American Water Works Association ANSI/AWWA 203-86 Revision of AWWA C203-78) AWWA STANDARD FOR COAL-TAR PROTECTIVE COATINGS AND LININGS FOR STEEL WATER PIPELINES—ENAMEL AND TAPE—HOT-APPLIED wena |Get Me. = ANSI /AWWA STO ee. Wo. 0205 /IKPT.STD/AY |” Date 213: JUN 8 Min 0205 First edition approved by AWWA Board of Directors April 25, 1940. This edition approved Fan, 26, 1986. Approved by American National Standards Institute, Inc., May 30, 1986. AMERICAN WATER WORKS ASSOCIATION 6666 West Quincy Avenue, Denver, Colorado 60235AWWA STANDARD ee ‘This document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standards describe minimum requirements and do not contain all of the engineering and administrative information normally contained in specifications. The AWWA standards usually contain options that must be evaluated by the user of the standard. Until each optional feature is specified by the user, the product or service is not fully defined. AWWA, publication of a standard does not constitute endorsement of any product or product type, nor does AWWA test, certify, or approve any product. The use of AWWA standards is entirely voluntary. AWWA standards are intended to represent a consensus of the water supply industry that the product described will provide satisfactory service. When AWWA revises or withdraws this standard, an official notice of action will be placed on the first page of the classified advertising section of the Journal AWWA. The action becomes effective on the first day of the month following the month of Journal AWWA publication of the official notice. AMERICAN NATIONAL STANDARD ‘An American National Standard implies a consensus of those substantially concerned with its scope and provisions. An American National Standard is intended as a guide to aid the ‘manufecturer, the consumer, and the general public. The existence of an American National ‘Standard does not in any respect preclude anyone, whether he has approved the standard or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standard. American National Standards are subject to periodic review, and ‘users are cautioned to obtain the latest editions, Producers of goods made in conformity with an ‘American National Standard are encouraged to state on their own responsibility in advertising ‘and promotional material or on tags or labels that the goods are produced in conformity with particular American National Standards. CAUTION NOTICE: The ANSI approval date on the front cover of this standard indicates completion of the ANSI approval process. This American National Standard may be revised or withdrawn at any time. The procedures of the American National Standards Institute require that ‘action be taken to reaffirm, revise, or withdraw this standard no later than five years from the date ‘of publication, Purchasers of American National Standards may receive current information on alt | standards by calling or writing the American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018 (212) 354-3300. Copyright ©1966 by American Water Works Association Printed in USAsR eq, t Tr iner's “ananth? . Committee Personnel The AWWA Standards Committee on Steel Pipe, which reviewed and approved this standard, had the following personnel at the time of approval: RD. Dickson, Chairman CM. Frenz, Vice-Chairman GJ. Tupac, Secretary Consumer Members J.A. Batt, Denver Water Board, Denver, Colo. (awwa) G.E. Block, South Central Connecticut Regional Water Authority, New Haven, Conn, (NEWWwaA) RS. Bryant, Department of Water and Power, Los Angeles, Calif. (AWWA) D.J. Cowling, US Bureau of Reclamation, Denver, Colo. (BUREC) J.L. Doane, Portland Bureau of Water Works, Pordand, Ore. (AWWA) CM, Frenz, Monroe County Water Authority, Rochester, N.Y. awwa) R.C. Moehle, Metropolitan Water District of Southern California, Los Angeles, Calif. (AWWA) K. Olson, Department of Public Utilities, Tacoma, Wash. (AWWA) E.C. Scheader, New York City Department of Environmental Protection, New York, N.Y. (awwa) General Interest Members GJ. Arch, Arch Consulting Service Inc., West Covina, Calif (AWWA) W.R. Brunzell, Alvord, Burdick & Howson, Chicago, Ill (AWWA) WLH. Cates, Consulting Civil Engineer, Monrovia, Calif. (awwa) RD. Dickson, James M. Montgomery Consulting Engineers, Pasadena, Calif. (awwa) L.J, Farr, CH2M Hill, Inc., Redding, Calif. (AWWA) RE, Gilmor, Riland Corporation, Denver, Colo. cawwa) GK. HicRox, Engineering Consultant, Houston, Texas, (aWs) G.D. Plant, Consulting Engineer, Napa, Calif. (awwa) L.T. Schaper, Black & Veatch, Kansas City, Mo. (awwa) D.C. Schroeder, Santa Ana, Calif. : (awwa) George Tupac, George Tupac and Associates, Pittsburgh, Pa. (awwa) W.W. Webster, Gordon Herkenhoff & Associates, Inc., Albuquerque, N.M. (AWWA) K.G. Wilkes, Escondido, Calif. (awwa) M.Y. Yoshii, Bechtel Energy Corporation, Memphis, Tenn. (AWWA) Robert Young, SPINK Engineering Corporation, Sacramento, Calif. (AWWA) Producer Members A.D, Harder, Ameron Pipe Division, Portland, Ore. cawwa) C.R, McCormick, Conduit Fabricators, Fairfield, Calif (SPFA) IR. Pegues, American Cast Iron Pipe Company, Birmingham, Ala. (MSS) HLR. Stoner, Koppers Company, Newark, N.J. cawwa) R.F. Strobel, 3M Company, St. Paul, Minn. cawwa) JA. Wise, Shaw Pipe Protection (Pacific), Ltd., Vancouver, B.C. cawwa)Contents SEC. PAGE SEC. PAGE Foreword 35 2 I History of Standard ty _ = IL Metrication Eves gta yacaiey ; 7 WII Information Regarding Use of Settee Hite ea Seine ras civ ¥ 3.10 Electrical Inspection... +24 YE Nea erent ve "3.1 Coating Repair... . 24 Standard 3.12 Manufacturer's Tests for arisen Physical Properties . oS LL Scope «-++.-+ eet 4 Handling, Transporting, and 1.2 Conditions Not Covered in Field Procedures This Standard .......+ 1 4.1 Handling and Transporting 1.3. References . U Enameled Pipe ...++.+++ 1.4 Definitions..... 3 4.2 Field Procedures .. 15 Materials and Workmanship - 3 43. Welded Field Joints—Lining 1.6 Affidavit of Compliance .. 3 and Coating : 1.7 Equipment......+-++++ 3 44° Mechanical Couplings ........ 18 Packaging and Marking ....... 3 45 Beckfilling : 2 Coal-Tar Enamel, Hot-Applied ‘ 21 General... ..csees Appendis 2.2 Inside Pipe.....+++ A Additional Protective Coatings, 23 Outside Pipe Wraps, and Procedures 24 Primers..... Al General . 2.5 Coal-Tar Enamels. ALLL Scope . 2.6 Contractor's Samples and Detailed ALL2 Coal-Tar Enamel and Bonded Information .. : .3 Double Asbestos-Felt or Other 27 Inspection, Testing, and Rejection -... 5 Performance-Comparable 2.8 Test Procedures for Primers and Outerwrap ...c.eeeee 29 Enamels (Laboratory Only)... 6 A.L3 Sand Shield : +29 29. Field-Bond Test Procedure for Primer A.14 Reinforced Cement-Mortar Shield... 29 and Enamel oe = 10 A.L5 Coal-Tar Enamel, Glass-Fiber Mat, 2.10 Outerwraps - 10 and Bonded Asbestos-Felt Wrap or 2.1L Whitewash Formula ..... se lt Other Performance-Comparble 2.12 Water-Emulsion Latex Paint........ 15 Outerwrap . see 90 2.13 Kraft Paper . +15 AQ Material Specifications.......+44++ 30 2.14 Shop Application of Primers and ‘A2L Glass-Fiber Mat ..... + 30 Coal-Tar Enamels . oS 2.15 Coating Repair . 2. Tables 3 Coal-Tar Tapes, Hot-Applied, for Fl Conversion Factors....+++++++ Special Sections, Connections, 1 Physical Properties of Coal-Tar and Fittings Enamel Used in This Standard ...... 3.1 General 2... 22 2 Specifications for Kraft Paper for 3.2 Inspection and Testing. 12 Polyethylene-Kraft Paper, a 33 Material Compliance «......4.0402. 22 ‘Two-Component Single Wrap . 34 Packaging... TETINII 22.3. Physical Properties of Tape .Foreword This foreword is for information only and it nova part of AWW C203. L. History of Standard, The first standard describing coal-tar enamel was developed by AWWA Committee ATA, later designated 8310D, and presently designated AWWA Standards Committee on Steel Pipe. At the same time that Committee ATA held its first ‘meeting in 1939, acommittee composed of steel pipe manufacturers and coating applicators ‘was set up to advise and cooperate with A7A. This cooperative committee is known as the AWWA Steel Water Pipe Manufacturers’ Technical Advisory Committee, and it has contributed much throughout the years toward the preparation of AWWA standards and advancement of the water utility industry. ‘The first AWWA standards for coal-tar enamel were approved Apr. 25, 1940, and were designated 7A.5 for steel water pipe in sizes 30 in. and over and 7A.6 for steel water pipe of sizes up to, but not including, 30 in, Revisions of these documents were approved on Oct. 3, 1949; June 21, 1950; May 1, 1951; and July 14, 1955. In 1951, the designations of 7.5 and 7A.6 were changed to C203 and C204. On Mar. 27, 1957, a revision was approved that combined the two standards into one document designated C203. Subsequent cevisions were approved Jan. 23, 1962; May 22, 1966; Jan, 29, 1973; and June 25, 1978. IL Metrication, Throughout the body of this standard, direct metric conversions (rounded) are set in parentheses next to US customary units and are not those specified in International Standards Organization (ISO) standards. Table F.1 lists useful conversion factors. IIL, Information Regarding Use of This Standard, To specify individual require- ments, the purchaser should refer to the appropriate sections of the standard and provide specific supplementary information regarding the following: 1, Standard used—that is, AWWA C203-86, Standard for Coal-Tar Protective Coatings and Linings for Steel Water Pipelines—Enamel and Tape—Hot-Applied, or any part or combination of Sec. 1, Sec. 2, and Sec. 3 thereof (Sec. 1.1). 2. Additional protection covered by Appendix A that may be required (Sec. 1.2) 3. Diameter, length, and location of pipeline, including maps and drawings necessary to show all details of the pipeline within the scope of the contract. Table Ft Conversion Factors Conversion Factor ‘Mec Equivalent British thermal units per pound (Bru/Ib) 5556 = calories/kilogrem (cal/ke) degree Fahrenheit (°F) (CE-32/18 = degree Celsius (°C) feet per minute (ft/min) +0305 = mettes per minute (m/min) US gallon (gal) * 3.785 = litre (L} inch in.) +25 400 = micrometre (ut) jnch-pound (corque) Gin) xO.113 = newron-merre (N'm) mil x25 ounce (force)/ineh (ozt/in.) x 10.945 Perms @ 73°F (23°C) 15.145 «10-1 pound (Ib) 0.4536 pound (force) x 4.446 pound (foree)/in. (Ibt/in.) 175.3 pound (force)/square inch (psi) 6395 square foot (ft?) 0.093 square inch (in) x 64524 AWWA C203-86 4, Length of pipeline requiring internal protection (Sec. 2.2). 5. Length of pipeline requiring each of the following types of exterior protection: (1) underground—normal or average conditions and any preference regarding finish coat of whitewash, water-emulsion latex paint, or kraft paper (Sec. 2.3); (2) underground— underwater or unusual conditions (Sec. 1.2 and Appendix A). 6. Affidavit of compliance, if required (Sec. 1.6) 7. Type of primer (Sec. 2.4). 8. Type of coal-tar enamel (Sec. 2.5.2). 9. Samples of materials, if required (Sec. 2.6 and Sec. 2.7.5). 10. Inspection, testing, and rejection (Sec. 2.7). 11. Type of outerwrap (Sec. 2.10) 12. Lining and coating of pipe ends (Sec. 2.14.9). 13, Trench backfilling (Sec. 4.2.3 and Sec. 4.5). 14. Inspection and testing responsibility (Sec. 3.2). 15, Width of tape (Sec. 3.6.1). 16. Length of tape roll (Sec. 3.6.2). 17, Thickness of tape (Sec. 3.6.3). 18, Single or double wrap (Sec. 3.8). 19. If materials only are being purchased under Sec. 2 of this standard, then the purchaser shall specify quantities for the following items: (1) primer by type (Sec. 2.4), (2) coal-tar enamel by type (Sec. 2.5and Table 1), (3) outerwrap (Sec. 2.10), (4) glass-fiber mat (Sec. A.2.1), and (5) affidavit of compliance, if required (Sec. 1.6). 20. If materials only are being purchased under Sec. 3 of this standard, then the purchaser shall specify, in addition to items 14-18 just listed, the following: (1) quantity of primer (Sec. 3.5), (2) quantity of tape (Sec. 3.6), and (3) affidavit of compliance, if required (See. 1.6). 21. AWWA C209, Standard for Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines, may also be used in combination with C203, if specified by the purchaser. 22. Application and use of materials covered in this standard should conform to ‘warnings and instructions provided by the manufacturers and with existing federal and local governmental regulations. IV. Major Revisions. Major changes made in this revision are 1. Reference to the use of AWWA C209 has been removed from the History of Standard noted in the Foreword and relocated as item 21 in Information Regarding Use of ‘This Standard, also in the Foreword. 2. Metric conversions have been added throughout the standard, and Table F.1, Conversion Factors, has been added. 3. The word felt, which used to refer to asbestos-felt outerwrap, has been changed t0 outerwrap, which will refer to any type of outerwrap used in the coating system except for kraft peper. 4. The Scope of the standard has been reworded to clarify the use of coal-tar enamel as an interior lining where the water in the pipeline exceeds 90°F (32°C) and when used as part of an exterior protection system where the in-service temperature exceeds 160°F (71°C). 5. Additional reference listings regarding surface preparation have been addedto the Reference section. 6, The term manufacturer has been listed and defined in the Definitions section. 7. Old Sec. 1.5, Access of Inspector, and Sec. 1.6, Facilities for Inspector, are now included in Sec. 2.7, Inspection, Testing, and Rejection. 8. Old Sec. 1.10, Packaging, has been renamed Sec. 1.8, Packaging and Marking.9. Old Sec. 27, Inspection and Testing by Purchasers, has been renamed Inspection, Testing, and Rejection, 10, The procedure for determining the results of the high-temperature test in the laboratory test procedures has been expanded to better define the distance obtained between the scribe lines before and after the enameied plate is subjected to the heat cycle. LL. A precautionary statement has been inserted in the section describing preparation of enamel for laboratory testing to avoid superheating the bottom of a container containing the enamel to be tested while heating with a gas flame. 12. A description of the knife to be used in the determination of enamel peel, whether in the laboratory, shop, or field, has been inserted in the peel test outlined in laboratory tests. 13. Temperature limitations of the applied enamel and a descriptive use of the knife while performing peel tests in the field have been inserted. 14, Sec. 2.10, Asbestos Coal-Tar Saturated Felt, has been retitled Outerwraps to preclude the possibility of only permitting the use of asbestos coal-tar saturated felt wraps in lieu of other outerwraps having at least five years proven performance. 15, Sec. 2.12, Water-Emulsion Latex Paint, has been added to permit the use of this paint should any of the ingredients in the outlined whitewash formula become unavailable. 16. Paragraphs in Sec. 2.14, Shop Application of Primers and Coal-Tar Enamels, previously identified only by numbers, have now been titled to highlight their contents. 17. Reference to receiving bulk deliveries of molten enamel has been addressed in Sec. 2.14.4, Preparation of Coal-Tar Enamel for Application. ~ 18. Sec. 2.14.12.4, relating to electrical inspection of the coal-tar enameled and wrapped pipe, has been included to caution against exceeding the dielectric strength of the enamel when outerwraps having a greater dielectric strength than enamel are used. 19. A cautionary statement relating to the thickness of enamel over weld seams has been inserted in Sec. 2.14.8. 20. Sec. 2.14.10.2, Hand-Dauber Requirements, has been expanded to allow for the use of special long-handled daubers 21. Sec. 2.15, Coating Repair, has been added. 