WP-P5-S1_19!8!15 General Specification of Main Laying Materials for Waterworks

General Specification of Main Laying Materials For Waterworks

WP-P5/ S1

WP- P5/ S1

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General Specification of Main Laying Materials For Waterworks

Department

Document Type

WP

Standard

WP-P5/ S1

Document Title General Specification of Main Laying Materials for Waterworks

Issue Approval Prepared By

Approved By

Eng. Osama Samaan Sleem Fadayel Engineer (Material Specifications) Specifications) Eng. Eid Auwid Khlaif Al-Idmat Engineer (Material Specifications) Specifications) Eng. Ali Al_obaidly Head, Materials Standards & Specifications Specifications Section 

Eng. Mohd Thani E.J. AL-Maadead Manager, Water Planning Department 

Signature:

 

Signature:

Issue No.

Date

Reason for re-issuing Standard

0.0

12/04/2015

First issue of the Standard.

1.0

19/8/2015

Updated & modified the Table of Contents

2.0 3.0 4.0 5.0 Key Words

:

Standard, Specification, materials, Manufacturer, Quality body certifier, ISO, BS, EN, WRc , Ductile Iron Pipes, Fittings &  Accessories, valves , Pumps, Water Meter, Copper, Polyethylene Pipes & Fittings and corrosion protection materials .

Review Frequency

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:

 Annually

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General Specification of Main Laying Materials For Waterworks

Department

Document Type

WP

Standard

WP-P5/ S1

Document Title General Specification of Main Laying Materials for Waterworks

Issue Approval Prepared By

Approved By

Eng. Osama Samaan Sleem Fadayel Engineer (Material Specifications) Specifications) Eng. Eid Auwid Khlaif Al-Idmat Engineer (Material Specifications) Specifications) Eng. Ali Al_obaidly Head, Materials Standards & Specifications Specifications Section 

Eng. Mohd Thani E.J. AL-Maadead Manager, Water Planning Department 

Signature:

 

Signature:

Issue No.

Date

Reason for re-issuing Standard

0.0

12/04/2015

First issue of the Standard.

1.0

19/8/2015

Updated & modified the Table of Contents

2.0 3.0 4.0 5.0 Key Words

:

Standard, Specification, materials, Manufacturer, Quality body certifier, ISO, BS, EN, WRc , Ductile Iron Pipes, Fittings &  Accessories, valves , Pumps, Water Meter, Copper, Polyethylene Pipes & Fittings and corrosion protection materials .

Review Frequency

Issue : 1

19/08/2015

:

 Annually

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Contents

Page

Title Page Document Control & Issue Record Page Contents of General Specification of Main Laying Materials for Waterworks Purpose Scope Responsibilities & Authorities  Abbreviations & Terminologies Terminologies

1 2 3 8 8 8 8

Section - 1 General 1.1 Suitability of Materials 1.2 Transport & storage of materials 1.3 Manufacturer ‘s Certification 1.4 Standards 1.5 Material Coating & Internal Components 1.6 Fasteners 1.7 Inspection 1.8 Packing 1.9 Technical clarification 1.10 Samples 1.11 Alternative Materials Section - 2 Ductile Iron Pipes and Fittings 2.1 General 2.2 Joints 2.3 Length of pipes 2.4 Marking 2.5 Certificate of Test 2.6 External & Internal Coating of Ductile Iron Pipes & Fittings During Manufactory 2.7 Factory Applied Polyethylene External Coating 2.8 Protection of Above Ground & Inside chambers D.I. Pipes & Fittings 2.9 special protection of D.I. Pipes & Fittings 2.10 Pipe Cutting 2.11 Packing Section - 3 Slip-On Coupling and Flange Adaptors and Dismantling Joints and Step Couplings 3.1 General 3.2 Slip-on couplings 3.3 Mechanical Collar’s 3.4 Flange adapters 3.5 Dismantling Joints 3.6 Step couplings 3.7 External And Internal Coating of Slip-on Couplings, Step Couplings, Flange Adapters And Dismantling Joints During Manufacture 3.8 Fasteners 3.9 Identification Metal Strip 3.10 Packing Section - 4 Corrosion Protection of Ductile Iron Pipes, Fittings & Accessories 4.1 Pipe Wrapping Tape 4.2 Wrapping Procedure

9 9 10 11 11 11 12 12 13 13 13 13 14 14 14 14 14 15

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4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25

Storage Packing Wrapping Tape Property Primer Packing Wrapping Tape Visco Elastic Poly Iso Butene Wrapping Procedure Storage Packing Wrapping Tape Property Polyethylene sleeving Marking Packing PVC Black self adhesive tape Joint molding putty Packing Storage Trench Marker Tape Marking Packing Lubricant Packing Slip-on Couplings, Flange Adapters and Dismantling Joint during Installation 4.26 Heat Shrink Sleeve 4.27 Packing Section - 5 Bedding and Surround Material’s 5.1 General 5.2 Imported Granular Material and Selected Excavated Material Section - 6 Gate valves 6.1 General 6.2 Motorised Actuator 6.3 Testing 6.4 Hand-wheel 6.5 Marking 6.6 Materials of Gate Valves 6.7 Gear box 6.8 Flanges 6.9 Gate valve stem seals 6.10 Material Coating & Internal Components 6.11 Accessories 6.12 Packing Section - 7 Butterfly Valve 7.1 General 7.2 Motorised Actuator 7.3 Testing 7.4 Hand-Wheel 7.5 Markings 7.6 Materials 7.7 Flanges 7.8 Coatings 7.9 Valve Keys

