AWWA MANUAL

Chapter

11

D
D

Protective Coatings and

Linings

Coatings for corrosion control are extremely effective when properly used. They are
considered to be the primary line of defense against corrosion of steel pipeline systems.
Coating costs are only a fraction of pipeline costs, yet coating is the major means of ensuring
long-term operation by preventing pipeline deterioration and corrosion leaks.

lt.l REQUIREMENTS OF GOOD PIPELINE COATINGS

AND LININGS - - - - - - - - - - - - - - - The requirements of a coating vary with the type of construction, the aggressiveness of the
environment in which it will serve, and the system operating conditions. The effectiveness
of a good protective pipeline coating depends on its permanence and the degree to which it
possesses physical resistance to hazards of transportation, installation, temperature change,
soil stress, and pressure; resistance to water penetration or absorption; effective electrical
insulative properties; and chemical inertness to soil, air, water, organic acids, alkalies, and
bacterial action. Coating effectiveness also depends on such general characteristics as ease of
application, high adhesion, compatibility of use with cathodic protection, and reasonable
cost. 1
The requirements of a lining also vary with the system and the environment. In
addition to the factors considered for coatings, linings must be judged on their smoothness
(low flow resistance), and they must meet toxicological requirements for potable water.

11.2 SELECTION OF THE PROPER COATING AND LINING _ _ __

Selection and recommendation of the lining and coating materials for use on underground
and underwater steel pipelines is one of the most important activities of the engineer.

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Selection for a given use is a matter of assessing the magnitude of the corrosion, installation,
and service hazards. Testing procedures have been developed to aid the engineer in
evaluating and selecting the coating system that best meets a system's needs.2- 5
Requirements for external coating and internal lining are different, so each should be
considered separately with respect to the anticipated corrosion severity.

Coating Selection
The corrosion potential for the exterior of steel pipe is difficult to judge because of the
variety of environments encountered. Resistivity of the soil (see Table 10-3, Chapter 10) is
the most important parameter for judging soil corrosivity. Soil chemical and physical
analyses, pH, moisture content, and existence of stray electrical currents are also important
factors that can aid in making the selection decision.
After the level of soil corrosivity is assessed, the other conditions that affect the
long-term performance of protective coatings should be considered. 1 Among these are
distorting stresses exerted on the coating during compaction and settling of the
backfill;
mechanical stresses created by certain soils having very high expansion and
shrinkage during wet and dry cycles;
penetration by growing roots;
action of bacteria and fungus in soil surrounding the pipeline;
penetration by rocks, clods, or debris in the backfill;
attack by soil chemicals or industrial wastes, chemicals, and solvents that may be
present along the pipeline route.
Coating performance depends on putting the pipeline into service with the least
amount of coating damage. The coating system selected must not only meet the corrosioncontrol needs, but must also allow economical transport.ation, handling, storage, and
pipeline construction with minimal coating damage or repair. To ensure precise control of
coating application and quality, many types of coatings are applied in a plant or shop. The
coating manufacturer can provide a guide to the proper protection during transportation,
handling, and storage of pipe that has been coated with such a system. General guidelines
are given in a later section of this chapter. There are several recognized testing procedures
that are used in evaluating coating system characteristics related to transportation, storage,
and construction. 6- 11 Among the characteristics to be considered are
resistance of the coating to cold flow or penetration under mechanical loading,
resistance of the coating to ultraviolet exposure and temperature cycling during
outdoor storage,
resistance of the coating to abrasion and impact.

