South African Specifications for Laying Pipes

8/11/2019 South African Specifications for Laying Pipes

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SPECIFICATION DWS 1110

CONSTRUCTION OF PIPELINES


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DWS 1110Construction of ipe!ines

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CONTENTS

CLAUSE PAGE

NUMBERS

1. SCOPE...............................................................................................................................................................................

2. STANDARDS....................................................................................................................................................................

3. MATERIALS............................................................................................................................................................... .....

3.1 PIPESANDFITTINGS........................................................................................................................................................3.2 VALVES............................................................................................................................................................................3.3 WATERMETERS...............................................................................................................................................................3.4 LININGANDCOATINGMATERIALS...................................................................................................................................3.5 POLYETHYLENESHEETS..................................................................................................................................................3.6 PRECASTREINFORCEDCONCRETECULVERTS..................................................................................................................3.7 CAST-IRONMANHOLECOVERSANDFRAMES...................................................................................................................3.8 FENCINGMATERIALSANDGATES....................................................................................................................................3. CEMENT..........................................................................................................................................................................3.1! AGGREGATESFORCONCRETEANDMORTAR....................................................................................................................3.11 WATERFORCONCRETEANDMORTAR..............................................................................................................................3.12 CONCRETE.......................................................................................................................................................................3.13 FORMWOR".....................................................................................................................................................................3.14 CONCRETEREINFORCEMENT...........................................................................................................................................3.15 #RIC"S............................................................................................................................................................................3.16 #AC"FILLMATERIAL.......................................................................................................................................................3.17 STORAGE$ HANDLINGANDTRANSPORTOFPIPES$ SPECIALSANDFITTINGS.....................................................................3.18 RECORDSOFMATERIALSONSITE....................................................................................................................................

3 1 REPAIRS

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8. NIGHT-CAPS......................................................................................................................................................................

8.1! PREVENTIONOFFLOTATION.............................................................................................................................................. REPAIRS TO LININGS! COATINGS AND PROTECTION OF JOINTS................................................................

.1 GENERAL............................................................................................................................................................................2 #ITUMENLININGSANDCOATINGS......................................................................................................................................3 CEMENT MORTAR&CONCRETE' LININGS..............................................................................................................................4 SHOPAPPLIEDEPO%YLININGSANDCOATINGS...................................................................................................................5 IN-SITUAPPLIEDEPO%YLININGS........................................................................................................................................6 PLASTICTAPEWRAPPING....................................................................................................................................................7 COALTARCOATINGS..........................................................................................................................................................8 PROTECTIONOFFLE%I#LECOUPLINGSANDFLANGES.......................................................................................................

1". CROSSING OF ROADS! RAILWAYS AND STREAMS.......................................................................................... .

1!.1 GENERAL.........................................................................................................................................................................1!.2 ROADCROSSINGS............................................................................................................................................................1!.3 RAILCROSSINGS..............................................................................................................................................................1!.4 STREAMCROSSINGS........................................................................................................................................................

11. CATHODIC AND LIGHTNING PROTECTION.............................................................................................. ........

11.1 CATHODICPROTECTION...................................................................................................................................................11.2 LIGHTNINGPROTECTION.................................................................................................................................................

12. HYDROSTATIC TESTING....................................................................................................................................... ...

12.1 GENERAL.........................................................................................................................................................................12.2 TESTPRESSURES..............................................................................................................................................................12.3 LEA"AGERATES..............................................................................................................................................................12.4 STATEOFVALVESDURINGTEST.......................................................................................................................................12.5 METHODOFTESTING......................................................................................................................................................

12 6 REMEDIAL MEASURES

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2!.8 SELECTED#AC"FILL.......................................................................................................................................................

2!. COMMON#AC"FILL.........................................................................................................................................................2!.1! CLEANINGOFSERVITUDE..............................................................................................................................................2!.11 LAYINGAND)OINTINGOFPIPINGANDSPECIALS...........................................................................................................2!.12 INSTALLATIONOFIN-LINEVALVES$ METERSANDFITTINGS...........................................................................................2!.13 PIPELINEOFF-TA"ESANDFITTINGS...............................................................................................................................2!.14 CHAM#ERS$ CULVERTSANDPIPELINESTRUCTURES.......................................................................................................2!.15 FENCING........................................................................................................................................................................2!.16 HYDROSTATICTESTING$ FRICTION*CAPACITYTESTINGANDDRAINING.........................................................................2!.17 STERILI+ATION..............................................................................................................................................................2!.18 LIGHTNINGPROTECTION...............................................................................................................................................

2!.1 CATHODICPROTECTION.................................................................................................................................................2!.2! MAR"ER#EACONS$ #ENCHMAR"S$ TRIANGULATIONPOINTS$ STAINLESSSTEELMAR"ERSANDMAR"INGAND

SCHEDULESOFINSTALLATIONS...................................................................................................................................

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1. SCOPE

"his specification covers the construction of pressure pipe!ines of stee! reinforced concrete prestressed concrete and fire2cement for the conveance of 4ater at amient temperatures5

2. STANDARDS

"he fo!!o4in Standard Specifications Codes of ractice and Reu!ations are referred to and sha!! app! as specified hereinafter5"he !atest issues sha!! app!:DWS1130 : Department of Water &ffairs 7Standard Specification for the manufacture and supp! of stee! pipes

specia!s and fittins for duties up to 6 Ma desin pressure57DWS1131 : Department of Water &ffairs 7Standard Specification for the !inin and coatin of stee! pipes and

specia!s57C2( : Department of Water &ffairs 7Standard Specification for the desin manufacture and supp! of

prestressed concrete non2c!inder pipes and matin fittins57C2C : Department of Water &ffairs 7Standard Specification for the desin manufacture and supp! of

stee! c!inder tpe prestressed concrete pipes and matin fittins57DWS.10 : Department of Water &ffairs 7Standard Specif ication for the supp! of va!ves57S&*S 6: : Stee! pipes and pipe fittins up to 1.0 mm nomina! oreS&*S 13. : -S% Metric !ac o!ts scre4s and nutsS&*S 136 : -S% Metric precision heaon2head o!ts scre4s and nutsS&*S 6 : Water taps

S&*S ; : *urnt c!a masonr unitsS&*S 80 : #o!e !ocation in fencin posts and droppersS&*S 308 : Cutac itumenS&*S .; : Wooden posts and droppers for fencesS&*S ;1 : ort!and cementS&*S .09 : Ma!!ea!e cast iron pipe fittinsS&*S .33 : *!ac po!eth!ene pipes for the conveance of !ip!ain and ared?S&*S 6;6 : Reinforced concrete pressure pipesS&*S ;19 : $!ectric 4e!ded !o4 caron stee! pipes for a


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*S 8010 : ipe!inesS-S 0..900 : ictoria! surface preparation standards for paintin stee! surfaces >S4edish?

&- 110 : Standard for 4e!din pipe!ines and re!ated faci!ities >&merican etro!eum -nstitue?Res//) : amph!et: re!iminar -nformation >She!! Chemica!s )B 'td?

&ct 8./1993 : %ccupationa! #ea!th and Safet act >as amended?&ct 6/19.6 :$p!osives act and reu!ations >as amended?&ct 103/19;; : (ationa! ui!din reu!ations and ui!din standards

2 7Desin for una!anced thrust for uried 4ater conduits7 C5&5 Mananaro >our5 &WW& une1968?

