1.

0 Scope
1.1 This procedure covers the materials and methods to be used in the shop lining and field joining of cement-lined
pipe for the Purchaser.
1.2. This procedure does not cover installed steel pipe.

2.0 Introduction
2.1. All cement-lined pipe shall meet the requirements of AWWA C205-12, “Cement–Mortar Protective Lining
and Coating for Steel Water Pipe—4 in. (100 mm) and Larger—Shop Applied”, except as modified by this
procedure.

3.0 References

3.1 American Petroleum Institute (API)

API Spec 5L Procedure for Line Pipe
3.2 American Water Works Association
AWWA C602, “Cement-Mortar Lining of Water Pipelines in Place
AWWA C205-12, “Cement–Mortar Protective Lining and Coating for Steel Water Pipe
3.3 ASME International (ASME)
ASME B31.3 Process Piping
4.0 General

4.1 Material selection and cement lining application.

Material selection and cement lining application supply and shall meet the requirements of HQSM

4.2 Pipe requirements.

4.1.6.1 Minimum wall thickness shall be 0.156 inch (3.96 mm) for NPS 4 and smaller pipe and 0.188 inch (4.78
mm) for NPS 6 pipe.
Thicker wall pipe is stiffer and less likely to bend and crack or damage cement linings.

4.1.6.2 Only new pipe shall be used. Used pipe shall not be used unless accepted by the Purchaser in writing.
Only new pipe is permitted for quality assurance reasons.

4.1.6.3 All pipe shall be straight to within 1/8 inch per 10 feet of pipe length. Any pipe with “doglegged” ends
shall be straightened.
If the pipe is not straight, it will wobble and vibrate during spinning. This requires the spinning speed to be slowed
and the lining to be less dense.
Doglegged ends are straight pipe with a bent end. Sometimes the last 3 or 4 feet (.91 or 1.22 m) are bent. These
can and must be straightened.

4.1.6.4 Maximum out-of-roundness, as the difference between maximum and minimum diameters, should not
exceed 1/32 inch (0.8 mm) or 0.5 percent of the nominal outside diameter (OD), whichever is larger. Out-of-round
pipe should be set aside and appropriately marked.
Sec. 4.2 Material

4.2.2 Portland cement.

4.2.2.1 Type Portland cement shall conform ASTM C-150, latest revision. By using the guidelines below,
Purchaser shall specify Type I, Type II, Type III, or Type V.

4.2.2.1.1 Type I shall be used for fresh water, where sulfate levels are below 200 ppm.

4.2.2.1.2 Type II shall be used for moderately sour water, where sulfate levels are below 1500 ppm.
4.2.2.1.3 Type III with less than 3 percent tricalcium aluminate shall be used where sulfate levels are above 5000
ppm.

4.2.2.1.4 Type V with less than 5 percent tricalcium aluminate shall be used for moderately high sour water, where
sulfate levels are below 5000 ppm.

Sulfates attack cement linings by reacting with the cement and forming products that occupy a greater volume
than the original cement. This causes the lining to crack and spall, leading to eventual failure.
Lining failure is avoided by using sulfate resistant Types III and V cement with limits placed on the amount of
tricalcium aluminate (C3A) in the cement. The engineer must know the sulfate level before specifying the type of
cement.
Sec. 4.3 Cement–Mortar Lining

4.3.1 General.

The minimum temperature for the wet mix shall be maintained at not less than 50°F (10°C), and the maximum
temperature should not exceed 90°F (32°C). Cement mix shall not be placed in pipe when the ambient temperature
is less than 40°F (4°C).

4.3.2 Thickness.

The minimum lining thickness shall be 3/16 inch (4.76 mm) for NPS 4 and smaller pipe and 1/4 inch (6.35 mm)
for NPS 6 pipe.

The cement lining must be at least 3/16-inch (4.76 mm) thick for gaskets to have sufficient bearing area on the
lining at the joints.
Sec. 4.4 Joining of Cement Lined Pipe

4.4.1 General.

4.4.1.1 The methods for joining of cement lined pipe in this section shall be applicable for nominal pipe sizes from
2 to 24 inches (50.8 to 609.6 mm).

4.4.1.2 All pipes, fittings, elbows, tees, etc., shall be in accordance with appropriate pipe class.

4.4.1.3 For valve connections, cement lining shall not interfere with valve operation.

4.4.1.4 A joint sealing compound such as X-Pando Pipe Joint Compound Special No. 2™ or equivalent shall be
used to seal cement joints.

