- Condition of Ductile Iron Prior to Surface Preparation
All ductile pipe and fittings shall be delivered to the application facility without asphalt, cement
lining, or any other lining on the interior surface. Because removal of old linings may not be
possible, the intent of this specification is that the entire interior of the ductile iron pipe and
fittings shall not have been lined with any substance prior to the application of the specified lining
material and no coating shall have been applied to the first six inches of the exterior of the spigot
ends.
- Lining Material
The Standard of Quality is Protecto 401 Ceramic Epoxy. The material shall be an amine cured
novalac epoxy containing at least 20% by volume of ceramic quartz pigment. Any request for
substitution must be accompanied by a successful history of lining pipe and fittings for sewer
service, a test report verifying the following properties, and a certification of the test results.
- A permeability rating of 0.00 when tested according to Method A of ASTM E-96-66,
Procedure A with a test duration of 30 days.
- The following test must be run on coupons from factory lined ductile iron pipe:
- ASTM B-117 Salt Spray (scribed panel) - Results to equal 0.0 undercutting after two years.
- ASTM G-95 Cathodic Disbondment 1.5 volts @ 77°F. Results to equal no more than 0.5mm
undercutting after 30 days.
- Immersion Testing rated using ASTM D-714-87.
- 20% Sulfuric Acid - No effect after two years.
- 140°F 25% Sodium Hydroxide - No effect after two years.
- 160°F Distilled Water - No effect after two years.
- 120°F Tap Water (scribed panel) - 0.0 undercutting after two years with no effect.
- An abrasion resistance of no more than 3 mils (.075mm) loss after one million cycles using
European Standard EN 598: 1994 Section 7.8 Abrasion Resistance.
- APPLICATION
- Applicator
The lining shall be applied by a certified firm with a successful history of applying linings to
the interior of ductile iron pipe and fittings.
- Surface Preparation
Prior to abrasive blasting, the entire area to receive the protective compound shall be inspected
for oil, grease, etc. Any areas with oil, grease, or any substance which can be removed by
solvent, shall be solvent cleaned to remove those substances. After the surface has been made
free of grease, oil or other substances, all areas to receive the protective compounds shall be
abrasive blasted using sand or grit abrasive media. The entire surface to be lined shall be struck
with the blast media so that all rust, loose oxides, etc., are removed from the surface. Only
slight stains and tightly adhering oxide may be left on the surface. Any area where rust
reappears before lining must be reblasted.
- Lining
After the surface preparation and within 8 hours of surface preparation, the interior of the
pipe shall receive 40 mils nominal dry film thickness of Protecto 401. No lining shall take place
when the substrate or ambient temperature is below 40 degrees Fahrenheit. The surface also
must be dry and dust free. If flange pipe or fittings are included in the project, the lining shall
not be used on the face of the flange.
- Coating of Bell Sockets and Spigot Ends
Due to the tolerances involved, the gasket area and spigot end up to 6 inches back from the
end of the spigot end must be coated with 6 mils nominal, 10 mils maximum using Protecto
Joint Compound. The Joint Compound shall be applied by brush to ensure coverage. Care
should be taken that the Joint Compound is smooth without excess buildup in the gasket
seat or on the spigot ends. Coating of the gasket seat and spigot ends shall be done after the
application of the lining.
- Number of Coats
The number of coats of lining material applied shall be as recommended by the lining
manufacturer. However, in no case shall this material be applied above the dry thickness
per coat recommended by the lining manufacturer in printed literature. The maximum or
minimum time between coats shall be that time recommended by the lining material
manufacturer. To prevent delamination between coats, no material shall be used for
lining which is not indefinitely recoatable with itself without roughening of the
surface.
- Touch-Up & Repair
Protecto Joint Compound shall be used for touch-up or repair in accordance with
manufacturer's recommendations.
- Inspection and certification
- Inspection
- All ductile iron pipe and fitting linings shall be checked for thickness using a magnetic
film thickness gauge. The thickness testing shall be done using the method outlined in
SSPC-PA-2 Film Thickness Rating.
- The interior lining of all pipe barrels and fittings shall be tested for pinholes with a
nondestructive 2,500 volt test. Any pinholes found shall be repaired prior to shipment.
- Each pipe joint and fitting shall be marked with the date of application of the lining
system along with its numerical sequence of application on that date and records
maintained by the applicator of his work.
- Certification
The pipe or fitting manufacturer must supply a certificate attesting to the fact that the
applicator met the requirements of this specification, and that the material
used was as specified.
- Handling
Protecto 401 lined pipe and fittings must be handled only from the outside of the pipe and fittings. No forks, chains, straps, hooks, etc. shall be placed inside the pipe and fittings for lifting, positioning, or laying. The pipe shall not be dropped or unloaded by rolling. Care should be taken not to let the pipe strike sharp objects while swinging or being off loaded. Ductile iron pipe should never be placed on grade by use of hydraulic pressure from an excavator bucket or by banging with heavy hammers.
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