Awwa C205 2012

ANSI/AWWA C205-12
(Revision of ANSI/AWWA C205-07)
The Authoritative Resource on Safe Water®
AWWA Standard
Cement–Mortar Protective
Lining and Coating for Steel
Water Pipe—4 In. (100 mm)
and Larger—Shop Applied
SM
Effective date: June 1, 2012.

First edition approved by AWWA Board of Directors June 26, 1941.
This edition approved Jan. 22, 2012.
Approved by American National Standards Institute Feb. 23, 2012.
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Copyright © 2012 American Water Works Association. All Rights Reserved.

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ISBN-13, print: 978-1-58321-886-0 eISBN-13, electronic: 978-1-61300-144-8

ISBN-10, print: 1-58321-886-6 eISBN-10, electronic: 1-61300-144-4
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Copyright © 2012 by American Water Works Association

Printed in USA
ii

Committee Personnel
The Steel Water Pipe-Manufacturers Technical Advisory Committee (SWPMTAC) Task Group
on updating ANSI/AWWA C205, which developed this standard, had the following personnel at
the time:
Henry H. Bardakjian, Chair

S.A. Arnaout, Hanson Pressure Pipe Inc., Dallas, Texas (AWWA)
H.H. Bardakjian, Consultant, Glendale, Calif. (AWWA)
B.J. Britton, W. Walsh Company, Attleboro, Mass. (AWWA)
R.J. Card, Manufacturing Consultant, Sugar Hill, Ga. (AWWA)
D. Dechant, Dechant Infrastructure Service, Aurora, Colo. (AWWA)
A. Fletcher, Tyco Water, Southbank, Australia (AWWA)
J.E. Hohider, Heitkamp Inc., Watertown, Conn. (AWWA)
B.D. Keil, Northwest Pipe Company, Pleasant Grove, Utah (AWWA)
J.L. Luka, American SpiralWeld Pipe Company, Columbia, S.C. (AWWA)
L. McKinney, Womble Company, Houston, Texas (AWWA)
R.D. Mielke, Northwest Pipe Company, Raleigh, N.C. (AWWA)
J. Olmos, Ameron International, Rancho Cucamonga, Calif. (AWWA)
G.F. Ruchti, Consultant, Punta Gorda, Fla. (AWWA)
B. Simpson, American SpiralWeld Pipe Company, Birmingham, Ala. (AWWA)
B. Vanderploeg, Consultant, Portland, Ore. (AWWA)
D.R. Wagner, Consultant, St. Louis, Mo. (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. (AWWA)

R.J. Card, Lockwood, Andrews & Newnam, Sugar Hill, Ga. (AWWA)
R.L. Coffey, HDR Engineering Inc., Omaha, Neb. (AWWA)
iii

H.E. Dunham, MWH Inc., Snohomish, Wash. (AWWA)
S.N. Foellmi, Black & Veatch Corporation, Irvine, Calif. (AWWA)
M.B. Horsley,* Horsley Engineering LLC, Overland Park, Kan. (AWWA)
R.L. Gibson, Freese and Nichols Inc., Fort Worth, Texas (AWWA)
J.K. Jeyapalan, Pipeline Consultant, New Milford, Conn. (AWWA)
R.A. Kufaas, Norske Corrosion & Inspection Services Ltd., Surrey, B.C. (AWWA)
J.L. Mattson, Corrosion Control Technologies, Sandy, Utah (AWWA)
W.J. Moncrief,* HDR Engineering Inc., San Diego, Calif. (AWWA)
E.N. Olson,† Standards Council Liaison, Brown and Caldwell, Gold Hill, Ore. (AWWA)
R. Ortega,* Lockwood Andrews & Newnam, Houston, Texas (AWWA)
E.S. Ralph,† Standards Engineer Liaison, AWWA, Denver, Colo. (AWWA)
A.E. Romer, AECOM, Newport Beach, Calif. (AWWA)
J.R. Snow,* MWH Americas Inc., Denver, Colo. (AWWA)
H.R. Stoner, Consultant, North Plainfield, N.J. (AWWA)
C.C. Sundberg, CH2M HILL Inc., Issaquah, Wash. (AWWA)
W.R. Whidden, Woolpert, Orlando, Fla. (AWWA)
Producer Members
S.A. Arnaout, Hanson Pressure Pipe Inc., Dallas, Texas (AWWA)

H.H. Bardakjian, Consultant, Glendale, Calif. (AWWA)
M. Bauer, Tnemec Company Inc., North Kansas City, Mo. (AWWA)
R.R. Carpenter, American SpiralWeld Pipe Company, Birmingham, Ala. (MSS)
D. Dechant, Dechant Infrastructure Service, Aurora, Colo. (AWWA)
W.B Geyer, Steel Plate Fabricators Association, Lake Zurich, Ill. (SPFA)
B.D. Keil, Northwest Pipe Company, Pleasant Grove, Utah (AWWA)
J.L. Luka,* American SpiralWeld Pipe Company, Columbia, S.C. (AWWA)
R.D. Mielke,* Northwest Pipe Company, Raleigh, N.C. (AWWA)
J. Olmos, Ameron International, Rancho Cucamonga, Calif. (AWWA)
G.F. Ruchti,* Consultant, Punta Gorda, Fla. (AWWA)
J.A. Wise, Canus International Sales Inc., Surrey, B.C. (AWWA)
* Alternate
† Liaison, nonvoting
iv

User Members
G.A. Andersen, New York City Bureau of Water Supply, Little Neck, N.Y. (AWWA)
J.H. Bambei Jr., Denver Water, Denver, Colo. (AWWA)
B. Cheng, Metro Vancouver, Burnaby, B.C. (AWWA)
R.V. Frisz, US Bureau of Reclamation, Denver, Colo. (USBR)
G. George, Tacoma Public Utilities, Tacoma, Wash. (AWWA)
T.J. Jordan, Metropolitan Water District of Southern California, La Verne, Calif. (AWWA)
M. McReynolds,* Metropolitan Water District of Southern California,
La Mirada, Calif. (AWWA)
G. Oljaca,* Metro Vancouver, Burnaby, B.C. (AWWA)
G.P. Stine, San Diego County Water Authority, San Diego, Calif. (AWWA)
N.A. Wigner, Los Angeles Department of Water & Power, Los Angeles, Calif. (AWWA)
J.V. Young, City of Richmond, Richmond, B.C. (AWWA)
* Alternate

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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 3 Definitions..........................................3
I. Introduction........................................ix
4 Requirements......................................4
I.A. Background.........................................ix
4.1 General................................................4
I.B. History................................................ix
4.2 Material...............................................5
I.C. Acceptance...........................................x
4.3 Surface Preparation..............................6
II. Special Issues.......................................xi
4.4 Cement–Mortar Lining........................6
II.A. Soft, Aggressive Waters........................xi
4.5 Cement–Mortar Coating...................10
II.B. Intermittent Operations......................xi
4.6 Cement–Mortar Overcoat..................14
II.C. Flow Velocity......................................xi
4.7 Field Joints.........................................16
II.D. Strain Limitations...............................xi
5 Verification.......................................18
II.E. Weld-After-Backfill.............................xi
5.1 Sampling and Testing Cement
II.F. Cement–Mortar Lining Thickness.....xii
Mortar for Linings.......................18
III. Use of This Standard..........................xii
5.2 Testing Cement Mortar
III.A. Purchaser Options and
for Coatings.................................19
Alternatives..................................xii
5.3 Calibration of the Manufacturer’s
III.B. Modification to Standard..................xiii
Equipment...................................20
IV. Major Revisions.................................xiii
5.4 Inspection and Testing by
V. Comments........................................ xiv Purchaser.....................................20
Standard 6 Delivery............................................21
1 General 6.1 General..............................................21
1.1 Scope...................................................1 6.2 Plastic End Caps................................21
1.2 Purpose................................................2 6.3 Affidavit of Compliance.....................21
1.3 Application...........................................2
Tables
2 References...........................................2 1 Cement–Mortar-Lining Thickness.......7
vii