4.4.1.5 If piping cannot be entered, excess joint sealing compound shall be cleaned from the internal pipe walls by
pulling a “poly pig join swab”, commonly referred to as a “pig on a rope”, through the joined pipeline segments.
4.4.2 Weld Requirements.

4.4.2.1 All pipe welds shall meet the latest edition of the applicable design code.

4.4.2.2 All welds shall be performed by qualified welders to a qualified weld procedure. Contractor shall submit
qualified weld procedures to Purchaser for review.

4.4.2.3 All fillet welds on sleeves shall be visually inspected.

4.4.2.4 All pipe and fitting full penetration butt welds shall be 5 percent random radiographed for acceptance.
Cement lined pipe shall not be joined by full penetration butt welds.
4.4.2.5 All piping sections to be fabricated by Contractor per Purchaser drawings shall be hydrotested by
Contractor when specified on the Purchaser drawings after installation.
Cement lining may absorb water during hydrostatic testing.
4.4.3 Butt Weld.

4.4.3.1 Partial penetration butt welding shall be the preferred method for joining cement lined pipe for non-water
service applications.

4.4.3.2 The ends of the pipe shall be beveled leaving a 1/16-inch (1.59 mm) landing area to line up the pipe.

4.4.3.3 Edges of the cement lining shall be smoothed and joint sealing compound (e.g., X-Pando Special No.2)
shall be applied to cement lining face.
4.4.3.4 A (E7018) shall be used. See Figure 1 for an example of a butt weld.

Figure 1: Butt Weld

4.4.4 Sleeves.

4.4.4.1 Sleeves may be used for joining pipe fittings, other fittings, and pipe as needed.
4.4.4.2 Sleeves shall be fillet welded to pipe fittings and piping on outside only.
4.4.4.3 Minimum size of fillet weld (leg) shall be 1.25 times nominal pipe thickness.
4.4.4.4 Sleeve width shall be 6 inches (152.4 mm).
4.4.4.5 Thickness of sleeve shall be 3/8 inch (9.52 mm) or thickness of pipe, whichever is greater. Figure 2 shows
details on the joint elements.
Figure 2:
4.4.5 Slip-on Flanges.

4.4.5.1 When a flange is required, a slip-on flange shall be used. It may be used for connections to appurtenances
such as valves, fire monitors, hydrants, etc.
4.4.5.2 Slip-on flanges shall be fillet welded at hub on outside and on inside to pipe with minimum size of fillet
weld (leg) to be 1.25 times nominal pipe thickness. Refer to Figure 4 for details on the slip-on flange joint
elements.

Figure 4: Slip-On Flange Joint Details

4.4.5.3 The practice for a welded slip-on flange joint for cement-lined pipe shall be as follows:
1) Cut pipe ends square. Finish grind to square profile as needed.
2) Fillet weld slip-on flanges to pipes using 1/8-inch (3.18 mm) E7018 electrodes.
3) Apply joint sealing compound from cement lining until almost flush with face of flange. Thickness of joint
sealing compound shall match ID of pipe cement lining. Check to be sure that joint sealing compound will not
interfere with proper seating of gasket. Gaskets shall be in accordance with appropriate pipe class.
4) When making up flanges, brush anti-seize compound (NOT joint sealing compound) on flange faces, then insert
gasket and bolt flanges together.
5) After flange is made up, fill gap with cement lining to cover exposed metal. Contour cement lining inside of slip
on flange with a smooth radius. Applied cement lining thickness shall equal ID of pipe. If unable to fill gap with
cement lining, cover exposed metal with joint sealing compound before flanges are bolted together.
6) Pipe may be put into service as soon as joint sealing compound has cured.
4.4.6 Branch Joints.

4.4.6.1 For branch joints, weld-o-let type connections shall be used. See Figure 5 for branch joint details.
Figure 5: Branch Joint Details

4.4.6.2 The practice for a welded branch joint for cement-lined pipe shall be as follows:
1) Interior of joint shall be readily accessible through either the main or branch pipe for application of cement joint
sealing compound after weld is complete
2) Hole for connection in a main pipe may be machine-made or torch-cut. Avoid breaking out more cement than
indicated in sketch.
3) Trim and bevel branch pipe to fit-up for full penetration weld. Avoid breaking out more cement than in Figure 5
4) Make full penetration weld using 1/8-inch (3.18 mm) E7018 electrodes.
5) Apply joint sealing compound so that bare pipe and lining ends are fully covered and well packed. Contour joint
sealing compound inside main pipe connection point with a smooth radius. Applied joint sealing compound
thickness should equal ID of cement lining.
6) Pipe may be put into service as soon as joint sealing compound has cured.