06-division 2-section 02205 upvc pipelines-version 2.0

ADSSC/GSCW Division 02 Section 02205

uPVC Pipelines. Materials. Installation and Testing Rev: 02 Jan. 2011 of 16

ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 2 SITEWORK

SECTION 02205 uPVC PIPELINES. MATERIALS, INSTALLATION AND TESTING

General Specification for Civil Works Abu Dhabi Sewerage Services Company

(ADSSC)



DOCUMENT CONTROL SHEET

Revision No. Date Revision Description/ Purpose of Issue

01 April 2008 First Issue.

02 Jan. 2011 ADSSC new logo

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TABLE OF CONTENTS

1 GENERAL ....................................................................................................... 4 1.1 SCOPE ................................................................................................ 4 1.2 RELATED DOCUMENTS ..................................................................... 4 1.3 STANDARDS ....................................................................................... 4 1.4 SUBMITTALS ....................................................................................... 5 1.4.1 PRODUCTS AND MATERIALS APPROVAL. ....................................... 5 1.4.2 METHOD STATEMENTS ..................................................................... 6 1.4.3 DRAWINGS. ........................................................................................ 7 1.5 QUALITY CONTROL............................................................................ 7

2 PRODUCTS ..................................................................................................... 8 2.1 PIPE DESIGN REQUIREMENTS ......................................................... 8 2.2 PIPES AND FITTINGS ......................................................................... 9 2.2.1 uPVC FOR NON-PRESSURE APPLICATION...................................... 9 2.3 QUALITY CONTROL TESTS ............................................................. 10 2.3.1 uPVC PIPES AND FITTINGS. ............................................................ 10 2.3.2 TYPE TESTS ..................................................................................... 11

3 EXECUTION .................................................................................................. 12 3.1 PIPE INSTALLATION ......................................................................... 12 3.2 HYDROSTATIC TESTING OF PIPELINES ........................................ 14 3.2.1 HYDROSTATIC TESTING OF PIPELINES GENERAL. ..................... 14 3.2.2 HYDROSTATIC TESTING OF NON PRESSURE PIPELINES ........... 14 3.3 DEFLECTION MEASUREMENT OF PIPELINES ............................... 15


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1 GENERAL

1.1 SCOPE

This section of the specification gives the requirements for unplasticised Polyvinyl Chloride (uPVC) 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 Submittals. Section 01000-08 Quality control. Section 01000-09 Materials and equipment. Section 02120 Utility excavation, surround and backfill. Section 02300 Sewage works.

1.3 STANDARDS

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

ASTM D2665 Stanard Specidfication for PVC plastic drain, waiste

and vent pipe and fitt BS EN 681 Elastomeric seals. Material requirements for pipe joint

seals used in water and drainage applications. BS EN 1092-2 Circular flanges for pipes, valves and fittings (PN

designated). Steel, cast iron and copper alloy flanges. Specification for cast iron flanges.

BS EN 1401-1 Plastics, piping system for not pressure underground drainage and sewerage. Unplasticized polyvinylchloride (PVC-U). Specification for pipes fittings and the system

ISO 1167 Thermoplastic pipes for the transport of fluids. Resistance to internal pressure. Test method.

ISO 2045 Single sockets for unplasticised polyvinyl chloride (PVC-U) and chlorinated polyvinyl chloride (PVC-c) pressure pipes with elastic sealing ring type joints. Minimum depths of engagement.

ISO 2048 Double socket fittings for unplasticised polyvinyl chloride (PVC-U) pressure pipes with elastic sealing ring type joints. Minimum depths of engagement.

ISO 2505-1 Thermoplastic pipes. Longitudinal reversion. Determination methods.

ISO 2505-2 Thermoplastic pipes. Longitudinal reversion. Determination parameters.

ISO 2507 Unplasticised polyvinyl chloride (PVC-U) pipes and fittings. Vicat softening temperature. Test methods and specification.


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ISO 3126 Plastic pipes. Measurement of dimensions. ISO 3127 Thermoplastic pipes. Determination of resistance to

external blows. Round the clock method. ISO 4065 Thermoplastic pipes. Universal wall thickness table. ISO 9000 Quality management systems. ISO 11922-1 Thermoplastic pipes for the conveyance of fluids.

Dimensions and tolerances. 1.4 SUBMITTALS

1.4.1 PRODUCTS AND MATERIALS APPROVAL.

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

i. The manufacturer's complete and detailed specification and test

results of the proposed uPVC pipes and fittings required for the Works including Manufacturer’s Certifications of compliance with this section of the standard specification. Information on all items listed in Table 1.4.1 shall be given.

ii. 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.

iii. 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.


