37
Weld-After-Backfill: A Growing Industry Practice Bob Buchanan Ralph Warner Dennis Dechant

Weld-After-Backfill: A Growing Industry Practice€¦ · Weld-After-Backfill. Weld-After-Backfill is the sequence of assembling a welded joint, welding the outside joint (if required),

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Weld-After-BackfillA Growing Industry Practice

Bob BuchananRalph Warner

Dennis Dechant

Weld-After-Backfill

bull W-A-B is a growing practice in steel water pipeline construction

bull W-A-B sequencendash Assemble the joint in the trenchndash Weld the outside of the joint if specifiedndash Apply the exterior coating(s)ndash Backfill the pipendash Remove interior bracingndash Weld the inside joint at a later time

W-A-B History

bull W-A-B has been used for the past 16 years on projects ranging from 36rdquo pipe in San Diego to 120rdquo pipe in Charlotte

bull Safety Constructability and Pipeline Integrity are principle reasons to use W-A-B

bull 1st project using W-A-B was the Lake Texoma 72rdquo line built in 1989

bull More than 50 major projects have been constructed using W-A-B in the past 16 years

Sample Listing of W-A-B Projects SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE

Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)

State Project Year Footage Dia Wall (t) Owner EngineerCalifornia

Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery WatsonSan Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson EngineeringMiramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDMMiramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL

ColoradoEast Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKeeChimney Park Pipeline 003200 11000 60 0313 Greeley CO Boyle EngineeringPleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill

FloridaReplacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp HansenReplacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas CountyCypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery WatsonNorth Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenNorth Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenGroundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons EngineeringSouth Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKeeSouth Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKeeTampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDRTampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen

GeorgiaLawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp EddyShoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons EngineeringShoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering

OregonSunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES IncNo Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis

New Jersey Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group

New YorkSitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark

North Carolina120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer

TexasLake Texoma Pipeline 1989 30000 72 0313 North Texas MWDCooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp NicholsSurface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp NewnamPlano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp NicholsEast Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp NewnamLake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWHCarrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp NewnamCarrizo Design 2 2003 41000 60 Various San Antonio Water System CEC6B-1 2003 5000 84 438 Houston Lockwood Andrews amp NewnamElla Blvd 2003 8000 54 283 Houston Lockwood Andrews amp NewnamHempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp NewnamWilliamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam

UtahSandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle EngineeringPoint of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill

VirginiaMilitary Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers

June 04

Constructability ndash Open Trench

bull Conventional Constructionbull Pipe exposed to thermal stressbull Risk of flooding amp floating pipebull Interrupted backfillbull Welding in critical path

Expansion Joint

Welded Joints

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240
SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE June 8 2005
Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004
Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)
State Project Year Footage Dia Wall (t) Owner Engineer Contractor
California
Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery Watson EJ Meyer
San Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson Engineering TC Construction
Miramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDM City of San Diego
Miramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL VA Artukovich
Colorado
East Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKee ERS amp Garney JV
Chimney Park Pipeline 20032004 11000 60 0313 Greeley CO Boyle Engineering BT Construction
Pleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill Barnard Const Hi Country Pipeline
Florida
Replacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp Hansen Westra Construction
Replacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas County Kimmins Construction
Cypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery Watson Dallas 1 Construction
North Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen John D Stephens
North Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen Rockdale Construction
Groundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons Engineering Dallas 1 Construction
South Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKee Westra Construction
South Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKee Kenko Construction
Tampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDR Barnard Const
Tampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen Kenko Barnard Const
Georgia
Lawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp Eddy John D Stephens
Shoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons Engineering John D Stephens
Shoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering Rockdale Pipeline Inc
Oregon
Sunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES Inc Kerr Contractors Inc
No Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis John L Jersey amp Sons
New Jersey
Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group Conti Enterprises Inc
New York
SitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark Bat-Con Construction
North Carolina
120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer John D Stephens
Texas
Lake Texoma Pipeline 1989 30000 72 0313 North Texas MWD John D Stephens
Cooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp Nichols Oscar Renda Contracting
Surface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Plano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp Nichols Oscar Renda Contracting
East Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam Ramex
84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Lake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWH JD StephensO Renda
Carrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp Newnam McLean Construction Inc
Carrizo Design 2 2003 41000 60 Various San Antonio Water System CEC Heyl Construction
6B-1 2003 5000 84 438 Houston Lockwood Andrews amp Newnam Texas Sterling
Ella Blvd 2003 8000 54 283 Houston Lockwood Andrews amp Newnam Heyl Construction
Hempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp Newnam Jalco
Williamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam McLean Construction Inc
Utah
Sandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins Nix Construction Inc
15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle Engineering Condie Construction
Point of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill WW Clyde Co
Virginia
Military Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers Bryant Electric
Wisconsin
54 Parallel Raw Water Trans Main 2005 77000 54 305-500 City Of Green Bay Alvord Burdick amp Howson Garney Construction
This list represents a sample for reference and is not intended to be a comprehesive list
Joint coatings were either tape wrap or shrink sleeves
joints were mortar coated prior to welding
polyurethane coated pipe
polyurethane lined pipe
Pri-Tec coated pipe

Weld-After-Backfill

bull W-A-B is a growing practice in steel water pipeline construction

bull W-A-B sequencendash Assemble the joint in the trenchndash Weld the outside of the joint if specifiedndash Apply the exterior coating(s)ndash Backfill the pipendash Remove interior bracingndash Weld the inside joint at a later time

W-A-B History

bull W-A-B has been used for the past 16 years on projects ranging from 36rdquo pipe in San Diego to 120rdquo pipe in Charlotte

bull Safety Constructability and Pipeline Integrity are principle reasons to use W-A-B

bull 1st project using W-A-B was the Lake Texoma 72rdquo line built in 1989

bull More than 50 major projects have been constructed using W-A-B in the past 16 years

Sample Listing of W-A-B Projects SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE

Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)

State Project Year Footage Dia Wall (t) Owner EngineerCalifornia

Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery WatsonSan Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson EngineeringMiramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDMMiramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL

ColoradoEast Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKeeChimney Park Pipeline 003200 11000 60 0313 Greeley CO Boyle EngineeringPleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill

FloridaReplacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp HansenReplacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas CountyCypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery WatsonNorth Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenNorth Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenGroundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons EngineeringSouth Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKeeSouth Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKeeTampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDRTampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen

GeorgiaLawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp EddyShoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons EngineeringShoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering

OregonSunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES IncNo Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis

New Jersey Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group

New YorkSitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark

North Carolina120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer

TexasLake Texoma Pipeline 1989 30000 72 0313 North Texas MWDCooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp NicholsSurface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp NewnamPlano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp NicholsEast Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp NewnamLake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWHCarrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp NewnamCarrizo Design 2 2003 41000 60 Various San Antonio Water System CEC6B-1 2003 5000 84 438 Houston Lockwood Andrews amp NewnamElla Blvd 2003 8000 54 283 Houston Lockwood Andrews amp NewnamHempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp NewnamWilliamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam

UtahSandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle EngineeringPoint of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill

VirginiaMilitary Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers

June 04

Constructability ndash Open Trench

bull Conventional Constructionbull Pipe exposed to thermal stressbull Risk of flooding amp floating pipebull Interrupted backfillbull Welding in critical path

Expansion Joint

Welded Joints

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240
SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE June 8 2005
Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004
Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)
State Project Year Footage Dia Wall (t) Owner Engineer Contractor
California
Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery Watson EJ Meyer
San Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson Engineering TC Construction
Miramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDM City of San Diego
Miramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL VA Artukovich
Colorado
East Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKee ERS amp Garney JV
Chimney Park Pipeline 20032004 11000 60 0313 Greeley CO Boyle Engineering BT Construction
Pleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill Barnard Const Hi Country Pipeline
Florida
Replacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp Hansen Westra Construction
Replacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas County Kimmins Construction
Cypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery Watson Dallas 1 Construction
North Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen John D Stephens
North Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen Rockdale Construction
Groundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons Engineering Dallas 1 Construction
South Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKee Westra Construction
South Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKee Kenko Construction
Tampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDR Barnard Const
Tampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen Kenko Barnard Const
Georgia
Lawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp Eddy John D Stephens
Shoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons Engineering John D Stephens
Shoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering Rockdale Pipeline Inc
Oregon
Sunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES Inc Kerr Contractors Inc
No Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis John L Jersey amp Sons
New Jersey
Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group Conti Enterprises Inc
New York
SitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark Bat-Con Construction
North Carolina
120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer John D Stephens
Texas
Lake Texoma Pipeline 1989 30000 72 0313 North Texas MWD John D Stephens
Cooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp Nichols Oscar Renda Contracting
Surface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Plano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp Nichols Oscar Renda Contracting
East Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam Ramex
84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Lake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWH JD StephensO Renda
Carrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp Newnam McLean Construction Inc
Carrizo Design 2 2003 41000 60 Various San Antonio Water System CEC Heyl Construction
6B-1 2003 5000 84 438 Houston Lockwood Andrews amp Newnam Texas Sterling
Ella Blvd 2003 8000 54 283 Houston Lockwood Andrews amp Newnam Heyl Construction
Hempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp Newnam Jalco
Williamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam McLean Construction Inc
Utah
Sandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins Nix Construction Inc
15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle Engineering Condie Construction
Point of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill WW Clyde Co
Virginia
Military Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers Bryant Electric
Wisconsin
54 Parallel Raw Water Trans Main 2005 77000 54 305-500 City Of Green Bay Alvord Burdick amp Howson Garney Construction
This list represents a sample for reference and is not intended to be a comprehesive list
Joint coatings were either tape wrap or shrink sleeves
joints were mortar coated prior to welding
polyurethane coated pipe
polyurethane lined pipe
Pri-Tec coated pipe

W-A-B History

bull W-A-B has been used for the past 16 years on projects ranging from 36rdquo pipe in San Diego to 120rdquo pipe in Charlotte

bull Safety Constructability and Pipeline Integrity are principle reasons to use W-A-B

bull 1st project using W-A-B was the Lake Texoma 72rdquo line built in 1989

bull More than 50 major projects have been constructed using W-A-B in the past 16 years

Sample Listing of W-A-B Projects SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE

Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)

State Project Year Footage Dia Wall (t) Owner EngineerCalifornia

Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery WatsonSan Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson EngineeringMiramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDMMiramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL

ColoradoEast Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKeeChimney Park Pipeline 003200 11000 60 0313 Greeley CO Boyle EngineeringPleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill

FloridaReplacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp HansenReplacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas CountyCypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery WatsonNorth Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenNorth Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenGroundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons EngineeringSouth Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKeeSouth Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKeeTampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDRTampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen

GeorgiaLawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp EddyShoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons EngineeringShoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering

OregonSunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES IncNo Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis

New Jersey Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group

New YorkSitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark

North Carolina120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer

TexasLake Texoma Pipeline 1989 30000 72 0313 North Texas MWDCooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp NicholsSurface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp NewnamPlano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp NicholsEast Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp NewnamLake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWHCarrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp NewnamCarrizo Design 2 2003 41000 60 Various San Antonio Water System CEC6B-1 2003 5000 84 438 Houston Lockwood Andrews amp NewnamElla Blvd 2003 8000 54 283 Houston Lockwood Andrews amp NewnamHempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp NewnamWilliamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam

UtahSandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle EngineeringPoint of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill

VirginiaMilitary Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers

June 04

Constructability ndash Open Trench

bull Conventional Constructionbull Pipe exposed to thermal stressbull Risk of flooding amp floating pipebull Interrupted backfillbull Welding in critical path