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7.10 Accessories 7.11 Packing Section - 8 Air Valves 8.1 General 8.2 Air Valves construction materials 8.3 Single air valve large orifice type 8.4 Single air valve small orifice type 8.5 Double air valve 8.6 Coatings 8.7 Markings 8.8 Packing Section - 9 Fire Hydrants 9.1 General 9.2 Marking 9.3 Materials 9.4 Connections 9.5 Coatings 9.6 Testing 9.7 Stand pipes 9.8 Accessories 9.9 Packing 9.10 Above Ground Fire Hydrant (pillar type) 9.11 Marking 9.12 Coating 9.13 Testing 9.14 Accessories 9.15 Packing Section - 10 Check Valve 10.1 General 10.2 Check Valves construction materials 10.3 Coatings 10.4 Markings 10.5 Packing Section - 11 Other Types of Valves 11.1 General 11.2 Coatings 11.3 Markings 11.4 Flow Control Valves 11.5 Material Specification 11.6 Pressure Regulating Valves/ Pressure Reducing Valves 11.7 Material Specification 11.8 Altitude Valves 11.9 Material Specification 11.10 Packing Section - 12 Pumps 12.1 General 12.2 Scope 12.3 Conflicts & Deviations 12.4 Applicable Standards and Codes 12.5 Technical Submittal: 12.6 Design Considerations 12.7 General Requirements:

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12.8 Pump Construction Requirements: 12.9 Accessories 12.10 Protection of Moving Parts 12.11 Pumps Coating 12.12 Inspection & Testing 12.13 Site Acceptance Test:12.14 Retention of Pump Efficiency for Sustainable Performance: 12.15 Spare Parts, Tools And Accessories 12.16 Maintenance 12.17 Vibration, Noise And Temperature Monitoring 12.18 Temperature Monitoring: 12.19 Vibration Monitoring: 12.20 Guarantee & Warranty 12.21 Nameplates, Marking & Labeling 12.22 Packing Section - 13 Surface Boxes & Manhole Covers, Marker Posts & Indicator Plates 13.1 General 13.2 Gate valve surface boxes (up to 300mm Ø valves) 13.3 Gate valve manhole covers (400mm Ø valves and above) 13.4 air valve manhole covers 13.5 Butterfly valve manhole covers 13.6 Stopcock and ferrules (SC) surface box 13.7 Under ground fire hydrant manhole covers 13.8 Washout manhole covers 13.9 Marker post 13.10 Indicator plate 13.11 Aluminum Indicator Plate 13.12 Packing Section - 14 Copper Tubes 14.1 General 14.2 Sheathing 14.3 Tube Sizes 14.4 Packing Section - 15 Copper Fittings, Ferrules, Stopcocks & Poly Adapters 15.1 General 15.2 Marking 15.3 Materials 15.4 Universal swivel ferrule 15.5 Marking 15.6 Stopcocks 15.7 Marking 15.8 Saddles 15.9 Packing Section - 16 Electronic Flow Meters District 16.1 General 16.2 Flow Sensor and Transmitter 16.3 Pressure Gauge 16.4 Pressure Transmitters and Differential Pressure Transmitters 16.5 Asset Management System Section - 18 S.S. Repair clamps & under pressure Drilling Tees 17.1 General

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17.2 Marking 17.3 Materials 17.4 Lengths of the clamp 17.5 Flanges 17.6 Packing Section - 18 Concrete and Ancillary Items 18.1 General 18.2 Pre-cast concrete chamber sections 18.3 Impregnated fiber board Section - 19 Polyethylene Pipes & Fittings for Service Connections (MDPE) 19.1 General 19.2 Polyethylene Pipes (Material) 19.3 Length and Size 19.4 Fittings 19.5 Stop Valve: 19.6 Flanged Fittings: 19.7 Saddle Straps 19.8 Ferrule 19.9 Joints 19.10 Marking 19.11 Packaging 19.12 Packing 19.13 Handling & Storage Section - 20 uPVC Duct 20.1 General 20.2 Marking 20.3 Packing Section - 21 Water Service Cabinet 21.1 GENERAL 21.2 Water Service Cabinet (Standard – Flushed Type) 21.3 Water Service Cabinet (Standard – Surface Mounted Type)  APPENDIXES I. Typical Drinking Water Quality II. Site Environmental Conditions III. Drawings 1. Water Meter Service Cabinet 2. Precast Concrete Chamber Slab Construction Details 3. Marker Post, Backing Plates, and Plate 4. Surface Box & Manhole Cover IV. WORLDWIDE KNOWN QUALITY BODY CERTIFIER V. PRE - ARRANGEMENT INSPECTION

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1. Purpose This Standard provides “Materials Standards & Specifications Section’s Engineers” the specification of materials used for water works. 2. Scope

This Standard is applicable to all materials used for waterworks. 3. Responsibilities & Authorities

Responsibilities and authority for ensuring that the steps in this guideline shall be carried out are specified at relevant steps in the guideline and include: Manager, Water Planning Department Head, Materials Standards & Specifications Section  Materials Standard Engineer.  Materials Specification Engineer.  If the responsible personnel listed above are absent, these responsibilities shall be designated to the relevant staff. 

