ANSI/AWWA C206-11
(Revision of ANSI/AWWA C206-03)
The Authoritative Resource on Safe Water®
AWWA Standard
Field Welding of
Steel Water Pipe
SM
Effective date: March 1, 2011.
First edition approved by AWWA Board of Directors Jan. 10, 1946.
This edition approved Jan. 23, 2011.
Approved by American National Standards Institute Jan. 4, 2011.
6666 West Quincy Avenue
Advocacy
Denver, CO 80235-3098
Communications
T 800.926.7337
Conferences
www.awwa.org
Education and Training
Science and Technology
Sections
Copyright © 2011 American Water Works Association. All Rights Reserved.
AWWA Standard
This document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standards describe
minimum requirements and do not contain all of the engineering and administrative information normally contained in specifications. The AWWA standards usually contain options that must be evaluated by the user of the standard. Until each optional
feature is specified by the user, the product or service is not fully defined. AWWA publication of a standard does not constitute
endorsement of any product or product type, nor does AWWA test, certify, or approve any product. The use of AWWA standards
is entirely voluntary. This standard does not supersede or take precedence over or displace any applicable law, regulation, or
codes of any governmental authority. AWWA standards are intended to represent a consensus of the water supply industry that
the product described will provide satisfactory service. When AWWA revises or withdraws this standard, an official notice of
action will be placed on the first page of the classified advertising section of Journal AWWA. The action becomes effective on
the first day of the month following the month of Journal AWWA publication of the official notice.
American National Standard
An American National Standard implies a consensus of those substantially concerned with its scope and provisions. An American
National Standard is intended as a guide to aid the manufacturer, the consumer, and the general public. The existence of an
American National Standard does not in any respect preclude anyone, whether that person has approved the standard or not,
from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standard. American National Standards are subject to periodic review, and users are cautioned to obtain the latest editions. Producers of goods
made in conformity with an American National Standard are encouraged to state on their own responsibility in advertising and
promotional materials or on tags or labels that the goods are produced in conformity with particular American National Standards.
Caution Notice: The American National Standards Institute (ANSI) approval date on the front cover of this standard indicates
completion of the ANSI approval process. This American National Standard may be revised or withdrawn at any time. ANSI
procedures require that action be taken to reaffirm, revise, or withdraw this standard no later than five years from the date of
publication. Purchasers of American National Standards may receive current information on all standards by calling or writing
the American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036; (212) 642-4900, or
e-mailing info@ansi.org.
All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopy, recording, or any information or retrieval system, except in the form of brief excerpts or
quotations for review purposes, without the written permission of the publisher.
Copyright © 2011 by American Water Works Association
Printed in USA
ii
Copyright © 2011 American Water Works Association. All Rights Reserved.
Committee Personnel
The task group for updating ANSI/AWWA C206 had the following personnel:
B. Nash Williams, Chair
S.A. Arnaout, Hanson Pressure Pipe, Dallas, Texas
H. Bardakjian, Manufacturer’s Consultant, Glendale, Calif.
B. Buchanan, Canusa-CPS, Toronto, Ont.
J. Buratto, Lifelast Inc., Vancouver, Wash.
B. Card, Manufacturer’s Consultant, Sugarhill, Ga.
D. Dechant, Manufacturer’s Consultant, Aurora, Colo.
B. Hansen, National Welding Corporation, Midvale, Utah
B.D. Keil, Northwest Pipe Company, Portland, Ore.
G. Kohlbeck, Felker Brothers, Marshfield, Wis.
J. Luka, American SpiralWeld Pipe Company, Columbia S.C.
R. Mielke, Northwest Pipe Company, Raleigh, N.C.
G. Ruchti, American SpiralWeld Pipe Company, Punta Gorda, Fla.
R.N. Satyarthi, Baker Coupling Company, Los Angeles, Calif.
H. Stoner, Consultant, North Plainfield, N.J.
M.A. Vanderbosch, CAB Inc., Oakwood, Ga.
D.R. Wagner, Wagner Consulting, St. Louis, Mo.
B.N. Williams, National Welding Corporation, Midvale, Utah
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
The AWWA Standards Committee on Steel Pipe, which reviewed and approved this standard, had
the following personnel at the time of approval:
John H. Bambei Jr., Chair
Dennis Dechant, Vice-Chair
John L. Luka, Secretary
General Interest Members
W.R. Brunzell, Brunzell Associates Ltd., Skokie, Ill.
R.J. Card, Lockwood Andrews & Newnam, Sugar Hill, Ga.
R.L. Coffey, HDR Engineering Inc., Omaha, Neb.
H.E. Dunham, MWH Inc., Bothell, Wash.
iii
Copyright © 2011 American Water Works Association. All Rights Reserved.
(AWWA)
(AWWA)
(AWWA)
(AWWA)
S.N. Foellmi, Black & Veatch Corporation, Irvine, Calif.
M.B. Horsley,* Black & Veatch Corporation, Kansas City, Mo.
J.K. Jeyapalan, Pipeline Consultant, New Milford, Conn.
R.A. Kufaas, Norske Corrosion & Inspection Services Ltd., Surrey, B.C.
J.L. Mattson, Corrosion Control Technologies, Sandy, Utah
D.L. McPherson,* MWH Americas Inc., Cleveland, Ohio
W.J. Moncrief,* HDR Engineering Inc., San Diego, Calif.
R. Ortega,* Lockwood Andrews & Newnam, Houston, Texas
E.S. Ralph,† Standards Engineer Liaison, AWWA, Denver, Colo.
A.E. Romer, AECOM, Newport Beach, Calif.
H.R. Stoner, Consultant, North Plainfield, N.J.
C.C. Sundberg, CH2M HILL Inc., Issaquah, Wash.
G.J. Tupac, G.J. Tupac & Associates Inc., Sun City West, Ariz.
W.R. Whidden, Post Buckley Schuh & Jernigan, Orlando, Fla.