Expansion Joint

Welded Joints

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

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Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240
SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE June 8 2005
Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004
Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)
State Project Year Footage Dia Wall (t) Owner Engineer Contractor
California
Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery Watson EJ Meyer
San Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson Engineering TC Construction
Miramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDM City of San Diego
Miramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL VA Artukovich
Colorado
East Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKee ERS amp Garney JV
Chimney Park Pipeline 20032004 11000 60 0313 Greeley CO Boyle Engineering BT Construction
Pleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill Barnard Const Hi Country Pipeline
Florida
Replacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp Hansen Westra Construction
Replacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas County Kimmins Construction
Cypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery Watson Dallas 1 Construction
North Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen John D Stephens
North Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen Rockdale Construction
Groundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons Engineering Dallas 1 Construction
South Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKee Westra Construction
South Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKee Kenko Construction
Tampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDR Barnard Const
Tampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen Kenko Barnard Const
Georgia
Lawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp Eddy John D Stephens
Shoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons Engineering John D Stephens
Shoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering Rockdale Pipeline Inc
Oregon
Sunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES Inc Kerr Contractors Inc
No Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis John L Jersey amp Sons
New Jersey
Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group Conti Enterprises Inc
New York
SitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark Bat-Con Construction
North Carolina
120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer John D Stephens
Texas
Lake Texoma Pipeline 1989 30000 72 0313 North Texas MWD John D Stephens
Cooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp Nichols Oscar Renda Contracting
Surface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Plano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp Nichols Oscar Renda Contracting
East Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam Ramex
84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Lake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWH JD StephensO Renda
Carrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp Newnam McLean Construction Inc
Carrizo Design 2 2003 41000 60 Various San Antonio Water System CEC Heyl Construction
6B-1 2003 5000 84 438 Houston Lockwood Andrews amp Newnam Texas Sterling
Ella Blvd 2003 8000 54 283 Houston Lockwood Andrews amp Newnam Heyl Construction
Hempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp Newnam Jalco
Williamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam McLean Construction Inc
Utah
Sandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins Nix Construction Inc
15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle Engineering Condie Construction
Point of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill WW Clyde Co
Virginia
Military Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers Bryant Electric
Wisconsin
54 Parallel Raw Water Trans Main 2005 77000 54 305-500 City Of Green Bay Alvord Burdick amp Howson Garney Construction
This list represents a sample for reference and is not intended to be a comprehesive list
Joint coatings were either tape wrap or shrink sleeves
joints were mortar coated prior to welding
polyurethane coated pipe
polyurethane lined pipe
Pri-Tec coated pipe

Sample Listing of W-A-B Projects SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE

Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)

State Project Year Footage Dia Wall (t) Owner EngineerCalifornia

Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery WatsonSan Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson EngineeringMiramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDMMiramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL

ColoradoEast Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKeeChimney Park Pipeline 003200 11000 60 0313 Greeley CO Boyle EngineeringPleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill

FloridaReplacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp HansenReplacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas CountyCypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery WatsonNorth Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenNorth Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp HansenGroundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons EngineeringSouth Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKeeSouth Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKeeTampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDRTampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen

GeorgiaLawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp EddyShoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons EngineeringShoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering

OregonSunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES IncNo Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis

New Jersey Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group

New YorkSitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark

North Carolina120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer

TexasLake Texoma Pipeline 1989 30000 72 0313 North Texas MWDCooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp NicholsSurface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp NewnamPlano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp NicholsEast Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp NewnamLake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWHCarrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp NewnamCarrizo Design 2 2003 41000 60 Various San Antonio Water System CEC6B-1 2003 5000 84 438 Houston Lockwood Andrews amp NewnamElla Blvd 2003 8000 54 283 Houston Lockwood Andrews amp NewnamHempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp NewnamWilliamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam

UtahSandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle EngineeringPoint of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill

VirginiaMilitary Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers

June 04

Constructability ndash Open Trench

bull Conventional Constructionbull Pipe exposed to thermal stressbull Risk of flooding amp floating pipebull Interrupted backfillbull Welding in critical path

Expansion Joint

Welded Joints

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240
SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE June 8 2005
Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004
Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)
State Project Year Footage Dia Wall (t) Owner Engineer Contractor
California
Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery Watson EJ Meyer
San Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson Engineering TC Construction
Miramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDM City of San Diego
Miramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL VA Artukovich
Colorado
East Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKee ERS amp Garney JV
Chimney Park Pipeline 20032004 11000 60 0313 Greeley CO Boyle Engineering BT Construction
Pleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill Barnard Const Hi Country Pipeline
Florida
Replacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp Hansen Westra Construction
Replacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas County Kimmins Construction
Cypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery Watson Dallas 1 Construction
North Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen John D Stephens
North Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen Rockdale Construction
Groundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons Engineering Dallas 1 Construction
South Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKee Westra Construction
South Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKee Kenko Construction
Tampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDR Barnard Const
Tampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen Kenko Barnard Const
Georgia
Lawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp Eddy John D Stephens
Shoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons Engineering John D Stephens
Shoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering Rockdale Pipeline Inc
Oregon
Sunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES Inc Kerr Contractors Inc
No Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis John L Jersey amp Sons
New Jersey
Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group Conti Enterprises Inc
New York
SitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark Bat-Con Construction
North Carolina
120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer John D Stephens
Texas
Lake Texoma Pipeline 1989 30000 72 0313 North Texas MWD John D Stephens
Cooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp Nichols Oscar Renda Contracting
Surface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Plano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp Nichols Oscar Renda Contracting
East Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam Ramex
84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Lake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWH JD StephensO Renda
Carrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp Newnam McLean Construction Inc
Carrizo Design 2 2003 41000 60 Various San Antonio Water System CEC Heyl Construction
6B-1 2003 5000 84 438 Houston Lockwood Andrews amp Newnam Texas Sterling
Ella Blvd 2003 8000 54 283 Houston Lockwood Andrews amp Newnam Heyl Construction
Hempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp Newnam Jalco
Williamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam McLean Construction Inc
Utah
Sandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins Nix Construction Inc
15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle Engineering Condie Construction
Point of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill WW Clyde Co
Virginia
Military Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers Bryant Electric
Wisconsin
54 Parallel Raw Water Trans Main 2005 77000 54 305-500 City Of Green Bay Alvord Burdick amp Howson Garney Construction
This list represents a sample for reference and is not intended to be a comprehesive list
Joint coatings were either tape wrap or shrink sleeves
joints were mortar coated prior to welding
polyurethane coated pipe
polyurethane lined pipe
Pri-Tec coated pipe

June 04

Constructability ndash Open Trench

bull Conventional Constructionbull Pipe exposed to thermal stressbull Risk of flooding amp floating pipebull Interrupted backfillbull Welding in critical path