4. Abbreviations & Terminology KM : Qatar General Electricity and Water Corporation KAHRAMAA : Qatar General Electricity and Water Corporation WP MSS GIS NDS

:Water Planning :Materials Standards & Specifications Section :Geographical Information System :Planning & Network Development Section Term

Description British Standard- one of the international standard used in BS General Specifications for main laying materials for waterworks International Standards Organization - one of the international ISO standards used in General Specifications for main laying materials for waterworks. Water Research Council- international body who certifies the WRC non-toxicity of material if contact with potable water. Manufacturer A company whose business is manufacturing a certain product  An item intended to be used in a certain construction works or Material projects.  A detailed exact statement of particulars, especially a Specification statement prescribing materials, dimensions and quality of work for something to be built, installed or manufactured.

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Section - 1

General 1.1

SUITABILITY OF MATERIALS

1.1.1 All materials in direct contact with potable water must have a health certificate issued by Worldwide Known Quality Body Certifier (See Appendix ‘IV’) in accordance with requirement of BS6920 “Suitability of Non-Metallic Products for use in direct contact with Water Intended for Human Consumption with regards to their effect on the quality of Water”. 1.1.2 All pipe-laying materials shall be suitable for use with the range of chemical characteristics of the water and complies with KAHRAMAA Water Quality Requirements & GCC Standards as detailed in Appendix ‘I’. 1.1.3 All materials shall be suitable for using and storing in the environmental conditions detailed in Appendix ‘II’ with minimum working water temperature at 50º C, unless otherwise specified, all works shall conform to PN16 standards and other standards noted elsewhere in this specification. 1.1.4 The Tenderer shall supply materials from any of the latest approved KAHRAMAA manufacturers list and furnish to Water Network Planning Department for review and approval. 1.1.5 All the relevant Technical documents of the materials/manufacturers must be in Original OR  Notarized copy and shall be submitted from the Manufacturer for Technical Evaluation. 1.1.6 All materials shall be inspected and tested to ensure compliance with KAHRAMAA requirements and General Specifications for Main laying Materials. The testing shall be carried out according to relevant standards approved by Water Network Planning Department. 1.1.7 All The Engineer may test any materials before they leave the manu facturer’s premises or after delivery to the site. 1.1.8 The Engineer may reject any materials after delivery to the site should he consider them unsatisfactory, notwithstanding any preliminary test approval of the materials at the manufacturers  premises. 1.1.9 The cost of all tests necessary to ensure compliance with the Project Documentation, shall be  borne by the Contractor. 1.1.10 The number of samples to be tested at the local testing laboratory, must be not less than One Number of each diameter of the ordered materials, the cost of all tests necessary to ensure compliance with the Project Documentation, shall be borne by the Contractor. 1.1.11 The Local test certificates shall be issued by:I. II. III.

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Manufacturer premises Central Materials Laboratory. An approved third party testing laboratory or other organization.

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1.2

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TRANSPORT & STORAGE OF MATERIALS 1.2.1 All materials handling, transporting and storing should comply with KAHRAMAA and manufacturer recommendation to avoid damages due to double handling. 1.2.2 During transport, extra care needed to avoid damaging the coating of the materials. Cleaning any foreign matter deposited on Materials during transport. 1.2.3 All materials to be stored are strictly in accordance with the KAHRAMAA requirements/Manufacturer storage recommendation at all times, all corrosion  protection materials shall be stored under the shade and not to be exposed under direct sunlight. 1.2.4 Upon materials delivery to the Contractor’s stores at site, the contractor should unpack, open all crates etc., and unload to areas as directed by the Store controller or KAHRAMAA Site Engineer. The contractor shall provide all timbers and  packing, necessary for the correct stacking of pipes, fittings and other delivered materials. 1.2.5 After inspection the contractor shall shift and stack the approved materials to areas as directed by store controller/KAHRAMAA Site Engineer. 1.2.6 All Coated materials such as (Epoxy, Polyurethane, and Risen) shall be handled with special care during loading, transportation and unloading to avoid accidental damage. 1.2.7 The Pipes may be stored in the open areas; however it shall be stacked off the ground on 150 x 100 mm timber skids to be provided by the Contractor. The stacking shall be done according to the manufacturer's recommendations. 1.2.8 Fittings, rubber gaskets, nuts, bolts etc. shall be withdrawn from storage and delivered to the site to suit the daily construction requirements. 1.2.9 All materials which are subject to deterioration by Ultraviolet Light such as Rubber gaskets, fixing materials, instruments, polyethylene sheeting etc. must be stored so that they are not exposed to direct sunlight. 1.2.10 Materials which are liable to deteriorate shall be used in the order of delivery. 1.2.11 The provision and correct usage of broad band slings is particularly important for the lowering of pipes into the trench. The Contractor shall take the utmost care to  prevent any damage to the coating or sleeving during lowering-in, alignment,  jointing and final removal of the lifting sling. In all cases an approved non metallic sling must be used for the handling of pipes and fittings.

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1.3

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MANUFACTURER ‘S CERTIFICATION 1.3.1 The Applicant must have a valid ISO 9001 Certificate issued by the granting certifier body holding BS EN ISO/IEC 17021:2011 certificates. 1.3.2 The applicant must have successful records of experiences for supplying of minimum 15 year in International market and 5 year minimum in regional / GCC market for prequalifying. 1.3.3 Provide the QA/QC plan. 1.3.4 Provide organization chart including personals Crucial Vita.

