Thermal Pipe Systems - Pre-insulated, Gasketed, Hot Water, Chilled Water, Dual Temperature Copper Pipe System - Copper-Core (CSI Format Specification). All square bracket locations [ ] call for a choice to be made or user input.

SPECIFICATION SECTION [23xxxx]

UNDERGROUND PIPE AND FITTINGS

PART 1 - GENERAL

1.01	SECTION INCLUDES

A.	Extent of pipe and fittings required by this Section is indicated on drawings and/or specified herein.

B.	Types of pipe and fittings specified in this Section include the following:

1.	Piping Materials:

a.	Pre-insulated copper piping system with gasketed joints.

2.	Pipe Fittings:

a.	Uninsulated brazed copper fittings.

1.02	QUALITY ASSURANCE

A.	Manufacturers:  Firms regularly engaged in manufacture of pipe and fittings of types and sizes required, whose products have been in satisfactory use in similar service for not less than 3 years.

B.	All materials and installation shall be in conformance with the following:

1.	[Applicable State Code]

2.	ANSI B31.1 "Power Piping".

3.	ANSI B31.9 "Building Service Piping".

C.	Acceptable Manufacturers:

1.	Thermal Pipe Systems, Inc.

2.	Or Engineer’s approved equal.  

1.03	SUBMITTALS

A.	Product Data:  Submit catalog cuts, specifications, installation instructions, and dimensioned drawings for each type of pipe, fitting, and joint for each piping system.

1.04	DELIVERY, STORAGE, AND HANDLING

A.	Where possible, store materials inside and protected from weather.  Where outside storage is necessary, elevate above grade and enclose with durable, waterproof wrapping.

B.	Protect flanges and fittings from moisture and dirt by inside storage and enclosure or by packaging with durable, waterproof wrapping.

PART 2 - PRODUCTS

2.01	PRE-INSULATED COPPER PIPING SYSTEM WITH INTEGRAL GASKETED JOINTS.

A.	Piping:  Copper pre-insulated pipe shall be used for [domestic hot] [heating hot] [chilled] [dual-temperature] water systems.

B.	Copper Carrier Pipe and Fittings:			

1.	Copper carrier pipe shall be [Type K] [Type L] hard drawn copper and comply with ASTM B-88.  The core pipe shall be suitable for use at maximum working pressures of 150 psi at 250oF.

2.	Connections between straight lengths shall be by EPDM rubber o-ring seals contained in a machined bronze coupling.  A stop shoulder shall be part of the internal coupling profile to positively prevent coupling displacement.
 
3.	Fittings shall be uninsulated and compatible with [Type K] [Type L] copper pipe.  Fitting connections shall be brazed or as specified to meet project requirements.  Fittings shall be wrapped with underground PVC tape.

C.	Casing Pipe: Casing for the pre-insulated pipe system shall be [PVC] [HDPE] [FRP].

[Polyvinyl Chloride (PVC) casing pipe shall be of virgin PVC resin meeting the minimum classification requirements of ASTM D1784.  [The thickness shall be defined by a maximum SDR ratio of [32.5] [51] [102] (O.D./Thickness) but not less than 60 mils.]  [The thickness shall be defined by multiplying the jacket nominal diameter by [30 mils] [20 mils] [10 mils] but not less than 60 mils.]  [The thickness shall be defined by a minimum [3%] [2%] [1%] of its nominal diameter but not less than 60 mils. For example, a 6" pipe cased in a 10" jacket with thickness requirement of SDR 51 or 20 mils/diameter inch or 2% all result in a thickness of 0.200".] 

[High Density Polyethylene (HDPE) jacket shall be [seamless] [spiral seamed] conforming to ASTM D1248, Type III, Grade P34. The thickness shall be defined by a minimum 1% of its nominal diameter but not less than 150 mils. For example, a 12" pipe cased in a 16" jacket with thickness requirement 16 mils/diameter inch or 1% all result in a thickness of 0.160".].]

[Fiberglass Reinforced Plastic (FRP) casing pipe shall be filament wound, polyester resin/fiberglass reinforcement composite directly applied on the insulating foam.  The minimum thickness for the FRP casing shall be [0.125"] [0.185”] for all casing sizes.]