22, Sec. 2.14, Field Procedure and Enameling, has been renumbered and retitled Sec. 4, Handling, Transporting, and Field Procedures.This page intentionally blank.American Water Works Association 4 ANSI/AWWA C203-86 Revision of AWWA C203-78) AWWA STANDARD FOR COAL-TAR PROTECTIVE COATINGS AND LININGS FOR STEEL WATER PIPELINES—ENAMEL AND TAPE—HOT APPLIED SECTION 1: GENERAL Sec. 11 Scope ‘This standard provides for coal-tar protective exterior coatings and interior linings for buried steel water pipelines installed in all soils under normal construction conditions. When the coal-tar enamel is used as a protective interior lining of steel water pipelines, the temperature of the pipeline water must not exceed 90°F (32°C), and its flow rate must be sufficient to prevent stagnation. When properly applied coal-tar enamel is used as part of a protective system for the exterior of steel water pipelines, the service temperature of the Pipeline must not exceed 160°F (71°C). Sec, 2 covers hot-applied coal-tar enamel and its exterior and interior application to pipe, special sections, connections, and fittings. Sec. 3 covers hot-applied coal-tar tape and its exterior application to steel-water-pipe special sections, connections, and fittings. The tape-coating system is not intended for extensive shop- or field-coating of steel pipelines. Sec, 1.2 Conditions Not Covered in This Standard This standard does not include the additional protective coatings, wraps, and procedures provided for in Appendix A, unless they are required by the purchaser's, specifications Sec. 1.3 References This standard references the following documents. The latest edition ofeach document forms a part of this standard to the extent specified herein. In case of any conflict, the requirements of this standard shalt prevailatta “AWWA C2086 ASTM* Cb4—Specification for Reftactories for Incinerators and Boilers, ASTM D5—Test Method for Penetration of Bituminous Materials ASTM D36—Test Method for Softening Point of Bitumen (Ring-and-Ball Apparatus). ASTM D71—Test Method for Relative Density of Solid Pitch and Asphalt (Dis- placement Method). ASTM D76—Specification for Tensile Testing Machines for Textiles. ASTM D146—Methods of Sampling and Testing Bitumen-Saturated Felts and Woven Fabrics for Roofing and Waterproofing (Revision A). ASTM D388—Classification of Coals by Rank, ASTM D546—Method for Sieve Analysis of Mineral Filler for Road and Paving Materials, ASTM D737—Test Method for Air Permeability of Textile Fabrics ASTM D882—Test Methods for Tensile Properties of Thin Plastic Sheeting. ASTM D1000—Methods of Testing Pressure-Sensitive Adhesive Coated Tapes Used for Electrical Insulation (Revision A). ASTM D1238—Test Method for Flow Rates of Thermoplastics by Extrusion Plastomerer. ASTM D1505—Test Method for Density of Plastics by the Density-Gradient Technique. ASTM D1918—Test Method for Asbestos Content of Asbestos Textiles. ASTM D2103—Specification for Polyethylene Film and Sheeting. ASTM D2415—Test Method for Ash in Coal Tars and Pitches. ASTM F17—Definitions of Terms Relating to Flexible Barrier Materials ASTM F64—Test Method for Corrosive and Adhesive Eifects of Gasket Materials on Metal Surfaces ‘AWWA C204—Standard for Chlorinated Rubber-Alkyd Paint System for the Exterior of Aboveground Stee! Water Piping. ‘AWWA C205—Standard for Cement-Mortar Protective Lining and Coating for Steel Water Pipe—4 In. and Larger—Shop Applied. ‘AWWA C209—Standard for Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines. BSt-4164—Coal-Tar Based Hot-Applied Coating Materials for Protecting Iron and Steel Including Suitable Primers Where Required. NACEt TM-01-70—Visual Standard for Surfaces of New Steel Airblast Cleaned with Sand Abrasive NACE TM-01-75—Visual Standard for Surfaces of New Steel Centrifugally Blast Cleaned with Steel Grit and Shot. SSPC§-SP1—Surface Preparation Specification No. 1, Solvent Cleaning. SSPC-SP6—Surface Preparation Specification No. 6, Commercial Blast Cleaning. SSPC-SP10—Surface Preparation Specification No. 10, Near-White Blast Cleaning. TAPPI** T-403—Test for Bursting Strength of Paper. ‘TAPPI T-404—Test for Tensile Breaking Strength and Elongation of Paper and Paper Board (Using Pendulum-Type Tester). erican Society for Testing and Materials, 1916 Race St, Philadelphia, PA 19103 ‘British Standard Insticution, 2 Park Street, London, England WIA 23S, National Association of Corrosion Engineers, 1440 South Creek Dr, Houston, TX 77084, Stee! Suructutes Painting Council, 4400 Fifth Ave. Pittsburgh, PA 15213 Technical Association ofthe Pulp and Paper Industry, 15 Technology Parkway South, Norcross, GA 30092. iCOAL-TAR COATINGS AND LININGS 3 ‘TAPPI T-410—Test for Grammage of Paper and Paperboard (Weight Per Unit Area). ‘TAPPI T-411—Test for Thickness (Caliper) of Paper, and Paperboard, and Combined Board. TAPPI T-414—Test for Internal Tearing Resistance of Paper. Sec. 14 Definitions In this standard, the following definitions shall apply: 14.1 Purchaser: The person, firm, or governmental agency entering into a contract, ‘or agreement for the purchase of any materials or for any work to be performed under this standard. 1.4.2 Contractor: ‘The person or fiem that enters into a contract or agreement with the purchaser to furnish any products or to perform any work under this standard. 1.4.3 Manufacturer: The person or firm that manufactures the products covered by this standard. 1.44 Inspector: An authorized representative of the purchaser who is entrusted with the inspection of products and production records and observance of production operations and quality control tests to ensure that the products comply with the purchaser's specifications and this standard. 145° Blast cleaning: Blast cleaning with sand, steel shot, or grit. 1.4.6 Centrifugal casting: The process of applying coal-tar enamel to the inside surface of pipe, whereby molten coal-tar enamel introduced into the pipe is spread on the pipe surface and held thercon by the centrifugal force developed by rotating the pipe about its longitudinal axis until the enamel has cooled and solidified and become bonded to the Pipe. Sec. 1.5 Materials and Workmanship All materials shall be of the specified quality. All work shall be done in a thorough, ‘workmanlike manner. The entire operation of priming the pipeand heating and applying the coal-tar enamel coatings and coal-tar tapes shall be performed by and under the supervision, of experienced persons skilled in the application of coel-tar enamel. Sec. 1.6 Affidavit of Compliance ‘The purchaser may require that the contractor furnish an affidavit that all materials and ‘work furnished comply with the applicable requirements of the purchaser's specifications or with this standard, Sec. 1.7 Equipment ‘The contractor’s equipment for blast cleaning, priming, énameting, wrapping, and taping shall be of such design and manufacture and in such condition as to permit applicators to follow the procedure and obtain results prescribed in this standard, Sec, 1.8 Packaging and Marking All coal-tar enamel and primer and all wraps purchased or used under this standard shall be packaged in suitable containers. The containers shall be plainly marked with the name of the manufacturer, type of material, and batch or lot number. If the enamel in the molten state is shipped via tank truck or other container, then the bill of lading or some other written documentation, agreeable to the manufacturer and purchaser, shall have sufficient information on it to indicate the type of material and batch or lot number. Special requirements for packaging coal-tar tape are specified in Sec. 3.4.Smemeeeg SECTION 2: COAL-TAR ENAMEL, HOT-APPLIED sammmm 6 Sec. 2.1 General Except as otherwise provided for specials, fittings, field joints, and repairs, all coatings and linings covered in Sec. 2 shail be hot-applied in the shop by mechanical means. Sec. 2.2 Inside Pipe For the inside of all pipe, a coat of primer shall be followed by a hot coat of coal-tar enamel. Pipe less than 27 in, (686 mm) in diameter shall be joined in a manner that eliminates the need for entering the pipe to complete or repair the coal-tar lining atthe joints. Pipe that is 27 in, (686 mm) or larger in diameter may be joined by any suitable method, including welding. Sec. 2.3 Outside Pipe For the outside of all pipe, a coat of primer is followed by a hot coat of coal-tar enamel ¢€ conto which shall be applied a single layer of specified outerwrap. The coating shall then be finished with either one coat of water-resistant whitewash, water-emulsion latex paint, or a single wrap of kraft paper. Except when one of the three equivalent finishes is specified by the purchaser, the choice of finish coat shall be the contractor's option. Sec. 2.4 Primers (See Table 1) ‘Type A (coal-tar) and type B (fast-drying, synthetic) primers are covered by this standard. Unless type A is specified in the purchaser's specifications, type B, which may be used under all conditions when coal-tar enamel is applicable, shall be used, ‘Type A primer shall not be specified for either laboratory testing or field usage when (1) e the enamel will be applied less than 16h or more than 72h after priming, (2) the temperature and humidity conditions are such that adequate drying of the primer and bonding of enamel cannot be obtained within 24 h, (3) the pipe is to be coated with type I enamel and will be handled at temperatures below 30°F (-1°C), 24.1 Type A (coal-tar) primer. Coal-tar primer shall consist only of processed coal-tar pitch and refined coal-tar oils, suitably blended to produce a liquid that may be applied cold by brushing or spraying and that will produce an effective bond between the metal and a subsequent coating of coal-tar enamel. The primer shall contain no benzene or e other toxic or highly volatile solvents. This prohibition shall extend to added pigments and inert fillers. The primer shall show no tendency to settle out in the container. 24.2 Type B (fast-drying, synthetic) primer, Fast-drying, synthetic primer shall consist of chlorinated rubber, synthetic plasticizer, and solvents. These primers shall be suitably compounded to produce a liquid coating that can be readily applied cold by brushing or spraying and that will produce a suitable and effective bond between the metal and subsequent coating of coal-tar enamel. 24.3 Application properties. Both primers shall have good spraying and brushing properties and minimal tendency to produce bubbles during application. The primers shall ry hard to the touch, when applied as recommended. 2.44 Manufacturer. The primer, whether type A (coal-tar) or type B (fast-drying, synthetic), and the coai-tar enamel shall be from the same manufacturer. Sec. 2.5 Coal-Tar Enamels (See Table 1) 25.1 Quality of enamel, ‘The quality of coal-tar enamel for use in potable-water systems, as defined in this standard, is affected by the quality of the coal that is carbonized and by the temperature of carbonization, as well as by the subsequent methods of pitch @COAL-TAR COATINGS AND LININGS 5 Table | Physical Properties of Coal-Tar Enamel Used in This Standard Enamel Type Enamel Type I Test Minicoum Maximum Minimum Maximum Soltening point, ASTM D36 220°F (104°C) 240°F (116°C) 220° F (104°C) 240°F (116°C) Filler (ash), ASTM D2415, % by weight 3 35 2 38 Fineness filer, through 200 mesh, ASTM D546, % by weight 0 - 90 ~ Specific gravity at 77°F (25°C), ASTM D7L 14 16 1M 16 ‘Penetration at 77°F (25°C) 100-g weight, 5, AWWA C203, Sec. 28.1, 5 10 10 Ey at 115°F (46.1°C) 50-g weight, 5s, AWWA C203, Sec. 2.8.1 2 30 15 35 “High-temperature test at 160°F (71°C) (sag), AWWA C203, Sec. 28.9 - Yoon. (1.6 mm) - Yiein. 1.6 mm) Low-temperature test at -10°F (-23.3°C) (racking), AWWA C203, Sec. 2.8.10 - one N/A N/A Low-temperature test at -20°F (-28.9°C) (cracking), AWWA C203, Sec. 28.10 N/A N/A - none Ienpact test at 77°F (25°C) 650-g ball, 8-fedrop, AWWA C203, Sec. 28.12 Direct impact, disbonded area = 16in - 10 int (10323 mm?) (6452 mm*) Indirect impact, disbonded area - in? - Din? (6871 mm?) (1290 am?) {Peel test, AWWA C203, Sec. 28.11 no peeling no peeling “For static conditions shove 5°F (-15°C), use enamel with 5-10 penetration at 77°F (25°C); below 5°F (15°C) and above =10°F(-23°C), use 10-15 penetration; and below -10°F (-28°C) and above -20°F (-29°C), ote 15-20 penetration enamel (‘Staric conditions are those conditions under which the pipe isnot being handled.) “PType I enamel in the 5-10 penetration range at 77°F (25°C) shall be tested with synthetic primer type B processing and by the particulars of formulation. To meet the basic quality requirements, coal-tar shall be produced from coal that has a minimum heating value of 13.000 Bru/Ib (7.223 * 10° cal/kg) on a moisture-and-mineral-matter-free basis (ASTM D388) and that has been carbonized in a slot-type coke oven at a temperature of not less than 1652°F (900°C). 25.2. Composition of the enamel, ‘The enamel shall be AWWA coal-tar enamel, type I or type IT, as specified by the purchaser. The enamel shall be composed of a specially processed coal-tar pitch combined with an inert mineral filler. The enamel shall contain no asphalt of either petroleum or natural base. The enamel shall have the physical properties shown in Table 1 f Sec. 2.6 Contractor’s Samples and Detailed Information When required by the purchaser's specifications, the contractor shall submit to the purchaser for testing, prior to any work under this standard, a 50-Ib (23-kg) sample of the coal-tar enamel and a |-gt (1-L) sample of the primer proposed to be furnished. Samples shalt be taken from a production run at the manufacturer's plant and shall be identified by batch or lot numbers, The contractor shall submit with the samples a certified copy of results, of tests made by the manufacturer covering the physical and performance characteristics of the samples. This certificate shall indicate the coverage rate of the primer in ft?/gal m?/L), the application temperature of the enamel, and the method of application of the enamel to the test plates. Sec. 2.7 Inspection, Testing, and Rejection 2.7.1 Purchaser's inspection option. At the purchaser's option, the entire procedure of applying the protective coating material may be rigidly inspected from the time the bareye 6“ awwa cz0s.86 pipe is received until installation of the coated pipe is completed. Such inspection shall not relieve the contractor of the responsibility for furnishing material and performance of work @ in accordance with this standard, 2.7.2 Access of inspector. ‘The inspector shall have free access to those parts of all, plants and construction facilities that are concerned with furnishing materials or the performance of work under this standard. 2.7.3 Facilities for inspector. The contractor shall furnish the inspector reasonable facilities and space without charge for the inspection, testing, and obtaining of necessary information desired regarding the character of material used, the application, the progress, and the manner of work. 2.7.4 Coating work. When an inspector is furnished by the purchaser, all coating ‘work must be done in the presence of the inspector. All such work done in the inspector’s absence will be subject to rejection unless specifically allowed by the inspector. If, at any time, itis found that the procedure of applying the protective coating material is not in accotdance with this standard, all such coating work may be rejected, 2.7.5 Submission and testing of samples. Prior to acceptance of the contractor's material, samples of material submitted by the contractor will be tested by the purchaser. If ¢ ‘any sample is found not to conform to the standard, material represented by such sample will be rejected. If samples of the contractor's materials that have been previously accepted are found not to conform to the standard, all such material will be rejected. 2.7.6 Site for sample testing. Samples submitted to the purchaser will be tested in the purchaser's laboratory or in a responsible commercial laboratory designated by the purchaser. 2.7.7 Expense of testing. The expense of testing all samples of material originally “offered by the contractor will be borne by the purchaser. The expense of all subsequent tests necessitated by failure of samples of materials originally offered to comply with this standard will be paid for by the contractor. 