GRP Pipelien Material

ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 2 SITEWORK

SECTION 02200 GRP PIPELINES MATERIALS, INSTALLATION AND TESTING

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GRP Pipelines. Materials, Installation and Testing

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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

03

04

05

06

07

08

09

10

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TABLE OF CONTENTS 1

GENERAL ..........................................................................................................4 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.5 1.6

2

PRODUCTS........................................................................................................9 2.1 2.2 2.2.1 2.2.2 2.3 2.3.1

3

SCOPE ...................................................................................................4 RELATED DOCUMENTS .......................................................................4 STANDARDS..........................................................................................4 SUBMITTALS .........................................................................................5 PRODUCTS AND MATERIALS APPROVAL .........................................5 METHOD STATEMENTS .......................................................................7 DRAWINGS. ...........................................................................................7 QUALITY CONTROL..............................................................................7 DELIVERY, STORAGE AND HANDLING ..............................................8 PIPE DESIGN REQUIREMENTS...........................................................9 PIPES AND FITTINGS .........................................................................10 BURIED GRP .......................................................................................10 EXPOSED GRP....................................................................................12 QUALITY CONTROL TESTS ...............................................................13 GRP PIPES AND FITTINGS ................................................................13

EXECUTION.....................................................................................................16 3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1

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PIPE INSTALLATION ...........................................................................16 HYDROSTATIC TESTING OF PIPELINES..........................................18 HYDROSTATIC TESTING OF PIPELINES GENERAL........................18 HYDROSTATIC TESTING OF PRESSURE PIPELINES .....................19 HYDROSTATIC TESTING OF NON PRESSURE PIPELINES ............20 DEFLECTION MEASUREMENT OF PIPELINES.................................21 GRP PIPELINES. .................................................................................21

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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. Section 01000-07 Section 01000-08 Section 01000-09 Section 02120 Section 02300

1.3

Submittals. Quality control. Materials and equipment. Utility excavation, surround and backfill. Sewage works.

STANDARDS All activities relating to this section of the standard specification shall comply with the following or approved equal standards. ASTM C581

ASTM D2290

ASTM D2584 ASTM D2924

ASTM D3262 ASTM D4161

BS 3396 BS 3532 BS 4549-1

BS EN 681

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Standard practice for determining chemical resistance of thermosetting resins used in glass fiber reinforced structures intended for liquid service. Standard test method for apparent hoop tensile strength of plastic or reinforced plastic pipe by split disc method Standard test method for ignition loss of cured reinforced resins. Standard test method for external pressure resistance of “fiberglass” (Glass fiber reinforced thermosetting resin) pipe. Standard specification for “fiberglass” (Glass fiber reinforced thermosetting resin) sewer pipe. Standard specification for “fiberglass” (Glass fiber reinforced thermosetting resin) pipe joints using flexible elastomeric seals. Woven glass fibre fabrics for plastics reinforcement. Method of specifying unsaturated polyester resin systems. Guide to quality control requirements for reinforced plastics mouldings. Guide to the preparation of a scheme to control the quality of glass reinforced polyester mouldings. Elastomeric seals. Material requirements for pipe joint seals used in water and drainage applications.

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BS EN 1394

BS EN 1092-2

BS EN14020 BS EN 14118 BS EN 14364

ISO 3126 ISO 4633 ISO 9000

Plastic piping system Glass reinforced thermosetting plastic (GRP) pipes. Determination of the apparent initial circumferential tensile strength Circular flanges for pipes, valves and fittings (PN designated). Steel, cast iron and copper alloy flanges. Specification for cast iron flanges. Specification for textile glass rovings Reinforcement: Specification for textile glass mats (chopped strand and continuous filament mats) 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 Plastic pipes. Measurement of dimensions wall thickness table. Joint rings for water supply, drainage and sewerage pipelienes: Specification for materials Quality management systems.

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.

ii.

iii.

iv. v.

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The manufacturers design calculations, complete and detailed specification and test results 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 below shall be given. Should any details 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. Submit to the Engineer the results of all quality control tests carried out on the manufactured pipes and fittings as soon as practicable after testing and in any case not later than the time of delivery of the relevant pipes and fittings to the site. Pipe manufacturer’s guarantee that the pipe and its materials are suitable for its intended use. Joint materials and gaskets.

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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 diameter

mm

Class of pipe

-

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

kN/m2

Longitudinal tensile strength

kN/m2

Hoop flexural modulus

GN/m2

Hoop tensile strength

kN/m2

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Notes to Table 1 •

* ** ***

1.4.2

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.

METHOD STATEMENTS a) The Contractor shall submit method statements to the Engineer for approval 4 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. ii. iii. iv.

