4
3
2
1
0
rev.
16.06.2013
05.06.2008
12.03.2008
08.06.2004
02-02-2002
date
Description/issued for
prepared
authorised
client:
ADWEA
project:
STANDARD SPECIFICATIONS FOR WATER WORKS
title:
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project phase:
tender:
project:
document: W-P-SS-001
SKN
QA/QC
QA/QC
rev: 4
AMD
sheet: 1
of: 23
Table of Contents
page
1.
2.
3.
4.
5.
6.
JOINTS .................................................................................................. 9
6.1
Flexible Joints ......................................................................... 9
6.2
Flanged Joints ........................................................................ 10
6.3
Restrained Joints ................................................................... 10
7.
8.
9.
10.
11.
12.
13.
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 2
of: 23
14.
15.
POLYETHYLENE SLEEVES............................................................... 22
16.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 3
of: 23
1.
SCOPE OF SPECIFICATIONS
This specification covers the general requirements for Ductile Iron (D.I.) pipes, fittings and
accessories including material specifications, internal lining, external coating, joints,
polyethylene sleeves etc. This specification sets the minimum acceptable requirements. In
case of difference between this specification and the specified international standards then
the most stringent requirements shall prevail
2.
ISO 527
ISO 887
ISO 974
ISO 2230
Ductile iron pipes, fittings, accessories and their joints for water or
gas applications.
ISO 3506
ISO 4014
ISO 4032
ISO 4179
Ductile iron pipes and fittings for pressure and non-pressure pipeline
Centrifugal cement mortar lining
ISO 4587
ISO 4633
Rubber seals Joint rings for water supply, drainage and sewerage
pipeline Specification for materials.
ISO 16134
ISO 6506-1
ISO 6708
ISO 7005-2
ISO 7268
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 4
of: 23
ISO 7483
ISO 8179-1
ISO 8179-2
Ductile iron pipes External coating Part 2: Zinc rich paint with
finishing layer.
ISO 8180
ISO 8501-1
ISO 9001:2000
ISO 10804
ISO 8503-1
EN 1092-2
EN 14901
EN 15189
EN 197-1
BS 2782
BS 3416
BSEN 10025
DIN 30671
DIN 30672
DIN 4226
ASTM E 28
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 5
of: 23
3.
MPa
Type of casting
DN 40 to DN 2 000
DN 40 to DN 1 000
DN 1 100 to DN 2000
420
10
420
By agreement between contractor and ADWEA, the 0,2% proof stress (Rp0,2) may be
measured. It shall be not less than:
- 270 MPa when A > 12 % for DN 40 to DN 1 000 or A > 10% for DN > 1 000:
-
4.
D.I. PIPES
All D.I. pipes supplied shall be truly circular, of uniform thickness and supplied in the
longest practicable length so as to minimise the number of joints, as per EN 545 (table 3).
Unless otherwise specified in the drawings or in the Particular Specification all pipes, joints
and fittings shall be suitable for the maximum pressure under which they will operate
(normal service pressure + surge pressure or the maximum site test pressure whichever is
greater) and shall sustain without damage or substantial leakage the specified site
hydrostatic test pressure.
Nominal iron wall thickness of pipes & fittings shall be according to either EN 545 :2006 or
EN 545 : 2010. DI pipes & fittings manufacturer shall provide certificates from recognized
international agencies to confirm process compliance to relevant international standards (ie.
EN 545 : 2006 or EN 545 : 2010)
In case of EN 545 : 2006
The nominal iron wall thickness of pipes shall be in accordance with class K9 of EN 545 :
2006 and calculated as a function of the nominal size, DN, by the K class formula, with a
minimum of 6 mm for pipes and 7 mm for fittings:
e
Where :
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 6
of: 23
Class 40
K<9
K>9
40 to 300
40
0,5 (K+1)
50
25b
350 to 600
40
0,5K
40
16
700 t0 1 000
0,5 (K-1)
32
10
1 1000 to 2 000
0,5(K-1)
25
10
The works hydrostatic test pressure is less for fittings than for pipes because the
shape of the fittings makes it difficult to provide sufficient restraint to high internal
pressure during the test.
b
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 7
of: 23
Emin
PFA
SF
DE
Rm
DN
For pipes centrifugally cast, the minimum wall thickness e min, shall not be less tham 3.0mm.
