Pipeline Separation Design and

Installation Reference Guide

Version 9

May 2006
Publication Number 06-10-029
Pipeline Separation Design & Installation
Reference Guide

Version 9

Prepared by:
Washington State Water Reuse Workgroup
Washington State Department of Ecology
Water Quality Program
Washington State Department of Health
Office of Environmental Health and Safety

With Acknowledgment to Primary Authors:

Craig L. Riley, WDOH, Water Reclamation & Reuse Program
and
Michael Wilson, WDOH, Office of Drinking Water

July 2006
Publication Number 06-10-029
 You can print or download this document from our Web site at:
http://www.ecy.wa.gov/biblio/0610029.html

For more information contact:

Department of Ecology
Water Quality Program
Program Development Services Section
P.O. Box 47600
Olympia, WA 98504-7600

Telephone: 360-407-6401

Headquarters (Lacey) 360-407-6000

Regional
Whatcom Pend
San Juan Oreille
Office
location Skagit Okanogan
Northwest Stevens
Island Central Ferry
425-649-7000 509-575-2490
Clallam Snohomish
Chelan
Jefferson Spokane
Ki Bellevue
Douglas
ts Lincoln Spokane
ap
Grays King
Eastern
Harbor Mason
Kittitas Grant 509-329-3400
Pierce Adams Whitman
Lacey
Thurston
Southwest
Lewis
Pacific Yakima Franklin Garfield
360-407-6300
Wahki akum Yakima Columbia
Benton Walla Asotin
Cowlitz Skamania Walla

Klickitat
Clark

Persons with a hearing loss can call 711 for Washington Relay Service.
Persons with a speech disability can call 877-833-6341.

If you need this publication in an alternate format, please call the Water Quality
Program at 360-407-6401. Persons with hearing loss can call 711 for Washington Relay
Service. Persons with a speech disability can call 877-833-6341.
 Table of Contents

EXECUTIVE SUMMARY ................................................................................... 1

Introduction................................................................................................................... 1
Separation Standards..................................................................................................... 1
Separation-the Final Protection..................................................................................... 2
Special Construction Design......................................................................................... 2
Conclusions................................................................................................................... 2
INTRODUCTION ............................................................................................... 3
Need for this Guidance ................................................................................................. 3
Background ................................................................................................................... 3
The Need for Pipeline Separation ................................................................................. 4
Importance of adequate separation .................................................................. 4
Leakage Damage .............................................................................................. 4
Public Health and Safety Protection................................................................. 5
Product Contamination..................................................................................... 6
Maintenance & Repair...................................................................................... 7
Pipeline Separation Challenges..................................................................................... 8
PIPE SEPARATION STANDARDS ...................................................................... 9
Elements of Adequate Separation................................................................................. 9
Current Standard ........................................................................................................... 9
Published Separation Criteria .......................................................................... 9
Horizontal Separation..................................................................................... 10
Vertical Separation ......................................................................................... 11
Current States’ Standards............................................................................... 11
Engineering and Soils Mechanics Methods................................................................ 13
Soils Properties Impacts on Critical Trench Depth........................................ 14
Parallel Trench Separation vs. Critical Trench Depth................................... 15
MINIMUM PIPE SEPARATION DETERMINATION PROCEDURES ................... 18
General........................................................................................................................ 18
Current Procedures...................................................................................................... 18
Streamlined Procedures .............................................................................................. 18
Sidewall Safety Zone .................................................................................................. 18
Construction / Repair Work Space ................................................................. 19
Minimum Trench Sidewall Cover Depth......................................................... 20
Horizontal Dimension..................................................................................... 21
Minimum Pipe Cover ...................................................................................... 21
Design Review Conditions ......................................................................................... 22
Regulatory Approval Requirements................................................................ 22
Recommendations for Alternatives to Standard Separation for Condition B............. 24
Typical Construction Details – Condition B............................................................... 24
Case-by-case Approval Requirements – Condition C ................................................ 26

Pipeline Separation Design and Installation Reference Guide Page iii

 General ........................................................................................................... 26
Approval Requirements................................................................................... 26
Approval Process ............................................................................................ 26
Suggested Solutions ........................................................................................ 27
Common Utility Corridor Construction- Condition C.................................... 28
Pipeline Crossing – Condition C .................................................................... 29
ENGINEERING DESIGN AND LOCATION APPROACH .................................... 30
General Considerations .................................................................................. 30
Engineering Judgment .................................................................................... 30
Trench Protection ........................................................................................... 30
Basic Design Approach................................................................................... 30
Multiple Barriers of Protection ...................................................................... 30
Record Information Accuracy......................................................................... 31
Trigger Conditions.......................................................................................... 31
Design Considerations.................................................................................... 31
Specific Design Concerns ............................................................................... 32
Soil Strengths Data ......................................................................................... 32
Pipe Leakage................................................................................................... 33
Conditions Causing Leaks .............................................................................. 33
Pipeline Deterioration .................................................................................... 34
Mechanics of Pipe Failure Due to Leaks........................................................ 34
Allowable Leakage.......................................................................................... 35
Excavation Site Conditions ............................................................................. 35
Repair and Replacement Excavations ............................................................ 36
CONCLUSIONS ............................................................................................... 37

Table of Figures

Figure 1: Pavement damage due to pipe leak ..................................................................... 4

Figure 2: Water line break repair ........................................................................................ 5
Figure 3: Sewer break ......................................................................................................... 5
Figure 4: Pipeline exposure during repair........................................................................... 6
Figure 5: Waterline exposed by sewer collapse.................................................................. 7
Figure 6: Collateral utility damage due to sewer collapse.................................................. 7
Figure 7: Standard horizontal pipe separation detail ........................................................ 10
Figure 8: Standard horizontal pipe separation new construction detail of reclaimed
water in developed utility corridor .................................................................... 10
Figure 9: Standard pipe crossing new construction detail - vertical separation .............. 11
Figures 10 and 11: Mechanism for parallel trench collapse ............................................ 13
Figure 12: Critical trench depth based on soils properties............................................... 15

Page iv Pipeline Separation Design and Installation Reference Guide

Figure 13: Parallel pipe excavation mechanics................................................................ 15
Figure 15: Causes of cave-ins (trench surcharges) from Saskatchewan Labour
Ministry .......................................................................................................... 20
Figure 16: Pipe separation assessment decision tree ....................................................... 23
Figure 17: Typical benched - common trench construction detail .................................. 25
Figure 18: Typical pipe crossing construction detail Condition B separation................. 25
Figure 19: Condition C utility tunnel............................................................................... 27
Figure 20: Common underground utility corridor ........................................................... 28
Figure 21: Condition C -vertical pipe crossing................................................................ 29
Figure 22. Lincoln and Spokane county soil types .......................................................... 33
Figure 24: Sand boils resulting from joint failure............................................................ 34
Figure 25: Typical trench surcharge conditions............................................................... 36
Figure 26: Field conditions - typical trench surcharge .................................................... 36

List of Tables
Table 1: Utility separation regulations and standards from various states ...................... 12
Table 2: Soil Strength Properties ..................................................................................... 14
Table 3: Estimates of horizontal pipe separation vs. critical trench depth for
water line buried at 3.5 feet................................................................................ 16
Table 4: Estimates of horizontal pipe separation vs. critical trench depth for sanitary
sewer line buried at 6.0 feet ............................................................................... 16
Table 5: Trench sidewall cover estimate ......................................................................... 21
Table 6: Conditions for separation in design with space available.................................. 22
Table 7. An Example of soils information from the NRCS Web site.............................. 32
Table 8. Allowable leakage based on standard specifications......................................... 35

Pipeline Separation Design and Installation Reference Guide Page v

Page vi Pipeline Separation Design and Installation Reference Guide
Executive Summary
Introduction
As water reclamation and recycling assumes a larger and more important role in the
management of water resources, challenges in designing and locating piping systems for
the distribution of reclaimed water are daunting. Existing standards require horizontal
and vertical separations between potable water, reclaimed water, storm water and sanitary
sewage that are rarely available in developed urban areas. While special construction
practices are allowed to overcome these obstacles, regulatory approval is required on a
case-by-case basis. This process is cumbersome, and increases design and construction
costs, as well as the completion schedules. The Washington State Department of
Ecology and the Department of Health developed this guidance in response to the need
for a streamlined process and to assist utility engineers with pipeline separation design
and installation.

Pipeline separation is a necessity for protection of public health and safety, property and
the quality of the pipeline contents. Pipeline failure or leaks can result in pipeline
contamination that increases risks public health and safety. Pipelines do not have to
rupture completely or collapse to cause concern. Even the process of excavating one
pipeline to repair a leak creates the risk of complete failure of adjacent pipelines.

Separation Standards
The current pipeline separation standards are based on accumulated field and design
experience, and the Ten State Standards. 1 These standards generally require a minimum
horizontal separation of 10 feet between parallel pipes, and 18 inches of vertical
separation. Many states have adopted these standards as guidance or regulation.