1.4.3

Procedures for handling, storage and installation of pipes. Hydrostatic testing procedures for GRP non pressure pipelines. Hydrostatic testing procedures for GRP pressure pipelines. Deflection measurement procedures for GRP pipelines.

DRAWINGS. a) The Contractor shall submit drawings to the Engineer for approval 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. ii.

iii.

1.5

Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof. 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. All data on curve and bends for both horizontal and vertical alignment.

QUALITY CONTROL 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 24 hours notice of carrying out the following activities on site.

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i. ii. iii. 1.6

Installation of pipeline. Hydrostatic testing of pipeline. Deflection measurement of pipeline.

DELIVERY, STORAGE AND HANDLING a) Delivery, storage and handling of products and materials shall be in accordance with the manufacturer’s recommendations, Section 0100009 of the specification and the following provisions: i. ii.

iii.

iv.

v.

Delivery storage and handling shall at all times be performed in a manner to avoid product damage. 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. 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. 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. Stack non-crated pipes to the approval of the Engineer. 

 

Stack spigot and socket pipes so that successive pipe layers have sockets protruding at opposite ends of the stack. Stack pipes of different sizes and thickness separately. 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 packings until they are needed. viii. The Contractor shall visually inspect all products upon delivery to site and report any damage to the Engineer. 

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

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Any products damaged during delivery, storage and handling shall be marked by the Contractor and set aside. Proposals for repair of any damaged products shall be submitted in writing to the Engineer for approval. Any damaged products deemed unsuitable for repair by the Engineer shall be removed from site and replaced.

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2

PRODUCTS

2.1

PIPE DESIGN REQUIREMENTS The design requirements for GRP pipes shall be as given in Table 2.1.1 below unless otherwise indicated on the drawings. Table 2.1.1 – Design Requirements GRP Pipe Material and Class/Stiffness

Pipe Diameter mm

Cover < 6m

Cover > 6m

Gravity Pipelines 150

-

GRP (10,000)

200

-

GRP (10,000)

250

-

GRP (10,000)

300

-

GRP (10,000)

350

GRP (5,000)

GRP (10,000)

400

GRP (5,000)

GRP (10,000)

450

GRP (5,000)

GRP (10,000)

500

GRP (5,000)

GRP (10,000)

600

GRP (5,000)

GRP (10,000)

700

GRP (5,000)

GRP (10,000)

800

GRP (5,000)

GRP (10,000)

900

GRP (5,000)

GRP (10,000)

1000

GRP (5,000)

GRP (10,000)

GRP (10,000)

GRP (10,000)

Pressure Mains

Exposed Pipes and Fittings GRP (10,000) Notes to Table 2 1) 2) 3)

2

The GRP pipe stiffness given in brackets is in N/m . Use GRP for pressure mains unless otherwise stated on drawings. Pressure mains shall be designed for an internal vacuum of 1 bar.

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2.2

PIPES AND FITTINGS

2.2.1

BURIED GRP a) All GRP components shall be designed and fabricated by one manufacturer. b) GRP pipes and fittings shall be manufactured in compliance with BS EN 14364 and fabricated to meet the minimum strength requirements. c) Resins. Vinylester resin shall be used in the internal resin rich liner of the pipe and fittings. Isophthalic or vinylester resins shall be used in the structural wall of the pipes and fittings. All resins shall be tested in accordance with ASTM C-581. Provide resin systems to the requirements of BS 3532 type-B. d) Additives. The use of additives such as fire retardant, UV inhibitors or coloured pigments or dyes shall be subject to the approval of the Engineer and will only be approved in exceptional circumstances. e) Glass for sewage applications. Use C glass veil in the internal resin rich liner with a surface treatment compatible with the resin. Use acid resistant glass fibres for reinforcement to comply with the applicable standards. f)

Aggregates and fillers. Sand aggregates shall be a clean, graded silica sand containing no impurities and be in accordance with BS EN 14364.

g) Fillers in accordance to BS EN 14364 shall not be permitted. h) Pipes and fittings shall be provided with an internal resin rich liner of a minimum thickness of 1.5mm comprising an innermost layer (i.e. that in contact with the liquid) suitably reinforced with C glass veil. Build up the remainder of the liner in layers of powder bound acid resistant glass chopped strand mat or chopped acid resistant glass roving depending on the method of manufacture with a glass content of between 25% and 35% by weight. Ensure no aggregate becomes embedded in the resin rich liner. i)

Pipes and fittings shall be provided with an external vinylester resin rich layer.

j)

Manufacture all pipes by an approved process utilising a rotating mould or mandrel and equipment which accurately controls the quantities and placing of all resin glass and aggregates.