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Table 1.4.1 – Product Information For uPVC Pipe and Fittings

Product Information Units

Manufacturing Details

Name of manufacturer -

Manufacturing process for pipes -

Manufacturing process for bends and fittings -

Joint type -

Details of all additives used in the manufacture -

Summary of Design Criteria

Minimum depth of cover m

Maximum depth of cover m

Maximum working pressure KN/m2

Design test pressure

KN/m2

Internal vacuum pressure KN/m2

Pipe Details

Class of pipe -

Nominal external diameter mm

Wall thickness mm

Standard pipe length m

Notes to Table 1.4.1 1) Pipe data to be provided for every diameter in each class of pipe. 1.4.2 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. Procedures for handling, storage and installation of pipes.


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ii. Hydrostatic testing procedures for uPVC non pressure pipelines.. iii. Deflection measurement procedures for uPVC pipelines.

1.4.3 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. Drawings of the pipes, fittings, joints, pipe specials and the

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

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

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

1.5 QUALITY CONTROL

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.

i. Installation of pipeline. ii. Hydrostatic testing of pipeline. iii. Deflection measurement of pipeline.

1.6 DELIVERY, STORAGE AND HANDLING

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

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

manner to avoid product damage. ii. Pipes and fittings shall not come in contact with any sharp

projections that may cause damage to the pipes and fittings during transportation loading and unloading. Ensure that pipes and fittings are well secured during transit and adequately supported along their length. Cover pipes and fittings of plastic materials during


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transportation. Do not allow pipe to overhang the end of a vehicle during transportation.

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

iv. Store pipes and fittings on a flat level area as recommended by the pipe manufacturer. Ensure that pipes and fittings supplied either on pallets or crated, remain on the pallets or in their crates until required.

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

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. Store uPVC 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.

Store rubber joint rings in a well ventilated place free from exposure to sunlight and in their original packings until they are needed.

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

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.

2 PRODUCTS

2.1 PIPE DESIGN REQUIREMENTS

The design requirements for uPVC pipes shall be as given in Table 2.1.1 below unless otherwise indicated on the drawings.


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Table 2.1.1 – Design Requirements uPVC

Pipe Diameter mm Pipe Material and Class/Stiffness

Cover < 6m Cover > 6m

Gravity Pipelines

150 -

160 OD uPVC (Class 10) uPVC (Class 16)

200 -


250 -


300 -

315 OD uPVC (Class 10) uPVC (Class 16) 2.2 PIPES AND FITTINGS

2.2.1 uPVC FOR NON-PRESSURE APPLICATION.

a) All uPVC components shall be designed and fabricated by one manufacturer.

b) Use polyvinyl chloride, together with those additives that are needed for

the manufacture and performance of pipe to this section of the standard specification. Pigments may be added to achieve the manufacturer's nominal pipe colour.

c) Provide uPVC pipes and fittings capable of withstanding the working

pressure, test pressure, and the loading specified.

d) For sewage applications pipes and fittings shall be suitable for carrying domestic sewage at temperatures up to 40o

C and having a maximum sulphide concentration of 50 mg/litre.

e) Recycled material shall not be used.

f) Supply pipes in straight lengths of not greater than 6 metres excluding the depth of any socket.

g) Determine the nominal pipe wall thicknesses from the table in ISO 4065.

h) Comply with the limits specified in ISO 11922 when measuring the

nominal outside diameters and wall thicknesses in accordance with ISO 3126.


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

j) 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. Joints shall be capable of withstanding a "draw" of 13mm over and

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

ii. Joints shall be capable of withstanding a deflection of not less than one and a half degrees 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. Single sockets shall be in accordance with ISO 2045. v. Double sockets shall be in accordance with ISO 2048 may be used

adjacent to structures or special fittings. vi. The ends of cut pipes shall be suitably chamfered prior to making

the joint. vii. Solvent welded joints shall not be permitted for buried pipelines.

k) Ensure that all pipes including cut lengths and all fittings before despatch

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

i. The letters uPVC. ii. The manufacturer's name initials or identification mark. iii. The nominal external diameter in millimetres. iv. The pressure classification in bars. v. The date of manufacture and batch number. vi. A stamp to show that they meet the required inspection

requirements and hydraulic tests at the point of manufacture. vii. Stencil on each end of the pipe in legible letters the pipe

identification number. 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.

2.3 QUALITY CONTROL TESTS

2.3.1 uPVC PIPES AND FITTINGS.

Use the results of appropriate type tests for the proposed pipes and fittings to determine the properties of the pipes. Carry out each type test on representative samples of the pipes and fittings to be used. If the manufacturer does not have appropriate results of these tests available or if alterations are proposed to the method of manufacture, pipe design or pipe


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composition, carry out all the type tests required by the Engineer to prove the adequacy of the proposed pipes.

2.3.2 TYPE TESTS

a) Vicat Softening Point. Ensure that the deformation temperature of each tested sample is not lower than 79o

C, when two random samples taken from the pipe are tested in accordance with ISO 2507.

b) Impact Resistance. Ensure that the pipe sample when tested to ISO 3127, have a true impact rate (TIR) below 10% at a confidence level of 90%.

c) Heat Reversion. Ensure that at no position around the pipe the length

changes by more than 5% when three samples of each pipe size are tested to ISO 2505. Samples shall not show faults such as cracks, cavities or blisters during or after the tests.

d) Hydraulic Test. Test specimens of pipe of each pipe size in accordance

with ISO 1167, three specimens at 20oC and a further three specimens at 60o

Table 2.3.1 – uPVC Hydraulic Test

C. Ensure that samples of pipe will sustain the stresses without failure for the times and temperatures given in table 2.3.1 below.