In 1968, engineers at Utah State University investigated the effects of trench excavation
on separation distances from a buried parallel pipe. Their work resulted in a relationship
between the distance from the trench face to the parallel pipe [sidewall thickness, X]
necessary to prevent trench wall failure, the critical trench depth [Z], which depends on
soil strength characteristics; the depth of bury [H] of the parallel pipe; and size of the
parallel pipe [D]:

X H
= 3⋅
D Z

An analysis using this relationship shows that, in some instances, distances less than the
standard horizontal separation distance can be justified. However, this distance is highly
dependent on site and soil conditions. In almost all conditions, a minimum sidewall
coverage depth of 2 to 3 feet is necessary to allow sufficient room for maintenance and
repair efforts in the trench, the minimum pipe-to-pipe separation should be 3½ to 4 feet.

1
Great Lakes Upper Mississippi River Board of State Public Health and Environmental Managers –
Recommended Standards of Water Works, Criteria for Water Works, Section 8.6.

Pipeline Separation Design & Installation Reference Guide Page 1

Separation-the Final Protection
Pipeline separation provides the final barrier of protection in the multi-barrier approach to
pipeline protection. Other barriers include: 1) the selection of the pipe material, 2) pipe
jointing method, 3) pipe bedding procedures and 4) thrust restraint or blocking. Barriers
are intended to reduce risks to public health and safety; protect property; prevent
contamination of the pipeline contents; protect pipeline customers and prevent collateral
damage to other adjacent facilities. Pipeline separation is the final and most important
barrier because it remains in place when the other barriers fail.

Special Construction Design

Most urbanized areas do not have the space available for standard separation distances.
However, special construction methods can be used to assure equivalent levels of
protection. Special construction methods are necessary whenever the minimum
horizontal and vertical separations cannot be maintained. There are many common
methods in use today. In selecting the special construction method and design, the design
engineer needs to consider design factors such as external forces, impacts of ground
water, and soils-strength characteristics.

Conclusions
To streamline the design and approval process, the agencies have identified three design
conditions.
Š Condition A exists when adequate separation distance is available and requires no
unusual design considerations.
Š Condition B exists when available horizontal separation is between 4 and 10 feet,
and/or available vertical separation is between 6 and 18 inches. For Condition B,
special construction methods developed, presented, and approved during the
engineering phase of the project and included in the construction drawings
through standard details are acceptable.
Š When Condition C exists, available separation is less than 4 feet horizontally
and/or 6 inches vertically. Under Condition C, the agencies must approve special
construction on a case-by-case basis.

Page 2 Pipeline Separation Design & Installation Reference Guide

Introduction
Need for this Guidance
The installation of reclaimed water transmission and distribution piping is a major portion
of any water reclamation project. The cost of piping and the challenges in fitting
additional buried utilities into crowded utility corridors is often a deciding factor in
assessing the project feasibility. Compliance with commonly used standards for
horizontal and vertical pipe separation is proving difficult for nearly every project.
Currently, the Department of Health and the Department of Ecology (the agencies) have
allowed variations from these standards on a case-by-case approval basis. This approach
is cumbersome and time consuming for the utility and the regulatory agencies. The
agencies recognized the need for a more streamlined, responsive approach.

The agencies developed this guidance to streamline the approach to pipeline separation.
These guidelines:
Š Provide background information regarding the basis for pipeline separation
standards;
Š Describe the present standards developed from experience and soils mechanics;
Š Describe modes of pipeline failure, the results of pipe failure, and factors that
should be considered in the design of special conditions, and
Š Provide general design guidance regarding approaches that can be approved by
the regulatory agencies and can be applied without case-by-case, individual
location approvals.

Background
Underground utility pipes provide the core services necessary to urban life. Drinking
water transmission and distribution, wastewater collection and stormwater drainage
systems now share underground corridors with natural gas, telecommunications,
television and electrical power. In many water-limited areas, piped irrigation water lines
are common, with reclaimed water being added to the collection of buried utilities. In
order to allow access for maintenance and repair, utilities must compete for precious
space in increasingly congested public right-of-ways.

The design of underground utilities commonly focuses on the selection of the pipe size to
assure manageable pipeline velocities and internal pressure ratings. Other design
concerns include:
Š Pipe materials to address service life and product quality
Š Pipe wall thickness to address internal and external pressures and forces
Š Corrosion control needs and methods
Š Valves for isolation and drainage
Š Pipe jointing methods and
Š Thrust restraint and control

Pipeline Separation Design & Installation Reference Guide Page 3

During the design phase, engineers may not focus on the impact of existing, adjacent
pipelines. This is because a construction project focuses on isolating, protecting, and
addressing these conditions on a large scale. The original design should also address the
needs during maintenance and repairs. Unfortunately, many pipeline failures occur
because of the lack of attention to affects on and from existing pipelines.

The Need for Pipeline Separation

Importance of adequate separation
Many people do not easily understand or recognize the role of pipeline separation in
protecting public health and the environment. However, pipeline contamination can
expose pipeline customers to pollutants. Contamination results from cross-connections,
leaks, or complete pipe failure of adjacent underground pipes. Pipeline designers can
increase pipeline reliability through the proper selection of pipe materials, wall thickness,
pipe joint systems, thrust restraint systems, pipe bedding, and internal and external
corrosion control. But ultimately, pipelines corrode, leak, and fail. Adequate separation
between pipelines provides the final barrier of protection. This minimizes incidental
damage during the repair of other pipelines
and leakage effects between pipes.
Adequate separation also assures sufficient
room to repair leaks and replace broken
sections. Finally, separation reduces the
potential for pipeline failure caused by a
leak or failure of its neighboring pipeline.
Figure 1: Pavement damage due to pipe leak
Leakage Damage
The benefits provided by assuring pipeline
integrity are neither readily recognized nor
easily quantified, until a problem arises. Figure 1: Pavement damage due to
Underground pipelines are out of sight, and pipe leak
out of mind. Commonly, we are aware of problems with these buried pipes only when a
water line break shuts water off at home, or a sewer backs up into the basement. But
these two instances represent inconveniences compared to more common results from
pipeline leaks. The following photos show graphic damage created by leaking municipal
utilities. Figure 1 shows pavement damage due to a leaking sewer and the consequences
of a water main break in a residential area. Figures 2 and 3 show extensive damage
caused to neighborhood streets by the collapse of a water or sewer line.

Page 4 Pipeline Separation Design & Installation Reference Guide

Public Health and
Safety Protection
In extreme cases, attempts
to repair damage to
pipelines and the leaks
from the pipeline can
result in the death of
utility workers. Between
1992 and 2001, 542
fatalities occurred in the
United States that were
attributed to trench and
excavation cave-ins. 2
However, fatalities are
not limited to utility
workers alone. A leaking
water main in North Carolina
Figure 2: Water line break repair
was implicated in a mudslide.
The mudslide, in turn, caused
the road to collapse into a house, killing a resident.
Figure 2: Water line break repair
The risk to public safety is obvious. The extent of property damage and injury can range
from slight to catastrophic.

All piped utilities suffer

damage, aging and
wear. These problems
can allow leakage or
infiltration of ground
water into the pipe.
This reduces the quality
of the pipeline contents
and results in
additional costs for
delivery, maintenance,
or disposal of the pipe
contents.
Figure 3: Sewer break
Leaks in potable water
lines can pose a
significant health risk. Figure 3: Sewer break
In addition, they can
cause a loss of revenue
from a water system that has an investment in the withdrawal, treatment, and distribution.

2
Centers for Disease Control, Occupational Fatalities During Trenching and Excavation Work --- United
States, 1992—2001, April 23, 2004

Pipeline Separation Design & Installation Reference Guide Page 5

Potable distribution and reclaimed water pipelines that operate under pressure and are
subject to customer demands, fluctuating reservoir levels, and pump operation cycles.
Hydraulic transients result from pump starts and stops, power failures, main breaks
system operation, or sudden demand changes. This can result in both pressure surges and
negative pressure conditions in the pipe. 3 Leaks may push water out of the pipeline, as
well as pull water, soil, and naturally-occurring microbes back into the pipelines. This
can result in contamination of the pipeline contents from micro-organisms and chemicals
present in the soils surrounding the pipeline. These micro-organisms inoculate the pipe
and support microbiologic regrowth. Pathogenic microorganisms are often more prolific
in microbiologic regrowth materials.

