SECTION STEEL PIPE COATING AND LINING. 1. Exterior: Polyurethane coating with a cement mortar armor coating. 2. Interior: Polyurethane lining.

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1 SECTION STEEL PIPE COATING AND LINING PART 1 GENERAL 1.1 WORK INCLUDED A. This section covers the work necessary to apply external coating and internal lining on steel pipe, fittings, and specials; field coating and lining of joints; and field repair of coating and lining damage, complete. B. Provide the following coatings and linings for the 18-inch to 72-inch diameter steel pipe installed between the downstream tunnel portal and the flow control structure. 1. Exterior: Polyurethane coating with a cement mortar armor coating. 2. Interior: Polyurethane lining. C. Provide the following coatings and linings for the 8-inch to 48-inch diameter steel pipe and fittings installed inside the flow control structure. 1. Exterior: Paint System No. 5, moisture cured urethane, as specified in Section 09900, PAINTING AND PROTECTIVE COATINGS. 2. Interior: Polyurethane lining. D. Provide the following coatings and linings for the 72-inch diameter steel casing pipe installed in tunnels excavated by microtunnel boring machine. 1. Exterior: Polymer concrete coating. 2. Interior: Cement mortar lining, field applied. E. Provide the following coatings and linings for the 72-inch diameter buried steel pipe between the upstream tunnel portal and the inlet. 1. Exterior: Polymer concrete coating. 2. Interior: Cement mortar lining, shop applied or field applied. F. Provide coatings and linings for other pipe, fittings, and specials as shown on the Drawings and as specified herein. 1.2 REFERENCE STANDARDS A. General: The latest revision of the following minimum standards shall apply to the coating and lining materials, testing, and installation except where standards that are more stringent are applicable STEEL PIPE COATING AND LINING

2 1.3 DEFINITIONS 1. American Water Works Association (AWWA): a. C205, Cement-Mortar Protective Lining and Coating for Steel Water Pipe- 4-inch and Larger Shop Applied. b. C216, Heat-shrinkable Cross-linked Polyolefin Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines. c. C222, Polyurethane Coatings for Interior and Exterior of Steel Water Pipe and Fittings. d. C602, Cement-Mortar Lining of Water Pipelines in Place 4 inches (100 mm) and Larger. 2. ASTM, International (ASTM): a. C33, Standard Specification for Concrete Aggregates. b. C150, Standard Specification for Portland Cement. c. D4541, Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers. 3. NSF International (NSF): 61 Drinking Water System Components Health Effects. 4. National Association of Corrosion Engineers (NACE): Recommended Practice RP-0188, Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates. 5. The Society for Protective Coatings(SSPC): a. SP-1 - Solvent Cleaning Surface Preparation. b. SP-2 - Hand Tool Cleaning Surface Preparation. c. SP-3 - Poor Tool Cleaning Surface Preparation. d. SP-6 - Commercial Abrasive Blast Surface Preparation. e. SP-10 - Near White Metal Abrasive Blast Surface Preparation. A. Manufacturer's Representative: Employee of manufacturer who is factory trained and knowledgeable in technical aspects of their products and systems. B. Coating and Lining: Unless otherwise indicated, where Coating and Lining is referenced, the term shall include polyurethane coating and linings and polymer concrete coatings. 1.4 ABBREVIATIONS A. ANSI: American National Standards Institute. B. AWWA: American Water Works Association. C. MDFT: Minimum Dry Film Thickness. D. Mil: Thousandths of an Inch STEEL PIPE COATING AND LINING

3 E. OSHA: Occupational Safety and Health Act. F. SSPC: The Society for Protective Coatings (formerly Steel Structures Painting Council). 1.5 SUBMITTALS DURING CONSTRUCTION A. General: 1. Submittals shall be made in accordance with SUBMITTALS. 2. Catalog cuts and other manufacturer's information shall be submitted for all materials provided on a system-by- system basis. 3. Provide copies of paint system submittals to the coating and lining applicator. 4. Indiscriminate submittal of manufacturer's literature only is not acceptable. B. Action Submittals: 1. Polyurethane Coatings and Linings and Polymer Concrete Coatings: a. For each coating system, furnish a Material Safety Data Sheet (MSDS), the manufacturer's technical data sheets, and paint colors available (where applicable) for each product used in paint system. b. Technical and performance information that demonstrate compliance with Specification. c. Manufacturer s written instructions and special details for applying each type of protective coating or lining. d. Curing requirements for polymer concrete coating. e. Detailed chemical and gradation analysis for each proposed abrasive material and abrasive mixes used for centrifugal wheel abrasive blast equipment. C. Informational Submittals (Coating and Linings): 1. In accordance with Section 01640, MANUFACTURERS SERVICES, Manufacturer s Certificate of Compliance that products furnished meet requirements of this Specification. 2. Lining Materials: Certificate that lining system is currently approved for potable water contact in accordance with NSF 61 and satisfies current applicable governmental health and safety requirements for use in potable water. 3. Coating and lining factory site visit letter by manufacturer s technical representative STEEL PIPE COATING AND LINING

