05-Division 2-Section 02200 GRP Pipelines Materials-Ver 2.0

ADSSC/GSCW Division 02 Section 02200

GRP Pipelines. Materials, Installation and Testing Rev: 02 Oct. 2010 Page 1 of 30

ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 2 SITEWORK

SECTION 02200 GRP PIPELINES MATERIALS, INSTALLATION AND TESTING

General Specification for Civil Works Abu Dhabi Sewerage Services Company

(ADSSC)



DOCUMENT CONTROL SHEET

Revision No. Date Revision Description/ Purpose of Issue

01 April 2008 First Issue.

02 October 2010 Second Issue _ Technique of Centrifugal Cast technology as an alternative manufacturing technology available in the region is included

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TABLE OF CONTENTS

1 GENERAL......................................................................................................... 4 1.1 SCOPE ................................................................................................. 4 1.2 RELATED DOCUMENTS ...................................................................... 4 1.3 REFERED STANDARDS ...................................................................... 4 1.4 SUBMITTALS ....................................................................................... 8 1.4.1 PRODUCTS AND MATERIALS APPROVAL ........................................ 8 1.4.2 METHOD STATEMENTS .................................................................... 10 1.4.3 DRAWINGS. ....................................................................................... 10 1.5 QUALITY CONTROL .......................................................................... 10 1.6 DELIVERY, STORAGE AND HANDLING ........................................... 11 2 PRODUCTS ........................................................................................ 12 2.1 PIPE DESIGN REQUIREMENTS ........................................................ 12 2.2 PIPES AND FITTINGS. ....................................................................... 13 2.2.1 BURIED GRP ...................................................................................... 13 2.2.1.1 General ............................................................................................... 13 2.2.1.2 Materials and pipe wall construction .................................................... 13

Table 2.2.1.5.1: Summary of test requirements for non-end-load-bearing flexible joints ............ 18 2.2.2 EXPOSED GRP ..................................................................................... 19 2.3 QUALITY CONTROL TESTS .................................................................... 20 2.3.1 GRP PIPES AND FITTINGS .................................................................. 20

2.4 PRODUCT WARRANTY ................................................................................. 23 3 EXECUTION ................................................................................................... 23

3.1 PIPE INSTALLATION ......................................................................... 23 3.2 MANDATORY INSTALLATION MONITORING ................................... 26 3.3 FIELD HYDROSTATIC TESTING OF PIPELINES .............................. 26 3.3.1 HYDROSTATIC TESTING OF PIPELINES GENERAL. ...................... 26 3.3.2 HYDROSTATIC TESTING OF PRESSURE PIPELINES ..................... 27 3.3.3 HYDROSTATIC TESTING OF NON PRESSURE PIPELINES ............ 28

3.4 FIELD DEFLECTION MEASUREMENT OF PIPELINES ................................. 29 3.4.1 GRP PIPELINES. ............................................................................................ 29


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1 GENERAL

1.1 SCOPE

This section of the specification gives the requirements for Glass Reinforced Plastic (GRP) pipeline materials and the installation and testing thereof for sewerage systems.

1.2 RELATED DOCUMENTS

The following sections of the specification shall be read in conjunction with this section including the stipulations and conditions drawn in the Tender Documents. Section 01000-07 Submittals. Section 01000-08 Quality control. Section 01000-09 Materials and equipment. Section 02120 Utility excavation, surround and backfill. Section 02300 Sewage works.

1.3 REFERED STANDARDS

All activities relating to this section of the standard specification shall comply with the following or approved equal standards. Note: Dated references do not take later revisions or amendments to these publications into account. We recommend, however that users who use this quality specification should check if later versions of the standards listed below could be applied. If a reference is not dated, the latest version of the standard indicated shall apply. Statutory provisions shall always apply as amended from time to time.

Generally applicable:

ASTM C581 Standard practice for determining chemical resistance of thermosetting resins used in glass fiber reinforced structures intended for liquid service.

ASTM D2290 Standard test method for apparent hoop tensile strength of plastic or reinforced plastic pipe by split disc method

ASTM D2584 Standard test method for ignition loss of cured reinforced resins.

ASTM D2924 Standard test method for external pressure resistance of “fiberglass” (Glass fiber reinforced thermosetting resin) pipe.

ASTM D3262 Standard specification for “fiberglass” (Glass fiber reinforced thermosetting resin) sewer pipe.

ASTM D4161 Standard specification for “fiberglass” (Glass fiber reinforced thermosetting resin) pipe joints using flexible elastomeric seals.

BS 3396 Woven glass fiber fabrics for plastics reinforcement.

BS 3532 Method of specifying unsaturated polyester resin systems.

BS 4549-1 Guide to quality control requirements for reinforced plastics moldings. Guide to the preparation of a scheme to control the quality of glass reinforced polyester moldings.


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BS EN 681 Elastomeric seals. Material requirements for pipe joint seals used in water and drainage applications.

BS EN 1394 Plastic piping system Glass reinforced thermosetting plastic (GRP) pipes. Determination of the apparent initial circumferential tensile strength

BS EN 1092-2 Circular flanges for pipes, valves and fittings (PN designated). Steel, cast iron and copper alloy flanges. Specification for cast iron flanges.

BS EN14020 Specification for textile glass roving

BS EN 14118 Reinforcement: Specification for textile glass mats (chopped strand and continuous filament mats)

BS EN 14364 Plastic piping system for drainage and sewerage with or without pressure. Glass reinforced-thermosetting plastics (GRP) based on unsaturated polyester resin (UP). Specification for pipes and fittings

ISO 3126 Plastic pipes. Measurement of dimensions wall thickness table.

ISO 4633 Joint rings for water supply, drainage and sewerage pipelines: Specification for materials

ISO 9000 `Quality management systems.

For the centrifugally cast GRP Pipes & Fittings the following standards contain definitions

that are referenced in this document making them part of the quality specification. DIN/BS EN 14364 Plastics piping systems for drainage and sewerage with or

without pressure – Glass-reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP)

DIN 16 869 Part 1 Centrifugally cast and filled glass fibre reinforced polyester resin pipes - dimensions.

DIN 16 869 Part 2 Glass-fibre reinforced polyester resin pipes (UP-GF) – Centrifugally cast – filled Part 2: General quality requirements, testing.