k) 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

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be designed to achieve a minimum working life of 60 years under all applicable loadings, environmental and installation conditions. l)

Minimum initial specific stiffnesses are detailed in Table 2 above. Use pipes that achieve a minimum hoop flexural modulus of 15.0 GN/m 2 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 t 3 /12 where t is the whole wall thickness of the manufactured pipe.

m) Fabricate pipes and fittings capable of withstanding the working pressures, test pressures and loadings specified. n) Pipes and fittings shall be suitable for carrying domestic sewage at temperatures up to 40oC and having a maximum sulphide concentration of 50 mg/litre. o) Pipes and fittings to be designed to withstand up to 5% long term deflection in their installed conditions. p) Pipes and fittings to be capable of withstanding a 95% lower confidence limit strain of 0.85% over 60 years without failure or cracking when tested in accordance with the strain corrosion type test requirements specified herein. q) Conform to BS 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. r)

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 debonding.

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

All buried joints shall be spigot and socket type with EPDM rubber sealing rings in accordance with BS EN 681. The sealing rings shall be supplied by the pipe manufacturer. i.

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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

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pipeline and must not be less than 6mm or greater than 13mm or as recommended by the pipe manufacturer. ii. 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. iii. The pipe joints shall be capable of withstanding an external pressure equivalent to 10m head of water without leakage in both the straight and deflected positions. iv. Joint couplers may be used adjacent to structures or special fittings. v. When a pipe is cut or turned down in order to form a joint fully seal the exposed surfaces with a continuous coating of vinylester resin. vi. 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 supplier 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. t)

Ensure that all pipes including cut lengths and all fittings before despatch from the pipe manufacturer's works are indelibly marked as follows: i. ii. iii. iv. v. vi.

The manufacturer's name, initials, or identification mark. The nominal internal diameter in mm. The length in m. Mark the classification i.e. pressure rating, stiffness. The date of manufacture and batch number. A stamp to show that they meet the required inspection requirements and hydraulic tests 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 a) GRP pipes and fittings utilised 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. b) 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.

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i. ii. iii. iv.

v.

Resin in the structural wall shall be vinylester. No sand aggregate shall be used. Minimum wall thickness shall be 10mm. Additional exterior stiffeners may be required to maintain circularity on large diameter pipes and shall be installed to the manufacturer’s requirements. An exterior resin rich 1.0mm thick and pigmented with UV inhibitor shall be provided on all exposed pipes and fittings.

c) Use flanged joints for all exposed pipes and fittings inside treatment plants, process structures, pumping stations, and valve chambers. i. ii. iii.

iv.

Flanges shall be filament wound with epoxy or vinylester resins. Flanges made by hand lay up methods shall not be accepted. All bolts shall be stainless steel grade 316. 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 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. 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. Carry out the quality control tests listed below at the frequency stated. Ensure that records of all tests and inspections are maintained by the manufacturer. Provide the Engineer with two copies of all test certificates and reports. i.

ii.

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Inspect all raw materials to ensure that they comply with the relevant standard. Check all deliveries of resin for consistency by viscosity and reactivity. Do not use any resins deviating from the manufacturer's published figures. Check all deliveries of sand and aggregates for grading, moisture content and purity. Strain Corrosion Test. Carry out control tests for each class and diameter during the manufacture of pipes and in accordance with ASTM D3262 on at least three specimens at each of two strains. Ensure the strains are at levels at which failure can be predicted from the strain corrosion type test results to occur at 100 hours and

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at 1000 hours. No failures times shall be below the lower 95% confidence limit of the type test regression line. Ensure that at least one specimen at each strain level has a failure time above the type test regression line. Calculate the failure strain at 60 years from the results of the quality control test using the least squares method. The acceptable value shall not be less than 0.85%. 

iii.

Hydraulic Test. Perform an internal hydraulic pressure test for every pipe at the manufacturer's works prior to delivery. Apply a test pressure of 15m water head for gravity pipes. Apply 1.5 times the pipe design pressure for pressure pipes. Apply the test pressure for a minimum period of 5 minutes without signs of leakage. In addition to the above. 



iv.

v.

Maintain at test pressure the first pipe and thereafter every thirtieth pressure pipe and every one hundredth gravity pipe of each diameter 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 bar 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.

Wall Thickness. 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. Stiffness. Test a minimum of one pipe for every 30 pipes manufactured to determine the initial specific stiffness in accordance with the test method detailed in BS EN 14364. Test a minimum of one pipe of each class and diameter of pipe. Ensure that no test specimen has an initial specific stiffness of less than that specified. In addition. 

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In the event that a specimen fails the strain corrosion test, reject all pipes in that class and diameter pertaining to that batch which has been manufactured and or installed.