1.4

STANDARDS 1.4.1 The Tenderer shall follow the latest KAHRAMAA General Specifications of Main laying Materials for Waterworks. 1.4.2 In case of materials were not mentioned in this document, the Tenderer shall follow the latest edition of one of the following appropriate relevant standards such as BS, ISO, EN or DIN with all subsequent amendments up to the year of the materials order. Submit complete documents to Water Network Planning department for further evaluation.

1.5

MATERIAL COATING & INTERNAL COMPONENTS 1.5.1 All materials in direct contact with potable water must have a health certificate issued by Worldwide Known Quality Body Certifier (See Appendix IV) as per requirement of BS6920 "Suitability of Non-Metallic Products for use in contact with Water Intended for Human Consumption with regards to their effect on the quality of Water” 1.5.2 Coating shall be smooth and mirror finish without any air bubbles or pebbles, and the thicknesses shall as per the relevant specifications given below; I. II. III.

The minimum thickness is 300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. The minimum thickness is 300 micron Electrostatic ally applied epoxy coating. The minimum thickness is 300 micron Fluidized bed epoxy coating.

1.5.3 The coating quality shall conform to the following tests as per the relevant specifications given below; 

Adhesion Test: Coating adhesion to metal shall not be less than 12N/mm² (BSI BS EN ISO 4624).

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Holiday Test: Coating porosity shall be “zero” on 3 kV DC tester.

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Hardness: Intrinsic Rockwell hardness shall be between50 - 60.

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1.5.4 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not be develop, when tested by 3 kV DC tester. 1.6

FASTENERS 1.6.1 All Bolts, Nuts & Washers connected to Valves, Fire Hydrants, Couplings, Adaptors and Dismantling Joints shall be Mild steel with hot dipped zinc galvanized, with minimum thickness 70 micron. 1.6.2

All Bolts, Nuts & Washers connected to Valves, Fire Hydrants, Couplings, Adaptors and Dismantling Joints shall be protect with putty and wrapping tape.

1.6.3 Saddle Strap fasteners should be Stainless Steel “A4”. 1.7

INSPECTION 1.7.1 Pre-Inspection Arrangement shall comply with the requirements as per the attached  procedure. (See Appendix V). 1.7.2 KAHRAMAA reserves the right to inspect the materials in the factory. 1.7.3 The manufacturer shall allow access at all times during manufacturing and testing to the premises in which the material being manufactured. 1.7.4 Upon receipt of materials at the contractor's site store, materials to be inspected by Supervising Consultant of the subject project. 1.7.5 Upon KAHRAMAA Engineer receipt of the Materials Request for Inspection, he will visit the contractor store. If any damage on the Pipe’s / Fitting’s is observed and it can be repaired, it's the contractor's responsibility to perform the repair in accordance with the manufacturer's recommendations and the approval of KAHRAMAA - repair works should be carried under direct supervision of the manufacturer. 1.7.6 KAHRAMAA reserves the right to reject the supplied material during final inspection or at later date, if found not as per the General Specification and will have the right to put the Manufacturer under “ ON HOLD “ or “ BLACK LISTED “ until further action. 1.7.7 The non-repairable rejected materials, which were not complying with KM Specifications during inspection and marked by the Engineer (rejected), must be removed by the Contractor and to be shipped outside State of Qatar and proof of shipping documents to be submitted to KAHRAMAA. 1.7.8 KAHRAMAA reserves the right to witness all types of testing locally, and the tests shall be carried out in accordance with applicable standards and codes.

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1.8

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PACKING 1.8.1 The material/item shall be packed in compliances with KM and Manufacturer recommendation and procedure. 1.8.2 At Site, (from the pre-Inspection arrangement) all items shall be packed individually and put into the wooden box, which shall be close and open type. Every layer in wooden box shall be clamped properly to avoid abrasion during transit and damage to coating. 1.8.3 The cutting of pipes shall be kept to a minimum and after cutting the remaining length of calibrated pipes shall be suitably marked and re-stacked together with the remaining calibrated pipes.

1.9

TECHNICAL CLARIFICATION 1.9.1 In case there are disputes, KAHRAMAA shall have the right to ask the manufacturer all the technical documents that will help out in clarifying this dispute.

1.10 SAMPLES 1.10.1 Samples shall be provided when required by the engineer or instructed by the  project documentation. Materials subsequently supplied shall conform to the quality of the samples which have been approved by the engineer. 1.10.2 Each sample shall bear a securel y fixed label bearing the following information: I. II. III.

Project Identification. Contractor Identification. Sample Identification including all information as to Manufacturer, Model Number, and Catalogue Number.

1.10.3 Materials subsequently supplied shall conform to the quality of the samples which have been approved by the engineer. 1.11 ALTERNATIVE MATERIALS 1.11.1 The Contractor may propose the use of alternatives to materials specified in the Project Documentation, Due to some problems or delay with the Manufacturer / Supplier, Such proposals shall be complete with all supporting information showing that the alternative Materials are complying with KAHRAMAA latest specification. 1.11.2

The use of alternative materials shall only be permitted if it is approved in writing  by the Engineer. 

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Section - 2

Ductile Iron Pipes and Fittings 2.1

GENERAL These Clauses Shall Be Read In Continuation Of Section 1 Of This Specification . 2.1.1 All pipes and fittings shall be manufactured from approved grade of ductile iron. 2.1.2 All manufacture and testing shall be in accordance with the latest edition of BSEN545/ISO 2531, 4179, 8179 including any subsequent amendments and as specified  below.