27 #arnessed Aoints for 4ater pipe C5&5 Mananaro >our5 &WW& u! 1969?-S% ;00. : Meta!ic f!anes

3. MATERIALS

3.1 Pipes and fittings

35151 Stee! pipes specia!s and coup!ins

3515151 Stee! pipes specia!s and f!ei!e coup!ins sha!! conform to the 7Department of Water &ffairs7 Standard Specification DWS11305

351515 'inins and coatins to stee! pipes and specia!s sha!! conform to the 7Department of Water &ffairs7 Standard SpecificationDWS11315

3515 restressed concrete pipes and specia!s

351551 (on2c!inder tpe prestressed concrete pipes and specia!s sha!! conform to the 7Department of Water &ffairs7 StandardSpecification 7C2(75

35155 $medded stee!2c!inder tpe and !ined stee!2c!inder tpe prestressed concrete pipes and specia!s sha!! conform to the7Department of Water &ffairs7 Standard Specification 7C2C75

35153 Reinforced concrete pipes

Reinforced concrete pressure pipes sha!! conform to S&*S 6;65

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35159 *o!ts nuts and 4ashers

3515951 *o!ts and nuts sha!! conform to S&*S 13. or S&*S 1365 *o!ts sha!! e of sufficient !enth for at !east t4o scre4 threads toprotrude from the nut 4hen assem!ies are fu!! tihtened5

351595 Washers sha!! e of appropriate materia! and dimensions sha!! conform to S&*S 1195

351510 ,asets

,asets for f!aned Aoints sha!! e of compressed asestos fire to *S 81. ,rade 7&7 and fu!! faced 4ith a minimum thicnessof 3 mm5 +or pressures up to and inc!udin 16 Ma c!oth2inserted ruer ma e used5

3.2 Valves

3551 a!ves sha!! conform to the 7Department of Water &ffairs7 Standard Specification DWS .105

355 Stop cocs sha!! e rass or unmeta! heav pattern scre4do4n tpes conformin to S&*S 65

3.3 Water meters

35351 Water meters at off2taes sha!! e capa!e of meterin f!o4 4ithin an accurac of E of true f!o4 over rated f!o4 ranes5"urndo4n ratios sha!! not e !ess than 1:10 for sin!e meters and 1:0 for compound meters5

3535 $ach meter sha!! e insta!!ed comp!ete 4ith strainers or dirt traps on the upstream side5

35353 Meters of 0 mm si@e and sma!!er sha!! e rotar piston tpe domestic meters 4ith interators ca!irated in cuic metres5-nterators sha!! have at !east seven effective cc!ometer diits5

3535 Meters !arer than 0 mm sha!! e 7Spar!in7 or simi!ar tpe rotar meters 4ith interchanea!e mechanisms5 Meters sha!! esupp!ied comp!ete 4ith one spare mechanism for ever five or part of five meters of simi!ar si@e and ratin5 -nterators sha!! eca!irated in cuic metres 4ith at !east seven effective cc!ometer diits5

3 4 Lining and coating materials

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Cast2iron manho!e covers and frames sha!! conform to S&*S ..85

3.# $encing materials and gates

35851 Droppers and posts sha!! conform to S&*S 80 and S&*S .;5

3585 ,a!vani@ed 4ire sha!! conform to S&*S 6;.5

35853 We!d mesh sha!! conform to CBS 5

3585 Diamond mesh sha!! e a!vani@ed and sha!! conform to the re(a%? e


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3.14 !oncrete reinforcement

35151 *ar reinforcement sha!! conform to S&*S 905

3515 We!ded stee! faric reinforcement sha!! conform to S&*S 105

3.15 *ric)s

*ui!din rics and !ocs sha!! conform to S&*S ;5

3.16 *ac)fill material

351651 ,enera!

Materia! for eddin of pipes and for se!ected acfi!! around pipes sha!! e free from veeta!e matter and hard sharp and f!aepartic!es or other materia!s harmfu! to the pipes or to the protective coatins of pipes5

35165 *eddin materia! sha!! e either of the fo!!o4in tpe:

3516551 "pe &: +ine! raded composed of materia! 4ith the fo!!o4in properties:

>i? ercentae mass passin: ;. mm screen 2 100E0. mm screen 2 80 to 100E000 mm screen 2 0 to .E

>ii? 'i''? as determined in accordance 4ith S&*S Method 8.1 sha!! not e more than 30E 4hen performed on a!!the materia! passin the 0. mm sieve5

>iii? !asticit inde >-? as determined in accordance 4ith S&*S Method 8. sha!! not e more than 1. 4hen performed ona!! the materia! passin the 0. mm sieve5

>iv? 'inearshrinae >'S? as determined in accordance 4ith S&*S Method8.3 sha!! not eceed .E 4hen performed on

1!


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351653 -tems - 3516551 to 3516553 are convenient! summari@ed in the fo!!o4in ta!e:

$RC$("&,$ *H M&SS &SS-(, SCR$$(S &""$R*$R, '-M-"S S#&'' (%"$IC$$D

M&"$R-&'/"H$ 9.mm ;.mm 0.mm 000mm '-J)-D'-M-"

'&S"-C-"H-(D$I

'-($&RS#R-(B&,$

>''?E >-? >'S?E

+ine! raded & 100 100 802100 02. 30 1. .Medium raded * 100 802100 60280 020 3. 18 ;.,ranu!ar C 100 ;02122 30260 023. 0 0 10

35165 Se!ected acfi!!

3516551 +or pipe!ines 4ith oranic coatins or for fire2cement pipe!ines se!ected acfi!! sha!! conform to the re60E? mass of an samp!e of the materia! sha!! meet the re


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351;5 Storae

351;551 ipes sha!! enera!! e distriuted and stored as c!ose as possi!e to the !ain position in order to minimise dou!e hand!in5Where pipes are strun a!onside the trench the shou!d e p!aced on the side a4a from ecavated materia!5

351;55 Where pipes specia!s and fittins are to e stocpi!ed in u! storae ards the Contractor sha!! mae his o4n arranements fora suita!e area 4hich sha!! meet 4ith the $nineerKs approva!5 "he stocpi!in area sha!! e ade


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&reas 4hich cannot e tested 4hi!st pipes are supported on crad!es or other4ise sha!! e tested 4hi!st pipe is suspended aove

the trench immediate! prior to !ain5 Defective areas of !inins and coatins sha!! e mared 4hen detected and sha!! erepaired to the $nineerKs approva! 4ith materia!s specified respective! for the oriina! and/or coatin5 Repaired !inins andcoatins sha!! e inspected and re2tested after repair and sha!! have the same properties as specified for the oriina! ones5

351953 Repairs to dented stee! pipes and specia!s sha!! on! e attempted if the dimensions et4een the !o4est point of a dent and theoriina! pipe contour is !ess than E of the outside diameter of the pipe or specia! for pipes and specia!s up to ..88 mm %D and1E of the outside diameter for !arer pipes and specia!s5 Repair of these minor dents sha!! e done as approved the $nineerand a!! such reparis sha!! e tested the app!ication of a de penetrant to detect cracs or !aminations in the meta!5

35195 Dents in stee! pipes or specia!s of 4hich the depth eceed the aove !imits and an dents 4hich contain scratches or rooves or4hich affect the curvature of pipe arre!s at 4e!ds sha!! e cut out cuttin of a !enth of pipe arre! !on enouh to e!iminatethe defect5 Damaed sections sha!! e rep!aced in accordance 4ith the $nineerKs instructions5 "he ends of pipes intended forfie!d 4e!din sha!! e rechamfered to 30 G . 4ith 4idth of root face 16 mm G 08 mm5

35195. &!! fire2cement pipes 4ith cracs in the pipe od or chipped ends 4hich etend further than 0 mm into the pipe odmeasured from the oriina! pipe end sha!! e reAected5 Where instructed the $nineer the eterior surfaces of fire2cementpipes sha!! e 4iped 4ith 4et ra to faci!itate the detection of hair cracs5

351956 Concrete pipes sha!! e free from structura! cracs and there sha!! e no chips that 4ou!d e detrimenta! to the performance ofthe pipe5

3.2& aintenance of cleanliness

35051 $nd covers to pipes and specia!s sha!! e ept firm! in position unti! insta!!ation of same in the trench5

3505 "he interior surfaces of a!! pipes specia!s va!ves and fittins sha!! at a!! times e ept free from dust si!t forein matter andaccess for rodents anima!s and irds sha!! e prevented5 ipes and specia!s sha!! not e used as she!ters staff or for thestorae of arments too!s materia!s food containers or simi!ar oods5 articu!ar care sha!! e eercised at a!! times to preventfacae! contamination of pipe interiors staff casua! visitors or passers5

4. DESIGN AND SETTING OUT

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515351 ipe!ines sha!! e !aid in straiht !ines or rades et4een chanes of direction or rades5 "he pipe rade sha!! fo!!o4 the enera!

confiuration of the round and sha!! not e f!atter than 1:.005 "he fo!!o4in minimum depths of cover to natura! round !eve!over the cro4n of the pipe sha!! e maintained:

'%C&"-%( M-(-M)M D$"# %+ C%$R %$R CR%W(%+ -$ -( mm

Cu!tivated round 900e!d ;.0"hrouh to4ns and ui!t2up areas 900)ncu!tivated round 4ith sha!!o4 roc 600N

N SuAect to the $nineerKs approva!