The nominal wall thickness enom, is equal to the emin + (1.3 + 0.001DN)
For centrifugally cast pipes, nominal pipe wall thickness for preferred ductile iron pressure
classes shall be according to EN 545 2010 Table 16
All pipes shall be subject to Inspection during manufacturing.
The name of manufacturer, nominal diameter (DN), PN rating when applicable, and year of
manufacturing shall be cast or cold stamped inside the socket. The CONTRACT number,
reference to International Standard, C pressure class of pipe shall be painted on the pipe.
Pipes shall be hydrostatically pressure tested for leak tightness and certified at the
manufacturer's plant prior to coating or lining for at least 10 seconds at test pressures (bar).
For centrifugally cast pipes the internal hydrostatic pressure shall be raised until it reaches
the works hydrostatic test pressure equal to the pressure class and limit to the pressure of
preferred classes. For fittings and non centrifugally cast pipes test pressure shall be:
Pipes not centrifugally cast and fittings
DN
All thickness classes
40 to 300
25
350 to 600
16
700 t0 2600
10
Unless otherwise stated in the Particular Specification all D.I. pipes supplied shall be of
socket and spigot end.
It shall be the CONTRACTOR's sole responsibility to order a percentage (minimum 2%) of
the total length per diameter of pipes as calibrated pipes, for the purpose of cutting etc.
These pipes shall be clearly marked and shall not be used for normal pipe laying unless it
becomes clear that they are not required for the purpose of cutting any more. The
percentage to be ordered shall give due regard to any changes in route which may occur
during the course of the work for whatever reason.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 8
of: 23
Contractor shall consider in his design the seismic zone as defined by the municipality.
5.
D.I. FITTINGS
All D.I. fittings supplied shall be truly circular of uniform thickness according to ISO 2531
and EN 545.
All fittings shall be subject to Inspection during manufacturing.
Dimensions and nominal iron wall thickness of fittings shall be in accordance with the ISO
2531/EN 545.
For fittings the thickness '' e ''is the nominal thickness corresponding to the main part of the
body. The actual thickness at any particular point shall be increased where necessary to
meet localised high stresses depending on the shape of the casting (e.g. at internal radius
of bends, at the branch body junction of tees, etc).
Name of manufacturer, nominal diameter (DN), the PN rating, and year of manufacturing
shall be cast or cold stamped inside the socket or on the barrel of the fittings. The contract
number, clients name, reference to EN 545 and class shall be painted on the fitting.
Fittings shall be pressure tested for leak tightness and certified at the manufacturer's plant
prior to coating or lining. The pressure test shall be carried out for at least 10 seconds either
with air at a pressure of 1 bar or with water at the pressure indicated below:
25 bar for fittings DN 300 and smaller (for fittings with PN 10 flanges test pressure shall
be 16 bar)
6.
JOINTS
6.1
FLEXIBLE JOINTS
Flexible joints shall be of spigot and socket "push-on" type suitable for angular deflection in
any direction and capable of axial movement to compensate for thermal expansion or
contraction and ground movement. All flexible joints for D.I. pipes and fittings shall be
designed in compliance with ISO 2531/EN 545. Test certificate to be provided.
Joints may permit angular deflection to accommodate ground movements and to negotiate
large radius bends. All joints shall be designed to be fully flexible. Consequently, the
allowable angular deflection declared by the manufacturer shall not be less than
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 9
of: 23
Rubber ring joints shall be of a type that will not deteriorate under local conditions either
during storage or during operation. The rubber gasket shall be of EPDM elastomer or
equivalent in accordance with ISO 4633 suitable for drinking water supply.
Where mechanical type joints are specified, proposed and approved they shall be supplied
complete with approved gaskets, glands, hot dipped galvanized or cadmium plated bolts or
ductile iron bolts, nuts and all other necessary accessories. Where retainer glands are
specified they shall be supplied with bolts and/or other necessary accessories.