2.2

JOINTS 2.2.1 Spigot & socket pipes & fittings joints shall be provided with approved integrally cast ‘push-in’ type joints, each joint being supplied with an approved jointing - ring designed by the manufacturer solely for the purpose of sealing the joint. 2.2.2 All flanged pipes & fittings shall be provided with integrally cast/ or rotatable flanges drilled to BS EN 1092-2, PN16. 2.2.3 All flanged pipes, fittings and valves shall be supplied with approved EPDM multilayer cotton reinforced rubber gasket; which in comply with the requirement of BS6920 and shall be kept in a sealed sun proof bag with written information of the same. 2.2.4 The manufacture specification of all-joint details, gaskets and jointing rings shall be supplied to the Engineer by the Tenderer / Contractor for approval. 2.2.5 All jointing materials shall comply with Clause 1.1.1 of this specification.

2.3

LENGTH OF PIPES 2.3.1 All pipes shall be supplied in the lengths of 5.50/6.00 meters or as per project requirement.

2.4

MARKING 2.4.1 All pipes & fittings shall be marked in accordance with the latest edition of BSEN545/ISO-2531. 2.4.2 Additional marking on the pipes and fittings must be included such as;

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Tender Number



Contractor's Name



Manufacturer's Name



Year of manufacture



Standard

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2.5

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CERTIFICATE OF TEST 2.5.1 The Tenderer / Contractor shall provide signed certificates stating the results of all tests as specified in BSEN 545 / ISO 2531, 4179, 8179 and BS 3416. 2.5.2 KAHRAMAA reserves the right to witness tensile tests on bar test pieces selected on the basis of not more than one test piece for every batch of 100 pipes. 2.5.3 Where specified tests are to be witnessed, the tests shall be carried in accordance with the manufacturer’s quality control procedure of the relevant international standard.

2.6

EXTERNAL & INTERNAL COATING

OF

DUCTILE IRON PIPES & FITTINGS DURING

MANUFACTORY 2.6.1 All materials shall conform and meet all the requirements of the latest edition of BSEN545/ISO2531, ISO4179, ISO8179, BS3416 and BS6920. 2.6.2 All ductile iron pipes and fittings shall be internally lined by centrifugal method with Sulphate Resistance Cement (SRC) mortar lining as per requirement of the latest edition of BSEN 545 or ISO 4179 or epoxy coating. 2.6.3 D.I. Pipes and Fittings shall be cured in curing chambers. 2.6.4 For D.I. Fittings coated with epoxy externally/internally, it shall be conformed one of the following method; 

Fusion bonded epoxy coating shall be minimum thickness 300 micron (Polymeric anticorrosion) coating as per WIS No. 4-52-01.



Electrostatic ally applied epoxy coating shall be minimum thickness 300 micron.

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Fluidized bed epoxy coating shall be minimum thickness 300 micron.



The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017 or Black.

2.6.5 The external coating shall be of metallic Zinc coating of 130 gm/m2 on pipes and Zinc rich paint coating of 150 gm/m2 on D.I. Fittings as per the latest edition of BSEN 545 or ISO 8179. 2.6.6 The external finishing layer to all pipes & fittings after the application of the Zinc coating shall be of bitumen coating as per the latest edition of BS3416, Type 2. 2.6.7 The internal cement lining shall be uniformed and smooth as possible and shall be within the tolerance limit acceptable by the International standards. 2.6.8 The thickness of internal cement lining in D.I. Pipes & Fittings shall be as follows in accordance with the latest edition of BSEN 545 as follows (See table 01):Table (01) Thickness of Internal Cement Lining Issue : 1

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Nominal Size 80-300mmØ 350-600mmØ 700-1200mmØ 1400-2000mmØ

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Thickness 4.0mm 5.0mm 6.0mm 9.0mm

2.6.9 The contractor is to supply confirmation from manufacturer that cement lining to be used is suitable for use with the range of chemical characteristics of water detailed in Appendix “I.” 2.6.10 The internal section of sockets of pipes and fittings shall be painted with a minimum 100-micron thick epoxy coating. The coating shall be suitable for use in contact with  potable water at +50 C. 2.7

FACTORY APPLIED POLYETHYLENE EXTERNAL COATING 2.7.1 The factory applied polyethylene external coating shall be applied by extrusion or any other approved method as per BSEN 14628-2005 (Ductile iron pipes, fittings and accessories External polyethylene coating for pipes Requirements and test methods). 2.7.2 The factory applied polyethylene external coating shall be type PE-D pipe zinccoated with minimum thicknesses accordance with latest edition of BSEN 146282005 as follows (See table 02):Table (02) MINIMUM COATING THICKNESSES Nominal Size Thickness 80-250mmØ 2.50mm 300-450mmØ 3.0mm 500-1200mmØ 3.50mm 1400-2000mmØ 4.0mm 2.7.3 The color code of polyethylene external coating shall be Blue color RAL5000/5001/5005/5010/5017.

2.8

PROTECTION OF ABOVE GROUND & INSIDE CHAMBERS D.I. PIPES & FITTINGS 2.8.1 External coating of ductile iron pipes & fittings to be laid above ground or inside chambers shall be coated with zinc primer as per ISO 8179, and then followed by an application of bituminous finish coating. Bituminous finish coating shall contain aluminum of not less than 20% in the dry film and shall be in silver.