51535 Where trench depths eceed the eterna! !oad capacit of pipes the eddin sha!! e se!ected in accordance 4ith S&*S 100 '*and the eterna! !oads ca!cu!ated in accordance 4ith S&*S 0105

515353 Def!ections in the pipe ais of reater than 111 sha!! on! e made 4ith manufactured ends5 Sma!!er def!ections ma emade as specified hereinafter5

51535 Computations and desin of anchor and thrust !ocs sha!! e in accordance 4ith 7Desin for )na!anced "hrust for *uriedWater Conduits7 C5&5 Mananaro pu!ished in ourna! of &merican Water Wors &ssociation une 19685 (umerica! va!uesfor shear 7O7 >ranu!ar soi!s? for cohesion 7C7 >c!as? and unit 4eiht 7H7 of soi!s sha!! e otained testin samp!es of soi!s in

an approved !aorator5 Where these va!ues cannot e determined eperimenta!! the sha!! e taen as the fo!!o4in 4ith unitsin the -mperia! sstem to suit the specified desin methods5

"H$ %+ S%-' -( D$,R$$S

7c7C%#$S-%( -(

!s/ft

7H7)(-" W$-,#"

-( !s/ft3

er soft and 4et c!a 0 00 100Soft c!a and turf 00 100Dr and ver stiff c!a 10 1 .00 100Dr sand 3 0 90C!ae sands 30 00 90D d d ! 3 1 000 100

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-n the fina! !aid position pipe invert !eve!s sha!! e 4ithin G . mm of the invert !eve!s on approved dra4ins utnon4ithstandin this to!erance the same direction of rade as per approved dra4ins sha!! e maintained and the rade

sha!! not e f!atter than 1:.005

>c? ositions of fittins specia!s and va!ves

+ittins specia!s and va!ves sha!! e insta!!ed 4ithin . m of the p!an position indicated on the approved dra4ins5

>d? *enchmars and trianu!ation points

&!! !eve!s sha!! e reduced !eve!s aove mean sea !eve! and sha!! e indicated to the nearest 000. m5 &!! co2ordinatessha!! e ased on the app!ica!e 'o sstem and sha!! e indicated to the nearest 01 m5 'eve!!in sha!! e carried out toan accurac such that the c!osin error et4een enchmars does not eceed 003 times the sa? &ccurate determination of as2!aid invert !eve!s of the pipe!ine efore acfi!!in commences5>? &ccurate fiin trianu!ation of a!! chanes in direction efore acfi!!in commences5

>c? &ccurate determination of eact as !aid chainaes of a!! specia!s chanes in direction and/or rade va!ves off2taesstructures etc5 taen a!on the pipe!ine efore acfi!!in commences5

>d? "he esta!ishment of permanent surface ench mars a!on the pipe!ine route at interva!s not eceedin t4o i!ometres

and accurate !eve!!in of same5 *ench mars to e sited 4ithin the pipe!ine servitude 4idth as indicated on the dra4ins5

>e? "he esta!ishment of permanent surface trianu!ation points a!on the pipe!ine route at interva!s not eceedin .i!ometres and determination of co2ordinates of same5 "rianu!ation points to e sited 4ithin the pipe!ine servitude 4idthas indicated on the dra4ins5

55 'eve!s and co2ordinates over an section of pipe!ine acfi!!ed sha!! e made avai!a!e to the $nineer on re


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.5156 "he issue of the +ina! Certificate in terms of the ,enera! Conditions of Contract sha!! e suAect to the Contractor producin tothe $nineer a certificate sined the !ando4ner or !essee in


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5.5 emporary fencing of (or)ing areas

.5.51 Where demanded o4ners or instructed the $nineer the Contractor sha!! fence one or oth sides of the pipe!ine servitudeas ma e re


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6.3 0eneral levelling

65351 -f o4in to ecessive cross2fa!!s the Contractor re&ct 6 of19.6 and amendments?5 *!astin sha!! not e carried out 4ithout the approva! of the $nineer5 Such approva! sha!! not re!ievethe Contractor of an of his !iai!ities o!iations or riss under the &ct or the Contract5 roper precautions sha!! e taen toprotect persons the 4ors and the propert and the $nineer ma instruct the use of !astin mats at the ContractorKs epenseover an or a!! sections of ecavations 4hether in open countr or other4ise5 "he Contractor sha!! co!!ect f! roc if animmediate! after each !ast5 *!astin ma e prohiited 4here in the opinion of the $nineer inAur to persons and/or damaeto propert and/or service and uti!it insta!!ation is !ie!5

When !astin 4ithin .00 metres of an permanent structure aove or e!o4 round inc!udin pipe!ines ui!dins etc5descried in c!ause 1051;51 and 1051;5 of the $p!osives Reu!ations no5 160 of the $p!osives &ct no5 6 of 19.6 the peapartic!e ve!ocit as defined in a technica! u!!etin 7$p!osive "oda7 no5 ; March 198 of &$ P C- sha!! at no stae eceed .mm/s adAacent to an of these structures5 "hese pa partic!e ve!ocities sha!! e measured an approved irorecorder and

ti ! ! it t f h ! t th f !! ! th f hi h f !! ithi th !i it Sh !d ! ti

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;51535151 Minimum trench 4idths sha!! enera!! e as fo!!o4s:

-$ (%M-(&' *%R$ -( mm W-D"# %+ "R$(C# -( mm

300 and sma!!er;00 and sma!!er!arer than ;00

D G 300D G 600D G 800

Widths of trenches sha!! e maintained at the ase of the trench and the !aid pipe!ine sha!! e !ocated centra!! in the trench to

ena!e acfi!! to e effective! rammed e!o4 the !o4er ha!f of the pipe on oth sides of the pipe5

;5153515 &t tie2ins on 4e!ded pipe!ines trenches sha!! e ecavated to a 4idth of not !ess than 900 mm in ecess of the minimum 4idthsto a depth of not !ess than ;.0 mm e!o4 pipe invert !eve! and for a !enth of not !ess than 900 mm centred on the Aoint5 +orpipe!ines 4ith f!ei!e Aoints sufficient space sha!! e a!!o4ed around Aoints to permit proper main and inspection of Aoints5

;51535 "rench depth

;5153551 ,enera!

"renches sha!! e ecavated to the rades and !eve!s sho4n on the approved dra4ins and depths sha!! e so contro!!ed that auniform depth of eddin underneath the pipe!ine is ensured5

;515355 "rench ottoms

;51535551 "renches sha!! e ecavated and trimmed to a depth of not !ess than 1.0 mm e!o4 the underside of pipes in the case of 4e!dedor coup!ed stee! and fire2cement pipe!ines and not !ess than 00 mm e!o4 the underside of pipes in the case of f!aned stee!pipes or prestressed or reinforced concrete pipes 4ith socet2end diameter in ecess of pipe arre! outside diameters5 "hesedepths sha!! e maintained for the fu!! 4idth and !enth of the trench and a!! stones rocs or other proAections trimmedaccordin!5

;5153555 "he Contractor sha!! advise the $nineer 4henever trench ottoms have een ecavated and trimmed and are read forinspection5 (o trench ottoms sha!! e covered 4ith eddin materia! or pipes !aid unti! the inspection has een carried out andthe trench ottoms passed5 +ai!ure of the Contractor to comp! 4ith this c!ause sha!! render the Contractor !ia!e to re2open

d i t t t h tt f i ti t th C t t K

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.2 *ac)filling

;551 ,enera!

;55151 "he Contractor sha!! neotiate direct! 4ith !ando4ners or !essees in reard to orro4 pits for paddin or se!ected acfi!!materia!5 &!! such sites sha!! e suAect to the approva! of the $nineer5

"he $nineer sha!! e ept fu!! informed of a!! neotiations that are in proress et4een the Contractor and the !ando4ners or!essees5 -t is essentia! that the Contractor sha!! mae prompt pament to !ando4ners or !essees for an roa!ties for orro4 pitsand for an areed amounts to e paid to the !ando4ners or !essees for the use of orro4 pits access roads use of roundoutside servitudes etc5

;5515 -t is desira!e that trenches sha!! e acfi!!ed as soon as possi!e after pipe !ain to curtai! therma! movements of the pipe!inedamae to coatins and f!otation of the pipe!ine shou!d the trench fi! ! 4ith 4ater5 &t no time sha!! acfi! !in !a more than .00metres ehind the !ast pipe !aid5 &!! specif ied tests on pipe arre!s and Aoints sha!! therefore e carried out as soon as possi!e5

;55153 "he Contractor ma use his discretion as 4hether to acfi!! around Aoints efore the pipe!ine is hdrostatica!! tested5 "heContractor sha!! e responsi!e for the !ocation and repair of an !eas on the pipe!ine under hdrostatic test and no etrapament 4i!! e made for an re2ecavation and suse


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;55 Se!ected acfi!!