Expansion Joint

Welded Joints

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240
SAMPLE LISTING OF PROJECTS USING WELD AFTER BACKFILL SEQUENCE June 8 2005
Steel Water Pipe Manufacturers Technical Advisory Committee AWWA 2004
Compiled by Weld After Backfill Task Group Ralph Warner Chair (National Welding Corp)
State Project Year Footage Dia Wall (t) Owner Engineer Contractor
California
Flume Replacement Project 2000 24000 42 amp 48 0250 Helix Water District Montgomery Watson EJ Meyer
San Diego Pipeline 2 Segment A 2002 25000 48 0375 City of San Diego Wilson Engineering TC Construction
Miramar WTP Improv Project 2002 3200 36 amp 48 0250 City of San Diego CDM City of San Diego
Miramar Road Pipeline 2002 25000 36 19 to 63 City of San Diego ASL VA Artukovich
Colorado
East Cherry Creek Transmission Main 2003 59000 54 amp 48 400 ECCV Sanitation District Camp Dresser amp McKee ERS amp Garney JV
Chimney Park Pipeline 20032004 11000 60 0313 Greeley CO Boyle Engineering BT Construction
Pleasant Valley Pipeline 2003 46000 67 283 No Colo WCD CH2MHill Barnard Const Hi Country Pipeline
Florida
Replacement of 54 amp 60 Main 1993 18000 60 0375 Pinellas County Greeley amp Hansen Westra Construction
Replacement of 54 amp 60 Main 1995 45000 60 0375 Pinellas County Kimmins Construction
Cypress Bridge A 1994 33000 66 0340 West Coast Reg Water Montgomery Watson Dallas 1 Construction
North Central Hillsborough Intertie 1 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen John D Stephens
North Central Hillsborough Intertie 2 2001 32000 84 0445 Tampa Bay Water Greeley amp Hansen Rockdale Construction
Groundwater Treatment Plant 2001 16000 84 amp 72 0445 Tampa Bay Water Parsons Engineering Dallas 1 Construction
South Central Hillsborough Intertie 1 2001 35000 72 0370 Tampa Bay Water Camp Dresser amp McKee Westra Construction
South Central Hillsborough Intertie 2 2001 35000 72 0375 Tampa Bay Water Camp Dresser amp McKee Kenko Construction
Tampa Bay Reservoir 2003 10000 84 438 amp 100 Tampa Bay Water Greeley amp Hansen HDR Barnard Const
Tampa Bay Reservoir Pipeline 2003 32000 84 438 Tampa Bay Water Greeley amp Hansen Kenko Barnard Const
Georgia
Lawrenceville - Lake Lanier Trans 1997 45000 78 0625 Gwinnett County Metcalf amp Eddy John D Stephens
Shoal Creek RWI 1 2003 4000 72 0375 Gwinnett County Parsons Engineering John D Stephens
Shoal Creek RWI 2 2003 28000 72 0375 Gwinnett County Parsons Engineering Rockdale Pipeline Inc
Oregon
Sunset Highway 26 Transmission Line 1999 25000 48 0250 Tualatin Valley Water Dist Consulting Engineers EES Inc Kerr Contractors Inc
No Hills Water Taransmission Main 2003 9800 36 0250 City of Corvalis City of Corvalis John L Jersey amp Sons
New Jersey
Jersey City Aqueduct Relocation 2005 7600 72 410 NJ Turnpike Authority The RBA Group Conti Enterprises Inc
New York
SitheIndependence Main 1993 18000 36 0375 City of Oswego Nussbaumer amp Clark Bat-Con Construction
North Carolina
120 Raw Water Line 1998 29000 120 0675 Charlotte-Mecklenburg MUD Hazen amp Sawyer John D Stephens
Texas
Lake Texoma Pipeline 1989 30000 72 0313 North Texas MWD John D Stephens
Cooper Lake Water Transmission 3 1992 58000 84 0375 North Texas MWD Freese amp Nichols Oscar Renda Contracting
Surface Water Treatment Program 1994 6000 66 0375 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Plano - McKinney Phase 3 1996 25000 96 0438 North Texas MWD Freese amp Nichols Oscar Renda Contracting
East Water Program Contract 2A 1996 8000 84 0375 City of Houston Lockwood Andrews amp Newnam Ramex
84 Water Main Contract 2B-1 1998 2933 84 0423 City of Houston Lockwood Andrews amp Newnam Texas Sterling
Lake Chapman Water Project 2001 174000 72 0438 City of Irving CH2MHillMWH JD StephensO Renda
Carrizo Design 2B 2003 32000 60 Various San Antonio Water System Lockwood Andrews amp Newnam McLean Construction Inc
Carrizo Design 2 2003 41000 60 Various San Antonio Water System CEC Heyl Construction
6B-1 2003 5000 84 438 Houston Lockwood Andrews amp Newnam Texas Sterling
Ella Blvd 2003 8000 54 283 Houston Lockwood Andrews amp Newnam Heyl Construction
Hempstead Highway 2003 16000 54 283 Houston Lockwood Andrews amp Newnam Jalco
Williamson Cnty 48 Waterline Reloc 2005 5000 48 269 Williamson Cnty - BrazosRA Lockwood Andrews amp Newnam McLean Construction Inc
Utah
Sandridge Pipeline 1999 9000 48 0188 0313 Weber Basin WCD Bowen amp Collins Nix Construction Inc
15000 South Water Transmission Line 2001 22000 48 0375 Jordan Valley WCD Boyle Engineering Condie Construction
Point of The Mtn Aqueduct 2005 63000 60 025 - 040 Metro Water Dist of SLC CH2MHill WW Clyde Co
Virginia
Military Highway Route 13 1993 12000 48 VA Dept of Transportation HDR Engineers Bryant Electric
Wisconsin
54 Parallel Raw Water Trans Main 2005 77000 54 305-500 City Of Green Bay Alvord Burdick amp Howson Garney Construction
This list represents a sample for reference and is not intended to be a comprehesive list
Joint coatings were either tape wrap or shrink sleeves
joints were mortar coated prior to welding
polyurethane coated pipe
polyurethane lined pipe
Pri-Tec coated pipe

