ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 2 SITEWORK

SECTION 02230 DI PIPELINES. MATERIALS, INSTALLATION AND TESTING

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 1 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description / Purpose of Issue

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April 2008

First Issue.

02

Jan. 2011

ADSSC new logo

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ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 2 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

TABLE OF CONTENTS
1 GENERAL ....................................................................................................... 4 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.5 1.6 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 SCOPE ................................................................................................ 4 RELATED DOCUMENTS ..................................................................... 4 STANDARDS ....................................................................................... 4 SUBMITTALS ....................................................................................... 5 PRODUCTS AND MATERIALS APPROVAL. ....................................... 5 METHOD STATEMENTS .................................................................... 5 WORKING DRAWINGS. ...................................................................... 5 QUALITY CONTROL............................................................................ 5 DELIVERY, STORAGE AND HANDLING............................................. 6 GENERAL REQUIREMENTS............................................................... 7 WALL, FLOOR, SLAB AND ROOF PENETRATIONS .......................... 7 PROTECTIVE COATINGS ................................................................... 7 MARKING OF PIPES AND FITTINGS.................................................. 9 INSTALLATION .................................................................................. 10 JOINTING PIPES AND FITTINGS...................................................... 10 TESTING............................................................................................ 10

PRODUCTS ..................................................................................................... 7

EXECUTION .................................................................................................. 10

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 3 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

1 1.1

GENERAL SCOPE This section of the specification gives the requirements for Ductile Iron (DI) pipeline and fitting materials and the installation and testing thereof for sewerage systems. Valves, penstocks and actuators are specified in the appropriate sections of the General Specification for Mechanical and Electrical Works.

1.2

RELATED DOCUMENTS The following sections of the specification shall be read in conjunction with this section. Section 01000-07 Section 01000-08 Section 01000-09. Section 02120 Submittals. Quality control. Materials and equipment. Utility Excavation, Surround and Backfill

1.3

STANDARDS All activities relating to this section of the specification shall comply with the following or approved equal standards. ASTM G14 ASTM G42 BS EN 545 BS EN 598 Standard test method for impact resistance of pipeline coatings. Standard test method for cathodic disbonding of pipeline coatings subjected to elevated temperatures. Ductile iron pipes, fittings and their joints for water pipelines. Requirements and test methods. Ductile iron pipes, fittings, accessories and their joints for sewerage applications. Requirements and test methods. Elastomeric seals Materials requirements for pipe joint seals used in water and drainage applications. Vulcanised rubber. Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Cast iron flanges. Founding spheroidal graphite cast iron Epoxy coating (heavy duty) of ductile iron fittings and accessories Hot rolled products of structural steels Ductile iron pipelines. Polyethylene sleeving for site application

BS EN 681-1

BS EN 1092-2

BS EN 1563 BS EN 14091 BS 10025 ISO 8180

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 4 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.4 1.4.1

SUBMITTALS PRODUCTS AND MATERIALS APPROVAL. a) In order to verify compliance with the specification the Contractor shall submit information for all products and materials used in the Works to the Engineer for approval sufficiently in advance of their use in accordance with the Contract programme allowing for ordering and approval times. Reference shall also be made to Section 01000-09 of the specification on products and materials approval. Information to be submitted shall comprise but not necessarily be limited to: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. Manufacturers name. Suppliers name. Pipe diameters and pressure ratings. Manufacturers technical data. Support details. Connection details. Manufacturers quality control and test procedures. Manufacturers hydraulic test reports. Manufacturers guarantee. Joint materials and gaskets. Detailed information on coatings.

1.4.2

METHOD STATEMENTS a) The Contractor shall submit method statements to the Engineer for approval 4 weeks in advance of commencing the site activity in accordance with Section 01000-07 of the specification. These shall comprise but not necessarily be limited to: i. ii. iii. Procedures for handling, storage and installation of pipes including cleaning and repair. Hydrostatic testing procedures. A detailed statement for local application of coatings.

1.4.3

WORKING DRAWINGS. a) The Contractor shall submit drawings to the Engineer for approval in advance of commencing the site activity in accordance with Section 01000-07 of the specification. These shall comprise but not necessarily be limited to: i. Drawings of the pipes, fittings, joints, pipe specials and the assembly thereof.