;5551 Se!ected acfi!! comprises acfi!! materia! p!aced and compacted in trenches from the top !eve! of comp!eted eddins up to a!eve! of 300 mm aove the cro4n of pipes5

;555 &s soon as possi!e after comp!eted eddins have een inspected and accepted the $nineer se!ected acfi!! sha!! ep!aced and compacted even! on oth sides of the pipe compaction to e pneumatic rammers or virator ro!!ers or ma ep!aced as a hdrau!ic fi!! and compacted poer virators5 "he method adopted sha!! e suAect to the $nineerKs approva!5Whatever method is adopted and approved reat care sha!! e eercised at a!! times to prevent damae to pipe coatins ordisturance of the pipe !eve! or rade f!otation or other4ise5

;5553 -f compaction is pneumatic rammers or virator ro!!ers compaction sha!! e in !aers not eceedin 1.0 mm in the !oose4atered to optimum moisture content and compacted to densities as per C!ause ;5565

;555 "he top surface of the comp!eted se!ected acfi!! sha!! e !eve! over the fu!! 4idth and !enth of the trench5 "he compactedse!ected acfi!! sha!! comp!ete! fi!! a!! spaces et4een the pipe and trench 4a!!s inc!udin an cavities that miht eist in trench4a!!s5

;555. -f se!ected acfi!! of the re00? mm measured in !oose and each !aer sha!! ecompacted sufficient! to a densit of at !east 80E of the Modified &&S#"% maimum dr densit to prevent !ater sett!ement5"he trench sha!! e fi!!ed to the !eve! to 4hich the topsoi! 4as oriina!! separate! removed5 "he top of the trench sha!! then ecomp!ete! fi!!ed 4ith the topsoi! and compacted up to the oriina! round !eve!5 "he top of the trench ma e mounded to 1.0

t id f tt! t id d t ! d i f th d i t i t f d ith

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. LAYING AND !OINTING OF PIPES AND SPECIALS

#.1 0eneral

85151 ipe!ines sha!! e !aid to straiht rades et4een vertica! ends and sha!! e 4ithin the specified to!erances to the routes and!eve!s indicated on the approved 4orin dra4ins5

8515 ipes sha!! e !aid free from co!d stresses5 (o def!ections sha!! e taen in curvature of pipes ut sha!! e taen 4ith approvedprefaricated ends 4ith eceptions as hereinafter specified5

85153 &!! def!ections under 6 of the ais of pipe!ines 4ith f!ei!e Aoints ma e made spreadin the def!ection over not !ess than .numer of Aoints provided a!4as that the def!ection in an one Aoint does not eceed those recommended the manufacturer ofthe Aoint after a!!o4ance for pipe sett!ement heave or other round or pipe movements5

8515 &!! def!ection in the ais of utt 4e!ded stee! pipe!ines of under 11. or !ess sha!! e made scarfin e


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&t the point of insta!!ation of the thrust f!ane the pipe coatin sha!! e stripped of the pipe for a distance of 300 mm5 "he f!ane

sements sha!! e dou!e fi!!et 4e!ded to the pipe arre! around the fu!! circumference and a!so a!on oth sides of the sp!it 4hichsha!! e chamfered for 4e!din5 &fter 4e!din the coatin and !inin of the pipe sha!! e made ood5

8555; "emporar c!osure pipes

"emporar c!osure pieces of the same standard diameter and 4a!! thicness as the pipe!ine sha!! norma!! e Aointed 4ith f!anesand/or f!ei!e coup!ins ecept 4here other4ise specified or instructed the $nineer5

85558 &ccess e


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8553 (o 4e!din sha!! e carried out durin rain or hih 4ind or under dust conditions un!ess the 4e!der the 4e!d area and the 4e!d

are ade


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85.535 oints sha!! e made and coup!ins assem!ed to the manufacturerKs instructions5 *o!ts sha!! e p!aced 4ith o!t heads

a!ternate! pointin in opposite directions5

85.5353 3 of the numer of coup!in o!ts e


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8585 "he Contractor sha!! at his o4n epense mae ood an damae to va!ves and fittin or c!oin of off2taes or ma!2functioninof fittins 4hich resu!t from his fai!ure to eep the pipe!ine in a thorouh! c!ean condition5

#.% ight"caps

85951 Meta! niht2caps sha!! e used to c!ose off a!! ends of each !aid section of pipe4or 4hen 4or is stopped at the end of the da orfor !oner periods and sha!! e !eft on the ends of sections of comp!eted pipe4or unti! such sections are tied2in 4ith theremainder of the comp!eted pipe!ine5 "he niht2caps sha!! consist of a stee! p!ate 4e!ded into a ha!f coup!in 4hich must eprovided 4ith a sufficient numer of !us to secure the rin and aset and sha!! e stron enouh to 4ithstand eterna! 4aterand earth pressure in the event of f!oodin or co!!apse of earth and the Aoint sha!! e 4atertiht5

8595 "he Contractor sha!! a!so at his o4n epense !an2off a!! air va!ves scour va!ves and off2taes 4ith 6 mm thic !an f!anes4hich sha!! e o!ted 4ith at !east four o!ts to tee f!anes or sha!! e fied to p!ain ended tee ranches ha!f coup!ins 4e!ded

to the !an f!anes5 "hese sha!! e 4atertiht and sha!! not e removed unti! the va!ves or other fittins are aout to e fitted5

85953 (ot4ithstandin the use of niht2caps the Contractor sha!! at his o4n epense mae ood a!! damae to pipe !inins and fittinscaused the inress of dirt 4ater si!t sand deris vermin insects and other forein matter5 "he Contractor sha!! at his o4nepense and to the satisfaction of the $nineer c!ean the interior of the pipe!ine of such contaminants5

#.1& Prevention of flotation

851051 ipes to e encased in concrete sha!! e prevented from f!otation durin concretin operations5 &part from this specia! casedurin concretin operations the Contractor sha!! prevent the f!otation of pipe4or due to storm4ater or round4ater enterin the

trench efore acfi!!in has een comp!eted5

85105 Methods adopted to prevent f!otation sha!! not damae coatins or !inins and sha!! e approved the $nineer5(ot4ithstandin this the Contractor sha!! at his o4n epense repair a!! damae to pipe4or caused f!otation and/or themethods adopted to prevent it5

". REPAIRS TO LININGS# COATINGS AND PROTECTION OF !OINTS

%.1 0eneral

26


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9555 & f!ood coat of hot app!ied itumen sha!! e app!ied to primed repair areas of coatins to ive a coatin thicness not !ess than1. mm at an point5

95553 & sin!e 4rap of !ass fire tissue saturated 4ith hot itumen sha!! then e app!ied around the 4ho!e circumference of the Aoint orover the 4ho!e area of repair 4hichever is app!ica!e in a manner such that the tissue auts the ede of the eistin coatin5 "heapp!ied !ass fire sha!! e ironed 4ith hot irons to ensure comp!ete ondin ec!usion of air and comp!ete imprenation 4ithitumen5

9555 & second sin!e 4rap of !ass fire tissue saturated 4ith hot itumen sha!! then e app!ied such that the t4o 4raps of tissueover!ap at !east .0E of the 4idth of the tissue and at !east one 4rap of tissue auts the edes of the eistin coatin5 "hesecond 4rap of !ass fire tissue sha!! e ironed 4ith hot irons to ensure comp!ete ondin ec!usion of air and comp!eteimprenation 4ith itumen5

9555. & f!ood coat of hot app!ied itumen sha!! then e app!ied to ive a coatin thicness aove the !ast 4rap of !ass fire tissue of at

!east 10 mm5

95556 "4o further 4raps of !ass fire tissue saturated 4ith hot itumen sha!! then e app!ied in succesion each 4rap as aove utsuch that at !east one !aer of tissue over!aps the eistin coatin not !ess than .0 mm5 %ver!ap of successive !aers of tissueto e at !east .0E of tissue 4idth5

9555; & further f!ood coat of hot app!ied itumen sha!! then e app!ied over the repair to ive a minimum coatin thicness of 1 mm overthe !ast !ass fire tissue !aer and to over!ap the eistin coatin at !east 100 mm5