6.2
FLANGED JOINTS
Flange ended pipes and fittings shall only be used when connecting to valves or other
special fittings as approved by ADWEA/ENGINEER.
The flanges shall be raised faced and integrally cast or welded on. Screwed on flanges or
glued on flanges are not acceptable. Rotatable flanges may be used for pipes and fittings
up to DN 600.
The dimensions and drilling of the flanges shall be to ISO 7005-2 or EN 1092-2. However in
case connections have to be made to other systems based on other standards contractor is
responsible to verify. The pressure rating of the flanges shall be as given in the Data Sheet
or Particular Specification. Flanged joints shall be supplied complete with gaskets, hot
dipped galvanized or cadmium plated nuts, bolts and washers.
Rubber gaskets shall be EPDM elastomer or equivalent approved in accordance with ISO
4633 suitable for drinking water supply. The gasket shall be minimum 3 mm thick and shall
be reinforced as per pipe system requirement. For piping systems with pressure rating of
PN 16 or above gaskets shall be steel reinforced. The dimensions of the flange gaskets
shall be to ISO 7483.
The nuts, bolts, washers shall be of steel having minimum tensile strength of 400 N/mm2
hot dipped galvanised or cadmium plated. Nuts and bolts shall be suitable for the pressure
rating specified in the Particular Specification. Nuts and bolts shall be to ISO 4014 and
4032 and washers to ISO 887.
6.3
RESTRAINED JOINTS
D.I. pipes and fittings with restrained joints shall be utilised where pipelines have to cross
roads through existing ducts/ culverts/ NDRC or in areas with restricted accessibility where
the use of concrete thrust blocks/ line anchor is prohibited, or as directed by
ADWEA/ENGINEER. The CONTRACTOR shall submit with his bid full details of the type of
restrained joints he proposes to use.
Whenever in the course of work the CONTRACTOR intends to utilise restrained joints he
shall obtain prior approval from ADWEA/ENGINEER.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 10
of: 23
Calculation of the number of pipe lengths with restrained joints required shall follow the
manufacturer's recommendation and shall be subject to ADWEA/ENGINEER approval.
Restrained joints shall be designed to resist the axial thrust forces but maintaining flexibility
and angular deflection. Restrained joints shall be designed in accordance with ISO 10804-1
and EN 545. The joint shall be capable of withstanding the greater of the test pressure or
the service pressure + the surge pressure.
The type of restrained joint shall be subject to ADWEA/ENGINEER approval.
The thrust resisting mechanism shall be separated from the sealing action of the gasket and
shall not be in contact with potable water in the pipeline.
7.
7.1
GENERAL
Unless otherwise specified in the Data Sheet or Particular Specification all D.I. pipes shall
be internally lined with cement mortar in accordance with the following specification and
shall be certified as suitable for use with potable water by an internationally accepted
organisation.
For DI Fittings, cement mortar lining or fusion bonded epoxy shall be acceptable except for
fittings inside chamber and pump house which shall be coated with non toxic fusion bonded
epoxy..
The cement mortar lining for D.I. pipes and fittings shall be in accordance with the
requirement of EN 545.
The internal surface of the socket bell of all zinc/bitumen coated D.I. pipes and fittings shall
be painted with zinc rich paint (150g/m), with a non toxic epoxy of bitumen finishing layer of
100 microns minimum or non-toxic solvent-free two part epoxy coating applied to a
minimum dry film thickness (DFT) of 300 microns or equivalent corrosion protection system
to be approved by ADWEA/ENGINEER. The thickness of the coating may be reduced only
at the gasket locating ring to conform to manufacturer's recommended tolerances.
7.2
SURFACE PREPARATION
Prior to cement lining application the inner surfaces of pipes and fittings shall be cleaned of
dirt, loose rust particles, grease, oil or any other material which could be detrimental to good
contact between the metal and the lining.