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2.8.2 The internal section of sockets of pipes and fittings shall be painted with a minimum 100-micron thick epoxy coating. The coating shall be suitable for use in contact with  potable water at +50 C. 2.9

SPECIAL PROTECTION OF D.I.

PIPES & FITTINGS

2.9.1 External coating of ductile iron pipes & fittings to be laid on location of high water table shall be coated with Polyurethane/Epoxy coating with minimum thickness of 300 microns. 2.9.2 External coating of ductile iron pipes & fittings to be laid on location of high water table shall be coated with Polyurethane/Epoxy coating with minimum thickness of 300 microns. 2.9.3 Ductile iron pipes and fittings which are completely immersed in water (i.e. piping inside reservoir) shall be coated with a minimum 300microns thickness fusion  bonded epoxy. 2.10 PIPE CUTTING 2.10.1 Unless specified otherwise the Contractor shall supply a minimum of 2% of pipes of each diameter gauged (calibrated) along two third of the pipe entire length starting from the spigot end. These pipes shall be clearly marked by the factory and stored separately in the Contractor's store yard. 2.10.2 Where it is necessary to cut pipes, the cutting shall be neatly and accurately  performed by machine so as to leave the pipe end a true circle and normal to the pipe axis and the cut ends shall be chamfered and painted as per manufacturer's recommendations for damaged coatings and generally to the original coating (Zinc & Primer / Epoxy) of the D.I. pipes and fittings. 2.11 PACKING 2.11.1 Pipes of small diameters shall be packed in bundles. Every pipe shall be separated from each other with the help of properly designed wooden spacers. The bundle shall be secured firmly with proper straps and well faced wooden base supports for  proper transport, handling and storage. Every bundle shall have only one length of  pipe. 2.11.2 For big diameters, it should be supplied separately. 2.11.3 All pipes and fittings shall be supplied with plastic end caps & shall be maintain in good condition until the pipe is ready to be installed in the trench. 2.11.4 The packing shall be as per Section 1, Clause 1.8 of this specification.  Issue : 1

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Section - 3

Slip-On Coupling and Flange Adaptors and Dismantling Joints and Step Couplings 3.1

GENERAL These clauses shall be read in continuation of Section 1 of this Specification.

3.2

SLIP-ON COUPLINGS 3.2.1 Slip-on couplings shall be manufactured from either cast iron or rolled steel and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 3.2.2 Couplings shall be similar in design to that detailed in BS-8010, Section 2.1, and ‘Slip-on Couplings’. 3.2.3 For New Potable Water Network Construction, Couplings are recommended up to 300mm Ø only, 400mm Ø and above, a mechanical Collar is to be used.

3.3

MECHANICAL COLLAR ’S 3.3.1 Mechanical Collars shall be manufactured from Ductile Iron and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 3.3.2 Mechanical Collars shall be suitable for normal pressure test up to PN-16.

3.4

FLANGE ADAPTERS 3.4.1 Flange adapters shall be manufactured from either cast iron or rolled steel and shall  be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 3.4.2 Flange adapters shall be suitable for jointing the flanges to PN-16, as detailed in BSEN 545 / ISO 2531. 3.4.3 Flange adapters shall be similar in design to that detailed in BS-8010, Section 2.1, ‘Flange adapters’.

3.5

DISMANTLING JOINTS 3.5.1 Dismantling Joints shall be suitable for jointing the flanges to PN-16, as detailed in BSEN 545 / ISO 2531. 3.5.2 Dismantling Joints shall be similar in design to that detailed in BS-8010, Section 2.1, ‘Flange adapters’.

3.6

STEP COUPLINGS 3.6.1 Step couplings shall be manufactured from either cast iron or rolled steel and shall  be suitable to joint between two pipes of different materials.

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3.7

EXTERNAL AND INTERNAL COATING

OF

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SLIP-ON COUPLINGS, STEP COUPLINGS,

FLANGE ADAPTERS AND DISMANTLING JOINTS DURING MANUFACTURE 3.7.1 All Slip-on couplings, step couplings, flange adapters and dismantling joints shall be coated both, internally and externally as per one of the following methods; 

Fusion bonded epoxy coating shall be minimum thickness 300 micron (Polymeric anticorrosion) coating as per WIS No. 4-52-01.



Electrostatic ally applied epoxy coating shall be minimum t hickness 300 micron.



Fluidized bed epoxy coating shall be minimum thickness 300 micron.



The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017 or Black.

3.8

FASTENERS 3.8.1 All nuts and bolts must be made of Stainless Steel Grade “A4” or Grade 316L.

3.9

IDENTIFICATION METAL STRIP 3.9.1 All couplings and flange adapters shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing.