4 4. Coating and lining applicator s quality control records, including environmental conditions, dry film thickness, and adhesion tests, when requested by the CONSTRUCTION MANAGER. D. Informational Submittals (Cement Mortar): 1. In accordance with Section 01640, MANUFACTURERS SERVICES, Manufacturer s Certificate of Compliance that products furnished meet requirements of this Specification. 2. Lining Materials: Certificate that lining system is currently approved for potable water contact in accordance with NSF 61 and satisfies current applicable governmental health and safety requirements for use in potable water. 3. Field and Shop Applied Cement Mortar Lining: Include description of machine to be used and list of similar projects where machine was used. Identify pipeline owner, pipe size, and total footage. 4. Shop Applied Cement Mortar Lining: a. Cement mortar lining compressive strength tests in accordance with AWWA C205. b. Cement mortar coating absorption tests in accordance with AWWA C QUALITY ASSURANCE A. Coating and Lining Applicator's Experience and Certification: 1. Coating and lining applicator shall be certified by the coating manufacturer as an approved applicator. 2. Written certification within 1 year prior to coating and lining application work shall be supplied by the coating manufacturer. B. The coating and lining manufacturer s technical representatives shall provide qualified technical representatives, employed by the coating manufacturer, at the shop for 1 day, minimum, at the start of coating and 1 day, minimum, at the start of lining. During this visit, the manufacturer s representative shall conduct inspections as required to ensure that coating and lining application is in conformance with their recommended methods and conditions. C. A written report of the manufacturer s representatives visits, test data collected, description of deficiencies observed, and recommended corrective actions shall be submitted to the CONSTRUCTION MANAGER within 3 working days after each visit by the manufacturer s representatives. After all corrective recommendations have been completed, the manufacturer s representative shall return and certify that the application complies with the manufacturer s coating application recommendations STEEL PIPE COATING AND LINING

5 D. Additional visits by the coating and lining manufacturer s representatives shall be made at sufficient intervals during surface preparation and coating or lining as may be required for product application quality assurance, to determine compliance with manufacturer s instructions, and as may be necessary to resolve problems attributable to, or associated with, manufacturer s products furnished for this Project. 1.7 OBSERVATION OF WORK A. The CONTRACTOR shall give the CONSTRUCTION MANAGER a minimum of 7 days advance notice of the start of any work to allow scheduling for shop or field observation. B. Provisions shall be made to allow CONSTRUCTION MANAGER s representative full access to facilities and appropriate documentation regarding coating and lining application. C. Observation by the CONSTRUCTION MANAGER s representative or the waiver of observation of any particular portion of the work shall not be construed to relieve the CONTRACTOR of his responsibility to perform the work in accordance with these Specifications. D. All materials shall be subject to observation for suitability as the CONSTRUCTION MANAGER s representative may elect, prior to or during incorporation into the Work. PART 2 MATERIALS 2.1 GENERAL A. Coatings and linings will be stored, handled, and applied per the manufacturer s written directions. Exterior and interior pipe surfaces shall be cleaned, coated, and lined in accordance with referenced AWWA Standards, written directions of the coating manufacturer, and these Specifications, whichever is more stringent. B. Pipeline coating and lining shall be the product of a single manufacturer. Substitutions during the Project will not be permitted STEEL PIPE COATING AND LINING

6 2.2 EXTERIOR COATINGS, SHOP APPLIED A. Buried Pipe and Fittings: 1. Plural Component Polyurethane: a. Plural component polyurethane coating materials (referred to hereafter as polyurethane) shall meet the requirements of AWWA C222, except as modified herein. b. Coating: Self-priming, plural component, 100 percent solids, polyurethane, suitable for burial or immersion, and shall be the product of one of the following approved manufacturers: 1) Futura Coatings (Protec II), Hazelwood, Missouri. 2) CONSTRUCTION MANAGER approved equal. 2. Cement Mortar Armor Coat: a. Cement mortar armor coating materials shall meet the requirements of AWWA C205, except as modified herein. b. Cement: Conform to ASTM C150, Type II. c. Aggregate shall be silica sand or other aggregate that is not subject to leaching. Conform to ASTM C33. d. Cement mortar mixture shall consist of 1 part cement to not more than 3 parts aggregate. e. Water for Cement Mortar: Clean and free from organic matter, strong alkalis, vegetable matter, and other impurities. Use no more than 4-1/2 gallons of water per sack of cement. 3. Polymer Concrete Coating: Epoxy based polymer concrete shall be Lone Star Powercrete J, or CONSTRUCTION MANAGER approved equal. B. Exposed Pipe and Fittings: 1. Moisture cured urethane, as specified in Section 09900, PAINTING AND PROTECTIVE COATINGS. 2. Manufacturer of shop-applied primer shall be as specified for moisture cured urethane coatings in Section 09900, PAINTING AND PROTECTIVE COATINGS, for compatibility with field-applied coatings. Alternate manufacturers will be considered only if applicable fabricators and field coating applicators associated with this coating system submit a joint request for an alternate coating manufacturer. 2.3 INTERIOR LININGS, SHOP APPLIED A. Plural Component Polyurethane: 1. Plural component polyurethane lining materials (referred to as polyurethane) shall meet the requirements of AWWA C222, except as modified herein STEEL PIPE COATING AND LINING