6 2.7.8 Certified test reports. The contractor shall furnish the purchaser with a certified copy of results of tests made by the manufacturer covering physical and performance characteristics of each batch of enamel and primer to be supplied under this standard. When required by the purchaser’s specifications, the contractor shall furnish, or allow the purchaser to collect, samples of the material representative of each batch of enamel and primer. Certified test reports and samples furnished by the contractor shall be properly identified with each batch of enamel and primer. 2.7.9 Coating and application specification submittals. After the contractor has e¢ obtained approval from the purchaser for the coal-tar enamel and primer proposed to be furnished, the contractor shall submit the coating manufacturer's detailed specifications for the coal-tar enamel and primer supplied for the project, with instructions for the handling and application of the material. This information shall include: method of application of primer and coverage in ft?/gal (m?/L), minimum and maximum drying time of the primer before application of enamel, application temperature of enamel, maximum allowable temperature to which enamel may be heated, and maximum time enamel may be held in heating kettles at application temperature. Sec. 2.8 Test Procedures for Primers and Enamels (Laboratory Only) ‘The primers and enamels shall have the physical characteristics listed in Table 1 when tested by the procedures indicated therein. The procedures referenced to AWWA C203 shall be performed as specified in the following sections. 2.8.1 Determination of penetration. ‘This method is based on the penetration test for bitumen as defined in ASTM D5, modified for the determination of penetration of coal-tar enamel. e — EeCOAL-TAR UOATINGS AND LININGS 2.8.1.1 Penetration determination precautions. Coal dispersion pitches have a tendency to form a hard, thin skin while hot. Penetration values determined by this method tend to show a wide variation, dependent on the prior preparation of the sample, which is not ‘easy 0 control, and on the point chosen on the surface for the test. Nore: The behavior and performance of these coal dispersion pitches is a function of the property of the body of the material and not of any surface skin. 2.8.1.2 Description of penetration test method. The penetration is carried outat the specified temperature, using a penetrometer, by means of which a standard needle is applied to the sample for 5s under specified load. 3 Apparatus. Apparatus as described in the following subsections is required. 2.8.1.3.1 Penetration needle, The penetration needle described and defined in ASTM DS and BS-4164 shall be used. 2.8.1.3.2 Penetrometer. Any suitable penetrometer that permits the needle holder to move in the guide without appreciable friction and that is capable of indicating the depth. of penetration to the nearest 0.1 mm shall be used. The total moving weight (needle, needle holder, and superimposed weight) shall be 50 g + 0.25 g or 100 g + 0.25 g, as required. 2.8.1.3.3 Water bath. A constant-temperature water bath having a capacity of not less than 10 L shall be used. The temperature shall be regulated at the temperature of test £0.1°C. The bath shall have a perforated shelf supported in a position not less than 50mm. from the bottom and not less than 100 mm below the top of the bath. 28.1.3.4 Transferdish. A transfer dish for the sample container—that is, a dish or tray of such capacity 5 will ensure complete immersion of the container during the test—shall be used. Itshall be provided with some means that will ensure a firm bearing and. prevent rocking of the container. 2.8.1.3.5 Sample containers. Sample containers shall be open cylinders of either steel or brass having a wall thickness of 3 mm. The cylinder shall have an internal diameter of 40 mm and 2 depth of 40 mm. The two ends shall be machine-finished, perfectly smooth, and perpendicular to the axis. A suitable flat brass plate shall be provided. Note: The container can be readily prepared from a section of pipe. 2.8.1.3.6 ‘Thermometers. A bath thermometer designated as ASTM 17F, 64C, ot 64F shall be used. 28.1.3.7 Timers. .A timing device of suitable accuracy to mect the requirements of the repeatability of the method shall be used. 2.8.1.3.8 Sample melting pot. A sample melting pot of steel 3-mm thick, 80 mm in diameter, and 100 mm in height shall be used. The pot is provided witha loose-fitting lid. 2.8.2 Procedure for determination of penetration. To begin the test, 250-300 g of the sample shall be broken into small pieces not greater than‘/2in. (13 mm) in size. The sample shall be heated slowly in a melting pot, keeping the lid on when not being stirred, Until the pieces have melted, they must be stirred continuously to avoid local overheating and. excessive loss of vapor. {tis convenient to fill the penetrometer vessels, the rings for the softening point tests, and the mold for the specific gravity test all together from the same sample of melted ‘material ‘The brass plate should be well polished and preferably coated with a nonmigratory smooth film-forming release agent to prevent sticking of the enamel to the plate. The sample containers shall then be placed on the plate so that close contact is maintained between rim and plate. When the temperature of the sample is about 60°-70°C above the expected softening point, the heated sample container shall be filled to approximately three-quarters, full and allowed to cool to ambient temperature. ‘The container shall be inverted and placed in a transfer dish in the water bath, which is kept at the appropriate temperature, for 1h,8 AwWwa c205.86 ‘The penetrometer needle shall be cleaned with toluene, dried, and inserted into the penetrometer. The needle holder shall be loaded to bring the total moving weight to that 6 required for the test. The transfer dish containing the sample container shall be filled with, water from the constant-temperature bath and placed on the table of the penetrometer. Care must be taken to ensure that the sample container does not move or rock during the test. The needle shall be slowly lowered until the tip just makes contact with its image on the surface of the sample or, ifthe surface is matte, until scratch contact can just be detected. A suitably : placed light can be an aid in obtaining precise adjustment of the needle to the sample surface. Depending on the type of penetrometer used, the dial reading shall be noted or returned to zero. The needle holder shall be released quickly and held free for exactly 5 s and then locked. The depth of penetration, in tenths of a millimetre, shall be read from the scale and recorded. If the container moves in any way, the determination shall be discarded. Three readings shall be made within the limits of repeatability. The needle shall be applied to the surface at least 10 mm ftom the edge of the dish and 10 mm from any previous hole. 28.3 Preparation of test plates for primer and enamel application. Conduct all performance tests on steel plates free of all oil and grease, Blast one side of each plate toa uniform steel gray surface between SSPC-SP6 and SSPC-SPIO. This is equivalent to @ NACE TM-O1, between NACE no. 3 and NACE no. 2. For blasting, use either a sharp, dry send having a minimum of 50 percent retained on a 30-mesh screen or ano. 50 steel grit with an air pressure of not less than 90 psi (620 kPa) at the blasting nozzle. A height-of-blast profile of 3 mils (0.1 mm) is intended. 28.4 Priming cesr lates. Freshly prepare all test plates as specified in Sec, 2.8.3 and prime using the coverage rate recommended by the manufacturer. Apply the primer with a new, clean, flat-bristle brush of I-in, (25-mm) width. Prime and dry plates while they are lying horizontal in a well-ventilated room with the temperature between 70°-90°F (21°-32°C) and @ relative humidity of not more than 60 percent. 28.5. Time lapse before application of enamel. e 2.8.5.1. Coal-tar primer. If type A (coal-tar) primer is used, apply the enamel not less than 16 h and not more than 72 b after the primer has been applied. 285.2 Fast-drying, synthetic primer. If type B (fast-drying, synthetic) primer is used, apply the enamel not less than I h or more than five days after the primer has been applied. 28.6 Preparation of enamel for testing. Break about 30 Ib (13.6 kg) of enamel into pieces, each approximately 4 in. (102 mm) in maximum dimension, and melt rapidly with agitation over a large gas burner in a covered metal container of uniform cross section of not € less than 8 in. (203 mm) or more than 12 in. (305 mm) in diameter. Interpose a V/s-in. to '/y-in, (3-mm to 6-mm) thick steel plate between the bottom of the container and the gas flame to avoid superhesting, 2.8.7 Initial hearing. As soon as the application temperature is reached, apply the enamel to the primed test plates required for the following tests: high temperature, low ‘temperature, impact, and peel. 28.8 Enamel application and thickhess. Apply the enamel at temperatures recom- mended by the coating manufacturer. Apply the enamel to @ thickness of */s to / in. (1.6mm to2.4 mm) on al test plates by flooding a minimum of 1 qt(1 L)ofenamel over each a plate. The desired thickness may be achieved by adjusting the angle of the plate during pouring or by use of a doctor blade. 2.8.9 High-temperature test. . Prepare and test two plates in accordance with the following method: 2.8.9.1 Use L2-in, x 12-in. % Yes-in. (305-mm 305-mm * 2,8-mm) plates. Enamel ‘one side in the manner previously described with a '/e-in. (13-mm) uncoated border left around the four edges of the plate. Let cool, then scribe lines | in, (25 mm) apart across the face of the enamel surface and continue on the uncoated surface of the plate to the edge. @OAL-TAR COATINGS AND LININGS 9 2.8.9.2 Store the plates prepared by this method in a vertical position so that the scribed lines are horizontal in a chamber in which the temperature is maintained at 160°F (71°C) for 24h. Atthe end of this period, remove the plates and cool to room temperature. Rescribe the face of the enamel after the test plate is placed in the exact position as it was when the initial scribe lines were made. Measure the distance between the old and new scribe lines, average the measurements, and record as the sag of the enamel. 28.10 Low-temperature test. Place the two plates used in the high-temperature test in an air chamber in which the temperature is maintained at -10°F or -20°F (-23,3°C or -28.9°C), as specified for the test, for 6h. At the end of this period, remove the plates, place ‘them on an insulated surface, allow them to reach room temperature, and examine for cracking or disbonding of the enamel. 2.8.11 Peel test. Use two plates, 12in. 12in, x /2in, (305 mm x 305 mmx 13 mm), enameled on one side in the manner previously described. After the application of enamel, cool the plates to room temperature. 28.111 Test of bond after 12h at room temperature. Store the first test plate ina horizontal position with the enameled side up at room temperature for at least 12 h, but not more than 24 h. Test the condition of the bond over a temperature range of 80°-160°F (27°-719C) at suecessive intervals of 20°F (11°C), that is, 80°F, 100°F, 120°F, 140°F, and 160°F (27°C, 38°C, 49°C, 60°C, and 71°C). Allow a tolerance of + 2°F (1°C) on these ‘temperature requirements. Heat the plate by immersing it fora period of approximately /h in a water bath maintained at the selected temperature. At the end of the heating period, remove the plate from the bath and immediately test for peel as follows: ‘The knife to be used in the peel test shall be made having a moderately stiff steel blade and handle not to exceed 7 in. (178 mm) in length with the dimensions of the exposed blade as follows: Ysin. to % in, (16 mm to 19 mm) wide, Ys in. (3.2 mm) thick, and approximately 3 in, (76 mm) long. The blade’s edge shall be ground square, then sharpened to produce a 40°-50° beveled edge over its entire width. With the knife edge, cut two parallel lines through the enamel approximately in: (19 mm) apart and approximately 4 in, (102mm) in length. With the edge of the knife blade, and ensuring that knife-biade to stee!-plate contact exists, cut under the enamel strip at one end and loosen the enamel from the plate the full ‘width of the strip for about '/ in. (13 mm). Place the knife blade under the loosened end and, with a firm grip, apply a slow, steady pull upward on the enamel strip. Measure and record the length to which the strip of enamel has pecled or lifted prior to breaking. Peeling, stripping, or lifting of not more than sin, (3.2mm) shall be recorded as no peeling, The use of the water bath for the 80°F (27°C) test shall be omitted when room temperature is in the range of 80°F + 2°F (27°C + 1°C). The 80°F (27°C) test shall be omitted if the penetration of the applied enamel is less than 10 at 77°F (25°C). * 28.112 Test of bond after 72 h at 160°F (71°C), Store-the second test plate in a horizontal position, with the enameled side up, in a chamber maintained at 160°F + 2°F (71°C £ 1°C) for 72h = 2 h. At the end of this period, remove the plate, cool to room temperature, and test for condition of bond over a temperature range of 80°-160°F (27°~ 71°C) as above. The 80°F (27°C) test shall be omitted if the penetration of the applied enamel is less than 10 at 77°F (25°C). 28.12 Impact tests. Use two plates, 12 in, * 12 in, x Yea in, (305 mm * 305 mm x 2.8 mm), enameled on one side in the manner previously described. The plates used in the high-temperature test, Sec. 2.8.9, may be used in the impact test. After the plates have reached room temperature, immerse in a water bath maintained at a temperature of 77°F (25°C) for a period of atleast 1 h before testing. Remove each plate from the water bath, dry with a soft clean cloth, and immediately subject to the following tests; 28.12.1 Direct impact. Support each plate on a true plane surface of a block of wood. Drop a 650-g steel ball with a well-polished spherical surface from a height of 8 ft (2.4 m) above the surface of the plate, Drop the ball so as to strike the enamel at a point atlo Awwa c203.36 least 4 in, (102 mm) from any edge ofthe plate. After one such impact, determine the area of ‘enamel that has been shattered and loosened from the plate. Shattered enamel is coating that has been knocked off the plate by the impact ofthe steel ball. Loosened enamel is coating that hhas not been shattered, but can be temoved easily and readily from the plate by the fingers or, with very little force, by the use of aknife blade or similar instrument. Record the average disbonded area of the two plates in in.? (cm?) 2.8.12.2 Indirectimpact. After the two plates have been subjected to direct impact, place them with the coated faces down ona wooden block through which a 3'/-in, (89-mm) diameter hole has been cut. Drop the same ball from a height of 8ft(2.4m)above the surface of the plate so as to strike the steel plate at a point over the center of the hole in the wooden support block. The point of impact shall be at least 4 in. (102 mm) from any edge of the plate and atleast 3in. (76 mm) from the point of direct impact. After one such impact, estimate the area of enamel that has been shattered and loosened from the plate, as previously described. Report the average disbonded area of the two plates in in.? (em), Sec. 2.9 Field-Bond Test Procedure for Primer and Enamel ‘The field-bond test for coal-tar enamel adhesion shall be performed using a knife as described in Sec. 2.8.11.1 at the 50°-80°F (10°-27°C) normal operating temperature of steel water pipe. The test shall be applicable without modification to both interior lining and exterior coating with or without reinforcement. If the penetration of the enamel after application