K.E. Wilson,† Standards Council Liaison, Post Buckley Shuh & Jernigan Inc.,
Tampa, Fla.
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
Producer Members
S.A. Arnaout, Hanson Pressure Pipe Inc., Dallas, Texas
H.H. Bardakjian, Consultant, Glendale, Calif.
M. Bauer, Tnemec Company Inc., North Kansas City, Mo.
R.R. Carpenter, American SpiralWeld Pipe Company, Birmingham, Ala.
D. Dechant, Dechant Infrastructure Service, Aurora, Colo.
W.B. Geyer, Steel Plate Fabricators Association, Lake Zurich, Ill.
B.D. Keil, Northwest Pipe Company, Pleasant Grove, Utah
J.L. Luka, * American SpiralWeld Pipe Company, Columbia, S.C.
R. Mielke,* Northwest Pipe Company, Raleigh, N.C.
J. Olmos, Ameron International, Rancho Cucamonga, Calif.
J.A. Wise, Canus International Sales Inc., Langley, B.C.
(AWWA)
(AWWA)
(AWWA)
(MSS)
(AWWA)
(SFPA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
User Members
G.A. Andersen, New York City Bureau of Water Supply, Little Neck, N.Y.
J.H. Bambei Jr., Denver Water, Denver, Colo.
* Alternate
† Liaison, nonvoting
iv
Copyright © 2011 American Water Works Association. All Rights Reserved.
(AWWA)
(AWWA)
B. Cheng, Metro Vancouver, Burnaby, B.C.
D.W. Coppes, Massachusetts Water Resources Authority, Southborough, Mass.
R.V. Frisz, US Bureau of Reclamation, Denver, Colo.
G. George, Tacoma Water, Water Supply Section, Tacoma, Wash.
T.J. Jordan, Metropolitan Water District of Southern California, La Verne, Calif.
M. McReynolds,* Metropolitan Water District of Southern California,
La Mirada, Calif.
G. Oljaca,* Metro Vancouver, Burnaby, B.C.
G.P. Stine, San Diego County Water Authority, San Diego, Calif.
N.A. Wigner, Los Angeles Department of Water & Power, Los Angeles, Calif.
J.V. Young, City of Richmond, Richmond, B.C.
* Alternate
v
Copyright © 2011 American Water Works Association. All Rights Reserved.
(AWWA)
(NEWWA)
(BUREC)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
This page intentionally blank.
Copyright © 2011 American Water Works Association. All Rights Reserved.
Contents
All AWWA standards follow the general format indicated subsequently. Some variations from this
format may be found in a particular standard.
SEC.
PAGE
SEC.
PAGE
Foreword
I
Introduction...................................... ix
4
Requirements
4.1
Materials............................................ 3
I.A
Background....................................... ix
4.2
General Requirements........................ 4
I.B
History............................................... x
4.3
Joint Types......................................... 5
I.C
Acceptance......................................... x
4.4
II
Special Issues..................................... xi
III
Use of This Standard......................... xi
Qualification of Welding
Procedures, Welders, and
Welding Operators....................... 6
III.A Purchaser Options and
Alternatives................................. xi
4.5
Welding Electrodes............................ 7
4.6
Welding Procedure Details................. 7
III.B Modification to Standard................. xii
4.7
Repair of Welds................................ 10
IV
Major Revisions..................................xii
5
Verification
V
Comments...................................... xiii
5.1
Inspection........................................ 10
5.2
Testing............................................. 11
5.3
Rejection.......................................... 12
Standard
1
General
1.1
Scope................................................. 1
6
Delivery
1.2
Purpose.............................................. 1
6.1
Marking........................................... 12
1.3
Application......................................... 2
6.2
Packaging and Shipping................... 13
2
References......................................... 2
6.3
Affidavit of Compliance................... 13
3
Definitions........................................ 2
Figure
1
Look-Box for Vacuum Testing of
Circumferential Weld Seams...... 13
vii
Copyright © 2011 American Water Works Association. All Rights Reserved.
This page intentionally blank.
Copyright © 2011 American Water Works Association. All Rights Reserved.
Foreword
This foreword is for information only and is not a part of ANSI*/AWWA C206.
I.
Introduction.
I.A. Background. The provisions of this standard describe the requirements
for welding steel water pipe joints in water transmission and distribution lines. The
purchaser for each project is responsible for determining if any unusual circumstances
related to the project require additional provisions that are not included in the standard.
The design of field-welded joints is not discussed in this standard. Useful information on this subject may be found in AWWA Manual M11, Steel Pipe—A Guide for
Design and Installation,† and in Useful Information on the Design of Plate Structures.‡
After the welded field joint has been completed, if the pipe has been coated or
lined, the joint shall be coated and lined with a coating system compatible with that
on the body of the pipe, in accordance with the requirements for field repairs stated in
the appropriate AWWA coating or lining standard.
For lap-welded pipe with an inside diameter equal to or exceeding 48 in. (1,200
mm) and where the purchaser deems single welding to be acceptable, inside welding is
recommended. Safety precautions shall be utilized in all pipe sizes, although when pipe
with inside diameters less than 48 in. (1,200 mm) down to 27 in. (675 mm) are welded
from the inside, additional safety precautions shall be observed. Interior welding on pipe
diameters less than 27 in. (675 mm) is not recommended.
Pipe requiring inside welds with limited access should be supplied with 3-in.
(75-mm) diameter weld lead pass holes at approximately 400-ft (122-m) centers to
allow passage of welding leads to the joint location. Shorter distances between pass
holes may be required, depending on actual project conditions. Pass holes in the
pipe will permit shorter welding leads and thus avoid erratic voltage drops caused
by excessively long welding leads. The pass hole is fabricated using a weldable-grade,
inside-threaded pipe half coupling welded to a hole cut through the pipe wall. After
using the pass hole, a weldable grade plug shall be threaded into the opening and
seal-welded to secure.