DIN-4060 Elastomer seals for pipe joints in drain and sewer - Requirement and Testing

DIN EN ISO 178 Plastics – Determination of flexural properties (ISO 178:1993) DIN-53769- Part 3 Testing of GRP pipes

- Determination of Initial and Long term Ring stiffness DIN EN ISO 527-1 Plastics – Determination of tensile properties – Part 1: General

principles DIN EN ISO 527-2 Plastics - Determination of tensile properties - Part 2: Test

conditions for molding and extrusion plastics DIN-53758 Testing of Plastic articles

- Short time test for determining the effect of internal pressure on hollow Objects

DIN-53769 - Part 6 Testing of GRP pipes under pulsating internal pressure DIN EN ISO 62 Plastics – Determination of water absorption


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DIN EN 1120 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Determination of the resistance to chemical attack from the inside of a section in a deflected condition

DIN EN 705 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes and fittings – Methods for regression analyses and their use

DIN EN ISO 1183-1 Plastics - Methods for determining the density of non-cellular plastics - Part 1: Immersion method, liquid pyknometer method and titration method

DIN EN ISO 1183-2 Plastics - Methods for determining the density of non-cellular plastics - Part 2: Density gradient column method

DIN-16945 Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins

DIN-16946- Part 1 Cured casting Resins - Testing DIN-16946- Part 2 Cured casting Resins - Types DIN-53505 Testing of Rubber, elastomers and plastics - Shore Hardness

testing A & D DIN-19565- Part 5 Prefabricated UP-GF Manholes for use in sewerage system -

Dimensions & Technical delivery conditions DIN EN ISO 75 Plastics – Determination of temperature of deflection under load DIN EN ISO 527-4 Plastics – Determination of tensile properties – Part 4: Test

conditions for isotropic and orthotropic fibre-reinforced plastic composites

DIN EN ISO 10468 Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term specific ring creep stiffness under wet conditions and calculation of the wet creep factor (ISO/DIS 10468:1999)

DIN EN ISO 14828 Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the long-term specific ring relaxation stiffness under wet conditions and calculation of the wet relaxation factor (ISO/DIS 14828:1999)

DIN EN 681-1 Elastomeric seals – Material requirements for pipe joint seals used in water and drainage applications – Part 1: Vulcanized rubber

DIN EN 1119 Plastics piping systems – Joints for glass-reinforced thermosetting plastics (GRP) pipes and fittings – Test methods for leak tightness and resistance to damage of flexible and reduced articulation joints

DIN EN 1226 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Test method to prove the resistance to initial ring deflection

DIN EN 1228 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of initial specific ring stiffness

DIN EN 1393 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of initial longitudinal tensile properties


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DIN EN 1394 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of the apparent initial circumferential tensile strength

DIN EN 1447 Plastics piping systems – Glass-reinforced thermosetting plastics (GRP) pipes – Determination of long-term resistance to internal pressure

ASTM D2997 Standard Specification for Centrifugally cast “ Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe.

ASTM D 1599-99 Standard Test Method for Resistance to Short-Time Hydraulic Pressure of Plastic Pipe, Tubing, and Fittings

ASTM D 2412-96a Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

ASTM D 2583-95 Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impresser

ASTM D 2997-01 Standard Specification for Centrifugally Cast “Fiberglass“ (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe

ASTM D 3517-01 Standard Specification for “Fiberglass“ (Glass-Fiber-Reinforced Thermosetting-Resin) Pressure Pipe


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1.4 SUBMITTALS

1.4.1 PRODUCTS AND MATERIALS APPROVAL

a. In order to verify compliance with the specification the Contractor shall submit information for all products and materials used in the Works to the Engineer for approval sufficiently in advance of their use in accordance with the Contract programme allowing for ordering and approval times. Reference shall also be made to Section 01000-09 of the specification on products and materials approval. Information to be submitted shall comprise but not necessarily be limited to:

i. The manufacturers design calculations, complete and detailed specification,

standard Quality Control test results including the latest Type Tests (Long Term test) results not later then three years from the date of approval submission of the proposed GRP pipes and fittings required for the Works including Manufacturers Certificates of compliance with this section of the standard specification. Information on all items listed in Table 1.4.1 below shall be given.

ii. Should any details, including materials of the pipes and fittings be altered in

any way during manufacture from those proposed and approved by the Engineer, submit for the Engineer's approval the revised details and test results, including Type Test results {incase of altering of material (Long Term 10,000hrs tests.)}

iii. Submit to the Engineer the results of all standard quality control tests

carried out on the manufactured pipes and fittings as soon as practicable after testing as and in any case not later than the time of delivery of the relevant pipes and fittings to the site.

iv. Pipe manufacturer’s guarantee that the pipe and its materials are suitable

for its intended use and application.

v. Joint materials and gaskets.

vi. Standard produced pipe lengths shall be 12 meter for Filament Wound (FW) and 6 meter for Centrifugal Cast (CC). Tolerance shall be governed by the relevant manufacturing standard.


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Table 1.4.1 – Product Information for GRP Pipe and Fittings

Product Information Units Manufacturing Details Name of manufacturer - Manufacturing process for pipes - Manufacturing process for bends and fittings - Joint type - Summary of Design Criteria Nominal internal /external diameter mm Pressure Class of pipe (PN) kN/m

2

Minimum depth of cover m Maximum depth of cover m Maximum working pressure kN/m

2

Design test pressure kN/m2

Internal vacuum pressure kN/m2

Pipe Wall Structure Nominal total wall thickness mm Inner liner Resin** Type % Glass* Type % Thickness mm Structural wall Resin** Type % Chopped Glass** Type % Hoop Glass** Type % Aggregate** Type % Thickness mm External layer Resin***Type % Glass***Type % Thickness mm Minimum Initial Pipe Properties Stiffness (SN) N/m

2

Longitudinal tensile strength N/mm Hoop flexural modulus GN/m

2

Hoop tensile strength N/mm2

Last date of publishing the Type Test (Long Term) results Notes to Table 1.4.1

a) • Pipe data to be provided for every diameter in each class of pipe. * By weight of liner. ** By weight of structural wall. *** By weight of layer.


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1.4.2 METHOD STATEMENTS

a) The Contractor shall submit method statements to the Engineer for approval, 4-8 weeks in advance of commencing the site activity in accordance with Section 01000-07 of the specification. These shall comprise but not necessarily be limited to:

i. Procedures for handling, storage and installation of pipes.

ii. Hydrostatic testing procedures for GRP non pressure pipelines, where necessary, as per manufacturing standard.

iii. Hydrostatic testing procedures for GRP pressure pipelines.

iv. Deflection measurement procedures for GRP pipelines, where

necessary, as per manufacturing standard. 1.4.3 DRAWINGS.

b) The Contractor shall submit drawings to the Engineer for approval well in advance of commencing the site activity in accordance with Section 01000-07 of the specification. These shall comprise but not necessarily be limited to:

i. Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.

ii. Pipe laying diagram and schedule showing location, length, design

designation and designation by number of each pipe section and pipe special to be furnished and installed.

iii. All data on curve and bends for both horizontal and vertical alignment.