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Foreword
This foreword is for information only and is not a part of ANSI/AWWA C205.
I. Introduction.
I.A. Background. Cement–mortar-lined-and-coated steel pipe was first used
in the United States in the late 1800s. Some of the first pipelines were in service for
almost a century by the time the first national standard was written. However, it was
not until the 1920s that a practical method of plant-applied cement–mortar lining was
developed. The first plant-applied linings were installed by standing the pipe on end,
placing a tapered plug with a rope attached to the leading end inside the pipe, placing
enough cement mortar on top of the plug to coat the pipe, and then pulling the plug
up through the pipe. Improvements in the lining process were developed, and the
centrifugal process for plant-applied cement–mortar lining emerged.
Cement–mortar-lined and cement–mortar-coated steel pipe combines the physical
strength of steel with the protective qualities of cement mortar. The lining, applied
centrifugally, creates a smooth, dense finish that protects the pipe from tuberculation
and provides a measure of corrosion protection. The smooth interior surface provides a
high flow coefficient for the design life of the pipeline under normal operating condi-
tions. In addition, the cement–mortar coating results in a tough, durable, and rugged
coating that forms an alkaline environment where oxidation or corrosion of the steel
is inhibited.
I.B. History. The first edition of this standard, designated 7A.7-41, Standard
Specifications for Cement–Mortar Protective Coating for Steel Water Pipe of Sizes
30 Inches and Over, was approved by the AWWA Board of Directors on June 26,
1941. Before that, a tentative draft had been published in the January 1940 Journal -
American Water Works Association for review and comment.
The first edition provided a section for the field application of cement–mortar
lining, which was deleted by action of the Board of Directors effective June 30, 1951.
Pending the promulgation of AWWA C602, Cement–Mortar Lining of Water Pipe-
lines—4 In. (100 mm) and Larger—In Place, the ninth, tenth, and eleventh printing
of 7A.7 (AWWA C205) continued to carry the withdrawn section.
The next edition, published in 1962, was a major revision and provided for pipe
sizes of 4 in. (100 mm) and larger. The standard was subsequently revised in 1971,
1980, 1985, 1989, 1995, 2000, and 2007. This edition was approved on Jan. 22, 2012.
ix

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 the 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 April 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.
Various certification organizations may be involved in certifying products in accor-
dance with NSF/ANSI 61. Individual states or local agencies have authority to accept
or accredit certification organizations within their jurisdiction. Accreditation of certi-
fication 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
* Persons outside the United States should contact the appropriate authority having jurisdiction.
† NSF International, 789 N. Dixboro Road, Ann Arbor, MI 48105.
‡ American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.
§ Both publications available from National Academy of Sciences, 500 Fifth Street, N.W., Washington,
DC 20001.

(noncarcinogens) and risk characterization methodology (carcinogens). Use of Annex A
procedures may not always be identical, depending on the certifier.
ANSI/AWWA C205 does not address additives requirements. Thus, 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. The purchaser of cement–mortar linings or coatings is
cautioned about the following concerns:
II.A. Soft, Aggressive Waters. Soft, aggressive waters, as well as prolonged
contact with heavily chlorinated water, may be injurious to cement–mortar linings.
When this environment is anticipated, further studies may be necessary to determine
the suitability of this type of lining.
II.B. Intermittent Operations. Cement–mortar linings are best suited for
pipelines that are continuously filled with water. When cement–mortar-lined pipelines
are operated under prolonged empty conditions, special precautions may have to be
taken to prevent excessive drying out of the cement–mortar lining.
II.C. Flow Velocity. Cement–mortar linings perform best when flow velocities
are in normal ranges. When the flow velocity exceeds approximately 20 ft/sec (6.1 m/sec),
special studies may be required to determine the suitability of this type of lining material.
II.D. Strain Limitations. Consideration should be given to limiting the
maximum strains (or stresses) developed in the steel cylinder of cement–mortar-lined
or -coated steel water pipe from internal pressure to ensure the long-term design life of
the system.
II.E. Weld-After-Backfill. Weld-after-backfill is the sequence of assembling
a lap-welded joint, welding the outside (if required), applying the exterior coating,
backfilling the pipe, and then welding the inside joint at a later time (where inside
welding is safe and practical). Welding inside field joints after backfill may damage
or compromise the performance of shop and field-applied dielectric coatings. Prior to
specifying or approving weld-after-backfill, consult with the manufacturers 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 coating complies with this
standard after completion of welding.
xi

II.F. Cement–Mortar Lining Thickness. Properly applied cement mortar
will inherently have some variations of thickness. The mortar lining thickness may
be slightly less than the minimum thickness at localized areas provided the average
thickness is not outside of the thickness tolerances given in Table 1 of the standard.
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. When purchasing protective cement–
mortar lining or coating for steel water pipe under the provisions of this standard, the
following items (including specific details where applicable) should be specified by the
purchaser:
1. Standard used—that is, ANSI/AWWA C205, Cement–Mortar Protective
Lining and Coating for Steel Water Pipe—4 In. (100 mm) and Larger—Shop-Applied,
of latest revision.
2. Whether compliance with NSF/ANSI 61, Drinking Water System
Components—Health Effects, is required.
3. If interior lining only, exterior coating only, or both lining and coating are
required.
4. Footage, inside diameter after lining, lengths of pipe sections, steel-wall
thickness, type of joint, and information regarding fittings.
5. Details of other federal, state or provincial, and local requirements (Sec. 4.1.3).
6. Whether reinforcing wire should be galvanized (Sec. 4.2.1.1).
7. Type of wire-fabric reinforcement required, if limited to a single type
(Sec. 4.2.1.2).
8. Type of cement required, if other than Type I, Type II, or Type V
(Sec. 4.2.2.1).
9. Whether application of a primer at holdbacks is required (Sec 4.2.7).
10. Lining options or restrictions, if any, such as thickness of lining (Sec. 4.4.2),
thickness tolerances (Sec. 4.4.2), and length of lining holdback (Sec. 4.4.2).
11. Coating options or restrictions, if any, such as type of undercoat, if any
(Sec. 4.5.1); length of coating holdback (Sec. 4.5.3); thickness of mortar coating
(Sec. 4.5.3); minimum thickness (Sec. 4.5.3); type of reinforcement (Sec. 4.5.5); and
method of curing (Sec. 4.5.9).
12. Whether cement–mortar overcoat is required (Sec. 4.6), and whether
cement–mortar overcoat in a single application is allowed (Sec. 4.6.5.1, 4.6.5.2, and
4.6.6.1).
xii

13. If cement–mortar overcoat cracks between 1/ 16 in. (1.6 mm) and 1/ 8 in.
(3.2 mm) in width require repair (Sec. 4.6.8.2).
14. If additional testing of cement mortar for linings is required (Sec. 5.1.1).
15. The basis of payment for additional testing specified or ordered by the pur-
chaser (Sec. 5.1.1).
16. If an affidavit of compliance is required (Sec. 6.3).
III.B. Modification to Standard. Any modification to the provisions, definitions,
or terminology in this standard must be provided by the purchaser.
IV. Major Revisions. The major revisions to this edition of the standard are
summarized as follows:
1. Added a new section in the foreword under Sec. II, Special Issues, on
cement–mortar lining thickness.
2. A definition for moist curing was added in Section 3.
3. Sec. 4.2.1.3, Ribbon mesh, was revised to clarify that wire shall conform to
the physical and chemical requirements of ASTM A82.
4. The title of Sec. 4.2.7, Paint was changed to Primer, and the specific proper-
ties were changed to more general properties.
5. Sec. 4.4.3, Equipment, was deleted and the information was moved to a new
Sec. 4.4.4.1 for better readability.
6. Sec. 4.4.6, Defective lining, was revised to include a new section 4.4.6.2,
Lining Shrinkage, that includes information on the drying shrinkage of cement–
mortar linings.
7. Sec. 4.5.2, Cement mortar: the second paragraph for the pneumatic process
for the mortar was revised to state that the Portland cement can be measured by weight
or volume, because many pneumatic systems go by volume. This same change was
made to Sec. 4.7.3, Outside field joints (Sec. 4.7.3.1, Material), for the material used in
the field joint grouting mortar since it will be difficult to prepare the mix by weight in
the field.
8. Sec. 4.5.2, Cement mortar: the third paragraph was revised to clarify that
the acid-soluble chloride ion (Cl–) content needs to be determined in accordance with
ASTM C1152 or AASHTO T260.
9. Sec. 4.5.5.5, Special reinforcement: the last two sentences were deleted
because they are design related and are covered in Manual M11.
10. Sec. 4.5.8.2 and Sec. 4.6.8.2, Coating cracks: the repair procedure of paint-
ing cracks with an epoxy coating was deleted as an option for both the cement–mortar
coating and overcoat sections.
xiii