7.3
CEMENT
Cement to be used shall be of any cement type (OPC or SRC) complying with the
requirements of EN 197-1. The type of cement chosen by the CONTRACTOR shall be as
per manufacturer's fabrication standards process.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 11
of: 23
7.4
AGGREGATES
Only clean, rounded or crushed natural mineral materials aggregates shall be used in
accordance with the requirement of the latest issue of ISO 4179 standards.
The sand used shall have a controlled granulometric distribution from fine to coarser
elements. The granulometric curve of the sand shall be appropriate to the lining thickness
and method of application.
The cleanliness of sand shall be evaluated in terms of organic impurities and clay bearing
substances. The test of organic impurities shall be carried out by a colorimetric method in
accordance with the standards in force in the producing country; the sand shall not produce
any coloration darker than that of the reference solution.
The determination of the content of clay-bearing substances in the sand (having dimensions
less than 63 microns to 90 microns depending on the country) shall be carried out in
accordance with the standards in force in the producing country; it shall not exceed 2% by
mass.
7.5
ADDITIVES
The use of cement additives is allowed, subject to ADWEA/ENGINEER approval, provided
that they do not adversely affect the quality of the lining, and that of the transported water.
Contractor shall declare the type of additive he is using if any.
Additives shall not contain any elements which impart potable change in colour, taste or
odour or present a health hazard. Certificates of non toxicity prepared and signed by
recognised, independent laboratories, shall be made available to ADWEA/ ENGINEER.
7.6
WATER
Water used for the mortar shall be of potable water quality, water provided by the local
authority / utility is acceptable and shall not contain elements which influence the hardening
of the lining or the quality of the water flowing through the finished pipes. Water used for the
mortar shall be deemed to comply with EN 545: 2010 clause 4.5.3.1 requirements.
7.7
MORTAR
Mortar for the lining shall be composed of cement, sand and water. The mortar shall be
well mixed and of proper consistency to produce a dense homogenous lining that will
adhere firmly to the DI pipe or fitting surface.
Weight of cement and sand shall be accurate to + 3%.
The mortar shall contain at least than one part of cement to 3.5 parts of sand by mass as
per ISO 4179.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 12
of: 23
7.8
METHOD OF LINING
Lining application and quality for finished surface shall be in accordance with ISO 4179.
All pipes shall be lined by a centrifugal process. The consistency of the mortar and the time
and speed of spinning the pipe shall be so adjusted to minimise the segregation of
aggregates from the cement.
Fittings shall be lined by a spray method.
In all cases a smooth finish of the lining shall be obtained, entirely free from cavities or
visible air bubbles, so that minimum thickness and optimum density are ensured at all
points.
The lining shall be uniform and extend from the spigot end up to the beginning of the socket
cavity on the other side. The socket shall be left free of mortar.
No seal coat shall be applied to the cement lining unless otherwise instructed and approved
by ADWEA/ENGINEER.
7.9
CURING
After application to pipes and fittings, the cement mortar shall be cured under controlled
conditions (minimum 48 hours at more than 15 deg.C and 75% relative humidity).
Alternative methods of curing are subject to approval of ADWEA/ENGINEER.
7.10
7.11
Normal
80 600
5.0
4.5
3.5
700 1200
6.0
5.5
4.5
1400 2000
9.0
8.0
7.0
2200 2600
12.0
10.0
7.0
Client
Project:
Title:
project phase:
DN (mm)
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 13
of: 23
N.B.:
7.12
MECHANICAL PROPERTIES
The cement mortar lining shall have adequate resistance against compression and bending
action. Representative test pieces shall have the following minimum properties after 28
days.
7.13
Compression Strength
2
N/mm
Bending Strength
2
N/mm
< 0.35
50
6.0
Cracking - provided that the longitudinal length of a crack is not more than 600 mm,
width of crack not more than 0.8 mm, circumferential cracks are not more than 50% of
the circumference.
b)
Crazing - provided that individual cracks are less than the limits given in a), crazing
over an area not exceeding 25% of the lining area may be acceptable.
c)
Debonding - area of disbondment and radial displacement shall not exceed the values
given in EN 545.
The following tests and measurements shall be conducted, recorded and filed with
frequencies according to ISO 4179.