* American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.
† Steel Pipe—A Guide for Design and Installation, AWWA Manual M11, AWWA, Denver, Colo.
(2004).
‡ Useful Information on the Design of Plate Structures, Steel Plate Engineering Data, Vol. 2, American
Iron and Steel Institute, 1101 17th St. NW, Ste. 1300, Washington, DC 20036.
ix
Copyright © 2011 American Water Works Association. All Rights Reserved.
I.B.
History. This standard was first approved as tentative by AWWA in January
1946 and by the American Welding Society (AWS) in October 1945. It was advanced
to standard status by AWWA in 1950 and by AWS in 1951. The joint AWWA–AWS
activity continued through revisions in 1957 (AWWA C206-57, AWS D7.0-57) and 1962
(AWWA C206-62, AWS D7.0-62a). The joint committee was dissolved in 1971, and the
standard was assigned to the AWWA Standards Committee on Steel Pipe. Subsequent
editions of the standard were published in 1975, 1982, 1988, 1991, 1997, and 2003. This
edition was approved by the AWWA Board of Directors on Jan. 23, 2011.
I.C. Acceptance. In May 1985, the US Environmental Protection Agency
(USEPA) entered into a cooperative agreement with a consortium led by NSF
International (NSF*) to develop voluntary third-party consensus standards and a
certification program for direct and indirect drinking water additives. Other members
of the original consortium included the American Water Works Association Research
Foundation (AwwaRF, now Water Research Foundation†) and the Conference of
State Health and Environmental Managers (COSHEM). The American Water Works
Association (AWWA) and the Association of State Drinking Water Administrators
(ASDWA) joined later.
In the United States, authority to regulate products for use in, or in contact with,
drinking water rests with individual states.‡ Local agencies may choose to impose
requirements more stringent than those required by the state. To evaluate the health
effects of products and drinking water additives from such products, state and local
agencies may use various references, including
1. An advisory program formerly administered by USEPA, Office of Drinking
Water, discontinued on Apr. 7, 1990.
2. Specific policies of the state or local agency.
3. Two standards developed under the direction of NSF, NSF/ANSI 60,
Drinking Water Treatment Chemicals—Health Effects, and NSF/ANSI 61, Drinking
Water System Components—Health Effects.
4. Other references, including AWWA standards, Food Chemicals Codex,
Water Chemicals Codex,§ and other standards considered appropriate by the state or
local agency.
* NSF International, 789 N. Dixboro Road, Ann Arbor, MI 48105.
† Water Research Foundation, 6666 W. Quincy Avenue, Denver, CO 80235.
‡ Persons outside the United States should contact the appropriate authority having jurisdiction.
§ Both publications available from National Academy of Sciences, 500 Fifth St. NW, Washington, DC
20418.
x
Copyright © 2011 American Water Works Association. All Rights Reserved.
Various certification organizations may be involved in certifying products in accordance with NSF/ANSI 61. Individual states or local agencies have authority to accept
or accredit certification organizations within their jurisdiction. Accreditation of certification organizations may vary from jurisdiction to jurisdiction.
Annex A, “Toxicology Review and Evaluation Procedures,” to NSF/ANSI 61 does
not stipulate a maximum allowable level (MAL) of a contaminant for substances not
regulated by a USEPA final maximum contaminant level (MCL). The MALs of an
unspecified list of “unregulated contaminants” are based on toxicity testing guidelines (noncarcinogens) and risk characterization methodology (carcinogens). Use of
Annex A procedures may not always be identical, depending on the certifier.
ANSI/AWWA C206 does not address additives requirements. Users of this standard should consult the appropriate state or local agency having jurisdiction in order to
1. Determine additives requirements, including applicable standards.
2. Determine the status of certifications by parties offering to certify products
for contact with, or treatment of, drinking water.
3. Determine current information on product certification.
II. Special Issues. This standard has no applicable information for this
section.
III. Use of This Standard. It is the responsibility of the user of an AWWA
standard to determine that the products described in that standard are suitable for use
in the particular application being considered.
III.A. Purchaser Options and Alternatives. The following information should be
provided by the purchaser.
1. Standard used—that is, ANSI/AWWA C206, Field Welding of Steel Water
Pipe, of latest revision.
2. Whether compliance with NSF/ANSI 61, Drinking Water Treatment
Chemicals—Health Effects is required.
3. Details of other federal, state or provincial, and local requirements (Sec. 4.1.1).
4. Provisions for alleviation of thermal stresses (Sec. 4.2.6).
5. Type of joint (Sec. 4.3).
6. Lap joint (Sec. 4.3.2).
7. Butt joint (Sec. 4.3.3).
8. Option regarding backing rings (Sec. 4.3.3.1).
9. Seal weld of butt straps to facilitate an air test (Sec. 4.3.4).
10. Notch tough weld criteria, if required, temperature of test, and test values
(Sec. 4.6.10).
11. Weld inspection, if required (Sec. 5.1.3).
xi
Copyright © 2011 American Water Works Association. All Rights Reserved.
12. Testing methods, if required (Sec. 5.2).
13. Nondestructive testing of welded joints if substituted for hydrostatic tests
(Sec. 5.2.2).
14. Affidavit of compliance (Sec. 6.3).
III.B. Modification to Standard. Any modification of the provisions, definitions,
or terminology in this standard must be provided by the purchaser.
IV. Major Revisions. Major changes made to the standard in this revision
include the following:
1. Information on inside welding of pipe with limited access was added to the
foreword (Sec. I.A).
2. Definitions for procedure qualification record (PQR), weld-after-backfill,
welding procedure specification (WPS), and welder qualification record were added
(Section 2).
3. Deleted the permeation section since it is not applicable for welded steel
pipe.
4. Added requirement for materials to comply with the Safe Drinking Water
Act and other federal regulations (Sec. 4.1.1).
