 2 5 to calculate the neces sary bearing area. Place a screw jack between the cap or valve and the timber (Figure 55). Tighten jack until firmly wedged against the cap or valve. Wedge the pipe solidly in place, so it cannot move vertically or horizontally when pressure is applied. Figure 56 Volume of Water Required for Testing in gallons Per 100 Feet Pipe Size Approximate Gallons 3 4 75 6 169 8 300 10 468 12 674 14 917 16 1,198 18 1,516 20 1,872 24 2,696 TESTING At this point, the line has been partially backfilled, with coupling and fittings exposed. It should now be tested before further backfilling. If possible test sections should not be more than 1,000 feet long. Be sure the concrete thrust blocks have been cured 24 hours to prevent cracking. If the entire line is not complete at this point, temporary test ends may be installed and given temporary thrust blocking. HYDROSTATIC TEST It is advantageous to test a pipe line in short sections. A run of one thousand feet would be ideal. This is especially true at the beginning of a job, as it gives the contractor and all concerned a check on the initial in stallation. Some jobs are installed in their entirety before testing, and any installation errors are carried through the whole job. Corrective repairs are then very expensive. The pipe should be bedded by hand tamping good compaction soil under, alongside and over the top of the pipe to a depth of 12 inches. All fittings should be thrust blocked to virgin soil. If the permanent block is made of poured cement, at least 24 hours should be allowed for curing. The size of the thrust area can be figured by using the tables on pages 24 and 2 5 of this manual. The end cap, usually a mechanical type, with a tapped offset bleeder should be temporarily blocked to virgin soil at the ditch end or by timbers set in notches in the ditch wall. A jack should be used between the cap and the blocking to take up any movement of the cap until the blocking is firmly set. If the couplings are left uncovered for inspection, the soil around the bottom half should be firmly tamped. Sufficient earth load should be placed on the pipe be tween couplings to resist any upward thrust. If the couplings are not left open, complete the backfill after soil has been hand tamped to 12" over pipe and couplings. Line should be filled as slowly as possible to avoid any' unnecessary surges. Venting air from the line is of major importance. Each coupling is in itself a small air dome. Pressure pipe is seldom laid to grade, so there are high and low sections along the line. If the high section elevation is considerably above the low part of the line, a large amount of air will be trapped. Corporation stops or automatic air relief valves should be installed at these high points. Air can be blown from hydrants in pipe sizes up to 8". In larger diameter pipes air will not enter the hydrant branch, so it will be necessary to install the air vents at high points. Low static water pressure (50 psi) held on the line for at least twenty-four hours will force any normal amount of air from the test section. Some water will be absorbed by the pipe during this time. Before the line is brought up to full test pressure, all air vents should be opened and any remaining air blown from the line again. A test pressure of 30 psi over the actual working pressure is generally sufficient unless the specifications call for a higher pressure*. This pressure should be held constant for two hours. Gauge readings should be taken at the low point in the line. This will insure that the test pressure does not exceed the specified pressure anywhere in the line. The leakage test should be made with normal con stant working pressure. Generally, the engineer will specify the leakage allowance and describe the methods for