7 2. Lining: Self-priming, plural component, 100 percent solids, NSF 60 and 61 approved polyurethane, suitable for immersion, and shall be the product of one of the following approved manufacturers: a. Futura Coatings (Protec II PW), Hazelwood, Missouri. b. CONSTRUCTION MANAGER approved equal. B. Cement Mortar Lining: 1. Cement mortar lining materials shall meet the requirements of AWWA C205 and AWWA C602, except as modified herein. 2. Cement: Conform to ASTM C150, Type II. 3. Aggregate shall be silica sand or other aggregate that is not subject to leaching. Conform to ASTM C Water for Cement Mortar: Clean and free form organic matter, strong alkalis, vegetable matter, and other impurities that could reduce the strength, durability, or other quality of the mortar. 2.4 EXTERIOR JOINT COATING, FIELD APPLIED A. Heat Shrink Sleeves: 1. Filler Mastic: Size and type shall be as recommended by the sleeve manufacturer for type of pipe and joint. 2. Primer: Provide manufacturer s recommended primer. 3. Joint Coating: Two-piece, heat shrink, cross-linked polyolefin wrap or sleeve with a mastic sealant, 85 mils minimum thickness, suitable for pipeline operating temperature, as recommended by the manufacturer. 4. Provide standard recovery sleeve for girth weld. 5. Sleeve length shall provide a minimum of 3 inches overlap onto intact pipe coating on each side of the joint. Width to take into consideration shrinkage of the sleeve due to installation and joint profile. 6. Manufacturers: Canusa, or approved equal. B. Cement Mortar Coating or Armor Coat: 1. Cement mortar joint materials for exterior joints shall meet the requirements of AWWA C205, except as modified herein. 2. Water-Impermeable Bands: Polyethylene foam-lined fabric with steel strapping of sufficient strength to hold the fresh mortar, resist rodding or the mortar and allow excess water to escape. a. 100 percent closed-cell. b. Chemically inert, insoluble in water, resistant to acids, alkalis, and solvents. c. Manufacturer and Product: Dow Chemical Company; Ethafoam STEEL PIPE COATING AND LINING

8 3. Fabric Backing: a. Cut and sewn into strips wide enough to overlap shop-coated areas by 4 inches on either side. b. Strips shall have slots for steel strapping on outer edges. 2.5 INTERIOR JOINT LINING, FIELD APPLIED A. Polyurethane Lining: Materials for field lining of pipe joints shall be the same as those used for shop-applied lining, as recommended by the lining manufacturer, subject to CONSTRUCTION MANAGER approval. Installation CONTRACTOR shall provide materials for field lining of pipe joints. B. Cement Mortar: Materials for cement mortar lining of field-welded joints shall meet the requirements of AWWA C EXTERIOR COATINGS, FIELD REPAIR A. General: Field coating shall be compatible with the shop-applied coating system or shall be provided by the same manufacturer. B. Polyurethane Coating: 1. Polyurethane coating system repair shall be in accordance with the coating manufacturer s recommended procedures. 2. Coating material for repairs greater than 6 inches diameter on polyurethane coated pipe shall be the same as the existing coating, or for repairs less than 6-inches diameter, repair coating as recommended by the polyurethane coating manufacturer, subject to the CONSTRUCTION MANAGER approval. Repair coating shall have adhesion and performance characteristics equal to the existing coating or lining. C. Polymer Concrete Coating: Polymer concrete coating repair material shall be the same product shop applied to the pipe. PART 3 EXECUTION 3.1 GENERAL A. Inspect and provide substrate surfaces prepared in accordance with these Specifications and the printed directions and recommendations of coating manufacturer whose product is to be applied STEEL PIPE COATING AND LINING

9 3.2 APPLICATION SCHEDULE A. It is the intent of these Specifications that all buried, submerged, and exposed steel pipe, fittings, and specials be coated and lined, whether specifically mentioned or not, unless otherwise indicated. B. Provide the protective coating or lining system as shown on the Drawings and as specified herein. C. Pipe Passing through Structure Walls or Floors: Coat the exterior of pipe and fittings passing through a modular seal in a structure wall or floor with the specified polyurethane coating system without the cement mortar armor coat. Extend the polyurethane coating system a minimum of 12 inches into the structure. D. Transitions Between Buried and Exposed Pipe: 1. Provide a minimum of 12 inches overlap of the two coating systems. 2. The coating applicator shall determine the compatibility of the coating material on buried pipe with the exposed coating system. Applicator shall provide tie coats and/or surface preparation as required to ensure adhesion between the two coating systems. Provide specific written instructions from the finish coating manufacturer for surface preparation requirements and tie coat materials. E. Flexible Couplings: As specified in Section 02500, CONVEYANCE PIPING GENERAL. Field finish as specified in Section 09900, PAINTING AND PROTECTIVE COATINGS. 3.3 ENVIRONMENTAL CONTROLS A. General: 1. CONTRACTOR shall provide heating, cooling, or dehumidification equipment as required to meet the surface preparation and coating and lining application environmental requirements as specified and recommended by the coating manufacturer. 2. Products shall comply with federal, state, and local requirements limiting the emission of volatile organic compounds and worker exposure. 3. Comply with applicable federal, state, and local, air pollution and environmental control regulations for surface preparation, blast cleaning, disposition of spent aggregate and debris, and coating application STEEL PIPE COATING AND LINING