5. Added a section on double-welded lap joints and single-welded lap joints
with air testing (Sec. 4.3.2.2 and Sec. 4.3.2.3)
6. Added a paragraph on butt joints without a backing ring (Sec. 4.3.3.1)
7. Revisions were made to Sec. 4.3.4, Butt-strap joints.
8. Revisions were made to Sec. 4.4, Qualification of Welding Procedures,
Welders, and Welding Operators, including the addition of qualifications for tack
welders.
9. The clearance between faying surfaces of lap joints was revised (Sec. 4.6.3).
10. A requirement for the fillet weld size was added (Sec. 4.6.3).
11. A new section on weld-after-backfill was added (Sec. 4.6.4).
12. The permissible metal temperature of the pipe wall during welding was lowered. (Sec. 4.6.5)
13. A requirement for repair of arc-strikes was added (Sec. 4.6.8.4).
14. A requirement for Charpy V-notch specimens was added (Sec. 4.6.10).
15. A section on visual inspection was added (Sec. 5.1.4)
16. The section on Ultrasonic testing without backing rings was deleted (old
Sec. 5.2.2.2) and incorporated into a revised Sec. 5.2.2.1, Testing of field-butt joints
with or without backing rings.
17. The testing section on lap joints was renamed to Testing field fillet weld
joints, and was revised (new Sec. 5.2.2.2).
18. Information on marking of pipe segments was added to Sec. 6.1.
xii
Copyright © 2011 American Water Works Association. All Rights Reserved.
V.
Comments. If you have any comments or questions about this standard,
please call AWWA Engineering and Technical Services at 303.794.7711, FAX at
303.795.7603, write to the department at 6666 West Quincy Avenue, Denver, CO
80235-3098, or e-mail at standards@awwa.org.
xiii
Copyright © 2011 American Water Works Association. All Rights Reserved.
This page intentionally blank.
Copyright © 2011 American Water Works Association. All Rights Reserved.
ANSI/AWWA C206-11
(Revision of ANSI/AWWA C206-03)
AWWA Standard
Field Welding of Steel Water Pipe
SECTION 1:
Sec. 1.1
GENERAL
Scope
This standard describes manual, semiautomatic, and automatic field welding
by the metal arc-welding processes for steel water pipe manufactured in accordance
with ANSI*/AWWA C200, Standard for Steel Water Pipe—6 In. (150 mm) and
Larger. This standard describes field-performed, full circumferential welding of
three types of pipe joints: (1) lap joints; (2) butt joints; and (3) butt-strap joints.
This standard also applies to other welding required in field fabrication and installation of specials and appurtenances. However, when possible, fabrications should
be performed by the manufacturer at a manufacturing facility. The design of fieldwelded joints is not covered within this standard.
This standard recognizes AWS† D1.1 as the supporting document.
Welding of gasketed joints may require modification to the parameters of this
welding standard.
Sec. 1.2
Purpose
The purpose of this standard is to provide minimum requirements for field
welding and inspection of steel water pipe, including requirements and inspection.
* American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.
† American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126.
1
Copyright © 2011 American Water Works Association. All Rights Reserved.
2
AWWA C206-11
Sec. 1.3
Application
This standard can be referenced in documents for field welding of steel water
pipe. The stipulations of this standard apply when this document has been referenced and then only to field welding of steel water pipe.
SECTION 2:
REFERENCES
This standard references the following documents. In their latest editions,
they form a part of this standard to the extent specified within the standard. In any
case of conflict, the requirements of this standard shall prevail.
ANSI/AWWA C200—Steel Water Pipe—6 In. (150 mm) and Larger.
ASME* Sec. VIII Division 1—Boiler and Pressure Vessel Code, Rules for
Construction of Pressure Vessels.
ASTM† A135—Standard Specification for Electric-Resistance-Welded Steel
Pipe.
ASTM A370—Standard Test Methods and Definitions for Mechanical Testing of Steel Products.
AWS A2.4—Standard Symbols for Welding, Brazing, and Nondestructive
Examination.
AWS A3.0—Standard Welding Terms and Definitions Including Terms for
Brazing, Soldering Thermal Spraying, and Thermal Cutting.
AWS D1.1—Structural Welding Code—Steel.
AWS QC1—Standard for AWS Certification of Welding Inspectors.
Steel Pipe—A Guide for Design and Installation. AWWA Manual M11.
AWWA, Denver, Colo.
SECTION 3:
DEFINITIONS
The following definitions shall apply in this standard:
1. CJP: Complete joint penetration.
2. Constructor: The party that provides the work and materials for placement or installation.
* ASME International, Three Park Avenue, New York, NY 10016.
† ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428.
Copyright © 2011 American Water Works Association. All Rights Reserved.
Field Welding of Steel Water Pipe 3
3. CWI: Certified welding inspector.
4. Faying surfaces: The mating surface of a member that is in contact with,
or in close proximity to another member, to which it is to be joined.
5. Full fillet weld: A fillet weld with both legs of the weld equal in size to
the thickness of the thinner member joined.
6. Manufacturer: The party that manufactures, fabricates, or produces
materials or products.
7. NDT: Nondestructive testing.
8. PQR: Procedure qualification record. A record of the welding variables
used to produce an acceptable test weld and the results of the tests conducted on
the weld to qualify a welding procedure specification.
9. Purchaser: The person, company, or organization that purchases any
materials or work to be performed.
10. WPS: Welding Procedure Specification. A document to describe the
range of voltage, amperage, travel speed, and other parameters intended to be utilized in the welding process.
11. WQR: Welder Qualification Record. The document to describe the
welder testing and results of that testing that allows certification of a welder to
perform welding.
12. Weld-after-backfill: The sequence of assembling a lap-welded joint,
welding the outside weld (if required), applying the external joint pipe coating system, backfilling the pipe, then welding the inside joint at a later time (where inside
welding is safe and practical)
13. Welder or welding operator: A person who performs a manual, semiautomatic, or automatic welding operation.
14. Welding symbols: Symbols used on documents to define weld type, size,
location, and geometry.