Product Contamination
Pipe leaks or breaks can cause contaminants to spread into the environment or from pipe
to pipe. Either condition requires pipe repair to maintain product quality. During the
excavation and repair of one
pipe, adjacent pipes remain in
service and vulnerable to
failure. Pipes exposed or
damaged during an
excavation repair of an
adjacent pipe (Figure 4) often
represent the largest source of
leaks. Pipelines undergoing
repair provide the best
opportunity for contaminants
to enter large openings
created during the repair
process.
Figure 4: Pipeline exposure during repair

Figure 4: Pipeline exposure during repair Contamination of the

contents of underground
pipelines occurs when the contents of one pipe leaks out and into the soil, and then is
drawn into an adjacent underground pipe. Even small leaks present a contaminant
source. Materials outside the pipe can be drawn into the pipe during pressure surges and
vacuum conditions created by hydraulic transients.

Pipe-to-pipe contamination includes: 1) raw sewage leaking into water mains, 2)

chemical leakage into reclaimed water mains, 3) raw ground water leaks entering potable
pipelines, or 4) contaminated soil being drawn into drinking water systems. Raw sewage,
petroleum, or chemical products can leak into the environment causing environmental
degradation. In the case of natural gas pipelines, leaks can cause explosions.

3
Gullick, LeChevallier, Svindland, & Friedman, Occurrence of Transient Low and Negative Pressures in
Distribution Systems, Journal AWWA, 96:11; November 2004

Page 6 Pipeline Separation Design & Installation Reference Guide

Collateral Damage
All underground utilities are
at risk of a leak or pipe
failure. The leak or failure
can severely damage adjacent
utilities. The collapse of a
sewer can cause damage to
adjacent utilities, as depicted
in Figure 5. This figure
shows a worker standing on a
water main as the excavation
is being dewatered from
another portion of the hole.
Figure 6 shows damage to
electrical, gas, and telephone
utilities.
Figure 5: Waterline exposed by sewer collapse Figure 5: Waterline exposed by sewer collapse
Maintenance & Repair
All underground pipelines
eventually require
maintenance and repair. In
an effort to maximize their
water resources, public water
systems increasingly require
leak detection and correction.
Maintenance to repair small
leaks, broken valves, or
leaking valve stems requires
excavation to access the pipe
or valves.
Figure 6: Collateral utility damage due to sewer collapse

The process of locating and

exposing underground
utilities for repair places
other buried utilities in
jeopardy of creating more Figure 6: Collateral utility damage due to sewer
leakage from movement of collapse
unsupported, exposed joints, or directly from excavation equipment. Primary
components of any maintenance program include 1) ease of access for maintenance and
2) repair and protection of workers and adjacent utilities. Proper design decisions ease
future maintenance just as poor design decisions complicate repair or replacement.

Pipeline Separation Design & Installation Reference Guide Page 7

Pipeline Separation Challenges
The protective barrier provided by adequate separation creates additional design and
economic challenges. With increasing needs, utilities must maximize utility corridors in
public right-of-ways. Either utilities must widen utility corridors at great expense for
additional land, if available, or remove and relocate an existing utility.

Alternatively engineers can devise strategies that will provide an equivalent level of
protection as that afforded by adequate spacing. This alternative process requires more
time; and stretches completion schedules. However, the benefits include reliability and
protection for public health and safety, with potential savings in construction materials
and effort.

Page 8 Pipeline Separation Design & Installation Reference Guide

Pipe Separation Standards
Elements of Adequate Separation
Excavations are made to install or repair underground pipes. To do so, provide sufficient
room between the trench wall and the pipe on both sides to conduct the work. The
agencies recommend a 12- to 18-inch minimum distance.

The design adage holds very true for underground pipelines:

All of the really important mistakes are made the first day (during design).

The design must focus on maintenance and repair, not just the installation of a new
pipeline.

Current Standard
The current pipeline separation standards address conditions where potable and non-
potable pipelines run parallel to each other, and where these pipelines cross vertically.
The best-known standards are those published in well-known and used utility design
guidelines and standards. However, parallel separation requirements follow the
principles of soil mechanics. The approach based on soil mechanics provides a basis for
reduction of horizontal separations under some conditions, and reinforces the need for
significant separations in others.

Published Separation Criteria

The current standards are based on standard practices developed decades ago and
published as the Ten State Standards. 4 These standards have been widely adopted and
can now be found in other industry standards and state regulations such as:

Š American Water Works Association - Manual M24- Dual Distribution Systems

and California –Nevada Section AWWA – Guidelines for Distribution of
Nonpotable Water
Š Washington State Department of Ecology – Criteria for Sewage Works Design
Š Washington State Department of Health – Water System Design Manual

The current standards require a minimum horizontal separation of 10 feet between

separate trenches, and vertical separations of at least 18 inches. Pipe crossings require a
minimum vertical separation of 18 inches with the section of the top pipe centered over
the bottom. When these separations cannot be provided, special construction methods
must be provided.

4
Ibid 1

Pipeline Separation Design & Installation Reference Guide Page 9

Horizontal Separation
The minimum horizontal separation required between potable and reclaimed water
pipelines that run parallel to other nonpotable pipelines is 10 feet of clear, pipe-to-pipe
separation. Figure 7 provides a cross-section of a typical urban street with drinking water
pipelines, reclaimed water distribution pipes and sanitary sewers. Figure 8 illustrates a
typical cross-section after a reclaimed water retrofit.

Figure 7: Standard horizontal pipe separation detail

Figure 8: Standard horizontal pipe separation new construction

detail of reclaimed water in developed utility corridor

Page 10 Pipeline Separation Design & Installation Reference Guide

Vertical Separation
The minimum vertical separation between potable and nonpotable pipelines at crossings
is 18 inches (Figure 9). Potable water lines should cross above the nonpotable lines.
When the nonpotable line must cross above the potable pipeline, the engineer should
encase one or both of the pipelines encased with a pressure rated casing pipe extending at
least 10 feet on either side of the crossing.

Figure 9: Standard pipe crossing new construction detail - vertical separation

Current States’ Standards

While many states have adopted the Ten State Standards as regulation, several other
states have adopted different pipeline separation standards. Some regulations address
only water and sewer separations, while others address water, reclaimed water, and
sanitary sewer separations jointly or separately. Unfortunately, the standards do not
provide a great deal of consistency regarding horizontal and vertical separations, other
than the requirements to provide a minimum separation. Table 1 provides a summary of
pipeline separation standards for several states.

Pipeline Separation Design & Installation Reference Guide Page 11

 Table 1: Utility separation regulations and standards from various states
State Drinking Drinking Water Reclaimed Source of Standard Notes
Water-Sanitary – Reclaimed Water – Sanitary
Sewer Water Sewer
Utah 10 ft horizontal 10 ft horizontal 10 ft horizontal Utah Administrative If reclaimed water
or 3 ft Code is below or above
horizontal sewer
Massachusetts 10 ft horizontal Not addressed 2001 Guidelines and Reclaimed water
Policies for Public not specifically
Water Systems addressed
Oklahoma 10 ft horizontal 5 ft horizontal Not addressed Oklahoma Sewer and water
Regulations for line cannot
Public Water occupy same
Systems; Water trench
Pollution Control
Facility Construction
California 10 ft horizontal Reference to Reference to California Safe If unable to meet
& 1 ft vertical Cal-Nevada Cal-Nevada Drinking Water Act separation;
AWWA AWWA separation as far
Guidelines for Guidelines for as possible in
Distribution of Distribution of separate trenches
Non-Potable Non-Potable
Water Water
Georgia 10 ft horizontal 3 ft outside to 3 ft outside to Georgia Guidelines Maximum
Not is same outside of pipe, outside of pipe for Water obtainable
trench with 18 inches from Reclamation and separation
sewer bottom of water Urban Water Reuse possible; water-
and top of reuse & Minimum sewer separations
Standards for Public less than 10 ft –
Water Systems case by case
review
Texas 9’ outside to Not specifically Not specifically Texas Administrative Parallel
outside in all addressed addressed Code, Title 30, Part installations
directions 1, Chapter 290.44 require separate
trenches
Texas Special Non-pressure sewers: PE determination of no leaks; water 2 ft above, minimum 4 ft horizontal
Conditions New waterline: minimum 150 psi pressure rated pipe; water 2 ft above, minimum 4 ft horizontal
Crossings: water 2 ft above sewer; if sewer leaking – replace 9 ft either side of water (18’ total) with
150 psi rates pipe; New water line installation above sewer – segment centered over sewer 9 ft to
joint both directions; New water over existing non pressure sewer – water centered over sewer, sewer
to have minimum pipe stiffness of 150 psi at 5% deflection, sewer embedded in cement stabilized
sand [2½ bags cementer per cubic yard of mixture] 6 inches above and 4 inches below sewer

Page 12 Pipeline Separation Design & Installation Reference Guide

Engineering and Soils Mechanics Methods
Research at Utah State University in 1968 identified mechanisms of failure and trench
collapse for the excavation of parallel trenches. The researchers identified mechanisms
for failure of a parallel buried pipe related to the separation distance to a newly excavated
trench. They also developed design guidance to assure adequate separation from the
trench wall to the parallel pipe. The information and the following illustrations in
Figures 10 and 11 were taken from Structural Mechanics of Buried Pipes. 5