10 4. Do not perform abrasive blast cleaning whenever the relative humidity exceeds 85 percent, whenever surface temperature is less than 5 degrees F above the dew point of the ambient air. 5. Do not applied coatings or linings when: a. Surface and ambient temperatures exceeds the maximum or minimum temperatures recommended by the paint manufacturer or these Specifications. b. In dust or smoke-laden atmosphere, blowing dust or debris, damp or humid weather, or under conditions that could cause icing on the metal surface. 6. Where weather conditions or project requirements dictate, CONTRACTOR shall provide and operate heaters and/or dehumidification equipment to allow pipe surfaces be abrasive blasted and coated as specified and in accordance with the manufacturer s coating and lining application recommendations. B. Temperature Control: 1. When temperatures are above or below the coating manufacturer s recommended application temperatures, the CONTRACTOR will provide temperature controls to permit work to proceed within the temperature limitations of the project. 2. Heating shall be with indirect fired heaters that do not increase humidity levels within the work area. Heaters shall be sized for the area to be heated. 3. Provide tenting, baffles, or bulkheads as required to zone and control the heating or cooling effectiveness. 3.4 SHOP-APPLIED COATINGS AND LININGS SYSTEMS A. General: 1. Applicator Qualifications: a. Equipment will be certified by the coating manufacturer to meet the requirements for material mixing, temperature control, application rate, and ratio control for multi-part coatings. b. Equipment not meeting the written requirements of the coating manufacturer shall be rejected for coating application until repairs or replacement of the equipment is made to the satisfaction of the CONSTRUCTION MANAGER. c. All personal applying the coating and lining system shall provide certification of attendance at the coating manufacturer s training class within the last 3 years. 2. Coating manufacturer shall provide to the CONSTRUCTION MANAGER a copy of the manufacturer s coating and lining application STEEL PIPE COATING AND LINING

11 quality assurance manual prior to beginning coating application. Strict conformance to the requirements of the manual will be required. Deviation from the requirements of the manual will be grounds for the CONSTRUCTION MANAGER to reject the applied coating or lining. Rejected coating or lining shall be removed to bare metal and reapplied using proper application methods in accordance with the quality assurance manual and the requirements of these Specifications. 3. Coating and lining applied under improper environmental conditions will be rejected and shall be removed to bare metal and reapplied under proper environmental conditions. 4. Pipes that exceed the allowable quantity of coating or lining defects, regardless of size or cause, shall be rejected and the coating removed to bare metal and recoated or relined. B. Surface Preparation: 1. Polyurethane Coatings and Linings and Polymer Concrete Coatings: a. Visible oil, grease, dirt, and contamination shall be removed in accordance with SSPC SP-1, solvent cleaning. b. Surface imperfections such as metal slivers, burrs, weld splatter, gouges, or delaminations in the metal shall be removed by filing or grinding prior to abrasive blast surface preparation. c. In cold weather or when moisture collects on the pipe and the temperature of the pipe is less than 45 degrees F, preheat pipe to a temperature above 50 degrees F and 5 degrees F above dew point. d. Pipe shall be cleaned by abrasive blasting with a mixture of steel grit and shot to produce the surface preparation cleanliness as specified. Recycled abrasive shall be cleaned of debris and spent abrasive. e. Protect prepared pipe from humidity, moisture, and rain. Keep pipe clean, dry, and free of flash rust. All flash rust, imperfections, or contamination on cleaned pipe surface shall be removed by reblasting prior to primer application. f. Priming and coating of pipe shall be completed the same day as surface preparation. g. Abrasive Blast Requirements for Polyurethane Coatings and Linings and Polymer Concrete Coating: SSPC SP-10, Near White Metal Blast with 3 mil angular profile, minimum, or as required by the manufacturer, whichever is greater. 2. Cement Mortar Armor Coating: a. Polyurethane coating shall be cleaned in accordance with SSPC SP-1 prior to application of cement mortar armor coating. b. Roughen the surface of the polyurethane coating by light brush blasting or other surface roughening method approved by the STEEL PIPE COATING AND LINING

12 polyurethane manufacturer if required for uniform application of the cement mortar armor coating. 3. Cement Mortar Linings: Clean in accordance with AWWA C205. C. Product Application: 1. Polyurethane Coating: a. Pipe temperature shall be between 75 and 100 degrees F and 5 degrees F above dew point during coating application. Coating application shall be performed in an environmentally controlled area that meets or exceeds the written environmental application requirements of the coating manufacturer. b. Thickness: One coat, 40 mils total dry film thickness, minimum. c. Coating adhesion, thickness and holiday testing shall be tested as specified this section. d. Complete coating repairs as specified this section. 2. Cement Mortar Armor Coat: a. Polyurethane coated steel pipe shall have a cement mortar Armor coat applied over the exterior pipe coating in accordance with AWWA C205, except as modified herein. b. Cement mortar coating shall be 1 inch thick, minimum. c. Mortar coating shall be held back 3 inches, minimum, behind dielectric coating system cut back at joints. d. Mortar Coating Reinforcement: 1) Reinforce coating with one layer of spirally-wound No. 12 gauge wire spaced at 1-inch centers or with No. 14 gauge steel wire spaced at 1/2-inch centers positioned at the third points of the mortar coating. Coating may alternatively be reinforced with 2 inch by 4 inch No. 13 gauge welded wire mesh. 2) Lap ends of reinforcement strips 4 inches and tie or loop free ends to assure continuity of reinforcement. 3) Special Fittings: a) Coating for steel plate specials may be reinforced with 2-inch by 4-inch No. 13 gauge welded wire mesh. b) Two layers of mesh shall be positioned at the third points of the coating thickness. 4) All steel wire reinforcement placed in the mortar coating shall be electrically isolated from the pipe. Electrical isolation will be tested using high voltage spark test by the manufacturer prior to shipment to the project site. Provide certification that electrical isolation of reinforcement wire from steel pipe STEEL PIPE COATING AND LINING