15. Welding terms: Welding terms shall be interpreted in accordance with
the definitions given in AWS A3.0, supplemented by Annex B of AWS D1.1.
SECTION 4:
Sec. 4.1
REQUIREMENTS
Materials
4.1.1 General. Material provided and work completed shall meet the
requirements of this standard.
Copyright © 2011 American Water Works Association. All Rights Reserved.
4
AWWA C206-11
Materials shall comply with the requirements of the Safe Drinking Water Act
and other federal regulations for potable water, wastewater, and reclaimed water
systems as applicable.
Sec. 4.2
General Requirements
4.2.1 Construction drawings. Construction drawings shall be the purchaser’s drawings or approved constructor’s drawings.
4.2.2 Equipment. The constructor’s equipment for welding shall be
designed and maintained in such condition as to permit qualified welding operators to follow the welding procedure details (Sec. 4.6) and obtain the results prescribed.
4.2.3 Welding process. Welding shall be performed by any welding process that will (1) produce a joint meeting the minimum strength requirements of
the base metals and (2) meet the welding procedure qualification required in
Sec. 4.4 of this standard, except that the short-circuiting transfer mode of the gas metal
arc-welding process shall not be used for weld sizes greater than 3/ 16 in. (4.8 mm).*
4.2.4 Safety and environmental considerations. Welding, cutting, and
grinding operations will produce smoke and fumes. In confined spaces, the constructor may be required to utilize exhaust ventilation systems, employ air monitoring equipment, and take other actions to ensure meeting safety regulations.
Interior pipe welding shall only be performed after safe and adequate access and
egress is provided for the personnel. Federal, state or provincial, and local regulations shall also be followed.
4.2.5 Pipe condition. Prior to welding, ends of pipe to be welded shall be
in conformance with the requirements for end preparation for field joints in accordance with ANSI/AWWA C200. Any linings or coatings shall be held back in an
amount that is appropriate for the type of joint.
4.2.6 Thermal-stress control. For welded joint pipelines, variations in pipe
temperature at the time of installation, and the temperature difference between
the pipeline and the temperature of the fluid being transported during operation,
may induce thermal stresses. Anticipated thermal stresses should be evaluated by
the purchaser.
Various methods are available to reduce thermal stresses, such as shading
the pipe in the trench, using backfill as insulation, making certain joint welds
* Metric conversions given in this standard are direct conversions of US customary units and are not those specified
in International Organization for Standardization (ISO) standards.
Copyright © 2011 American Water Works Association. All Rights Reserved.
Field Welding of Steel Water Pipe 5
(particularly when closure joints are made) at a time of day when the temperature
is the lowest, or a combination of these methods.
If specified by the purchaser, sleeve-type couplings may be used in lieu of
welded joints to control thermal stresses, as long as the movement in each joint is
less than 0.375 in. (9.5 mm) or as recommended by the coupling manufacturer.
Sec. 4.3
Joint Types
4.3.1 General. Joints shall be lap joints, butt joints, or butt-strap joints, as
specified by the purchaser.
4.3.2 Lap joints. Lap joints shall be full-fillet single-welded unless otherwise specified by the purchaser. Field joints shall be assembled so that seams in
adjacent pipe sections are offset from each other by at least five times the thickness
of the thinner of the pipes being joined.
4.3.2.1 Single-welded lap joints. At the option of the constructor, and
subject to the purchaser’s approval, single-welded lap joints may be welded from
either the outside of the pipe or from the inside of the pipe if the diameter is large
enough.
4.3.2.2 Double-welded lap joints. If specified by the purchaser, doublewelded lap joints with full-fillet welds shall be required.
4.3.2.3 Single-welded lap joints with air testing. If specified by the purchaser, single-welded lap joints with air testing shall be completed by the addition
of a second weld to facilitate the air test described in Sec. 5.2.2.2. This second weld
shall only be a seal weld.
4.3.3 Butt joints. Butt joints shall be single-groove with a backing ring or
double-groove welded, at the option of the purchaser, and shall be CJP butt welds.
Field joints shall be assembled so that seams in adjacent pipe sections are offset
from each other by at least five times the thickness of the thinner of the pipes being
joined.
4.3.3.1 Single-groove butt joints. At the option of the purchaser, singlegroove butt joints may be welded from the outside of the pipe or from inside the
pipe if the diameter is large enough. Backing rings will assist in proper alignment
and may be used unless otherwise prohibited. The exterior backing ring should
remain after welding unless otherwise required. The interior backing ring may
remain after welding, subject to evaluation of possible interference with the interior
lining, with agreement of the purchaser. Depending on the welding process used,
the butt joint without a backing ring may require back grinding or gouging, then
Copyright © 2011 American Water Works Association. All Rights Reserved.
6
AWWA C206-11
back welding on the opposite side of the bevel to achieve a CJP butt weld. Back
grinding or gouging ensures complete removal of embedded slag.
4.3.4 Butt-strap joints. Butt straps shall receive complete circumferential
single-welded full fillet welds, either on the inside or outside of the butt strap. If
specified by the purchaser, a double-welded butt strap with full-fillet welds shall
include welding both the inside and outside of the butt strap. Butt straps may be
shop-attached by welding to one pipe end or shipped loose for field attachment
and welding. The butt straps shall have a minimum plate thickness equal to the
thinnest member being joined and shall be fabricated from material of equivalent
minimum physical properties and compatible chemical properties to the thinnest
member being joined. Strap width shall be not less than 4 in. (102 mm) for pipe
less than 36 in. (900 mm) in nominal diameter and 6 in. (152 mm) for pipe 36 in.
(900 mm) nominal diameter and larger. The minimum lap between pipe ends and
the edge of the butt strap shall be 1 in. (25 mm) for pipe less than 36 in. (900 mm)
in nominal diameter and 2 in. (51 mm) for pipe 36 in. (900 mm) nominal diameter and larger. Longitudinal seams of butt straps shall be joined by CJP welded
butt joints. See AWS D1.1 for various joint details.