is less than 10, the peel test shall be evaluated atno lower than 65°F (18°C). Not ‘more than one test each of interior lining and exterior coating shall be performed on each. pipe section unless either test fails. If the coating or lining temperature measured with a surface thermometer is above 80°F (27°C) or below 50°F (10°C), pour sufficient hot or cold water over the rest area to adjust the enamel and substrate temperature within this range. Uniess the temperatures of the steel pipe and the enamel system at the peel test location are within 5°F (3°C) of each other, and also within the temperature limits outlined in the preceding para,raph, incorrect peel test results will be obtained. Using 2 knife, heated if necessary (but not so much as to cause the enamel system 10 fume), make two parallel cuts through the coating or lining, ensuring knife-blade to steel-pipe contact, about4in. (102mm) long and '/+in. (19 mm) apart. With the knife blade's beveled edge, and ensuring knife-blade to pipe contact exists, loosen the enamel the full width of the cut and lift slowly upward. An even pressure, in alight reciprocating manner, shall be applied when determining the enamel’s bond to avoid imparting shock stresses within the coating and thereby causing a shattering separation of the enamel from the surface that may then be erroneously interpreted as a bond failure. The bond is satisfactory if the length of peel is no greater than the width of cut before the enamel breaks. Ifthe peel length exceeds the cut width, the testis a failure and two additional tests shall bbe mace at two different locations on the same section. If both tests are satisfactory, the pipe section shall be accepted. If either additional test fails, the pipe section shall be rejected. Sec. 2.10 Outerwraps 2.10.1 Outerworap background. Asbestos felt, as described in Sec. 2.10.2, has been regarded for many years as the industry standard for outerwraps being used with coal-tar enamel. The inert outerwrappers described in Sec. 2.10.3, Sec. 2.10.4, and Sec. 2.10.5 are ‘made a part of this standard as an alternative to the asbestos felt described in Sec. 2.10.2. Other types of inert outerwraps have found industry acceptance and have performed satisfactorily during recent years. Ifan alternative outerwrap is specified by the purchaser or proposed to be furnished by the supplier, unless otherwise waived by the purchaser, the supplier shall furnish documentation that the alternative outerwrap has a minimum of five years satisfactory. in-service performance.COAL-TAR COATINGS AND LININGS IL 210.2 Coal-rar-saturated asbestos felt. 2.10.21 Description. ‘The wrapper shall be composed of an asbestos feit having an asbestos content of not less than 85 percent ofthe desaturated felt, when tested in accordance with ASTM D1918. The asbestos shall be bonded with any suitable material and the complete composition saturated with a distilled coal-tar. The felt may be nonperforated or ‘may be perforated with /«-in. (1.6-mm) perforations on |-in. (25-mm) staggered centers, as specified in the purchaser's specifications. Bither type of felt, nonperforated or perforated, shall be reinforced lengthwise with parallel fiberglass yarns on nominal '/s-in. (6.4-mm) centers, 2.10.2.2 Physical characteristics, The finished felt shall have the following physical characteristics: 2.10.2.2.1 Appearance. ‘The finished coal-tar-saturated asbestos felt shall have a ‘calendered surface free from visible external defects. When unrolled at temperatures of 32°-100°F (0°-37.8°C), the felt shall not stick to such an extent as to cause tearing. The test method shall be in accordance with ASTM D146. 2,10.2.2.2 Weight per 100 f (9.3 m?). Exclusive of all comminuted surfacing or sand that has been added to prevent sticking in the rolls, the weight shall be not less than 121b (5.4 kg) nor more than 15 1b (6,8 kg) pet 100 ft? (9.3 m"). The test shall be conducted in accordance with ASTM D146, 2.10.2.2.3 Tensile strength. After test samples from the inside of the roll have been, aged in free air for 72 h, the average tensile strength with fiber grain shall be not less than 25 Ibf/in, (4378 N/m) of width. The test method shall be in accordance with ASTM D146, See. 13. 2.10.2.2.4 Pliability. After test samples from the inside of the roll have been aged in free air for 72h there shall be no cracking of felt when bent over a I-in. (25-mm) mandrel at ‘TPE (25°C), as determined by the following test method: Cut five 6-in, (152-mm) trips with the fiber grain as shown in ASTM D146, Figure 1, D-1 to D-5, and immerse in water at 77°F (25°C) for 10-15 min, Bend these strips through. 180° at a uniform speed, in exactly 2, around a mandrel with a diameter of | in. (25 mm). *2,10.2,2.5 Saturation, After test samples from the inside of the roll have been aged in free air for 72 h the saturation-by-extraction shall be 23 + 5 percent of the weight of the extracted felt. The test method shall be in accordance with ASTM D146, omitting correction for éntiained carbonaceous materials, calculated as follows: 9% saturation = 100 x —¥eight of extracted saturant_ weight of extracted felt 2,10.2.2.6 Lossomheating, The loss on heating shall not be more than 10 percent, as, determined by the following test method: Cut two samples, 6 in. x 12 in. (152 mm x 305 mm), of saturated felt. Weigh each strip and suspend by wire hooks for 2 h in an oven maintained at 200°F + 5°F (93.3°C + 3°C). Care shall be taken that the felt does not touch the oven side or other samples of felt and that localized overheating of the samples does not take place. Remove from the oven, cool in a desiccator, and weigh. Compute the percentage of loss in weight based on the original weight of the sample minus the weight of surfacing. The average of the result on the two samples shall be reported as the loss on heating. 2.10.2.2.7 Thickness. The thickness of reinforced felt shall be not less than 18 mils (05 mm). The test method shall be in accordance with TAPPI T-411. 210.3. Pipeline glass-fiber felt. 2.10.3.1 Description. This outerwrap shall be a nonwoven, thick, glass-fiber mat that has been uniformly impregnated and heavily coated with e material that is compatible with coal-tar enamel. The glass-fiber mat may be of a reinforced or nonreinforced type.2 AWWA C203-86 2.10.3.2 Physical characteristics. The finished material shail have the following, physical characteristics: 2.10.3.2.1 Appearance. ‘The finished outerwrap shall have a smooth, uniform surface, free of visible defects. Fine mineral matter (surfacing material) may be applied to the surface co prevent sticking berween layers. Loose or unbonded surfacing material shall be removed from the surface of the wrap by brushing or other suitable means before packaging. When unrolled at temperatures between 32°- 10°F (0°-38°C), the outerwrap shall not stick to such an extent as to cause tearing. The test method shail be in accordance with ASTM D146. 2.10.3.2.2 Weight. The total weight, including comminuted surfacing, shall not be less than 126/100 ft (586 g/m?) nor more than 15 Ib/100 (732 g/en?). The weight of the base glass-fiber mat, before coating, shall nor be less than 1,7 Ib/100 ft? (83 g/m?). The test shall be in accordance with ASTM D146. 2.10.3.2.3 Thickness. ‘The thickness shall not be less than 30 mils (0,76 mm). The test method shall be in accordance with TAPPI T-41 !, modified. At 10 equally spaced areas selected by sampling, measure the thickness with an Ames dial reading in units of ten thousandths of an inch. Use a circular foot and anvil, both 1 in.? (645 mm?) in area, exerting a pressure of 2 psi (13.8 kPa). Make all measurements in an atmosphere of 50 * 2-percent relative humidity and at 73°F + 2°F (23°C + 1°C) 2.10.3.2.4 Breaking strength. After test samples from inside of the roll have been aged in free air for at least 2 h at 77°F + 2°F (25°C < 1°C), the average strength in the longitudinal direction shall be not less than 35 Ibf/in. (6130 N/m) of width. The average breaking strength in the transverse direction shall be not less than 27 Ibf/in. (4730 N/m) of width, The test method shall be in accordance with ASTM D882, modified. Cut 10 specimens of 1 in, x6 in. (25 mm x 152 mm) with the longer dimensions along the roll and 10 specimens with the longer dimensions across the roll. The size of the clamps of the tensile testing machine should be wider than 1 in. (25 mm), and the clamps should be attached to swivels that are free to move in any direction. Grip the specimen from cach end, leaving a distance of at least 3 in. (76 mm) between the jaws. Initiate the breaking of the load by causing the lower clamp of the machine to travel ata uniform speed of 12 in./min (305 mm/min). Disregard the reading of any specimen that breaks nearer than “4 in. (13 mm) from either clamp, and test an additional specimen in its place. Report the average of the results of 10 individual tests on specimens cut along the roll as the longitudinal breaking strength and the average of the results of 10 individual tests on specimens cut across the roll as the transverse breaking strength. Readings should be to the nearest pound of force (Newton). 210.325 Pliability. After test samples from inside the roll have been aged for at least 2h at 77°F + 2°F (25°C = 1°C) there shall be no cracking of the wrapper when bent over a l-in, (25-mm) mandrel, as determined by the following test method: (Cut five 6-in. (152-mm) strips with the fiber grain as shown in ASTM D146, Figure 1, D-1 10 D-5, and immerse in water at 77°F (25°C) for 10-15 min. Bend these strips through 180° at a uniform speed, in exactly 2s, around the mandrel. 2,10.3.2.6 Weight loss on heating. The loss on heating shall be not more than 2 percent, as determined by the following test method: ‘Cut two samples 6 in. « 12 in, (152mm *305 mm). Remove all loose surfacing material from both sides of the sample to preclude any loose particles falling off in the oven during heating and/or testing, Weigh each strip. Suspend the strips by wire hooks for 2h in an oven maintained at 180°F + 5°F (82°C + 3°C). Care should be taken that the samples do not touch each other or the sides of the oven and that localized overheating of the samples does not take place, Remove from the oven, cool in a dessicator, and weigh. Compute the percentage of loss in weight based on the original weight of the sample. The average of the result on the two samples shall be reported as the weight loss on heating.COAL-TAR COATINGS AND LININGS 13, 2.10.4 Polyethylene-Rraft paper, a two-component single wrap. 2.10.41 Description. The polyethylene film wrapper is comprised of two elements wound ona single core. The 4-mil (0.1-mm) black polyethylene film perforated on a |'/2-in. (38.1-mm) square pattern with /s-in, (0.8-mm) maximum diameter holes is one elementof_ the wrap. The second elements a 70-tb (31.75-kg) basis weight per 3000 ft (114g/m?) ream polycoated kraft paper. The film element can be produced by blown or cast method, The finished film element should be made from a resin that would produce a film with properties described in the following sections. 2,104.2 Physical characteristics. The finished material shall have the following physical characteristics: 2.10.42.1 Appearance. The finished composite wrapper will have an external surface of polyethylene-coated kraft paper with the poyethylene-coated side applied on the outside of the wrap to obtain-a kraft-paper wrapping that is shrink resistant from wetting and drying. The two separate elements will be wound on common 3-in, (76-mm) core with an offset of % in.- in. (16 mm-19mm) between the film element edge and the paper element edge. The film and kraft-paper elements shall be lightly adhered with pressure-sensitive ghie spots 6 in. (152 mm) apart along each edge of the paper element approximately 1'/2in.-2 in, (38.1 mm-51 mm) from each edge. 2.10.4.2.2 Weight. The combined weight of the wrapping elements shall be approximately 4.5 1b/100 ft? (220 g/m?). Approximate weight of the kraft paper shall be 2.6 Ib/100 ft? (127 g/m). The polyetinylene film shall weigh approximately 1.9 Ib/100 ft? (93 g/m 2.10.4.2.3 Thickness. The thickness of the film element shall be 4 mils (0.1 mm) plus or minus 10 percent, as determined by ASTM D2103, method—general, 2.10.4.24 Tensile strength. The tensile strength of the film element before perforating shall be 2100 psi (14 480 kPa) minimum in the machine direction and 1800 psi (12410 kPa) minimum in the cross-tensile ditection, as determined by ASTM D882, method B. 2.10.4.2.5 liability. The film element shall be bent over /a-in, (13-mm) mandrel in asi arc of 180° at a uniform speed of approximately 1 s at 0°F + 2°F (-17.8°C + 1°C) without breaking, as determined by ASTM D146, modified. 2.10.4.2.6 Meltindex. ‘The meltindex of the polyethylene resin used shall be within the range of 0.15-0.45, as determined by ASTM D1238, Low-density fractional-melt polyethylene resins are acceptable. 2,10.4.2.7 Density. The range of resin density from which the film element is made shall be from 0.90-0.92, as determined by ASTM D150s. 2.10.4.2.8 Elongation. The film element elongation shall be 2 minimum of 400 percent in the longitudinal direction and 400 percent in the’ transverse direction, as determined by ASTM D882, method B. 2.10.4.2.9 Heat seal. During application of polyethylene-coated kraft paper, the latent heat from the pipe-coating enamel shall heat-seal the extended edges of the polyethylene film element. The heat-sealed edge will provide a continuous sleeve preventing the film element from unwinding. 2.104.210 Kraft-paper specification is listed in Table 2. 2.10.5 Polyethylene-elastomer laminate, a two-component single orap. 2.10.51 Description. The polyethylene-laminate wrapper is comprised of two components. The backing of @ polyethylene film is one component of the wrap. The polyethylene film shall have a minimum thickness of 9 mils (229 um). The second element is an elastomer-based component laminated to the polyethylene film, The elastomer component shall havea minimum thickness of I mil (25 am). The laminate wrapper may be made by any process that produces a product meeting the properties described in the following sections. The wrapper shall be supplied in roll form,14 AWWA CaOH86 Table 2 Specifications for Kraft Paper for Polyethylene-Kraft Paper, a Two-Component Single Wrap Test ‘Specification Basis weight, TAPP T-410 16/3000 fe? 5% kg/mm?) 5%) Polyethylene coating, 15/3000 ft % (egy) %) Caliper, TAPPE T-411 75 mils * 10% ‘Mullen, TAPPI T-403 1b kg), minioum 4118.6) ‘Tear,* for 16 ply, TAPPI T-414 ‘Machine direction only, grams, minimum 134 Machine dizection plus cross direction, grams, minimum 286 Tensile" TAPPI T-404 ‘Cross direction, Ibf/in. (N/m) width, minimum 23.5 (4100) ‘Focal machine direction plus eross direction Ibf/in. (N/m) widch, ‘minimum 644 (11 280) ‘Other characteristics ‘The kraft-paper element shall be perforated in the composite wrap on 1'rin.(38.1-mm) squere patterns and applied concurrently with the film element from the same core, “Cross ensile can compensate for machine direction ter reciprocally, and total tensile can compensate for toa ear reciprocally (L.Otensile ‘equivalent ro 5.0 points tex, 2.10.5.2 Physical characteristics. The finished material shall have the following physical characteristics: 2.10.5.2.1 Polyethylene component. Composition shall be either low- or high- density polyethylene or a blend of low- and high-density polyethylene plus suitable additives. The polyethylene shall consist of high-molecular-weight film-grade resins with densities in the range of 0.90-0.96, as determined by ASTM D1505, The melt index range of the resins shall range from 0.5-2.5, as determined by ASTM D1505. The minimum thickness shall be 9 mils (229 um), as determined by ASTM D1000. 2.10.5.2.2 Elastomer-based component. The component shall consist of an elastomer compound based on a stable synthetic rubber and suitable additives. The elastomer content typically shall not be less than 20 percent by weight, The minimum thickness shall be 1 rail (25 um), as determined by ASTM D1000. 