SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

STANDARD

SPECIFICATION

FOR

ANTI-BACTERIA

HIGH IMPACT RESISTANT 3 LAYERS

HIGH QUALITY PVC WATER PIPE

2009

Rev. 3

ii
 Table of Contents

1. Compliance with standards ... 1

2. Marking of Pipes and Fittings ... 1

3. Materials used in Manufacture ... 1

4. Classification ... 2

5. Thickness and Diameter ... 2

6. Lengths ... 3

7. Tolerance on Dimensions ... 3

8. Joints ... 3

9. Fittings ... 4

10. Pipe End-cap ... 4

11. Freedom from Defect ... 4

12. Type of Testing .......5

13. Color Of Pipes ... 7

14. List of Appendix

Appendix A: Ductile Iron Epoxy Coated Fittings Drawing

Appendix B: Table E2 - Dimension & Thickness of pipe

Appendix C: Tensile Test (Extract from Appendix G of KS M3401:1995)

Appendix D: Jointing Procedure

 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

1. Compliance with Standards

The anti-bacteria high impact resistant three layer water pipe and uPVC fittings (for
sizes below 80mm diameter) or Epoxy Coated Ductile Iron fittings (for sizes
80mm diameter and above) to be supplied shall be of classes C, D or E specified
in the Bill of Quantities and shall be of approved manufacture.

Subject to the specified requirements of this Section, the three layer anti-bacteria pipe
with the Inner & Outer skin layer of High Impact Resistant Strength and centre
layer of High Tensile Strength shall be manufactured in accordance to
MS628:Part 1:1999 or BS3505:1986 for plain ended pipe.

The bell-mouth pipes, with one end bell mouthed containing a super tight wide profile
EPDM Rubber Ring seal and one end plain ended shall be manufactured in
accordance to MS628:Part 1:1999 or BS3505:1986 and MS628: Part 2 Section
2.1:1999 or BS4346:Part 2:1970.

uPVC joints and fittings for pipes shall be manufactured in accordance to MS628: Part 2
Section 2.1:1999 or BS4346:Part 2:1970.

Fittings for pipes sizes of 80mm diameter and above shall be made of ductile iron (with
hot fusion epoxy coated) and complying to BS EN545:2002 but fabricated
according to the Epoxy Coated Ductile Iron fittings drawing. (See Appendix A)

2. Marking of Pipes and Fittings

2.1 All pipes and fittings shall be indelibly marked at intervals of not greater than 3
meters with the following:-

a) the manufacturers distinguishing mark,

b) the nominal size and class,
c) the letters JBA/JKR at least 10mm height for the pipe size 155mm
diameter and above; for smaller pipe, the height of the letters will be
adjusted to suit the pipe size.
d) the date or the last two digits of the year of manufacture, and
e) the batch number.

2.2 In addition, all specials shall bear the diameter of the branch in the case of tees
and the angle in case of bends and angle branches on the outside.

3. Materials used in Manufacture

3.1 The material used in the manufacture of pipes, shall consist substantially
of polyvinyl chloride, to which may be added only those additives with anti-
bacterial properties and function and other additives which are needed to
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 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

facilitate the manufacture of the polymers pipe with good finish, mechanical
strength, capacity and also the ability to actively eliminate bacteria in the water
flowing through the pipe.

3.2 None of these additives shall be used separately or together in quantities

sufficient to constitute a toxic hazard or to impair the fabrication properties of the
pipes, joints and fittings (in particular long term mechanical strength and impact
strength). The NO-LEAD, NO-ZINC additives shall be used for pipe dry
compound.

3.3 The addition of the manufacturers own rework material produced during the
manufacture and works testing of pipes, joints and fittings complying with this
specification is permissible but limited to center layer only up to 3% maximum
only. No other external sourced recycled material shall be used. Maximum
contents of CaCo3 shall not exceed 3% during the compound mixing. So, center
layer shall not use any pigment coloring and skin layer shall be very light grey to
avoid to mix any external recycled material.

3.4 When tested by method 120B of BS2782 (Methods of Testing Plastics), the
deformation temperature of the material under load shall not be lower than
75Centigrade.

3.5 Manufacturer shall have test certificate in accordance with JIS Z2801 using
E.Coli bacteria. The bacteria reduction rate shall be minimum 99%.

4. Classification

4.1 The pipes, joints and fittings shall be classified in accordance to the Maximum
Permissible Working Pressure as in Table E1.

