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BLUE BRUTE /big blue /ULTRA BLUE AWWA C900/C905/C909 ASTM F1483INSTALLATION GUIDEBuilding essentialsfor a better tomorrow

WARNINGRUPTURE HAZARDImproper installation or misuse of tapping tools may causepipes under high pressure to rupture and result in highvelocity airborne fragmentation leading to serious injuries. Before and during installation, always: C onsult and follow the FULL VERSION of the productinstallation guide Closely follow job specifications Use protective gear and equipment Before and during tapping, always: C onsult and follow Uni-Bell Publication Uni-PUB-08-07,“Tapping Guide for PVC Pressure Pipe.” Use the correct tapping tools B leed air from pipes at high spot before tapping Use protective gear and equipmentPlease contact JM Eagle Product Assurance at (800) 621-4404to obtain full version of the appropriate installation guideor for further assistance.

blue brute /big blue / ULTRA BLUE Contents1.0Receiving and Handling Pipe Shipments . . . . . . . . . . . . . . . . . . . . 81.1Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.2Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.3Cold Weather Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.4Stockpiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.5Gasket Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.6Loading Transfer Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.7Distributing Along the Trench . . . . . . . . . . . . . . . . . . . . . . . . 132.0Trench Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1Working Ahead of the Pipe Laying Crew . . . . . . . . . . . . . . . . 132.2Curves in the Trench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142.2.1Blue Brute AWWA C900 andUltra Blue AWWA C909 (4"-16") . . . . . . . . . . . . . . . . . . . . 142.2.2Big Blue AWWA C905 (14"- 48") . . . . . . . . . . . . . . . . . . . . . .152.3Trench Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.4Trench Depths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.5Planning for Thrusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.6Preparation of Trench Bottom . . . . . . . . . . . . . . . . . . . . . . . . 182.7Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.7.1Placement of Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.7.2Pulling the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.7.33.0Closure of Casing After Pipe Installation . . . . . . . 21Pipeline Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.1Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.2Lowering Pipe and Accessories into Trench . . . . . . . . . . 233.3Assembly of JM EAGLE PVC Pipe . . . . . . . . . . . . . . . . . . . . . . . 243.4Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.5Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.6Beveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.7Locating Reference Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.8Assembly at Fittings and Adaptors . . . . . . . . . . . . . . . . . . . 283.9Thrust Blocking and Anchorage at Fittings . . . . . . . . . . 293.9.1Determining Size and Type of Thrust Blocking . . . 293.9.2Upward Thrusts at Fittings . . . . . . . . . . . . . . . . . . . . . 323.9.3Anchorage of Pipe on Slopes . . . . . . . . . . . . . . . . . . . 323.9.4Anchorage of Valves in the Line . . . . . . . . . . . . . . . . . 333.9.5Construction of Thrust Backing . . . . . . . . . . . . . . . 333.10Installation at Hydrants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.11Thrust-Restraint Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.12Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.12.14.0Direct Taps, Saddles, and Valves . . . . . . . . . . . . . . . 35Pipe Embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354.1Bedding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.2Backfilling and Tamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.2.14.3Completing the Backfill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384.3.14.4Haunching and Initial Backfill . . . . . . . . . . . . . . . . . . 36Final Backfill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Compaction Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.04.4.1Tamping Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394.4.2Mechanical Tampers . . . . . . . . . . . . . . . . . . . . . . . . . . . 404.4.3Flood or Water Tamping . . . . . . . . . . . . . . . . . . . . . . . . 404.4.4Water-Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414.4.5Sheeting and Trench Boxes . . . . . . . . . . . . . . . . . . . . . 41Pipe Testing and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.1Pipe Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.1.15.2Deflection Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Testing Water Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425.2.1Filling the Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.2.2Relieving Air from the Line . . . . . . . . . . . . . . . . . . . . . 455.3Pressure-Strength Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.4Making Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.5Making Repairs to Damaged Pipelines . . . . . . . . . . . . . . . . . . 48Appendix 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

The physical (or chemical) properties of JM Eagle Blue Brute PVC C.I.O.D.Distribution Pipe (AWWA C900) ,Big Blue PVC C.I.O.D. Transmission Pipe (AWWAC905), Ultra Blue PVCO C.I.O.D. Distribution Pipe (AWWA C909), and UltraBlue PVCO I.P.S. Distribution Pipe (ASTM F1483) presented in this booklet,represent typical average values obtained in accordance with acceptedtest methods and are subject to normal manufacturing variations. Theyare supplied as a technical service and are subject to change withoutnotice. Check with JM Eagle Product Assurance to ensure currentinformation.How This Guide Can Help YouThis booklet was written especially for the installer and those who directactual handling and installation of JM Eagle PVC Blue Brute , Big Blue , andUltra Blue pipe. This guide should be used in conjunction with the followingindustry accepted installation and testing practices which are applicable.This document should not be considered a full guide or manual in lieu of:1. ASTM D2774-04 (or later) “Underground Installation of ThermoplasticPressure Piping.”2. ASTM F690-86 (2003) (or later) “Underground Installation ofThermoplastic Pressure Piping Irrigation Systems.”3. ASTM F1668-96 (2002) (or later) “Construction of Buried Plastic Pipe.”4. ASTM F645-04 (or later) “Selection, Design, and Installation ofThermoplastic Water-Pressure Piping Systems.”5. ASTM D2321-05 (or later) Underground Installation of ThermoplasticPipe for Sewers and Other Gravity-Flow Applications.”6. ASTM F1417-92 (2005) (or later) “Installation Acceptance of PlasticGravity Sewer Lines Using Low-Pressure Air.”7. AWWA C605 “Underground Installation of Polyvinyl Chloride (PVC)Pressure Pipe and Fittings for Water.”4BLUE BRUTE /BIG BLUE /ULTRA BLUE INSTALLATION GUIDE