2.10.5.2.3 Polyethylene-elastomer leminate—total system. The laminate shall consist of @ polyethylene film and an elastomer-besed component. The minimum thickness shall be 10 mils (254 um), as determined by ASTM D1000, Elongation shall not be less than 100 percent, as determined by ASTM D1000. Tensile strength shall not be less than 15 Ibf/in. (2600 N/m) width, as determined by ASTM D1000. 2.10.5.3 Heat seal. During application, the latent heat from the coal-tar enamel shall promote the seal of the edges of the polyethylene-elastomer laminate by producing @ continuous bond at the overlap and preventing the wrapper from unwinding, Sec, 2.11 Whitewash Formula Alll whitewash to be used shall be mixed as follows: 2.11.1 Ingredients. Whitewash ingredients shall include 50 gal (189 L) water, | gal (38 L) boiled linseed oil, 150 Ib (68 kg) processed quicktime, and 10 Ib (4.5 kg) salt 2.11.2 Mixture, Add salt to water, then add lime and oil slowly and simultaneously, and mix thoroughly. Allow mixture to stand for not less than three days before it is used."ane ww COAL-TAR COATINGS AND LININGS 15 Sec. 2.12 Water-Emulsion Latex Paint ‘Water-emulsion latex paints shall be a stabilized, pigmented dispersion of water- insoluble film forming high-molecular-weight (100 000 and higher) synthetic polymeric ‘materials in water. This paint must be able to produce, after application and drving, a film that can adhere to the coal-tar enamel, that is white in color, water resistant, and able to ‘withstand exterior exposure without degradation for a minimum of 90 days. NOTE: Discoloration of the paint film by the coal-tar enamel is not deemed asa failure. ‘This paint shall not be applied where or when its needed drying time can be retarded, thus ruining the paint, The paint shall not be applied to heavily moisture-laden or wet surfaces, and it shall not be applied to surfaces that will be exposed to rain before the paint film is dry, or when the relative humidity is above 80 percent, or when either the ambient air temperature or the substrate temperature is below 40°F (4°C). Sec. 2.13 Kraft Paper Keaft paper shall be smooth 75-Ib (34-kg), [00-percent sulfate. It may be imprinted at intervals with the name of the applicator or steel pipe manufacturer. NOTE: The 75-Ib (34-kg) designation is the weight of 500 sheets of paper measuring 24 in. x 36 in, (610 mm x 914 mm) in size, Sec. 2.14 Shop Application of Primers and Coal-Tar Enamels ‘The contractor shail furnish all labor, equipment, and material required, shall prepare all surfaces to be coated, and shall apply the primer and coal-tar enamel to all interior and exterior surfaces to be coated. 2141 Unblasted surfaces—cleaning, blasting, and protecting after blasting. 2.14.11 Cleaning and blasting. Before the metal is blast cleaned, all oil and grease on the surfaces shall be thoroughly removed by flushing with a suitable solvent (such as xylene or 1,1,1 trichloroethane) and wiping with clean rags. The use of dirty or oily rags or dirty solvent will not be permitted (see SSPC-SP1). All foreign matter not removable by blast, cleaning shall be removed by suitable means. All metal surfaces shall be thoroughly cleaned by blasting. Blast-cleaning operations shall remove all rust, scale, and other impurities from the surface, exposing base metal over all, presenting a grayish matte appearance between SSPC-SP6 and SSPC-SP10. This is equivalent to NACE no. 3 and NACE no. 2 a8 described in NACE TM-01-70 or TM-O1-75. Blasted surfaces that rust before a priming coat has been applied shall be cleaned of all rust by buffing or wire- brushing, or shall be reblasted. Adequate air separators shall be used to effectively remove all cil and free moisture from the air supply to the blaster. . 2.14.1.2 Protecting after blasting. After being cleaned, the pipe shall be protected from, and be maintained free of, oil, grease, and dirt that might fall on the pipe before it has received its final enamel coat. During blast cleaning, any pipe found to show pits shall be set aside immediately, pending examination by the inspector for acceptance, reconditioning, or rejection 214.2 Priming. 2.14.21 Blasted surfaces—cleanliness, moisture content, and allotted time between blasting and priming. All blasted steel surfaces shall be cleaned of dust and gritand shall be primed immediately following blasting and cleaning. The surfaces shall be dry at the time the primer is applied, and no primer shall be applied during rain or fog unless the pipe to be primed is protected from the weather by suitable housing. 2.14.22 Fouled or thickened coal-tar primer. The use of coal-tar primer that has become fouled with foreign substances or has thickened through evaporation of the solvent oils will not be permitted. 2.14.23 Methods of primer application. At the option of the contractor, the application of the primer shall be by hand brushing, spraying, or other suitable means and46 AWWA C203-86 shall be in accordance with instructions for application, as supplied by the manufacturer of the primer. The apparatus to be used for application of the primer shall be acceptable to the inspector. Spray-gun apparatus to be used shall include a mechanically agitated pressure pot and an air separator that will remove all oil and free moisture from the air supply. 2.14.24 Condition of primer after application. After application, the priming coat shall be uniform and free from floods, runs, sags, drips, holidays, or bare spots. Any bare spots or holidays shall be recoated with an additional application of primer. All runs, sags, floods, or drips shall be removed by scraping and cleaning, and the cleaned area shall be retouched or remedied by reblasting and repriming. Suitable measures shall be taken to protect wet primer from contact with rain, fog, mist, spray, dust, or other foreign matter tantil completely hardened and enamel applied. 2.14.2.5. Priming in cold weather. In cold weather, when the temperature of the steels below 45°F (7°C), or atany time when moisture collects on the steel, the steel shall be warmed to a temperature of approximately 85°-100°F (30°-38°C), which shall be maintained long enough to dry the pipe surface prior to priming. To facilitate spraying and spreading, the primer may be heated and maintained during the application ata temperature of not more than 120°F (49°C). 2.44.2.6 Primerdry time, The minimum and maximum drying times ofthe primer, or the period between application of primer and application of coal-tar enamel, shall be in. accordance with instructions issued by the manufacturer of the primer. If the enamel is not applied within the allowed maximum time after priming, the pipe shall be reprimed with an additional light coat of primer oF the entire prime coat shall be removed by reblasting and the pipe reprimed. 2.14.3 Preheating of primed pipe. 2.14.3.1 Enameling of primed pipe during cold weather or high humidity. During cold weather, when pipe surface temperature is below 45°F (7°C), or during rainy or foggy weather, when moisture tends to collect on cold pipe, enameling shall be preceded by warming of the primed pipe. Warming shall be done by any method that will heat pipe ‘uniformly to recommended temperature without injury to primer. Steel temperature of pipe shall not exceed 160°F (71°C). 2.14.3.2 Enameling of primed pipe after heating. After being heated and while pipe is at its highest temperature, inside-lining enamel shall be applied. Coating of the outside of the pipe with coal-tar enamel shall proceed immediately after the spinning operation is completed, while the pipe is still warm from preheating and centrifugal casting. 2.144 Preparation of coal-tar enamel for application. 2.14.41 Equipment used. The enamel shall be heated in suitable agitated heating kettles equipped with accurate and easily read recording thermometers. The thermometers will be checked and adjusted by the inspector whenever necessary. The charts therefrom shall constitute a basis for acceptance or rejection of any enamel due to improper heating or handling, ot both. 2.14.4.2 Procedures for enamel supply and operating kettles. The operating or supply kettles, or both, shall be provided in sufficient numbers so that the enamel may be heated and coordinated with the application procedure, Bulk deliveries of molten enamel may be received in lieu of enamel received solidified in containers. The molten enamel may be transferred directly to the supply or operating kettles. The operating kettles shall be constructed with mechanical mixers to provide continuous mixing of the enamel. So-called roofer's kettles that do not contain agitators and that are designed to heat materials used in the roofing industry will not be permitted. No enamel shall be held in the operating kettles at application temperatures for a longer period than recommended by the manufacturer or stated in the manufacturer’s instructions. The enamel heated in supply Kettles shall not exceed the temperatures and melting periods recommended by the coating manufacturer. Operating kettles (unless of the mechanically agitated type) shall not receive a continuousCOAL-TAR COATINGS AND LININGS 17 supply of unmelted enamel during the time they are in use, bur shall be completely emptied of one charge and cleaned frequently, as required, before the next charge of unmelted ‘enamel is added. In the operation of field patching, a heating kettle not exceeding 50 gal (189 L) in capacity may be used continuously. Kettles shall be covered with hinged lids that may be securely fastened down and shall be tightly closed during the heating and application of enamel, except when necessary for loading and stirring. 2.14.4.3 Size of solidified enamel for kettle charge. When the Kettles are being loaded, any solidified enamel shall be broken into pieces suitable for the heating equipment 2.1444 Maintenance of enamel, Both solidified and molten enamel shall be ‘maintained moisture- and dirt-free at all times prior to, and at the time of, heating and application. 2.1445 Heating of enamel, The solidified enamel charge shall be melted and brought up to application temperature, Excessive kettle-skin temperatures that injure the enamel shall be avoided. Molten enamel received via bulk delivery shall be transferred from the supply kettle o the operating kettle or directly to the weir. The temperature at which the enamel will be applied shall be in accordance with the recommendations of the manufacturer. The hot enamel shall be thoroughly and continuously stirred for a minimum of 5 min, and intervals between stirring shall not exceed 15 min, regardless of whether the ‘enamel is being dispensed from kettles or is being held ready for use. Iron paddles shall be used for stirring, Wooden paddies will not be permitted. 2.14.4.6 Enamel maximum temperature and kettle residency limits. The maximum. temperature of the supply or operating kettles to which the enamel may be heated and the ‘maximum time that the enamel may be held in the kettles at application temperature shall be in accordance with the instructions supplied by the manufacturer, 2.14.4.7 Overheatedor extended residency enamel. Enamel that has been heated in excess of the maximum allowable temperature or that has been held at application temperature for a period in excess of that specified, shall be condemned and rejected. Fluxing the enamel will not be permitted. 2144.8 Unused enamel. Excess enamel remaining in a kettle at the end of any heating shall not be included in a fresh batch in an amount greater than 10 percent of the batch. Kettles shall be emptied and cleaned frequently, as required. The residual material removed in cleaning the kettles shall not be blended with any enamel. 2.14.4.9 Limits for the loss of enamel penetration during application. A minimum of 50 percent of the original enamel penetration at 77°F (25°C) shall be retained in the applied enamel, This minimum penetration shall be evidence of satisfactory melting and handling practice. The inspector may periodically take samples of the enamel as it is being applied to the pipe. If the penetration is less than 50 percent of the original enamel penctration at 77°F (25°C) in any kettle, the inspector may reject the enamel in that kettle. ‘The cost of such tests shall be borne by the purchaser, if the penetration exceeds 50 percent of the original value, or by the contractor, if itis less. 2.14.4.10 Kettle screens. When applying the enamel, all kettles shall be equipped with suitable screens to exclude particles of foreign matter or other deleterious materials that ‘could cause flaws in the finished coating. 2.14.3 Application of coai-tar enamel to interior surfaces. 2145.1 Enameling during cold weather or high humidities. The primed-steel surface to be enameled shall be dry and clean at the time the enamel is applied, No enamel shall be applied during cold weather, rain, or fog unless the pipe is preheated or protected by suitable housing. 2.14.5.2. Methods ofapplication. The application of the enamel to the inside surface of all pipe other than specials shall be by centrifugal casting by either the trough method (Sec. 2.14.6) or the retracting-weir or feed-line method (Sec. 2.14.7).18 AWWA C2m3-86 2.14.5.3 Condition of enamel after application. During application of enamel, the pipe shall be revolved at the speed best suited to produce a smooth, glossy lining of uniform thickness. Finished coal-tar enamel lining shall be free from wrinkles, sags, blisters, ot blowholes. Thickness of lining shail be 2 in. (2.4 mm), and the allowable variations in thickness shall not exceed * '/s2 in. (+ 0.8 mm). All pieces of lined pipe in which there are excessive rough areas or other irregularities, as determined by the inspector, shall be sttipped of the entire lining and relined as required in this standard for original lining, 2.14.54 Cooling of enamel lining, Water used for chilling the enamel lining following centrifugal casting shall not be applied until the enamel has hardened sufficiently to prevent water marks. 2.14.6 Centrifugal casting of coal-tar enamel by the trough method. 2.14.6.1 Rotation of pipe. Pipe shall be rotated on rubber-tired or stee! wheels with suitable guards or hold~down wheels to prevent the pipe from leaving the rolls during spinning operations. 2.14.6.2 Pouring trough requirements. Molten enamel shall be introduced into the pipe by a pouring trough extending the full length of the pipe in either one or two sections ‘The pouring trough shall be level and shall have astraight and even pouring lip. The trough may be heated, either by electric heating elements or by a gas flame, to a temperature best adapted to the equipment available. 2.14.6.3 Filling of trough with molten enamel. Transfer of moiten enamel from kettles to pouring troughs shall be conducted in such a manner as to prevent excessive loss of heat, Hot enamel shall be held in the pouring troughs between filling and pouring for not more than 1 min, Enamel shall not be poured from troughs into the pipe until the pipe has, reached its maximum speed of rotation, 2.14.6.4 Pouring of enamel into the pipe. Enamel shall be poured by inverting the ‘trough with a uniform rotation and at such speed as to distribute the enamel evenly throughout the pipe 2.14.6.5 Cleaning of trough. Immediately after the pouring operations, the trough shall be righted and removed from the pipe and, when necessary, cleaned of alexcess enamel remaining in the trough, Such enamel may be reused, if itis clean and free of dirt, by adding it to fresh batches in quantities not exceeding 10 percent of unmelted enamel. 2.14.7 Centrifugal casting of coal-rar enamel by the retracting-tveir or feed-line method. 2.14.71 Rotation of pipe. Pipe shall be rotated on rubber-tired or steel wheels with suitable guards or hoid-down wheels to prevent the pipe from leaving the rolls during spinning operations. 