1.5 QUALITY CONTROL

Inspection of the products by the manufacturer shall be in accordance with the definitions in the product standards and in additional quality specification, as per the selected technique of the manufacturing.

a) Prior to dispatch of any product and/or material from source the Contractor

shall notify the Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect and test the product and/or material prior to delivery in accordance with Section 01000-08 of the specification.

b) Products and materials shall be from a manufacturer/supplier who operates

a quality control system which is registered to ISO 9000 series or approved equal.

c) To allow the Engineer to inspect the Works the Contractor shall give the

Engineer a minimum of 48 hours notice of carrying out the following activities on site.


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i. Installation of pipeline.

ii. Hydrostatic testing of pipeline.

iii. Deflection measurement of pipeline. 1.6 DELIVERY, STORAGE AND HANDLING

a) Delivery, storage and handling of products and materials shall be in accordance with the manufacturer’s recommendations, Section 01000-09 of the specification and the following provisions:

i. Delivery storage and handling shall at all times be performed in a

manner to avoid product damage.

ii. Pipes and fittings shall not come in contact with any sharp projections that may cause damage to the pipes and fittings during transportation loading and unloading. Ensure that pipes and fittings are well secured during transit and adequately supported along their length. Cover pipes and fittings of plastic materials during transportation. Do not allow pipe to overhang the end of a vehicle during transportation.

iii. Ensure that pipes and fittings are lifted using nylon or large diameter rope slings positioned at a quarter of the pipe length from each end. Do not allow the use of wire rope chains or unpadded forks or clamps on forklifts to lift pipes.

iv. Store pipes and fittings on a flat level area as recommended by the pipe

manufacturer. Ensure that pipes and fittings supplied either on pallets or crated, remain on the pallets or in their crates until required.

v. Stack non-crated pipes to the approval of the Engineer.

o Stack spigot and socket pipes so that successive pipe layers have sockets protruding at opposite ends of the stack.

o Stack pipes of different sizes and thickness separately. o Do not allow stacked pipes to exceed 2m in height or as

recommended by the supplier whichever is the lesser. vi. Store GRP pipes and fittings under opaque cover and out of direct

sunlight at all times. Maintain a free flow of air around the pipes at all times.

vii. Store rubber joint rings in a well ventilated place free from exposure to

sunlight and in their original packing until they are needed.

viii. The Contractor shall visually inspect all products upon delivery to site and report any damage to the Engineer.

o Any products damaged during delivery, storage and handling shall

be marked by the Contractor and set aside. o Proposals for repair of any repairable products shall be submitted in

writing to the Engineer for approval.


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o Any damaged products deemed unsuitable for repair by the Engineer shall be removed from the site and replaced, with an equal.

2 PRODUCTS

2.1 PIPE DESIGN REQUIREMENTS

The design requirements for GRP pipes shall be, as given below unless otherwise indicated on the drawings or on recommendations of Manufacturer depending on site conditions (soil, installation, compaction, loads etc.) in compliance to the Special Warranty conditions, quoted else where in this document.

Design Requirements of GRP pipes.

a. Minimum initial specific stiffness

i. For Gravity Pipe lines in buried installation with cover depths less than 6 m shall be 5000 N/m2 (SN 5000).

ii. For Gravity Pipe lines in buried installation with cover depths more than 6 m shall be 10000 N/m2 (SN 10000).

iii. For all pressure main shall be 10000 N/m2 (SN 10000).

iv. For all exposed pipe lines shall be 10000 N/m2 (SN 10000).

b. Any variance due to the site condition such as native soil condition, installation, burial depths, deflection limits, buckling and vacuum requirements or others which necessitates increasing the stiffness (SN) value of GRP pipe shall be governed by the Manufacturer’s design.

c. Use GRP for pressure mains unless otherwise stated on drawing

d. Pressure mains shall be designed as per the requirement of Table 15 of BS/DIN EN 14364.

e. All GRP pipes installed up to 10.0m cover depth shall be buried in granular surround or as specified by the Manufacturer according to the ground conditions. For cover depths exceeding 10.0m, the pipe shall have concrete surround or Manufacturer to suggest suitable higher stiffness pipe.


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2.2 PIPES AND FITTINGS.

2.2.1 BURIED GRP

2.2.1.1 General a) All GRP components shall be designed and fabricated by one manufacturer. b) GRP pipes and fittings shall be manufactured in compliance with BS/DIN EN

14364 and fabricated to meet the minimum strength requirements. c) Manufacture all pipes by an approved process utilizing a rotating mould or

mandrel besides equipment which accurately control the quantities and placement of all resins, glass and aggregates.

d) Use resins, reinforcements, and aggregates to produce pipes and fittings when combined as a composite structure to satisfy the performance requirements of this section of the specification. Pipes and fittings must be designed to achieve a minimum working life of 60 years under all applicable standard loadings, environmental and installation conditions.

e) Both internal and external surfaces shall be free from irregularities, which would impair the ability of the component to conform to the requirements of European Standard BS/DIN EN 14364.

2.2.1.2 Materials and pipe wall construction

The pipe or fitting shall be constructed using chopped and/or continuous glass filaments, strands or roving, mats or fabric, synthetic veils, and polyester/ vinyl ester resin without fillers and if applicable additives necessary to impart specific properties to the resin. The pipe as whole and the part of pipe used for fittings may also incorporate aggregates. All the raw materials used shall be from the pre-approved ADSSC’s approved list of suppliers.

Filament Wound (FW) GRP pipes and fittings: a) Resins.

o Vinyl ester shall be used in the internal resin rich liner of the pipe and fittings. Isophthalic or vinyl ester shall be used in the structural wall of the pipes and fittings, as per the design application requirements. All resins shall be tested in accordance with ASTM C-581or applicable standard. Provide resin systems to the requirements of BS 3532 type-B or to applicable standard.

o Resins shall be cured to achieve 90% of the manufacturer’s recommended Barcol hardness value, and may be tested by external laboratories for their authenticity of type by random sampling, during the project.

b) Additives. o The use of additives such as fire retardant, UV inhibitors or colored pigments

or dyes shall be subject to the approval of the Engineer & ADSSC and will only be approved in exceptional circumstances.

c) Glass for sewage applications. o As per the manufacturing technique, use C glass veil in the internal resin rich

liner backed by powder bonded acid resistant glass chopped strand mat. Use acid resistant glass roving for further structural layer reinforcement to comply


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with BS/DIN/ EN 14364. All glass shall have a surface treatment compatible with the resin

d) Aggregates and fillers.

o Sand aggregates shall be clean, graded silica sand containing no impurities and be in accordance with BS/DIN EN 14364.

o Fillers (other then sand aggregates) shall be permitted in accordance to BS/DIN/ EN 14364, provided the necessity is scientifically tested, justified and approved by the Engineer and ADSSC on all accounts of performance, including Qualifying Tests using Long Term type tests, at minimum a of 10,000 hrs.

