07-division 2-section 02206 vc pipelines-version 2.0

ADSSC/GSCW Division 02 Section 02206

VC Pipelines. Materials, Installation and Testing Rev: 02 Jan. 2011 of 9

ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 2 SITEWORK

SECTION 02206 VC 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

03

04

05

06

07

08

09

10


(ADSSC)



TABLE OF CONTENTS

1 GENERAL ....................................................................................................... 4 1.1 SCOPE ................................................................................................ 4 1.2 RELATED DOCUMENTS ..................................................................... 4 1.3 STANDARDS ....................................................................................... 4 1.4 SUBMITTALS ....................................................................................... 4 1.4.1 PRODUCTS AND MATERIALS APPROVAL. ....................................... 4 1.4.2 METHOD STATEMENTS. .................................................................... 5 1.4.3 WORKING DRAWINGS. ...................................................................... 5 1.5 QUALITY CONTROL............................................................................ 5 1.6 DELIVERY, STORAGE AND HANDLING ............................................. 6 1.7 WARRANTY ......................................................................................... 7

2 PRODUCTS ..................................................................................................... 7 2.1 PIPES AND FITTINGS ......................................................................... 7 2.2 QUALITY CONTROL TESTS ............................................................... 8

3 EXECUTION .................................................................................................... 8 3.1 PIPE INSTALLATION ........................................................................... 8 3.2 TESTING OF PIPELINES .................................................................... 9


(ADSSC)



1 GENERAL

1.1 SCOPE

This section of the specification gives the requirements for vitrified clay (VC) pipeline materials and the installation and testing thereof for use in gravity 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. Section 03300 Cast in place concrete.

1.3 STANDARDS

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

BS 295 Pt 1 Vitrified clay pipes and fitting and joints for drains and

sewers. Requirements BS 295 Pt 4 Vitrified clay pipes and fitting and joints for drains and

sewers. Requirement for special fittings, adaptors and compatible accessories.

BS EN 1610 Construction and testing of drains and sewers. BS EN 681 Elastomeric seals. Material requirements for pipe joint

seals used in water and drainage applications. Vulcanised rubber.

ISO 9000 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 required shall comprise but not necessarily be limited to:

i. The manufacturer’s design calculations, complete and detailed

specification and test results of the proposed VC pipes and fittings required for the Works including manufacturers certificates of


(ADSSC)



compliance with this section of the specification. 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.

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

v. Joint materials and gaskets. 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. ii. Testing procedures for VC pipelines.

1.4.3 WORKING DRAWINGS.

a) The Contractor shall submit drawings to the Engineer for approval in advance of commencing the site activity in accordance with Section 0100007 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, including details of reinforcement cage assemblies.

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.


(ADSSC)



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.

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.

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. If the pipes are delivered in crates they should remain crated until installation.

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

vi. 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.


(ADSSC)



1.7 WARRANTY

a) The manufacture and the Contractor shall jointly guarantee the vitrified clay pipes system to be free from defects in materials and workmanship for a period of 10 years from the date of completion of the Works.

b) The Contractor shall furnish ADSSC with the manufacturer’s guarantee

and warranty certificates for all materials and components used. 2 PRODUCTS

2.1 PIPES AND FITTINGS

a) Vitrified clay pipes and fittings shall be manufactured to BS 295 Part 1.

b) Joints for vitrified clay pipes.

i. All buried joints shall be spigot and socket type with rubber sealing rings in accordance with BS EN 681-1 or be made of polypropelylene couplings with sealing rings. The couplings and sealing rings shall be supplied by the pipe manufacturer.

ii. The EPDM rubber sealing ring shall be of acceptable composition and must be contained in a groove on the spigot end of each pipe to ensure proper positioning and confinement in the annular space.

iii. The sealing rings shall be extruded or moulded and cured in such a manner that they will be dense, homogeneous and free from porosity, blisters, pitting and other imperfections. The rings must be extruded or moulded with smooth surfaces to the specified size within a tolerance of ±6 percent on any dimension, measured at any cross-section. Joints in the ring shall be vulcanised and not glued.

iv. Joints shall be capable of withstanding a draw of 13mm over and above the initial jointing allowance and remain 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.

v. 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.

vi. 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.

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

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

i. The manufacturer's name, initials, or identification mark.


(ADSSC)



ii. The nominal internal diameter in mm. iii. Crushing strength. iv. The date of manufacture. v. A stamp to show that they meet the required inspection

requirements and hydraulic tests at the point of manufacturer. vi. The project or contract number.

2.2 QUALITY CONTROL TESTS

a) The crushing strength of vitrified clay pipes shall not be less than the values specified in BS 295-1 for the respective classes of pipes shown on the drawings.

b) Bending moment resistance of vitrified pipes shall be not less than the

values given in BS EN 295-1 table 5 for respective crushing strength..

c) Vitrified clay pipes and fittings shall be tested airtightness and watertightness as pr Cl 2.14 and Cl. 2.18 of BS EN 295.

d) Vitrified clay pipes shall be rejected for any of the following reasons.

i. Failure to pass the airtightness or hydrostatic test. ii. Having the bore smaller that minimum as given in table 1 of BS EN

295. 3 EXECUTION

3.1 PIPE INSTALLATION

a) Install pipe, fittings, and accessories in accordance with BS EN 1610 and manufacturer's instructions.

b) Install bedding, surround and backfill as specified in section 02120 of the

specification and as shown on the drawings.

c) Install appurtenant facilities on the pipeline such as manholes, chambers, inlet structures and catch basins as specified in section 02300 of the specification.

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.

f) Pipe cutting shall be done only by chain or disc cutter, leaving a smooth

cut at right angles to the axis of the pipe.

g) When installing pipes, ensure the joint is cleaned and lubricated and that


(ADSSC)



the rubber gasket is inserted in the groove of the socket end of the pipe.

h) 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.

3.2 TESTING OF PIPELINES

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) Test should be according to BS EN 1610 Cl.13.2 air test LC.

c) In case the air test fails and the fault cannot be detected the Contractor

will carry out water test according to BS EN 1610 Cl. 13.3.

d) 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.

END OF SECTION

07-division 2-section 02206 vc pipelines-version 2.0

Documents