testing. If not, use the leakage allowance table on page 29 of this manual. A straight sided vessel (JJ gal. drum) that can be calibrated to gallons per inch of depth can be used to pump from. After the test limit is up, the amount of water pumped from the drum can be measured and checked with the specified leakage allowance. A meter which has been checked for ac curacy can also be used. If either of the above tests fail, the following check points may be helpful in locating the leak: 1. A hydrant valve held open by a piece of rag, wood or some other foreign matter. When the valve is held slightly open, line pressure will be relieved through the hydrant drain. 2. Dirt or foreign material under the coupling gasket. 3. Pipe not sufficiently covered in trench. 4. Fittings and valves in test section not sufficiently blocked. 5. Corp. cocks not tightly closed. 6. Air in line (no relief valve). 7. Leakage through valve at end of test section. 8. Valve Bonnet plug leaking. 9. Packing on valves and wet-barrel hydrants leaking. *AWWA recommendation for test pressure is 50 per cent greater than operating pressure, however, we feel 50 psi greater than operating pressure is sufficient. f 28 10. Test pump leaking. Check-valve as well as gatevalve. 11. Curves not sufficiently thrust blocked. 12. Testing too long a section of pipeline. 13. Insufficient saturation time (24 hours). 14. Ruptured pipe--cracked, blown out. 15. Broken couplings. 16. Faulty accessory equipment--valves, fittings, hy drants, saddles, corps., relief valves. 17. Faulty test gauge. 18. Test pump suction line drawing air. Occasionally a leak will not show on the surface due to good draining soil under the pipe. Sensitive transis torized leak detectors can be employed to locate a hardto-find leak. After all tests are made, all couplings left open for inspection should be covered, tamped and final backfill completed. Allowable Leakage per 100 Couplings* Pipe Test Pressure at Lowest Point in Line --psi Diameter SO 75 100 125 150 200 225 in. Leakage -- gph 4 0.71 0.87 1.00 1.02 1.23 1.42 1.51 6 1.06 1.29 1.51 1.68 1.84 2.12 2.25 8 1.42 1.72 2.00 2.24 2.45 2.84 3.00 10 1.77 2.15 2.50 2.79 3.07 3.54 3.75 12 2.12 2.58 3.00 3.35 3.68 4.24 4.52 14 2.48 3.01 3.50 3.91 4.28 4.96 5.26 16 2.83 3.44 4.01 4.47 4.89 5.68 6.00 18 3.18 3.87 4.52 5.02 5.52 6.37 6.75 20 3.54 4.30 5.00 5.58 6.12 7.08 7.51 24 4.24 5.16 6.00 6.69 7.34 8.50 9.01 `The data are based on lfO psi and represent a leakage of approx imately 30 gpd per mile of pipe per inch of pipe diameter for pipe in 13-ft. lengths. Note: UNDER NO CIRCUMSTANCES IS AIR TESTING OF A/C PRESSURE PIPE RECOM MENDED. FINAL BACKFILL After completion of test, backfill around the ex posed couplings and fittings should be carried out as detailed in "Initial Backfill" on Page 26. Curved tamp ing bars should be used to compact the backfill under the couplings. Fill After Testing Follow the same procedures until the backfill has been built up in 4-inch layers to 12 inches above the pipe. After the pipe line has been properly covered to the 12" depth, the balance of the excavated earth may be moved into the trench by a bulldozer or other me chanical methods. Water Tamping Where the soil is loose and friable enough to pro vide good drainage, water compacting may be used. This starts after initial backfill has been completed, and the entire pipe including couplings have been covered to a depth of 12 inches. Three to four inches of water is run on top of the initial backfill. The balance of the excavated earth is then moved into the trench. The puddling action of the water compacts the earth without further hand or mechanical tamping. Trench on Slope If the trench is on a slope, use extra care in back filling and packing. Until the earth completely settles, the trench is in