Note: Filled pipes and fittings shall only be allowed on a project once the satisfactory Long Term test results are in hand & all conditions as stipulated above are met in advance.

e) Wall construction o Liner layer

i. The inner liner layer shall comprise minimum 1.5 mm thick rich Vinyl ester Resin suitably reinforced with C glass veil and backed up by remainder of liner in layers of powder bound acid resistant glass chopped strand mat or roving depending on the method of manufacture with a glass content of between 25% and 35% by weight. Sand aggregate shall not be used in the liner layer

ii. The pure resin used in this inner liner layer must conform to requirements given in BS/ DIN EN 14364 and to stipulation of section “a” as above.

iii. Resins shall be cured to achieve 90% of the manufacturer’s recommended Barcol hardness value.

Structural layer o Build up the structural layers by acid resistant glass chop roving or

continuous roving with a glass content of between 25% and 35% by weight. The structural layer shall consist of glass reinforcement and a thermosetting isopathalic polyester resin with or without sand aggregates.

o Aggregates can be used as per the manufacturing techniques applied, however ensure no aggregate becomes embedded in the internal resin rich liner layer.

o Outer layer

i. Pipes shall be provided with an external vinyl ester resin rich layer, with C- glass Veil.

ii. The resin used in the outer layer will be Vinyl ester and in accordance to BS/DIN EN 14364 shall have a Glass Transition temperature of at least 75 °C. In addition a sample shall be tested for HDT in accordance with Method A of DIN EN ISO 75 - 2.

iii. The use of special constructions is permitted when the pipe is expected to be exposed to extreme climatic, environmental or ground conditions, for example provision for the inclusion of pigments or inhibitors for


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extreme climatic conditions or fire retardation, upon the approval of the Engineer.

f) Wall thickness o The minimum total wall thickness, including the liner shall be declared by the

manufacturer. o Use pipes with wall thickness that achieve a minimum hoop flexural modulus

of 15.0 GN/m2 over the whole pipe wall thickness for pipes of 350mm diameter and above, and 12.0 GN/m2 for pipes of less than 350mm diameter. This shall be demonstrated by the application of the equation S = (EI)/D3 to show that the hoop flexural modulus of a pipe is not less than the required minimum figure where S is the stiffness of the manufactured pipe, D is the mean diameter of the manufactured pipe, E the required hoop flexural modulus and “I “being given by t3/12 where t is the whole wall thickness of the manufactured pipe.

g) Fittings

o Fittings shall be manufactured similar to the pipe construction or better thereof as per the existing world wide standard manufacturing techniques, complying with applicable standards on performance and testing.

Centrifugally cast (CC) GRP pipes and fittings:

a) Resin

o Vinyl ester shall be used in the internal resin rich liner of the pipe and fittings. Isophthalic or vinyl ester shall be used in the structural wall of the pipes and fittings, as per the design application requirements. All resins shall be tested in accordance with ASTM C-581or applicable standard. Provide resin systems to the requirements of BS 3532 type-B or to applicable standard.

o The resin used in the liner layer will be Vinyl ester and in accordance to BS/DIN/EN 14364 shall have a Glass Transition temperature of at least 75 °C. In addition a sample shall be tested for HDT in accordance with Method A of DIN EN ISO 75 - 2.

o Resins shall be cured to achieve 90% of the manufacturer’s recommended Barcol hardness value and may be tested by external laboratories for their authenticity of type by random sampling, during the project.

. b) Additives.

o The use of additives such as fire retardant, UV inhibitors or colored pigments or dyes shall be subject to the approval of the Engineer & ADSSC and will only be approved in exceptional circumstances.

c) Glass for sewage applications. o As per the manufacturing technique, use ‘E’ Glass as reinforcement for the

manufacturing as per BS/DIN EN 14364 (section 4.2) and DIN 16869-1 (section 5) , glass shall be of the following types:

i. Type 'E' glass, comprising primarily oxides of Silicon, Aluminium and Calcium (alumina– calcosilicate glass) or Silicon, Aluminium and Boron (alumino-borosilicate glass).


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ii. The chopped glass filament reinforcement shall be made from continuously drawn filaments of a glass conforming to type E Glass, and shall have a surface treatment compatible with the resin to be used in chopped filaments form of long and short fibers.

d) Aggregates and fillers. o Sand aggregates shall be clean, graded silica sand containing no impurities

and be in accordance with BS/DIN EN 14364. o Fillers (other then sand aggregates) shall be permitted in accordance to

BS/DIN/ EN 14364, provided the necessity is scientifically tested, justified and approved by the Consultant and the Client on all accounts of performance, including Qualifying Tests using Long Term type tests, at minimum a of 10,000 hrs.

o Note: Filled pipes and fittings shall only be allowed on a project once the satisfactory Long Term test results are in hand & all conditions as stipulated above are met in advance.

o e) Wall construction

o Liner layer i. The inner liner layer shall comprise minimum 1.5 mm thick pure Vinyl ester

Resin without Glass reinforcement and sand aggregates. ii. The pure resin used in this inner liner layer must conform to requirements

given in BS/DIN EN 14364 and to stipulation of section “a” as above. iii. Resins shall be cured to achieve 90% of the manufacturer’s recommended

Barcol hardness value. o Structural layer

i. The structural layer shall consist of glass reinforcement and a thermosetting isopathalic polyester resin with sand aggregates.

ii Aggregates can be used as per the manufacturing techniques applied, however ensure no aggregate becomes embedded in the internal resin rich liner.

o Outer layer i. This layer shall be formed of mortar in vinyl ester resin with sand

aggregates and without reinforcement of glass or synthetic filaments. ii. The resin used in the outer layer will be Vinyl ester and in accordance to

BS/DIN EN 14364 shall have a Glass Transition temperature of at least 75 °C. In addition a sample shall be tested for HDT in accordance with Method A of DIN EN ISO 75 - 2.

iii. The outer protective layer shall have a sand content with a minimum percentage of 65 % of sand for corrosion protection.

iv. The use of special constructions is permitted when the pipe is expected to be exposed to extreme climatic, environmental or ground conditions, for example provision for the inclusion of pigments or inhibitors for extreme climatic conditions or fire retardation, upon the approval of the Engineer.

f) Wall thickness o The minimum total wall thickness, including the liner and outer protective

layer shall be declared by the manufacturer, which shall be complying to the standard performance criteria.


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o Use pipes with wall thickness that achieve a minimum hoop flexural modulus of 15.0 GN/m2 over the reinforced wall thickness for pipes of 350mm diameter and above, and 12.0 GN/m2 for pipes of less than 350mm diameter. This shall be demonstrated by the application of the equation S = (EI)/D3 to show that the hoop flexural modulus of a pipe is not less than the required minimum figure where S is the stiffness of the manufactured pipe, D is the mean diameter of the manufactured pipe, E the required hoop flexural modulus and I being given by t3/12 where t is the reinforced wall thickness of the manufactured pipe.

g) Fittings o Fittings shall be manufactured similar to the pipe construction or better

thereof as per the existing standard manufacturing techniques, complying with applicable standards on performance and testing.