1.	The [PVC] [HDPE] [FRP] casing-foam system shall be suitable for H-20 highway loading with two feet of cover providing that the pipe bedding and backfill material are properly placed and compacted to H-20 specifications.
  
2.	The [PVC] [HDPE] [FRP] casing pipe shall be configured to provide a positive end separation between carrier pipe ends to allow expansion.

D.	End Seals:  End seals for pre-insulated copper pipe shall be a high temperature (HT) Ethylene Propylene Diene Monomer (EPDM) molded rubber compound.  All surfaces shall be smooth and free of voids.

E.	Polyurethane Foam Insulation:

1.	Polyurethane foam insulation shall meet the following specifications:

Type:					Two component urethane
Compressive Strength:		35 psi parallel min at 5% comp.
Shrinkage:				None at 70ºF
Free Rise Density:			2.0 to 3.0 lbs/cubic foot
Aged "K" (70ºF - 72 hrs)		0.160 BTU-in/hr-ft²-ºF 
Closed Cell Content:		90%

2.	Polyurethane insulation thickness when used with PVC casing, as a general guide:

				Carrier Pipe		Insulation 
				Size (in.)		Thickness (in.)

				1			1.13
				1 1/4			1.00
				1 1/2			1.17
				2			0.92
      				2 1/2			1.64
				3			1.39
				4			0.89
				6			1.84

3.	Insulation concentricity:  Carrier pipe shall be concentric to casing pipe. The allowable maximum deviation from center line of carrier pipe shall be plus or minus 1/4 inch at the casing center point and plus or minus 1/16 inch at the end seals.

F.	Wall Penetration Sleeves: Provide wall penetration sleeves where piping passes through masonry or concrete walls.  Sleeves in outside walls below and above grade shall be schedule 40 or standard weight coated black steel pipe or as specified by the Design Engineer.  Sleeves shall be held securely in proper position and location during construction. Sleeves shall be of sufficient length to pass through entire thickness of walls or slabs.  Refer to typical detail of wall penetration as shown.  In existing concrete manholes or building walls, penetrations may be made using the "core drilling" method, providing proper care is taken to drill the holes to the size needed and square to the line of the pipe.	

G.	Wall Penetration Seals:  All wall penetrations shall be sealed to prevent water from entering the building or manhole.

1.	Mechanical Sleeve Seals:  Modular mechanical type, consisting of interlocking synthetic rubber links shaped to continuously fill annular space between pipe and sleeve, connected with bolts and pressure plates which cause rubber sealing elements to expand when tightened, providing watertight seal and electrical insulation.

2.	Manufacturer:  Subject to compliance with requirements, provide mechanical sleeve seals of the following:

a.	Thunderline Corp.

b.	Proset

PART 3 - EXECUTION

3.01	GENERAL

A.	Installation of the piping system shall be done in accordance with the appropriate publications including ANSI B31.1 and the following specifications and instructions.  A manufacturer's field representative may conduct an installation clinic to pre-qualify contract personnel in the proper procedures for the installation.

B.	Pipe shall be accurately cut to dimensions established at the construction site and worked into place without springing or forcing, properly clearing all openings and equipment.  Excessive cutting or other weakening of structural members to facilitate installation shall not be permitted.  Pipe ends shall have burrs removed by reaming and shall be installed to permit free expansion and contraction without damage to joints.  Good workmanlike practices shall be followed.

C.	Open ends of pipe lines and equipment shall be properly capped or plugged during installation to keep dirt or other foreign matter out of the system.

3.02	RECEIVING AND HANDLING SHIPMENTS

A.	Inspection:  Each shipment shall be inspected upon arrival at the jobsite.  It is the responsibility of the installing contractor to ascertain whether there has been any loss or damage.  The carrier is the contractor's agent.  Any pipe or equipment that arrives damaged or is lost in shipment shall be reported by the contractor.  Make overall inspection of the load.  If load is intact, ordinary inspection while unloading should be enough to make sure that the pipe has arrived in good condition.  It is the responsibility of the receiver to make certain that there has been no loss or damage.  Note specifically that any end packaging shall not show signs of damage.  If the load has shifted or end packing is damaged, then each piece shall be carefully inspected for damage.  The ends specifically shall be inspected for scars, nicks, etc.  Other obvious damage shall also be cause for rejection.  Check total quantities of each item against tally sheet (pipe, fittings, etc.).  Any damaged or missing items shall be noted on delivery receipt and the receipt returned to the carrier.  Notify the carrier immediately and make claim in accordance with the carrier's instructions.  Do not dispose of damaged material; follow procedure as directed by the carrier.