For butt-strap joints, the seams of adjacent pipe sections may be in alignment,
provided the butt-strap seams are offset from the pipe seams by at least five times
the thickness of the thinner member involved in the joint. At the option of the
constructor and subject to the purchaser’s approval, the butt strap may be welded
from the outside of the pipe, or from inside the pipe if the diameter is large enough.
With the purchaser’s approval, either the inside or the outside weld may be a seal
weld to facilitate an air test as described in Sec. 5.2.2.2, if the other weld provides
sufficient strength to carry all loads anticipated at the joint.
Sec. 4.4
Qualification of Welding Procedures, Welders, and Welding Operators
4.4.1 General. Joint-welding procedures to be used for work under the
provisions of this standard and welders, welding operators, and tack welders shall
be qualified by tests, except procedures that comply with Sec. 4.4.2. General
requirements for qualification shall be in accordance with AWS D1.1, Qualification. (Note: A pipeline is not “tubular construction” as defined in AWS D1.1.)
Written procedures shall be prepared by the constructor and shall be made available to the welders at the jobsite and to those authorized to examine the welds.
4.4.2 Welding-procedure qualification record (PQR). The PQR document provides the verification that the welding method and operating values
provide the required metallurgical and mechanical characteristics. The WPS
Copyright © 2011 American Water Works Association. All Rights Reserved.
Field Welding of Steel Water Pipe 7
will provide the operating ranges (voltage, amperage, travel speed, etc.) allowed
during the actual welding operations. Certain joint-welding procedures, as outlined in AWS D1.1, Prequalification of Welding Procedure Specifications, are
prequalified and are exempt from tests. Other procedures shall be qualified in
accordance with AWS D1.1.*
4.4.3 Welder, welding-operator, and tack welder qualification. Welders and
welding operators shall be qualified by tests as prescribed in AWS D1.1.† The WQR
document provides certification that the welder, welding operator, or tack welder is
qualified to perform welding under this standard. The welder and welding-operator
qualification will remain in effect indefinitely unless (1) the welder is not engaged in
a given process of welding for which the welder or welding operator is qualified for a
period exceeding six months or unless (2) there is some specific reason to question a
welder’s or welding operator’s ability.
A tack welder who passes the tests as prescribed in AWS D1.1 shall be considered eligible to perform tack welding indefinitely in the positions and with the
process for which the tack welder is qualified unless there is some specific reason to
question the tack welder’s ability.
4.4.3.1 Records. Records of the test results shall be kept by the constructor and shall be available to the purchaser.
Sec. 4.5
Welding Electrodes
4.5.1 General. Welding electrodes shall be the same classification as those
used for the welding-procedure qualification in Sec. 4.4.2. When low-hydrogen
electrodes are used for welding, the constructor shall control the storage and handling of electrodes to maintain the low-hydrogen characteristics as recommended
by the electrode manufacturer.
Sec. 4.6
Welding Procedure Details
4.6.1 General. Welds in the pipe and the attachments shall be performed
in strict accordance with the qualification procedures stated in Sec. 4.4. Weld symbols shall be as defined under AWS A2.4. Special welding conditions shall be fully
explained by added notes or details.
* AWS D1.1, Table 4.7, refers to qualification of welding procedures with a base metal included in group I and
group II of Table 3.1 in AWS D1.1. For the purposes of AWWA C206, group I and group II materials shall
include pipe produced to ASTM A135, grades A and B.
† AWS D1.1, Sec. 3.3, 4.7.3, and 5.2, state that the base metal used in the qualification test shall comply with
Table 3.1 of the procedure described in AWS D.1.1.
Copyright © 2011 American Water Works Association. All Rights Reserved.
8
AWWA C206-11
4.6.2 Preparation of welding surfaces. Surfaces to be welded shall be free
from moisture, scale, slag, heavy rust, grease, coatings, paint, primer, cement, or
any other foreign material. Joint surfaces shall be smooth, uniform, and free from
defects that adversely affect proper welding. After wire brushing, any residual
light film of rust remaining on the cut or sheared edges to be welded need not be
removed. Surfaces that were previously torch cut or air-arc gouged shall be ground
to remove slag and oxidation.
4.6.3 Lap-joint assembly. Clearance between faying surfaces of lap joints
shall not exceed 1/ 8 in. (3.2 mm) at any location for fillet welds on pipe having wall
thicknesses less than or equal to 5/ 16 in. (7.9 mm), and clearance between faying
surfaces of lap joints shall not exceed 3/ 16 in. (4.8 mm) at any location for fillet
welds on pipe having wall thicknesses greater than 5/ 16 in. (7.9 mm). In the event
the faying surfaces exceed these tolerances, verify if the pipe ends comply with the
required manufacturing tolerances; if so, the constructor shall fit the area to within
the tolerances stated in this section. The minimum overlap of the assembled belland-spigot sections of the joint shall be 1 in. (25 mm) or three times the thickness
of the belled pipe, whichever is greater. No part of any field weld shall be closer
than 1 in. (25 mm) to the nearest point of tangency to a bell radius. Joint fabrication tolerances shall be in accordance with ANSI/AWWA C200.
The fillet weld size shall be the specified thickness plus the root opening
between the two overlapping plates. The finished weld shall create a 45° angle relative to the adjoining members.
4.6.4 Weld-after-backfill sequence. Welding inside field joints after backfill is an acceptable practice under this standard, provided the requirements of
ANSI/AWWA C205, C206, C209, C214, C215, C216, and other applicable
AWWA standards are followed. Consult with the manufacturers subject to the
above-referenced standards regarding recommended products, installation, and
backfill procedures required for the weld-after-backfill sequence. At the request of
the purchaser, the manufacturer shall provide testing or historical information to
verify that the exterior joint coating will comply with the applicable material standard and the coating manufacturer’s requirements after completion of the welding.