Lining Selection
The function of an internal lining is to prevent internal corrosion and to produce and
maintain a smooth surface to enhance flow capacity. Cement-mortar linings and coatings for
steel waterlines are durable and have provided many years ofexcellent service. Pipe surfaces
covered with cement-mortar are protected by the alkaline cement environment, which
passivates the steel and prevents iron corrosion in most natural environments. The
passivation occurs quickly in newly coated surfaces and is not destroyed by moisture and
oxygen absorbed through the mortar coating. Cement-mortar linings provide low hydraulic
frictional resistance, and any leached products from mortar lining carrying soft water are
nontoxic and anticorrosive.
Coal-tar enamel, coal-tar epoxy, and fusion -bonded epoxy exhibit excellent corrosionresistance properties and provide the required smoothness to maintain flow capacity. They

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1l 7

protect steel water lines by electrically insulating the coated pipe surfaces from the
environment. When reinforced, the coatings provide additional resistance to physical
damage.
Regardless of the lining material selected, consideration should be given to the effects of
cavitation and silts on the lining.

11.3 RECOMMENDEDCOATINGSANDLININGS - - - - - - Current AWW A standards list coatings and ljnings for steel water pipe that are believed to
be the most reliable, as proved in practice. The AWW A Steel Pipe Committee is alert,
however, to the possibilities of new developments, and additions to and modifications of
existing standards will be made as deemed advisable. The current list of AWW A coating and
lining standards for pipe protection is as follows:
A WWA C203, Standard for Coal-Tar Protective Coatings and Linings for
Steel Water Pipelines-Enamel and Tape-Hot-Applied. AWW A C203 12 describes
the material and application requirements for shop-applied coal-tar protective coatings and
linjngs for steel water pipelines intended for use under normal conditions when the
temperature of the water in the pipe will not exceed 90F (32C). The standard covers
coal-tar enamel applied to the interior and exterior of pipe, special sections, connections, and
fittings; it also covers hot-applied coal-tar tape applied to the exterior of special sections,
connections, and fittings.
Coal-tar enamel is applied over a coal-tar or synthetic primer. External coal-tar enamel
coatings use bonded asbestos-felt and fibrous-glass mat to reinforce and shield the coal-tar
enamel. The applied external coating is usually finished with either a coat of whitewash or a
single wrap of kraft paper.
Internally, the coal-tar enamel is used without reinforcement or shielding. The hot
enamel is spun into the pipe and provides a smooth internal lining having low hydraulic
frictional resistance.
The standard provides a rigid yet reasonable manufacturer's guide for the production of
the coating, calls for tests of material and its behavior to ensure the purchaser that the
product has the desired qualities, and furnishes directions for the effective application of the
coating.
AWW A C205, Standard for Cement-Mortar Protective Lining and Coating
for Steel Water Pipe-4 In. and Larger- Shop Applied. AWW A C205 14 describes
the material and application requirements to provide protective linings and coatings for steel
water pipe by shop application of cement mortar.
Cement mortar is composed of Portland cement, sand, and water, well mixed and of the
proper consistency to obtain a dense, homogeneous lining or coating. Internally, the cement
mortar is centrifugally compacted to remove excess water and produce a smooth, uniform
surface. Externally, the coating is a reinforced cement mortar, pneumatically or mechanically
applied to the pipe surface. Reinforcement consists of spiral wire, wire fabric, or ribbon
mesh. The standard provides a complete guide for application and curing of the mortar
lining and mortar coating.
A WWA C209, Standard for Cold-Applied Tape Coatings for the Exterior of
Special Sections, Connections, and Fittings for Steel Water Pipelines. AWW A
C209l5 covers the use of a cold primer and cold-applied tape on the exterior of special
sections, connections, and fittings for steel water pipelines installed underground in any soil
under normal or average conditions. Tapes with both polyvinyl chloride and polyethylene
backing are listed. The thicknesses of the tapes vary; however, all tapes may be sufficiently
overlapped to meet changing performance requirements. Cold-applied tapes provide ease of
application without the use of special equipment and can be applied over a broad application
temperature range. If severe construction or soil conditions exist where mechanical damage