95558 -n the case of armoured coatins a sin!e 4rap of itumen saturated !ass fire 4oven 4rap sha!! e app!ied at .0E over!ap overthe !ast itumen f!ood coat and e ironed 4ith hot irons to ensure comp!ete imprenation of itumen and ondin5 "he 4oven4rap sha!! then e fo!!o4ed a further f!ood coat of hot app!ied itumen to ive a minimum thicness of not !ess than 1 mm overthe 4oven 4rap5

95559 "he repaired surface sha!! then e ironed smooth neat! feathered into the eistin coatin5

955510 & heav !ime24ash coat sha!! e app!ied over the repaired areas of coatins immediate! after inspection and acceptance of therepair the $nineer5

955511 When heatin itumen the temperature sha!! never eceed 3.C5 *itumen sha!! on! e heated in tota!! enc!osed ett!ese


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955 Surface preparation

95551 We!ded Aoints and !arer repairs i5e5 area in ecess of . mm diameter

"he comp!ete area of the 4e!d un!ined sections and heat affected !ined sections sha!! e chipped scraped and 4ire rushed toremove a!! s!a oi! rease itumen coa! tar and oidation deposist5 "he 4e!d ead sha!! e round do4n so that the heiht ofthe upset meta! and f!ash on the inner surface sha!! not eceed 10 mm5 &!! 4e!d spatter sha!! e removed scrapin and/orrindin5 "he entire surface inc!udin the 4e!d seam sha!! e entire! smooth and free from Aaed or sharp protuerances5

"he comp!ete surface to e !ined and/or coated sha!! then e rit !asted to produce a riht stee! finish in accordance 4ith S-S0..900 ,rade Sa 35 Where this deree of c!ean!iness does not accurate! match the stee! co!our use a standard of 9.Eaverae otained photo e!ectric ref!ectance meter 4hich is ca!irated for the stee! and tpe of rit ein used tain 100percent as the deree of finish otained 4hen no futher increase in ref!ectance is otaind etended !astin5 &!! air used for

rit !astin sha!! e free of a!! oi! and moisture5 ,rit of 4hich .0E sha!! not e round sha!! e dr and free of forein mattersuch as sa!ine or c!a contents itumen or ituminous tpe contaminants oi! or other de!eterious sustances5 artic!e si@e sha!!e such as to produce an anchor pattern profi!e eceedin .0 micrometres in depth ut not eceedin ;. micrometres in depthas determined micrometer aue or porta!e microscope fitted 4ith a ca!irated focussin no5

&fter !astin a!! dust and deris sha!! e removed vacuum c!eanin dr rushin or dr air !ast to a deree such that apiece of c!ear adhesive tape pressed to the rit !asted surface and therupon transferred to a 4hite ti!e sha!! sho4 no dust orderis pic up 4hen compared 4ith a standard pattern5

"hereafter the rit !asted surface inc!udin . mm 4ide strip of sound epo !inin or coatin sha!! e coated 4ithin hours5

9555 Sma!!er repairs i5e5 area sma!!er than . mm diameter

"he area of repair inc!udin at !east . mm of sound epo !inin around the area of repair sha!! then e rued 4ith a mediumrade emer paper5 %n! &!uminium %ide arasives sha!! e used5 Stee! surfaces and heat affected epo !ined surface sha!!e rued do4n to a riht stee! finish standard Sa 3 of S-S 0..9005 "he . mm minimum 4idth of sound epo surroundinthe area of repair sha!! e rued to remove the !inin !oss or a!! sins of cha!in 4hichever is app!ica!e5

"he comp!ete surface to e repaired inc!udin the emer papered ede of the eistin !inin or coatin sha!! e 4iped 4ith aso!vent recommended the supp!ier of the epo and coated 4ithin hours of the surface ein prepared as descried aove5

9553 &pp!ication of epo

28


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9556 &deand heatin if re


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9585156 #eatin of itumen sha!! conform to C!ause 955165

9585 o!urethane and tape 4rappin

958551 Coup!ins sha!! e protected coverin 4ith po!urethane foamed in2situ and 4rapped 4ith po!eth!ene tape5

95855 "he coatin of the pipe sha!! proAect at !east 100 mm into the mou!d over 4hich !enth of coatin ref!ective finish sha!! e carefu!!removed5

958553 "he uncoated portions of the pipe and the eposed portions of the coup!in sha!! e c!eaned of a!! dust rust oi! and rease andiven coats of an approved co!d app!ied itumnious primer that sha!! e compati!e 4ith the coatin and 4ith po!urethane5

95855 "he coats of primer app!ied to the pipe ends and coup!in components sha!! e comp!ete! dr efore the foam is app!ied andsha!! e capa!e of 4ithstandin the chemica! and therma! effects of the foamin process 4ithout deradation either of the primer

or of the foam5

95855. "he foam fi!!er sha!! e formed a sheet meta! mou!d providin a minimum of . mm cover of foam to a!! uncoated areas ofpipe ends coup!in components ondin 4e!ds and ond conductors5 "he eterna! surface of the mou!ded foam sha!! e in theform of a smooth centra! c!inder surroundin the coup!in 4ith smooth conica! etension over!appin the pipe coatin 100mm at each end5 "he tanent of the an!e et4een the conica! surface and the ais of the pipe sha!! not e reater than 0.5

958556 "he foam sha!! e produced in2situ the 7Carado! C/Caradate7 30 sstems as descried in re!iminar -nformation amph!etRes//) pu!ished She!! Chemica!s )B 'imited or e


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95855 7Denso7 tape or e


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1&.3 -ail crossings

105351 Crossins of rai!4a tracs sha!! e made utt 4e!ded or f!aned stee! pipes 4ithin a stee! or reinforced concrete s!eeve orreinforced concrete cu!vert a!! in accordance 4ith approved dra4ins and the S&*S 011 Code of ractice5 ipes !arer than.0 mm nomina! ore sha!! cross throuh cu!verts on!5 Stee! pipes sha!! etend over the fu!! 4idth of the rai! reserve p!us at !east. m on each side5

10535 Stee! s!eeve pipes sha!! have a 1 mm minimum 4a!! thicness e !ined 4ith a itumen prime coat and sha!! e armour coated5Wherever possi!e reinforced concrete s!eeve pipes sha!! e insta!!ed pushorin underneath rai!4a tracs un!ess other4isespecified5

105353 Stee! pipes at rai!4a crossins sha!! have:

10535351 Wa!! thicnesses increased at !east 0E aove the re


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11. CATHODIC AND LIGHTNING PROTECTION

11.1 !athodic protection

115151 ,enera!

11515151 "he cathodic protection of pipe!ines sha!! enera!! e carried out in accordance 4ith S&*S 011: art 1: 7Code of ractice forthe Cathodic rotection of *uried and Sumered Structures75

1151515 Stee! pipe!ines shou!d e made e!ectrica!! continuous ensurin that ondin ca!es are insta!!ed across a!! f!aned or f!ei!eAoints and around iso!atin va!ve inside the chamers a!! in accordance 4ith dra4ins5

-n the case of reinforced and prestressed2concrete pipe!ines this 4i!! enera!! not app! un!ess other4ise specified5

11515153 "he cathodic protection sstem or 4ors provided under this Contract sha!! e uaranteed aainst fau!t desin materia!s and4ormanship for a period of five ears from date of commissionin5 Durin this period the Contractor sha!! rectif at his o4ncost an defects 4hich are the resu!t of fau!t desin materia!s and 4ormanship5 (orma! 4ear and tear and ma!functionin dueto maAor chanes in the conditions under 4hich such sstems or 4ors have to operate other than 4eather and 4hich cou!d nothave een reasona! foreseen at the time of insta!!ation sha!! e ec!uded5

11515 -nspection of -nsu!atin oints

1151551 &fter insta!!ation the insu!atin Aoints must e inspected to ensure their comp!iance 4ith the specifications and dra4ins and totest their efficienc for satisfactor e!ectrica! insu!ation5 "he inspection sha!! e 4itnessed the $nineer Desiner of thecathodic protection insta!!ation and Contractor5

115153 Soi! resistivit surve and report

11515351 Where a fu!! report on soi! resistivities a!on the pipe!ine route and orro4 pits for eddin and se!ected acfi!! materia! is notavai!a!e from separate contracts the Contractor sha!! carr out a comprehensive soi! resistivit surve5