1.5

QUALITY CONTROL a) Prior to dispatch of any product and/or material from source the Contractor shall notify the Engineer in writing in sufficient time to allow
DI Pipelines. Materials, Installation and Testing

ADSSC/GSCW

Division 02

Section 02230

Rev: 02

Jan. 2011

Page 5 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

the Engineer the opportunity to inspect and test the product and/or material prior to delivery in accordance with Section 01000-08 of the specification. b) Products and materials shall be from a manufacturer/supplier who operates a quality system which is registered to ISO 9000 series or approved equal. c) Manufacturers shall have a minimum of 5 years manufacturing experience with the type of pipes being proposed. d) To allow the Engineer to inspect the Works the Contractor shall give the Engineer a minimum of 24 hours notice of carrying out the following activities on site. i. ii. 1.6 Installation of pipeline. Hydrostatic testing of pipeline.

DELIVERY, STORAGE AND HANDLING a) Delivery, storage and handling of products and materials shall be in accordance with the manufacturer's recommendations, Section 0100008 of the specification and the following provisions. i. ii. Delivery storage and handling shall at all times be performed in a manner to avoid product damage. Pipes and fittings shall not come in contact with any sharp projections that may cause damage to the pipes and fittings during transportation loading and unloading. Ensure that pipes and fittings are well secured during transit and adequately supported along their length. Do not allow pipe to overhang the end of a vehicle during transportation. Ensure that pipes and fittings are protected from damage while being lifted. The hooks used shall be padded. Use only nylon or reinforced fabric slings and ropes if they are in direct contact with pipes and fittings . Store pipes and fittings on a flat level area and raised above the ground on timber bearers. Provide timber bearers at spacings recommended by the pipe manufacturer. Store joint materials and gaskets in a well ventilated place free from exposure to sunlight and in their original packings until they are needed. The Contractor shall visually inspect all products upon delivery to site and report any damage to the Engineer. Any products damaged during delivery, storage and handling shall be marked by the Contractor and set aside. Proposals for repair of any damaged products shall be submitted in writing to the Engineer for approval. Any damaged products deemed unsuitable for repair by the Engineer shall be removed from site and replaced.
DI Pipelines. Materials, Installation and Testing

iii.

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ADSSC/GSCW

Division 02

Section 02230

Rev: 02

Jan. 2011

Page 6 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

2
2.1

PRODUCTS
GENERAL REQUIREMENTS a) Pipework and fitting materials and coatings shall be suitable for their intended use, shall be internally chemically resistant to the conveyed fluid and any gasses produced by the fluid and shall externally be chemically resistant to the surrounding environment. b) Pipework and fittings shall be manufactured to the requirements of BS EN 545 or 598 as appropriate with the thickness class for pipework being k9 and for fittings k12 unless specified otherwise. c) Pipework and fittings shall be PN16 flanged to BS EN 1092-2 Flanged joint gaskets shall be rubber, full faced, of 3mm nominal thickness to BS EN 6811. Bolts, nuts, washers, anchor plates and all fixings shall be of stainless steel grade 316 and shall remain unpainted. d) Contact between dissimilar materials shall be prevented by the use of suitable washers, bushes and bedding pads so as to avoid galvanic reactions. e) Flanged pipe and fittings shall be factory produced and shall not be fabricated on site. f) Valves and other devices mounted in pipework shall be supported independently of the pipes to which they connect.

2.2

WALL, FLOOR, SLAB AND ROOF PENETRATIONS a) Pipework passing through concrete walls, floors, slabs and roofs shall have integrally cast paddle flanges as shown on the drawings and shall provide a watertight installation. The coating to the paddle flange shall be similar to that of the pipe/fitting. b) Thrust/anchor flanges shall be used were pipework or fittings are cast into walls etc and shall be designed to restrain the installed equipment. Thrust/anchor flanges shall be integrally cast or factory welded onto the pipe piece as approved by the Engineer. Bolted or screwed on flanges are not acceptable. The coating to the thrust/anchor flange shall be similar to that of the pipe/fitting.

2.3

PROTECTIVE COATINGS a) Pipes shall be protected internally with factory applied fusion bonded epoxy or polyurethane. The minimum dry film thickness of the fusion bonded epoxy coating shall be 300 m. Thickness of the polyurethane application is given in the Table 2.3.1

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 7 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

Table 2.3.1 Thickness of Internal Polyurethane Application DN 100 - 600 700-1000 1100-1500 1600-2000 Nominal thickness of polyurethane (m) 1500 1800 2200 2500

b) Pipes shall be protected externally with metallic zinc coat (min 200g/m2) and epoxy finish layer (min thickness 80m), metallic zinc coat (min 200g/m2) and bituminous paint (min thickness 100m) or polyurethane. Selection of the external coating shall be made on the base of soli conditions, refer to Table 2.3.2 Table 2.3.2 External Coating of the Pipes Depending on the Soil Conditions Soil characteristics Resistivity >1500Ohmcm without water table >2500Ohmcm with water table 750Ohmcm <Resistivity 1500 Ohmcm without water table 1500Ohmcm<Resistivity 2500Ohmcm with water table Resistivity 750Ohmcm without water table 1500Ohmcm with water table Resistivity 250Ohmcm without water table 500Ohmcm with water table External Coating Metallic zinc + epoxy finish layer Metallic zinc + bituminous paint