2.2.1.3 Mechanical and other characteristics The pipe class for a specific application shall depend on the required diameter (DN), the pressure rating (PN) necessary for the application, and the pipe stiffness (SN) derived from the structural analysis depending on site conditions (soil, installation, compaction, loads etc.). a) Minimum initial specific stiffness.

o As detailed in section 2.1.as above. o For other nominal stiffness class in certain areas in accordance to defined

parameters of BS/DIN EN 14364. b) Minimum initial specific longitudinal tensile strength shall be in

o accordance to BS/DIN EN 14364. c) Fabricate pipes and fittings capable of withstanding the working pressures, test

pressures and loadings specified. d) Pipes and fittings shall be suitable for carrying domestic sewage at

temperatures up to 50ºC and having a maximum sulphide concentration of 50 mg/litre.

e) Pipes and fittings to be designed to withstand up to 5% long term deflection in their installed conditions.

f) Conform to BS/DIN EN 14364 for pipe dimensions and tolerances. Deviations in diameters and wall thicknesses of pipe ends and coupling shall be such that the seal at the joints is not affected.

g) Ensure that the internal surfaces of the pipes and fittings are smooth, and that the internal and external surfaces are clean and free from defects such as protruding fibres, pits, cracks, blisters tackiness and embedded foreign matter. The core of the pipe wall shall be free of bubbles, voids, cracks and de-bonding.

h) All bends shall be long radius bends unless otherwise approved by the Engineer.

I ) latest Type Tests (Long Term test) results not later then three years from the date of submission of the proposed GRP pipes and fittings required for the Works including Manufacturers Certificates of compliance with this section of the standard specification, to be provided. (Refer to table 2.3.2 given below)

2.2.1.4 Joints General


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Joint performance shall be according to section 07 of BS/DIN EN 14364; in general. a) All buried joints shall be Non-end-load-bearing flexible joints of spigot and

socket type (including double socket designs) with EPDM rubber in full faced elements or rings in accordance with BS/DIN EN 681; manufactured according to the individual manufacturing technique and supplied as integral part of the pipe or separately. The sealing rings shall be supplied by the pipe manufacturer.

b) Non-end-load-bearing flexible joints with elastomeric seals shall be tested using test pieces conforming to BS/DIN EN 14364, for conformance to the test performance requirements under hydrostatic pressure.

c) For pipes up to and including 600mm nominal internal diameter joints shall be capable of withstanding a deflection of not less than one and a half degrees in any direction and remaining watertight. For pipes over 600mm nominal internal diameter joints shall be capable of withstanding a deflection of half degree in any direction and remaining watertight.

d) Joints shall be capable of withstanding a draw of 13mm over and above the initial jointing allowance and remaining watertight. The initial jointing allowance is the gap between the spigot and the shoulder of the socket measured parallel to the centre line of the pipeline and must not be less than 6mm or greater than 13mm or as recommended by the pipe manufacturer.

e) Additionally the pipe joints shall be capable of withstanding an external pressure equivalent to 10 m head of water without leakage in both the straight and deflected positions.

f) Joint couplers may be used adjacent to structures or special fittings. g) When a pipe is cut or turned down in order to form a joint fully seal the

exposed surfaces with a continuous coating of vinyl ester resin. h) Do not use butt/wrap joints without obtaining the approval of the Engineer.

Approval will only be given if the Contractor can demonstrate that this type of joint is the most suitable method of forming the joint. Such joints will be formed by specialist operatives under the supervision of the pipe manufacturer and fully in accordance with his recommendations. Use materials to be compatible with the pipes to be joined. Obtain the Engineer’s approval for the material along with the method, before work commences.

Table 2.2.1.4: Summary of test requirements for non-end-load-bearing flexible joints

Property to be tested

Tests to be performed Test pressure in Bars Duration

Initial Leakage Initial Pressure 1.5 x PN 15 min External pressure differential

Negative pressure a - 0.8 bar (- 0.08 MPa) 1 h

Misalignment and Draw Positive static pressure 2.0 x PN 24 h

Angular deflection and draw

Initial pressure 1.5 x PN 15 min

Positive static pressure 2.0 x PN 24 h


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a Relative to atmospheric, i.e. approximately 0.2 bar (0.02 MPa) absolute.

2.2.1.5 MARKING

a) Ensure that all pipes including cut lengths and all fittings before dispatch

from the pipe manufacturer's works are indelibly marked as follows:

i. The manufacturer's name, initials, or identification mark. ii. The nominal internal diameter in mm. iii. The length in m. iv. Mark the classification i.e. pressure rating, stiffness. v. The date of manufacture and batch number. vi. A stamp to show that they meet the required inspection requirements

and hydraulic tests (where applicable) at the point of manufacturer. vii. Stencil in legible letters the pipe identification number on the inside

and outside at each end. Ensure that the same number appears on all record sheets and documents relating to the manufacture delivery and testing of that pipe.

viii. The manufacturing standard. ix. The project or contract number.

2.2.2 EXPOSED GRP GRP pipes and fittings utilized for exposed service inside treatment plants, process

structures, pumping stations, and valve chambers shall be designed to resist all bending stresses, thrust forces, surge pressures, negative pressures and vibratory forces.

a) Exposed pipe and fittings shall be manufactured in the same manner and with the same materials as buried pipe, along with the following requirements unless otherwise approved by the Engineer.

i. Resin in the structural wall shall be Isophthalic or Vinyl ester. ii. Additional exterior stiffeners may be required to maintain circularity on large

diameter pipes and shall be installed to the manufacturer’s requirements. iii. Design of the outer layer of the pipes shall be formed of an vinyl ester resin

with or without sand aggregates and with or without reinforcement of glass. The outer protective layer shall have a minimum thickness of 1 mm and protect the structural layer against extraneous causes (atmospheric conditions, mechanical damage, UV and chemical stress). For Centrifugally Cast GRP Pipe the outer protective layer shall have a sand content with a minimum percentage of 65 % of sand against ultra – violet influences.

iv. Use flanged joints for all exposed pipes and fittings inside treatment plants, process structures, pumping stations, and valve chambers.

v. Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed with epoxy or vinyl ester resins only.

vi. All bolts shall be stainless steel grade 316. vii. Flanged pipe joints must incorporate an annular gasket at the joints and

these gaskets must cover the full face of the flange with holes cut in them corresponding to the bolt holes in the flanges. Drill flanges to BS EN 1092 (metric units) type PN16. If approved by the Engineer, use a plain ring


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covering the flange between the bolt circle and the bore of the pipe. Use 3mm thick gaskets incorporating two layers of cotton fabric insertions evenly spaced in the gasket. When flanged joints are to be made, secure the bolts and the nuts initially to finger tightness. Thereafter the final tightening of the nuts shall be effected by torque spanners in such sequence that diametrically opposite nuts are tightened together to achieve the manufacturers recommended torque.

viii. All joints shall be in accordance with the manufacturer's instructions. 2.3 QUALITY CONTROL TESTS 2.3.1 GRP PIPES AND FITTINGS

a) Routine Factory Quality Control Tests. i. Carry out the quality control tests listed below at the frequency stated. ii. Ensure that records of all tests and inspections are maintained by the

manufacturer. iii. Provide the Engineer with two copies of all test certificates and reports.

b) Raw Material Inspection. i. Inspect all raw materials to ensure that they comply with the relevant

standard. ii. Check all deliveries of resin for consistency by viscosity and reactivity.