danger of becoming a gulley. Planks, 8 to 10 inches wide and 3 feet wider than the trench can be placed on edge across the top of the trench to act as baffles. Bury them into the ground, leaving from 2 to 4 inches exposed (Figure 57). Drive 2" x 4" stakes into the solid ground to support the baffles. Depending on the slope, baffles should be used at frequent enough intervals to prevent wash-out. Rocks can also be used on top of the trench to prevent erosion. MAKING CLOSURES AND REPAIRING PIPE Repairing Bruises, Holes or Gouges A repair clamp (Figure 58) may be used to reinforce damaged pipe areas such as punctures, flexural breaks, blown corporation stops or damage caused by rocks or excavating machinery. Figure 58 29 Cut Off Section A Remachine Shaded Area Figure 59 r-p<n - ~ Tbo-i Figure 61 Figure 62 Cutting Out Damaged Portion Pipe sections damaged before installation can be cut off, and the balance used for short lengths where needed. See Page 22 for cutting instructions. If the coupling area of the pipe has been chipped or cracked more than /z inch from the end (Figure 59) cut off the damaged area at least one inch beyond the defect and re-machine the end (Page 22). Shallow scratches on the machined end of the pipe should be sanded smooth so the rubber ring can seal the area. Deeper scratches or gouges will prevent the ring from seating and the entire area should be cut off, and the end of the pipe re-machined (Page 22). When installing repair clamps, clean surface under the clamps with a file or wire brush. Follow manu facturer's instructions for installation. If a pipe section must be replaced in the field, dig the trench at least 12 inches wider than the diameter of the pipe, and 2 feet longer at each end than for the pipe section being replaced. This provides room for removing or assembling the coupling. Replacing Damaged Pipe in the Line If the pipe has not been damaged and is being re moved for insertion of fittings, remove the couplings by holding the cutting tool parallel to the pipe (Figure 60). Use a cold chisel, hack saw or carpenter's saw. Be careful not to damage machined surfaces of pipe to be left in trench. Dig a coupling hole 6" longer than the coupling. If the pipe is damaged, break the damaged pipe with a sledge hammer. Remove broken pieces of pipe from couplings. Remove couplings, dig a coupling hole 12 inches long under each pipe end. After couplings have been removed, use either of the following methods to replace section: Where a field machining tool is available, a special closure section may be made by machining each pipe end back 8 inches to receive the full length of the coupling (Fig. 61). Each end is machined back 8 inches to receive the full length of the coupling. Use extra lubricant when placing couplings on the repair length. After placing couplings on the repair length, align each end with the fixed pipes in the trench. Lubricate the fixed pipe ends and slide couplings into place, complet ing the joint. Do not place couplings on repair section until ready to install. Also, one length MEO and two lengths FM pipe will make a 13-foot closure. If length is shorter than 13 feet use one length MEO and two lengths FM pipe (one cut to length) as in Figure 62. Allow '/>" space between pipe ends. I ' Lubricate the end of the fixed pipe and the ring in the coupling and assemble a coupling and FM piece. Place a coupling on the MEO section and join to the FM piece. Lubricate both ends of the field cut FM piece to the full length of the coupling. Slide the couplings on to the pipe until the bevelled lip is clear of the couplings. Lubricate the ends of the MEO, the fixed pipe and the coupling rings. Align the field piece and slide the couplings into place. When installing FM pieces lube the FM heavily for the length of the