Aggregates.
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 14
of: 23
8.
8.1
GENERAL
Depending on the existing local conditions the external coating of D.I pipes and fittings shall
be one of the following as given in the Data Sheets or Particular Specifications.
1.
Metallic zinc with bituminous coating layer. (Standard coating for pipes + fittings)
2.
Zinc rich paint with bituminous coating layer. (Standard coating for fittings)
3.
4.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 15
of: 23
The internal surface of the socket end shall be painted with a layer of zinc rich paint 150
g/m2 (zinc content not less than 85%) plus a layer of non-toxic bituminous paint to a
minimum DFT of 100 microns and a mean average DFT of 120 microns.
8.3
The mass of the zinc rich coating shall not be less than 150 g/m with a local minimum of
130 g/m and shall contain minimum 85% zinc in the dry film.
The external surface of the D.I. fitting spigot end at a minimum length of 250mm and the
internal surface of the socket end, which may have direct contact with potable water, shall
have a non-toxic bituminous paint applied to a minimum dry film thickness of 100 microns,
and a mean average DFT of 120 micron.
Note:
Contractor shall provide for paragraph 8.2 & 8.3 a table which correlates the thickness with
the mass of zinc.
8.4
POLYURETHANE COATING
8.4.1
GENERAL
This section covers the factory application of solvent free polyurethane coating to D.I. pipes
and fittings by airless, hot-spray techniques. . The surface of the D.I pipe shall be coated
with polyurethane in accordance with EN 15189, with an average thickness of 2000 microns
and a minimum thickness of 1500 microns. The external surface of the spigot end at a
minimum length of 250mm and the internal surface of the socket end which may have direct
contact with potable water shall have non-toxic solvent free two part epoxy coating applied
to a minimum dry film thickness of 300 microns in accordance with EN 14901 with the
exception of designated areas such as joint areas, edges, etc., with localised minimum
thickness of 100 microns is permissible as described in clause 3.13 of the European
Standard EN 14901:2006. The manufacturer shall provide a third party certificate of
conformity with the EN 15189 which shall cover the performance requirements (see 8.4.2)
and the inspection requirements (see 8.4.5)
8.4.2
Performance requirementThe manufacturer shall prove that the polyurethane
lining has been tested for the performance requirements as mentioned in EN 15189 and the
obtained results meet the requirements of the standard as detailed in the following table.
No
Parameter
Chemical resistance
Client
Project:
Title:
project phase:
Requirement
Less than 15% weight
increase after immersion.
Less than 2% weight loss
after drying.
Test Method
Immersion in deionised water
EN ISO 62 method 2
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 16
of: 23
Chemical resistance
Impact strength
Immersion in diluted
Sulphuric acid 10% EN
ISO 62 method 2
Dropping weight
High voltage test
Indentation resistance
< 10 % at 10 MPa
Indentation test
Elongation at break
> 2,5 %
Tensile test
Specific coating
resistance in 0,1 M NaCl
> 10 m
Ratio of coating
resistance
0,8
8.4.3
SURFACE PREPARATION
All slag shall be removed and all sharp edges shall be ground down. Prior to blasting, all oil,
grease, etc. shall be removed. All surfaces to be coated shall be blast cleaned to ISO
8501-1. Level SA 2.5.
The CONTRACTOR shall ensure that the type of abrasive used, its particle size and the
blasting pressure used are suitable for achieving the required profile. The compressed air
used in blasting shall be clean, dry and oil free.
After blast cleaning all dust shall be removed by vacuum or a clean, oil free, dry air blast.
The application of the coating shall follow with the least possible delay.
Any pipe not coated within 4 hours after blast cleaning shall be completely re-blasted before
coating.
The surface to be coated shall be maintained at a temperature of at least 5 C above the
dew point of the surrounding atmosphere at all times during the coating procedure.
8.4.4
APPLICATION
The polyurethane coating shall be applied using airless spray painting equipment strictly in
accordance with the paint manufacturer's recommendations.
The paint shall be applied in a continuous process to achieve a covering film free from
misses, tears, runs, sags, etc. and the minimum dry film thickness at any point as stated in
Table 1 above.