2.14.72 Supplying enamel to the weir or feed lines. Molten enamel shall be supplied to the weir or feed line from a reservoir through supply pipes and maintained at application temperature by means of insulation and by the use of suitable methods of heating both reservoir and supply line. Supply of enamel shall be by means of a power-driven circulation pump. 2.14.7.3 Application of enamel using weir or feed lines. ‘The hot enamel shall be introduced into the rotating pipe by means of a retractable feed line or a traveling weir with pouring lip parallel to the longitudinal axis of the pipe. By either method, the discharge element of the supply mechanism shall travel the entire length of the pipe. The speed of travel shall be properly coordinated with the speed of rotation to ensure complete uniform application of the molten enamel. 214.8 Application of coal-tar enamel and outersorap system to exterior surfaces 2.14.81 Primed surfaces, ‘The primed-steel surface to be enameled and wrapped shall be dry and clean atthe time the enamel is applied. Any damage occurring to the primer coat shall be repaired by retouching before application of the enamel, 2.14.8.2 Application ofenamel. External enamel shall be applied by pouring on the revolving pipe and spreading to the specified thickness. Enamel shall be applied so that eachCOAL-TAR COATINGS AND LININGS 19 spiral resulting from the spreading operations shall overlap the preceding spiral, producing a continuous coat that is free trom defects, skips, or holidays. The thickness of coating shall be ¥/2 in. (2.4 mm), and the allowable variation in thickness shall not exceed + 2 in. (£08 mm). Where the protrusion of the weld seam interferes with this thickness, the thickness of the enamel above the weld seam shall meet the thickness specified. 2.148.3 Application of outerwrap. Outerwrap shall be mechanically applied in a continuous end-feed machine or in a lathe-type machine or by other suitable outerwrap application equipment. The outerwrap shall be applied to, but not buried in, the outer surface immediately following the final coat of enamel. The outerwrap should then be, if so specified, immediately followed by a kraft-paper final wrap so that the kraft-paper wrap can develop adhesion with the outerwrap. 2.14.8.4 Prevention of the gassing of the outerwrap. If low-porosity outerwrap, ‘which has been stored, is applied under ambient high-humidity conditions, “gassing,” that is, the formation of craters or voids in the enamel beneath the outerwrap, may occur. To prevent gassing, apply a film of outerwrap saturant or hot enamel to the underside of the outerwrap before ic is drawn into the enamel on the pipe. NOTE: Some outerwraps, because of composition, are required to be stored in a dry, covered area and in the original packaging until immediately prior to use, Check with the manufacturer for proper storage and stacking requirements. 2.14.85 Overlapping of outerwrapping during application. The outerwrap, as specified in Sec, 2.10, shall be of suitable width for smooth, spiral application and shall be of approximately uniform width. The lap of the wrap shall be not less than '/2 in. (13 mm). The outerwrap shall be applied neatly and smoothly with bleed-out between laps and shall be free of wrinkles and buckles. 2,14.8.6 Conditioning of outerwrap surface after application. The outside surfaces are tobe given a whitewash, water-emulsion latex paint, or kraft-paper finish coat following, final inspection. The spirally wrapped kraft paper shall be tack-bonded with enamel at frequent intervals NOTE: Some outerwraps, which are based on polymeric composition, may not require that"their outside surface be given the aforementioned finish coat. Check with the manufacturer as to whether or not the surfaces require finish coats. 2.14.8.7 Exterior protection thickness requirements. The resultant construction of the exterior protection shall be: primer; coal-tar enamel (Yiaein. + Ysoin, (2.4-mm + 0.8-mm] thick); bonded outerwrap; and finish coat, if the finish coat is specified. 2.14.8.8 Handling pipe immediately after application. ‘The costed pipe shall not be rolled or supported on its enameled and wrapped surface until sufficiently cooled and hardened to avoid deformation of the coating system.” 2.14.9 Application of coal-rar enamel at ends of pipe section. 2.14.9.1 Pipe sections to be field welded. When pipe sections are to be joined together by field welding, a band that is free of protective materials shall be lefton the inside and outside surfaces at the ends of the sections. This band shall be of sufficient width, as specified in the purchaser's specifications, to permit the making of field joints without injury to the lining and coating. 2.14.9.2 Pipe sections to be joined with mechanical couplings. When pipe sections are tobe joined together with mechanical couplings, a band free of protective materials shall be left on the exterior surface at the ends of the sections. This band shall be of sufficient width, as specified in the purchaser's specifications, to permit joint makeup. The interior enamel lining shail extend to the pipe end. 2.14.93 Bell-and-spigot ends. For bell-and-spigot ends with rubber gasket, the interior enamel lining shall extend from the end of the pipe at the spigot end to the holdback in the bell end. The exterior coating shall extend from the lip of the bell to the holdback on the spigot end. The exposed steel surfaces on the inside of the bell and the outside of the20 AWWA Ca05.86 spigot end shall be given a coating of type B (fast-drying, synthetic) primer to a dry-film thickness of 2.5 mils + 0.5 mil (0.06 mm = 0.01 mm). 2.14.94 Miscellaneous joints. For joints other than those specified in this standard, the length of pipe to be left bare at the ends shall be in accordance with the purchaser's, specifications. 2.14.10 Specials—cleaning, priming, lining, and coating. 2.14.10. Cleaning, priming, lining, and coating of specials. ‘The results of cleaning, priming, lining, and coating of specials shall be equivalent to the results of similar work on straight pipe sections. Methods deviating from the prescribed procedure shall be acceptabie to the inspector. If the shape precludes spinning, the lining and exterior coating shall be applied using hand daubers and equipment listed in the following sections or using other suitable methods. 2.14.10,2 Hand-dauber requirements. Hand-enameling daubers shall be of the size best adapted for the work. Daubers shall be made of the best grade of Tampico fiber set in solid hardwood handles. Mops, sweeps, or knot daubers shall not be used. Long-handled. horseshoe daubers or glass mops will be acceptable for large arcas and flat work. 2.14.10.3 Enameling buckets. Enameling buckets shall be filled from the heating kettles with ladles or from spigots attached to the kettles and shall not be dipped for filing, Buckets shall be kept clean and free of dirt at all times and shall be set on suitable pads or blocks, not directly on the ground or on enameled surfaces. Buckets shall not be allowed to accumulate excess chilled enamels, but shall be kept clean. 2.14.10.4 Minimum enamel temperature. Enamel shall not be used from the cnameling buckets below the minimum temperature specified by the manufacturer. 2.14.10,5 Dripsand splashes of enamel. All drips and splashes of enamel on primed surfaces shall be carefully scraped off before the hand-brushed coat of enamel is applied. 2,14.10.6 Application of the enamel. All primed surfaces shall be double-coated by applying the enamel with hand daubers. The brush strokes of enamel shall be made in the direction of flow. All brush strokes shall overlap and form a continuous coating. The daubing may be done by the double-lap or “shingling” method. The work shall be done in a workmanlike manner, and no indiscriminate smearing of the enamel will be permitted. On all welds, the strokes of the first coat of enamel shall be applied along the weld. 2.14.10.7 Holiday detection, specials. Enamel that is hand-applied to the exterior of specials shall be examined with a 7200-V maximum holiday detector. Holidays shall be repaired prior to the application of the bonding coat of enamel for the outerwrap. 2.14.11 Fitsings. All fittings, such as manholes, service connéctions, air valves, and blowoff connections, shall be protected with primer and coal-tar enamel, and the same application procedure shall be used as specified in Sec. 2:14.10. 2.14.12 Elecerical inspection of coal-tar enamel-coated pipe. 2.14.12.1 Electrical inspection—contractor’s responsibility. After lining, coating, and wrapping operations have been completed, the contractor shall conduct electrical inspection ofall exterior coating of the pipe with an electric holiday detector. The contractor shall also electrically inspect all interior linings applied or repaired by hand daubing and subjected to traffic of personnel entering the pipe, or that otherwise exhibit any evidence of physical damage. Any defect in the coating and lining shall be satisfactorily repaired at the ‘expense of the contractor. 2,14.12.2 Electrical equipment requirements. The clectrical equipment used to test the enamel in the shop and yard, as well as in the field, shall be a portable, low-amperage, adjustable-voltage, pulse-type holiday detector using an audible signaling device. The holiday detector shail be furnished with a coil-spring electrode or a suitable brush-type electrode. The primary input wattage shall be no higher than 20 W, and the minimum pulses at crest voltage shall be 20/s. The operating voltage of the detector shall be as determined in Sec. 2.14.12.4, but in no case shall exceed 15 000 V.COAL-TAR COATINGS AND LININGS 21 2.14.12.3 Required adjustment of detector voltage. Because of variables such as relative humidity and temperature, the detector voltage shall be adjusted no less than twice per S-h working shift: once just before starting work at the beginning of the shift and then again after 4 h. Holiday detectors with operable meters that detect variances in the voltage and are used to assist in adjusting the unit’s voltage normally need not be corrected more than once during an 8-h shift. Correction of this type of equipment shall be made at the beginning of the shift. To ensure proper inspection voltage, the equipment shall be grounded properly in accordance with the manufacturer's instructions for the equipment. 2.14.124 Setting of equipment’s voltage prior toinspection. ‘The operating voltage of the detector shall be determined by the following procedure: Select a coated and wrapped portion at the overlap of the outerwrap approximately 15 in, (381 mm) from the end of one pipe length. This location represents the maximum, thickness of the exterior coating and wrapping on the pipe. Puncture the coating and wrapping with a sharp knife point, awl, ice pick, or a similar sharply pointed tool, ‘Move the detector electrode back and forth over the puncture, and reduce the voltage until the detector ceases to register the known holiday. Place a strip of dry specified outerwrap, its thickness being the same as the outerwrap applied to the pipe (Sec. 2.10), over the known holiday. Move the detector electrode back and forth over the felt strip and slowly increase the voltage until the detector begins to register the known holiday under the outerwrap. CAUTION: Some outerwraps, because of their thickness or composition, may have @ dielectric strength greater than that of the coal-tar enamel. Care should be given to the amount of voltage applied when setting the electrical equipment to detect the known, holiday, so as not to override the dielectric strength of the enamel. Excessive voltage may induce holidays in the enamel, thereby giving erroneous readings. Contact the manufacturer of the outerwrap for proper test-voltage information. 2,14.12.5 Speed of travel during inspection, After the voltage has been properly adjusted, as outlined above, the electrode shall be passed over the coated and wrapped surfaces one time only, at the rate of approximately 30-60 ft/min (9.2-18.3 m/min). 2.14.12.6 Holidays—marking and repair. Any holidays or missed places will be indicated by an electric spark between the electrode and the metal surface. All holidays or missed places so indicated shall be marked by chalk or crayon and repaired, When repairs are being made, the outerwrap shall be cut from round the holiday. The bared area shall be repaired with the same system as the original coating or lining. After the repairs are completed, the repaired areas shall be retested with the electric holiday detector. 214.13 Whitewash, teater-emulsion latex paint, or Rraft-paper finish coat. Outside surfaces of all pipe, specials, and fittings shall be given ¢ finish coat of water-resistant whitewash, water-emulsion latex paint, or wrap of kraft paper immediately following final inspection. Some outerwraps, based on polymeric composition, may not require the outside surface to be given the aforementioned finish coat. Check with the manufacturer as to whether or not the outer surface requires a finish coat. Sec. 2.15 Coating Repair 2.15.1 All damages, flawed areas, and holidays. These areas shall be repaired using repair materials made by the manufacturer of the material originally used to coat the pipe. In no case is damaged enamel to be repaired by applying enamel over loose or damaged enamel where the damage goes down to the metal or where the bond of the enamel has been destroyed, Damaged areas are generally categorized into three types: pinpoint or bubble, exposed metal, or extensive damage. Repair of these types is discussed in the following sections. Repairs are to be made using materials meeting the original specification.22 AWWA Cz03.86 2.15.2 Repair of pinpoint- or bubble-type damage, Remove ditt, foreign matter, kraft paper, and outerwrap with a sharp knite, taking care not to damage surrounding enamel. Pour correctly heated enamel over prepared area to specified thickness and cover with a patch of outerwrap. 2.15.3 « Repair of exposed-metal type damage. These damaged areas are those up t approximately 4 in, by 4 in. in size. Repair by removing the dirt foreign matter, and all disbonded enamel, and then bevel the surrounding edges. Clean metal surface properly, using wire brushes if required, and reprime bare area. After primer has dried, apply correctly heated enamel over prepared area to specified thickness and cover with a layer of outerwrap, 2.15.4 Extensive-damage type damage. This type relates to defects such as partially uncoated, unbonded enamel; severe cracking; excessive holidays; or inadequate film thickness. Enameled pipe having these conditions shall be reprocessed. 2.15.5. Electrical inspection. Repaired areas shall be electrically inspected in accor- dance with Sec, 2.14.12, ‘Sema’ SECTION 3: COAL-TAR TAPES, HOT-APPLIED, FOR SPECIAL SECTIONS, CONNECTIONS, AND FITTINGS Sec, 3.1 General ‘The protective coating system described in this section consists of a cold primer and heated coal-tar tape, shop- or field-applied to the exterior surfaces of steel-water-pipe special sections, connections, and fittings. Sec, 3.2 Inspection and Testing Unless otherwise provided in the purchaser's specifications, the contractor shall be responsible for the performance of and costs forall laboratory test requirements as specified herein, Except as otherwise specified, the contractor may use the contractor's own facilities or a commercial laboratory acceptable to the purchaser. Sec. 3.3 Material Compliance ‘Materials shall be as specified herein. Components not specified shall be selected by the contractor and shall be subject to all applicable provisions of this standard. Sec. 3.4 Packaging 3.4.1 Individual roll, Each roll of tape shall be packaged in such a manner as to prevent the roll from adhering to the packaging material of the box. 3.4.2 Multiple rolls. Multiple rolls shall be packaged in quantities not to exceed the weight limitation of the box specification. Each roll of tape shall be protected from adhering to other rolls of tape, to the box, or to the packaging material by the use of dividers. 