coupling, lube both rings well both inside and outside of the lip and then push hard. This installation will place one CERTA-SPACER band at each coupling (where applicable). Check the spacing on the FM pieces to assure proper pipe end separation. Rasp the cut end of the field cut piece to conform with factory machining. Another method can be used to replace a full section of pipe with a single full section. Place coupling on one fixed end, cocked slightly. Assemble new length in coupling in the normal manner. Set free end over until it aligns with fixed pipe. Couple in place with a full circle repair clamp. When pipe is in place, backfill and tamp in the normal manner (Page 26). SPECIAL INSTALLATIONS Certain-teed pipe has the strength and lightness needed to simplify many "problem" installations. If you have any unusual installation problems, send a complete description to your nearest Certain-teed Sales Office. They will be glad to offer suggestions. Installation Using "A" Frames or "H" Frames Where the pipe must be supported above the ground, timber "A" frames, (Figure 64) or "H" frames (Figure 63) may be used. "H" frames offer the most substantial support, and should be used where vertical thrusts are encountered. Use 2" x 4" or heavier timbers driven far enough in the ground to offer adequate support. Support the pipe above and below by timbers nailed to vertical supports. Use two supports per 13-foot length, located approximately 3 1 inches from each end (under the painted rings). Shorter lengths also require two supports, located one-fifth the distance from each end. "A" frames are often used to anchor emergency lines. Use 2 x 4's long enough to drive firmly into the ground and nail together above the pipe. Locate the "A" frames as described under "H" frames above. Figure 64 Installations for Bridge Crossings Bridge crossing installations should follow the recom mendations of a competent engineering authority. Certain-teed will be glad to work with you on any problems you may encounter. f 31 CASINGS Pipe under railroads, highways, etc., should be in stalled in casings. Wooden skids are used to move the pipe through the casing and to keep the weight of the line off of the couplings. The skids should be at least 24" long, 2" wide and thick enough to give clearance between the casing bot tom and the coupling. (Figure 6f). Round or bevel the leading edges of the skids and notch as shown. When strapping or wiring the skids onto the pipe place the skids at 1/5 the distance from each pipe end and approximately 20 from the center line of the pipe. Pass a cable, with an eye, through the casing and pipe. Place a wooden block, slightly longer than the OD of the coupling, through the eye and pull the pipe into the casing. Assemble the next section of pipe and proceed as above. After the pipe is completely installed in the casing sand should be washed in with a pressure hose until it is level with the top of the pipe. Be careful not to allow too much water to accumulate as the pipe could float and cause uneven bearing. Expansion Joints For normal installations the FLUID-TITE coupling provides sufficient flexibility to eliminate the need for expansion joints. For bridge crossings, expansion joints are necessary. RECOVERY Certain-teed pipe can be dug up and re-used after any period of service. It can be used again on the same pressure service as it was originally designed to withstand. MINIMUM CASING SIZES (IN INCHES) Pipe Size 3 4 6 8 10 12 14 16 18 20 24 Casing Size 9 10 12 16 18 20 24 26 32 33 40 Figure 65 t 32 - 4< .rjrj r innrr--C lr m ' i ------V I FOR CERTAIN-TEED* FLUID-TITE* ASBESTOS-CEMENT based on the Hazen-Williams Formula C=140 HS Pipe & Plastics CERTA1NTEED "rU*J CERTAIN-TEED PRODUCTS CORPORATION, P. 0. Box 860, Valley Forge, PA 19482 CERTAIN-TEED and FLUID-TITE are registered trademarks of Certain-teed Products Co., Valley Forge, Pa. SECTION IV DIMENSIONS OF CERTAIN-TEED ASBESTOS-CEMENT PRESSURE PIPE FLUID-TITE COUPLINGS ACCESSORIES >1 37 CERTAIN-TEED FLUID-THE Pipe End With CERTA-SPACER Band NOM. SIZE PIPE & CLASS 3" - 100 4" - 100 18" - 100 20" - 100 24" - 100 3" - 150 4" - 150 18" - 150 20" - 150 24" - 150 3" - 200 4" - 200 NOM. I.D." 3.00 4.00 18.00 20.00 24.00 3.00 4.00 18.00 20.00 24.00 3.00 3.95 B.O.D."