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may occur, a suitable overwrap of an extra thickness of tape or other wrapping may be
required.
A WW A C210, Standard for Liquid Epoxy Coating Systems for the Interior
and Exterior of Steel Water Pipelines. AWWA C210 16 describes a liquid epoxy
coating system, suitable for potable water service, which will provide corrosion protection to
the interior and exterior of steel water pipe, fittings, and special sections installed
underground or underwater. The coating system consists of one coat of a two-part
chemically cured inhibitive epoxy primer, and one or more coats of a two-part chemically
cured epoxy finish coat. The finish coat may be a coal-tar epoxy coating, or it may be an
epoxy coating containing no coal tar. The coating system may alternately consist of two or
more coats of the same epoxy coating without the use of a separate primer, provided the
coating system meets the performance requirements of AWWA C210.
These coatings are suitable when used for corrosion prevention in water service systems
at temperatures up to 140F (60C). The products are applied by spray application,
preferably airless.
The liquid epoxy system described in the standard differs from the customary product
commercially available in that it has a very high flexibility, elongation, and impact
resistance. Any liquid epoxy offered for water utility purposes must meet the requirements
of AWWA C210.
AWWA C213, Standard for Fusion-Bonded Epoxy Coating for the Interior
and Exterior of Steel Water Pipelines. AWWA C213 17 describes the material and
application requirements for fusion-bonded epoxy protective coatings for the interior and
exterior of steel water pipe, special sections, welded joints, connections, and fittings of steel
water pipelines installed underground or underwater under normal construction conditions.
The epoxy coatings are suited for corrosion prevention in potable water systems operating at
temperatures up to 140F (60C).
Fusion-bonded epoxy coatings are heat activated, chemically cured coating systems.
The epoxy coatings are furnished in powder form. Except for welded field joints, they are
plant- or shop-applied to preheated pipe, special sections, connections, and fittings using
fluid bed, air, or electrostatic spray.
A WWA C214, Standard for Tape Coating Systems for the Exterior of Steel
Water Pipelines. AWWA C214 18 covers the materials, the systems, and the application
requirements for prefabricated cold-applied tapes for the exterior of all diameters of steel
water pipe placed by mechanical means. For normal construction conditions, prefabricated
cold-applied tapes are applied as a three-layer system consisting of ( 1) primer, (2) corrosion
preventive tape (inner layer), and (3) mechanical protective tape (outer layer). The primer is
supplied in the form of a liquid consisting of solid ingredients carried in a solvent. The
corrosion preventive tape and the mechanical protective tape are supplied in suitable
thicknesses and in roll form. The standard covers application at coating plants.
AWWA C602, Standard for Cement-Mortar Lining of Water Pipelines-4 In.
(100 mm) and Larger-In Place. A WWA C602 19 describes the materials and
application processes for the cement-mortar lining of pipelines in place, covering both newly
installed pipes and older pipelines. Detailed procedures are included for surface preparation
and application, surface finishing, and curing of the cement mortar.

11.4 COATING APPLICATION

This manual does not furnish details on methods of coating and paint application, but the
importance of obtaining proper application cannot be overemphasized. Effective results
cannot be secured with any coating material unless adequate care is taken in preparing the

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surfaces for coating, in applying the coating, and in handling the pipe after coating. AWW A
standards provide the requirements for obtaining good coating work. The coating
manufacturer, the applicator, and the engineer should all cooperate to see that the work is of
the prescribed quality. Many excellent sources of information have been published dealing
with the protection of steel pipe, the pitfalls of coating work, and the means of avoiding these
problems. 2021

Coating of Special Sections, Connections. and Fittings

The coating and lining of special sections, connections, and fittings are described in AWW A
Standards C203, C205, C209, C210, C213, C214, and C602. 12 I4-I 9 The materials used are
the same specified for use with steel water pipe. The methods of application may differ from
those prescribed for pipe because of the variety of physical configurations encountered.
Pipe joints are normally coated in the field with materials similar to those used on the
main body of the pipe. These are described in the appropriate AWW A coating standards.