11. Sec. 4.5.9.4, Membrane curing, was revised to allow other membrane-
forming compounds to be used.
12. Sec. 4.6.5.1, General, and Sec. 4.6.6.1: the approval by the purchaser
to allow for a single pass application of the cement–mortar overcoat was deleted
because Sec. 4.6.5.1 already includes additional provisions for the use of a single pass
application.
13. Sec 5.2, Testing of Cement–Mortar Coating, was revised to clarify that the
section is referring to mortar coatings applied in accordance with Sec. 4.5.
14. A new Sec. 5.3 was added for Calibration of the Manufacturer’s Equipment.
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 [email protected].
xiv

ANSI/AWWA C205-12
(Revision of ANSI/AWWA C205-07)
AWWA Standard
Cement–Mortar Protective Lining and

Coating for Steel Water Pipe—4 In.
(100 mm) and Larger—Shop-Applied
SECTION 1: GENERAL
Sec. 1.1 Scope

This standard describes the material, application, and curing of shop-applied
cement–mortar protective linings and coatings for steel water pipe and fittings and
field jointing of cement–mortar-lined-and-coated steel water pipe and fittings.
1.1.1 Pipe-lining application methods. The inside of pipe shall receive a
cement–mortar lining applied by centrifugally spinning or by a method known to
provide equivalent results.
1.1.2 Fitting lining application methods. The application of cement–mor-
tar linings to miters, angles, bends, reducers, and other special sections, the shape
of which precludes application by the spinning process, shall be accomplished by
mechanical placement, pneumatic placement, or hand application and finished to
produce a smooth, dense surface.
1.1.3 External coating. The outside of pipe and specials shall receive a
reinforced cement–mortar coating applied by mechanical placement, pneumatic
placement, or a method known to provide equivalent results.
1
2 AWWA C205-12
1.1.4 Field application. For field application of cement–mortar lining,

refer to ANSI*/AWWA C602, Standard for Cement–Mortar Lining of Water
Pipelines in Place—4 In. (100 mm) and Larger.
1.1.5 Design considerations. For design considerations either for welded
steel pipe or for cement–mortar linings and cement–mortar coatings, refer to
AWWA Manual M11, Steel Pipe—A Guide for Design and Installation.
Sec. 1.2 Purpose

The purpose of this standard is to provide the minimum requirements for
shop-applied cement–mortar lining and coating of steel water pipe, including
material, application, inspection, handling, and field-jointing requirements.
Sec. 1.3 Application

This standard or sections of this standard can be referenced in documents
for purchasing and receiving steel water pipe and fittings that have been lined or
coated with cement mortar. This standard can be used as a guide for the material
requirements, material testing, cement–mortar application, inspection, handling,
and field jointing of cement–mortar-lined or -coated steel water pipe and fittings.
The stipulations of this standard apply when this document has been referenced by
the purchaser.
SECTION 2: REFERENCES
This standard references the following documents. In their latest editions,

these documents form a part of this standard to the extent specified within this
standard. In any case of conflict, the requirements of this standard shall prevail.
AASHTO† T260—Standard Method of Test for Sampling and Testing for
Chloride Ion in Concrete and Concrete Raw Materials.
ANSI/AWWA C602—Cement–Mortar Lining of Water Pipelines in
Place—4 In. (100 mm) and Larger.
ASTM‡ A82—Standard Specification for Steel Wire, Plain, for Concrete
Reinforcement.
* American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.
† American Association of State Highway & Transportation Officials, 444 North Capitol Street Northwest,
Washington, DC 20001.
‡ ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428.

Cement–Mortar Protective Lining and Coating for Steel Water Pipe 3
ASTM A185—Standard Specification for Steel Welded Wire Fabric, Plain,

for Concrete Reinforcement.
ASTM A497—Standard Specification for Steel Welded Wire Fabric,
Deformed, for Concrete Reinforcement.
ASTM C31/C31M—Standard Practice for Making and Curing Concrete
Test Specimens in the Field.
ASTM C33—Standard Specification for Concrete Aggregates.
ASTM C35—Standard Specification for Inorganic Aggregates for Use in
Gypsum Plaster.
ASTM C39—Standard Test Method for Compressive Strength of Cylindri-
cal Concrete Specimens.
ASTM C94—Standard Specification for Ready-Mixed Concrete.
ASTM C150—Standard Specification for Portland Cement.
ASTM C172—Standard Practice for Sampling Freshly Mixed Concrete.
ASTM C309—Standard Specification for Liquid Membrane-Forming Com-
pounds for Curing Concrete.
ASTM C494—Standard Specification for Chemical Admixtures for Concrete.
ASTM C497/C497M—Standard Test Methods for Concrete Pipe, Manhole
Sections, or Tile.
ASTM C511—Standard Specification for Moist Cabinets, Moist Rooms, and
Water Storage Tanks Used in the Testing of Hydraulic Cements and Concretes.
ASTM C881—Standard Specification for Epoxy-Resin-Base Bonding Systems
for Concrete.
ASTM C1152—Standard Test Method for Acid Soluble Chloride in Mortar
and Concrete.
AWWA Manual M11—Steel Pipe—A Guide for Design and Installation.
SECTION 3: DEFINITIONS
The following definitions shall apply in this standard:

1. Accelerated curing: The process of maintaining a constantly moist surface
on the cement mortar by creating a humid atmosphere at an elevated temperature.
2. Autogenous healing: The process by which cracks in concrete or cement
mortar are healed by the formation of calcium carbonate in the presence of moisture.
3. Constructor: The party that provides work and materials for placement
or installation.

4 AWWA C205-12
4. Free water: Total water content of the cement–mortar mix in excess of
moisture absorbed by the mix.
5. Manufacturer: The party that manufactures, fabricates, or produces
materials or products.
6. Mechanical placement: The process of applying cement mortar by pro-
jecting the cement mortar at a high velocity against the surface or by any mechani-
cally operated system that provides equivalent results.
7. Moist curing: The process of maintaining a constantly moist surface on
the cement mortar by covering the pipe ends with plastic or wet burlap for the
mortar lining and spraying water for the mortar coating.
8. Pneumatic placement: The process of applying cement mortar by propel-
ling the cement mortar against any surface using compressed air.
9. Purchaser: The person, company, or organization that purchases any
materials or work to be performed.
10. Rebound: Cement mortar that does not adhere to the pipe during the
application of the cement–mortar coating.
11. Spinning: The process of applying cement mortar to the inside surfaces
of the pipe and compacting the cement mortar by the centrifugal force resulting
from spinning the pipe about its longitudinal axis until the cement mortar has
consolidated sufficiently to allow removal of the pipe from the equipment.
12. Supplier: The party that supplies material or services. A supplier may
or may not be the manufacturer.
SECTION 4: REQUIREMENTS
Sec. 4.1 General

4.1.1 Equipment. The equipment for applying cement mortar and for car-
rying and transporting lined, coated, or lined-and-coated pipe shall permit workers
to follow the procedure of and obtain results required by this standard.
4.1.2 Materials and workmanship. Materials provided by the manufac-
turer shall be new and of the quality specified. Work shall be done in a thorough,
professional manner by workers skilled in their various trades.
4.1.3 Compliance. Materials shall comply with the requirements of the Safe
Drinking Water Act and other federal regulations for water systems as applicable.
4.1.4 Manufacture. During the entire period of the application of the lining
and coating, and the curing thereof, the pipe section shall be carefully supported and

handled to prevent damage to the cement mortar. If a pipe section must be moved,
this procedure shall be done to protect against damage. Any damaged portion of the
lining or coating shall be removed and replaced.
Sec. 4.2 Material