** 3.93 5.05 20.30 22.50 27.00 4.03 5.14 21.20 23.54 28.22 4.18 5.32 O.D.i +.02" 3.74 4.64 19.90* 22.12* 26.48* 3.84 4.81 20.94* 23.28* 27.96* 3.84 4.81 O.D.2 .02" 3.90 4.80 20.06* 22.28* 26.64* 4.00 4.97 21.10* 23.44* 28.12* 4.00 4.97 X= 1.15" .06" * -- O.D.i & O.D.2 Tolerance for 18", 20" & 24" = .03 ** - Subject to Manufacturing Tolerances C .06" 2.60 2.90 4.88 4.88 4.88 2.60 2.90 4.88 4.88 4.88 2.60 2.90 P .06" .50 .75 1.00 1.00 1.00 .50 .75 1.00 1.00 1.00 .50 .75 OC 2 16 16 22 o 22 22 16 16 22 22 22 16 16 < CER11IN-TEED. FLUID-TITE and CERTA-SPACER are registered trademarks of Certain-teed Products Corp., Valley Forge, Pa. J8 bCIflAIN-IttUe FLUID-TITE Coupling A NOM. SIZE PIPE & CLASS +.025" B B.O.D." H +.025" * +.000" -.063" L +.25" -.00" 3" - 100 4.57 3.850 5.25 4.500 6.25 F -.000" G +.04" -.00" .812 .62 R +.01" J +.03" -.00" .125 .375 4" - 100 5.57 4.755 6.25 4.875 6.50 .812 .70 .125 .375 18" - 100 21.20* 20.080* 23.20 8.500 11.10 1.300 1.00 .125 .50 20" - 100 23.42* 22.300* 25.40 8.500 11.10 1.300 1.00 .125 .50 24" - 100 27.78* 26.660* 30.40 8.500 11.10 1.300 1.00 .125 .50 3" - 150 4.69 3.950 5.55 4.500 6.25 .812 .62 .125 .375 4" - 150 5.74 4.925 6.66 4.875 6.50 .812 .70 .125 .375 18" - 150 22.24* 21.120* 25.33 8.500 11.10 1.300 1.00 .125 .50 20" - 150 24.58* 23.460* 27.97 8.500 11.10 1.300 1.00 .125 .50 24" - 150 29.26* 28.140* 33.44 8.500 11.10 1.300 1.00 .125 .50 3" - 200 4.69 3.950 5.75 4.500 6.25 .812 .62 .125 .375 4" - 200 5.74 4.925 6.88 4.875 6.50 .812 .70 .125 .375 OC +0 -1 18 18 12 12 12 18 18 12 12 12 18 18 B= 20 2 for 3" & 4"; B= 30 2 for 18" thru 24" * - A and B Tolerance for 18", 20" and 24": +.040" ** -- Subject to Manufacturing Tolerances. CERTAIN-TEED* , FLUID-TITE and CERTA-SPACER are registered trademarks of Certain-teed Products Corp., Valley^ Forge, Pa. 39 CERTAIN-TEED CG FLUID-TITE Pipe yyyyyyyy y^^yy-y?^ XvXv .vyv^v i mr ill avIvMvX1!' i BOD NOM. SIZE PIPE & CLASS NOM. I.D. 6" - 100 8" - 100 10" - 100 12" - 100 14" - 100 16" - 100 6.00 8.00 10.00 12.00 13.60 15.50 o.d2 B.O.D.** O.D., .02 7.16 9.32 11.46 13.70 15.36 17.50 6.91 9.11 11.24 13.44 15.07 17.15 O.D.| o.d.2 .02 7.07 9.27 11.40 13.60 15.23 17.31 ID. C .06 2.40 2.40 2.40 2.90 3.25 3.25 P +. - .06 .75 .75 .75 1.00 1.00 1.00 6" - 150 8" - 150 10" - 150 12" - 150 14" - 150 16" - 150 5.80 7.80 10.00 12.00 14.00 16.00 7.12 9.32 11.85 14.11 16.41 18.65 6.91 9.11 11.66 13.92 16.22 18.46 7.07 9.27 11.82 14.08 16.38 18.62 2.40 2.40 2.40 2.90 3.25 3.25 .75 .75 .75 1.00 1.00 1.00 IS" - 200 5.70 7.36 8" - 200 10" - 200 12" - 200 14" - 200 7.60 9.60 11.44 13.60 9.68 11.88 14.11 16.44 16" - 200 15.50 18.74 ** Subject to Manufacturing Tolerances. x= 1.50 " .06" 40 6.91 9.11 11.66 13.92 16.22 18.46 7.07 9.27 11.82 14.08 16.38 18.62 2.40 2.40 2.40 2.90 3.25 3.25 .75 .75 .75 1.00 1.00 1.00 aO .02 16 16 16 16 18 18 16 16 16 16 18 18 16 16 16 16 18 18 CERTAIN-TEED CG FLUID-TITE Coupling NOM. SIZE 8. CLASS A .025 Bi .025 6" - 100 8" - 100 10" - 100 12" - 100 14" - 100 16" - 100 7.65 9.85 11.98 14.18 15.95 18.03 7.20 9.40 11.53 13.73 15.39 17.47 b2 .025 7.03 9.23 11.36 13.56 15.20 17.28 B.O.D. 8.40 10.80 13.30 15.55 17.60 19.80 M +.000 -.060 3.50 3.50 3.50 4.50 5.20 5.20 L +.25 -.06 7.00 7.00 7.00 8.00 9.00 9.00 F MIN. .76 .76 .76 .76 .83 .83 G +.030 -.010 .92 .92 .92 .92 1.00 1.00 J +.000 -.040 .42 .42 .42 .42 .42 .42 Ji +.020 -.000 .18 .18 .18 .18 .25 .25 6" - 150 7.65 7.20 7.03 8.76 3.50 7.00 .76 .92 .42 .18 8" - 150 9.85 9.40 9.23 11.32 3.50 7.00 .76 .92 .42 .18 10" - 150 12.40 11.95 11.78 14.36 3.50 7.00 .76 .92 .42 .18 12" - 150 14.66 14.21 14.04 17.00 4.50 8.00 .76 .92 .42 .18 14" - 150 17.10 16.54 16.35 19.80 5.20 9.00 .83 1.00 .42 .25 16" - 150 1 9.34 18.78 18.59 22.28 5.20 9.00 .83 1.00 .42 .25 6" - 200 7.65 7.20 7.03 9.35 3.50 7.00 .76 .92 .42 .18 8" - 200 9.85 9.40 9.23 12.00 3.50 7.00 .76 .92 .42 .18 10" - 200 12.40 11.95 11.78 15.15 3.50 7.00 .76 .92 .42 .18 12" - 200 14.66 14.21 14.04 17.90 4.50 8.00 .76 .92 .42 .18 t 14" - 200 17.10 16.54 16.35 20.50 5.20 9.00 .83 1.00 .42 .25 16" - 200 19.34 18.78 18.59 23.20 5.20 9.00 .83 1.00 .42 .25 Subject to Manufacturing Tolerances. 41 PIPE ADAPTORS PAD 2 SIZE 3 4 8 10 12 14 16 18 20 24 NOMINAL I.D. 2.92 3.73 7.45 8.94 10.98 13.17 15.16 17.34 19.02 22.98 PAD 2 - CLASS 100 Li" 0.5" L2" 0.5" 15 15 15 15 15 19.5 19.5 19.5 19.5 19.5 8 8 8 8 8 11.5 11.5 11.5 11.5 11.5 O.D.1" 3.74 4.64 9.11 11.24 13.44 15.07 17.15 19.90 22.12 26.48 Tolerance O.D.1 and O.D.2, 3" through 24"; 0.020" Note: For 6" Connections use Fully-Machined Pipe O.D.2" 3.96 4.80 9.05 11.10 13.20 15.30 17.40 19.50 21.60 25.80 PAD 3 - CLASS 150 & 200 PAD 3 SIZE 3 8 10 12 14 16 18 20 24 NOMINAL I.D. 2.92 7.45 8.94 10.98 13.17 15.16 16.81 18.15 21.82 Li" 0.5" 15 15 15 15 19.5 19.5 19.5 19.5 19.5 L2" 0.5" 88 8 8 8 11.5 11.5 11.5 11.5 11.5 O.D.1" 3.84 9-11 11.66 13.92 16.22 18.46 20.94 23.28 27.96 Class 200 3 2.92 PAD 3 - CLASS 200 15 8 3.84 For Class 200 Adaptors 3M through 16" only. Tolerance O.D. 1 and O.D. 2, 3" through 24"; 0.020" Note: For 4" and 6" Connections use Fully-Machined Pipe O.D.2" 3.96 9.05 11.10 13.20 15.30 17.40 19.50 21.60 25.80 3.96 42 PAD 5 SIZE 3 4 10 12 14 16 18 20 24 PAD 5 - CLASS 100 TO CLASS 150 & 200 NOMINAL I.D. Li" + 0.0" -0.5" Lz" + 0.0" -0.5" O.D.i" 0.020 2.92 3.80 9.76 11.44 13.30 15.16 17.34 19.63 23.37 15 15 15 15 19.5 19-5 19-5 19.5 19.5 8 8 8 8 11.5 11.5 11.5 11.5 11.5 3.74 4.64 11.24 13.44 15.07 17.15 19.90 22.12 26.48 Note: For 6" and 8" Connections use Fully-Machined Pipe For Class 200 Adaptors 3" through 16" only O.D.2" 0.020 3.84 4.81 11.66 13-92 16.22 18.46 20.94 23.28 27.96 CERTAIN-TEED FLUID-TITE THREADED BRASS INSERT COUPLING TBIC A.W.W.A. THREAD NATIONAL PIPE THREAD (NPT) CLASS 100 OR FT. HD. 225 CLASS 100 OR FT. HD. 225 CLASS 150 OR FT. HD. 325 CLASS 150 OR FT. HD. 325 CLASS 200 OR FT. HD. 450 CLASS 200 OR FT. HD. 450 Size Tap Size Size Tap Size 3" \ 4" 1 m 3" ) t---t nr*k> bo 10" \ 12" J J10" \ 12" Where 2-inch services are required, use an increaser from the 114 The head loss from either tap to 2 is negligible. Tap placement at manufacturers option. or IV2 NPT, p 43 STRAP ClAM** Not Furnished by Certain-teed PRESSURE PIPE COUPLING ADAPTOR FLUID-TITE pipe to ips steel pipe COUPLING SIZE 3 4 6 8 10 12 OR PVC PIPE CAS CLASSES 100, 150, 200 As" 0.025" 4.430 5.520 7.410 9.450 11.550 13.550 Bs" 0.025" 3.560 4.560 6.685 8.685 10.810 12.810 Cs" 0.025" 3.620 4.630 6.765 8.775 10.910 12.920 G ' +0.03" -0.01" 0.625 0.700 0.625 0.625 0.625 0.625 Other Dimensions For other dimensions not shown, refer to standard coupling dimension page 39. Note For excessively oval steel pipe, field reworking of the Bs to the Cs dimension is permitted. How To Connect FLUID-TITE Pipe To Other Pipe, Fittings And Valves All connections marked with an asterisk (*) are with CERTA-SPACER -- All others are Common Groove (CG). "Where No" is indicated, Class 150 pipe should not be used in Class 100 fittings. CNJ f 45 L 4 PRESSURE PIPE COUPLING REDUCER FLUID-TITE pipe to FLUID-TITE pipe COUPLING REDUCER SIZE Class 100 4 to 3 6 to 4 8 to 6 10 to 8 12 to 10 14 to 12 16 to 14 18 to 16 20 to 18 24 to 20 Class 150 4 to 3 6 to 4 8 to 6 10 to 8 12 to 