7. Rubber Gasket Joints that it is not cut or damaged, the piperelaid, and the gasket position againchecked.

encase the outside joint except for anopening near the top where mortargrout is to be poured into the jointrecess.

8. Irlside Joint Recess

After the band is properly secured, thejoint recess shall be moistened with waterand then filled with mortar consistingof 1 part Portland cement to 2 partsof sand mixed with water to theconsistency of thick cream. The mortargrout shall completely fill the outsideannular space between the ends of thepipe and around the completecircumference. After the recess has beenfilled, the opening shall be clo~d and themortar allowed to ~t before bedding andbackfilling at the joint.

7.1 Before AssemblyBefore joining the spigot into the bell ofthe pipe previously laid. the spigotgroove, the rubber gasket and the bellshall be thoroughly cleaned. Then thespigot groove, the rubber gasket and thefirst 2 inches of the bell shall be lubri-cated with a soft, vegetable soapcompound. Gasket shall be positionedin spigot groove so that the rubber isdistributed uniformly around thecircumference.

Note: Uniform distribution of gasket may beaccomplished by passing a smooth, round steelrod under gasket and up onto opposite edge ofgasket groove, then moving the rod in thisposition around the entire circumference ofthe spigot.

8.1 Pipe, 21-lnch Diameter and SmallerPrior to assembling the joint, the insideshoulder of the bell shall be "buttered"with a stiff mortar consisting of 1 partPortland cement to 1 '12 parts of sand.An accessory such as a specially designedrubber ball wrapped with burlap shallbe used (1) to provide back-up againstwhich the mortar is squeezed while thecentered spigot is pushed "home" and(2) to hold mortar in place in theassernbled joint while alignment andgrade are adjusted, the next bell is"buttered" and the next spigot iscentered. The accessory shall screed offexcess mortar to leave a smooth andcontinuous surface between pipe sectionsas it is drawn through the pipe.

7.2 AssemblyPipe shall be joined together to providethe proper space between abutting endsof pipe. To maintain the laying lengthshown on the contract drawings, thewidth of the space provided at the jointmay be varied to compensate for thepermissible manufacturing tolerance inpipe lengths of plus or minus % inch.In pipel ines 24 inches and larger, metalor wooden spacers shall be placed againstthe inside shoulder of the bells. Joints insmaller pipelines shall be prepared inaccordance with Section 8.1.

9.2 Asphalt or Coal-Tar Wrapped PipeAfter the joint has been properlyassembled, areas to be coated shall bethoroughly cleaned. An asphalt orcoal-tar wrap shall then be applied inaccordance with the recommendations ofthe pipe manufacturer. Coal-tar coatedfield joints shall be inspected as requiredby Section 2.14.3.5 of "Coal-Tar EnamelProtective Coatings and Linings forSteel Water Pipelines-Enamel and Tape-'-Hot Applied" (ANSI/AWWA C203).

8.2 Pipe, 24-lnch Diameter and LargerAfter the pipe zone bedding and backfillhave been densified, the inside jointrecess of pipe 24 inches in diameter andlarger shall first be moistened, thenfilled and pointed with a stiff cementmortar consisting of 1 part cement tolY. parts of sand. The finished joint shallbe smooth and flush with the adjacentpipe surfaces. Interior joint pointingoperations shall not be conducted withintwo joints of pipe laying operations.

10. Anchorage for Bends and FittingsWhere indicated on the contractdrawings, suitable means of anchoring thepipeline against movement shall beprovided. Details of anchorages shall beas specified by the engineer or assubmitted by the contractor andapproved by the engineer. Anchorageof the pipeline may be provided bycasting concrete thrust blocks or byfield-welding joints.

For long radius curves and for slightchanges or correction in alignment andgrade, joints may be pulled on one sideof pipe and most joint designs may bepartially closed on opposite side. Theamount of deflection must not exceedthat recommended for the type ofjoint being used.