4.2.1 Reinforcement.
4.2.1.1 Wire. Steel wire shall be a minimum size of W0.5 (0.080 in.
[2 mm]). The wire shall conform to the requirements of ASTM A82. Reinforc-
ing wire need not be galvanized unless otherwise specified by the purchaser.
4.2.1.2 Wire fabric. Reinforcement shall be 2 × 4 W0.5 × W0.5 welded
wire fabric. The wire shall conform to the requirements of ASTM A185 or ASTM
A497. Unless otherwise specified by the purchaser, wire-fabric reinforcement may
be either crimped or uncrimped.
4.2.1.3 Ribbon mesh. Ribbon mesh shall be 1 in. × 1 in. (25 mm × 25 mm)
mesh of 18-gauge wire or 11/ 2 in. × 11/ 2 in. (38 mm × 38 mm) mesh of 17-gauge
wire. The wire shall conform to the physical and chemical requirements of
ASTM A82. The mesh shall not be crimped.
4.2.2 Portland cement.
4.2.2.1 Type. Cement for mortar shall conform to ASTM C150. Type
I, Type II, or Type V may be used unless the purchaser specifies a particular type.
Sampling and testing shall conform to the individual ASTM specifications desig-
nated in that standard. The maximum alkali content shall be 0.60 percent when
experience indicates the aggregate sources are reactive to alkalis.
4.2.2.2 Inspection. Satisfactory facilities shall be provided for identify-
ing, inspecting, and sampling cement at the site of lining and coating. The pur-
chaser shall have the right to inspect the cement and obtain samples for testing.
4.2.2.3 Storage. Cement shall be stored in a weather-tight, dry, and well-
ventilated structure.
4.2.2.4 Unsuitable cement. Cement containing lumps shall be rejected
and shall immediately be removed from the work site.
4.2.2.5 Temperature. If the temperature of the cement exceeds 150°F
(66°C), it shall not be used until it is cooled to or below that temperature.
4.2.3 Fine aggregate.
4.2.3.1 General. Fine aggregate for cement mortar shall consist of natu-
ral sand or sand obtained by crushing stone or gravel and shall comply with the
requirements of ASTM C33.

6 AWWA C205-12
4.2.3.2 Gradation. Gradation may be modified by the manufacturer, as

approved by the purchaser, to provide a lining and coating of maximum density.
4.2.3.3 Mortar-lining fine aggregate. For cement–mortar-lining thick-
nesses of 1/ 2 in. (13 mm) or less, 100 percent of the fine aggregate shall pass a
US Standard Sieve No. 4.
4.2.4 Water.
4.2.4.1 General. The water used for cement mortar and for curing linings
or coatings shall conform to the applicable requirements of ASTM C94. The water
may be fresh or recycled concrete process water and shall be free from injurious
amounts of oil, acid, strong alkalies, salts, or organic matter.
4.2.5 Admixtures. Cement mortar may contain a water-reducing, set-
controlling admixture conforming to ASTM C494. No admixture shall contain
injurious amounts of chlorides. The purchaser shall be advised of the type and
amount of any admixtures if specified by the purchaser.
4.2.6 Curing compound. Curing compound for curing cement–mortar
linings and coatings shall comply with ASTM C309.
4.2.7 Primer. When specified, a rust-inhibiting primer for bare steel sur-
faces at holdbacks of cement–mortar lining or coating shall be applied, to a thick-
ness that will not impair the clearances required for proper installation of the joint.
Sec. 4.3 Surface Preparation
4.3.1 Cleaning surfaces. Surfaces to be cement–mortar lined or cement–
mortar coated shall be cleaned to remove loose or other foreign matter that could
interfere with the adherence of the cement mortar.
Sec. 4.4 Cement–Mortar Lining

4.4.1 General. Cement mortar shall be composed of Portland cement,
fine aggregate, and water, well mixed and of proper consistency to obtain a dense,
homogeneous lining that will adhere firmly to the pipe surface. Cement mortar for
lining shall consist of one part cement to not more than three parts fine aggregate
by weight. Only enough water to obtain proper placement characteristics of the
batched cement mortar shall be used, and the free water content of the cement–
mortar lining mix shall not exceed 71/ 2 gal (28.4 L) per 94 lb (43 kg) of cement.
The acid-soluble chloride ion (Cl–) content of the cement–mortar lining mix,
expressed as a percentage of the weight of cement, shall not exceed 0.15 percent as
determined in accordance with ASTM C1152 or AASHTO T260.

Table 1 Cement–mortar-lining thickness

Nominal Pipe Size Nominal Lining Thickness Tolerance
in. (mm) in. (mm) in. (mm)

4–10 (100–250) 1/ 40 (6) –1/ 16, + 1/ 8 (–1.6, +3.2)
11–23 (275–575) 5/ 16 (8) –1/ 16, + 1/ 8 (–1.6, +3.2)
24–36 (600–900) 3/ 80 (10) –1/ 16, + 1/ 8 (–1.6, +3.2)
over 36 (over 900) 1/ 20 (13) –1/ 16, + 3/ 16 (–1.6, +4.8)
4.4.2 Thickness. Cement–mortar lining shall be uniform in thickness,

except at joints, other discontinuities in the pipe wall, or localized areas. Lining
thickness shall be as listed in Table 1 or as specified by the purchaser. Ends of
lining shall be left square and uniform with regard to the longitudinal axis of the
pipe, and the lining holdback shall be as specified by the purchaser for the type of
joint required. The lining thickness requirements shall be maintained by mechani-
cal-end retaining rings and verified by physical measurements prior to curing.
4.4.3 Mixing. The cement mortar shall be mixed in batches. The amount
of Portland cement and fine aggregate entering into each batch shall be measured
by weight. The quantity of water entering the mixer shall be measured automati-
cally by an adjustable device, or it shall be otherwise measured to ensure that the
correct quantity of water is being added.
4.4.4 Machine lining.
4.4.4.1 Equipment. Straight sections of pipe shall be lined by using a
spinning machine specifically designed and built for the purpose of rotating the
pipe section and centrifugally applying cement–mortar linings to the interior of
steel pipe. Rotating the pipe and centrifugally applying the lining is the preferred
method. Contact the manufacturer to determine diameter limitations. For large-
diameter pipe that cannot be lined with the centrifugal method, the purchaser
shall consult with the manufacturer for alternative lining methods.
4.4.4.2 Bracing. When required to prevent distortion or vibration during
spinning, each section of pipe shall be suitably braced with external or internal sup-
ports appropriate to the equipment.
4.4.4.3 Placement. During the application of the lining by a spinning
machine, the entire quantity of mortar required for completion of the lining of the
section of pipe shall be placed without interruption.