Deflect each of the stiffness test specimens to the amounts indicated in Table 3 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.

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Table 2.3.1 – GRP Quality Control Tests Nominal Stiffness

5,000N/m2

10,000N/m2

No visible damage as evidenced by surface cracks at a deflection of. No structural damage at a deflection of.

12%

9%

20%

12%

vi.

Longitudinal Tensile Strength. Measure in accordance with BS EN 14364 the tensile strength of a minimum of one in every 30 pipes manufactured for each class and diameter. vii. Cure. Perform in accordance with BS 4549 Part 1 a Barcol hardness test on a minimum of one in every 30 pipes manufactured. viii. Loss on Ignition. Test in accordance with ASTM D2584 a minimum of one in every 30 pipes manufactured. ix. Joint Tests. Test in accordance with the requirements of ASTM D4161 a minimum of two jointed pipes in every 100 pipes manufactured with the following exceptions.  

x. xi.

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.

Determine the initial circumferential tensile strength of pressure pipes in accordance with BS EN 1394. Reject any pipe or fitting which fails any of the quality control tests that are to be carried out on each and every pipe or fitting.

b) In the event of a pipe failing any of the tests outlined above, carry out the relevant test on a further ten pipes of that class and diameter as follows. i.

Carry out the relevant test on five of these pipes produced sequentially and immediately prior to the failed pipe and five immediately following. 



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If any one of these ten pipes fails, cease the fabrication 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. 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 and fittings to be used. If the manufacturer does not have results of these

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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 except that the tests will be conducted at 23 +/-2oC ambient temperature except for strain corrosion which will be tested at 40 oC +/- 2oC. Table 2.3.2 – GRP Type Tests Property

Test method

Long term specific stiffness and creep factor under deflection Long term strain corrosion resistance

Impact resistance Long term hoop tensile strength



ISO 10468 ASTM D3262, the test results to be extrapolated to 60 years. The 95% lower confidence limit failure strain must not be less than 0.85% ASTM D2444 ASTM D2290 the test results shall be extrapolated to 60 years

Conduct test to determine the external pressure resistance in accordance with ASTM D2924.

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 and manufacturer's instructions. i.

ii.

iii.

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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. 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. 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.

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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 backfall 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)

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Excavation for or laying of GRP shall not proceed until an approved device for gauging pipe deflections is on site.

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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. 



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. 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.

3.2

HYDROSTATIC TESTING OF PIPELINES

3.2.1

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. ii.

iii.

No testing will be permitted until seven days after thrust blocks and other holding down works have been completed. 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. 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. ADSSC/GSCW

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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.

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 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)

3.2.2

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.

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 either the design test pressure specified in the drawings or 1.5 times the working pressure, 1.5 times the surge pressure or 1.5 times the pump closed valve pressure, whichever is the greatest. Unless otherwise specified herein, working pressure for all pumping mains is 6 bar and the design test pressure is 9 bar. Immediately prior to commissioning, complete the pipeline and retest the entire pipeline. i. ii.

iii. iv.

ADSSC/GSCW

Fill each pipeline or section with water and displace all free air from the pipeline. Raise the pressure in the pipeline by pumping water until the highest of the working pressure/surge pressure/pump closed valve pressure is attained in the lowest part of the section. Maintain at this level by further pumping until it is steady for a period of not less than 24 hours. Monitor the pipeline over a period of 24 hours without further pressurisation.

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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 and retest the pipeline until it passes. viii. Visually inspect all exposed pipe, fittings, valves and joints during the tests. 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 make up 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 ‘f’ 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. 3.2.3

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

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d) Not more than 7 days prior to handover all pipelines shall be subject to an infiltration test as follows: i.

ii. iii. iv.

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. Dewatering shall have been discontinued for at least 3 days prior to test. Volume of water infiltrating into the pipe shall be accurately measured for a minimum period of 1 hour. 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. 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. 3.3

DEFLECTION MEASUREMENT OF PIPELINES

3.3.1

GRP PIPELINES. a) For pipe length greater than 3.0m 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 thereafter. For pipe lengths of less than 3.0m, measure these 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.

ii.

ADSSC/GSCW

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. 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.

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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 (a) and (b) 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 (a) above and pipes exhibiting any deflection in excess of 2% in (b) above or 4% in (c) above, expose the pipe and replace and recompact the surrounding bedding material. Replace the pipe should the deflection exceed 5%. Any pipe to be replaced must be taken away from site and not be incorporated into the permanent works. d) Subject pipes exposed for recompaction and pipes replaced for other reasons, to the three deflection checks listed in clause 3.03 A.1. above. Carry out deflection checks on adjacent pipes for 50m either side of the recompacted 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

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GRP Pipelien Material

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