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CHAPTER 1 INTRODUCTION

Pipeline construction is complex and demanding, and requires the services of skilled contractors and craftsmen. Construction quality control and assurance are strict job requirements. The design engineers drawings and specications usually describe the quality and nal results the owner expects. The constructor must then select the construction procedures to complete the work as envisioned by the project designer. The best results are obtained when good interpersonal relationships exist between all parties. This manual provides help for those readers with limited technical backgrounds or those without specic working knowledge of a variety of pipe materials, although the level of detail should satisfy those who have wider work experiences. Nontechnical personnel needing basic information regarding the pipeline installation process will also nd this manual useful. Technical literature on uid transportation often focuses on the design phase of project development. In contrast, journal articles or conference papers contain better references to eld work. Brochures from pipe manufacturers are a signicant source of basic facts about this work. However, distribution is limited for all these, which can be frustrating for less experienced technical personnel or the casual reader. Combining pipeline data from multiple sources of information into one book should be one of the main benets to readers of this manual. Discussion of oil and gas pipelines is not included here because federal mandates and regulations standardize such work. This manual does not discuss no-dig or underwater construction because of site complexities and still-evolving technology in those elds.
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1.1 TARGETED READERSHIP

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This manual addresses three general groupsexperienced professionals, inexperienced professionals, and nontechnical decision makers, each with distinct interests. 1.1.1 Experienced Professionals Professionals familiar with only one or two types of pipeline installation will benet from this manuals briengs on many types of installations. Designers, consulting engineers, specication writers, and project planners will nd this manual a useful source of information for cost comparisons, route analyses, and numerous other investigations. Construction superintendents, project estimators, and foremen can also prot from this manuals descriptions, especially when working with new or unfamiliar pipe types. A constructors staff may use the references and information in this manual to assist in preparing bids for a job. Construction inspectors comprise an important group targeted by this manual. The text provides background for many provisions in construction specications for pipelines, especially if the designers reasons for using a certain procedure are not apparent or traditional. This manual is intended to help inspectors become more effective at inuencing constructor performance by better specication enforcement. It also provides inspection tips on observing acceptance tests for the nished pipeline. 1.1.2 Inexperienced Professionals Young engineers or inspectors can use this manual as a ready source of information specically related to their work. Field persons must often rely on information from many sources, usually the spoken word. This process, though often useful, can transmit unreliable information. This manual helps inexperienced professionals because reliable technical data from many sources is bound into a single volume. 1.1.3 Decision Makers This nontechnical group often plays a large part in developing the practical components of a pipeline project. Decision makers may consist of elected government ofcials or legal or nancial personnel who exercise some degree of control over engineered works. Because their control may vary from casual to absolute, they cannot be ignored. This manuals realistic approach to pipeline installation procedures may help educate these young engineers and answer questions relevant to the serious responsibilities associated with evaluating a pipeline project.

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1.2 TERMINOLOGY
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In this manual, a pipeline is dened as a buried conduit formed by a manufactured pipe laid in a trench or embankment condition. This denition includes typical water transmission and distribution pipelines as well as highway culverts, sewers, and other drainage and pressure pipes. Some entire pipeline reaches are installed in select environments by boring, jacking, or microtunneling methods. This type of work is specied in locations sensitive to disruption caused by equipment working on the surface or when a pipe is located under very deep earth cover. Pipes with diameters up to 36 in. (915 mm) or larger are commonly installed in this manner, and only the investment costs for exceptional equipment will limit placing much larger pipe sections. Trenchless methods for installing pipe are important recent developments and might be included for certain parts of constructing a traditional pipeline. However, those construction techniques differ substantially from work performed in traditional pipeline installation; therefore, discussion of this evolving technology is outside the scope of this manual. The term construction practice often appears in this manual and describes typical actions or techniques a constructor might use to complete eld installation of pipe. Field work included within the denition of construction practice might encompass storing unlaid pipe, excavating a trench, assembling and testing joints, and compacting backll. The actual installation of most pipeline components described will vary based on weather, available labor and equipment, legal restraints, and other variables. All the techniques and procedures described are considered to represent practical construction practices. Construction practice descriptions have been collected here from many sources, such as knowledgeable individuals, pipeline operating organizations, pipe manufacturers, and pipe trade associations. Most of the recommended practices have a long history of success to conrm their reliability. However, technology evolves constantly, and all procedures recommended here represent judgments based on the authors current collective experiences and skills. In summary, this manual strongly recommends methods and practices that have produced the most successful results for both the constructor and the project owner. The expressed goal of th manual is to guide pipeline construction in ways that allow the constructor to comply with all contract specications while performing efcient and protable work. A pipeline facility produced in this manner will likely have a long-term operational record of uid delivery service with minimum maintenance costs.