Metallic zinc + epoxy finish layer + polyethylene sleeve Metallic zinc + bituminous paint + polyethylene sleeve Polyurethane with average thickness 1000 m Polyurethane with average thickness 2000 m

c) Fittings shall be protected internally and externally with a factory applied fusion bonded powder epoxy resin coating. The minimum dry film thickness of the coating shall be 300m. d) The powder epoxy resin coating shall be applied by electrostatic spray. The powder material and method of application shall be subject to the approval of the Engineer. e) Pipework and fittings shall be blast cleaned to SA2 and grease and other foreign matter shall be removed prior to application of the coating. f) The temperature of the metal shall be adjusted to ensure complete polymerisation of the powder material.

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 8 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

g) After application of coating the coating shall be allowed to cure before being cooled with water to permit handling and inspection. h) The coating shall be free from blisters, pinholes, runs, sags or any other irregularities and shall have uniform colour, gloss and thickness. i) The coatings shall be free from holidays. Every pipe and fitting shall be inspected for holidays over 100% of its coated surface. For the epoxy or Rilsan coatings the holiday detector shall be set at 2.2kV with a rate of travel of the probe over the surface shall not exceed 300mm/s. For polyurethane coating the voltage shall be rated as in the Table 2.3.3

Table 2.3.3 Voltage Rating for the Holiday Testing of Polyurethane Internal Coating DN 100 - 600 700-1000 1100-1500 1600-2000 j) Holiday test 3kV 3.6kV 4.4kV 5kV

The minimum impact resistance of the coating when tested in accordance with ASTM G14 shall be 18J without causing holidays.

k) The coating shall not show any tendency for disbondment or blistering. Cathodic disbondment test shall be carried out in accordance with ASTM G42. The maximum coating disbondment shall be 5mm radius from the edge of the artificial holiday. l) Method of site application of the internal and external coatings at the cutoff or repaired pipes has to be produced by the pipe supplier and approved by the Engineer

m) Polyethylene sleeve, when, used shall be in accordance with ISO 8180. The PE sleeve shall be black, UV resistant with the thickness 250 m with maximum minus tolerance of 10% n) Dismantling joints, step couplings and flange adapters shall of be of steel grade S275 to BS EN 10025 or ductile iron grade 420/12 to BS EN 1563 with factory applied fusion bonded epoxy coating or Rilsan Nylon coating of minimum thickness of 300 m. Bolts, nuts, studs, and washers shall be stainless steel SS316 2.4 MARKING OF PIPES AND FITTINGS Marking shall be applied to pipes and fittings in such a manner that it is legible after installation and durable throughout the construction period. Each standard and random length of pipe and fitting shall be marked before dispatch from the pipe manufacturers works as required in BS EN 545 and 598.

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 9 of 10

General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

3
3.1

EXECUTION
INSTALLATION a) Install in accordance with manufacturers recommendations and instructions. b) Verify dimensions of valves and fittings to assure work will fit together properly and conform to the arrangement shown on the drawings. c) Accurately determine dimensions essential for proper location and orientation of cast in items.

3.2

JOINTING PIPES AND FITTINGS a) Thoroughly clean the faces of the flanges of all oil, grease, and foreign material prior to connecting flanged pipe. b) Check gaskets for proper fit and thoroughly clean. c) Assure proper seating of the flange gasket. d) Tighten bolts so that the pressure on the gasket is uniform. Use torquelimiting wrenches to ensure uniform bearing insofar as possible. e) If bolted joints leak when the hydrostatic test is applied, remove gaskets and reset and retighten bolts.

3.3

TESTING a) All sections of DI pipeline and fittings shall be hydrostatically tested to the satisfaction of the Engineer. The test pressure shall be such that the section being tested will be subjected to 1.5 times the working pressure. The working pressure shall be the maximum pressure that can be developed in the system. b) All coatings and linings shall be tested for dry film thickness and for continuity using a holiday detection unit. Where holidays are detected or the DFT is less than required, the area shall be recoated in accordance with the manufacturers recommendations.

END OF SECTION

ADSSC/GSCW

Division 02

Section 02230

DI Pipelines. Materials, Installation and Testing

Rev: 02

Jan. 2011

Page 10 of 10