8 AWWA C205-12
4.4.4.4 Finish. After the cement mortar has been distributed to a uni-
form thickness, the rotation speed shall be increased to produce a dense mortar
with a smooth surface.
4.4.4.5 Surplus water. Provision shall be made for removal of surplus
water by air blowing or by tilting of the pipe.
4.4.4.6 Lining ends. The lining at the ends of the pipe section shall be
left square and uniform with regard to the longitudinal axis of the pipe, and the
lining holdbacks shall be as specified by the purchaser for the type of joint required.
4.4.5 Lining of specials.
4.4.5.1 General. The application of cement–mortar lining to miters,
angles, bends, reducers, and other special sections, the shape of which precludes
application by the spinning process, shall be accomplished by mechanical place-
ment, pneumatic placement, or hand application and finished to produce a smooth,
dense surface.
4.4.5.2 Reinforcement. Wire-fabric reinforcement or ribbon-mesh rein-
forcement shall be applied to the interior of fittings larger than 24 in. (610 mm) and
shall be secured at frequent intervals by tack welding to the pipe, by clips, or by wire.
When using 2 in. × 4 in. (50 mm × 100 mm) fabric, the wires on 2 in. (50 mm)
spacing shall extend circumferentially around the fitting. Repaired areas of machine-
applied linings at miters, pipe ends, outlets, and other cuts made in the lining for fab-
rication of the fitting need not be reinforced if the longitudinal width of the repair
area does not exceed 12 in. (300 mm). Repairs for longitudinal widths exceeding
6 in. (150 mm) not utilizing reinforcement shall be bonded to the steel and adja-
cent faces of the lining with a bonding agent conforming to ASTM C881, Type II.
4.4.5.3 Thickness. Thickness shall be as required for spun lining of
straight sections, except that it may be varied by feathering or filleting to a smooth
transition with adjoining sections of pipe.
4.4.5.4 Handwork. Cement mortar for handwork shall be of the same
materials and in the same fine aggregate-Portland cement proportions as the
cement mortar for machine lining except that plaster sand conforming to ASTM
C35 may be used in place of fine aggregate conforming to ASTM C33 and richer
cement mix may also be used in place of the proportions for machine lining. Areas
shall be cleaned to remove loose or other foreign matter that would interfere with
the adherence of the cement mortar and, if necessary, shall be moistened with
water just before the placing of the cement mortar.

4.4.6 Defective lining.

4.4.6.1 General. Defects, including but not restricted to fine aggregate
pockets, voids, oversanded areas, blisters, and cracking as a result of impacts, shall
be removed and replaced by hand or pneumatic placement to the same thickness as
required for the cement–mortar lining.
4.4.6.2 Lining shrinkage. Contraction of the mortar lining from the
steel cylinder after curing and drying shrinkage is an inherent characteristic of
mortar linings. After the introduction of water in the pipeline, the mortar lining
will expand volumetrically and most of the drying shrinkage will be recovered.
4.4.6.3 Lining cracks. Temperature and shrinkage cracks in the cement–
mortar lining up to 1/ 16 in. (1.6 mm) in width need not be repaired. Cracks wider
than 1/ 16 in. (1.6 mm) need not be repaired if it can be demonstrated to the satis-
faction of the purchaser that the cracks will heal autogenously under continuous
soaking in water. The autogenous healing process may be demonstrated by any
procedure that keeps the lining of the pipe continually wet or moist. Pipe used in
the demonstration shall be representative of the pipe to be supplied, and water for
the moistening of the pipe shall be chemically similar to the water to be carried in
the pipeline.
4.4.7 Curing of lining.
4.4.7.1 General. Immediately after completion of spinning, the pipe sec-
tions may be moved to a curing area. Care shall be exercised to prevent damage
to the lining. At the option of the manufacturer, linings shall be cured by the
accelerated curing method, by the moist curing method, or by a combination of
both accelerated and moist curing. Accelerated curing or moist curing may be used
interchangeably on a time-ratio basis of 51/ 3 hr of moist curing to 1 hr of acceler-
ated curing. In any case, the total curing period shall be equivalent to 96 hr of
moist cure and the minimum curing period before applying the exterior coating
shall be equivalent to 24 hr of moist cure. The lining shall be kept continually
moist until completion of the minimum curing period.
4.4.7.2 Moist curing. Moist curing may be used only if the minimum
ambient temperature exceeds 40°F (4°C) continuously during the required mini-
mum curing period. No credit shall be allowed for any time during which the
temperature drops below 50°F (10°C).
4.4.7.2.1 On arrival at the curing area, but not later than 30 min after
completion of the lining operation, pipe ends shall be covered with plastic or wet
burlap for a minimum moist-curing period of 24 hr before applying the exterior

10 AWWA C205-12
coating, if this coating is specified. If a cement–mortar exterior coating is not speci-

fied, the lining shall be moist cured for 96 hr before shipment. The ends of the
pipe sections shall be kept closed with plastic end caps during the curing period,
except when sprinkling heads are used, the reinforcement and outside coatings are
being applied, or accelerated curing is being substituted. If the plastic end caps are
installed at that time, they can be used for shipping to the jobsite as indicated in
Sec. 6.2. The manufacturer shall exercise care and diligence to avoid drying out or
cracking of the lining.
4.4.7.3 Accelerated curing. On arrival at the curing area, but not later
than 30 min after completion of the lining operation, accelerated curing may
begin. The temperature of the pipe shall not be raised above 95°F (35°C) by the
introduction of heat for 4 hr after final placement or until the cement mortar has
taken its initial set, whichever occurs first.
The ambient vapor shall then be maintained at a temperature between 90°F
(32°C) and 125°F (52°C) at a relative humidity of not less than 85 percent for a
minimum curing period of 6 hr, after which the exterior coating may be applied,
if this coating is specified. The accelerated curing shall be maintained for a mini-
mum period of 6 hr before applying exterior coatings or for a total of 18 hr before
shipment.
4.4.7.4 Alternative curing methods. When allowed by the purchaser, alter-
native curing methods may be substituted, provided that the method used by the
manufacturer produces a cured lining equivalent to that set forth in Sec. 4.4.7.2 and
4.4.7.3.
Sec. 4.5 Cement–Mortar Coating
4.5.1 General. When specified, the external protection of steel pipe shall
be a reinforced cement–mortar coating applied over the outer surfaces of the pipe
sections and specials. If the pipe has been cement–mortar lined, the curing times
specified in Sec. 4.4.7 must elapse before the coating is applied.
4.5.2 Cement mortar. Cement mortar applied by mechanical placement
shall consist of not more than three parts fine aggregate to one part Portland
cement by weight. The water in the mixture shall be carefully controlled. The
moisture content of the mixture shall not be less than 7 percent of the total dry
weight of the mix.
Cement mortar applied by the pneumatic process shall consist of not more
than three parts fine aggregate to one part Portland cement by weight or volume.

The water in the mixture shall be carefully controlled. The moisture content of the
mixture shall not be less than 7 percent of the total dry weight of the mix.
The acid-soluble chloride-ion (Cl–) content of the cement–mortar mix shall
not exceed 0.15 percent, expressed as a percentage of cement weight as determined
in accordance with ASTM C1152 or AASHTO T260.
Rebound not exceeding one-fourth the total mix weight may be used as
replacement material for fine aggregate only. Rebound not used within 1 hr shall
be discarded.
4.5.3 Thickness. Cement–mortar coating shall be uniform in thickness
except at joints or other discontinuities in the pipe and shall be 3/ 4 in. (19 mm)
minimum thickness unless otherwise specified by the purchaser. Ends of coatings
shall be uniform and square to the longitudinal axis of the pipe, and the coating
holdback shall be as specified by the purchaser for the type of joint required. For
coating thicknesses greater than 11/ 4 in. (32 mm), special considerations for instal-
lation deflection control may be required.
4.5.4 Equipment. Straight and special sections of the pipe shall be
coated with cement mortar applied by pneumatic, mechanical, or other place-
ment methods known to provide equivalent results.
4.5.5.1 General. Unless otherwise specified by the purchaser, the rein-
forcement for the coating of pipe sections may be spiral wire, wire fabric, or wire
mesh (ribbon mesh) in accordance with the provisions of Sec. 4.2.1. Reinforcement
shall be free of oil, grease, and other contaminants that might reduce the adher-
ence between the coating and reinforcement. Reinforcement with surface oxida-
tion may be used, provided that the surface is not pitted. Reinforcement shall be
placed in the middle third of the coating.
4.5.5.2 Spiral wire. The ends and splices in the wire shall be attached by
welding or other suitable means acceptable to the purchaser. The wire reinforce-
ment may be applied under moderate tension while the cement–mortar coating is
being applied. Maximum spacing of the wires shall be 11/ 2 in. (38 mm).
4.5.5.3 Wire fabric. Splices shall be made by welding or other suitable
means acceptable to the purchaser. Circular and longitudinal joints shall be lapped
a distance of at least one mesh. When using 2-in. × 4-in. (50-mm × 100-mm)
fabric, the wires on 2-in. (50-mm) spacing shall extend circumferentially around
the pipe.