1151535 & fu!! report of such surve toether 4ith the ContractorKs proposa!s for cathodic portection of the pipe!ine and appurtenantfittins sha!! e sumitted to the $nineer at !east 4orin das efore pipe!ain is due to commence5 -n the case ofprestressed concrete pipe!ines such report sha!! e sumitted at !east 4orin das efore pipe manufacture is due tocommence5

33


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"he conductors !aid para!!e! 4ith the pipe!ine sha!! e free of sudden ends and ins and a!! Aoints in the !onitudina! conductorssha!! e !ap Aoints 4ith t4o compression co!!ars5 "he numer of Aoints in !onitudina! conductors sha!! e ept to a minimum5

115555 +or a!! conditions of tpe 7*7 the five continuous conductor sstem specified aove for tpe 7&7 sha!! e emp!oed and in additionthereto the numer of continuous !onitudina! conductors in the hori@onta! p!ane aove the pipes sha!! e increased from three tosi 4ith the conductors spaced even! apart5 "he eiht conductor sstem sha!! run the entire !enth of the pipe!ine section undertpe 7*7 conditions and in addition etend at each end of this section for a distance of 10 metres5 -nverted 7)7 conductor ondssha!! e insta!!ed at the commencement and the end of each eiht conductor protection sstem5 -n addition the entire pipe trenchin such areas sha!! e acfi!!ed 4ith soi! approved the $nineer5

1155553 +or a!! conditions of tpe 7C7 the !onitudina! conductors sha!! terminate 4ith the insta!!ation of an inverted 7)7 conductor ond4ith the eception of the upper t4o outer conductors 4hich sha!! etend eond the 7)7 ond and rise to round !eve! 4here eachconductor sha!! e connected to a !o4 vo!tae sure diverter or ap unit5 & short !enth of C insu!ated ca!e sha!! e run fromeach sure diverter or ap unit and e onded to the stee! pipe!ine5 "he connections et4een the coated stee! pipe and the

sure diverter sha!! e comp!ete! insu!ated and sea!ed from contact 4ith the round usin means approved the $nineer soas to oviate the possii!it of stra DC current enterin the protected stee! pipe4or5

"he sure diverter units sha!! e insta!!ed in concrete chamers to e ui!t aove round !eve!5 "he chamers sha!! e fitted 4ithcast2iron !oca!e manho!e covers5 "he construction of these chamers sha!! e such that the 4i!! never ecome 4ater!oed5

115555 +or a!! condition of tpe 7D7 inverted 7)7 conductor onds sha!! e insta!!ed at the termina! ends of the concrete pipe sections andthe protection sstem specified for tpe 7C7 conditions insta!!ed at oth ends of the stee! pipe section5 -n addition the !onitudina!conductors protectin the concrete pipe sections sha!! e continued and run toether in a para!!e! sha!!o4 trench a!onside thepipe!ine and not more than 3 metres in p!an a4a from it5 "he conductors sha!! e uried in soi! free of stones or rocs and thesoi! 4e!! compacted5

115555. +or a!! conditions of tpe 7$7 inverted 7)7 conductor onds sha!! e insta!!ed Aust efore the pipe!ine ecomes eposed and theconductors run toether in a para!!e! sha!!o4 trench a!onside the pipe!ine over the distance the pipe!ine is e!evated aove theround5 Where the pipe!ine aain enters the round these re


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1155356 "he Continuous e!ectrica! circuit throuh the !onitudina! prestressin 4ires sha!! e interrupted at interva!s of approimate! 1

m 4ith a 324a spar ap the centre e!ectrode ein connected to a rounded !ead5

115535; Care sha!! e eercised durin main ood of interior Aoints if an that the e!ectrica! continuit at Aoints is not interrupted5

1155358 &fter comp!etion of a pipe!ine and after a!! Aoints have een made ood the e!ectrica! continuit of the pipe!ine sha!! e checedover sections et4een 324a spar aps5 "he Contractor sha!! at his o4n epense search and detect interruption in continuitand sha!! repair same to the satisfaction of the $nineer5

12. HYDROSTATIC TESTING

12.1 0eneral

15151 ipe!ines sha!! e hdrostatica!! tested as pipe!ain proceeds and after insta!!ation of a!! va!ves specia!s and fittins5

1515 "he Contractor sha!! e responsi!e for providin a!! 4ater re


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155 "he Contractor sha!! e permitted to test aainst a c!osed in2!ine iso!atin va!ve5 #e shou!d ear in mind ho4ever that va!ve atesand sea!s are not epected to c!ose drop tiht at differentia! pressures eceedin the desin pressure of the va!ve5 Desin

pressures of va!ves sha!! e e


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test parts or the 4ho!e of the pipe!ine at the ContractorKs o4n epense and no c!aims for esca!ation in costs or for 4hatever otherreasons the Contractor miht consider to sumit c!aims sha!! e considered ecept 4here such re2tests are the resu!t from

damaes caused to the pipe!ine the $mp!oer5

13. +-L9':

1351 &!! pipe!ines for the conveance of pota!e 4ater sha!! e steri!i@ed5

135 &s soon as the 4ho!e pipe!ine has passed a hdrostatic test test 4ater sha!! e scoured to ensure a f!ushin ve!ocit of not !essthan 1 m/sec21 over the entire !enth of the pipe!ine5

1353 ota!e 4ater treated 4ith sodium hpoch!oride or ca!cium hpoch!oride or ch!orine as to a ch!orine concentration of not !ess

than . m!21 free avai!a!e ch!orine sha!! e introduced into the pipe!ine or section of pipe!ine to e steri!i@ed5 %n comp!etion offi!!in 4ith ch!orinated 4ater the ch!orine concentration in 4ater samp!ed at an point a!on the section of pipe!ine fi!!ed sha!! note !ess than 3 m!21 free avai!a!e ch!orine5

135 -n determinin ch!orine concentrations the Contractor sha!! satifsf the $nineer that the method adopted does measure freeavai!a!e ch!orine concentration and not tota! ch!orine residua!s the !atter ein the easier to determine means of simp!ecomparators5

135. Ch!orinated 4ater sha!! e retained for at !east hours durin 4hich a!! air va!ves in2!ine iso!atin va!ves epass va!ves ranchiso!atin va!ves and scours sha!! e operated in order to epose a!! interior surfaces of these appurtenances to the ch!orinated4ater5

1356 &fter hours retention of ch!orinated 4ater in the pipe!ine samp!es dra4n at an point a!on the pipe!ine sha!! contain not !essthan 0. m!21 free residua! ch!orine5 Where necessar additiona! ch!orine sha!! e inAected to maintain ch!orine residua!sprovided a!4as that the hours minimum retention time 4ith 4ater containin an initia! free ch!orine residua! of at !east 3 m!21and a fina! free residua! of not !ess than 0. m!21 is maintained5

135; %n comp!etion of steri!i@ation of an section of pipe!ine the 4ater in that section ma e retained or ma e passed a!on thepipe!ine to other sections to e steri!i@ed5

1358 rovided c!ean!iness of pipe!ines has een maintained durin transport storae and !ain and provided futhermore that testin4ater is of pota!e


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15. MISCELLANEOUS CONSTRUCTION WORKS AND WORKMANSHIP

15.1 $encing

1.5151 "emporar fences

1.515151 "emporar fences sha!! e stocproof5

1.51515 Where used to fence off the pipe!ine 4orin area across properties or camps protected vermin2proof fencin 7Aaca! proof7nettin 4ire sha!! e provided5

1.515153 "he minimum standard sha!! e five strands of . mm thic a!vanised 4ire sufficient! spaced5

1.51515 "he Contractor sha!! supp! insta!! and maintain temporar ates of the standard as specified hereunder at such points asintructed the $nineer for access across the temporari! fenced off 4orin area or to parts of properties severed temporar fences5

1.515 ermanent stoc2proof fences

1.51551 !ain stoc fencin sha!! e 1 metre hih and sha!! have at !east 6 strands of dou!e ared . mm thic a!vanised 4ire orsin!e ared 9. mm thic a!vanised 4ire5 Spacin of 4ire strands sha!! e in accordance 4ith the enera! practice forfencin in the particu!ar area5

1.5155 +encin standards at !east 18 metre !on either of 3 m21 iron -2section or creosote imprenated hard4ood of ;0 to 100 mmminimum diameter sha!! e erected vertica!! and e spaced at 1 metres interva!s 4ith at !east droppers of !enth minimum ;.mm more than fence heiht et4een standards5