The result was a dimensionless

relationship that correlates the
diameter of the buried pipe (D),
the depth of bury of the pipe (H),
the critical trench depth (Z), and
the side-wall cover, or minimum
horizontal spacing from the
trench face to the face of the pipe
(X). The ratio between the
critical trench depth and the
depth of bury of the pipe, and the
ratio between side-wall cover to
pipe size is given by Equation 1:

X H
= 3×
D Z
Where:
Figures 10 and 11: Mechanism for parallel trench collapse

X = side cover or minimum

horizontal spacing, feet
D = pipe diameter, feet
H = depth of bury of the pipe,
feet
Z = critical trench depth, feet
Figures 10 and 11: Mechanism for parallel trench collapse
The critical trench depth (Z)
is the depth at which the native soil will stand in a vertical cut without sloughing or
raveling. The engineer can estimate critical trench depth based on field experience, from
a field cut, or estimated from the principles of soils mechanics. The soils mechanics
method uses soils properties of unit soil weight (pcf [γ]), soil cohesion (psf [C]), and the
soil friction angle of the trench wall ([φ]) as follows:

5
Reynold King Watkins, PhD., P.E. and Loren Runar Anderson, PhD., Structural Mechanics of Buried Pipes, Utah
State University, CRC Press, 2000, ISBN 0-8493-2395-9

Pipeline Separation Design & Installation Reference Guide Page 13

Equation 2:

2C
= tan[ 45° − ϕ ] or Z =
[2C ]
γZ 2 ⎡ ⎛ ϕ ⎞⎤
⎢γ tan ⎜ 45° − 2 ⎟⎥
⎣ ⎝ ⎠⎦

Soils Properties Impacts on Critical Trench Depth

Critical trench depth is directly depended upon the soil cohesive strength, C. Typical
strength characteristics of soils are shown in Table 2 below. 6

Table 2: Soil Strength Properties

Group Soil density, g, Soil friction
Symbol pcf Cohesion, C, psf angle Description
Minimum Maximum Compacted Saturated ϕ, degrees, o
GW 125 135 0 0 38 well graded, clean sands, gravel sand mixtures
GP 115 125 0 0 37 poorly graded clean gravels, gravel-sand mixture
GM 120 135 - - 34 silty gravels, poor graded gravel - sand silt
GC 115 130 - - 31 clayey gravels, poorly graded gravel-sand-clay
SW 111 130 0 0 38 well graded clean sands, gravely sands
SP 100 120 0 0 37 poorly graded clean sands sand-gravel mix
SM 110 125 1050 420 34 silty sands, poorly graded sand-silt mix
SM-SC 100 130 1050 300 33 sand-silt-clay mix with slightly plastic fines
SC 105 125 1550 230 31 clayey sands, poorly graded sand-clay mix
ML 95 120 1400 190 32 inorganic silts and clayey silts
ML-CL 100 120 1350 460 32 mixture of organic silt and clay
CL 95 120 1800 270 28 inorganic clays of low-to-medium plasticity
OL 80 100 - - - organic silts and silt-clays, low plasticity
MH 70 95 1500 420 25 inorganic clayey silts, elastic silts
CH 75 105 2150 230 19 inorganic clays of high plasticity
OH 65 100 - - organic and silty clays

Table 2 also displays the effect of soil properties on basic soil strength. Coarse-grained
soils such as sands and gravels exhibit no cohesive force, which would result in predicted
critical trench depths (Z) of zero. The presence of ground water also greatly influences
soils strength. Under saturated conditions, cohesive soils such as clays, which normally
exhibit significant cohesive strength, develop cohesive strength that is often less than ⅓
of the dry, compacted value. Critical trench depth depends on soil density.

Figure 12 shows a comparison of predicted critical trench depths related to soils

classifications in cohesive soils based on the range of reported soil densities and the
condition of the soils.

6
Civil Engineering Reference Manual, Professional Publications, Inc., San Carlos CA; Page 9-17

Page 14 Pipeline Separation Design & Installation Reference Guide

 Critical Trench Depth Predicted by Soils Mechanics
Minimum Soil
90
Density
Compacted
80

Critical Trench Depth, ft

70 Minimum Soil
60 Density
Saturated
50

40 Maximum Soil
30 Density
Compacted
20

10
Maximum Soil
- Density
SM SM-SC SC ML ML-CL CL MH CH Saturated
Soils Classification

Figure 12: Critical trench depth based on soils properties

Cohesive soils have a wide range of predicted critical trench depths. The differences in
the predicted critical trench depths for cohesive soils are noteworthy. These predictions
reinforce the need to base design decisions on the worst-case excavation conditions
expected along the pipeline route.

Parallel Trench Separation vs. Critical Trench Depth:

Estimates of pipe and trench separation distances based on soils properties and critical
trench depths help confirm the written standards. Equation #1 can predict horizontal
trench wall-to-pipe and pipe-to-pipe separation. Engineers should design separation to
include sufficient space between the pipe and the trench wall for construction or repair
activities at least 12 inches, and preferably 18 inches wide as shown in Figure 13.

Figure 13: Parallel pipe excavation mechanics

Tables 3 and 4 illustrate the affect of soils properties and the size and depth of cover of an
adjacent pipe on minimum sidewall coverage or horizontal spacing. These tables predict

Pipeline Separation Design & Installation Reference Guide Page 15

the sidewall cover thickness required for excavation parallel to a water line and a sanitary
sewer based on Equation 1. The calculations in Table 3 assume the water line is buried at
a typical depth of 3½ feet, and varies from 6 inches to 24 inches in diameter. The
calculations in Table 4 assume the sanitary sewer is buried at a typical depth of 6 feet,
and varies in size from 6 inches to 24 inches.

Table 3: Estimates of horizontal pipe separation vs. critical trench depth for water
line buried at 3.5 feet

Horizontal Separation Requirements for Parallel Pipes

X/D = 3H/Z & X = 3HD/Z

Burial Depth, H, ft = 3.5 feet Parallel Waterline

Pipe Diameter, D, inches
Critical
Depth, Z, ft 6 8 10 12 15 18 24
2.00 2.6 3.5 4.4 5.3 6.6 7.9 10.5
2.50 2.1 2.8 3.5 4.2 5.3 6.3 8.4
3.00 1.8 2.3 2.9 3.5 4.4 5.3 7.0
3.50 1.5 2.0 2.5 3.0 3.8 4.5 6.0
4.00 1.3 1.8 2.2 2.6 3.3 3.9 5.3
4.50 1.2 1.6 1.9 2.3 2.9 3.5 4.7
5.00 1.1 1.4 1.8 2.1 2.6 3.2 4.2
5.50 1.0 1.3 1.6 1.9 2.4 2.9 3.8
6.00 0.9 1.2 1.5 1.8 2.2 2.6 3.5

Table 4: Estimates of horizontal pipe separation vs. critical trench depth for
sanitary sewer line buried at 6.0 feet

Horizontal Separation Requirements for Parallel Pipes

X/D = 3H/Z & X = 3HD/Z

Burial Depth, H, ft = 6.0 feet Parallel Sanitary Sewer

Pipe Diameter, D, inches
Critical
Depth, Z, ft 6 8 10 12 15 18 24
2.00 4.5 6.0 7.5 9.0 11.3 13.5 18.0
2.50 3.6 4.8 6.0 7.2 9.0 10.8 14.4
3.00 3.0 4.0 5.0 6.0 7.5 9.0 12.0
3.50 2.6 3.4 4.3 5.1 6.4 7.7 10.3
4.00 2.3 3.0 3.8 4.5 5.6 6.8 9.0
4.50 2.0 2.7 3.3 4.0 5.0 6.0 8.0
5.00 1.8 2.4 3.0 3.6 4.5 5.4 7.2
5.50 1.6 2.2 2.7 3.3 4.1 4.9 6.5
6.00 1.5 2.0 2.5 3.0 3.8 4.5 6.0

Page 16 Pipeline Separation Design & Installation Reference Guide

As an example, a project engineer proposes a new pipeline installation parallel to and
below an existing 18 inch-diameter waterline that is buried 42 inches (3½ feet) deep. If
the soils along the project route are cohesive and stand to a critical trench depth of 3 feet,
the engineer should provide a minimum trench side wall thickness of 5.3 feet. The
design should also include an 18 inch work space. Thus, the design should provide
minimum pipe-to-pipe horizontal separation of 6.8 feet (5.3 + 1.5).

These examples shown in the tables reveal that, in addition to soils strength, the size and
depth of bury of the adjacent parallel pipe have a significant effect on minimum side wall
cover thickness. By including a minimum 18 inch repair zone, the minimum pipe-to-pipe
separation in a soil exhibiting a critical trench depth of 4 feet varies from: :

Š 3 to 4 feet for typical water distribution pipes of up to 10 inches in diameter at

relatively shallow depths of bury (i.e., 42 inches-Table 3) and
Š 4½ to 5 feet for typical sanitary sewers at relatively shallow depths of bury (i.e., 6
feet – Table 4).