Constructability ndash Open Trench

bull Conventional Constructionbull Pipe exposed to thermal stressbull Risk of flooding amp floating pipebull Interrupted backfillbull Welding in critical path

Expansion Joint

Welded Joints

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Constructability ndash Closed Trench

bull Weld After Backfill Sequencebull No Thermal Stressesbull No risk of floating pipebull Consistent Backfillbull Installation independent of welding

Last Inside Weld

Last Outside Weld

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Safety Considerations

bull W-A-B provides better and safer access to work inside the pipe

bull Provides shortened open trench exposuresbull Benefits the contractor designer and owner

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Safety - Internal Access

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Weld-After-Backfill

bull Challenges the exterior field joint coating

bull AWWA (SWPMTAC) has been trying to bring the standards up to date with field practice

bull Research by Canusa-CPS National Welding and Northwest Pipe done to determine best practices

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Weld-After-Backfill Trials

bull Trials conducted to evaluate the effects of welding on the external field joint coating

bull Common field welding techniques evaluated

bull Several coating system designs tested

bull Objective to optimize current practices

bull Observations results and conclusions determined variables that affect performance

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipebull Standard heat-shrink sleeves alonebull Standard heat-shrink sleeves with underlaysbull Buried with compacted sand backfillbull Welded ndash FCAW SMAWbull Excavated and inspected

ndash Visual assessmentndash Holiday testndash Adhesion test

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Coating Systems Tested

bull Heat-Shrinkable Sleeves of various designndash Backing and adhesive type variables

bull Underlay materials evaluatedndash Various types or no underlay

bull System design evaluated

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Typical Welding Methods

bull FCAW (Flux Core Arc Welding)ndash High production benefitndash Requires more equipment - shielding gases wire

feederndash Requires more expertise to weld effectively

bull SMAW (Shielded Metal Arc Welding)ndash Simplest (most common) welding methodndash Generally less efficient that FCAWndash Commonly done by ldquorigrdquo welders

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Test Assembly

Backfill Box over Pipe

Two Pipe Joints

Two Bell Ends with lsquoPuprsquo between them

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Weld-After-Backfill Trials

bull Systems applied to a 48rdquo OD 250rdquo wall pipendash Standard heat-shrink sleeves alonendash Standard heat-shrink sleeves with underlaysndash Applied buried amp welded internally

Compacted soil

External Sleeve

Internal Weld

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Heat-Shrink Sleeve Installation

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Backfilling Prior to Welding

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Internal Welding

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Temp Stick Measurements

Heat affected area

Temperature Under SleeveHeat-Affected Area

0

200

400

600

800

1000

1200

30 70 110

150

190 30 70 11

015

019

023

0

Time

Hea

t-Affe

cted

Are

a Te

mp

FCAW 1SMAW 1-1SMAW 1-2FCAW 2SMAW 2-1SMAW 2-2

Temp Test 1 Temp Test 2

Weld-After-Backfill Trials

bull Temperature measured inside the pipe amp under the sleeve

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Chart2

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area
993
74
111
370
165
117
572
420
136
650
510
299
704
505
777
721
470
858
731
440
837
734
415
780
722
395
720
712
378
669
675
369
631
654
357
594
599
345
566
585
336
541
578
327
522
583
319
500
532
312
483
505
304
464
455
297
451
442
439
426
427
409
415
380
405
362
396
351
390
336
382
314
374
312
366
303
357
349
342
337
332
327
323
319
314
311
306
302
299
167
167
4622
230
653
4352
10004
6476
9032
7124
869
6818
8762
5882
6692
7718
4784
635
7736
4676
5882
7538
4568
572
8996
4244
590
8438
662
806
662
779
6458
7574
6422
734
6206
7214
5486
7034
590
6854
590
671
5522
6548
5162
6404
509
626
5198
617
5126
608
5054
599
4964
5882
4856
5792
4802
5684
473
5612
4802
5522
4784
545
482
5396
482
5324
4838
5252
4784
5198
4694
5126
4622
5072
4586
5018
4442
4946
4316
4874
4262
4838
4208
4784
419
473
4154
4676
4136
4622
4082
4568
455
455

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240
0 0 0 0 0 0
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
0 0 0 0 0 0
5 5 5 5 5 5
10 10 10 10 10 10
15 15 15 15 15 15
20 20 20 20 20 20
25 25 25 25 25 25
30 30 30 30 30 30
35 35 35 35 35 35
40 40 40 40 40 40
45 45 45 45 45 45
50 50 50 50 50 50
55 55 55 55 55 55
60 60 60 60 60 60
65 65 65 65 65 65
70 70 70 70 70 70
75 75 75 75 75 75
80 80 80 80 80 80
85 85 85 85 85 85
90 90 90 90 90 90
95 95 95 95 95 95
100 100 100 100 100 100
105 105 105 105 105 105
110 110 110 110 110 110
115 115 115 115 115 115
120 120 120 120 120 120
125 125 125 125 125 125
130 130 130 130 130 130
135 135 135 135 135 135
140 140 140 140 140 140
145 145 145 145 145 145
150 150 150 150 150 150
155 155 155 155 155 155
160 160 160 160 160 160
165 165 165 165 165 165
170 170 170 170 170 170
175 175 175 175 175 175
180 180 180 180 180 180
185 185 185 185 185 185
190 190 190 190 190 190
195 195 195 195 195 195
200 200 200 200 200 200
205 205 205 205 205 205
210 210 210 210 210 210
215 215 215 215 215 215
220 220 220 220 220 220
225 225 225 225 225 225
230 230 230 230 230 230
235 235 235 235 235 235
240 240 240 240 240 240

Combined 1amp2 Pass Chart

FCAW(degF)
SMAW 1st(degF)
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature (Welding)
0
74
165
993
420
370
510
572
505
650
470
704
440
721
415
731
395
734
378
722
369
712
357
675
345
654
336
599
327
585
319
578
312
583
304
532
297
505
455
442
426
409
380
362
351
336
314
312
303