1.51553 Droppers sha!! either e rided "2section iron droppers or creosote imprenated hard4ood of 30 mm minimum diameter ort4isted a!vanised 4ire droppers of dou!e mm thic 4ire5

1.5155 &t each chane of direction and at interva!s not eceedin 00 metres on straihts strainin or corner posts sha!! e provided5Strainin or corner posts sha!! e 1 metres !on uried to a depth of at !east ;.0 mm into the round and proper! staed in thedirection of direct pu!! of the 4ire5 *acfi!!in in a!! post ho!es sha!! e thorouh! conso!idated to ive ade


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1.55151 &!! concrete 4or sha!! e finished to the !ines !eve!s s!opes and out!ines sho4n on the dra4ins or as other4ise directed5

1.5515 &!! eposed concrete surfaces sha!! e finished such that surface irreu!arities sha!! not eceed a to!erance of G 8 mm and sha!!e rued do4n 4ith a carorundum stone to present a surface of even co!our and a smooth and p!easin appearance5 &!!eposed edes sha!! e chamfered a 0 mm chamfers fied to shutterin5 )n!ess other4ise specified a!! f!oors sha!! have a4ood2f!oat finish5

1.55153 Surfaces sha!! e free from honecomin and ecrescences5 #onecomin to the etent that in the opinion of the $nineerthe strenth of the structure is impaired or the reinforcement is suAect to corrosion or !ac of ond sha!! e removed andrep!aced 4ith satisfactor concrete at the ContractorKs epense 4ithin ; hours of the concrete oriina!! ein p!aced5

1.5515 "he minimum concrete cover to reinforcement of concrete surfaces permanent! in contact 4ith round sha!! e .0 mm and fora!! other surfaces sha!! e 0 mm5

1.5515. &!! precast units sha!! e stee!2tro4e!!ed on upper surfaces to present a dense homoenous surface5

1.55156 S!iht spa!!in of top edes of manho!es to e covered precast or cast2in2situ cover s!as sha!! e permitted provided themaimum dimension of the spa!! measured a!on an face sha!! not eceed . mm and provided further that no reinforcement iseposed5 "he maimum permissi!e difference in an of the t4o measurements taen to opposite corners diaona!! acrossrectanu!ar or s


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15.5 +ervitude road

1.5.51 "he Contractor sha!! ui!d a servitude road metres 4ide a!on as much of the !enth of the pipe!ine as is practica!e for the useof the $mp!oerKs vehic!es for patro!!in and maintainin the comp!eted pipe!ine5 "he road sha!! e ui!t as sho4n on thedra4ins or in the specification un!ess other4ise instructed the $nineer in 4ritin5 -t sha!! e ui!t to conform c!ose! to theshape of the natura! round to prevent interference 4ith the surface drainae5

1.5.5 &fter the pipe!ine servitude has een c!eared of a!! ou!ders trees ush and other veetation and prior to trenchin operationsthe Contractor sha!! mar out the area of the road4a to the $nineerKs approva!5 "hereafter a!! topsoi! and rass sha!! eremoved over the 4idth of the road to an approimate depth of 00 mm means of a motorrader or scraper the ecavatedmateria! ein p!aced in 4indro4s para!!e! to and c!ear of the edes of the road4a on one or oth sides5

"he 4indro4s ma e f!attened so as not to restrict pipe!ain operations5 "he $nineer ma order a reater or !esser depth oftopsoi! to e thus removed to epose susoi! or to remove unsuita!e materia! dependin on site conditions5

1.5.53 When trenchin operations commence materia! surp!us to acfi!!in re


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1655 revious! painted surfaces

revious! primed or painted surfaces in sound condition sha!! e 4iped 4ith ra soaed in 4hite spirit to remove a!! sins ofdust deris itumen oi! and rease5 Where necessar cha!ed or s!iht! 4eathered surfaces sha!! e iven a !iht sandin toepose fresh paint !aers5

1653 aintin

165351 rime coat and second coat

16535151 *are stee! or cast2iron surfaces

-mmediate! after c!eanin and not more than hours after c!eanin provided surfaces are ept dr and free of dust a coat of

approved co!d app!ied ituminous primer sha!! e app!ied rush or ro!!er to a minimum dr fi!m thicness of 100 micrometres5&s soon as the prime coat is dr to the touch a second coat of an approved ituminous paint sha!! e app!ied rush to aminimum dr fi!m thicness of 1.0 micrometres5 &!! coats sha!! e app!ied even! and sha!! e free from tears and runs5 "hecoats sha!! e ept dr and free of dust and deris5

1653515 revious! primed surfaces

-mmediate! after c!eanin and not more than hours after c!eanin provided surfaces are ept dr and free of dust and deris acoat of an approved ituminous paint sha!! e app!ied rush to a dr fi!m thicness of not !ess than 1.0 micrometres5 "hecoat sha!! e app!ied even! and sha!! e free from tears and runs5 "he coats sha!! e ept dr and free of dust and deris5

16535 +ina! coat

&s soon as second coats are dr to the touch one coat of ituminous ased a!uminium paint sha!! e app!ied rush to a drfi!m thicness of not !ess than 1.0 micrometres5 "he coat sha!! e app!ied even! and sha!! e free from tears and runs5 aintcoats sha!! over!ap coated portions of pipes and specia!s at !east ;. mm5

165353 revious! painted or epo coated surfaces

&!! previous! painted or epo coated surfaces eposed to soi! )2ras and in chamers sha!! e overcoated 4ith a .0micrometre thic additiona! !aer of recoata!e a!iphatic po!urethane co!our as per Departmenta! co!our codin5

165 &!! paintin sha!! e carried out under the supervision of a si!!ed eperienced and competent painter5 (o paintin sha!! e done

42


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sha!! e incorporated on the outside of chamers founded on undistured round i5e5 scour va!ves ref!u va!ves iso!atin va!vesone of the road and rai!4a crossin access chamers etc5

"he eacons sha!! a!! e accurate! numered !eve!!ed and trianu!ated 4ith the fo!!o4in data to the specified accurac hardstamped on it:

>i? *eacon numer5

>ii? Measured chainae5

>iii? Reduced !eve! aove MS' to an accurac of U >001G000. length of pipeline in km

>iv? 7I7 and 7H7 co2ordinates in metres to the app!ica!e 7'07 sstem accordin to the Surve &ct 19; for a C!ass *accurac5

"he free standin comined eacons sha!! e sited net to manho!es and firm! concreted2in in a undistured round in aposition such that ecavations for the repair of the pipe!ine 4i!! not distur or damae the eacons5

%n comp!etion of trianu!ation the threaded portion of the trianu!ation pins sha!! e covered 4ith a raphite/rease compoundand the end covers firm! scre4ed ac hand5

1;53 &!! chamers constructed on the pipe!ine sha!! e c!ear! mared on the outside to denote the appurtenances housed in each andthe chainaes thereof5 Marin sha!! e stenci!!in in e!!o4 road marin paint in !etters not sma!!er than sevent five >;.?mm5 &!! marins sha!! face the upstream direction5 &reviations to e used sha!! e as fo!!o4s:

&ir va!ves:

"rip!e 2 & >"?Dou!e 2 & >D? Sin!e !are

2 & >S'?Sin!e sma!! 2 & >SS?

&nti2vacuum 2 & >av?-so!atin va!ves 2 -Scour va!ves 2 Sc

&ccess on! 2 &I&ir va!ve in conAunction 4ith access 2 & >" or D or S'?/&IRef!u va!ves 2 R-nsu!atin f!anes 2 -+Water meters 2 M

43


44/53


>h? %n the p!an vie4 the !ocation seria! numers and reduced !eve!s of permanent enchmars5

>i? %n the p!an vie4 the !ocation seria! numers and co2ordinates of permanent trianu!ation points5

>A? %n the profi!e the eact measured !ocation and chainae of propert oundaries crossed the pipe!ine5

>? %n the dra4ins a !ist of seria! numers and co2ordinates of a!! chanes in direction on the pipe!ine5

18515 Structura! detai!s of a!! chamers thrust !ocs road rai!4a and stream crossins and a!! other structures erected a!on thepipe!ine5

185153 Detai!ed assem!ies of va!ves cross connections off2taes etc5

18515 7&s ui!t7 dra4ins sha!! enera!! conform to the !aout of the tender dra4ins sha!! e on si@e &1 sheets 4ith t4o and a ha!f>.? mm minimum si@e !etterin5

18515. rints of 7&s ui!t7 dra4ins sha!! e sumitted to the $nineer for his perusa! and comment efore fina! transparencies aresumitted5