Note: In all cases, the exterior coating manufacturer should be consulted
to verify its product is intended for the weld-after-backfill application with the
project-specific conditions. The constructor shall adhere strictly to the specified
stab depth minimum and joint gap tolerances.
4.6.5 Weather conditions. Welding shall not be performed when the
ambient temperature is less than 0°F (–18°C), or when surfaces are wet from rain,
Copyright © 2011 American Water Works Association. All Rights Reserved.
Field Welding of Steel Water Pipe 9
condensation, snow, or ice, or during periods of high wind, unless the work is
properly protected. Regardless of the ambient conditions, the metal temperature in
the pipe wall shall not be less than 32°F (0°C) at any point within 3 in. (76 mm)
of the point of welding or four times the pipe wall thickness, whichever is greater.
4.6.6 Preheating. Preheating of the joints to be welded shall be performed
in accordance with AWS D1.1, Prequalified Minimum Preheat and Interpass Temperature. When preheating is required, it shall extend ahead of the point of welding a minimum distance of four times the plate thickness, but not less than 3 in.
(76 mm), on each side of the seam. Proper preheat temperature shall be determined
periodically during welding by checking the material at a point at least four times
the plate thickness, but not less than 3 in. (76 mm), on either side of the seam.
4.6.7 Tack welding. Small erection tack welds used in the assembly of joints
need not be removed provided (1) they are sound and their size does not exceed the
subsequently applied root pass; (2) they do not interfere with welding procedures
required for closure joints to control thermal stresses (Sec. 4.2.6); (3) they do not
prevent the proper distribution of the annular space to control the distance between
faying surfaces in lap joints (Sec. 4.6.3); (4) the electrodes used in making the tack
welds shall be the same as used in the final welds; and (5) welding is performed in
strict accordance with the qualification procedures stated in Sec. 4.4.
4.6.8 Weld appearance and weld contour. The welds shall be applied using
con­tinuous stringer beads, or a weave pattern meeting AWS D1.1, Visual Inspection Acceptance Criteria for Statically Loaded Nontubular Connections. Each
bead shall be cleaned and descaled before the succeeding bead is applied. Welded
joints shall not be covered or coated until after welding is completed and the weld
accepted.
4.6.8.1 Surface pass. The surface pass on welds shall be central to the
seam, and all surface passes shall be smooth and free from depression. The final
weld surface shall be free from weld slag and porosity.
4.6.8.2 Undercutting, overlapping, and finished fillet weld. Undercutting of the base metal in pipe and adjoining the weld, which exceeds AWS D1.1
requirements, is a defect and shall be repaired. Burning back the inside or outside
corner during application of a fillet weld shall be permitted if the edge can be
clearly defined. The finished fillet weld shall be free of grooves, deep valleys, or
ridges and shall contain no abrupt changes in the section at the toe.
4.6.8.3 Lap- or fillet-weld legs and faces. Lap or fillet welds shall have
legs of equal size, except when specified otherwise. The faces of fillet welds may be
flat to slightly convex.
Copyright © 2011 American Water Works Association. All Rights Reserved.
10
AWWA C206-11
4.6.8.4 Cracks, Pinholes, Porosity, and Arc Strikes. Cracks in welds and
base metal, incomplete fusion, lack of complete joint penetration (including fillet
welds that do not penetrate past the point of intersection of the members being
joined), and weld overlap are unacceptable. Pinholes and porosity are unacceptable
and shall be repaired according to Sec. 4.7. Arc strikes outside the weld boundary are unacceptable and shall be ground flush with the base metal and shall be
repaired according to Sec. 4.7 if additional weld metal is required.
4.6.9 Matching butt joints. Butt joints shall be accurately aligned and
retained in position during the welding operation so that, in the finished joint, the
abutting pipe sections shall not be misaligned by more than 20 percent of the pipe
wall thickness or a maximum of 1/ 8 in. (3.2 mm), whichever is less.
4.6.10 Notch tough welds. When required for the pipe material and requested
by the purchaser, welding procedures shall be qualified to provide notch tough welds.
Filler material shall meet the same toughness requirements as the base metal or as
required by the purchaser’s documents. If not otherwise specified, the minimum
average value of absorbed energy shall be 20 ft-lb (33.9 N-m) at 32°F (–0°C) or the
lowest anticipated service temperature, whichever is lower. Charpy V-notch (CVN)
transverse specimens shall be prepared in accordance with the requirements of ASTM
A370 and AWS D1.1 Section 4, Part D, Requirements for CVN Testing.
Sec. 4.7
Repair of Welds
4.7.1 Repair of defective welds. Welds that are defective shall be repaired
to meet the requirements of Sec. 4.5 and 4.6.
4.7.1.1 Defects in welds. Defects in welds or defective welds shall be
removed and that section of the joint shall then be rewelded. The amount of material removed shall be limited to that required to correct the defect. After the repair
is made, the joint shall be checked by repeating the original test procedure.
SECTION 5:
Sec. 5.1
VERIFICATION
Inspection
Inspection or a lack of inspection shall not relieve the constructor of the responsibility for performing work in accordance with this standard. The constructor shall
notify the purchaser before performing any work under the provisions of this standard so that the purchaser can prepare for the inspection.
5.1.1 Access. The purchaser shall have free access to those areas of the project that are involved with the performance of any work pertaining to this standard.
Copyright © 2011 American Water Works Association. All Rights Reserved.
Field Welding of Steel Water Pipe 11
5.1.2 Facilities. The constructor shall provide the purchaser with reasonable facilities and space for inspection, testing, and obtaining the information
required to determine the character of materials used, the progress and conditions
of the work, and the results obtained.