TABLE E1 Classification of Pipe

Maximum Permissible
Class of
Working Pressure
Pipe
At 20C At 30C
C 9 bar 8.1 bar
D 12 bar 10.8 bar
E 15 bar 13.5 bar

5. Thickness and Diameter

5.1 The pipes shall be designated by the nominal size and shall conform to the
outside diameters and wall thickness given in Table E2. (See Appendix B)

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 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

6. Lengths

6.1 The standard length of pipes shall be 6 meters or 5.8 meters. Other lengths may
be supplied if required by the purchaser and by agreement with the
manufacturer.

6.2 The manufacturer may supply not more than 10% of the order in lengths
decreasing by multiples of 150mm, provided that the minimum length of any pipe
shall be not less than 3.4 meters. The ends of the shortened pipes shall be cut
and turned to the correct dimension for jointing.

6.3 The contractor shall supply free of charge the extra joints required due to the
supply of shorter length pipes.

7. Tolerance on Dimensions

7.1 Mean tolerances on outside diameters shall conform to the requirements of Table
E2. (See Appendix B) An out of roundness tolerance of + 0.5% on mean outside
diameter is permitted.

7.2 A tolerance of +10mm shall be allowed on the length of an individual pipe but the
total length of pipe supplied shall be not less than the total length ordered.

8. Joints

8.1 Below 80mm: (Plain Ended pipe)

The copper compression joint for PVC pipe shall be used. The copper
compression joint shall be only supplied by pipe manufacturer to guarantee the
coordinated water seal.

Alternatively: The manufacturer approved uPVC coupler joints (for pipes sizes
below 80mm nominal diameter) shall be used. Each coupler joint shall consist of
uPVC sleeve suitable for jointing with IPS WELD-ON solvent cement with IPS
Primer only. Joint fittings shall also use pure virgin resin only without mixing any
recycled material.

8.2 80mm and Above: (Plain ended pipe or Bell mouth pipe)

Two types of joint are acceptable and shall be designed to suit actual site
condition. One is the Hot Fusion Epoxy Coated Ductile Iron Coupling Joint and
another is the Bell mouth joint with Rubber Ring pre-inserted at factory. The
rubber ring shall be manufactured of EPDM Rubber complying with the
requirements of MS672:1999 or BS EN 681-1:1996.

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 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

8.3 Each bell-mouth pipe shall be supplied complete with the required super tight
wide profile rubber rings in the socket. The profile rubber rings and bell-mouth of
pipe are moulded into a 3 step belling depth to ensure that the rubber ring stay
firmly in place during insertion of the pipe into the socket.

8.4 The completed joint shall be watertight when the pipes are deflected to angles up
to 5 and subjected to 3.6 plus or minus 0.1 times the Maximum Permissible
Working Pressure specified.
8.5 Jointing method shall be carried out as described in Appendix D as follows:-

D1) Rubber Ring Joints (for bell-mouth/spigot end pressure pipes)

D2) Ductile Iron Epoxy Coated fittings/Joint
D3) Solvent Cement Joint with IPS Weld-On Solvent cement and primer

9. Fittings

9.1 Connection between Anti-Bacteria High Impact Resistant Three Layer Pipes

Hot Fusion Epoxy Coated Ductile Iron Fittings shall be used for jointing anti-
bacteria high impact resistant three layer pipes. These fittings consist of a
Ductile Iron body, rubber ring(s), necessary numbers of gland together with L-
shaped hot dip galvanized ductile iron bolt(s) and nut(s) and self locking gland,
PP washer, PP lock ring. (See Appendix A)

9.2 Connection between Anti-Bacteria High Impact Resistant Three Layer Pipes
and Other Pipes

Epoxy Coated Ductile Iron Fittings Stepped Coupling shall be used for jointing
the anti-bacteria high impact resistant three layer pipes and interconnection with
other types of pipes. One end of the adaptor shall have the same external
diameter and allowable tolerance as those of other types of pipes, while the other
end shall have the same external diameter and allowable tolerance as those of
anti-bacteria high impact resistant three layer pipes. Dimension shall be
coordinated with other pipe to be connected.

10. Pipe End-cap

10.1 Both sides of pipe end shall be properly covered with black color polymer
end-cap to prevent debris going inside of the pipe. Center of end-cap shall have a
hole to ventilate properly.
10.2 This is optional item with additional cost.

11. Freedom from Defect

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 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

11.1 The walls of pipes, joints and fittings shall be homogeneous throughout and the
internal and external surface shall be clean, smooth and reasonably free from
grooves, blisters, wrinkles, dents, heat marks and other defects that would impair
their performance in service.

12. Type of Testing

12.1 Tensile Test on Anti-Bacteria High Impact Resistant Three Layer Pipes

Tensile strength test shall be carried out as described in Appendix G of Korean

Standard KS M 3401:1995 (See Appendix C). A specimen shall be taken from
each machine at least once in every 8 hours run time and shall be tested to meet
the requirement specified.