Do not use any resins deviating from the manufacturer's published figures.

iii. Check all deliveries of sand and aggregates for grading, moisture content and purity.

iv. All resin type may be tested for quality and authenticity in external laboratories as and when deemed fit by the Engineer/ADSSC.

c) Hydraulic Test as per relevant manufacturing & testing standard For Filament wound GRP pipes.

i. Perform an internal hydraulic pressure test for every pipe at the manufacturer's works prior to delivery.

ii. Apply a test pressure of 15m water head for all gravity pipes. iii. Apply 1.5 times the pipe design pressure or surge pressure, which ever

is greater for all pressure pipes. Apply the test pressure for a minimum period of 5 minutes without signs of leakage.

iv. In addition to the above. Maintain at test pressure the first pipe and thereafter every 360

meter of pressure pipe and every 1200 meter of gravity pipe of each diameter produced for a minimum of 4 hours without signs of leakage.

Perform an internal low pressure air test for every pipe fitting at the manufacturer's works prior to delivery. Apply a test pressure of 0.1 bars for a minimum period of 5 minutes without signs of leakage or distress. Manufacture fittings which are of mitred construction from pipe which has successfully passed the tests defined above.

Follow section ( k) ,given below for Rejections


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For Centrifugally cast GRP pipes i. Perform an internal hydraulic burst pressure test for minimum 1 pipe

specimen or 360 meters, which ever comes first of pressure pipes produced.

ii. Burst pressure shall be more than 4 times the pressure rating of the Pipe. Testing is to be carried out as per relevant standard.

iii. In addition to the above. Maintain at test pressure the first pipe and thereafter every 360

meter of pressure pipe and every 1200 meter of gravity pipe of each diameter produced for a minimum of 4 hours without signs of leakage.

Perform an internal low pressure air test for every pipe fitting at the manufacturer's works prior to delivery. Apply a test pressure of 0.1 bars for a minimum period of 5 minutes without signs of leakage or distress. Manufacture fittings which are of mitred construction from pipe which has successfully passed the tests defined above.

Follow section (k), given below for Rejections.

d) Wall Thickness. i. Measure the wall thickness for each pipe and fitting. Maintain the total

thickness of nowhere less than the minimum or greater than the maximum quoted by the manufacturer's specification relating to initial stiffness. However minimum is governed by section 5.1.2 of BS/EN/14364.

e) Stiffness. i. Test a minimum of one pipe, for every 360 m pipe length manufactured

or any pipe length supplied for a project, whichever comes first to determine the initial specific stiffness in accordance with the test method detailed in BS/DIN EN 14364.

ii. Test a minimum of one pipe of each class and diameter of pipe. iii. Ensure that no test specimen has an initial specific stiffness of less than

as defined in section 2.1. iv. In addition.

Deflect each of the stiffness test specimens to the amounts indicated in Table 2.3.1 below according to its nominal stiffness. Ensure that at the lower deflection there is no visible damage as evidenced by surface cracks, and at the higher deflection there is no indication of structural damage as evidenced by interlaminar separation, separation of the liner or coating (if incorporated) from the structural wall, tensile failure of the glass fibre reinforcement, fracture or buckling of the pipe wall as per standard for inspection available.

Table 2.3.1 – GRP Quality Control Tests

Nominal Stiffness 5,000N/m2 10,000N/m

2


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No visible damage in liner layer as evidenced by surface cracks at a deflection of : 12% 9%

No structural damage at a deflection of: 20% 15%

f) Longitudinal Tensile Strength.

i. Measure in accordance with BS/DIN EN 14364 the tensile strength of a minimum of one pipe, for every 360 m pipe length manufactured or any pipe length supplied for a project, whichever comes first for each class and diameter, as per applied standard.

g) Cure. i. Perform in accordance with BS 4549 Part 1 Barcol hardness test on a

minimum of one in every 30 pipes manufactured. h) Loss on Ignition.

i. Test in accordance with ASTM D2584 a minimum of one pipe, for every 360 m pipe length manufactured or any pipe length supplied for a project, whichever comes first for each class and diameter, as per applied standard.

i) Joint Tests. i. Test in accordance with the requirements of ASTM D4161 or, DIN EN

1119 a minimum of two jointed pipes in every 1200 meter of pipes manufactured with the following additions. Conduct the positive test pressure. Conduct the negative pressure test to determine the adequacy of

the joint design against infiltration. Apply an external test pressure of 1.0 bar (gauge) to two sections of pipe assembled with a deflected joint.

j) Initial Circumferential Tensile strength. i. Determine the initial circumferential tensile strength of pressure pipes in

accordance with BS/DIN EN 1394. k) Rejection

i. Proceed as stipulated below if any pipe or fitting which fails any one of the quality control tests as per this section 2.3.

ii. In the event of a pipe failing any of the tests outlined, carry out the relevant test on a further 120 meters of pipes of that class and diameter as follows. Carry out the relevant test on 60 meters of these pipes produced

sequentially and immediately prior to the failed pipe and 60 meters immediately following.

If any one of these test on 120 meters of length fails, cease the manufacturing of pipes of that class and diameter. Discussions will be held between the Contractor and the Engineer to establish the significance of the failures. The suitability of manufactured pipes for the proposed installation conditions will be determined in the light of the test failures and the Engineer reserves the right to reject all the pipes of that class and diameter.


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Use the results of appropriate type tests to the proposed pipes and fittings to determine the properties of pipes. Carry out each type test on representative samples of the pipes. If the manufacturer does not have results of these tests available or if alterations are proposed to the method of manufacture, pipe design or laminate structure, carry out all the type tests required by the Engineer to prove the adequacy of the proposed pipes. Conduct the type tests as stipulated in Table 2.3.2 in accordance with the requirements of the mentioned standards and that the tests will be conducted at 23 +/-2ºC ambient temperature except for strain corrosion & long term failure pressure which will be tested at 40ºC +/- 2ºC.

Table 2.3.2 – GRP Type Tests (Long Term Tests for a minimum of 10,000 hrs)

Property Test method to BS/EN/14364 Long term specific stiffness and creep factor under wet and deflected condition.(min 18 samples)

ISO 10468, ISO 14828, ISO 10471, DIN 53769 the test results shall be extrapolated to 60 years. Section 5.2.2 of BS/EN/DIN 14364 shall be governing.