13 3. Polymer Concrete Coating: a. Preheat pipe to remove residual moisture. Pipe temperature shall not exceed 130 degrees F. b. Immediately after preheating pipe, spray apply polymer concrete coating using equipment recommended by the polymer concrete coating manufacturer. c. Coating shall be applied by hot airless spray. Preheat components before and during application as recommended by the coating manufacturer. d. Apply coating in multiple layers to achieve a minimum coating thickness of 50 mils. Allow sufficient time between layers of coating. Do not exceed the manufacturer s recommendations for recoating. e. Apply coating layers in a uniform manner to a thickness that does not result in runs in the material. f. Cured coating shall be uniform in color, gloss, and thickness and shall be free of blisters, pinholes, fisheyes, sags and other irregularities. g. Coating shall be completely cured prior to handling and installation. Obtain specific recommendations in writing for coating cure from the polymer concrete coating manufacturer. h. Coating dry film thickness and holiday testing shall be as specified in this section. 4. Polyurethane Lining: a. Pipe temperature shall be between 75 and 100 degrees F and 5 degrees F above dew point during coating application. Coating application shall be performed in an environmentally controlled area that meets or exceeds the written environmental application requirements of the coating manufacturer. b. Thickness: One coat, 40 mils total dry film thickness, minimum. c. Lining adhesion and holidays testing shall be tested as specified this section. d. Complete lining repairs as specified this section. 5. Cement Mortar Lining: a. Shop Application: 1) Cement mortar line steel pipe and fittings in the shop in accordance with AWWA C205. 2) Shop applied cement mortar lining shall be uniform in thickness over the full length of the pipe joint. 3) Centrifugally line straight sections of pipe. Lining of special pieces or fittings shall be by mechanical, pneumatic, or hand placement. Provide cement mortar lining of uniform thickness. Finish to a smooth dense surface STEEL PIPE COATING AND LINING

14 4) Brace and support pipe during lining application to minimize pipe distortion or vibration. Bracing and supports shall not damage the pipe, coating, or lining. 5) Tightly close the ends of the pipe and fittings with plastic sheet caps within 30 minutes of lining application. 6) Damage to the cement mortar lining, including disbondment, cracking, or blistering, caused by improper curing, shipping, handling, or installation shall be repaired in accordance with AWWA C205 and to the satisfaction of the CONSTRUCTION MANAGER. 6. Exposed Pipe: Prepare surfaces and apply primer as specified in Section 09900, PAINTING AND PROTECTIVE COATINGS. D. Holdbacks and Cutbacks: 1. Field-Welded Joints: 6 inches, minimum. a. Permalock Joints: Hold back exterior coating as required to allow field assembly of joint. b. Coating cutbacks or holdbacks shall be made straight and cut through the full thickness of the coating. Cutbacks shall be completed in a manner that permits field coating of joints in accordance with the manufacturer s recommendations and as specified herein. 3.5 CEMENT MORTAR LINING OF PIPELINES IN PLACE A. General: 1. Except for requirements specified in this section, field lining of steel pipe in place shall be in accordance with AWWA C After joints are completed and bedding and backfill or grout have been placed, begin cleaning and lining operation with approval of CONSTRUCTION MANAGER. 3. Access for cleaning and lining operations shall be at pipe ends. No cutting of openings in pipe will be allowed. B. Protection of Appurtenances: 1. Prevent mortar from being thrown into pipe openings in accordance with AWWA C Outlet openings shall be trimmed, smoothed, and beveled. 3. Damaged or defective areas shall be repaired to satisfaction of the CONSTRUCTION MANAGER. 4. No pipe shall be lined until inspected and approved by the CONSTRUCTION MANAGER STEEL PIPE COATING AND LINING

15 C. Internal Cleaning: 1. Prior to placing lining, pipe shall be thoroughly cleaned of foreign matter, including water. 2. Cleaning may be by hand or mechanical method that is approved by the CONSTRUCTION MANAGER. 3. Waste materials and water from cleaning operations shall not be passed through sections of existing pipe or pipe that has already been lined. D. Placing Lining: 1. General: a. One-course application that is dense, smooth, without variation in quality, and of consistency to assure efficient machine operation and uniform lining on pipe wall. b. Thickness: Minimum 1/2 inch with tolerance of plus 1/8 inch and zero minus tolerance. 2. Machine Placement: a. Foreign material, including sand and loose mortar that has accumulated since surface preparation was completed shall be removed prior to placing lining. b. Machine Features: 1) Applicator head that is centered within pipe shall centrifugally project mortar at high velocity, in such a manner as to produce dense mortar and to equally distribute mortar on wall surface of pipe. 2) No compressed air shall be utilized in the process of mixing or application. 3) Mechanically driven rotating steel trowels that will immediately follow applicator and provide smooth hard surface of uniform thickness on wall surfaces. 4) Care shall be taken to compensate for torque so that machine will sit true in pipe and trowel faces will not vary in angle with mortar face during complete 360 degree cycle. 5) Trowels shall be cleaned at frequent intervals to prevent accumulated mortar from obtaining initial set and drawing sanded or unglazed finish. 6) Operation of trowels shall be continuous at all times during application and forward progress of machine. c. Progression of machine ahead of lining shall be such that nothing comes in contact with troweled surface until it has attained its initial set. d. Control of mechanical placing of mortar shall be provided to assure uniform thickness of lining is not less than that specified STEEL PIPE COATING AND LINING