185 Desin $nineer

18551 %ne comp!ete set of paper prints of the dra4ins supp!ied to the Contractor sha!! e mared 7&s ui!t7 4ith a!! chanes sho4n inred5

1855 Whenever the Contractor 4i!! e re


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19551553 -f in the !enth of 4e!ds so radioraphed more than . in an 0 Aoints successive! radioraphed sho4s defects the $nineerma increase the !enth of 4e!d to e eamined at his o4n discretion up to 100E of manua! and automatic 4e!ds5

1955155 &!! defects sha!! e repaired and re2radioraphed at the ContractorKs cost and such radioraph of repairs sha!! not e deemed toe inc!uded in the re


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0535 Rates sha!! e he!d to inc!ude for c!earin of 4ider areas 4here re


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2&.# +elected ac)fill

05851 Sha!! e measured per !inea! metre >m? of pipe!ine !aid and comp!ete! acfi!!ed5

0585 Rates sha!! e he!d to inc!ude for rinin in se!ected acfi!! 4ithin . m radius from point of app!ication for a!! costs androa!ties in openin up orro4 areas reinstatement of orro4 areas and access roads on comp!etion u!in p!acin into trenchspreadin !eve!!in compaction and testin of materia!s5

05853 $tra over rates for the use of po!eth!ene sheets or !anets in conAunction 4ith se!ected acfi!! of reG? or minus >2? va!ue5 Rates sha!! e he!d to inc!ude for everthin necessar tocomp!ete se!ected acfi!! up to 300 mm aove cro4n of pipe as per specification5

0585 $tra over rates for the use of approved roc shie!d in conAunction 4ith acfi!! 4hich do not meet specified reG? or minus >2? va!ue5 Rates sha!! e he!d to inc!ude fora!! epenses in ettin rocshie!d materia!s approved its app!ication to approva! of the $nineer and everthin necessar tocomp!ete se!ected acfi!! up to 300 mm aove cro4n of pipe as per specification5

2&.% !ommon ac)fill

05951 Sha!! e measured per !inea! metre >m? of pipe!ine comp!ete! acfi!!ed5

0595 Rates sha!! e he!d to inc!ude for movin of suita!e trench spoi! from areas 4here there is a surp!us to areas 4here there is ashortae over a free2hau! distance of 10 m for p!acin spreadin !eve!!in and compaction for rinin ac top soi! andreinstatement thereof over the trench for reinstatement of aricu!tura! drains and contours across servitude for a!! 4ors re


48/53


051156 $tra cover rates for marin .00 metre chainaes on cement mortar !inin and CC" surve of the !inin sha!! e priced as a!ump sum or per !inea! metre >m?5

2&.12 nstallation of in"line valves, meters and fittings

05151 Sha!! e measured per unit of comp!ete assem!5

0515 Rates sha!! e he!d to inc!ude for site storae hand!in and transport for a!! Aointin materia!s and insta!!ation as specified or asper dra4ins for oi!in and reasin of movin parts tihtenin up of !eain !ands and fina! paintin after insta!!ation and foreverthin necessar to comp!ete insta!!ation as per specification or dra4ins ecept for construction of chamers 4hich ismeasured separate!5

2&.13 Pipeline off"ta)es and fittings

051351 Sha!! e measured per unit of comp!ete assem!5

05135 Rates sha!! e he!d to inc!ude for site storae hand!in and transport for a!! Aointin materia!s for insta!!ation of a!! va!ves metersand fittins as per C!ause 051 and for everthin necessar to comp!ete the off2tae as per specification or dra4in ecept forconstruction of chamers 4hich is measured separate!5

2&.14 !hamers, culverts and pipeline structures

05151 Concrete sha!! e measured in accordance 4ith C!ause 8515 of S&*S 100 Section 7,&75

0515 Reinforcement sha!! e measured in tons nett and rates sha!! e he!d to inc!ude for cuttin endin p!acin and a!! racetsstoo!s and supportin stee!5

05153 Misce!!aneous ui!t2in stee! and iron 4or !ie che


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2&.1# Lightning protection

051851 Sha!! e priced as a !ump sum paa!e in proportion to !enth or pipe!ine protected5

05185 rices sha!! e he!d to inc!ude everthin necessar to fu!! protect the pipe!ine aainst !ihtnin stries or sures as specified5

2&.1% !athodic protection

051951 Resistivit surves sha!! e a rovisiona! Sum in the Schedu!e for this 4or to e performed specia!ist nominated Su2Contractors and sha!! e paa!e in fu!! on receipt and ratification the $nineer of the comp!ete surve report andrecommendations5

05195 *ondin of pipe!ine Aoints sha!! e measured per unit of Aoint onded and rates sha!! e he!d to inc!ude for ca!es thermo4e!dintest !eads insu!ation of ondin and test ca!es supp! de!iver and erection of test posts5

rovinsiona!


50/53


CONTRACT WF%%%%%%%

HYDROSTATIC TEST CERTIFICATE

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-$'-($: 555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555

-$ "$S"C%("R&C"

M$"#%D15 S&*S 100 '

D&"$ "$S" S$C"-%(: 55555555555555555555555555555555555555555555555555555

*$,-( >m?: 55555555555555555555555555 55555555555555555 55555555555555555 5

$(D >m?: 55555555555555555 55555555555555555 5555555555555555 555555555555

-$ D-&M$"$R >%D?5555555555555555555555555555555555 >mm?

-$ ,R&D$ &(D

t >mm?5555555555555555555555555555555555

'$(,"# %+ "$S"S$C"-%(

55555555555555555555555555555555555555555555

>m?

"$S" R$SS)R$

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>Ma?

&''%W&*'$ '$&B&,$ R&"$S15 S&*S 100 ' 2 C!ause ;5353Diamter !enth 00;. "est pressure >mm? >m? >Ma?

F 5555555555555555 555555555555555 555555555555 !itre

5 DWS 1110 2 C!ause 11/000 vo!ume 4ater in test section

F 5555555555555555 555555555555555 555555555555 !itre

"$S" )M

"H$: 555555555555555555555555555555555555555555555

M&()+&C")R$R: 5555555555555555555555555

R$SS)R$ ,&),$>S?

"H$: 5555555555555555555555555555555555555555555555555555555555

D-&M$"$R: 5555555555555555555555555555555555555555555555555

M$&S)R-(, D$-C$S: M$"$R%')M$: 55555555555555555555555555

D--S-%(S: 5555555555555555555555

R$C%RD$R5555555555555555555555

5555555555555555555555

5!


51/53

D$"&-'$D SC#$D)'$ %+ -(S"&''&"-%(S:VVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVV &,$: VVVVVVVVVVVVVVVVV%+ VVVVVVVVVVVVVVVV

>C'&)S$ 1;5.?S"R5(%5

C#&-(&,$ -(S"&''&"-%( '&(" D$SCR-"-%( (%5%++

S-=$ R$SS)R$R&"-(,

M&B$ -D M&RB C"$S"

C

R$M&RBS $R"&-(-(,"%:


52/53

51.A DWS 111!C,/0/, , P

CONTRACT WF

HYDROSTATIC TEST CERTIFICATE FOR GRP PIPES

SCHEME9 :::::::::::::::::::::::::::::::::::::::::::::::::::::.

PIPELINE9 :::::::::::::::::::::::::::::::::::::::::::::::::::::

PIPE TEST CONTRACT METHOD DATE TEST SECTION9 :::::::::::::::::...1. DWS 115! #EGIN &;'9 :::::::::::::::::::...

END &;'9 ::::::::::::::::::::...

PIPE DIAMETER LENGTH OF TEST PRESSURE ALLOWA#LE LEA"AGE RATE &OD' SECTION 1. DWS 115! - C


53/53

51.A&2'

COMMENTS LEA"AGES CH&;'

::::::::::::::::::::::::::::::::: :::::::::: ::::::::::::..::::::::::::::::::::::::::::::::: :::::::::: ::::::::::::..

::::::::::::::::::::::::::::::::: :::::::::: ::::::::::::..::::::::::::::::::::::::::::::::: :::::::::: ::::::::::::..

NAME SIGNATURE

CONTRACTOR ::::::::::::::::::. ::::::::::::::::::.

ENGINEER ::::::::::::::::::. ::::::::::::::::::.

INSPECTION AUTHORITY ::::::::::::::::::. ::::::::::::::::::.

Documents

South African Specifications for Laying Pipes