SpecificationsforDuctileIronPipe&Fittings

1OVERVIEW A.General:TheCONTRACTORshallfurnishandinstallductileironpipe,fittingsandallappurtenances, completeinplace,allinaccordancewiththerequirementsoftheContractDocuments.Where standards,specifications,ormethodsarecitedwithoutdates,thereferenceshallbeconstruedtoapply tothelatestrevisionineffectatthetimeofcontract. B.Manufacturer:Theterm"MANUFACTURER"shallmeanthepartythatmanufactures,fabricates,or producesmaterialsorproducts. C.ApplicableStandards: ANSI/AWWAC104/A21.4CementmortarLiningforDuctileIronPipeandFittingsforWater ANSI/AWWAC105/A21.5PolyethyleneEncasementforDuctileIronPipeSystems ANSI/AWWAC110/A21.10DuctileIronandGrayIronFittings,3in.through48in.forWaterand OtherLiquids ANSI/AWWAC111/A21.11RubberGasketJointsforDuctileIronPressurePipeandFittings ANSI/AWWAC115/A21.15FlangedDuctileIronPipewithDuctileIronorGrayIronThreadedFlanges ANSI/AWWAC150/A21.50ThicknessDesignofDuctileIronPipe ANSI/AWWAC151/A21.51DuctileIronPipe,CentrifugallyCastforWater ANSI/AWWAC153/A21.53DuctileIronCompactFittings,324and5464forWaterService ANSI/AWWAC600InstallationofDuctileIronWaterMainsandtheirAppurtenances ANSI/AWWAC606GroovedandShoulderedJoints ANSI/AWSD11.2GuideforWeldingIronCastings D.ShopDrawings/LaySchedules:TheCONTRACTORuponrequestshallsubmitcatalogcutsofpipeand fittingsinaccordancewiththerequirementsofthisSection. 1. Certifieddimensionaldrawingsofallpipes,fittings,andappurtenances. 2. Certifieddimensionaldrawingsofjoints,showingthemanufacturer'sallowabledeflections. 3. Copiesofthemanufacturer'sapprovedinstallationinstructionsforthetypesofjointsbeing used. E.Certifications:UponrequesttheCONTRACTORshallfurnishacertifiedaffidavitofcomplianceforall pipeandotherproductsormaterialsfurnishedunderthisSection,asspecifiedinthereferenced standardsandasspecifiedinSection2QualityAssurance. F.SampleCosts:Allexpensesincurredinmakingsamplesforcertificationofspecifiedtestsshallbe bornebytheMANUFACTURER. 2QUALITYASSURANCE A.ISO/ThirdPartyInspection: ThepipeandfittingMANUFACTURERshallbeISO9001:2000registeredorprovidetheservicesofan IndependentInspectionAgency.ISO9001:2000registrationshallhavebeencertifiedbyaqualifiedISO registrar. B.FactoryHydrostaticTest:Allpipeshallbesubjecttoafactoryhydrostatictestofatleast500psifora periodofnotlessthan10seconds.AllC153fittingsshallbesubjecttoafactoryhydrostatictestofat least350psi.AllC110fittingsshallbesubjecttoafactoryhydrostatictestofatleast250psi. C.Inspection:Allpipesandfittingsshallbesubjecttoinspectionattheplaceofmanufacture,in accordancewiththeprovisionsofthereferencedstandards. D.Tests:Allmaterialsusedinthemanufactureofthepipes,fittingsandspecialsshallbetestedin accordancewithrequirementsasapplicable.