9. Exterior Joint Recess

10.1 Concrete Thrust BlocksConcrete blocking shall be cast-in-placebetween undisturbed earth-bearingsurfaces and the fitting or bend to beanchored. Should any sloughing of the

*Plastic bands are closed-cell polyethylene foam excavation sides OCCUr, additionalstrips with cloth backing and are recommended t . d ft .

ng thef ed -' ... I I .concre e require a er removior ,mprov Joint protection, partlcu ar y In

aggresive soils. Additional information will loose earth shall be placed at thebe supplied on request. contractor's expense. Blocking shall,

7.3 After AssemblyAfter a joint is assembled, a thin metalfeeler gauge shall be inserted between belland spigot and the position of the rubbergasket checked around the completecircumference of the pipe. If gasket isnot in proper position, the pipe shallbe withdrawn, the gasket checked to see

9.1 Mortar Coated PipeAfter joining mortar coated pipe, a clothor plastic* band at least 8 inches inwidth shall be centered and secured overthe exterior joint recess. The band shallbe bound to the pipe by the use ofsteel box strapping or by an equivalentmethod and shall completely and snugly

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"Standard Test Method for RelativeDensity of Cohesion less Soils" (ANSI/ASTM C' 2049).

unless otherwise shown or directed, beso placro that joints of pipe and fittingswill beoccessible for repair.

Note: In this specification, a "cohesion lessfree-draining soil" is defined as a soil whosedry density in pounds per cubic foot at 70percent relative density is greater than its drydensity at 90 percent of laboratory standardmaximum dry density.

10.2 Field-Welded JointsWhere specifically permitted on thedrawings, or approved by the engineer.the contractor may substitute field-welded joints capable of withstandingaxial tension in place of. or in conjunctionwith. the regular rubber gasket joints.

water. Twenty-four hours before cappingand testing, cylinder shall be removedfrom water and allowed to drain and airdry. The average diameter of thecylinders used for calculating the cross-sectional area shall be determined beforethe cylinders are immersed in water.Cylinders shall otherwise be tested inaccordance with "Standard Test Methodfor Compressive Strength of CylindricalConcrete Specimens" (ANSI/ASTMC39).

12. Soil Cement Grout

Bedding and Backfill12.1 MaterialsSoil cement grout shall consist of amixture of properly selected soil.Portland cement and water. Portlandcement shall conform to the "StandardSpecification for Portland Cement"(ANSI/ASTM C 150), Type lor II.unless otherwise specified. The minimumcement content shall be two sacks (94pounds per sack) per cubic yard.

12.2 Mixing and PlacingSoil cement grout shall be thoroughlymixed and the presence of lumps, clodsor foreign matter shall be minimized.Water added in the mixer shall not exceedthat required to insure a fluid, readilypumpable mixture. Grout shall be placedin lifts on both sides of pipe in a mannerthat will prevent floating or shifting ofpipe. Light poling or vibration will bepermitted. Soil cement grout may notbe placed if the ground is frozen or theambient temperature is below 40 degreesFahrenheit.

11. Pipe Zone Bedding and BackfillPipe installation shall be classified asE'=400. E'=700, E'=1000, or Soil CementBedding along the entire reach of thepipeline as shown on the plans anddrawings. Bedding and backfill shallbe densified around the pipe to the heightover top of pipe as shown in Figure 1.

Soil may be any combination of gravel,sand, silt and clay, native or imported,which meets the following requirements:

Soils shall be blended sufficiently tosecure t~ best practicable degree ofdensity,.)d stability.

12.1.1 Not more than 10 percent of thematerial by weight shall be larger than314 inch, and none of the material shallbe larger than one inch.

Within 1 hour after placement, soilcement grout shall be covered with amaximum of 6 inches of damp earth.Pipe zone backfill may not be completeduntil 24 hours after placement of grout.Fill material shall not be dropped directlyon the pipe.

The dry oonsity of compacted soil foreach bedding and backfill shall be notless than shown in Figure 1.

Soil densities are expressed as a percentof the Icjx)ratory standard maximum drysoil density as determined in accordancewith "Sta'ldard Test Methods forMoisture-Density Relations of SoilsUsing 5.5-lb Rammer and 12-in. Drop"iASTM Designation: D 698 or AASHTODesignation: T 99).