16 E. Hand Application: 1. Use at sharp bends, specials, areas where machine placing is impossible or impractical and for correcting defective areas. 2. Wire Mesh: a. Place wire mesh in accordance with AWWA C205. b. Welded to inside of pipe prior to application of lining. F. Lining Finish: 1. Surface shall be smooth and shall not have sand finish. 2. Finish Test: a. Surface of machine-placed and hand-troweled linings at locations selected by CONSTRUCTION MANAGER. b. Tolerance: 1) Nine out of 10 shall conform to tolerance for finished surfaces. 2) 12-inch straight edge laid parallel to axis of pipe along surface of straight section of machine-placed or hand-troweled lining shall at no point have space between lined surface and straight edge greater than 1/16 inch. G. Curing: 1. After placing lining, pipe shall be closed and lining maintained in moist condition in accordance with AWWA C Use methods approved by CONSTRUCTION MANAGER that will assure moist atmosphere to keep lining damp. 3. Covering pipe openings to prevent circulation of air will not, by itself, be considered adequate curing method. H. Protection: For 10 days after cement mortar lining is placed, do not work or drive equipment within 20 feet of centerline of pipe. I. Inspection: 1. Allow access for CONSTRUCTION MANAGER s inspection prior to filling pipeline with water. 2. Conform to AWWA C602. J. Defective Lining: 1. Repair defects in cement mortar lining in accordance with AWWA C602, except CONSTRUCTION MANAGER will determine if full circle repair of lining shall be by machine or hand. 2. Repair mortar cracks wider than 1/16 inch STEEL PIPE COATING AND LINING

17 3.6 FIELD COATING OF JOINTS (EXTERIOR) A. General: 1. Clean pipe surface and adjacent coating of all mud, oil, grease, rust, and other foreign contaminates with a wire brush in accordance with SSPC SP-2, Hand Tool Cleaning, or SSPC SP-3, Power Tool Cleaning. Remove oil or grease contamination by solvent wiping the pipe and adjacent coating in accordance with SSPC SP-1, Solvent Cleaning. Clean the full circumference of the pipe and a minimum of 3 inches onto the existing coating. Abrasively blast in the field any exposed steel or primed joints that are rusting or corroding in accordance with SSPC SP-6, Commercial Blast. 2. Remove all loose or damage pipe coating at joint and either repair the coating as specified herein or increase the length of the joint coating, where reasonable and practical. 3. Electrically holiday inspect completed joint coating with high voltage spark tester. B. Heat Shrink Sleeve Joint Coating: 1. Store, handle, and apply field heat shrink sleeve coatings in accordance with AWWA C216 and these Specifications. 2. Store sleeves in shipping box and off the ground or concrete floors until use is required. Keep dry and sheltered from exposure to direct sunlight. Store as recommended by the sleeve manufacturer. 3. Metal surface shall be free of all dirt, dust, and flash rusting prior to sleeve application. 4. Preheat pipe uniformly to 140 to 160 degrees F or as recommended by the sleeve manufacturer. Monitor pipe temperature using a surface temperature gauge, infrared thermometer, or color changing crayons. Protect preheated pipe from rain, snow, frost, or moisture with tenting or shields and do not permit the joint to cool. 5. Prime joint with specified primer and fill all cracks, crevices, and gaps with mastic filler in accordance with the manufacturer s recommendations for the full circumference of the pipe. 6. Apply heat shrink sleeve when the sleeve is at a minimum temperature of 60 degrees F and while maintaining the pipe temperature above the preheat temperature specified. Apply sleeve in accordance with the manufacturer s instructions and center the sleeve over the joint to provide a minimum of 3 inches overlap onto the existing pipe coating. Apply sacrificial wear sleeve on the leading edge of the joint after the primary sleeve is installed. 7. Apply heat to the sleeve using either propane fired infrared heaters or wrap around heaters. Hold flame a minimum of 6 inches from the sleeve STEEL PIPE COATING AND LINING

18 surface. Periodically roll the coating onto the pipe surface. Heat from the center of the sleeve to the outer edge until properly seated, and then begin in the opposite direction. Monitor sleeve for color change, where appropriate, or with appropriate temperature gages. 8. Completed joint sleeve shall be fully bonded to the pipe and existing coating surface, without voids, mastic beading shall be visible along the full circumference of the sleeve, and there shall be no wrinkling or excessive burns on the sleeves. Sleeves that do not meet these requirements shall be removed and the joint recoated as directed by the CONSTRUCTION MANAGER. Minor repairs may be repaired using heat-applied patches. 9. Allow the sleeve to cool before moving, handling, or pushing of the pipe. Water quenching will be allowed only when permitted by the sleeve manufacturer. C. Cement Mortar Armor Coating: 1. Cement mortar armor coating shall be applied to the joints in accordance with AWWA C Field repair cement mortar coating in accordance with AWWA C FIELD LINING OF JOINTS (INTERIOR) A. Polyurethane Linings: 1. Field application shall be performed by a qualified CONTRACTOR with spray equipment that meets the application requirements of the lining system and personnel trained and certified by the coating system manufacturer on the proper application of the coating and lining system. 2. Provide heating and/or dehumidification equipment as required to meet the environmental conditions necessary for proper coating application. 3. Surface Preparation: a. Clean pipe surface and adjacent coating of all mud, oil, grease, and other foreign contaminants in accordance with AWWA C222. b. Remove loose or damaged lining at the joint and either repair the lining as specified herein or increase the length of joint lining, where reasonable and practical. c. Abrasive blast exposed steel to Near White Metal, SSPC SP-10. d. Brush blast existing lining 3 inches onto intact lining material. 4. Polyurethane Lining Application: a. Field lining application requirements shall be the same as the shop-applied lining requirements. b. Field linings shall be spray applied. c. Apply linings in accordance with the manufacturer s directions and these specifications. Apply coating 2 inches onto brush STEEL PIPE COATING AND LINING