For lower strength soils that will sustain only a 2-foot vertical trench wall, the minimum
required separations increase to 4 to 6 feet for the shallow water line and 7½ to 9 feet for
the shallow sanitary sewer.

These computations illustrate the variability estimated for minimum pipeline separation
distances when the engineer knows the soil properties and has accurate knowledge of the
adjacent underground pipelines. These computations also support the established
minimum separation standards that have been applied historically. These standards were
established as a one-size-fits-all approach without knowledge of local soils or adjacent
utilities.

Pipeline Separation Design & Installation Reference Guide Page 17

Minimum Pipe Separation Determination
Procedures
General
The design decisions locating underground pipelines must account for future excavation
for repair or replacement. This protects public health and the environment, as well as the
other underground utilities and surface improvements. The agencies have developed a
revised approach to the review and approval process for pipeline separations and
provided this guidance to allow designers discretion and more flexibility under many
conditions where standard 10-foot separation distances are not available.

This section provides the revised regulatory approach to review and approval, discussions
of engineering design, relevant location issues, and additional mitigation measures that
could be used for justification of shorter separation distances.

Current Procedures
Present project approval procedures require special design and installation proposals
whenever a nonpotable pipeline encroaches within 10 feet parallel to a potable water
main or within 18 inches at a vertical crossing. Under these conditions engineers must
propose special design and installation methods and then submit them to the regulatory
agencies. The agencies approve these special design and installation methods on a case-
by-case basis. This procedure can result in a multitude of separate reviews and approvals
during the course of one pipeline installation project.

Streamlined Procedures
The agencies have established streamlined procedures for three distinct sets of design and
field conditions based on space available, knowledge of soils properties and adjacent
utilities, and minimum distance designated for the sidewall safety zone. The first
condition occurs when standard separation distances are available and common design
practices are applied. The second condition occurs when the available vertical and/or
horizontal separation distances are less than the required minimum but greater than the
sidewall safety zone. The third condition exists when the available space for separation
is less than necessary for the sidewall safety zone.

Sidewall Safety Zone

The sidewall safety zone is a zone in which additional caution is necessary during the
design, construction, or repair process. Within this zone, the designers should collaborate
with representatives of all the responsible utilities and regulatory agencies. These
utilities may include the potable water system, sewage, storm water, reclaimed water,
gas, electric, telephone and communications, or any other underground utility purveyor.

The agencies have selected the minimum dimensions of the sidewall safety zone as 4 feet
horizontally between parallel pipes and 6 inches vertically at pipe crossings.

Page 18 Pipeline Separation Design & Installation Reference Guide

The agencies selected dimensions for the sidewall safety zone to define conditions that
warrant special consideration in the design and location of underground pipelines for
commonly encountered conditions in pipeline designs. The primary variables affecting
the decision include soils strength characteristics and the size and location of adjacent
buried pipelines (variables Z, D and H in Equation 1). In addition to these engineering
based concerns, engineers should include practical construction-related considerations.

These dimensions of the sidewall safety zone were selected to:

Š Allow space for construction or repair activities between the pipe and trench wall.
Š Provide a minimum trench sidewall cover depth for a parallel pipe.
Š Assure consideration of surface surcharge affects from operating construction
equipment or excavation spoil pile on the minimum trench sidewall thickness.
Š Allow for a minimum cover depth to assure protection from damage to pipes
during construction and from native materials and adjacent pipes.

Construction / Repair Work Space

Past practices set the definition of “adequate space” in construction trenches at 12 inches.
Historically, trench dimensions used in construction estimates were based on a minimum
trench width equal to the outside pipe diameter plus 1 foot on each side of the pipe. More
recently, due to construction safety requirements, 4-foot trench widths are used to
accommodate trench boxes and other trench safety equipment (Figure 14). This practice
provides a working zone of 2 feet from the pipe centerline to the trench wall, and allows
work space of at least 18 inches for
pipes up to 12 inches in diameter. Trench Box Working Zone
Construction practices for larger
pipes require sufficient space for
bedding under the pipe haunch in
lifts and to allow for compaction by
either manual tamping or the use of Max trench depth
plate compactors. A minimum of 24 allowed without Trench box
trench safety
inches between the trench wall and
4'

equipment Available work space

pipe is necessary to complete this
work. However, for the majority of
smaller pipe installations, an 18-inch
4'

Trench width to accomodate trench box

work space under normal
construction practices should be Figure 14: Trench working zone
adequate. Figure 14: Trench working zone

The practice of assuring 18 inch work space is also consistent with the “best practices” of
the National Utility Contractors Association, which defines an “excavation tolerance
zone” as the “width of the facility plus 18 inches on either side of the outside edge of the
underground facility on a horizontal plane.” 7

7
National Utility Contractors Association, Excavation Best Practices and Liability Protection.

Pipeline Separation Design & Installation Reference Guide Page 19

Minimum Trench Sidewall Cover Depth
The agencies used the Utah State University model presented in Equation 1 in selecting a
minimum sidewall safety zone. This cover depth depends on typical soil characteristics
and size and effective depth of bury of parallel underground pipes. Both the soil
characteristics expected along a pipeline route and effective depth of bury vary much
more than the expected sizes of the underground pipes. The selection of the sidewall
safety zone was based on conditions that should be expected in the majority of designs
and installations throughout this region. The conditions selected were:

Š Pipe – 6-inch to 8-inch diameter: Current minimum pipe size for both water
distribution pipes and gravity sewers of 8 inches generally represents the largest
proportion of pipe lengths inventoried in water system plans and wastewater
facility plans. The current minimum sizes increased from the previous minimum
standard 6-inch diameter pipes.
Š Soils strength characteristic – critical trench depth = 4 feet: Critical trench depth
depends on the cohesive strength of soils, which depends on the characteristics of
the soils that are predominant within the construction zone. These soils
characteristics will presumably apply within established most cities and towns in
this region. Most municipalities developed along the banks of rivers, lakes or the
ocean shore, where soils are commonly alluvial sand, gravel, and silt deposits.
Many alluvial soils are non-cohesive, resulting in a theoretical critical trench
depth of zero. Field experience shows that where cohesive soils are encountered
they exhibit trench walls up to about 4 feet without raveling or sloughing in dry
conditions. Depths greater than 4 feet can occur, but infrequently.
Š Effective depth of bury: Soils above a buried pipe exert pressure on the pipe,
while forces created by surface activities increase the effective pressure created
by the soils over the pipeline. The combination of soil pressure and surcharges
create the forces that can cause collapse to a parallel trench. The pressure
depends directly on the effective burial depth of the pipe.

Figure 15: Causes of cave-ins (trench surcharges) from

Saskatchewan Labour Ministry

Page 20 Pipeline Separation Design & Installation Reference Guide

The effective depth of burial depth was selected from considering common factors such
as the minimum pipeline burial depth of 36 inches to assure structural adequacy of the
pipe, minimum frost depth, which is 42 inches in the majority of this geographic region,
and a burial depth of 8 to 9 feet to accommodate service to sanitary sewers from
residential basements. In addition to the actual burial depth, surface activities
requirements during construction that result in a pressure surcharge were considered.
Surcharges are created by excavation spoil piles (Figure 15), operation of construction
equipment at the trench, and even local traffic on roads and streets, resulting in an
effective depth of bury much greater than the actual depth of bury. At a minimum,
surcharge from trench excavation spoils of at least 50% of the depth of the excavation
trench should be considered in establishing the effective depth of bury. For this analsyis,
a minimum effective depth of bury of 6 to 7 feet was used.
Results: Table 5 shows the Table 5: Trench sidewall cover estimate
minimum depth of cover for a X/D = 3H/Z
trench sidewall predicted by Effective Burial Depth, H, ft 6.0
Equation 1 of 2.3 feet to 3.0 feet Critical
for 6 and 8-inch diameter pipes. Depth, Z, ft Pipe Diameter, d, inches
2.00 4.5 6.0 7.5
Horizontal Dimension 2.50 3.6 4.8 6.0
For the horizontal dimension of the sidewall 3.00 3.0 4.0 5.0
safety zone use 4 feet. This represents the 3.50 3.6 3.4 4.3
minimum dimension predicted using the 4.00 2.3 3.0 3.8
Utah State University model (≈ 2½ feet),
while allowing adequate work space (18 inches = 1½ feet).

Minimum Pipe Cover

This guidance recommends using a minimum vertical separation of 6 inches. The
recommendation is based on recommended practices of pipe manufacturers for pipe
bedding and common construction practices. Pipe manufacturers’ standards require a
minimum depth of cover of 6 inches surrounding a pipe to prevent damage to the pipe
during installation. This depth assures sufficient separation between the pipe and any
object, such as a rock that may be driven into the pipe or rub against it. The 6-inch
separation allows settlement and pipe movement during compaction, without resulting in
pipe failure.