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
0 0
5 5
10 10
15 15
20 20
25 25
30 30
35 35
40 40
45 45
50 50
55 55
60 60
65 65
70 70
75 75
80 80
85 85
90 90
95 95
100 100
105 105
110 110
115 115
120 120
125 125
130 130
135 135
140 140
145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
185 185
190 190
195 195
200 200
205 205
210 210
215 215
220 220
225 225
230 230
235 235
240 240

Sheet1 (2)

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
FCAW 1 SMAW 1-1 SMAW 1-2 FCAW 2 SMAW 2-1 SMAW 2-2
FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF) FCAW(degF) SMAW 1st(degF) SMAW 2nd(degF)
0 993 74 111
5 370 165 117
10 572 420 136
15 650 510 299
20 704 505 777
25 721 470 858
30 731 440 837
35 734 415 780
40 722 395 720
45 712 378 669
50 675 369 631
55 654 357 594
60 599 345 566
65 585 336 541
70 578 327 522
75 583 319 500
80 532 312 483
85 505 304 464
90 455 297 451
95 442 439
100 426 427
105 409 415
110 380 405
115 362 396
120 351 390
125 336 382
130 314 374
135 312 366
140 303 357
145 349
150 342
155 337
160 332
165 327
170 323
175 319
180 314
185 311
190 306
195 302
200 299
205
0 167 167 75 75
5 462 230 239 110
10 653 435 345 224
15 1000 648 538 342
20 903 712 484 378
25 869 682 465 361
30 876 588 669 469 309 354
35 772 478 635 411 248 335
40 774 468 588 412 242 309
45 754 457 572 401 236 300
50 900 424 590 482 218 310
55 844 662 451 350
60 806 662 430 350
65 779 646 415 341
70 757 642 403 339
75 734 621 390 327
80 721 549 383 287
85 703 590 373 310
90 685 590 363 310
95 671 552 355 289
100 655 516 346 269
105 640 509 338 265
110 626 520 330 271
115 617 513 325 267
120 608 505 320 263
125 599 496 315 258
130 588 486 309 252
135 579 480 304 249
140 568 473 298 245
145 561 480 294 249
150 552 478 289 248
155 545 482 285 250
160 540 482 282 250
165 532 484 278 251
170 525 478 274 248
175 520 469 271 243
180 513 462 267 239
185 507 459 264 237
190 502 444 261 229
195 495 432 257 222
200 487 426 253 219
205 484 421 251 216
210 478 419 248 215
215 473 415 245 213
220 468 414 242 212
225 462 408 239 209
230 457 236
235 455 235
240 455 235

Sheet1 (2)

FCAW 1
SMAW 1-1
SMAW 1-2
FCAW 2
SMAW 2-1
SMAW 2-2
Time
Heat-Affected Area Temp
Temperature Under SleeveHeat-Affected Area

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720

Bar Chart1 (2)

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720

revised Chart 200F

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720

Chart1

Temperature degF Wire Welding
Temperature degF Rod welding 1st Pass
Temperature degF Rod Welding 2nd Pass
Time (Seconds)
Temperature (Deg F)
Weld After Backfill - Time vs Temperature
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
66
100
697
67
100
697
67
100
697
68
100
697
70
100
697
74
100
697
165
100
697
420
100
697
510
100
697
505
100
697
470
100
697
440
100
697
415
100
697
395
100
697
378
100
697
369
100
697
357
100
697
345
100
697
336
100
697
327
100
697
319
100
697
312
100
697
304
100
697
297
100
697
292
101
697
286
102
697
280
103
697
276
103
697
271
104
697
267
108
697
263
111
697
260
117
697
256
136
697
253
299
697
250
777
697
247
858
697
244
837
697
241
780
697
238
720
697
236
669
697
233
631
697
231
594
697
227
566
697
225
541
697
222
522
697
220
500
697
218
483
697
216
464
697
215
451
697
213
439
697
211
427
697
209
415
697
208
405
697
206
396
697
204
390
697
203
382
698
201
374
698
200
366
70
198
357
70
197
349
702
195
342
718
194
337
993
193
332
370
191
327
572
190
323
650
189
319
704
187
314
721
185
311
731
183
306
734
182
302
722
181
299
712
179
296
675
178
293
654
177
289
599
176
287
585
175
284
578
173
281
583
173
279
532
171
276
505
170
274
455
169
271
442
168
269
426
167
266
409
166
264
380
166
262
362
165
260
351
164
258
336
163
255
314
162
254
312
161
252
303
160
250
292
159
248
274
158
246
263
158
244
262
157
242
254
156
240
245
155
239
240
154
237
236
153
235
227
153
233
222
152
232
219
151
230
216
150
229
214
150
227
212
149
225
209
148
224
207
148
222
204
147
221
202
146
221
198
146
220
197
145
216
195
144
215
193
144
214
192
143
212
190
143
211
188
142
210
185
141
208
182
141
207
180
140
206
178
140
205
177
139
203
172
138
202
172
138
201
171
137
200
170
137
199
169
136
198
166
136
197
163
135
195
161
135
194
159
134
193
156
134
192
155
133
191
154
133
190
154
133
189
152
133
188
151
132
187
149
132
186
146
131
185
145
130
184
144
130
183