B.	Unloading Instructions:  The means by which the pipes are unloaded in the field is the decision and responsibility of the installing contractor.  To prevent the possibility of the core pipe from shifting within the casing pipe, do not stand a length on one end or raise it vertically.  Under no condition shall a pipe be dragged along the ground.  Do not lift fittings or pipe by inserting a bar, pipe, etc., inside of the core since damage to the pipe may result.  If any pipe is damaged in unloading and handling, mark the damaged area and set it aside.  Manufacturer's representative shall determine whether damaged casing can be repaired in the field and shall determine exact method for repair and instruct contractor in making repair.

C.	Storage:  Store pipe on dunnage in a flat area.  Support the barrel of the casing evenly.  Bell and spigot ends shall overhang dunnage.  Store random lengths separately where they will be readily available.  Individual lengths of pipe shall be stacked in piles no higher than 5 feet.  Protect pipe during long exposures (several months) to sunlight by covering it with canvas or other opaque material.  Provide for air circulation under the sheets.

D.	Loading Transfer Trucks:  Use trucks with long bodies so that pipe lengths do not overhang.  Make certain truck bed is smooth, without cross-strips, bolt heads, or other protrusions that could damage the pipe.  Short body trucks may be used if fitted with racks that properly support the pipe in a horizontal position.  The rack shall have supports spaced every 3 feet or less along the pipe lengths.  Pad the contact areas to avoid damage to the pipe.

3.03	EXCAVATION

A.	Excavation shall take into account the need for the thrust blocks at all fittings which are direct buried in the ground.  The trench bottom shall give uniform support along the entire length of any pipelines.  Where several pipelines are located in a common trench, the trench shall be wide enough to maintain the specified distances between adjacent lines, a minimum of 6" in pipe sizes up 6" diameter and 12" minimum in sizes 8" and larger.  The excavation shall be in a straight line.

3.04	TRENCHING

A.	The trench depth shall allow for a minimum cover height of 24" over the top of the casing pipe. Keep excavations free of water during construction.  If it is necessary to remove unsuitable material to a depth greater than specified, refill over excavated area to the proper depth with specified bedding material and compact in 6" lifts to 95% of maximum density in accordance with ASTM D1557, Method D.  Excavate and replace soil disturbed and weakened by the Contractor's operations or soils permitted to soften from exposure to weather with bedding material and compact it with a plate-type vibratory compactor.

B.	The width of the trench at the top of the pipe shall be held to the minimum required for efficient and proper installation.  The minimum recommended trench width at the top of the pipe shall be one foot greater than the outside diameter of the casing.  Where two or more pipes are in the same trench, use the distance between outside casing of the outside pipes plus one foot.  To determine the maximum trench width, use above method for minimum plus two feet.

3.05	DISTRIBUTING PIPE ALONG TRENCH

A.	Pipe lengths may be strung along the line of the trench so as to minimize additional handling during installation.

3.06	PLACING PIPE IN THE TRENCH

A.	The pipe may be passed into the trench by hand or mechanically.  The latest state and federal safety regulations shall be understood and observed. If slings are necessary, use only canvas straps.  Do not use cable or chain slings.

3.07	BEDDING

A.	Bedding material shall be sand, pea gravel, or other materials free of sharp objects, heavy clods, boulders, or frozen lumps as specified by the design engineer. The approved bedding shall be used 6" under, around and over the pipe. Utilize the best professional practices that apply to buried pressure piping.

3.08	ASSEMBLY OF PIPE AND FITTINGS

A.	Pipe and fittings shall be assembled in strict accordance with the manufacturer's printed directions by personnel who have been instructed in installation procedures by the manufacturer's representative.