12 AWWA C205-12
4.5.5.4 Ribbon mesh. Attachment of ends and splices in the wire shall
be by a means acceptable to the purchaser. When 1-in. × 1-in. (25-mm × 25-mm),
18-gauge wire mesh is used, the spiral lap shall be 1 in. (25 mm) and the spliced
lap 3 in. (76 mm). When 11/ 2-in. × 11/ 2-in. (38-mm × 38-mm), 17-gauge mesh is
used, the spiral lap shall be 11/ 2 in. (38 mm) and the spliced lap 41/ 2 in. (114 mm).
4.5.5.5 Special reinforcement. For cement–mortar coating design thick-
nesses greater than 11/ 4 in. (32 mm), an additional layer of reinforcement shall be
required for each 1/ 2 in. (13 mm) of additional incremental thickness.
4.5.6 Application of cement–mortar coating.
4.5.6.1 Application. Cement–mortar coating shall be applied by mechan-
ical or pneumatic placement to the specified thickness in one or more continuous
application(s). Allowance shall be made for splices of reinforcing wire. If applied
in more than one course, the interval between the first and last course shall not be
more than 2 hr. The cement mortar shall be projected at high velocity against the
exterior surfaces of the pipe or shall be applied by an equivalent method to produce
a hard, tight-adhering coating of the specified thickness.
The cement–mortar coating thickness shall be checked on each size of pipe
by a nondestructive method before removing the pipe from the coating machine.
4.5.6.2 Mix water. The water in the mixture shall be controlled by using
an adjustable moisture metering system. The moisture content of a sample of coat-
ing taken from the mixture shall not be less than 7 percent of the total dry weight
of the mix.
4.5.6.3 Placement temperature. The temperature of the cement–mortar
mix shall not be less than 40°F (4°C), nor shall the surface temperature of the steel
cylinder be greater than 95°F (35°C) at the time of placement.
4.5.6.4 Support. If required, the pipe shall be adequately braced with
interior struts or rings to prevent damage during handling and coating and, if
cement–mortar lined, to protect the lining.
4.5.6.5 Interrupted placement. If it is necessary to defer placing the coat-
ing of any portion of a pipe length, the interruption joint shall be a square shoulder.
Before placing fresh material against the joint, the contact surfaces shall be care-
fully cleaned and wetted to obtain adherence between the fresh material and that
previously placed. Care shall also be taken not to shatter or damage the material
previously placed or disturb the embedded reinforcement.
When reinforcement of the spiral-wire type is used, the end of the wire at the
edges of the portion to be left uncoated shall be attached to the pipe shell by weld-
ing or by other suitable means.

4.5.7 Coating of specials.

4.5.7.1 Reinforcement. Cement–mortar coating for pipe bends and other
special sections not adapted to the application of spiral-wire coating reinforcement
shall be reinforced with wire fabric or ribbon mesh. The fabric or ribbon mesh shall
be as specified in Sec. 4.2.1.2 or 4.2.1.3, shall be applied over the surface of the
pipe to be coated, and may be held away from the pipe shell with self-furring mesh,
furring clips, or an equivalent method. Ends of circumferential strips of reinforcing
shall be overlapped as specified in Sec. 4.5.5.3 or 4.5.5.4.
4.5.7.2 Application. The coating application shall conform to Sec. 4.5.6.1,
with the exception that hand application may be substituted for mechanical or
pneumatic placement.
4.5.7.3 Thickness. The coating thickness shall be as required for straight
sections, but may be varied by feathering or filleting to form a smooth transition
with adjoining sections.
4.5.8 Defective coating.
4.5.8.1 Sand pockets and porous spots. If any sand pockets or porous
spots exist, they shall be completely removed and replaced by pneumatic placement
or hand application of cement mortar in the proportion of two-and-one-half parts
fine aggregate to one part Portland cement by weight.
4.5.8.2 Coating cracks. Care shall be exercised to minimize the occur-
rence of cracks in the cement–mortar coating. However, hairline cracks need not
be repaired. The need for the repair of wider cracks must be determined by the pur-
chaser after evaluating the pipeline environment and, if required by the purchaser,
these cracks shall be repaired by the manufacturer. Repair procedures shall include
brushing or wiping neat cement into the cracks, autogenous healing of the cracks
by additional moist curing, or a combination of these methods.
Note: Repair procedures involving extensive chipping or routing of the
cracks should be avoided, as this procedure tends to deepen and lengthen the exist-
ing cracks and may damage the adhesion between the coating and the cylinder.
4.5.9 Curing of coating.
4.5.9.1 General. After the initial set has taken place, the cement–mortar
coating shall be cured by the moist or accelerated curing methods or, unless other-
wise specified by the purchaser, a membrane material may be applied immediately
following the coating application. Moist and accelerated curing may be used inter-
changeably on a time-ratio basis of 51/ 3 hr of moist curing to 1 hr of accelerated
curing.

14 AWWA C205-12
4.5.9.2 Moist curing. Moist curing shall begin as soon as the pipe or spe-
cial can be sprinkled with water without damage to the coating. The coating shall
be kept continually moist by intermittent or continuous spraying for a period of
at least four days. Moist curing may be used only if the minimum ambient tem-
perature exceeds 40°F (4°C) continuously during the minimum required curing
period, and no credit shall be allowed for any time during which the temperature
drops below 50°F (10°C).
4.5.9.3 Accelerated curing. Accelerated curing of the pipe or special may
begin immediately after completion of the coating operation or within 6 hr there-
after. The temperature of the pipe or special shall not exceed 95°F (35°C) by introduc-
ing heat until the cement–mortar coating has taken its initial set or until a period of
4 hr has elapsed, whichever occurs first. The relative humidity shall be not less than
85 percent at a temperature between 90° and 125°F (32° and 52°C) for at least 18 hr.
4.5.9.4 Membrane curing. Membrane curing shall consist of the complete
encapsulation of the coating by applying material that will retain the moisture of
the applied cement–mortar coating. When liquid membrane-forming compounds
are used, they shall be in accordance with ASTM C309.
4.5.9.5 Additional water application. The cement–mortar coating of pipe
stored in the manufacturer’s yard after curing shall be intermittently sprayed with
water, if necessary, to prevent drying until shipment to the jobsite.
Sec. 4.6 Cement–Mortar Overcoat
4.6.1 General. When specified, a reinforced cement–mortar overcoat
shall be applied over the specified dielectric coating. The curing temperature of
the cement–mortar overcoat shall not exceed the maximum allowable for dielectric
coating covered.
4.6.2 Cement mortar. Cement mortar shall conform to Sec. 4.5.2.
4.6.3 Thickness. The cement–mortar overcoat shall be uniform in thick-
ness except at joints or other discontinuities in the pipe. The overcoat shall have
3/ 4 -in. (19-mm) minimum thickness unless otherwise specified by the purchaser.
Ends of the overcoat shall be uniform and square to the longitudinal axis of pipe,
and the coating holdback shall be as specified by the purchaser for the type of joint
required.
4.6.4 Equipment. Equipment shall conform to the provisions of Sec. 4.5.4.
4.6.5.1 General. The reinforcement for the overcoat of pipe sections shall
be spiral wire, wire fabric, or wire mesh (ribbon mesh) in accordance with the