* The Tensile Strength shall be minimum 510Kgf/cm2 at 20 deg Celcius.

12.2 Flattening Test on Anti-Bacteria High Impact Resistant Three Layer Pipes

A) Straight Pipe
Insert a 50mm length of pipe sample between two flat plates, apply the load at
speed of 10 +2mm/min from the right angle of the axis of pipe until the specimen
is fully flattened, then examine the pipe for cracks, break or bubbles, etc. with
naked eyes.

* The specimen shall be no cracks or break after flattening test compressed up to

100%.
* The diameter of pipe shall be returning back to the original size of 50% at least
after compressed it not least than 80%.

B) Bellmouth Socket Pipe

Take the test piece from the straight part of the Bellmouth socket pipe, and carry
out the test on it as for the straight pipe.

12.3 Heat Reversion Test on Anti-Bacteria High Impact Resistant Three Layer
Pipes

Heat Reversion Test shall be carried out as described in Appendix A of MS628

Part1:1999 or BS3505:1986. The specification can be adjusted to suit the
requirements of the purchasers and by the agreement from the manufacturer.
As with Purchasers request, manufacturer can produce higher impact modified
pipe similar to HI-VP which strictly comply and surpass to KS M3401 HI-VP. In
such a case, heat reversion shall be less than 8%. SIRIM mark shall not be
printed with such a deviation.

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 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

12.3 Resistant to Acetone Test on Anti-Bacteria High Impact Resistant Three

Layer Pipes

Resistant to Acetone Test shall be carried out as described in Appendix B of

MS628 Part 1:1999 or BS3505:1986. The sample shall show no delamination or
disintegration. Flattening and/or swelling of the sample shall not be deemed to
constitute failure. A specimen shall be taken from each machine at least once in
every 8 hours run time and shall be tested to meet the requirements.

12.4 Factory Hydrostatic Test on Anti-Bacteria High Impact Resistant Three

Layer Pipes

When tested by the method described in Appendix C of MS628 Part 1:1999 or

BS3505:1986 the pipe shall withstand the appropriate Factory Hydrostatic Test
pressure for at least 1 hour without failure as shown in Table E3.

TABLE E3 Factory Hydrostatic Test Pressures

One specimen shall be taken at random from each machine at least once in
every 8 hours run time or once in every 300 meters run, whichever is the greater
quantity of pipe and shall be tested to meet the requirement.

12.5 Impact Strength Test at 20C on Anti-Bacteria High Impact Resistant Three
Layer Pipes

Impact Strength Test at 20C shall be carried out as described in Appendix F of

MS628 Part 1:1999 or BS3505:1986.

Initially, sufficient specimens shall be taken at random from each machine so that
at least one is taken per shift and at least 14 strikes made per extrusion line.

If no specimen fails (defined as fracturing or cracking through its complete wall

thickness), no further test specimens need be taken.

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 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

If, of the initial 14 strikes, one, two or three specimen fails, further specimens
shall be taken at random and tested to ensure a total of at least 42 strikes.

If, during the test, more than four specimens fail the test shall be discontinued
and the batch of pipes shall be rejected.

12.6 Stress Relief Test on uPVC Joints/Fittings (for sizes below 80mm diameter)

Stress Relief Test on fittings shall be carried out as described in Appendix A of

BS 4346: Part 1:1969. None of the specimens tested shall show blisters,
excessive delamination or cracking, or signs of weld line splitting. The weld line
or lines may become more pronounced during the test, but this shall be not be
deemed to constitute failure.
Special care shall be taken in examining the area around the point of injection,
where no crack or delaminations shall penetrate to a depth greater than 20% of
the wall thickness at that point.

The assessment of the depth of penetration at cracks or delaminations shall be

carried out by sectioning the specimen at the point of injection and measuring the
depth to which those defects penetrate the wall thickness at the specimen.

12.7 Factory Hydrostatic Test on Copper Compression Joint or uPVC Fittings (for
sizes below 80mm diameter)

Short term Factory Hydrostatic Test on fittings shall be carried out as described in
Appendix E.2 of BS4346: Part 1:1969. The specimen shall withstand a pressure
of 3.6 + 0.1 times the working pressure for 1 hour without showing signs of
leakage or creeping.

Fittings that have been used for the hydrostatic pressure tests are not suitable for
subsequent use in service and shall not be taken back into stock.

13. Color of Pipes

13.1 The Anti-Bacteria High Impact Resistant Three Layer Pipe shall be of Light Grey
Color.
13.2 The color could be changed to clients preference but in such a case, SIRIM
mark can not be printed since SIRIM only allow using light Grey color due to the
current MS standard clause.