E.TestCosts:TheMANUFACTURERshallperformsaidmaterialtestsatnoadditionalcosttothe OWNER.TheENGINEERshallhavetherighttowitnessalltestingconductedbytheMANUFACTURER, providedthattheMANUFACTURER'sandCONTRACTOR'sscheduleisnotdelayedfortheconvenienceof theENGINEER. F.PlantAccess:Duringthemanufactureofthepipeandfittings,theENGINEERshallbegivenaccessto allareaswheremanufacturingandtestingisinprocessandshallbepermittedtomakeallinspections necessarytoconfirmcompliancewiththeSpecifications. G.Affidavits:UponrequesttheCONTRACTORshallsubmitaffidavitsofcompliancefromthe MANUFACTURERforthefollowing: 1. DuctileironpipeinaccordancewiththerequirementsofAWWAC151andthese specifications. 2. Cementmortarliningofductileironpipe,specials,andfittingsinaccordancewiththe requirementsofAWWAC104andthesespecifications. 3. PolyethyleneencasementforductileironpipinginaccordancewithAWWAC105(if specified). 4. Rubbergasketjointsforductileironpressurepipeandfittingsinaccordancewiththe requirementsofAWWAC111andthesespecifications. 5. Charpyimpacttestingofductileironusedinthemanufactureofpipeshallbeperformedin accordancewithAWWAC151. 6. Lowtemperature impact tests shall be made from at least 10% of the test pipe to assure compliance. H.Warranty:TheMANUFACTURERshallprovidetheOWNERa5yearwarrantyagainstmanufacturing defects. 3DUCTILEIRONPIPE A.Standards:DuctileironpipeshallconformtoAWWAC151,subjecttothefollowingsupplemental requirements.Thepipeshallbeofthediameterandclassshown,shallbefurnishedcompletewith rubbergasketsasindicatedintheContractDocuments.Ductileironpipeshallbemanufacturedor suppliedbyElectrosteelUSA,orequal. B.Markings:UponrequesttheCONTRACTORshallrequiretheMANUFACTURERtolegiblymarkspecials inaccordancewiththelayingscheduleandmarkingdiagram. C.LayingLengths:Pipelayinglengthsshallbeprovidedin18footand20footnominallengthswith allowabletrimpipelengthsinaccordancewithAWWAC151andspecialshorterlengthsprovidedas requiredbytheDrawings. D.DesignParameters:Allductileironpipesshallbedesignedandmanufacturedinaccordancewith AWWAC150andAWWAC151,respectively,forthefollowingminimumoperatingconditions: 1. Theminimuminternaldesignpressureshallbe150psiwitha100psisurgeallowance,witha safetyfactorof2,foratotalinternaldesignpressureof500psi.Noreductionofsafetyfactorfor transientpressuresshallbeallowed. 2. Theexternalloadsdesigncriteriashallbeaminimumof4feetdepthofcoverat120lbs.per cubicfeetsoilweight,andliveloadbasedononeAASHTOH20truckload.Thethicknessdesign ofductileironpipeshallbeinaccordancewithAWWAC150. 3. Thehorizontaldeflectionofcementmortarlinedductileironpiperesultingfromexternalload conditionsshallnotexceedthreepercentofthepipediameter. 4. ThepipetrenchfordesignpurposesshallbenolessthanLayingconditionType2asdescribedin AWWAC150.

5. ForpurposesofrestrainedjointcalculationspertheDuctileIronPipeResearchAssociation (DIPRA)method,thesoilclassification1forboththenativetrenchsoilandalsothebackfillsoilto surroundthepipeshallbedefinedwithoneormoreofthefollowingoptions: 7. GoodSand 4. Silt2 1. Clay1 5. CohesiveGranular 2. Silt1 6. SandSilt 3. Clay2 1. AsdescribedinDIPRA's"ThrustRestraintDesignforDuctileIronPipe,"latestedition. E.MinimumPipeClass:DuctileironpipeshallconformtoAWWAC151.Allpipesshallhaveaminimum pressureratingasfollows: PipeSize(in) Class 4"12" 350 14"20" 250 24" 200 4FITTINGS A.General:FittingsshallbeductileironinaccordancewithAWWAC110,AWWAC153,orAWWAC606, latestrevisions. B.BuriedServiceFittings:Fittings,sizes4"24",withpushon,restrainedpushon,ormechanical jointsshallberatedfor350psiworkingpressure.Fittings,sizes30"64",withpushon,restrained pushon,ormechanicaljointsshallberatedfor250psiworkingpressure. C.AbovegroundServiceFittings:Fittings,sizes4"64",withflangedjointsshallberatedfor250psi workingpressure. 