provisions of Sec. 4.2.1. Reinforcement shall be free of oil, grease, and other con-
taminants that reduce the adherence between coating and reinforcement. Rein-
forcement with surface oxidation may be used provided that the surface is not
pitted. When wire fabric or mesh is used, it shall be placed immediately following
application of a 3/ 8-in. (9.5-mm) layer of mortar over the dielectric undercoat fol-
lowed by the final 3/ 8-in. (9.5-mm) layer of mortar. When spiral wire reinforcement
is used, it shall be placed in the middle third of the total thickness coating using a
single or multiple application of the mortar coating. The discontinuity between the
wire and the steel cylinder shall be verified. Reinforcement shall not be attached to
or otherwise be in contact with the steel pipe.
4.6.5.2 Spiral wire. Splices in the wire shall be made by suitable means
acceptable to the purchaser. The wire reinforcement shall be applied helically,
under slight tension. Attachment of ends in the wire shall be accomplished by lap-
ping and tying the wire at each end over the first layer of cement mortar or in the
middle third of the coating during a single application of the cement mortar if the
provisions of Sec. 4.6.5.1 can be met. Maximum spacing of wires shall be 11/ 2 in.
(38 mm).
4.6.5.3 Wire fabric. Splices shall be made by suitable means acceptable
to the purchaser. Wire fabric shall be applied over the first layer of cement mortar.
Circular and longitudinal joints shall be lapped a distance of at least one mesh.
When using 2-in. × 4-in. (50-mm × 100-mm) fabric, the wires on 2-in. (50-mm)
spacing shall extend circumferentially around the pipe.
4.6.5.4 Wire mesh. Splices shall be made by suitable means acceptable
to the purchaser. Wire mesh shall be applied over the first layer of cement mortar.
Circular and longitudinal joints shall be lapped a distance of at least 2 in. (50 mm).
4.6.6 Application of cement–mortar overcoat.
4.6.6.1 Application. The cement–mortar overcoat shall be applied by
mechanical or pneumatic placement to the specified thickness in one or more con-
tinuous applications. The interval between the first and last application shall not
be more than 2 hr.
When the cement–mortar overcoat is applied in two applications, the thick-
ness of the first layer of cement mortar shall be approximately 3/ 8 in. (9.5 mm).
Following the placement of the reinforcement, a second layer of cement mortar
approximately 3/ 8-in. (9.5-mm) thick shall be applied over the wire, wire fabric, or
wire mesh to bring the total thickness of the cement mortar to a minimum of
3/ 4 in. (19 mm).

16 AWWA C205-12
The cement mortar shall be projected at high velocity against the exterior
surfaces of the pipe, or shall be applied by an equivalent method, to produce a hard
coating of the specified thickness. The cement–mortar coating thickness shall be
checked on each size of pipe before removing the pipe from the coating machine.
4.6.6.2 Mix water. Mix water shall conform to the provisions of
Sec. 4.5.6.2.
4.6.6.3 Placement temperature. Placement temperature shall conform to
the provisions of Sec. 4.5.6.3.
4.6.6.4 Support. Support shall conform to the provisions of Sec. 4.5.6.4.
4.6.6.5 Interrupted placement. Interrupted placement shall conform to
the provisions of Sec. 4.5.6.5, except that the cement–mortar application shall con-
form to the provisions of Sec. 4.6.6.1.
4.6.7 Coating of specials.
4.6.7.1 Reinforcement. The reinforcement shall conform to the provi-
sions of Sec. 4.5.7.1, except that the reinforcement shall be applied over the 3/ 8-in.
(9.5-mm) thick first layer of cement mortar.
4.6.7.2 Application. The application shall conform to the provisions
of Sec. 4.6.6.1 with the exception that hand application may be substituted for
mechanical or pneumatic placement.
4.6.7.3 Thickness. The thickness shall conform to the provisions of
Sec. 4.5.7.3.
4.6.8 Defective coating.
4.6.8.1 Sand pockets and porous spots. Sand pockets and porous spots
shall be removed and repaired to conform to the provisions of Sec. 4.5.8.1.
4.6.8.2 Coating cracks. Care shall be exercised to minimize the occurrence
of cracks in the cement–mortar coating. However, cracks up to 1/ 16 in. (1.6 mm) in
width, or when allowed by the purchaser, up to 1/ 8 in. (3.2 mm) in width if cement–
mortar overcoat is not considered in pipe design, do not require repair. The need for
the repair of wider cracks shall be determined by the purchaser. Repair procedures
shall include brushing or wiping neat cement into the cracks, autogenous healing of
the cracks by additional moist cure, or a combination of these methods.
4.6.9 Curing of coating. Curing of coating shall conform to the provisions
of Sec. 4.5.9.
Sec. 4.7 Field Joints

4.7.1 General. This section covers material requirements and application
procedures recommended for the application of cement–mortar field joints.

4.7.2 Inside field joints.

4.7.2.1 Material. Cement mortar used for the joints shall be composed of
a minimum of one part Portland cement to not more than two parts fine aggregate
by weight or volume, dry mixed, and moistened with sufficient water to permit
packing and troweling without crumbling. Fine aggregate shall be graded within
the limits of ASTM C33 or plaster sand conforming to ASTM C35. Water shall be
clean and free from injurious quantities of organic matter, alkali, salts, and other
impurities.
4.7.2.2 Application. Inside joints of cement–mortar-lined pipe shall be
filled with cement mortar and finished off smooth and flush with the inside surface
of the pipe by troweling or by equivalent means. Before placing the joint cement–
mortar material against the surfaces of the lining, the surfaces shall be carefully
cleaned, have soap removed, and then be wetted to ensure a good contact between
the lining and the joint cement mortar. The pipeline shall not be put into service
until the mortar has cured for a minimum of 24 hr.
4.7.2.2.1 For pipe diameters 22 in. (550 mm) and larger. After the pipe
zone bedding and backfill have been densified to at least 1 ft (0.3 m) above the top
of the pipe, the inside joint recess of pipe 22 in. (550 mm) in diameter and larger
shall first be moistened, then filled and pointed with a stiff cement mortar. The
finished joint shall be smooth and flush with the adjacent pipe surfaces. Interior
joint pointing operations shall not be conducted within two joints of pipe-laying
operations.
4.7.2.2.2 For pipe diameters less than 22 in. (550 mm). Prior to assembling
the joint, the inside shoulder of the bell shall be “buttered” with a stiff mortar. An
accessory, such as a specially designed rubber ball wrapped with burlap, shall be used
to (1) provide backup against which the cement mortar is squeezed while the cen-
tered spigot is pushed “home,” and (2) hold cement mortar in place in the assembled
joint while alignment and grade are adjusted, the next bell is “buttered,” and the next
spigot is centered. The accessory shall screed off excess mortar to leave a smooth and
continuous surface between pipe sections as it is drawn through the pipe.
4.7.3 Outside field joints.
4.7.3.1 Material. Grout shall be composed of one part Portland cement
to not more than two parts fine aggregate by weight or volume, thoroughly mixed
with water to the consistency of thick cream. Fine aggregate graduation shall con-
form to the requirements of ASTM C33 or ASTM C35, except that 100 percent
shall pass a US Standard Sieve No. 16.

18 AWWA C205-12
4.7.3.2 Application. Outside field joints shall be coated with cement

mortar, retained by suitable water-impermeable bands or diapers to bridge the joint
and retain the cement mortar without leakage. Before filling, the cement–mortar
space shall be flushed with water so that the surface of the joint to be in contact
with the cement mortar will be moistened when the cement mortar is poured. The
joint shall be filled with cement mortar by pouring from one side only until the
cement mortar reaches at least the pipe spring line on the opposite side, and shall
be rodded with a wire or other flexible rod, or vibrated so that the cement mortar
completely fills the joint recess by moving down one side of the pipe, around the
bottom of the pipe, and up the opposite side. Pouring and rodding the cement
mortar shall be continued to allow completion of the filling of the entire joint
recess in one operation. Care shall be taken to leave no space unfilled. The exposed
portion of the grout at the top of the pipe shall be coated with a sealing compound
or covered with burlap or moist earth.
SECTION 5: VERIFICATION
Sec. 5.1 Sampling and Testing Cement Mortar for Linings

Mixed cement mortar for pipe-lining work shall be sampled at the frequency
according to Sec. 5.1.1. Compression test cylinders or centrifugal test cylinders
shall be prepared according to the procedures in Sec. 5.1.2 or 5.1.3.
5.1.1 Sampling and testing frequency. A set of at least two standard test
cylinders, 6 in. (150 mm) in diameter by 12 in. (300 mm) in length, shall be made
each day from the cement–mortar lining for each shift to satisfy the quality control
requirements of Sec. 5.1.5. Additional cement–mortar testing shall be specified by
the purchaser.
5.1.2 Cement–mortar test cylinders. The cement mortar shall be removed
from the mix in accordance with ASTM C172, or samples may be prepared by
omitting sufficient water from the production mix to obtain a 1- to 3-in. (25- to
75-mm) slump. Test cylinders shall be made in conformance with ASTM C31/
C31M. Cylinders of different sizes, such as 2 in. × 4 in. (50 mm × 100 mm), may
be used to test compressive strength.
5.1.3 Centrifugal test cylinders. Centrifugally spun test cylinders may be
substituted for cement–mortar test cylinders, at the option of the manufacturer. Test
cylinders shall be spun about their longitudinal axes in 6-in. (150-mm) diameter by