The vertical separation also considers pipe bedding compaction methods for pipes in tight
places. A minimum space of 6 inches achieves adequate backfill with select bedding and
hand tamper compaction.

Pipeline Separation Design & Installation Reference Guide Page 21

Design Review Conditions
Table 6 shows the three conditions designated based on space available.

Table 6: Conditions for separation in design with space available

Horizontal Separation Vertical Separation Space
Space Available Available
Minimum Maximum Minimum Maximum
¾ Condition A ≥10 feet N/A ≥ 18 inches N/A
¾ Condition B < 10 Feet > 4 feet < 18 inches > 6 inches
¾ Condition C ≤ 4 feet ≤ 6 inches

Regulatory Approval Requirements

Minimum requirements to receive regulatory approval will vary depending on the
separation space available.

For Condition A situations, the engineering design report and specifications must show
that the minimum horizontal and vertical separations of 10 feet and 18 inches,
respectively will be maintained between potable water and any nonpotable pipe, and
between reclaimed water and other nonpotable pipes.

For Condition B situations, engineers should include construction details and

specifications in the construction documents submitted for agency review and approval.
These details govern the location of pipelines within space limits shown above for
Condition B. In developing these standard construction details, engineers need to
consider critical or controlling design conditions such as expected soil cohesion,
excavation depth, pipe materials, surface imposed damage risk, and groundwater levels.

Condition C situations require special construction details on a case-by-case basis. The

engineer can identify these situations during design and provide construction details for
each location in the construction drawings in addition to connection details and other
critical locations.

In addition to the guidance above, Figure 16 provides a decision tree delineating the
considerations for the pipe separations.

Page 22 Pipeline Separation Design & Installation Reference Guide

 PIPE SEPARATION /
LOCATION CONDITION
DECISION TREE
Pipeline Basic pipeline
material & size route

Existing utility BASIC PIPELINE Hydraulics &

LOCATION &
locations / Topography
constraints DESIGN ISSUES

Utility corridor Basic Soils

constraints Data

Design Design Design

Condition A Condition B Condition C
H≥ 10’ 4’ ≤ H ≤ 10’ H ≤ 4’
V ≥ 18” 6” ≤ V ≤ 18” V ≤ 6”

Design approval Collaborative

Standard utility per engineering design decisions,
pipeline design report, typical case-by-case
procedures construction regulatory
details approval

Special design &

construction methods;
typical construction
details & specifications

Figure 16: Pipe separation assessment decision tree

Pipeline Separation Design & Installation Reference Guide Page 23

Recommendations for Alternatives to Standard Separation for
Condition B
Design engineers should consider several current designs options to provide protection to
public health and safety equivalent to the required minimum separations:

Š Common trench construction with separate undisturbed benches

Š Pipe and joint selection
o Thick wall, pressure rated pipe
o Special construction joints
o Restrained joint piping versus thrust blocks
o Substitution of pressure-rated pipe and joints in gravity installations
Š Pipe sleeves
Š Cement encasement
Š Controlled density fill between pipelines
Š Multiple pipe identification covers and location tapes
Š Vapor barriers or trench curtains

Typical Construction Details Condition – B

Designers should implement alternative design procedures when Condition B spacing is
encountered. The design engineer should include typical construction details (Figure 17)
for these locations in construction drawings. Include limitations for use of these details
such as:

Š Variations in soil types that would preclude the application of normal trenching
methods.
Š High groundwater conditions.
Š Saturated soils at the toe of the trench/
Š Limits to the critical trench depth for soils encountered along the route. Both
regulatory agencies should be aware of the potential conflicts of the standard
separation sand the designs proposed to address these conditions. Therefore, the
engineer must incorporate these limitations in the Facilities Plan, Engineering
Report, or Project Report for the project.

Figure 18 suggests the construction details for horizontal and vertical pipe separation
included as typical construction details that could be incorporated into pipe system
designs for Condition B.

Page 24 Pipeline Separation Design & Installation Reference Guide

 Figure 17: Typical benched - common trench construction detail

Plan View
Pressure Rate Casing Pipe Potable Water Line 1/2 length of pipe - 9' minimum

6" to 18" Vertical Separation

Case 1: New Potable Water
Line Constructed Above Nonpotable Pipeline -
Nonpotable / Sanitary Sewer Reclaimed Water or
Sanitary Sewer

New Nonpotable [Reclaimed Water / Sanitary Sewer/ Storm Sewer] Note: Casing must be
centered over lower pipe
above Potable Water Line
with joints spaced at least
9' from centerline of other pipe

6" to 18"
Vertical Separation
20' minimum length
Controlled Density Fill
Case 2: Nonpotable Pipeline
6" thick surrounding pipelines
Constructed Above Potable
Water Main Water Line Casing - minimum
18' w/ end centered minimum
Pressure Rated Casing Pipe 9' from nopotable pipeline

Condition B - Vertical Pipe Crossing

Suggested Construction Detail Plan View

Figure 18: Typical pipe crossing construction detail Condition B separation

Pipeline Separation Design & Installation Reference Guide Page 25

Case-by-case Approval Requirements – Condition C
General
Some situations will require special consideration and collaboration. The research into
the effect of soil properties indicates that the point at which failure occurs between
parallel trenches is sudden and catastrophic. The approach to minimum separation
standards provides a sufficient side wall safety zone including a safety factor during the
construction or repair phases. However, engineers may encounter some situations where
an adequate side wall safety zone is not available to assure minimum pipe support by the
soil structure. In these situations, the risk of pipe failure and collapse is the greatest.
Prevention of pipe failure and contamination is considered critical to the integrity of the
entire pipe system. All parties (the designer, management, operations staff, adjacent
utility purveyors and regulatory personnel) must remain aware of these instances, ensure
opportunities for collaboration, and integrate accumulated experience when the available
separation distances are within the side wall safety zone.
Approval Requirements
For pipes located within the sidewall safety zone, the design must meet the following
criteria: 4 feet or less horizontal pipe spacing and 6 inches or less vertical separation. In
these situations, the owner must obtain regulatory review and approval on a case-by-case
basis.
Approval Process
Engineers should propose Condition C design or location only when no other alternatives
exist. Regulatory agencies view pipeline installation in this zone as the last resort. An
engineering report must address all relevant issues in justifying the proposed location and
construction methods. To receive regulatory agency approval the engineer must address
all of the following factors:
1. Pipe material, wall thickness, deflection and structural integrity
2. Corrosion potential within the installation
3. Pipe joint type, deflection limits and integrity under deflection
4. Special bedding requirements or proposals
5. Pipe size, material specifications, and joint types for existing pipelines
6. Relative water quality and uses of proposed and existing pipelines
7. Relative levels of disinfectant residuals in the proposed and existing pipelines
8. Operating and surge pressures in the proposed and existing pipelines
9. Ability to control pressure and flows in adjacent underground utilities
10. Thrust restraint and thrust blocking of proposed and existing pipelines
11. Soils characteristics at the location
12. Ground water or water table conditions
13. Adjacent building and structure surcharges as it affects trench and pipe stability
14. Adjacent underground utilities and impacts
15. Comments and concerns of representatives of adjacent underground utilities
potentially affected by the proposed installation
16. Construction related impacts
a. Equipment and traffic vibration
b. Spoil pile surcharge impacts
c. Special structural support for adjacent pipelines

Page 26 Pipeline Separation Design & Installation Reference Guide

Suggested Solutions
The following sections address three potential Condition C pipeline locations:

Utility Tunnel – Condition C: The most common situation proposes a utility tunnel
crossing under a stream or railroad and highway rights-of-way. Figure 19 provides a
suggested construction detail to address Condition C concerns associated with utility
tunnels. The project design should consider:

1. Locating potable water and reclaimed water lines above the midline of the tunnel
and sanitary and storm sewers located below the midline as far as possible.
2. Encasing potable water pipeline in a pressure-rated pipe that is provided with
corrosion protection or is non-corrodible, and has fused joints and providing pipe
spacers to maintain the waterline centered in the water line casing.
3. Filling casing annular space or void with lean concrete, grout, bentonite or other
proposed fill that assures the void is completely filled. The regulatory agencies
must approve the construction methods to assure the void is completely filled.
4. Addressing methods that may be necessary to allow access for likely future
maintenance and repair of all of the utilities using the tunnel or boring casing,
such as casings that will allow removal of every utility pipe for future
maintenance.

