CHEMICAL PROCESS PIPING PVT. LTD.

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MUMBAI – 88

INSTALLATION GUIDELINE

00 For Information 24/12/2019 - - -

Rev. No. Reason for Issue Date of Issue Prepared by Checked by Approved by

© This document is, unless otherwise agreed in writing, the property of CPP, and shall not be reproduced, copied, disclosed to any third party or used for
any purpose other than that for which it is supplied or disclosed.

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Table of Contents
A] Under Ground Installation Guideline
1. GENERAL: ..............................................................................................................................................................3
2. SCOPE: ..................................................................................................................................................................3
3. SOIL CONDITIONS: ................................................................................................................................................3
4. TRENCHING: ..........................................................................................................................................................3
- FOUNDATION ............................................................................................................................................................... 4
- PROTECTION ................................................................................................................................................................ 4
5. EXCAVATION .........................................................................................................................................................5
- JOINTS TO BE EXECUTED WITHIN THE TRENCH..................................................................................................................... 5
- TRENCH WIDTH............................................................................................................................................................ 6
- TRENCH DEPTH AND MINIMUM COVER ............................................................................................................................ 7
- ROAD CROSSING........................................................................................................................................................... 7
6. SAND BEDDING .....................................................................................................................................................7
7. LOWERING ............................................................................................................................................................8
- DEWATERING............................................................................................................................................................... 8
8. BACKFILLING .........................................................................................................................................................8
- MATERIALS.................................................................................................................................................................. 8
9. PLACING AND COMPACTING PIPE BACKFILL MATERIALS .......................................................................................9

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A] UNDERGROUND INSTALLATION: PROCEDURE

1. GENERAL:

Guidelines on installation of buried pipe systems are given in AWWA C950 / M45.
It is important to understand the in situ soil conditions, prior to construction in order to prepare adequate
specifications and planning of construction methods. Classification of soils should be according to ASTM
D 2487 and ASTM D 2488.

2. SCOPE:

The scope of this procedure includes the soil conditions, trench details, excavation, installation, bedding,
anchorage and backfill. The following specification and guidelines for excavation, installation and backfill
procedures are generally in accordance with various International Standards for the design and
implementation of buried pipeline installations.

3. SOIL CONDITIONS:

It is important to understand in situ conditions prior to construction in order carry installation as per
designed. Depending on Soil conditions, the installation Civil Contractor may require different types of
foundations.

4. TRENCHING:

Standard trench details are shown in the CPP Drawing Number CPP 26171. Trenches shall be excavated to
the exact width and depth according to the size of pipe and the sides shall be left vertical as far as possible.
The pipe trench shall be taken sufficiently deep to give a minimum cushion of 1.5 meter above the top of
pipe.

The trench depth shall be sufficient to provide a minimum depth of cover, including the thickness of pre-
padding as specified in the drawing.

Special attention is required at transitions between above ground and buried installation.
The bottom of the trench shall be flat for a minimum of 25 m before the start of the belowground to the
above ground transition. In this section, elastic bending is not permitted. Wherever possible the pipe shall
be installed on undisturbed soil to avoid potential problems with differential settlement. Before the pipe is
laid in the trench, sharp objects e.g. rocks, bricks etc., shall be remove.

Trenches should be excavated true to line and level as specified and neatly trimmed prior to placing bedding
material. Trench construction will vary according to the types of soil encountered (stable or unstable). In
any case the trench bottom shall be flat and continuous.

- Trench walls for Stable Soil

Trench wall usually can be made vertical from the bed to the top of the pipe without the use of shoring or
sheet piling.

- Unstable trench walls and bottom

The trench will be excavated with vertical wall providing sheet shoring, Fig. 1 or with the natural slope of
the soil, Fig. 2. Refer Typical Installation Method details for Stable & Unstable Soil Drawing CPP 26171.

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- Foundation

The foundation shown in drawing is required when the trench bottom is unstable, i.e. made up of soils whose
displacement, due to variation in stress or moisture content is very high.

Depending on the conditions of the unstable trench bottom, the installation Civil Contractor may require
different types of foundations such as:

- Stabilization of the bottom material, by removing it for a minimum depth of 200 mm and replacing it
with stabilized gravel or sand, into which the unstable soil will not penetrate (ground capacity from 0.7
to 0.9 kg/cm2);

- Concrete material with a minimum depth of 150 mm (ground capacity from 0.5 to 0.7 kg/cm2);

- Piles capped by a concrete material (ground capacity from 0.5 to 0.7 kg/cm2). The above instruction
must be as strictly followed as larger is the pipe diameter.

- Protection

The trenches shall be strongly fenced and red light signals shall be kept at night to prevent accidents.
Sufficient care and protective measure shall be taken to see that the excavation shall not damage the
adjoining structures. The Civil Contractor shall be entirely responsible for any injury to life and damage to
the properties etc. Necessary protection work such as guide ropes, crossing places, barricades, caution
boards etc. shall be provided by the Civil Contractor. The Civil Contractor shall also provide facility for
crossing trench wherever required. The safety guidelines shall also be strictly adopted.

Fig.1. Typical Installation Method for Stable Soil.

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Fig.2. Typical Installation Method for Unstable Soil.

5. EXCAVATION

The excavation for the pipe trenches shall include removal of all materials of whatever nature and whether
in wet or dry condition necessary for laying of pipe lines exactly in accordance with alignment, levels,
grades and curves shown on the CPP Drawing Number (CPP 26171). Trenches shall be excavated to the
exact width and depth according to the size of pipe and the sides shall be left vertical as far as possible. The
pipe trench shall be taken sufficiently deep to give a minimum cushion of 1.5 meter above the top of pipe..
The trench bottom and sides shall be kept free of rocks, projections and other hard objects at all times before
and after lowering of the pipe. Any such items encountered shall be removed prior to pre-padding operations
so that the pipe is not damaged. The Trench Excavation shall meet the recommendations of AWWA M45.