All painted area shall be thoroughly dried before being over-coated and be free of all loose
particles, dust, debris and atmospheric contamination.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 17
of: 23
The external surface of the D.I. pipe spigot end at a minimum length of 250mm and the
internal surface of the socket end which may have direct contact with potable wall shall
have non-toxic solvent free two part epoxy coating applied to a minimum dry film thickness
of 300 microns.
8.4.5
INSPECTION
The pipe coating shall be completely free from porosity (holiday), voids, pinholes or other
defects. The following Routine test shall be performed by the manufacturer at his coating
application workshop with the frequencies defined in the following table and in accordance
with EN 15189
No
Parameter
Requirement
Surface
preparation
Surface
roughness
Ra > 10 m
Appearance and
continuity
Test Method
Visual
100 %
min 1/shift
EN ISO 8503-1
Minimum coating
thickness
Repairs
Non-porosity
No electrical break
through at required test
voltage
Hardness
> 70 Shore D
Adhesion
> 8 Mpa at 23 C
Frequenc
y
Visual
100 %
Manufacturers written
min.
1/shift
100 %
instructions
High voltage test at 10 kV
Each pipe
Hardness test
min.
1/shift
1 per 1 000
pipes
The CONTRACTOR shall provide and operate an approved non porosity (holiday) detector
with a loud alarm operating at the voltage specified. Non porosity detection shall be carried
out over 100% of surface area of each pipe. The non porosity test shall be carried out in
accordance with EN 15189.
8.4.6
REPAIRS
In the event that problems are detected or repairs are needed, the CONTRACTOR shall
take immediate steps to correct the situation.
Scars, dents, damaged areas and holidays shall be cleaned by removing all rust, scale, dirt
or foreign materials or loose coating.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 18
of: 23
Repairs either in the factory or subsequently on site are to be made by means of a repair
procedure approved by ADWEA/ENGINEER prior to commencement of work.
Any pipe subject to a coating repair procedure shall be fully re-examined in accordance with
above inspection requirements.
If cathodic protection is provided for the coated pipeline, coating at electrical connections
shall be repaired according to the approved repair procedure.
8.4.7
JOINT PROTECTION
All joints of polyurethane ductile iron coating coated pipes shall be protected by heatshrinkable pipe sleeves or collars. The heat-shrinkable sleeves or collars shall have a high
shrink ratio as well as high penetration resistant thick walled structure which together with
an internally coated adhesive mastic sealant shall ensure a reliable vacuum-tight anti
corrosion coating over the bare pipe joint and the polyurethane coated pipe ends.
The heat-shrinkable sleeve shall be manufactured from a radiation cross-linked, thermally
stabilized, UV-resistant modified polyolefin sheet material with an inner surface of a
controlled thickness visco-elastic sealant which shall be in accordance with the following
minimal requirements:
Heat-Shrinkable Sleeve Material
PROPERTY
TEST
METHOD
REQUIREMENT
TYPICAL
VALUE
Tensile strength
ISO 527
23C, CHS*
mm/min
50
17 MPa (min.)
24 Mpa
Ultimate elongation
ISO 527
23C, CHS*
mm/min
50
500% (min.)
750%
Impact brittleness
ISO 974
Below 40C
Pass
Thermal ageing
DIN 30672
Ultimate elongation
ISO 527
23, CHS*
mm/min
Water absorption
ISO 62
23C, 24 hrs.
0.1 % (max.)
0.05%
PROPERTY
TEST
METHOD
CONDITION
REQUIREMENT
TYPICAL
VALUE
Softening Point
ASTM E28
85C (min.)
92C
CONDITION
-25% loss
elongation
of
4%
Sealant Material
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 19
of: 23
DIN 30672
15 N/cm (min.)
25 N/cm
DIN 30672
12 N/cm (min.)
25 N/cm
23C,
1
mm
thickness, CHS*
50 mm/min
10 N/cm2 (min.)
15 N/cm2
ISO 4587
8.5
0.9 mm nominal
1.5 mm nominal
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 20
of: 23
The coating shall not show any tendency for disbandment or blistering.