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183
0 0 0
5 5 5
10 10 10
15 15 15
20 20 20
25 25 25
30 30 30
35 35 35
40 40 40
45 45 45
50 50 50
55 55 55
60 60 60
65 65 65
70 70 70
75 75 75
80 80 80
85 85 85
90 90 90
95 95 95
100 100 100
105 105 105
110 110 110
115 115 115
120 120 120
125 125 125
130 130 130
135 135 135
140 140 140
145 145 145
150 150 150
155 155 155
160 160 160
165 165 165
170 170 170
175 175 175
180 180 180
185 185 185
190 190 190
195 195 195
200 200 200
205 205 205
210 210 210
215 215 215
220 220 220
225 225 225
230 230 230
235 235 235
240 240 240
245 245 245
250 250 250
255 255 255
260 260 260
265 265 265
270 270 270
275 275 275
280 280 280
285 285 285
290 290 290
295 295 295
300 300 300
305 305 305
310 310 310
315 315 315
320 320 320
325 325 325
330 330 330
335 335 335
340 340 340
345 345 345
350 350 350
355 355 355
360 360 360
365 365 365
370 370 370
375 375 375
380 380 380
385 385 385
390 390 390
395 395 395
400 400 400
405 405 405
410 410 410
415 415 415
420 420 420
425 425 425
430 430 430
435 435 435
440 440 440
445 445 445
450 450 450
455 455 455
460 460 460
465 465 465
470 470 470
475 475 475
480 480 480
485 485 485
490 490 490
495 495 495
500 500 500
505 505 505
510 510 510
515 515 515
520 520 520
525 525 525
530 530 530
535 535 535
540 540 540
545 545 545
550 550 550
555 555 555
560 560 560
565 565 565
570 570 570
575 575 575
580 580 580
585 585 585
590 590 590
595 595 595
600 600 600
605 605 605
610 610 610
615 615 615
620 620 620
625 625 625
630 630 630
635 635 635
640 640 640
645 645 645
650 650 650
655 655 655
660 660 660
665 665 665
670 670 670
675 675 675
680 680 680
685 685 685
690 690 690
695 695 695
700 700 700
705 705 705
710 710 710
715 715 715
720 720 720

Sheet1

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800
Time (sec) Temperature degF Wire Welding Temperature degF Rod welding 1st Pass Temperature degF Rod Welding 2nd Pass
0 697 66 100
5 697 66 100
10 697 66 100
15 697 66 100
20 697 66 100
25 697 66 100
30 697 67 100
35 697 67 100
40 697 68 100
45 697 70 100
50 697 74 100
55 697 165 100
60 1 Min 60 697 420 100
65 697 510 100
70 697 505 100
75 697 470 100
80 697 440 100
85 697 415 100
90 697 395 100
95 697 378 100
100 697 369 100
105 697 357 100
110 697 345 100
115 697 336 100
120 2 Min 120 697 327 100
125 697 319 100
130 697 312 100
135 697 304 100
140 697 297 100
145 697 292 101
150 697 286 102
155 697 280 103
160 697 276 103
165 697 271 104
170 697 267 108
175 697 263 111
180 3 Min 180 697 260 117
185 697 256 136
190 697 253 299
195 697 250 777
200 697 247 858
205 697 244 837
210 697 241 780
215 697 238 720
220 697 236 669
225 697 233 631
230 697 231 594
235 697 227 566
240 4 Min 240 697 225 541
245 697 222 522
250 697 220 500
255 697 218 483
260 697 216 464
265 697 215 451
270 697 213 439
275 697 211 427
280 697 209 415
285 697 208 405
290 697 206 396
300 5 Min 295 697 204 390
300 697 203 382
305 698 201 374
310 698 200 366
315 70 198 357
320 70 197 349
325 702 195 342
330 718 194 337
335 993 193 332
340 370 191 327
345 572 190 323
350 650 189 319
360 6 Min 355 704 187 314
360 721 185 311
365 731 183 306
370 734 182 302
375 722 181 299
380 712 179 296
385 675 178 293
390 654 177 289
395 599 176 287
400 585 175 284
405 578 173 281
410 583 173 279
420 7 Min 415 532 171 276
420 505 170 274
425 455 169 271
430 442 168 269
435 426 167 266
440 409 166 264
445 380 166 262
450 362 165 260
455 351 164 258
460 336 163 255
465 314 162 254
470 312 161 252
480 8 Min 475 303 160 250
480 292 159 248
485 274 158 246
490 263 158 244
495 262 157 242
500 254 156 240
505 245 155 239
510 240 154 237
515 236 153 235
520 227 153 233
525 222 152 232
530 219 151 230
535 216 150 229
540 9 Min 540 214 150 227
545 212 149 225
550 209 148 224
555 207 148 222
560 204 147 221
565 202 146 221
570 198 146 220
575 197 145 216
580 195 144 215
585 193 144 214
590 192 143 212
595 190 143 211
600 10 Min 600 188 142 210
605 185 141 208
610 182 141 207
615 180 140 206
620 178 140 205
625 177 139 203
630 172 138 202
635 172 138 201
640 171 137 200
645 170 137 199
650 169 136 198
655 166 136 197
660 11 Min 660 163 135 195
665 161 135 194
670 159 134 193
675 156 134 192
680 155 133 191
685 154 133 190
690 154 133 189
695 152 133 188
700 151 132 187
705 149 132 186
710 146 131 185
715 145 130 184
720 12 Min 720 144 130 183

Temp Stick Photos

Before Welding

After Welding

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800

Temp Stick Data

Trial 2 FCAW

-40 -30 -20 -10 00 10 20 30 40

200

300

400

500

600

700

800

(ordmF)

Inches

Bell Side (d)

Spigot Side (d)

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800

Chart4

Spigot Side (d)
Bell Side (d)
(ordmF)
Inches
Trial 2 FCAW
-275
288
-213
25
-163
238
-125
15
-069
138
-063
125
-038
1

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured
200 200
300 300
400 400
500 500
600 600
700 700
800 800

Test 1

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100
Test 1 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-300 200 275
-250 300 213
-150 400 138
-119 500 100
-100 600 075
-063 700 056
-050 800 Obscured

Test 1

Spigot Side (d)
Bell Side (d)
Inches
Test 1Temp Stick Melt Back Distance(Deg F)

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100

Test 2

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Trial 2 Temp Stick Grid (FCAW Process)
Spigot Side (d) Temp (Deg F) Bell Side (d)
-275 200 288
-213 300 250
-163 400 238
-125 500 150
-069 600 138
-063 700 125
-038 800 100

Test 2

Spigot Side (d)
Bell Side (d)
Deg (F)
Inches
Trial 2Temp Stick Melt Back Distance

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448

Welding Process

Number of Passes Voltage Amperage Travel Speed

(inmin)Heat Input (Joulesin)