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1.3 TEXT ORGANIZATION

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This manual progresses sequentially from general to specic topics, making information easy to nd. Chapter 2 includes some basic technical concepts regarding the uses of natural soil during pipeline installation. Chapters 3 through 8 describe work common to all pipeline installations, regardless of the pipe material used. These procedures include excavation, use of the working area, spoil disposal, cleanup concerns, and many others. Describing this work early in the manual allows the uninformed reader to progress from the basics of pipeline installation to more complicated concepts. Chapters 9 through 19 describe specic construction procedures required by the characteristics of the type of pipe selected. These chapters consider pipes made from steel plate, ductile iron, plain or reinforced concrete, vitried clay, and man-made plastics. Differences in material characteristics have a signicant inuence on many of the construction procedures, so each chapter discusses a separate type of pipe, which allows ner technical distinctions and makes information easier to locate. In any case, the sample projects described are illustrations of experiences selected from other actual contract work. Construction practices may change over time and, for a given actual project, the job specications will supersede anything described in this text.

1.4 EMPHASIS ON CONSTRUCTION PRACTICES This manual addresses eld installation of actual pipelines or similar conduits, so the discussion is specically directed to the construction components of pipeline work. Design theory is included only when necessary to provide background information or to explain construction specications. This manual begins at the point where project construction drawings are complete, specications are written, and materials have been selected. Successful project design ultimately depends on conscientious, competent construction work. The project goal must involve delivering all expected hydraulic services while providing a low-maintenance pipe facility to the owner. To accomplish this goal, the eld work must proceed as the designer intended. Incompetent or decient construction will negate the designers intentions. Although this manual focuses on the construction aspects of pipeline installation, it is not a construction manual or a how-to book. Such publications are already available. Rather, the purpose of this manual is to provide better understanding of the practices used in typical situations

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encountered during pipeline system construction. It summarizes the composite views of typical constructors and engineers concerning those proven, effective, and practical construction practices that appear best to meet the project contract specications.

1.5 SOURCES OF INFORMATION Authors of this manual have considered and evaluated standard specications from many public and private agencies and trade/professional associations engaged in work related to pipeline construction. Appendix B presents a complete list of these sources. The following is a list of some of the main sources used: ASTM International (ASTM) and American Water Works Association (AWWA) standards American Concrete Pressure Pipe Association (ACPPA) U.S. Department of the Interior, Bureau of Reclamation Ductile Iron Pipe Research Association (DIPRA) Steel Tank Institute/Steel Plate Fabricators Association (STI/SPFA) National Clay Pipe Institute (NCPI) Uni-Bell PVC Pipe Association American Society of Civil Engineers (ASCE) Manuals and Reports on Engineering Practice: Manual 37, Design and Construction of Sanitary and Storm Sewers Manual 46, Pipeline Route Selection for Rural and Cross-Country Pipelines Manual 60, Gravity Sewer Design and Construction Manual 73, Quality in the Constructed Project: A Guide for Owners, Designers, and Contractors American Concrete Pipe Association (ACPA)

Inspecting Pipeline Installation