5.1.3 Weld inspection. When requested by the purchaser, a full-time
welding inspector shall be present whenever there is welding to be performed. The
welding inspector shall have prior pipe-welding inspection experience and shall
be a CWI in accordance with the provisions of AWS QC1 or otherwise meet the
qualification requirements stated in AWS D1.1.
5.1.4 Visual Inspection. Field welds shall be visually inspected by an individual who by training, experience, or both, in metals fabrication, inspection, and
testing, is competent to perform the visual inspection. Any of the weld defects
identified by visual inspection shall be cause for rejection, and the deficient weld
shall be repaired or replaced. The acceptance criteria for field welds shall meet the
requirements of AWS D1.1, Visual Inspection Acceptance Criteria for Statically
Loaded Nontubular Connections, except as modified in Sec. 4.6.8.4.
Sec. 5.2
Testing
Inspection and testing for weld integrity shall be performed unless otherwise
specified by the purchaser. All welds shall be visually inspected in accordance with
Sec. 5.1.4.
5.2.1 Hydrostatic test. Tests for leaks in all types of welded joint pipelines
shall be made by hydrostatically testing the entire pipeline, unless the procedures,
frequency of tests, and standards for acceptance or rejection of an alternative nondestructive method are approved by the purchaser. If leakage exceeds the amount
allowed in the purchaser’s documents, the leaks shall be located and repaired in
accordance with Sec. 4.7.
5.2.2 Alternative tests. In lieu of the hydrostatic test, the purchaser shall
approve nondestructive testing of welded joints.
5.2.2.1 Testing field-butt joints with or without backing rings. Field-butt
joints with or without a backing ring may be tested by 100 percent magnetic particle testing using acceptance criteria as stated in AWS D1.1 or 100 percent ultrasonic testing of 10 percent of the joints, using methods and acceptance criteria in
ASME Sec. VIII, Division 1.
5.2.2.2 Testing field fillet weld joints. Field fillet weld joints used for singlewelded lap joints, double-welded lap joints, and butt-strap joints may be tested using
magnetic particle testing procedures and acceptance criteria as stated in AWS D1.1.
Copyright © 2011 American Water Works Association. All Rights Reserved.
12
AWWA C206-11
Magnetic particle testing is not required for a seal weld used to facilitate air-tested
joints, unless the seal weld is a structural element of the joint.
Double-welded lap joints can also be tested by shop drilling and tapping a
1/ 4 -in. (6.4-mm) national pipe thread hole into the spigot or bell end of the pipe.
Apply 40 psi (276 kPa) of air, or other satisfactory gas, into the annular space
between the two fillet welds and maintain for a period of 5 min.
If the pressure remains at 40 psi (276 kPa), the test is complete. If the test
pressure drops below 40 psi (276 kPa), maintain the pressure at 40 psi (276 kPa)
from an external source and paint the welds with a soap solution. Mark any leaks
indicated by the escaping gas bubbles and repair leak indications per Sec. 4.7. Close
the threaded openings with pipe plugs or by welding.
Note: Radiographic and ultrasonic testing of lap joints shall not be utilized
because of the difficulty inherent in interpreting the results.
5.2.2.3 Vacuum box test. Both butt-joint welds and fillet welds may be
tested using a vacuum box. In this test, the weld is painted with a soap solution, a
clear plastic box with a foam perimeter is placed over the test section, and a vacuum
is induced in the box (see Figure 1). Mark any leaks indicated by the escaping gas
bubbles and repair according to Sec. 4.7.1. This test method may require additional
hold-back for coatings and linings to allow a proper seal.
Note: The vacuum box should be constructed of a sealed clear plastic cover
with an open bottom. The open bottom is sealed against the pipe surface by a
closed-cell foam rubber gasket. Vacuum gauges, valves, and vacuum pump or air
ejector are attached. The gauge should register a partial vacuum of at least 10 in.
(250 mm) of mercury when testing the weld seam.
Sec. 5.3
Rejection
Any work that is not in accordance with the requirements of this standard
shall be rejected. The constructor has the option of either repairing an unacceptable weld or removing and replacing the defective weld.
SECTION 6:
Sec. 6.1
DELIVERY
Marking
When required by the purchaser, pipe, fittings, and pipe specials shall have a
serial number or other identification mark that will reference the line diagram or
laying schedule. The welding operator and the subsequent inspections performed
Copyright © 2011 American Water Works Association. All Rights Reserved.
Field Welding of Steel Water Pipe 13
Acrylic Cover
R
Sponge Rubber Gasket
Section
Pipe Wall
2-Way Valve
Vacuum
Gauge
Air Ejector
Butt-Welded
Circumferential
Joint
Hose
to Compressor
Plan
Figure 1
Look-box for vacuum testing of circumferential weld seams
on each joint shall reference these serial numbers or other identification numbers
to document these tasks.
6.1.1 Exterior. The serial number or other identification mark shall be
painted in a conspicuous location on the exterior of each section of pipe, fitting, or
pipe special.
6.1.2 Interior. When joints require interior field welds, the serial number
or other identification mark shall be transferred to the finished interior of each section of pipe, fitting, or pipe special. The requirement to transfer serial numbers or
other identification marks to the interior shall be at the purchaser’s option.
Sec. 6.2
Packaging and Shipping
This standard has no applicable information for this section.
Sec. 6.3
Affidavit of Compliance
The purchaser may require an affidavit from the constructor stipulating that
all field welds on the pipe and attachments have been made in accordance with
applicable provisions of this standard.
Copyright © 2011 American Water Works Association. All Rights Reserved.
AWWA is the authoritative resource for knowledge, information, and advocacy to improve the quality and
supply of water in North America and beyond. AWWA is the largest organization of water professionals in
the world. AWWA advances public health, safety, and welfare by uniting the efforts of the full spectrum
of the entire water community. Through our collective strength, we become better stewards of water for
the greatest good of people and the environment.
1P-2.1M-43206-2/11-JP
Printed on Recycled Paper
Copyright © 2011 American Water Works Association. All Rights Reserved.