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Appendix C
Extract from Appendix G of KS M3401:1995

TENSILE TEST

G.1 Test Specimen

The test specimen shall be cut longitudinally from a length of pipe by either:-

a) Heating and flattening it at a temperature of 125C to 130C, then

machining it or routing it out from the tube wall, in which case the edges of
the specimen shall be polished to remove notches, or
b) Punching it from a section of pipe heated t o a temperature of 125C to
130C and subsequently flattening it. The cutting edges of the punch shall
have the profile shown in Fig. 2 and they shall be free from notches.

G.2 Procedure

Straight Pipe

Obtain 3 test pieces according to Table 8 and Figure 4 and test its tensile at
speed of 10 + 2 mm/min at the ordinary temperature ( 3) and take the average
value in accordance with KS M 3006 and calculate the tensile strength at 15C
with following formula:-
f = ft + 0.652 (t-15) { f = ft + 6.65 (t-15) }

Where f : Tensile strength at 15C (N/mm2) {kgf/cm2 }

ft : Tensile strength at tC (N/mm2) {kgf/cm2 }
t : Temperature during test (C) (Applicable range of temperature: 5C
to 30C)

Note (3) Ordinary temperature refers to 20 +15C (Grade 15 of temperature in KS

A 0006)

The recorded maximum load shall not differ from the true value by more than 1%
or 1.1 N whichever is the greater.

The tensile strength of the specimen shall be calculated from the maximum load
and the original area of cross section and shall be expressed in force per unit
area.
G.3 Sampling and Assessment of Results

A sample shall be taken from each machine at least once in every 8 hours
running and shall meet the requirements specified in 11.1
Appendix D

JOINTING PROCEDURE

D1) RUBBER RING JOINTS FOR BELL-MOUTH SOCKET PIPES

STEP 1. Check the Bellmouth socket end of pipe and the rubber ring & groove
to make sure they are clean.

STEP 2. Insert a retaining fork over the pipe at the socket to prevent the pipe
from moving.

STEP 3. Clean and lubricate the spigot end of pipe and insert it into the bell-
mouth socket until the reference mark using the wooden plank over the
bell-mouth socket at the other end and a metal bar to level the pipe
forward.

The jointing is complete.

NB. a) Use only clean cloth or paper towel for cleaning the pipe.
b) Use only the proper lubricant for jointing

D2) SOLVENT CEMENT JOINT FOR UPVC JOINT/FITTING

(USE ONLY IPS WELD ON PRIMER WITH SOLVENT CEMENT)
STEP 1. Chamfer the external edge of the spigot end.

STEP 2. Mark a reference circumferential line from the spigot end (with distance
equal to the socket depth)

STEP 3. Clean the pipe end and inner surface of the matching socket with
cleaning fluid (PRIMER) and apply an even layer of solvent cement to
the spigot covering the area corresponding to the socket depth. The
solvent cement is brushed onto the pipe surface along the pipe axis
towards the pipe end.

STEP 4. While the solvent cement is still wet, insert the spigot into the socket
with a slight twisting motion and hold for 10 seconds (straining time).
Excess solvent cement should be removed with a soft cloth and shall
be leave it for 24 hours at least for curing period before further
handling or water pressure test.

The jointing is complete.

 SPECIFICATION FOR ANTI-BACTERIA HIGH IMPACT RESISTANT 3-LAYER PVC-M WATER PIPE

NB. Only approved* uPVC fittings, cleaning fluid (PRIMER) and solvent cement
should be used. (* i.e. with SIRIM Certification)

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D3) EPOXY COATED DUCTILE IRON JOINT/FITTING

STEP 1. Check the accessories i.e. Ductile Iron fitting and Gland, Polymer
washer and Polymer Lock Ring and EPDM rubber ring are in good
condition.

STEP2. Clean the spigot end of the pipe and mark a circumferential line on the
spigot to indicate the socket depth.
.
STEP 3. Insert the following items into the spigot end of the pipe in the
sequence indicated below:-
a) Gland
b) Lock Ring (Groove Restraint or Plain type)
c) Polymer washer
d) EPDM rubber ring (NB. The outer face of the rubber ring should be
in line with the reference line on the spigot)

STEP 4. Insert the spigot end of the pipe into the Ductile Iron fitting.

STEP 5. Push the gland towards the fitting (as close as possible).

STEP 6. Insert one L bolt from the fitting side of the gland through the bolt
holder and screw on the nut (a few turns only to hold).

STEP 7. Rotate the gland and repeat with the next L bolt into the bolt holder
until all the bolts are in position.

STEP 8. Tighten each nut until all the nuts are fully tightened.

The jointing is complete.

NB. Check the gap between the fitting and the gland must be the same all
around.