Trench shall be made 150 mm to 300 mm deeper to accommodate sand bedding throughout the pipeline.
The sand filling shall be provided using clean river sand. The CPP may order such changes in the dimensions
and alignment of pipe trench as may be deemed necessary to secure satisfactory cover over pipeline.

- Joints to be Executed within the Trench

Wherever FRP jointing is to be carried out, Excavation and grade of the trench shall be sufficiently
deep and wide to provide a minimum working space on both sides of the pipe. CPP 26170 drawing
shows typical detail where Jointing is done in the Trench. For Trench width refer Table 1 of this
procedure. In any case the trench bottom shall be leveled off to provide a smooth continuous profile.
Refer Fig. 3.

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Fig.3. - Joints to be executed within the Trench

- Trench Width

Unless otherwise prescribed, trenches should be excavated with vertical side sand the width of the
trench at the top of the pipe should be determined from the following table 1:
Table 1
SIDE ALLOWANCE ON
PIPE DIAMETER
EACH
EACH(NB)
SIDE OF THE PIPE (P)
UP to 700 300 mm
750 to 1000 400mm
1050 to 2000 500mm
2050 to 3000 750mm

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- Trench Depth and Minimum Cover

The trench depth is determined by the intended service, properties, size of the pipe and local conditions
such as the properties of soil and combination of static and dynamic loading. The trench depth
prescribed should be adhered to by the pipe laying Civil Contractor and this should comply with the
backfill height as specified in the design. A minimum 1500mm of soil cover depth must be provided on
top of the Pipe.

- Road Crossing

For road crossing, a concrete slab/box culvert should be provided over the area wherever vehicle shall
pass. Care shall be taken, to ensure GRE/GRP piping is not subjected to any direct vehicular movement
load.

6. SAND BEDDING

Sand shall not contain any deleterious materials, which can cause damages of pipes. Sand bedding and
cushion shall be provided as required.

Sand shall be provided in one layer in such a depth as to result in 200 mm thick compacted bedding
after watering and ramming. Finished top of bedding shall be at required level. Excavated material shall
not be used for bedding and cushion.

When the trench traverses rocky ground or ground containing hard objects that could penetrate the
protective coating, special care shall be taken for sand bedding on the bottom of the trench prior to
installation of pipe.

At all times during construction the pipeline, the Civil Contractor shall take every precaution to prevent
damage to the pipe. No metal tools or heavy objects shall be permitted to come into contact
unnecessarily with the pipe. Any damage to the pipe from any cause during the installation of the
pipeline shall be repaired as directed by Civil Contractor at his cost.

The pipe should be uniformly and continuously supported through its whole length with firm stable
bedding material. Pipe bedding material should be sand as per the requirements on the backfill material.

The bedding should be placed so as to give complete contact between the bottom of the trench and the
pipe. The bottom of Sand Bedding should be well compacted to provide a minimum compaction
corresponding to 90% maximum dry density (refer IS 2720 – Part 7).

If the pipe is supported on grade elevation with use of timber or of tapered wedges, they must be
removed and not left in place. They can usually be pulled out after the bedding has been compacted to
the specified minimum compaction. The voids from which the timber has been removed must be
properly filled and compacted.

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7. LOWERING

After completing jointing of pipes, pipeline shall be lowered into the finished trench.

Width of the trenches shall be sufficient (refer Table 1) equal to about to enable lowering of pipe without
difficulty. The trench bottom shall not be uneven. Care shall be taken to provide bedding of sand of min
150 mm to 200mm thickness below the pipeline before the pipes are laid.

- Dewatering

The Civil Contractor shall have to arrange at his cost bailing or pumping out all water which may
accumulate in the trench during the progress of the work, either by percolation, seepage, spring, rain or
any other cause. Similarly he shall also have to arrange diverting surface flow if any, by providing
earthen bunds or by other means at his cost. The bunds shall be removed after the work is completed in
all respect at their own cost.

8. BACKFILLING

Backfilling material will be the same as used for bedding (maximum Particle size 18 mm).
Backfilling is ideally divided in two areas: primary backfilling which vertically extends from the lower
generatrix of the pipe as far as 70% of the diameter and secondary backfilling, extending as far as 150
to 300 mm from the top of the pipe. Backfilling up to the ground level with native material has to be
completed. Compaction can be made by using an impulsive compactor or any other suitable equipment.

- Materials

 Selected soil material for filling should be free from vegetation, lumps.

 The coarse gravel is to be used for backfilling and bedding.

 Gravel with partial size less than 50mm should be used for Pipe zone embedment.

 Gravel with partial size more than 50mm should be used for backfilling above pipe zone embedment

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9. PLACING AND COMPACTING PIPE BACKFILL MATERIALS

Place embedment materials by methods that will not disturb or damage the pipe. Work in and compact
the hunching material in the area between the bedding and the underside of the pipe before placing and
compacting the remainder of the pipe zone embedment.(See Fig. 4).Do not permit compaction
equipment to contact and damage the pipe. Use compaction equipment and techniques that are
compatible materials used and located in trench. Each layer should be compacted individually.

It is becoming common practice to leave the bedding un-compacted for a width of one-third of the pipe
diameter centered directly under the pipe. This reduces concentrated loads on the inverts. (See Fig. 1 &
2).

Fig.4. -Proper Compaction under Haunches

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