5JOINTDESIGNDUCTILEIRONPIPE,FITTINGSANDSPECIALS A.General:DuctileIronpipeandfittingsshallbefurnishedwithpushonjoints,pushonrestrained joints,mechanicaljoints,flangedjoints,andgroovedjointsasrequired. B.PushonJoints:PushonjointsshallconformtoAWWAC111.Unlessotherwisespecified,gasket materialshallbestandardstyrenebutadienecopolymer(SBR.)PushonjointsshallbePushtite,as manufacturedbyElectrosteelUSAorequal.Thepressureratingforpushonjointsshallbeaminimumof 350psiorthespecifiedpressureratingofthepipe,whicheverisless.Standardallowablejointdeflection for4"24"Pushtitepipeshallbefivedegrees. C.RestrainedJoints:Restrainedjointsshallbe"PushtiteRJ"asmanufacturedbyElectrosteelUSAor equal. D.FlangedJointsPipe:Candidatepipefor4"54"flangedpipethreadfabricationshallbeSpecial ThicknessClass53andfor60"64"flangedthreadfabricationshallbePressureClass350ductileiron pipes,allinaccordancewithAWWAC115.Threadedcompanionflangesforductileironpipeshallbe ductileironinaccordancewithAWWAC115.BoltcircleandboltholesshallmatchthoseofANSIB16.1 class125andANSEB16.5class150flanges.Theflangesshallberatedforatleast250psiworking pressure.Thethreadedflangesshallbeindividuallyfittedandmachinetightenedonthepipeends. Bolts,gaskets,andinstallationshallbeinaccordancewithAWWAC115,AppendixArequirements. Flangedgasketsshallhavearaisedbulbintheseatingareatoassurepropersealing.Flangefacingshall besmoothorwithshallowserrationsperAWWAC115. E.FlangedJointsFittings:FlangefittingsshallbeductileironinaccordancewithAWWAC110or AWWAC153.Theflangesshallberatedforatleast250psiworkingpressure.Bolts,gaskets,and installationshallbeinaccordancewithAWWAC110orAWWAC115,AppendixArequirements.Flange

gasketsshallhavearaisedbulbinthesealingarea.Flangefacingshallbesmoothorwithshallow serrationsperAWWAC110orAWWAC153. F.WeldedonThrustCollars:Weldedonthrustcollars,forwallpipeandpipethrustrestraint,shallbe weldedsteelcollarsdesignedforthethrustgeneratedby250psiworkingpressurewithasafetyfactor ofatleasttwo(2.0)againstfailure.WeldedonthrustcollarsshallbeasmanufacturedbyElectrosteel USAorequal.Themanufacturershallqualifyallweldingproceduresandwelderspertherequirements ofadocumentedqualityassurancesystembasedonANSI/AWSD11.2. G.MechanicalJoints:MechanicaljointsshallconformtoAWWAC111.Boltsshallbehighstrength,low alloysteelperAWWAC111.Unlessotherwisespecified,gasketmaterialshallbestandardstyrene butadienecopolymer(SBR)perthisstandard. 6CEMENTMORTARLINING A.CementmortarLiningforShopApplication:Exceptotherwiseprovidedherein,interiorsurfacesofall ductileironpipe,fittings,andspecialsshallbecleanedandlinedintheshopwithastandardthickness cementmortarliningappliedinconformitywithAWWAC104,Portlandcementmortar.Every precautionshallbetakentopreventdamagetothelining.Ifliningisdamagedorfoundfaultyatdelivery site,thedamagedorunsatisfactoryportionsshallberepairedorreplacedwithliningconformingto theseSpecifications. B.LiningThickness:TheminimumliningthicknessshallbeperAWWAC104,latestaddition. C.SealCoatorNonsealCoatCementmortarLining: AttheMANUFACTURERSoptionandinaccordancewithAWWA104,ductileironpipe,specials,and fittingsmaybesuppliedwithorwithouta1milasphalticsealcoating. 7EXTERIORCOATING A.BuriedDuctileIronPipeandFittings(noncorrosivesoils):Theexteriorofductileironpipe,specials, andfittingsshallbecoatedwitha1milasphalticcoatinginaccordancewithAWWAC151. B.BuriedDuctileIronPipe(corrosivesoils):Corrosioncontrolofductileironpipecanbeaddressedby eitherofthefollowingmethods: Whenspecified,loosepolyethyleneencasementshallbesuppliedandinstalledinaccordance withAWWAC105andM41. Ductileironpipeshallhave1milofzincweldedtoitsexteriorinaccordancewithEN545/ISO 2531.Zincshallbeappliedtoachieveameanmassof130g/m2 minimum (with local minimum of 110g/m2 ). A 3milepoxycoatingshallbeappliedoverthezincsurfacetoprovidemechanical protectionofthezinc.Thisepoxyshallbeprovidedinacolorsuitableforidentifyingthepipefor itsintendedapplication(i.e.blue=potablewater). C.AbovegroundDuctileIronPipeandFittings:Theexteriorofductileironpipe,specials,andfittings shallbecoatedwithoneofthefollowingcoatingsorprimers: AboveGroundExterior(MildExposure) Standard1milAsphalticCoatingperAWWAC151 AboveGroundInterior/ExteriorImmersion/Nonimmersion(MildtoAggressiveExposure) UniversalMoisturecuredUrethaneorMCFerroCladPrimer.CanbetopcoatedwithNSF61 certifiedcoatingswhereNSF61complianceisrequired.Shopcoatthickness:3.05.0milsdry filmthickness.