3.4.3, Primer. The primer shall be packaged in 1-gal 4-L) cans or 5-gal (19-L) pails. 3.44 Transportation. Both tape and primer shall be packaged to ensure acceptance and safe delivery at the destination. Sec. 3.5 Primer Primer shall be a coal-tar or suitable resin product. It shall be a liquid that can be applied without heating and shall produce an effective bond between the surface to be protected and the subsequent coating of coal-tar tape. Primer shall contain no benzene andCOAL-TAR COATINGS AND LININGS 23 shall not settle in the container to form a cake that cannot bé easily mixed by hand stirring. Depending on the application method, primer shall have good spraying or brushing properties and a minimum tendency to produce bubbles during application. Sec, 3.6 Tape 3.6.1 Composition, Tape shall be comprised of coal-tar component supported on fabric of organic or inorganic fibers. The coal-tar component shall comply with the quality provisions of Sec. 2.5 and Table 3. The fabric shall be thoroughly coated and completely covered on both sides with coal-tar component. Tape shall be furnished in standard widths as specified by the supplementary specifications or as recommended by the manufacturer. Rolls shall be wound on hollow cores having a minimum inside diameter of 11 in. (B75 mm), Tape shall have sufficient pliability ata temperature of 77°F (25°C) to unwind from the roll without disbonding the coal-tar component from the fabric. 3.6.2 Lengch. The standard length of tape on one roll shall be either 30 ft, 50 ft, or 75 t(9.2.m, 15.3 m, or 22.9 m),as specified by the purchaser's specifications, In the absence of aspecified length, the length of the rolls may be either 30 ft, 50 ft, or 75 £t(9.2m, 15.3 m, or 22.8 m) as selected by the supplier. 3.6.3 Thickness. ‘The variation in the thickness of the tape shall not exceed + 5 mils, (£127 4m) from the thickness specified in the purchaser’s specifications. In no case shall the thickness of the tape be less than 50 mils (1.27 mm). 3.6.4 General requirements. When heated toa condition permitting conformation to the surface to be coated, the tape shall withstand, without tearing, the tensile force necessary to obtain a tightly wrapped coating free of voids. The tape shall provide @ minimum thickness of 15 mils (0.4 mm) of coating between the steel surface and the inner face of the fabric when applied under the tension necessary to provide a void-free wrap, Should the tape havea plastic film separator of the type that is not removed prior to application, the separator shall not adversely affect the bond between overlapped sections of tape. Sec, 3.7 Application of Primer ‘3.7.1 Special sections, pipe connections, or fittings shall be free of all rust, weld spatter, or other contaminants, in accordance with Sec. 2.14.1.1, prior to application of primer. Primer shall be applied by brush, glove, or spray so as to give a coating thickness that is between 2 mils and 4 mils (0.05 mm and 0.10 mm) when wet. The primer shall be allowed to dry to the touch prior to tape application, Primer and tape shall be furnished by the same manufacturer, Table 3 Physical Properties of Tape Requirement Property ASTM Method ‘Maximum Tape ‘Width deviation—in. (mm) - - Y5(1.6) ‘Thickness mis (um) 7 50 (1270) = ‘Thickness deviation—mils (xm) - ~ 5.27) Coal-tar component Softening point—"F (°C) 3s 150 (65) 250,(121) Penetration, 77°F (25°C)/100 g/5 5 * 3 20 Fille-—% Deas 2 30 Film separator (if used and if ofthe type that is aot removed prior 10 application)—mils (am) - 0.25 (6.4) 0.5042.7) “AWWA C203, See. 28.12A AWWA cn0s.86 3.7.2 application is done in cold weather, the surface of the pipe shall be preheated until it is warm to the touch and until traces of moisture are removed, and then the primer shall be applied and allowed to dry. Sec. 3.8 Application of Tape ‘The tape shall be wrapped in accordance with the manufacturer's recommendations in ‘2 manner that shall meet the adhesion and holiday-detection requirements of this standard. In any event, there shall be a minimum of in, (12.5-mm) overlap per single wrap. Either single or double wraps shall be specified in the purchaser’s specifications. In application, ‘care shall be taken that there are ne air pockets or bubbles beneath the tape, and the tape shall ‘be in intimate contact with the primed steel. The manufacturer shall provide assistance in demonstrating the proper method of application if requested by the contractor or purchaser. Sec. 3.9 Adhesion Test 3.9.1 Adhesion tests shall be made to determine the proper bond between the coal-tar component of the tape and the properly primed pipe. The number of adhesion tests required to determine quality of application is at the inspector's option; but, to avoid extensive repair, itis desirable that no more than one test per special section, connection, or fitting should be performed unless defects are found in the first test. 3.9.2 The temperature of the tape and pipe to be tested shall be between! 50°F and 80°F (10°C and 27°C), and within 5°F (3°C) of each other. If the temperature is outside this range, hot or cold water shall be poured over the test area until this temperature range is attained. A test aree shall be selected by the inspector where the tape is smooth for 6 in (152 mm) in the longitudinal direction of the tape. Two knife cuts that are 6 in. (152 mm) Jong and 2in. (51 mm) apart shall be made through the tape. A flat blade shall be used to pry up 2in, (51 mm)of the fabric. This 2-in. (51-mm) flap of fabric shall be grasped firmly in one hand and shall be pulled with a quick motion in the direction of the remaining 4in. (102mm) of the 6-in, (152-mm) knife cut. 3.9.3 Theadhesionis satisfactory if(1) the tape tears atthe point of stripping or (2) the {fabric strips from the underlying coal-tar component, leaving no more than 10 percent of the primer or metal exposed. Sec. 3.10 Electrical Inspection ‘The electrical inspection of hot-applied tape wrapping for all special sections, connections, and fittings shall be in accordance with all provisions of Sec. 2.14.12; except, the second paragraph of Sec, 2. 14.12.4 shall be replaced by the following sentence: “Selecta coated and wrapped portion of the special section, connection, or fiting representative of the maximum thickness of the exterior coating and wrapping as determined by a thickness gauge.” The hot-applied tape wrapping shall pass the electrical inspection test if no electric spark occurs. If an electric spark occurs between the electrode and the metal surface, the holiday shall be marked with a suitable indicator to identify the area for repair. Sec, 3.11 Coating Repair 3.11.1 Alldamoges, flawed areas, and holidays. These areas shall be repaired using repair materials made by the manufacturer of the material originally used toccoat the pipe. In ro case is the damaged pipe to be repaired by applying tape over loose or damaged tape where the damage goes down to the metal or where the bond of the tape has been destroyed. 3.11.2 Repair of rape. The repair shall be made by removing the hot-applied tape from the area around the holiday and then using the same system of primer and hot-applied: COAL-TAR COATINGS AND LININGS 25 tape as the original wrapping. When completed, the area shall be retested following the D method of electrical inspection described in Sec. 3.10. Sec. 3.12 Manufacturer’s Tests for Physical Properties 3.12.1 Applicable tests. The following tests shall be made in the manufacturer's plant or laboratory to ensure the delivery of a product conforming to the standard. The method of sazupling and number of samples shall be as stated in the following subsections, unless otherwise specified in the purchaser’s specifications. 3.12.2 Tape width. Remove aspecimen of tape at least 3 (0.9m) long from each of three randomly selected rolls, and place the specimens on a smooth flat surface. Measure the width of each specimen at the widest and the narrowest points to the nearest /isin. (1.6mm), using a standard steel scale. The width deviation between specimens shall not exceed + Yigin, (& 1.6 mm), 3.12.3 Roll length. Determine the number of feet of tape in a roll by averaging the results of measurements on three randomly selected rolls. Accurately weigh each of the rolls, ‘without the core. Remove 6 ft (1.8 m) of tape, including the film or paper separator, from » cach roll. Weigh each 6-ft (1.8-m) specimen separately and determine the weight per foot, Calculate the length of the tape in each roll, and compute the average length of the rolls from this data, An average length less than that specified shall constitute failure of this test. 3.12.4 Tape thickness. Measure the thickness of the tape at no less than 10 locations at intervals of no ess than I ft(300 mm) on the three rolls of tape used under Sec. 3.12.2. The measurement shall be made with a micrometer calibrated to read in thousandths of an inch (millimetre) or smaller units and having contact feet of not less than ‘4 in, (6.4 mm) in diameter. Any thickness measurement outside the limits specified in Table 3 shall constitute failure of this test 3.12.5 Softening point, Three test specimens shall be taken from separate 6-ft D (1.8-m) sections of the three rolls of tape used under Sec. 3.12.2 and shall be chilled in a refrigerator to a temperature that will permit removal of the coal-tar component from the fabric by cracking and peeling when the tape is flexed. Care shall be taken that backing fibers ‘re not included in the coal-tar component sample. Heat the coal-tar component in a covered container at a temperature just above the temperature necessary to cause it to flow. Pour a part of the liquid coal-tar component into the softening-point mold, pour part into acup for uusein the penetration test, and keep part asa small specimen for use in the filler-content test. Determine the softening point in accordance with ASTM D36. A value outside the limits ) specified in Table 3 shall constitute failure of the tape to meet the softening-point requirements. : 3.12.6 Penetration, Test the specimen of coal-tar component obtained for penetra~ tion value in accordance with ASTM D5, A value outside the limits specified in Table 3 shall ‘constitute failure of the tape to meet the penetration requirements. 3.12.7 Filler content. ‘Test the coal-tar component specimen obtained for the filler content in accordance with ASTM D2415. A value outside the limits specified in Table 3 shall constitute failure of the tape to meet the filler requirements. 3.12.8 Laboratory adhesion test. Clean a section of 3-in. (76-mm) outside-diameter stee! pipe to the requirements of Sec. 2.14.1. The cleaned section of pipe shall be no less than 3 £t(900 mm) in length. Prime the cleaned section of pipe and apply a 2-in. (51-mm) width of tape spirally according to the manufacturer's instructions. Allow tape to set at room temperature for 18h, After it has completely set, take the end of the tape and pull it off by ‘hand. The coating is considered to have satisfactory adhesion if(1) the tape tears at the point of stripping or) the fabric strips from the underlying coal-tar component eeving no more than 10 percent of primer or base coat exposed.2 sume! SECTION 4: HANDLING, TRANSPORTING, AWWA C205-86 AND FIELD PROCEDURES samzmmexe: Sec. 4.1 Handling and Transporting Enameled Pipe 4.1.1 Handling. Protected pipe shall be handled at all times with equipmentsuch as stout, wide-belt slings and wide padded skids designed to prevent damage to the coating. Bare cables, chains, hooks, metal bars, or narrow skids shall not be permitted to come in contact with the coating, 4.1.2 Rail shipments. When shipped by rail, all pipe shall be carefully loaded on properly padded saddles or bolszers. All bearing surfaces and loading stakes shell be properly padded with approved materials. Pipe sections shall be separated so that they do not bear against each other, and the whole load shall be securely fastened together to prevent movement in transit. The pipe shall be loaded and tied into a unit load in strict accordance ‘with the current loading rules of the American Railway Association, whenever they arc applicable, 4.1.3. Truck shipments, In truck shipments, the pipe shall be supported in wide cradles of suitably padded timbers hollowed out on the supporting surface to fit the curvature of the pipe. All chains, cables, or other equipment used for fastening the load shall be carefully padded. For smaller-diameter pipe, sand- or sawdust-filled bags may be used. instead of hollowed-out timbers. 4.1.4 Inspection at destination. ‘The purchaser shall inspect the pipe and pipe protection on cars or trucks at destination, and if the pipe or pipe protection was damaged during shipment, claim shall be made against the carrier. 4.1.5 Temperature limitations for shipping. Coated pipe shall not be shipped or handled when it is anticipated that temperatures will occur which are lower than 30°F (17°C) above the crack temperature of the enamel, as defined in Table 1. 4.1.6 Payment for repair. Pipe and coating damaged in handling or transporting shall be repaired satisfactorily at no additional cost to the purchaser. Damaged coating shall bbe repaired in accordance with Sec, 2.15. Sec. 4.2 Field Procedures 4.2.1 Trench site. Pipe shall be stored along the trench side, suitably supported off the ground to avoid damage to the coating, 4.2.2 Hoisting, Pipe shall be hoisted from the trench side to the trench by means of wide-belt slings. Chains, cables, tongs, or other equipment likely to cause damage to the ‘enamel coating shall not be used nor shall dragging or skidding of the pipe be permitted. The contractor shall allow inspection of the coating on the underside of the pipe while it is suspended from the slings. Any damage shall be repaired before the pipe is lowered into the trench. 4.2.3 Bedding. Unless otherwise specified by the purchaser, where the trench traverses rocky ground or ground containing hard objects that could penetrate the protective coating, 2 layer of screened earth or sand not less than 3 in. (76 mm) thick shall be placed in the bottom of the trench prior to installation of pipe. Other suitable bedding materials may be used in place of earth or sand when approved by the purchaser. 4.2.4 Precautions. At all times during construction of the pipeline, the contractor shall use every precaution to prevent damage to protective coating on the pipe. No metal tools or heavy objects shall be permitted to come into contact unnecessarily with the finished coating. Workers will be permitted to walk on the coating only when necessary, in which case they shall wear shoes with rubber or composition soles and heels. The rule shail apply to all surfaces, whether bare, primed, or enameled. Any damage to the pipe or protective coatingDAL-TAR COATINGS AND LININGS 27 ‘om any cause during the installation of the pipeline and before final acceptance by the D purchaser shall be repaired by and at the expense of the contractor. Sec. 4.3 Welded Field Joints—Lining and Coating 4.3.1 Materials. The primer and cosl-tar enamel used shall be the same material as used for coating and lining the pipe. 43.2 Coating interior welds. Interior welds of field joints shall be cleaned and dried in accordance with Sec. 2.14.1. Primer shall then be applied in accordance with Sec. 2.14.2 and allowed to dry according to the coating manufacturer's instructions, Next, hot enamel shall be applied under the condition specified in Sec. 2.4.3.2, with daubers or other suitable ‘methods to the specified thickness and shall overlap the main body of the coating on each side of the weld to form a continuous coating free from defects. For coating field joints, holes through which hot enamel may be poured into enameling buckets inside the pipe shall be located at frequent intervals along the pipe. The requirements of this section apply to 27. (686-mm) pipe or larger, which will allow entry of personne! to clean the surfaces and apply primer and enamel. » 4.3.3. Coating exterior welds. Exterior joints shall be cleaned and dried in accordance with Sec. 2.14.1 and Sec. 2.14.2, respectively, and then primed. When the primers dry, the field joints shall be manually coated to the specified thickness. Ename! shall overlap the ‘coating on cach side of the field joint to form a continuous external coating free of defects. Alternatively, the exterior of the welded field joints may be coated using hot-applied coal-tar tapes meeting this standard or cold-applied tapes meeting AWWA C209. 