10 14 to 12 16 to 14 18 to 16 20 to 18 24 to 20 Clas s 200 4 to 3 6 to 4 8 to 6 10 to 8 12 to 10 14 to 12 16 to 14 I.D." 3.51 4.5 6 6.60 8.69 11.01 13.19 14.85 16.82 19.64 21.81 3.82 4.56 6.60 8.69 11.47 13.77 16.00 18.00 20.68 22.97 3.82 4.56 6.60 8.69 11.47 13-77 15.50 B.O.D." 5.25 7.16 9.32 11.96 13.70 15.55 17.60 20.30 23.20 27.00 5.55 7.12 9.44 11.85 14.36 17.00 19.80 22.28 25.33 28.22 5.75 7.3 6 9.68 12.00 15.15 17.90 20.50 L" +0.25 -0.00 6.25 6.50 6.50 6.50 7.00 7.75 8.00 8.00 11.10 11.10 6.25 6.50 6.50 6.50 7.00 7.75 8.00 8.00 11.10 11.10 6.25 6.50 6.50 6.50 7.00 7.75 8.00 X" 0.13 3.13 3-25 3.50 3.50 3.50 4.00 4.50 4.50 5.55 5.55 3.13 3.25 3.50 3.50 3.50 4.00 4.50 4.50 5.55 5.55 3.13 3.25 3.50 3.50 3.50 4.00 4.50 I.D. - Subject to Manufacturing Tolerances. Machining Not Required. B.O.D. Tolerance: Up to 10" to 8" Unit; -- 0.150" 12" to 10" Unit and Above; -- 0.200" Machining Not Required. 46 4 4 CONTENTS SECTION I Pages 3 to 9 (Certain-teed Asbestos-Cement Pipe with FLUID-TITE Coupling) High Quality Standards .................................................. 5 Advantages of Certain-teed Asbestos-Cement Pipe . 5 FLUID-TITE Couplings and Rings .......................... 7 Specifying Agencies ......................................................... 10 SECTION II Pages 11 to 15 (Receiving, Unloading, Handling and Storing) Inspection of Each Shipment ........................................ 12 Normal Procedure for Unloading ............................... 13 To Unload Truck or Freight Car ............................... 13 Number of Standard Lengths per Ton ..................... 15 SECTION III Pages 16 to 36 (Installing and Testing) Trenching .............................................................................. 17 Laying Pipe ......................................................................... 18 Pipe Laid on Trench Bottom ................................... 18 Pipe Laid on Earth Pads .......................................... 19 Field Cutting and Machining ........................................ 22 Tapping ................................................................................... 23 Thrust Blocking .................................................................. 24 Bearing Strength of Soils ............................................... 25 Initial Backfill ...................................................................... 26 Temporary Thrust Blocking .......................................... 27 Testing ...................................................................................... 28 Hydrostatic Test ................................................................. 28 Final Backfill .......................................................................... 29 Making Closures and Repairing Pipe............................ 29 Special Installations ........................................................ 31 Casings ...................................................................................... 32 FLOW CHART AND PROBLEM SOLUTIONS Pages 33 to 36 SECTION IV Pages 37 to 47 (Dimensions of pipe, couplings, and adaptors) Certain-teed FLUID-TITE Pipe End with CERTA-SPACER Band ..................................... 38 Certain-teed FLUID-TITE Coupling ............................ 39 CG FLUID-TITE Pipe ................................................... 40 CG FLUID-TITE Coupling .......................................... 41 Pipe Adaptors ..................................................................... 42 FLUID-TITE Threaded Brass Insert Coupling ... 43 Coupling Adaptor FLUID-TITE to Steel Pipe & PVC Pipe ...................................................................... 44 How to Connect Chart ..................................................... 45 FLUID-TITE Pressure Pipe Reducer Coupling ... 47 I < < t