12.1.2 The soil fraction passing theNo. 200 sieve shall, in combination withthe cement, be sufficient to insure thatthe soil remains in suspension while themixture is being placed.

12.1.3 Materials which containconsiderable amounts of organic mattershall not t>e used.

tn-place tests of soil density shall be madewn accordance with "Standard TestMethod for Density of Soil in Place bySand-C~ Method" (ASTM Designation:U 1556) or "Standard Test Method forDensity of Soil in Place by the Rubber-Balloon Method" (ANSI/ASTM D 2167).

13. DensificationRegardless of the method of densificationused, materials shall be brought up atsubstantially the same rate on both sidesof the pipe and care shall be taken so thatthe pipe is not floated or displaced.Fill material shall not be dropped directlyon the pipe.

Soil cement and water shall be soproportioned that the minimumcompressive strength will be at least 50psi at seven days as determined on twocompanion cylinders taken twice duringeach working shift. Material poured intocylinder molds shall not be vibc.ated or

tamped.

Forty-eight hours before testing,cylinders shall be totally immersed in

Cohesionk!ss free-draining soils shall beclassified ~ E'=700 and shall beconsolidated to 70 percent relativedensity when tested in accordance with

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3. Pipe zone backfill height over top of pipe (HT) shallbe at least % pipe inside diameter for pipe larger than24 inches, and 6 inches for pipe 24 inches or smaller.

4. E' values shown are Spangler's Modulus of SoilReaction.

5. Trench sides may remain vertical or may be sloped asrequired. See Section 1.

Pipe Zone Bedding and Backfill Classifications

Notes:1. Soil densities are expressed as a percent of maximum

dry soil density as determined by ASTM Designation:D 698 or AASHTO Designation T 99.

2. Backfills require that the contractor prepare a firm but

yielding subgrade.

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methods shall not distrub pipe zonebedding and backfill. Cohesive materialsshall be compacted with tamping or

rolling equipment. To prevent excessivelive loads on the pipe, sufficient densifiedbackfill but not less than 3 feet over thepipe shall be in place before power-operated hauling or rolling equipmenttravels over the pipe.

performed until a satisfactory test hasbeen completed. Regardless of the testresults, all detectable leaks shall berepai red by the contractor.

References

1. ..A Method of Determining PermissibleEarth Cover Loads on Concrete CylinderPipe." Ameron Engineering LibraryNo. 1-1.

13.1 Mechanical Col11>actionSoils identified as cohesive shall bedensified by compaction usingmechanical or hand tamping. Equipmentwith suitably shaped tCMnping feet shallbe used to compact the material andinsure that the ~ecified soil density isobtained beneath the haunches of thepipe. All material shall pass a .1 Y2-inchscreen and not more than 50 percentshall pass a No. 200 sieve. At the time ofplacement, the materials shall have theoptimum moisture content requ ired forcompaction, and the moisture contentshall be uniform throughout each layer.Materials shall be placed in layers notmore than 6 ind1es thick after

compaction.

Mobile pavement breakers or pile-drivingequipment shall not be used forcompacting backfill at any stage of theoperations.

2. "Guide Specifications for Installationof Concrete Pressure Pipe, RigidDesigns," Ameron.

Testing

3. Lowitz, C. A. and DeGroot, G., "Soil-Cement Pipe Bedding: Canadian River

Aqueduct," Proceedings, AmericanSociety of Civil Engineers, Journal,Construction Division, 94, C01, January,1968.

15. Hydrostatic Field TestsTest sections and test pressures shall beplanned so that during the field test nopipe section will be subjected to apressure less than 100 percent or morethan 120 percent of the actual operatingpipeline pressure.

Prior to testing, the section of thepipeline to be tested shall be filled withwater and placed under a slight pressurefor at least 48 hours. The pipeline shallthen be brought up to the test pressuredetermined by the engineer and thatpressure shall be maintained on thesection under test for a period of notless than 4 hours. Accurate means shallbe provided for measuring the quantityof water required to maintain fullpressure on the line for the test period.The volume of water required to maintainthe test pressure shall not exceed. ..*gallons per inch of diameter per mile ofpipe per 24 hours.