434 Hand enameling. All hand enameling shall be done in accordance with Ses. 2.14,3.1, Sec. 2.14.3.2, and the procedure outlined in Sec. 2.14.1 of this standard. Heating of enamel for field application shall be done in accordance with the procedure > outlined in Sec. 2.14.4. 4.3.5. Electrical inspection. All field enameling work shall be thoroughly inspected by the contractor, using an electrical detector in accordance with the procedure outlined in Sec. 2.14.12. Any flaws or holidays found shall be repaired, as outlined in Sec. 2.15, by the contactor. Electrical inspection used to detect flaws or holidays found in alternative coating systems will be as outlined in the applicable standard, Sec. 4.4 Mechanical Couplings ‘4.4.1 Cleaning, priming, and coating. Atthe point of manufacture, al couplings shall d be cleaned and then primed with the primer specified by the manufacturer of the coating used on the pipe. The couplings and the exposed pipe encis shall be reprimed in the field. ‘When the primer is dry, the couplings shall be assembled on the pipe, and the exterior surfaces of the couplings and adjacent exposed pipe ends shall be coated with the AWWA coal-tar enamel coating recommended by the manufacturer of the coating used on the pipe. ‘The coating shall be electrically inspected in accordance with Sec. 2.14.12. The coating shall be capable of conforming to the normal movement of the buried pipe without cracking. Sec. 4.5 Backfilling 4.5.1 Precautions. Backfilling shall be conducted at all times in such a manner as to avoid abrasion or other damage to coal-tar enamel protection on pipe. Unless otherwise specified by the purchaser, the following requirements shall be provided: 4.5.2 Placing of backfill. Placing of backfill around exterior-protected pipe shall be done only in the manner approved by the inspector after the inspector performs final inspection and acceptance of the exterior protection. 4.5.3 Installation and type of backfill. Immediately after pipe is placed and aligned in , the trench and before the joint is completed, loose backfill shall be placed about the pipe,28 AWWA C>03.86 ‘except at field joints, toa depth of approximately 6 in. (152 mm) above the pipe. This backfill shall be free of large stones, frozen lumps, trash, or material that may decay 4.5.4 Rocks and hard objects. If rocks or other hard objects are present in the backfill along any section of the pipeline, such backfill shall be screened before being placed about the pipe, of, at the option of the contractor, suitable waste backfill from other parts of the line may be transported to and pisced about the pipe in such sections. 4.5.5 Methodsof compaction. Compaction of backfill in the trench shall be by means of flooding, puddling, tamping, jetting, or a method agreeable to both the purchaser and the contractor. Rodding with metal rods will not be permittedAPPENDIX A Additional Protective Coatings, Wraps, and Procedures This appendix is for information only and is not a part of AWWA C203. SECTION A.1: GENERAL Sec, A-1.1 Scope ‘This appendix contains specifications governing the materials and application require- ments for wraps and shields other than those covered by AWWA C203, These additional exterior protective measures are designed for use when the pipe is to be installed underground or underwater under unusual conditions. They are nota part of AWWA C203 unless specifically included in the purchaser's specifications. Sec. A.1.2 Coal-Tar Enamel and Bonded Double Asbestos-Felt or Other Performance- Comparable Outerwrap A.1.2.1 This type of additional exterior protection is intended for use only on submarine lines, river crossings, or similar difficult installations, or where trench conditions are extraordinarily severe. A.L22 Theconstruction of this exterior protection shall be as follows: (1) primer; (2) coal-tar cnamel, “sein. = Yori, (2.4-mm + 0.8-mm) thick; (3) bonded asbestos-felt or other performance-comparable outerwrap; (4) coal-tar enamel, Ys2-in, (0.8-mm) minimums (5) bonded asbestos-felt or other performance-comparable outerwrap; and (6) whitewash, ‘water-emulsion latex paint, or kraft-paper finish coat. A.1.2.3° Outerwrap shall conform to the material specified in Sec. 2.10 of AWWA. 203. ‘A.1.24 Application of the outerwrap shall conform to the procedure specified in Sec. 2.148 of AWWA C203. A.L2.5 The pipe shall be whitewashed, water-emulsion latex painted, or wrapped with kraft paper in accordance with Sec. 2.14.8.6 of AWWA C203. Sec. A.1.3 Sand Shield A.L3.1_ This type of exterior protection is intended for use when the methods of backfill required in Sec. 4.5 of AWWA C203 are not available or are considered undesirable, or 2s provided in the purchaser's specifications. A.1.3.2. The pipe shall be lined inside and coated outsidé with coal-tar enamel in accordance with all provisions of AWWA C203. In addition, the entire pipeline, or such portions of the line as are designated in the purchaser's specifications, shall be completely surrounded by sand before any backfill is placed in the trench. A layer of sand toa minimum depth of 3 in. (76 mm) shall be placed in the trench before the pipe is laid, and the sand shall be placed about the pipe and over the pipe to a minimum cover of 3 in, (76 mm). Sec, A.1.4 Reinforced Cement-Mortar Shield When a reinforced cement-mortar shield is desired over the exterior coat of coal-tar ‘enamel, the materials and application procedures shall conform to the applicable require- ments of AWWA C205. The construction of this exterior protection shall be as follows: (1) primer; (2) coal-tar enamel, Yeoin. + Vein, (24-mm = 0.8-mm) thick; and (3) reinforced cement-mortar shield,sRAL Lig, 4 fe PLikpy 2 “Anaata™ Sec. A.1.5 Coal-Tar Enamel, Glass-Fiber Mat, and Bonded Asbestos-Felt Wrap or Other Performance-Comparable Outerwrap ‘agama SECTION A.2: MATERIAL SPECIFICATIONS Sec. A.2.1 Glass-Fiber Mat ‘A.15.1 This type of additional exterior protection is intended for use only where extraordinary soil conditions exist, or on such special construction as submarine lines ot river crossings. A.15.2. The construction of this exterior protection shall be as follows: 1) primer; (2) coal-tar enamel, Y/s-in. + Vsq-in. (2.4-mm + 0.8-mm) thick; (3) glass-fiber mat; (4) coal-tar enamel, Yx-in, (0.8-mm) minimum; (5) bonded asbestos-felt or other performance- comparable outerwrap; and (6) whitewash, water-emulsion latex paint, or kraft-paper finish coat A.1.5.3 Glass-fiber mat shall conform to the material specified in Sec. A.2.1. A.L5.4 Asbestos-felt or other performance-comparable outerwrap shall conform to the material specified in Sec. 2.10 of AWWA C203, A.L5.3 The glass-fiber mat shall be of suitable width for smooth, spiral application and shall be of approximately uniform width. The lap of the mat shall be not ess than /2in, (3 mm). Glass-fiber mat shall be mechanically applied in acontinuous end-feed machine, or ina lathe-type machine, or by other suitable outerwrap-application equipment. Application shall be simultaneous with the first coat of coal-tar enamel. The roll of glass-fiber mat shall bbe under tension sufficient to embed the mat in the enamel before the latter sets or cools. The ‘mat must be placed in the outer third of the first coat of enamel and not be pulled through the hot enamel to the metal surface. The second coat of hot coal-tar enamel shall be applied over the glass-fiber mat simultaneously with a single-bonded wrap of asbestos coal-tar-saturated felt or other performance-comparable outerwrap. Glass-fiber mat shall not be used when. ‘two wraps of asbestos coal-tar-sarurated felt or other performance-comparable outerwrap are applied in accordance with Sec. A.1.2. ‘A.15.6 Application of the asbestos-felt or other performance-comparable outerwrap shall conform to the procedures specified in Sec. 2.14.8 of AWWA C203, A.15.7 The pipe shall be whitewashed, water-emulsion latex painted, or wrapped with kraft paper as provided in Sec. 2.14.8.6 of AWWA C203, A.15.8 Enamel applied by hand to the exterior of specials or joints shall be examined for holidays in accordance with Sec. 2.[4.10.7 of AWWA C203, and holidays shall be repaired prior to the application of the glass-fiber mat and subsequent enamel and asbestos- felt or other performance-comparable outerwrap. AQ. Description. The glass-fiber mat shall be 2 thin, flexible, uniform mat, composed of glass fibers in an open porous structure, bonded with any suitable inner material that is compatible with hot coal-tar enamel. The mat may be of the reinforced or nonreinforced type. A2L2 Physical characteristics. The fi physical characteristics: A.2.1.2.1 Appearance. The finished wrap shall have a smooth surface free from visible defects. A.2.1.2.2 Weight. The weight shall be not less than 0.84 Ib/100 fe? (41 g/m?), as determined by ASTM D146. A.21.2.3 Thickness. The mat shall have a thickness of not less than 13 mils (0.3 mm), as determined by ASTM D146, modified. At 10 equally spaced areas selected by ed glass-fiber mat shall have the followingCOAL-TAR COATINGS AND LININGS 31 sampling, measure the thickness with an Ames dial reading in units of ten thousandths of an inch, Use a circular foot and anvil, both 1 in.? (645 mm) in area, exerting a pressure of 2 Ib/in# (13.8 kPa). Make all measurements in an atmosphere of 50-percent relative humidity and at 73°F + 2°F (23°C + 1°C), ‘A.2.124 Elmendorf tear strength. The mat shall have an Elmendorf tear strength in the longitudinal direction of not less than 0.22 1b (100 g) and in the transverse direction of riot less than 0.22 Ib (100 g) by test method ASTM [D689 or test method TAPPI T-414. To test, use an Elmendorf tear tester, Thwing-Albert Model 60-16 or equivalent, ‘capacity 0-3.5 Ib (0-1600 g). The instrament shall be securely anchored to a table and leveled. The pendulum shall be tested for zero by moving it to the left to the pendulum stop and then released, Adjustments shall be made if the pointer does not read zero after the pendulum stop has been released. The friction of the apparatus and the condition of the knife shall be verified and adjusted, if required, as provided in ASTM D689. Make tests at a temperature of 73°F + 4°F (23°C + 2°C) and 50 + 10 percent relative humidity. Cut 10 specimens from the mat using either a sample cutter or template noting machine direction (MD) and machine direction plus cross direction (MD plus CD). Sample size shal be 3in. = Vein. (76 mm 2mm) wide 2/2 Viein. (63 mm +2 mm) high. The test shall initially be performed using two plies. The number of plies may subsequently have to be varied as indicated in ASTM D689. The pendulum is moved to the left until the stop is engaged. After the specimen has been clamped into the apparatus with the 2Y:-in. (63-mm) slit in the vertical direction, the knife is depressed to make the sit and the stop depressed to release the pendulum. Record the number of plies, the reading of the pointer, and whether MD or MD plus CD tear. The entire procedure is repeated to obtain 10 individual readings, and then readings are averaged. This average, divided by the number of plies tested, gives the Elmendorf tear strength. ‘A.2.1.2.5 Breaking strength. In the case of nonreinforced glass wrap, the breaking strength in the longitudinal direction shall be no less than 4 Ibf/in. (700 N/m) width. In the case of reinforced glass wrap, the breaking strength in the longitudinal direction shall be no less than 13 Ibf/in, (2277 N/m) width. In either case, the breaking strength in the transverse direction shall be no less than 4 Ibf/in. (700 N/m) width, as determined by ASTM D146, modified. Cut 10 specimens of 3 in. » 22 in, (77 mm * 559 mm) with the longer dimension along the roll and 10 specimens with the longer dimension across the roll. In those instances where the wrapper width is less than 22:in. (559 mm), the specimen length shall be that of the wrapper length. Impregnate both ends of each specimen with a protective coating of shellac or methacrylate for a distance of 2/2in. (64 mm) and allow to dry. Testall specimens at 73°F = 2°F (23°C = 1°C) using a tension-testing machine of adequate capacity in which the clamps are attached to swivels that are free to move in any direction. The clamps shall be Lin. x3 in. (25 mm x 76 mm) and shall be covered with masking tape: Grip the specimen 2 in, (51mm) from each end, leaving 18 in, (457 mm) between the clamps. This gauge length may have to be adjusted, depending on wrapper width. However, the length should be a maximum consistent wich good clamping. Increase the breaking of the load by causing the lower clamps of the machine to travel at a uniform speed of 12 in./min (305 mm/min). Disregard the reading on any specimen that breaks nearer than 1/2 in, (13mm) from either clamp, and test an additional specimen in its place. Report the average of the results of 10, individual tests on specimens cut along the roll as the longitudinal breaking strength and the average of the results of 10 individual tests on specimens cut across the roll as the transverse breaking strength. ‘A.2.1.2.6 Pliability. There shall be no cracking of glass-fiber mat when bent over & pin. (3-mm) radius at 73°F £ 2°F (23°C + 1°C), as determined by ASTM D146, modified. Cut five specimens, | in, * 8 in, (25 mm * 203 mm) with the long dimension2 Awwacosss parallel to the length of the roll and immerse in water at 73°F + 2°F (23°C + 1°C) for 10-15 min. Remove each specimen individually and bend over a ‘/s-in. (6.4-mm) diameter mandrel e through 290° arc at uniform speed in approximately 25. Examine each specimen for cracks or breaks ‘A.2.1.2.7 Porosity. When related to pressure difference across the sample, the sglass-fiber mat shall have a porosity of not less than 0,022 in, (0.6 mm) and not more than 0.076 in. (1.9 mm) of water at an average air velocity of 200 ft/min (61 m/min), as determined by ASTM D737, modified. Provide five specimens, at least 10 in, x 10 in. (254 mm x 254 mm), representative of the unsaturated glass-fiber mat to be tested, or test five places on the unsaturated glass-fiber mat as widely separated as possible without cutting. The apparatus shall consist essentially of a suction fan for drawing air through a known area of unsaturated glass-fiber mat, ¢ circular orifice over which the mat tobe tested can be clamped, a means of measuring the pressure drop across the mat, and a means of ‘measuring the volume of air flowing through the mat. The clamp shall effectively eliminate edge leakage. The apparatus shell be capable of testing unsaturated glass-fiber mats of different thicknesses and of testing large pieces of glass-fiber mat without cutting. The instrument shall be calibrated directly with a precision instrument. Make all tests at 73°F = 6 2°F (23°C + 1°C) and 50-percent + 2-percent relative humidity. Mount the test specimen between the clamp and the circular orifice with sufficient tension to draw the unsaturated glass-fiber mat smooth. It shall not be distorted in its own. plane. Draw conditioned air through the known ares of the mat and through the calibrated flow meter at the rate of 200 ft/min (61 m/min) and record the pressure drop across the mat in inches (millimetres) of water, Report che average of the test results for the five test specimens or the five different locations on the glass-fiber mat as the porosity.