B.	A field representative of the carrier pipe manufacturer may conduct a construction seminar at the site to instruct Contractor's personnel in the proper methods and procedures for making field joints. Certification of instruction and competence shall be issued to those personnel so trained and only those so certified shall be permitted to perform work on the pipe

3.09	TESTING

A.	Testing shall be performed and system proven tight before closure of insulated field joints or backfilling.  Prior to testing, flush pipe system with fresh water until piping is free of dirt and foreign matter.  Use only fresh water for field tests.  Air must be removed from system before starting tests.

B.	[Operational Test:  Operate complete system, or testable portions thereof, as approved by the Engineer through two cycles.  Each cycle shall consist of a period of at least eight hours with hot water leaving the system within 20ºF of the design temperature [insert design temperature] and a period of at least four hours with heat off and no flow.]

C.	During pressure testing and operational test, examine system for leaks.  Repair joint leaks, replace damaged or porous pipe and fittings, and repeat all tests until satisfactory tests are achieved.

3.10	BACKFILLING

A.	Backfilling of trenches shall progress as rapidly as construction, testing, and acceptance of work permits. Uniformly compact and grade bottom of trenches.  After installation of pipe and bedding material, backfill as follows. Place initial backfill in layers to a depth of 12" of the initial bedding. Compact the material to a density equivalent to the surrounding undisturbed soil or to 90% of maximum density (ASTM D1557, Method D), whichever is greater. Backfill remainder of trench in one-foot lifts and compact to 90% maximum density (ASTM D1557, Method D).  For trenches excavated in roads, streets, or located under structures, place backfill in 6" layers to top of trench and compact each layer to at least 95% maximum density (ASTM D1557, Method D).

3.12	FIELD CUTTING PIPE TO A SPECIFIC LENGTH

A.	Field cutting of pipe shall be performed in strict accordance with the manufacturer's printed directions by personnel who have been instructed in installation procedures by the manufacturer's representative.  Manufacturer shall provide tapering tools for field tapering of bell and spigot ends of pipe.

3.13	THRUST BLOCKS

A.	Thrust blocks shall be installed wherever the pipe line changes direction, as at tees and elbows; changes of size, as at reducers and some crosses and tees; stops as a dead end; and develops thrust, as at a valve or similar equipment.  The above situations may occur either where the fittings, etc., are directly buried in the soil or where they are located in a manhole.

B.	Thrust blocks shall be designed for maximum anticipated test pressure.  Size and type of thrust blocks depend on pressure, pipe size, and the type of soil.

C.	Thrust blocks shall be installed using a concrete having a compressive strength of not less than 3000 psi minimum ultimate 28 days compressive strength, air entrained, with water reducing admixture.  The table below gives the thrust load at any fitting.  Dead end and anchor loads are equal to TEE shown below.  Thrust blocks shall be poured on and against undisturbed soil or soil tamped to 95% proctor density.

1.	Thrust at Fittings for Concrete Thrust Blocks in pounds at 100 psi pressure:

      				Size (in.)	TEE		90º Elbow	45º Elbow	

				1		100		140		75
				1 1/4		148		210		114
				1 1/2		207		293		159		
   				2		355		502		271
      				2 1/2		541		765		414
				3		767 		1,085		587	
				4		1,336		1,890		1,023	
      				6		2,496		4,167		2,255		

2.	For pressure other than 100 psi, increase loads proportionately (example: for 150 psi, multiply by 1.5; for 200 psi, multiply by 2.00; etc.).  

D.	Safe Bearing Loads:  The approximate safe bearing loads of various soils given in the following table are for horizontal thrusts when the depth of cover over the top of the pipe exceeds 2 feet.

SOIL					SAFE BEARING LOAD (lbs./sq. ft.)
				       
Soft Clay						1,000	
Sand							2,000
Sand and Gravel					3,000
Sand and Gravel Cemented with Clay		4,000	
Hard Shale						10,000

3.15	STARTUP PROCEDURE

A.	Startup procedure shall conform to generally accepted practices and be done in a workmanlike manner. The line shall be filled slowly from any available low-pressure source. The water may be introduced from lines in service directly through valved connections or by temporary connections to taps made in the new line.  All valves and other control points in the line that are open as the line filling begins shall be closed gradually to avoid the possibility of water hammer.

B.	Manufacturer's Written Certification:  After testing and prior to start-up of the system, the manufacturer must certify in writing that the system was installed per the manufacturer's installation instruction.

END OF SECTION