Long term resistance to strain corrosion .(min 18 samples)

ASTM D3681, DIN 53769, DIN EN 1120, the test results to be extrapolated to 60 years. Section 5.2.8 of BS/EN/DIN 14364 shall be governing. However, the 95% lower confidence limit failure strain must not be less than 0.85%,

Long term failure pressure.(min 18 samples)

ASTM D2992, DIN EN 1447, DIN 53769-2 the test results shall be extrapolated to 60 years Section 5.2.7 of BS/EN/DIN 14364 shall be governing.

2.4 PRODUCT WARRANTY

A corporate product warranty shall be provided by the Manufacturer for intended use/application of the product for a period of 60 years from the date of the Final Acceptance Certificate of the project issued by the Client.

3 EXECUTION

3.1 PIPE INSTALLATION

a) Trench excavation shall be carried out in accordance with Section 02120 of the specification.

b) Install pipe, fittings, and accessories in accordance with BS 8010, EN 1610 and manufacturer's instructions. i. Provide qualification details of the manufacturer's technical expert to be

assigned to the Contract. The technical expert shall have expertise, experience and skills necessary for advising and monitoring all aspects of transport, storage, handling and installation of pipes as appropriate.

ii. The technical expert shall provide comprehensive technical assistance to the Contractor throughout the Contract and regularly monitor the Contractor's activities and report on shortcomings.


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iii. The Contractor shall provide the Engineer and ADSSC copies of all instructions advice or reports given by the manufacturer's technical expert to him. The technical expert shall immediately inform the Engineer and ADSSC of any omission, variations and detractions from the approved handling and installation specification.

c) Install bedding, surround and backfill as specified in Section 02120 of the specification and shown on the drawings.

d) Install appurtenant facilities on the drainage pipelines such as manholes, chambers, inlet structures and catch basins as specified in Section 02300 of the specification.

e) Lay pipes from downstream to upstream with the socket end at the upstream end of each pipe.

f) The pipeline shall be within 20mm of the specified line and the invert level shall be within 6mm of the specified value and shall be such that there is no back fall at any point on a gravity pipeline.

g) Obtain satisfactory initial deflection test results for sections of pipeline laid between consecutive manholes or chambers prior to commencement of pipe laying in further sections.

h) When cut pipe is required, ensure that the cutting is done by a machine, leaving a smooth cut at right angles to the axis of the pipe.

i) When installing pipes, ensure the joint is cleaned and lubricated and that the rubber gasket is inserted in the groove of the socket end of the pipe. Align the spigot and insert home in the socket end. Use a metal feeler to check that the rubber gasket is correctly located. Spigot and socket flexible joints shall have the annular space between the pipe and socket sealed with an approved joint sealant to prevent the ingress of loose material or concrete. This sealing shall be carried out immediately on completion of a satisfactory initial hydraulic test prior to concreting or backfilling but not prior to the test.

j) Ensure that all pipes and fittings are sound and clean before laying. When pipe laying is not in progress, ensure that the pipe ends are at all times fitted with watertight plugs or caps. The plugs or caps shall only be removed for the purposes of making a connection of the pipe end or testing the pipeline. The plugs or cap shall be replaced immediately on completion of the test.

k) Protect bolted connections by an approved heat shrunk PVC sheath. Wrap the PVC sheath with a protective wrapping tape prior to backfilling in accordance with the specification.

l) Excavation for or laying of GRP shall not proceed until an approved device for gauging pipe deflections is on site. i. Use a suitable mechanised device to the approval of the Engineer for

gauging pipe deflections. Maintain devices for gauging pipe deflections in good working order. Submit calibration certificates before every period of use. o For pipes of less than 600mm diameter: Diametric dimensional

measurement of the pipe, both vertically and horizontally shall be made and recorded. Each deflection measurement taken along the length of the pipeline shall be identified and recorded. Provide a continuous print out or a visual display of the measurements on a remote monitor. The device shall be calibrated before each pipe length is tested.


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o For pipes of 600mm diameter and greater. Measure deflection by physical entry into the pipes. Use a regularly calibrated telescopic spring loaded graduated rod to measure percentage deflections in each diameter. Provide a suitable trolley to facilitate access into the pipe. Record all measurements.


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3.2 MANDATORY INSTALLATION MONITORING

It shall be absolutely mandatory for the manufacturer to give proper training with certification to educate contractor’s representative (name of the person and copy of the certificate to be provided) for installation procedures for their products and depute qualified personnel to monitor the installations intermittently throughout the course of the project execution and till the final commissioning test approvals from the designated authority. Any discrepancies or non compliance thereof, if observed, shall be promptly reported to Engineer or ADSSC for remedial measures. NOTE: In case of non compliance to the installation procedures set forth by the Manufacturer, further installation shall be stopped with immediate effect, by the Engineer without placing any project time lapse liability on the Engineer or ADSSC, by the main Contractor of award until it is otherwise advised. However a project delay penalty clause may be applied on the main Contractor as per the rules and regulations set by ADSSC.

3.3 FIELD HYDROSTATIC TESTING OF PIPELINES

3.3.1 HYDROSTATIC TESTING OF PIPELINES GENERAL.

a) Submit for the Engineer's approval details of the proposed methods and program for testing, including details of test equipment. Arrange for all tests to be witnessed by the Engineer or other person appointed by the Engineer. Provide everything necessary for carrying out testing and cleaning including water, pumps, gauges, piped connections, stop ends and all other temporary works. Ensure that pipelines are properly completed and supported before being put under test except as hereinafter detailed. i. No testing will be permitted until seven days after thrust blocks and

other holding down works have been completed. ii. In addition to any tests of individual joints or other interim tests, which

may be specified elsewhere, submit all parts of the pipelines to a final test.

iii. Notwithstanding the foregoing, carry out at any stage of construction other tests that the Engineer considers desirable to check materials and workmanship on the pipeline. Ensure that the obligations to perform successful tests under the Contract are achieved.

b) Use potable water for hydrostatic testing and pipeline cleaning. c) Test the pipeline in lengths between manholes or valve pits or such shorter

lengths as the Engineer may direct or permit. d) Use properly designed fittings for the purpose of temporarily closing the

openings in pipelines to be tested. Use fittings adequately strutted to withstand the pressure specified.

e) Ensure that the arrangement for testing a pipeline includes provision for the purging of air from the pipeline prior to a water test.

f) Where multiple pipelines are laid in common trench, test only one line at any one time.