4. Chappelear, D. L. and Gloyna, E. L.,"Innovations in the Laying and Beddingof Pipe," Civil Engineering-ASCE,

December, 1967, pp. 57-60

13.2 Hydraulic ConsolidationSoils identified as free-draining may bedensified by tamping or by consolidationwith water using any or all of thefollowing devices or rTW!thods: water jets,immersion type vibrators, bulkheadingand flooding, or sluicing. Consolidationof earth materials by hydraulic methodsshall be used only if both the materialsto be densified and the native soil inwhich the trend1 is excavated are freedraining. Materials shall pass a 1 Y2-inchscreen and not more than 15 percent shallpass a No. 200 sieve. The thickness oflayers shall not be more than thepenetrating depth of the vibrators jfconsolidation is performed by jetting andinternal vibration.

In the event that the rate of loss of waterduring the test is greater than that statedabove, the contractor shall locate theleaks and perform the required repairs.If necessary, additional tests shall be

14. Backfill Above Pipe ZoneTrench backfill above the pipe zonebedding and b;K;kfill to the surface of thenative ground shall be placed so that theresulting density will be approximatelyequivalent to the density of the originalmaterial in which the trench wasexcavated. Trench backfill shall not beplaced until conform~ce of pipe zonebedding and backfill with specifiedcompaction test requirements has beenconfirmed. Free-draining materials maybe densified by hydraulic methods ifthe native soil in whim the trench wasexcavated is also free-draining but such

.Since pipeline leakage is dependent on manyfactors. allowable values vary. Recommendedrequirements for specific designs may beobtained on request. A value of 50 gallons iscommonly used for pressure pipe with steelcylinder and rubber gasket joint.

6

To insure long life and trouble-freeservice from a successful pipelineinstallation, proper application by thecontracting agency of the essentialprinciples of excavation, laying andjointing, bedding, backfilling and fieldtesting is required. It is equally essentialthat these principles be reflected in thephrasing of contract documents and thatthe agency enfor~ them through itsinspection.

specification should be properlyadministered and enforced by thecontracting agency, there is noassurance-specific or implied-thatinclusion of these paragraphs in aspecification will insure a successful job,however, they should assist materiallyin accomplishing this objective.

The recommended practices presentedin this guide specification for theinstallation of rubber gasketed, cement-mortar lined pressure pipe, ranging fromsemi-rigid to flexible, are developed fromthe two basic concepts outlined below.80th should be rigorously maintainedto obtain best results.

First, each section of pipe should bekept substantially round duringunloading, storage and throughoutbackfilling operations. Properlyembedded pipe will remain essentiallyround because of the passive resistanceof the soil on its sides and the uniformsupport of the bedding. As the degreeof pipe flexibility increases, structuralbehavior becomes more dependent onthe supporting value of the pipe zonematerial.

Second, the manufacturer's recom-mendations for assembling pipe sectionsand completing joint protection shouldbe enforced. Rubber gaskets should bestretched uniformly when in positionon spigots; joint surfaces and gasketshould be clean and well lubricated;entry of spigot end into bell of adjacentpipe section should be performed withreasonable care; position of the gasketshould be checked after joint closure;and inside and outside annual jointrecesses should be correctly filled withcement mortar.

These specifications are intended to beused as a guide and should be amendedand expanded to meet the requirementsof a specific job. Because any

7

Scope the pipe be installed permanently ontimbers, earth mounds, pile bents orother similar supports unless specific pipedesigns which are adequate for theseabnormal conditions are provided bythe engineer.

This specification covers the usualprocedures involved in the installation ofmortar-lined pressure pipe, includingexcavation, laying, jointing, bedding,backfilling and testing. Th is specificationdoes not cover sheeting or bracing oftrenches, restorations required, specialobstructions or conditions, or generalcon tractu ra I obligations.