Underground Utility Tunnel

6" Natural Gas Pipeline
15" Potable Water Casing with Electrical
Pipe in Welded & Telecommunications Cable
Steel Casing
12" Reclaimed Water Line

Tunnel or boring casing

Potable & Reclaimed Water
Above Tunnel Mid-line
filled with lean concrete
CDF, grout or bentonite

8" Sanitary Sewer

12" Storm Sewer

Figure 19: Condition C utility tunnel

Pipeline Separation Design & Installation Reference Guide Page 27

Common Utility Corridor Construction- Condition C
At locations where a restricted, common underground utility corridor is required, the
engineering report should consider:
1. Selecting pipe materials for the lowest level pipelines presuming future
maintenance and repair is not possible.
2. Specifying fused or welded joints in the bottom and middle pipelines.
3. Limiting the length of these installations to very short distances, potentially 300 to
400 feet.
4. The upper most utilities will likely be natural gas, electrical or
telecommunications. When installing these utilities consider that they will be
affected by potential repair and maintenance of the water or reclaimed water
pipelines and may sustain damage during such repairs.
5. Locating appurtenances for maintenance of potable and reclaimed water lines
such as directional flow flushing to prevent impacts to the utility corridor from
runoff, vibrations, or pressure surges.

Figure 20 illustrates a suggested construction detail.

Condition C - Suggested Trench Construction Detail

Separtion less than 6"

Requires Commercial
Pipe Spacers

Minimum 18" Depth

Minimum 42" Bury Depth
Code Compliance
Frost Protection

Natural Gas Electrical &

Telecommunications

Potable Waterline
in Pressure Rated Reclaimed Water Line
Casing Pipe Note: Class A requires
Trench Backfilled Casing
With Controlled
Density Fill Pipe Material --
Noncorrosive or Corrosion
Protecton with fused joints
Sanitary Sewer

Storm Sewer

Depth of Bury Based

on Pipe Grade Requirements,
Minimum Vertical Separation
Requires Commercial Pipe Spacers

Figure 20: Common underground utility corridor

Page 28 Pipeline Separation Design & Installation Reference Guide

Pipeline Crossing – Condition C
For pipeline crossings of less than the required vertical separation distance, consider the
following protections at a minimum:
1. Provide both the new pipeline and the existing pipe in the crossing with casing
manufactured of pressure-rated pipe.
2. Provide commercial pipe spacers for the carrier pipes within each casing.
3. Provide controlled density fill of at least 6 inches in thickness around both cased
pipelines for the entire length of each casing.
4. Seal the casings at the ends.
5. Provide a commercial pipe spacer between to the two casings at the crossing to
assure a minimum separation is maintained.

Figure 21 provides a suggested construction detail.

Potable pipe above

Commerical Pipe Spacer nonpotable pipe

Vertical Separation
- 6" or less Note: Casing must be
Pressure Rated
Controlled Density Fill Casing Pipe centered over lower pipe
Surrounding Both Pipes with joints space at least
Minmum 6" Thick 9' from centerline of other pipe

Condition C Vertical Crossing

Controlled Density

Suggested Construction Detail Fill 6" thick surrounding

pipelines

Crossing Plan View

Figure 21: Condition C -vertical pipe crossing

Pipeline Separation Design & Installation Reference Guide Page 29

Engineering Design and Location Approach
General Considerations
Numerous issues and constraints face the design team in selecting the proper location,
size, and materials specifications. Several issues may significantly impact minimum
separation distances. This section addresses specific design-related issues. The
Departments of Health and Ecology (the agencies) do not intend to provide a complete or
exhaustive list of design issues or variables in this guidance, but rather to address the
majority of the important issues considered in the regulatory review and approval
process.
Engineering Judgment
No written guidance can replace professional judgment. The agencies do not intend that
these guidelines will supersede professional engineering judgment in any way. The
guidelines provide a description of basic acceptable practices applicable to many, but
certainly not all situations encountered. The agencies hope that deviation from these
standard approaches, although expected, will be limited. We recognize that when
developing other acceptable designs engineers must rely on professional engineering
judgment to demonstrate the designs achieve equivalent public health protection.
Trench Protection
The agencies do not intend for this guidance to impose a single set of requirements for
pipeline designers or maintenance supervisors to provide structural designs for trench
shielding or trench box protection. The agencies recommend that site control be
conducted by an individual certified in trench safety. The certified individual establishes
a competent responsible party to assure trench protection during construction and repair
excavations. These standards do not supersede or replace any trench safety and shoring
protection required by the Washington State Department of Labor and Industries.
Basic Design Approach
The agencies prefer use of the minimum standard separations wherever possible in
locating new or relocated buried utilities. The engineer should identify location conflicts
and limits on pipeline separation during the preliminary design phase. To the extent
reasonably possible, the design team should identify those locations that will trigger
Conditions B and C. Potential location conflicts should become apparent from baseline
information gathered from record drawings of existing pipes and utility corridors from
local utilities, as well surface features found during initial field reconnaissance of
potential pipeline routes.
Multiple Barriers of Protection
Pipelines provide economical and reliable transportation and delivery of consumable
products and removal of waste products. The two most common underground utilities –
drinking water and sanitary sewage – provide the foundation for a community’s public
health protection. All underground utilities provide services essential to the health and
welfare of communities. All essential services must have the highest degree of
reliability, and include multiple barriers of protection. Just as a potable water system
provides multiple protections through source protection, treatment and disinfection, the

Page 30 Pipeline Separation Design & Installation Reference Guide

distribution systems also require separate and duplicative barriers. The project team – the
design engineer, regulatory review staff, contractor and owner- must recognize that
adequate pipe separation from other underground utilities provides the final, protective
barrier.
Record Information Accuracy
Designs must begin with the best, available information. In the case of municipal
underground utilities, this is often found in “as-built” or record drawings of “existing”
pipelines or previous projects. Although this information can prove inaccurate, it may be
the best information available as the design begins. Designers should consider as-built
information during the initial design phase in determining the locations of potential
separation conflicts. The extent of reliance on the accuracy of these records will depend
on the judgment of the project design manager based on their professional experience.
Trigger Conditions
Special designs or pipe separation methods may not be necessary along the length of a
project. Soils properties and site constraints vary along the route in most pipeline
projects. Encroachment into the standard separation zones for a small portion of a
pipeline does not require that the length of pipeline under Condition A be designed for
Conditions B or C. The use of special pipeline designs or pipe separation methods is
necessary in locations with the potential for significant risks as a result of the pipe
locations. The design engineer should consider:
Š The length of the parallel installations; pipe lengths greater than the length of two
pipe ‘sticks’ or three or more pipe joints [36’-40’] would trigger special design.
Š Health risks associated with the products transported in the adjacent pipes.
Š The age and condition of existing pipe materials and joints.
Š Non-cohesive soils which will require pipe special pipe supports or trench
protection be used to excavate parallel trenches.
Š Pipe installations that do not allow for full compaction of support soils between
pipes.
Š Pipe distribution systems subject to high pressures, large pressure variations and
pipe velocity variations that tend to result in pipe thrust at bends and joints.
Design Considerations
As a project develops, site-specific conditions will be come apparent that will drive the
details of the project design. The different factors that should be evaluated to justify
smaller pipe separations include:
Š System pressure ranges and hydraulics that may affect the tendency of the pipes
to develop thrust during normal operations.
Š Anticipated range of soil characteristics such as cohesive strength; critical trench
depth and corrosion potential of the pipe material.
Š Range of current and future pipe sizes in the utility corridor.
Š Potential for saturated soil conditions at the deepest trench level.
Š Types of pipe material and pipe joints preferred or available.
Š Repair and patching methods for the pipe.
Š Available space for spoil pile location and material stockpiling during repairs.
Š Location of operating excavation and materials handling equipment.

Pipeline Separation Design & Installation Reference Guide Page 31

 Š Separation to adjacent traffic and impacts from traffic on trench stability.
Š The ability to accurately track, estimate or locate pipeline leakage.
Š Risk to public health and safety that could result from cross contamination from
leakage between adjacent pipes.
Š Capability, facilities and equipment available to contain, control and clean and
restore the pipe and produce quality to meet public health and safety standards.
Specific Design Concerns
Soils strength; trench construction – depth of bury, leakage impact, repair and
replacement mitigation

Soil Strengths Data

Detailed soils data can be difficult and expensive to obtain, Fortunately, for these design
purposes, only basic soils data is necessary to determine whether the soils are either
cohesive or non-cohesive. Soils that provide any level of cohesive force will likely
provide sufficient side wall coverage to allow smaller horizontal separation distance.
Non-cohesive soils generally will not support sufficient side wall cover, and require more
careful consideration.
Soils surveys provide information to a depth of 5 feet, which is valuable for most potable
water lines buried between 3½ and 5 feet deep. Soil survey information is available from
several locations electronically including these two websites:
National Resource Conservation Service at:
http://www.or.nrcs.usda.gov/pnw_soil/wa_reports.html

Washington State University at:

http://remotesens.css.wsu.edu/washingtonsoil/

Table 7. An Example of soils information from the NRCS Web site

General Soil O5 Region: O
Type:
Map Unit Soils derived from glacial outwash on river terraces; most soils are
Description: strongly loess-influenced in the upper part, gravelly or sandy in
the lower part, and have low water-holding capacity; some are
influenced by volcanic ash in the upper part
Moisture Xeric
Regime:
Temperature Mesic
Regime:
Taxonomic
Classification: Vitrandic Xerochrepts, Vitrandic Haploxerolls, Typic
Xerorthents, Typic Xeropsamments
Major Soil Series: Springdale-Garrison-Spens-Bisbee

Table 7 provides an example of soils information generated from the Washington State
University website. The NRCS website gives greater detail.