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g) Ensure that gauges used for testing pipelines have a dial diameter of not less than 100mm and a full scale reading not greater than twice the specified test pressure. Before any gauge is used, arrange for independent laboratory to check the accuracy of the gauge. Provide a dated certificate of its accuracy/calibration to the Engineer.

h) The Contractor must make his own arrangement for the supply and disposal of water used for testing which must be obtained from a source accepted by the Engineer.

i) The Contractor must complete the pipelines between the ends of laid and tested lengths of pipeline by tie-in sections of the shortest practical length.

j) Any other testing method if intended to be used shall be according to the adequate and satisfactory reference provided along with Engineer & ADSSC approval.

3.3.2 FIELD HYDROSTATIC TESTING OF PRESSURE PIPELINES

a) Divide pressure pipelines into sections not exceeding 500m in length or as directed by Engineer. Test each section separately.

b) Before pressure testing is started, re-check the pipes and the valves for cleanliness, and re-check the operation of all valves. Cap off the open ends of the pipeline (or sections thereof) with blank flanges or cap ends additionally secured where necessary with temporary struts and wedges. Complete all anchor and thrust blocks and fasten securely all pipe straps and other devices intended to prevent the movement of pipes.

c) Apply test pressure to the entire pipeline or section being tested to 1.5 times

working pressure or 1.5 times the surge pressure which ever is greater. Immediately prior to commissioning, complete the pipeline and test the entire pipeline. i. Fill each pipeline or section with water and displace all free air from the

pipeline. ii. Raise the pressure in the pipeline by pumping water until the highest of

the working pressure/surge pressure is attained in the lowest part of the section.

iii. Maintain at this level by further pumping until it is steady for a period of not less than 24 hours.

iv. Monitor the pipeline over a period of 24 hours without further pressurisation.

v. At the end of this period, measure the reduced pressure in the pipeline, the original test pressure restored by pumping and the loss measured by drawing off water or air from the pipeline until the pressure has fallen to match the reduced pressure previously noted.

vi. Ensure that the loss does not exceed 0.02 litre per millimetre of pipe diameter per kilometre of pipe per day for each bar of head applied.

vii. If the pipeline fails the test, locate the faults, repair the repairable or replace with equivalent and retest the pipeline until it passes.

viii. Visually inspect all exposed pipe, fittings, valves and joints during the tests.


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ix. After satisfactory completion of the 24 hour period test, bring the pipeline to test pressure and maintain it at this pressure, by pumping if necessary, for one hour. Disconnect the pumping and no water is allowed to enter the pipeline for a further period of two hours.

x. At the end of the two hours period, restore the original test pressure by pumping water into the pipeline. Determine the volume of makeup water required to achieve the test pressure specified and deemed to represent the cumulative loss during the two hour period of test.

xi. Ensure the loss does not exceed the limit stated in ‘vi’ above. If the pipeline fails the test, locate and repair the faults and repeat the test.

d) Ensure that all valves in the pipeline are satisfactorily operating under working pressure and that the pipelines have been finally cleaned out as specified hereafter.

e) Do not test pipes against closed valves.

3.3.3 FIELD HYDROSTATIC TESTING OF NON PRESSURE PIPELINES

a) Test all non pressure pipelines up to 1000mm diameter after completion of concrete or granular bedding up to the soffit of the pipeline. Clear the bedding around pipe joints to allow for visual inspection for leaks. Ensure that the trench is kept dry. Apply water head for testing of either depth to invert plus 1.0m, or 5.0m, whichever is the greater. Measure the head at the lower end of the pipeline.

b) Maintain the water head over a period of 30 minutes and if necessary, add

water from a measuring vessel at 10 minute intervals. Record the quantity of water added from the measuring vessel.

i. The leakage, quantity of water added, shall not exceed 0.5 x pipe

diameter (m) x length of pipe under test (m) litres. c) For non pressure pipes greater than 1000mm diameter, inspection for water

tightness, workmanship and compliance to this specification shall be carried out by man entry.

d) Not more than 7 days prior to handover all pipelines shall be subject to an

infiltration test as follows:

i. Test the pipeline in lengths between manholes or such shorter lengths as the Engineer may direct or permit. Maximum length to be tested shall be 1 kilometre.

ii. Dewatering shall have been discontinued for at least 3 days prior to test. iii. Volume of water infiltrating into the pipe shall be accurately measured

for a minimum period of 1 hour. iv. Maximum infiltration shall not exceed 1 litre per millimetre of pipe

diameter per kilometre of pipe per day. e) Keep a record of all tests and make them available for inspection. Hand over

test records to the Engineer for approval.


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f) Pipes or joints shall not be accepted if any leakage or damage is visible during an internal inspection.

g) If the result of any test or inspection does not comply with the requirements of

the specification, the Contractor shall investigate the reason and carry out remedial work to the approval of the Engineer at no cost to ADSSC The pipeline shall then be re-tested. This process shall be repeated until the requirements of the specification are satisfied.

h) The Contractor may be required to incorporate a 100mm tee on property connection laterals near the junction of the main sewer and this tee may be used to insert an expanding stopper in the lateral for testing purposes. On the satisfactory completion of such tests, remove all temporary fittings from the lateral. Provide the tee with a watertight cap or plug.

3.4 FIELD DEFLECTION MEASUREMENT OF PIPELINES

3.4.1 GRP PIPELINES.

a) For pipeline length greater than 6.0m measure the horizontal and vertical deflections for all GRP pipes at each end at points 100mm away from the joint, 1.5m away from the joint and at 3.0m intervals hereafter. For pipeline lengths of equal to and less than 6.0m, measure the mentioned deflections at each end at a point 100mm away from the joint, and at the mid-point. For GRP pipes installed with granular bed and surround, take measurements on at least three separate occasions as follows.

i. After the pipe surround material has been placed and compacted to

150mm above the pipe crown. Do not proceed with further pipe laying until this test has been satisfactorily completed.

ii. On completion of all backfill material up to ground level but before the dewatering is removed. Take this measurement within one day of the completion of backfilling.

iii. Immediately prior to the issue of a Provisional Acceptance Certificate. b) For GRP pipes with concrete surround, carry out the deflection testing as in

stages (i) and (ii) above. For proving the pipes immediately prior to the issue of the Provisional Acceptance Certificate, draw a pig or ball through the pipeline, sized so that it will not pass any point in the pipeline which has been deflected to a greater degree than that permitted in the long term.

c) For pipes exhibiting any negative deflection in the vertical in excess of 2% in (i)

above and pipes exhibiting any deflection in excess of 4% in (ii) above, expose the pipe and replace and re-compact the surrounding bedding material. Replace the pipe should the deflection exceed 5% in (iii) above. Any pipe to be replaced must be taken away from site and not be incorporated into the permanent works.

d) Subject pipes exposed for re-compaction and pipes replaced for other reasons,

to the three deflection checks listed in clause 3..4.1 above. Carry out deflection


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checks on adjacent pipes for 50m either side of the re-compacted or replacement pipes.

e) Tabulate the results of the deflection measurements. Submit copies of the

results to the Engineer immediately after each set of measurements has been taken.

END OF SECTION