8. AWWA C651 “Disinfecting Water Mains.”9. AWWA M23 “PVC Pipe – Design and Installation.”10. Uni-Bell UNI-PUB-09 “Installation Guide for PVC Pressure Pipe.”11. Uni-Bell UNI-B-6 “Recommended Practice for Low-Pressure AirTesting of Installed Sewer Pipe.”12. Uni-Bell UNI-Pub-06 “Installation Guide for PVC Solid-Wall SewerPipe (4-15 Inch).”13. Uni-Bell UNI-TR-1 “Deflection: The Pipe/Soil Mechanism.”14. Uni-Bell UNI-TR-6 “PVC Force Main Design.”15. Uni-Bell UNI-TR-7 “Thermoplastic Pressure Pipe Design and Selection.”This guide is meant as an explanatory supplement to the materials aboveon how to install JM Eagle PVC Blue Brute , Big Blue , and Ultra Blue pipe under normal conditions so as to comply with Standard JM Eagle Laying Specifications. Any discrepancies between the above standards andthe written information contained herein, should be brought to the attentionof JM Eagle Product Assurance immediately for resolution by JM Eagle ,prior to any actions by either contractor, engineer, or municipality.This guide is not intended to supply design information nor to assume theresponsibility of the engineer (or other customer representative) inestablishing procedures best suited to individual job conditions so as to attainsatisfactory performance.Engineers, superintendents, contractors, foremen, and laying crews will findmuch to guide them in the following specifications. This booklet will also beof help in determining pipe needs when ordering.BLUE BRUTE /BIG BLUE /ULTRA BLUE INSTALLATION GUIDE5

WarrantyJ-M Manufacturing Company Inc. (JM Eagle ) warrants that its standardpolyvinyl chloride (PVC), polyethylene (PE), conduit/plumbing/solvent weldand Acrylonitrile-Butadiene-Styrene (ABS) pipe products (“Products”)are manufactured in accordance with applicable industry specificationsreferenced on the Product and are free from defects in workmanshipand materials. Every claim under this warranty shall be void unless inwriting and received by JM Eagle within 30 days of the date the defectwas discovered, and within one year of the date of shipment from theJM Eagle plant. Claims for Product appearance defects, such as sunbleached pipe etc., however, must be made within 30 days of the date ofthe shipment from the JM Eagle plant. This warranty specifically excludesany Products allowed to become sun-bleached after shipment from theJM Eagle plant. Proof of purchase with the date thereof must be presented tothe satisfaction of JM Eagle , with any claim made pursuant to this warranty.JM Eagle must first be given an opportunity to inspect the alleged defectiveProducts in order to determine if it meets applicable industry standards, if thehandling and installation have been satisfactorily performed in accordancewith JM Eagle recommended practices and if operating conditions arewithin standards. Written permission and/or a Return Goods Authorization(RGA) must be obtained along with instructions for return shipment to JMEagle of any Products claimed to be defective.The limited and exclusive remedy for breach of this Limited Warranty shallbe, at JM Eagle’s sole discretion, the replacement of the same type, sizeand like quantity of non-defective Product, or credits, offsets or combinationof thereof, for the wholesale purchase price of the defective unit.This Limited Warranty does not apply for any Product failures causedby user’s flawed designs or specifications, unsatisfactory applications,improper installations, use in conjunction with incompatible materials,contact with aggressive chemical agents, freezing or overheating of liquidsin the Product, and any other misuse causes not listed here. This LimitedWarranty also excludes failure or damage caused by fire stopping materials,tread sealants, plasticized vinyl products or damage caused by the fault ornegligence of anyone other than JM Eagle , or any other act or event beyondthe control of JM Eagle .6BLUE BRUTE /BIG BLUE /ULTRA BLUE INSTALLATION GUIDE

JM Eagle’s liability shall not, at any time, exceed the actual wholesalepurchase price of the Product. The warranties in this document are theonly warranties applicable to the Product and there are no other warranties,expressed or implied. This Limited Warranty specifically excludes anyliability for general damages, consequential or incidental damages,including without limitation, costs incurred from removal, reinstallation,or other expenses resulting from any defect. IMPLIED WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARESPECIFICALLY DISCLAIMED AND JM Eagle SHALL NOT BE LIABLE INTHIS RESPECT NOTWITHSTANDING JM Eagle’s ACTUAL KNOWLEDGETHE PRODUCT’S INTENDED USE.JM Eagle’s Products should be used in accordance with standards setforth by local plumbing and building laws, codes or regulations and theapplicable standards. Failure to adhere to these standards shall void thisLimited Warranty. Products sold by JM Eagle that are manufactured byothers are warranted only to the extent and limits of the warranty of themanufacturer. No statement, conduct or description by JM Eagle or itsrepresentative, in addition to or beyond this Limited Warranty, shall constitutea warranty. This Limited Warranty may only be modified in writing signed byan officer of JM Eagle .BLUE BRUTE /BIG BLUE /ULTRA BLUE INSTALLATION GUIDE7

1.0 Receiving and Handling Pipe ShipmentsFigure 11.1 InspectionEach pipe shipment shall be inspected with care upon arrival. Each pipeshipment is carefully loaded at the factory using methods acceptable to thecarrier. The carrier is then responsible for delivering the pipe as receivedfrom JM Eagle . All shipments include an adequate amount of lubricantfor the pipe and a short form installation guide. IT IS THE RESPONSIBILTYOF THE RECEIVER TO MAKE CERTAIN THERE HAS BEEN NO LOSS ORDAMAGE (including smoke)