19 blasted edges of shop-applied lining at the holdback. Leave 1 inch of brush-blasted lining exposed to allow visual confirmation of abraded surface of shop-applied lining. d. Mask as required to prevent overspray. 5. Electrical holiday inspect the completed joint lining with high voltage spark tester as and repair defects as specified herein. B. Cement Mortar Linings: Prepare surfaces and line field-welded joints with cement mortar in accordance with AWWA C FIELD COATING OF EXPOSE D PIPE A. Field finish exposed pipe in the flow control structure as specified in Section 09900, PAINTING AND PROTECTIVE COATINGS. 3.9 APPLICATION SCHEDULE A. It is the intent of these Specifications that all new exposed buried, submerged, and exposed steel pipe, fittings, and specials be coated, whether specifically mentioned or not, unless otherwise indicated. B. Provide protective coating or lining as shown on the Drawings and as specified herein. C. Pipe Passing through Structure Walls or Floors: Coat the exterior of pipe and fittings passing through a modular seal in a structure wall or floor the specified polyurethane coating system without the cement mortar armor coat. Extend the polyurethane coating system a minimum of 12 inches into the structure. D. Transitions Between Buried and Exposed Pipe: 1. Provide a minimum of 12 inches overlap of the two coating systems. 2. The coating applicator shall determine the compatibility of the coating material on buried pipe with the exposed coating system. Applicator shall provide tie coats and/or surface preparation as required to ensure adhesion between the two coating systems. Provide specific written instructions from the finish coating manufacturer for surface preparation requirements and tie coat materials FIELD REPAIR OF COATING AND LINING A. General: 1. All areas where holidays are detected or coating is visually damaged, such as blisters, tears, rips, bubbles, wrinkles, cuts, or other defects shall STEEL PIPE COATING AND LINING

20 be repaired. Areas where no holidays are detected, but are visually damaged shall also be repaired. 2. Clean area to be repaired for a minimum distance of 6 inches in all directions from the damaged area by solvent wiping. B. Polyurethane Coating or Lining Repairs: 1. Shop and field coating repairs shall be completed in accordance with the manufacturer s written instructions and these Specifications, whichever is stricter. 2. Coating repairs on any joint of pipe shall not exceed an average of 2 per 100 square feet of surface area per joint of pipe or an individual defect greater than 6 inches in diameter. Holidays within a 4-inch radius of a holiday shall be counted as a single holiday. 3. Pipes exceeding the maximum number or size of coating defects shall be blasted to bare metal and recoated. 4. Pipe arriving in the field with defects or repairs exceeding the maximum number or size of coating defects will be returned to the shop for recoating at the CONTRACTOR s expense. 5. Surface defects, that do not expose the metal substrate, shall be repaired by power tool sanding with coarse sandpaper to roughen the coating surface and feathering the edges of the defect for a minimum of 3 inches around the defect. Apply a single coat of the specified patch coating material to a properly prepared surface at the specified coating thickness. 6. Deep defects, defined as defects which penetrate to the metal substrate or expose the metal substrate, shall be prepared to the metal substrate by power tool sanding to expose the metal and feather the coating edges a minimum of 6 inches. The metal surface and surrounding coating shall be reblasted to equal cleanliness and profile as the original surface preparation. Existing coating shall be roughened to the equivalent of coarse sandpaper by abrasive blasting. One coat of the specified coating material shall be applied over the repaired surface at the specified thickness. C. Polymer Concrete Coating Repairs: 1. Remove loose coating, rust, dirt, and other contaminants by hand (SSPC SP-2) or power tool cleaning (SSPC SP-3). Roughen area of intact coating around defect in accordance with the manufacturer s directions. Remove dust and other loose contaminants with a dry cloth, brush, or vacuum. 2. Preheat prepared area in accordance with the manufacturer s written directions to remove residual moisture STEEL PIPE COATING AND LINING