Test Temperature 0 Minimum Time to Failure Hrs C Induced Stress N/mm2

20

1 42

60 1000 10

e) Joint Tests. Two jointed pipes of each pipe size to be tested in

accordance with the requirements of Section 6.5 of ASTM D3262 but applying the following parameters in substitution.

i. Use a positive test pressure of 6m water head. ii. Conduct the negative pressure test to determine the integrity of the

joint against infiltration. Apply an external test pressure of 6m water head to two sections of pipe assembled with a deflected joint.

iii. Maintain 1.5o

iv. The Engineer may require fittings to undergo similar type tests to those specified above. Carry out such tests in accordance with the appropriate ISO standard. Use fittings of similar quality to those of the pipes being tested.

deflection during the deflected joint tests.

v. Quality Control Tests. Carry out the quality control tests listed below at the frequency stated. Records of all tests and inspections to be maintained by the manufacturer. Forward two copies of all test certificates and reports to the Engineer. Ensure that the raw materials are checked for compliance with the relevant standard.


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Superficial appearance. Ensure that the internal and external surfaces of every pipe are visually inspected both before shipment and after off loading at site and that they are free from defects.

Impact Resistance. Perform a programme of testing to ensure that the pipe complies with the type tests.

Heat Reversion. Test at least one specimen during every 8 hours production run from each machine. Test in accordance with ISO 2505. Ensure that the length does not change by more than 5% at any point around the sample. The tested samples should not show faults, such as cracks, cavities or blisters.

Hydraulic Test. Test at least one specimen during every 8 hour production run from each machine to comply with the requirements of the type test at 20o

Joint Test. Perform a programme of testing to demonstrate that the pipe joints continue to comply with the type tests.

C.

vi. Reject any pipe or fitting which fails any of the quality control tests

stipulated in this specification. In the event that the pipe fails any of the tests outlined above, repeat the relevant test on a further ten pipes of that class and diameter as follows.

Carry out the relevant test on five of these pipes produced

immediately and sequentially prior to and five immediately following the failed pipe. If any of the ten pipes fail, 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 will be determined and the Engineer reserves the right to reject all the pipes of that class and diameter.

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

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

iii. The Contractor shall provide the Engineer and ADSSC copies of all


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

c) Install bedding, surround and backfill as specified in Section 02120 of

the specification and shown on the drawings.

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

e) 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.

f) 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.

g) 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.

h) 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.

i) 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.

j) Excavation for or laying of uPVC pipes shall not proceed until an

approved device for gauging pipe deflections is on site.

k) 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. 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


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before each pipe length is tested. 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.

b) Use potable water for hydrostatic testing and pipeline cleaning.

c) Test the pipeline in lengths between manholes.

d) Use properly designed fittings for the purpose of temporarily closing the

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

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

f) 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.

g) 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.

3.2.2 HYDROSTATIC TESTING OF NON PRESSURE PIPELINES

a) Test all non pressure pipelines 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) Not more than 7 days prior to handover all pipelines shall be subject to an infiltration test as follows:


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i. Test the pipeline in lengths between manholes or such shorter lengths as the Engineer may direct or permit.

ii. Dewatering shall have been discontinued for at least 3 days prior to test.

iii. Volume of water infiltrating into the pipe shall be accurately measured for a minimum period of 1 hour.

iv. Maximum infiltration shall not exceed 1 litre per millimetre of pipe diameter per kilometre of pipe per day.

d) Keep a record of all tests and make them available for inspection. Hand

over test records to the Engineer for approval.

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

f) 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.

g) 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

a) As soon as possible after a line of uPVC pipes has been installed, hydrostatically tested and the trench backfilled, but before the dewatering is removed, draw a pig or ball through the pipeline, so sized that it will not pass any point in the pipeline which has deflected to a greater degree than that permitted after initial installation.

b) Immediately prior to the issue of a Provisional Acceptance Certificate,

draw a pig or ball through the pipeline, so sized that it will not pass any point in the pipeline which has deflected to a greater degree than that permitted in the long term.

i. If any of these tests indicate that the deflection may exceed the

permitted values, replace the pipe or the pipes. Remove from site any pipe or pipes which fail the deflection checks. Do not incorporate in the permanent works.

c) Apply the deflection checks on all replaced pipes. Carry out deflection

checks also on adjacent pipes for 20m either side of the removed pipes.


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d) The positive or negative deflections on the pipeline must not exceed the following values. (A reduction in diameter is considered to be a negative deflection)

i. 3% after initial installation. ii. 5% long term.

END OF SECTION

06-division 2-section 02205 upvc pipelines-version 2.0

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