Laying and Jointing

2.2 Subgrade for Soil Cement BeddingTrenches for pipe which is to be beddedwith a soil cement grout shall beexcavated to the depth and shapeindicated on the contract drawings. Allloose material shall be removed from thetrench.Note: The radius of the cradle excavationshould be sufficient to provide at least a 2-inchspace between pipe and subgrade for adequateplacement of the soil cement grout.

3. Special Subgrade DensificationExcavation and Subgrade

1. Trench WidthThe narrowest practicable trench widthat top of pipe which will allow properdensification of pipe zone bedding andbackfill materials shall be maintainedregardless of the type of soil in whichthe pipeline is to be laid, the depth ofthe excavation or the method ofdensification. If sides of the trenchremain vertical after excavation, andbedding and backfill are to be consoli-dated by hydraulic method, the minimumwidth of trench at top of pipe shall be 00plus 16 inches. If the pipe zone beddingand backfill require densification bycompaction, the width of trench atbottom of pipe shall be determined bythe space required for proper andeffective use of tamping equipment,but not less than pipe 00 plus 16 inches.

3.1 Unyielding MaterialWhere excavation is in rock, hardpan,shale or other similar hard and unyieldingmaterials, the trench shall be excavatedto a depth at least 4 inches below theestablished grade line and filled with well-densified material* to a depth 1 inchbelow the grade line. The subgrade shallthen be completed with 1 inch of looseselected materials as described inSection 2.1.

5.

LayingThe pipe shall be laid to the lines andgrades shown on the contract drawingsexcept as amended and supplementedby the manufacturer's tabulated layoutschedule and approved by the engineer.The work shall be scheduled so that thebell end of the pipe faces in the directionof laying wherever practicable. Whenlaying pipe, the pipe trench shall bekept free from water which might impairthe integrity of bedding and joiningoperations. Pipe sections to be beddedwith soil cement grout may be laid tograde using mounds of a free-drainingsoil near each end for temporary support.

3.2 Unstable MaterialWhen excavation is in soft, unstablematerial which is unsuitable as afoundation for pipe. such material shallbe removed as directed by the engineerand replaced with well-densified materialto a depth 1 inch below the establishedgrade line. The subgrade shall then becompleted with 1 inch of loose selectedmaterial as described in Section 2.1.

2. Normal SubgradeThe contractor shall prepare a subgradewhich will provide continuous, uniformsupport under the haunches of the pipeafter bedding and backfilling.

3.3 Non-Uniform MaterialVoids formed by removal of boulders orother interfering objects extending belowilormal excavation limits shall be filledwith suitable, well-densified material.

5.1 Handling and StorageHandling and storage of pipe shall be inaccordance with the recommendationsof the manufacturer. All necessaryprecautions shall be taken to maintainthe protection afforded by the lining andcoating. The pipe shall at all times behandled using proper equipment andmust never be pushed or dragged alongthe ground. Pipe shall further be handledand stored so that the dimensionalintegrity of joint configuration androundness of pipe are assured. Thedielectric resistance of asphalt or coal-tarcoatings shall be preserved by carefulstorage and handling, including slings andsupports padded as necessary.

4. Special SupportSpecial means of support may beprovided but under no conditions shall 6. Interior Bracing of Pipe

Design, installation and performance ofpipe bracing used during installationshall be the responsibility of thecontractor. Use of bracing placed whollyor in part by the manufacturer shall notrelieve the contractor of thisresponsibility.

*In this specification, "well-densified material"is defined as that which is densified to at least85 percent of the laboratory standardmaximum dry soil density as determined byASTM Designation: 0698, or at least 70percent relative density in free-draining soilsas determined by ANSI/ASTM 02049 (seeSection 11).

2.1 Flat Bottom TrenchesFlat bottom trenches shall be excavatedto a depth not less than 1 ind1 below theestablished grade line of the outsidebottom of the pipe. The exressexcavation shall then be filled with loosebank run material from whiffi all stoneslarger than 1 ind1 in diameter have beenremoved. This loose subgrade materialshall be graded uniformly to theestablished grade line for the full lengthof the pipe.

2