Trial 1 FCAW 1 26 200 86 36279 SMAW 2 28 110 67 27582

Trial 2 FCAW 1 24 180 89 29124 SMAW 2 29 110 75 25520

Trial 3 FCAW 1 22 200 100 26400 SMAW 2 30 150 71 38298

Trial 4 FCAW 1 20 180 92 23478 SMAW 2 30 150 70 38571

Trial 5 FCAW 1 24 220 79 39950 SMAW 2 27 140 65 34892

Trial 6 FCAW 1 24 190 84 32727 SMAW 2 27 140 57 39789

Trial 7 FCAW 1 23 190 93 28285 SMAW 2 26 130 68 29824

Trial 8 FCAW 1 23 190 93 28285 SMAW 2 27 140 52 43448

Heat Input

Note All SMAW Heat inputs were calculated on the second pass values

= (Joulesin)Voltage x Amperage x 60 Travel Speed

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448

Sheet1

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values
Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448

Sheet2

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values

Sheet3

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values

Welding Heat Input

bull Travel Speed is the most critical factor to heat applied during welding

bull Gaps in the pipe joint cause slower progress and therefore greater heat input

bull Quantity of metal deposited in a pass also affects heat input

Voltage Amperage Travel Speed (inmin)

Heat Input (Joulesin)

23 190 93 28285 26 130 107 19013 26 130 68 29824

FCAWSMAW - 1st Pass

Trial 7

SMAW - 2nd Pass

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values

Sheet1

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Heat Input Table
Welding Process Number of Passes Voltage Amperage Travel Speed (inmin) Heat Input (JoulesIn) Trial 7 Voltage Amperage Travel Speed (inmin) Heat Input (Joulesin)
Trial 1 FCAW 1 26 200 86 36279 FCAW 23 190 93 28285
SMAW 2 28 110 67 27582 SMAW - 1st Pass 26 130 107 19012
Trial 2 FCAW 1 24 180 89 29124 SMAW - 2nd Pass 26 130 68 29824
SMAW 2 29 110 75 25520
Trial 3 FCAW 1 22 200 100 26400
SMAW 2 30 150 71 38298
Trial 4 FCAW 1 20 180 92 23478
SMAW 2 30 150 70 38571
Trial 5 FCAW 1 24 220 79 39950
SMAW 2 27 140 65 34892
Trial 6 FCAW 1 24 190 84 32727
SMAW 2 27 140 57 39789
Trial 7 FCAW 1 23 190 93 28285
SMAW 2 26 130 68 29824
Trial 8 FCAW 1 23 190 93 28285
SMAW 2 27 140 52 43448
Note All SMAW Heat inputs were calculated on the second pass values

Sheet2

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Sheet3

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Weld-After-Backfill Trials

bull Temperature inside pipe amp under sleeve measured

T= 800-1000degFsleeve underside

T= gt800degFinside pipe wall

Compacted soil

Heat affected area

bull Conclusion High heat has an affect on the coating

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Eight Trials Completed

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Step down edge recovery due to heat effect at bell and spigot interface

Trial Photos ndash Effects of Heat

Crease in backing due to surface temp above the weld bead

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Peel testing note adhesive differences through heat affected area

Trial Photos ndash Adhesion Testing

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Peel test ndash note underlay adhesion

Trial Photos ndash Effects of Heat

PE backing visibly affected but adhesion good

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Field Trial San Antonio Water System

Note the dimpling from the backfill in the backing as a result of the weld heat

Pipe Size 60rdquo x 400rdquo

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Observations - Backings

bull Heated backings expand then contract as they cool Backfill pressure keeps the sleeve in place

bull Polyethylene backings in a single layer system will be affected as noted such that some reduction in mechanical properties may occur

bull Excessive gap in the pipe joint may allow heat flow-through which can affect the sleeve at the bell edge Keeping joints within tolerance very important to coating integrity

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Observations

bull Performance of a system is a result ofndash adhesives resistance to flow amp off-gas during

welding ndash the resistance of a backing to expand and contract

bull Some systems perform better becausendash adhesives with higher molecular weight fractions

have a lower propensity to off-gas and flowndash HDPE backings have more resistance to expansion

amp contraction

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Recommendations

bull Tight joint gap tolerancesbull Some specifiers request filler materials to

bridge the stepdown Heat tolerant fillers are then required such that they do not affect weld quality

bull Supply an underlay material that combines a thick low stretch HDPE backing and a butyl-based adhesive

bull Use a standard product as the outer sleeve

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Recommendations

bull Recommended system incorporates a specially designed underlay material and standard outer sleeve

bull Single layer systems possible and have been used successfully on thicker wall pipe

bull An extra layer provides assured protectionbull The growing use of WAB has created the

need to address the construction method on an industry wide level

Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

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Recommendations

bull At recent SWPMTAC meetings WAB text was proposed for inclusion in relevant standards

bull Requires that the system maintain minimum performance

bull In a demo of a single sleeve a peel test over the heat-affected area will yield a reduction in performance buthellip

bull It may still meet the requirements of the standard

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Recommendations

bull When an underlay material is used the underlay adhesive may be degraded but acts as sacrificial so the outer sleeve can be considered to be intact

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Weld-After-Backfill

bull The W-A-B construction method has advantages versus conventional weldingndash Improved safety during construction

bull Fewer obstructions inside pipebull Less risk from open trench outside pipe

ndash Improved Pipeline Integritybull Reduced thermal stressbull Consistent backfill

ndash Improved Productionbull Installation amp Welding on parallel pathsbull No interruptions for expansion joints

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

image2png

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the

outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside

joint at a later time (where internal welding is safe and practical) Welding inside field joints after

backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all

applicable AWWA standards are followed Consult with the manufacturers and all other responsible

parties regarding recommended products installation and backfill procedures required for the Weld-

After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing

or historical information to verify that the exterior joint coating will retain performance requirements as

per the applicable standard throughout the heat affected area

AWWA WAB Text

Weld-After-Backfill Weld-After-Backfill is the sequence of assembling a welded joint welding the outside joint (if required) applying the exterior coating(s) backfilling the pipe then welding the inside joint at a later time (where internal welding is safe and practical) Welding inside field joints after backfill (Weld-After-Backfill sequence) is an acceptable practice provided the requirements of all applicable AWWA standards are followed Consult with the manufacturers and all other responsible parties regarding recommended products installation and backfill procedures required for the Weld-After-Backfield sequence At the request of the purchaser the coating manufacturer will provide testing or historical information to verify that the exterior joint coating will retain performance requirements as per the applicable standard throughout the heat affected area

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