3.10 PACKING 3.10.1 The packing shall be as per Section 1, Clause 1.8 of t his specification. 

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Section - 4

Corrosion Protection of Ductile Iron Pipes, Fittings & Accessories 4.1

PIPE WRAPPING TAPE 4.1.1 The tape shall be supplied with width of 150 mm and 225 mm and with length 25 m, 30 m and 75 m per rolls. 4.1.2 Pipe diameters up to 200mmØ, 150mm width tape shall be used. 4.1.3 Pipe diameters 300mmØ and above, 225mm width tape shall be used. 4.1.4 For all types of fitting with diameters 100mmØ and above, 150mm width tape shall  be used. 4.1.5 For normal application, high water table (Sabkha), high resistivity and contaminated areas, the self adhesive wrapping tape shall be applied with a 55% overlap shall be applied and sufficient tension in accordance with manufacturer instructions to ensure complete conformability and smoothed out as application proceeds to avoid air  pockets. 4.1.6 Prior to backfilling the wrapped Pipes / joints shall be holiday tested, and the  porosity shall be “zero” on 3 kV DC tester. 4.1.7 Wrapped pipes shall not be permitted to lie down on the ground except when finally  positioned in the trench. 4.1.8 Wrapping tape dimension selection is Subject to Tenderer / Contractor Specification. 4.1.9 The adhesive compound shall be of the pressure sensitive type (that is, not requiring a primer in order to achieve bond to the substrata) and shall have thickness between 0.75 to 0.90mm. 4.1.10 The tape shall be supplied with a wider high quality silicon release paper covering complete tape and both sides of the tape shall have a minimum of 5mm wider silicon release paper to prevent edge contamination. 4.1.11 In case during storage at maximum storage temperature of 50  C for six months, the adhesive material shall not flow out of the release paper and there shall not be any end blocking. 4.1.12 Wrapping tape shall be marking in middle with the following information;    

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Manufacturers name & logo. Date of manufacture Width of the tape Batch Number

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4.2

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WRAPPING PROCEDURE 4.2.1 To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-Automatic Tape Wrapping Machine and for pipe diameters above 300mm, Fully Automatic Wrapping Machine should be used.

4.3

STORAGE 4.3.1 Wrapping tape shall be stored in dry, cool, well ventilated condition, the temperature of the store shall not exceed 30° C and out of direct sunlight.

4.4

PACKING 4.4.1 Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage shall separate each layer. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No/ Title, Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm.

4.5

WRAPPING TAPE PROPERTY 4.5.1 The wrapping tape shall be conforming to the following specifications given in Table 03. Table (03) WRAPPING TAPE PROPERTY DATA SHEET SR. Property Test Method Unit No. A. Physical 1 Color 1.1 Backing -----

1.2 1.3 2 3 4 5 6 7 8 9 10

Adhesive Compound Release Paper Backing Type Backing Thickness Min. Adhesive Thickness Min. Total Thickness Min. Elongation Tensile Strength Tape Modulus Tear Strength Impact Resistance (Two layers) 11 Flow coefficient of Bitumen 11.1 Viscosity at 200º C 11.2 Viscosity at 175º C 12 Adhesion to Steel 13 Adhesion to Tape Issue : 1

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Data

------------BS 2782 BS 2782 BS 2782 ASTM D1004 DIN 30627

------mm mm mm % N/mm2 N/mm2 N Nm

Blue RAL 5000/5001/5005/ 5010/5017 Black White/Cream PVC 0.75 0.75 1.5 270 14.8 50 50 15

Cone & Plate Cone & Plate ASTM D 1000 ASTM D 1000

Poise Poise N/mm N/mm

5.5 7.5 2.75 2.75

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B. 13 14 15 C. 16 17 18 D. 19 20 21 4.6

Electrical Dielectric Strength Insulation resistance Cathodic disbandment General Water vapor permeability Water absorption Bacterial growth disbandment Temperature Range For wrapping In service For storage

WP-P5/ S1

BS 2782 ASTM D 257 ASTM G 8

kV 30 Ohm/cm2 1012 mm2 NIL

BS 2782 ASTM D 570 ---

g/m2/24h % ---

0.4 0.1 NIL

-------

ºC ºC ºC

0 to + 50 0 to + 50 up to + 30

PRIMER  4.6.1 The primer shall be of fast drying type. It’s only purpose shall be to maintain the surface cleanliness condition of the cleaned prepared D.I. pipe surface prior to tape application. 4.6.2 The primer shall be supplied in 20 to 25 Liters drums with following specifications given in Table 04. Table (04) PRIMER DATA SHEET Property Flash Point, C º Weight Solid, % Viscosity, CP Coverage m2/l Type

4.7

Data 24 - 34 58 200 - 500 6 - 12 Bitumen solution

PACKING 4.7.1 Drums shall be put into a wooden box, which shall be close and open type. The  boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No. or Title, Type, Size and quantity of material in black or blue color letters with a minimum height of 50mm.

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4.8

WP-P5/ S1

WRAPPING TAPE VISCO ELASTIC POLY ISO BUTENE 4.8.1 The specification of visco elastic wrapping tape shall be according to ISO 21809-3 Amendment 1 for Non crystalline Poly Iso Butene tapes. 4.8.2 The tape shall be supplied with width of 100 mm and 200 mm and with length 10 m, 20 m or approved by Engineer depending upon the r equirements. 4.8.3 Pipe diameters up to 200mmØ, 100mm width tape shall be used. 4.8.4 Pipe diameters 200mmØ and above, 200mm width tape shall be used. 4.8.5 For all types of fitting with diameters 100mmØ and above, 100mm width tape shall  be used. 4.8.6 The wrapping tape shall consist of a polyolefin based corrosion preventing compound and a PE backing. 4.8.7 The corrosion preventing compound shall be a non-crosslinked, non-crystalline, lowviscosity polyolefin (that is, not requiring a primer in order to achieve bond to the substrate) and shall have thickness between 0.90 to 1.00 mm. 4.8.8 The tape shall be supplied with a high quality silicon release foil covering complete tape. 4.8.9 During storage at maximum storage temperature of +50° C, the adhesive material shall not flow out of the release foil and there shall not be any end blocking. 4.8.10 Wrapping tape shall be marking in middle with the following information;    

4.9

Manufacturers name & logo. Date of manufacture. Width of the tape. Batch Number.