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The WSU website generates general maps of each county. Figure 22 shows maps for
Lincoln and Spokane Counties. The engineer can find soils information by clicking on a
soil type designated by color with a mouse.

Soil O5

Figure 22. Lincoln and Spokane county soil types (Soil Type O5 is displayed in red)

In general, soils information available from soils maps or from local contactors and
utilities should provide sufficient information during the initial route location stages.

Pipe Leakage
Pipe leakage is so common that designers can easily
overlook the effects of leakage on the pipe design and
location process. Leaks affect the amount of soil
moisture or water in the immediate vicinity of a pipe.
This dramatically affects the cohesive strength of the soil.
Pipe failure may cause a leak; or a leak may help create
pipe failure (Figure 23). Pipeline designs need to
consider the fundamental conditions that create or allow
leaks during the design and pipeline location process. Figure 23: Pipe beam break due to
Figure 23: Pipe beam break due to corrosion corrosion

Conditions Causing Leaks

Pipeline leaks may be caused by external and internal forces on the pipes, corrosion and
deterioration, or construction problems. External forces include traffic loads, earth
loading, freeze and thaw cycles, earthquakes, and floods. External forces result in failure
when:
Š The pipe, acting as a beam in the soil, is not uniformly supported by adequate
pipe bedding.
Š The pipe is restrained from expansion and contraction, and differential thermal
stress is applied.
Š The force of rigid structures exerts pressure on the pipe.

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Internal pressures that can result in pipeline damage include working pressure and surge
pressures. All pipelines under pressure are subject to water hammer surges during
normal operation of pipes, valves, and even faucets and hose bibs. If the pipes are brittle,
hydraulic transients or water hammer can cause longitudinal cracks. Repetitive transient
pressure surges affect the fatigue strength of the pipe material compromising the wall
strength.

Pipeline Deterioration
Tuberculation and internal pipe corrosion can cause water quality degradation.
Tuberculation is the development of blister-like growths of metal oxides resulting from
metal pipe. Iron oxide tubercles often develop over pits in iron or steel pipe. These can
seriously restrict the flow of water. Tubercules 8 not only affect the pipe wall integrity,
but also increase pipe roughness. This, in turn, can result in larger pressure differentials
during operation and can compound the impacts of internal and external forces.
Figure 24: Sand boils resulting from joint failure
Construction Related Problems
Poor bedding during construction can
result in significant pipeline damage.
Under pressure tiny leaks in gaskets
result in major blowouts due to soil
mining at the joint. Construction
errors may include cracked bells, leaks
caused by rolled gaskets (common
with push-on joints), or a tiny bit of
sand between the gasket and the pipe.
Leaks from gaskets “sand blast” the
pipe from the outside in and increase at
an exponential rate. In extreme cases,
the soil mining extends to the surface
as shown in Figure 24.

Joint leaks in flexible pipe, including Figure 24: Sand boils resulting from joint failure
steel pipe, are common at welded
joints, especially if the pipe is deflected due to soil movement or seismic forces. Bedding
the pipe section with large and/or angular rocks can lead to breaks if the rock creates
point stresses on the pipe wall. Such improper bedding results in punctures or breaks in
the pipe ring.

Mechanics of Pipe Failure Due to Leaks

When leaks occur from beam breaks, joint leakage, main breaks or service line leaks, the
liquid flushes soil particles from the region of the leak. The flushing undermines pipe

8
The mounds characterized by reddish brown mounds of various heights attached to the interior of the pipe
walls, resulting from many years of iron and manganese bacterial growth that deposit iron and/or
manganese oxides along with particulate matter from the water trapped in the biomass from generations of
iron bacteria. These bacteria are common in all water sources. Over twenty different iron bacteria can
cause tuberculation. These bacteria are generally considered non-pathogenic. However, tubercules can aid
in microbiologic regrowth, fostering the growth of pathogenic microorganisms.

Page 34 Pipeline Separation Design & Installation Reference Guide

bedding. The loss of pipe bedding can cause over-deflection at pipe joints, excess pull on
joints, loss of thrust restraint, and loss of support from the soil underlying the pipe
section. Ultimately, total pipe failure may result.

Allowable Leakage
All pipes should be expected to leak. The perception that pipelines are “sealed tight” is
very common in the water and wastewater industry, but it is wrong. Standard
construction specifications acknowledge this fact by establishing “allowable leakage
rates” for the design life, when material quality and construction integrity are expected to
be the best and external pressures are at a minimum. Designs generally consider
allowable leakage limits for nearly all pipe materials, including some assumed to be
“leak-free.” Estimates of annual leakage shown in the spreadsheet model (Table 8)
indicate that adequately constructed pipelines can be expected to lose a significant
amount of water over time.

Table 8. Allowable leakage based on standard specifications

1/2
L= S*d*P L = allowable leakage in gallons per hour
133,200 S= length of pipe tested in feet
P= system pressure, psi

Allowable Leakage for 300 ft of pipe [1-urban block] in one year

Pipe Diameter System Pressure, psi
inches 30 40 50 60 70 80 90 100
6 1,776 2,368 2,959 3,551 4,143 4,735 5,327 5,919
8 2,368 3,157 3,946 4,735 5,524 6,314 7,103 7,892
10 2,959 3,946 4,932 5,919 6,905 7,892 8,878 9,865
12 3,551 4,735 5,919 7,103 8,286 9,470 10,654 11,838
18 5,327 7,103 8,878 10,654 12,430 14,205 15,981 17,757
24 7,103 9,470 11,838 14,205 16,573 18,941 21,308 23,676
36 10,654 14,205 17,757 21,308 24,859 28,411 31,962 35,514
48 14,205 18,941 23,676 28,411 33,146 37,881 42,616 47,351

The fluid leaked from the pipe remains in the vicinity of the pipe, and affects the soil
moisture content and water levels in the pipe excavation. This, in turn, affects the
cohesive strength of the soil and the critical trench depth at the excavation site.

Excavation Site Conditions

Pipeline repair excavations provide a special application of the principals used to
determine minimum sidewall coverage based on soil mechanics techniques. Soil strength
and external forces on trenches and parallel underground utilities differ dramatically
during repair operations. Undisturbed soil almost always exhibits greater strength than
disturbed soil, regardless of the compaction method used. When excavating adjacent to
an old trench, the prism of soil between the two trenches is generally very unstable. 9
Often the excavation backfill spoil pile or operating excavation equipment will be located
on top of the parallel utility line. This practice significantly increases the effective depth
9
S. Arasmith & H. Mason-Ploetz, Cave-in Protection and Competent Person Training Manual, Pg. 27

Pipeline Separation Design & Installation Reference Guide Page 35

of bury and the external loads and
increases the possibility of trench
sidewall failure due to the vibrations
caused by equipment or materials.
Figure 25 shows setback separations
required for three basic soils
classifications. 10 For the purposes of
this description: Type A soils are
classified as cemented soils, providing
the highest cohesive forces; Type B soils
are cohesive soils, and Type C soils are
classified as granular soils. These Figure 25: Typical trench surcharge
classifications do not directly relate to the soil conditions
group classifications shown previously.
Figure 25: Typical trench surcharge conditions
Figure 26 shows the importance and potential impacts of spoil bank locations in a field
excavation. Note that the right ditch bank appears to be stable at a relatively steep angle,
while the left bank is sloughing.
Figure 26: Field conditions - typical trench surcharge
Repair and Replacement Excavations: The
effectiveness of pipe repairs or replacement of
short sections during design is determined by
allowing sufficient room for safe and effective
repairs. Utilities with routine pipe repair
procedures can justify more congested designs
based on the standard practices and
procedures. The design should consider the
following factors:
Š Availability of certified competent
persons to oversee the excavation
Š Experienced designers for:
o Structural support of adjacent pipes
or pipe joints
o Trench shields
o Trench boxes
Š Provision of redundant pipe markings
or pipe identification systems to
prevent repair or tapping of the wrong
pipe.
Figure 26: Field conditions - typical trench
surcharge

10
Ibid, Page 27

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Conclusions
Many different issues significantly affect the decision making process used to set the
final location of a new pipeline relative to existing underground utilities. The design of a
new pipeline must consider needs to maintain and repair to all other adjacent utilities
along its entire route. Natural and induced conditions can lead to deterioration and
failure, which in turn leads to contamination and damage. The ability to readily and
effectively address these needs depends predominantly on the decisions made in the
original location of the pipeline.

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