9.
FLANGE ADAPTORS
Flange adapters shall be installed as shown on the drawings to facilitate removal of valves
and other items for servicing/replacement.
The studs, nuts, bolts shall be stainless steel grade 316. The gasket shall be EPDM to ISO
4633 suitable for drinking water.
The flange pressure rating shall be as given in the Data Sheet or Particular Specification.
The coating shall be factory applied non toxic fusion bonded epoxy powder or Nylon based
polyamide 11 coating system complying with the requirements of AWWC 224 with normal
dry film thickness of 300 microns and minimum DFT of 250 microns.
10.
STEPPED COUPLINGS
Stepped couplings shall be used to connect the spigot ends of two pipes of different
nominal diameters.
The nuts, bolts and washers shall be stainless steel 316. The gaskets shall be EPDM to
ISO 4633 suitable for drinking water.
The coating shall be factory applied non toxic fusion bonded epoxy powder or a Nylon
based polyamide 11 coating system with normal dry film thickness of 300 microns and
minimum DFT of 250 microns.
11.
DISMANTLING JOINTS
Dismantling joints shall be installed as shown on the drawings to facilitate removal of valves
and other equipment for servicing/replacement. The dismantling joints shall be of the
tied/restrained type.
The nuts, bolts, studs, tie rods, washer shall be stainless steel 316. The gaskets shall be
EPDM to ISO 4633 suitable for drinking water.
The pressure rating of the flanges shall be as given in the Particular Specification.
The coating shall be factory applied non toxic fusion boded epoxy powder or a Nylon based
polyamide 11 coating system with normal dry film thickness of 300 microns and minimum
DFT of 250 microns.
12.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 21
of: 23
The rubber gaskets shall be EPDM to ISO 4633 suitable for drinking water. The bolts, nuts,
washers shall be stainless steel 316.
The split tees shall be coated with non toxic fusion bonded epoxy powder or a Nylon based
polyimide 11 coating system with normal dry film thickness of 300 microns and a minimum
DFT of 250 microns.
13.
14.
THRUST/ANCHOR FLANGES
Thrust/anchor flanges shall be used where D.I. pipes or fittings are cast into the chamber
wall and shall be designed to restrain the connecting valves or other equipment installed
inside the chamber.
Thrust/anchor flanges shall be integrally cast or factory welded on to the pipe piece. Bolted
or screwed on thrust flanges are not acceptable.
The coating to the thrust/anchor flange shall be similar to that of the pipe/fitting.
The position of the thrust/anchor flange shall be as shown on the drawings or determined
on site.
15.
POLYETHYLENE SLEEVES
Protective polyethylene sleeves shall be used with all D.I. pipes and fittings to be installed in
buried condition and shall be in accordance with ISO 8180. The polyethylene sleeve
manufacturer shall be ISO 9001: 2000 Quality Management System certified.
The polyethylene sleeve shall be black, resistant to the effect of ultra violet light, The
minimum nominal thickness of the sleeve shall be not less than 200m microns with a
maximum minus tolerance of 10%.
The material shall be made from a polymer with a melt flow index as measured according to
BS 2782, of 10 or less and a density in the range of 0.910 to 0.935 g/ml. The sleeve shall
be free from pinholes, gels, undispersed raw materials and particles of foreign matter. The
film may not contain more than 5% by weight of material other than polyethylene.
Polyethylene sleeving shall be stored in cool dry store away form direct sunlight or
excessive heat. Rolls shall be supplied individually packed in black polyethylene sacks and
clearly marked according to ISO 8150 clause 7.
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 22
of: 23
16.
VENDOR DOCUMENTATION
The CONTRACTOR shall furnish the following vendor data as a minimum, with his bid:
Client
Project:
Title:
project phase:
ADWEA
STANDARD SPECIFICATIONS FOR WATER WORKS
SPECIFICATION FOR DUCTILE IRON PIPES, FITTINGS AND ACCESSORIES
project:
document: W-P-SS-001
rev: 4
sheet: 23
of: 23