WRAPPING PROCEDURE 4.9.1 Tools & Equipment required Temperature probe, Dew point tester, High voltage holiday tester. 4.9.2 The substrate should be free from condensing water which can be reached by keeping the temperature at least 3°C above dew point. The substrate should be dry, clean and protected against negative weather influences. 4.9.3 The area to be coated has to be clean, dry, and free from oil, grease and dust. All contamination including mill-scale has to be removed. De-gloss and degrease the surfaces by using an abrasive pad and isopropyl alcohol and e.g. a lint-free cloth.

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4.9.4 Minimum requirement for surface preparation is St 2 according to ISO 8501-1. Roughness profile should not be essential for adhesion. 4.9.5 Start wrapping with removal of a small part of the release liner and apply on the substrate without exerting any tension. Avoid air inclusions. Mould the tape tight onto the substrate surfaces. 4.9.6 Release foil should be removed only just prior to application onto the surface.   

Overlap of wraps Side-by-side overlap: > 10 mm Consecutive rolls: = 50 mm Overlap on Existing coating= 50 mm.

4.9.7 The appearance of the tape must look smooth and tight and should be shaped around all details and into corners. 4.9.8 Holiday testing should be carried out immediately after application of wrapping tapes with a voltage of 15 kV. A brush probe is recommended. No further testing is required. 4.9.9 The wrapped pipe should not be exposed to loads e.g. from supports- or lifting equipment. 4.9.10 To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-Automatic Tape Wrapping Machine and for pipe diameters above 300mm, Fully Automatic Wrapping Machine should be used, manual wrapping is also acceptable. 4.9.11 Pipelines: Machine wrapped or manually wrapped protective coating on buried ductile iron pipelines. Field joints, Flanges, Couplings bell and spigot joint manually wrapped. 4.9.12 If the wrapping on the pipe is damaged during transportation localized repair should  be performed as per above procedure. 4.9.13 If required extra mechanical impact resistance for Field Joints,Flanges & couplings can be achieved by applying an extra self-adhesive PE or PVC film on top of the tape wrap material. This will not be considered as extra corrosion prevention. 4.9.14 The self-adhesive PE or PVC film shall be applied with 50% overlap. 4.10 STORAGE 4.10.1 Store indoor, clean and dry, away from direct sunlight in a cool place below +50°C. Material should have Unlimited shelf life.

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4.11 PACKING 4.11.1 Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage shall separate each layer. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.12 WRAPPING TAPE PROPERTY 4.12.1 The wrapping tape shall also conform to the minimum requirement given which is  based on ISO 21809-3 Amendment 1(2011) and EN 12068 and shall be conforming to the following specifications given in Table 05. Table (05) WRAPPING TAPE PROPERTY DATA SHEET Property Test Unit Requirements Temp. Minimum thickness 23 °C mm 1.5 mm < Minimum Glass transition temperature °C application temp minus 20 Holiday detection at 5 No holiday kV/mm + 5 kV T + Drip resistance - 15  No drip at 80 °C °C - R S100 ≥ 108 Specific electrical insulation 23 °C Ω.m² R S100/R S70 ≥ 0,8 resistance

Test Method Annex A Annex E Annex B

max

Annex J

Annex K 

a

≥ 0.2

23 °C Peel strength test and adhesion test with respect to steel and to plant coating  before and after thermal ageing resistance and before and after hot water immersion test, both for 100 days at T + 20 °C (if reinforcement in the compound tape)

Impact resistance (Single layer) Issue : 1

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≥ 0.2

 N/mm

T

max

20 °C

J

Unclassified

Cohesive failure Coverage ≥ 95 % The coating shall leave a film of corrosion  protective coating material on the substrate. There shall  be no evidence of adhesive failure ≥ 4 

Annex D 18.5.9.2 (and N.3 and Annex I)

EN12068

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 N/mm²

Pressure Indentation resistance,

23 °C and Tmax

Holiday detection at 5 kV/mm + 5 kV Cathode disbandment 23 °C resistance at 28 days and Tmax Lap Shear Test 23 °C Peel strength (layer-to-layer) 23 °C  before and after thermal ageing resistance and before and after hot water immersion test both for 100 days at Tmax + 20 °C. UV Resistance 23 °C Lap Shear Test 23 °C Peel strength (layer-to-layer) 23 °C  before and after thermal ageing resistance and before and after hot water immersion test both for 100 days at Tmax + 20 °C. UV Resistance 23 °C MIC Resistance 23 °C Water absorption 23 °C Water vapour permeability

1

-

mm

EN 12068 ANNEX G

N/mm2 N/mm

Annex F (and Annex B) ≥ 0.02 cohesive failure Annex L ≥ 0.20 Annex M

gJ/m2 N/mm2 N/mm

17,5 EN12068 ≥ 0.02 cohesive failure Annex L ≥ 0.20 Annex M

gJ/m2 %

23 °C g/m2/day

Temperature for wrapping Temperature In service Temperature for storage *Extra mechanical Outer wrap applied.

WP-P5/ S1

°C °C °C

0 mm, no holiday Self-Healing*

17,5 pass < 0.02