21 3. Repair damaged coatings with the same polymer concrete coating material that was shop applied to the pipe. Apply the polymer concrete coating to the heated repair area. 4. Repair coatings shall overlap 1 inch minimum onto adjacent, intact coating. D. Cement Mortar Coating and Lining Repairs: Repair damaged cement mortar armor coatings and cement mortar linings in accordance with AWWA C205 and AWWA C602, except as modified herein, as approved by the CONSTRUCTION MANAGER. E. Exposed Pipe: Touch-up repair all damage to the primer and/or intermediate coats with the specified coating system prior to final coating of the pipe, as specified in Section 09900, PAINTING AND PROTECTIVE COATINGS INSPECTION AND TESTING A. General: 1. Applicator shall conduct quality control inspection and testing of the coating system in accordance with AWWA specifications, the manufacturer s written directions, and these Specifications. The frequency of testing and inspections shall be determined by the applicator. 2. CONSTRUCTION MANAGER s Representative will conduct quality assurance inspection and testing as defined herein for final acceptance of the pipeline coatings. Applicator quality control testing will not be acceptable for product acceptance. Coating repairs for quality assurance testing shall be repaired by the applicator as specified herein. B. Adhesion Testing for Polyurethane Coatings and Linings: 1. Provide a minimum of eight adhesion tests on four separate pipe sections. Four tests shall be performed on the interior lining and four tests shall be performed on the exterior coating. 2. Adhesion tests shall be performed before application of the cement mortar armor coating. 3. The pipe coating applicator shall repair all coating damage from adhesion testing. 4. Adhesion tests will be performed not less than 24 hours after coating application. Tests conducted prior to 24 hours will be acceptable only if the test meets or exceeds the adhesion criteria specified and the test was requested by the pipe fabricator. 5. Pipe will be randomly selected for adhesion testing. If any one of the pipes tested fails the adhesion test, the pipe will be rejected along with all other untested pipes within the same lot. Each pipe within the STEEL PIPE COATING AND LINING

22 rejected pipe lot will then be individually tested for adhesion and rejected on a pipe-by- pipe basis. 6. Polyurethane coatings or linings shall have an adhesion to steel of 1,500 pounds per square inch, minimum. 7. Polyurethane coating adhesion to steel substrates shall be tested using pneumatic pull off equipment, such as HATE equipment or equal, in accordance with ASTM D4541 and AWWA C222, except as modified in this section. 8. Dollies for adhesion testing shall be glued to the coating surface and permitted to cure for a minimum of 12 hours. Coating shall be scored around the dolly prior to conducting the adhesion test. Dollies shall be concave or convex to fit the pipe surface on any pipe less than 30 inches in diameter. 9. Failure shall be by adhesive failure only. Adhesive failure is defined as separation of the coating from the steel substrate. Glue failures in excess of the minimum required tensile adhesion would be accepted as meeting the specified adhesion requirements. 10. Adhesion tests will be conducted on polyurethane pipe coating and lining independently and will be accepted or rejected independently of the other. 11. Repair patches on the polyurethane coating shall be randomly selected for adhesion testing in a manner as described herein and at the discretion of the person conducting the adhesion tests. Inter-coat adhesion of repairs shall be not less than 50 percent of the specified polyurethane coating adhesion requirements to steel. C. Holiday Testing: 1. Polyurethane Coatings and Linings and Polymer Concrete Coatings: a. Holiday tests will be conducted on the completed coating or lining after a minimum of 1-hour cure using a high voltage spark test in accordance with NACE Standard RP-0188 and these Specifications. b. Holiday testing shall be performed at a voltage of 100 volts per mil of the minimum specified (not the average) coating thickness. c. Coating and lining thickness will be determined by dry film thickness testing and the average coating thickness used for holiday testing. D. Dry Film Thickness Testing: Polyurethane coatings and linings and polymer concrete coatings shall be tested for dry film thickness in accordance with SSPC PA-2 using a properly calibrated magnetic pull off or eddy current equipment. The averages listed in SSPC PA-2 shall be deleted. The absolute minimum coating and lining dry film thickness shall be as specified herein STEEL PIPE COATING AND LINING

23 3.12 HANDLING, TRANSPORTATION, AND STORAGE A. Pipe shall be handled in such a manner as to protect the pipe, coating and lining from damage. B. Handling equipment, materials, and procedures shall be submitted for approval by the CONSTRUCTION MANAGER. C. Coated and lined pipe shall not be shipped or installed until the coating and lining has developed full adhesion and cure. D. During coating and lining application, storage, loading, transportation, unloading, laying and installation, every precaution shall be taken to protect and prevent damage to pipe, lining, and coating. Forklift equipment shall have all bearing surfaces padded with suitable padding material. Lift pipe with web slings a minimum of 18 inches wide and of a type that will not damage the coating. Metal chains, cable, tongs, forklifts or other equipment likely to damage the coating will not be permitted. Dragging or skidding of pipe on grade or in the trench will not be permitted. E. Provide transportation vehicles with padded bolsters between each layer of pipe and heavy padding under load ties. Bolsters shall be curved to fit the outside of the pipe and 12 inches wide, minimum. All pipe contact locations shall be heavily padded with carpet during shipment to the project site and from the storage yard to the point of installation. F. Pipe shall not be stored on rocks, gravel, or other hard materials that might damage the coating. Provide padded 12-inch wide skids and chucks, sand bags, select loamy or sand berms, or suspended from cutback ends, where possible, to minimize coating damage. Pipe shall not be laid on asphalt without suitable padding at all contact points. G. Pipe shall be inspected by the CONTRACTOR at the project site for damage. Any damage to the pipe, lining, or coating shall be repaired as directed if, in the opinion of the CONSTRUCTION MANAGER, a satisfactory repair can be made; otherwise, the damaged section shall be replaced at the sole expense to the CONTRACTOR. H. No metal tools or heavy objects shall be permitted to come into contact unnecessarily with the finished coating. Workmen shall not be permitted to walk on the coating or lining except when absolutely necessary and approved by the CONSTRUCTION MANAGER. When permitted, shoes with rubber or composition soles and heels or other suitable footwear that will not damage coating or lining shall be used. END OF SECTION STEEL PIPE COATING AND LINING