11.5 GOOD PRACTICE - - - - - - - - - - - - - - The AWW A standards for protective coatings have been carefully prepared by experienced
individuals and are based on the best current practice. They should be used by incorporating
them in the job specification by direct reference. Modification should be made only by
experienced coating specialists.
For AWWA Standards C203, C205, C209, C210, C213, C214, and C602 12 14- 19 to be
complete for bidding purposes, the purchaser's job specifications must provide the
supplementary details required in each standard.

References
l. Control of External Corrosion on Underground or Submerged Metallic Piping
Systems. NACE Standard RP-01-69.
NACE, Houston, Texas (1983 revision).
2. Test for Cathodic Dis bonding of Pipeline
Coatings. ASTM Standard G8-79. ASTM,
Philadelphia, Pa. ( 1979).
3. Test for Water Penetration into Pipeline
Coatings. ASTM Standard G9-77. ASTM,
Philadelphia, Pa. (1977).
4. Test for Disbanding Characteristics of
Pipeline Coatings by Direct Soil Burial.
ASTM Standard Gl9-77. ASTM, Philadelphia, Pa. (1977).
5. Test for Chemical Resistance of Pipeline
Coatings. ASTM Standard G20-77.
ASTM, Philadelphia, Pa. (1977).
6. Test for Abrasion Resistance of Pipeline
Coatings. ASTM Standard G6-77. ASTM,
Philadelphia, Pa. ( 1977).
7. Test for Bendability of Pipeline Coatings.
ASTM Standard Gl0-77. ASTM, Philadelphia, Pa. (1977).
8. Test for Effects of Outdoor Weathering
on Pipeline Coatings. ASTM Standard
G 11-79. ASTM, Philadelphia, Pa. (1979).
9. Test for Impact Resistance of Pipeline
Coatings (Limestone Drop Test). ASTM

10.

11.
12.

13.
14.

15.

16.

Standard Gl3-77. ASTM, Philadelphia,

Pa. ( 1977).
Test for Impact Resistance of Pipeline
Coatings (Falling Weight Test). ASTM
Standard Gl4-77. ASTM, Philadelphia,
Pa. ( 1977).
Test for Penetration Resistance of Pipeline
Coatings (Blunt Rod). ASTM Standard
Gl7-77. ASTM, Philadelphia, Pa. (1977).
Coal-Tar Protective Coatings and Linings
for Steel Water Pipelines-Enamel and
Tape-Hot Applied. AWWA Standard
C203-78. AWWA, Denver, Colo. (1978).
(Reference deleted per errata issued in
June 1986.)
Cement-Mortar Protective Lining and
Coating for Steel Water Pipe-4 in. and
Larger- Shop Applied. AWWA Standard
C205-80. AWWA, Denver, Colo. ( 1980).
Cold-Applied Tape Coatings for the
Exterior of Special Sections, Connections,
and Fittings for Steel Water Pipelines.
AWW A Standard C209-84. AWW A,
Denver, Colo. ( 1984).
Liquid Epoxy Coating Systems for the
Interior and Exterior of Steel Water
Pipelines. AWWA Standard C210-84.
AWWA, Denver, Colo. ( 1984).

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17. Fusion-Bonded Epoxy Coating for the

Interior and Exterior of Steel Water
Pipelines. AWWA Standard C213-79.
AWWA, Denver, Colo. (1979).
18. Tape Coating Systems for the Exterior of
Steel Water Pipelines. AWW A Standard
C214-83. AWWA, Denver, Colo. ( 1983).
19. Cement-Mortar Lining of Water Pipelines-4 in. (100 rnm) and Larger-in
Place. AWW A Standard C602-83. AWW A,
Denver, Colo. (1983).

20. Good Painting Praccice-Volume l. Sy stems and Specifications- Volume 2. Steel

Structures Painting Manual. Steel Structures Painting Council, Pinsburgh, Pa.
21. Paine Manual. US BUREC, Denver, Colo.
(available from US Government Printing
Office, Washington, D.C.).