12-in. (300-mm) long steel molds at a speed that will simulate the compaction of
mortar in the lining to produce a spun-cylinder wall thickness of approximately
11/ 2 in. (38 mm). The net cross-sectional area of the hollow cylinder shall be used to
determine its compressive strength. Damaged cylinders shall not be tested.
5.1.4 Curing test cylinders. The initial cure of the cement–mortar test cyl-
inders shall be the same as for the pipe. After the initial cure, the test cylinders shall
be kept in a standard moist room (ASTM C511) or in lime-saturated water until
the cylinders are 28 days old or until time of testing, whichever is less.
5.1.5 Testing. Test cylinders shall be tested in accordance with ASTM
C39 by a commercial testing laboratory approved by the purchaser unless the man-
ufacturer has testing facilities at the work site. In this event, the tests shall be made
by the manufacturer. Certified test reports shall be submitted by the manufacturer
if required by the purchaser.
5.1.6 Strength of cement–mortar lining. Cement–mortar test cylinders
shall attain a minimum compressive strength of 4,500 psi (31 MPa) in 28 days or
at the time of testing or shipment if either time is less than 28 days.
The average of any 10 consecutive strength tests of cylinders representing each
cement–mortar mix shall be equal to or greater than the specified strength, and
not more than 20 percent of the strength tests shall have values less than the speci-
fied strength. No cylinder test result shall be less than 80 percent of the specified
strength.
Sec. 5.2 Testing Cement Mortar for Coatings
Samples of cured cement–mortar coating shall be taken for making absorp-
tion tests according to Sec. 5.2.1 for coatings applied in accordance with Sec. 4.5.
5.2.1 Absorption testing. A water-absorption test shall be performed on
samples of cured cement–mortar coating taken from each shift. The cement–mortar
coating samples shall have been cured in the same manner as the pipe. A test value
shall consist of the average of a minimum of three samples taken on the same day
from the same work shift. The test method shall be in accordance with ASTM C497/
C497M, Method A. The average absorption value for any 10 consecutive tests from
a working shift shall not exceed 10 percent, and no individual sample shall have an
absorption value exceeding 12 percent.
Tests for each shift shall be performed on a daily basis until conformance to
the absorption requirements has been established by 10 consecutive test values not
exceeding 10 percent, at which time testing may be performed on a weekly basis
for each shift. Daily testing shall be resumed for each shift whenever an absorption

20 AWWA C205-12
test result exceeds 10 percent. Daily testing shall be maintained until conformance
to the absorption requirements is reestablished by 10 consecutive test values not
exceeding 10 percent.
Sec. 5.3 Calibration of the Manufacturer’s Equipment

Instruments, gauges, and other testing and measuring equipment used in
activities affecting quality shall be of proper range, type, and accuracy to verify
conformance with specified requirements. Procedures shall be in effect to ensure
the equipment is calibrated and certified against standards that have known rela-
tionship to national standards, when such exists. Gauges must be calibrated and
certified for the piece of equipment of which they are a part.
Sec. 5.4 Inspection and Testing by Purchaser

5.4.1 Inspection at the manufacturer’s plant. Materials provided and work
performed by the manufacturer shall be subject to inspection by the purchaser at
the manufacturer’s plant. During inspection, the purchaser shall have free access
to the manufacturer’s plant necessary to ensure compliance with this standard. The
manufacturer shall provide reasonable assistance as necessary for this inspection.
5.4.2 Materials certification. If required in the purchaser’s documents, the
manufacturer shall provide a certification that the materials used have been tested
in accordance with and meet the requirements of the applicable ASTM specifica-
tion for wire, wire fabric, ribbon mesh, Portland cement, fine aggregate, and curing
compound, if used. In addition, if required in the purchaser’s documents, the man-
ufacturer shall provide certified copies of compression test results of the mortar.
5.4.3 Responsibility. Inspection by the purchaser or failure of the pur-
chaser to provide inspection shall not relieve the constructor or the manufacturer
of the responsibility to provide materials and to perform work in accordance with
this standard.
5.4.4 Tests. Tests the purchaser makes on material samples shall be made
without delay. If any sample fails to meet the requirements, the manufacturer shall
be notified immediately. Material affected by the test results shall be set aside pend-
ing final disposition.
5.4.5 Notice of Nonconformance. Material and pipe that are discovered to
be defective or that do not conform to the requirements of this standard may be
repaired in accordance with the provisions of this standard. Nonconforming mate-
rial and pipe shall be removed from the work site within a reasonable period of
time.

SECTION 6: DELIVERY
Sec. 6.1 General

Care shall be exercised during loading, hauling, and unloading to prevent
damage to any of the components of the completed pipe. Pipe and specials shall
be suitably braced, supported to provide sufficient bearing area to prevent damage
to the coating, and tied to prevent shifting or distortion of the pipe during trans-
portation.
Sec. 6.2 Plastic End Caps

Plastic end caps shall be securely fastened to completed pipe ends of com-
pleted pipe for protection of the cement–mortar lining. End caps shall be main-
tained in place until time of installation.
Sec. 6.3 Affidavit of Compliance

The purchaser may require an affidavit from the manufacturer or supplier
that the material provided complies with applicable requirements of this standard.

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.
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ANSI/AWWA C205-12

(Revision of ANSI/AWWA C205-07)

The Authoritative Resource on Safe Water®

Effective date: June 1, 2012.

6666 West Quincy Avenue Advocacy

Copyright © 2012 American Water Works Association. All Rights Reserved.

American National Standard

ISBN-13, print: 978-1-58321-886-0 eISBN-13, electronic: 978-1-61300-144-8

Copyright © 2012 by American Water Works Association

Copyright © 2012 American Water Works Association. All Rights Reserved.

Henry H. Bardakjian, Chair

John H. Bambei Jr., Chair

General Interest Members

W.R. Brunzell, Brunzell Associates Ltd., Skokie, Ill. (AWWA)

Copyright © 2012 American Water Works Association. All Rights Reserved.

S.A. Arnaout, Hanson Pressure Pipe Inc., Dallas, Texas (AWWA)

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

1 General 6.1 General..............................................21

1.1 Scope...................................................1 6.2 Plastic End Caps................................21

1.2 Purpose................................................2 6.3 Affidavit of Compliance.....................21

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Cement–Mortar Protective Lining and

Sec. 1.1 Scope

1.1.4 Field application. For field application of cement–mortar lining,

Sec. 1.2 Purpose

Sec. 1.3 Application

This standard references the following documents. In their latest editions,

Copyright © 2012 American Water Works Association. All Rights Reserved.

ASTM A185—Standard Specification for Steel Welded Wire Fabric, Plain,

The following definitions shall apply in this standard:

Copyright © 2012 American Water Works Association. All Rights Reserved.

Sec. 4.1 General

Copyright © 2012 American Water Works Association. All Rights Reserved.

Sec. 4.2 Material

Copyright © 2012 American Water Works Association. All Rights Reserved.

4.2.3.2 Gradation. Gradation may be modified by the manufacturer, as

Sec. 4.4 Cement–Mortar Lining

Copyright © 2012 American Water Works Association. All Rights Reserved.

Table 1 Cement–mortar-lining thickness

in. (mm) in. (mm) in. (mm)

4.4.2 Thickness. Cement–mortar lining shall be uniform in thickness,

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

4.4.6 Defective lining.

Copyright © 2012 American Water Works Association. All Rights Reserved.

coating, if this coating is specified. If a cement–mortar exterior coating is not speci-

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

Copyright © 2012 American Water Works Association. All Rights Reserved.

4.5.7 Coating of specials.